3126 B C10 C12 Shop Manual

SENR6553-02
April 2001
Disassembly and
Assembly
3100 HEUI Diesel Truck Engine
8WL1-Up (Engine)
1WM1-Up (Engine)
4ES1-Up (Engine)
2CW1-Up (Engine)
8HW1-Up (Engine)
7LZ1-Up (Engine)
i01097883
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. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
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 Crankshaft Rear Seal - Remove ........................... 45

Crankshaft Rear Seal - Install ............................... 45
Crankshaft Rear Seal Carrier - Remove and
Install ................................................................... 46
Disassembly and Assembly Section Flywheel Housing - Remove and Install ............... 48
Vibration Damper and Pulley - Remove and Install
Fuel Filter Base - Remove and Install .................... 5
............................................................................. 49
Fuel Transfer Pump - Remove ................................ 6
Crankshaft Front Seal - Remove ........................... 50
Fuel Transfer Pump - Install .................................... 7
Crankshaft Front Seal - Install .............................. 51
Fuel Pressure Regulator - Remove and Install ....... 8
Front Cover - Remove ........................................... 52
Unit Injector - Remove ............................................ 9
Front Cover - Install ............................................... 52
Unit Injector - Install .............................................. 10
Gear Group (Front) - Remove ............................... 53
Unit Injector Sleeve - Remove .............................. 10
Gear Group (Front) - Install ................................... 53
Unit Injector Sleeve - Install .................................. 11
Housing (Front) - Remove ..................................... 57
Injection Actuation Pressure Control Valve -
Housing (Front) - Install ........................................ 57
Remove ............................................................... 12
Camshaft Idler Gear - Remove and Install ............ 58
Valve Mechanism Cover - Remove and Install ..... 60
Disassemble ....................................................... 12
Rocker Shaft and Pushrod - Remove ................... 61
Rocker Shaft - Disassemble ................................ 62
Assemble ............................................................ 13
Rocker Shaft - Assemble ..................................... 63
Rocker Shaft and Pushrod - Install ....................... 63
Install ................................................................... 13
Cylinder Head - Remove ....................................... 64
Unit Injector Hydraulic Pump - Remove ................ 14
Cylinder Head - Install .......................................... 65
Unit Injector Hydraulic Pump - Install .................... 15
Lifter Group - Remove and Install ......................... 66
Turbocharger - Remove ........................................ 15
Camshaft - Remove .............................................. 68
Turbocharger - Disassemble ................................ 16
Camshaft - Install .................................................. 69
Turbocharger - Assemble ..................................... 17
Camshaft Gear - Remove and Install ................... 70
Turbocharger - Install ............................................ 17
Camshaft Bearings - Remove and Install ............ 70
Exhaust Manifold - Remove and Install ............... 18
Engine Oil Pan - Remove and Install ................... 72
Air Inlet Heater - Remove and Install ................... 19
Piston Cooling Jets - Remove and Install ............. 74
Air Inlet Heater Solenoid - Remove and Install .... 20
Pistons and Connecting Rods - Remove .............. 75
Air Inlet Cover - Remove and Install ..................... 20
Pistons and Connecting Rods - Disassemble ....... 76
Inlet and Exhaust Valves - Remove and Install ..... 21
Pistons and Connecting Rods - Assemble ........... 77
Inlet and Exhaust Valve Guides - Remove and
Pistons and Connecting Rods - Install .................. 79
Install ................................................................... 23
Crankshaft Main Bearings - Remove .................... 81
Inlet and Exhaust Valve Seat Inserts - Remove and
Crankshaft Main Bearings - Install ........................ 82
Install ................................................................... 24
Crankshaft - Remove ............................................ 83
Engine Oil Filter Base - Remove ........................... 26
Crankshaft Wear Sleeve (Rear) - Remove (If
Engine Oil Filter Base - Disassemble ................... 26
Equipped) ............................................................ 84
Engine Oil Filter Base - Assemble ........................ 27
Crankshaft Wear Sleeve (Rear) - Install ............... 84
Engine Oil Filter Base - Install .............................. 28
Crankshaft - Install ................................................ 85
Engine Oil Filter Bypass Valve - Remove and Install
Crankshaft Gear - Remove and Install ................. 86
............................................................................. 28
Bearing Clearance - Check ................................... 87
Engine Oil Cooler Bypass Valve - Remove and Install
Ether Atomizer - Remove and Install .................... 88
............................................................................. 29
Idler Pulley - Remove ............................................ 89
Engine Oil Cooler - Remove ................................. 30
Idler Pulley - Disassemble .................................... 89
Engine Oil Cooler - Install ..................................... 31
Idler Pulley - Assemble ......................................... 90
Engine Oil Pump - Remove .................................. 32
Idler Pulley - Install ............................................... 90
Engine Oil Pump - Disassemble ........................... 33
Belt Tensioner - Remove and Install ..................... 91
Engine Oil Pump - Assemble ................................ 34
Belt Tightener - Remove ....................................... 91
Engine Oil Pump - Install ...................................... 36
Belt Tightener - Disassemble ................................ 91
Water Pump - Remove ......................................... 36
Belt Tightener - Assemble .................................... 92
Water Pump - Disassemble ................................. 37
Belt Tightener - Install ........................................... 93
Water Pump - Assemble ...................................... 38
Fan Drive - Remove ............................................. 93
Water Pump - Install ............................................. 39
Fan Drive - Disassemble ...................................... 94
Water Temperature Regulator Housing - Remove and
Fan Drive - Assemble .......................................... 94
Install .................................................................. 40
Fan Drive - Install .................................................. 95
Water Temperature Regulator - Remove and Install
Engine Control Module - Remove and Install ....... 96
............................................................................. 41
Alternator - Remove and Install ........................... 96
Engine Lifting Bracket - Remove and Install ........ 43
Electric Starting Motor - Remove and Install ....... 97
Engine Support (Front) - Remove and Install ....... 43
Air Compressor - Remove and Install .................. 98
Flywheel - Remove ............................................... 44
Air Compressor Drive Gear - Remove ................ 101
Flywheel - Install ................................................... 44
Air Compressor Drive Gear - Install .................... 102
4
Table of Contents
Index Section
Index ................................................................... 103
5
Disassembly and Assembly Section
Disassembly and Assembly 2. Place an identification mark (5) on crankcase

breather (3) and fuel filter base (9). This will aid
Section in installation purposes.
3. Loosen clamp (2) and remove hose (7) from

i01205005 crankcase breather (3).
Fuel Filter Base - Remove and 4. Remove bolt (1) and the washer. Remove
Install crankcase breather (3) and the O-ring seal from
fuel filter base (9).
SMCS Code: 1262-010
5. Disconnect tubes (6) and (8) from fuel filter base
Removal Procedure (9). Cap the tubes immediately.
Table 1 6. Remove four bolts (4) and the washers. Remove

fuel filter base (9) and the gasket from the
Required Tools engine.
Tool Part Number Part Description Qty
Strap Wrench Installation Procedure
A 2P-8250 1
Assembly
NOTICE
Keep all parts clean from contaminants.
NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened
component life.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
NOTICE during performance of inspection, maintenance, test-
Care must be taken to ensure that fluids are contained ing, adjusting and repair of the product. Be prepared to
during performance of inspection, maintenance, test- collect the fluid with suitable containers before open-
ing, adjusting and repair of the product. Be prepared to ing any compartment or disassembling any compo-
collect the fluid with suitable containers before open- nent containing fluids.
ing any compartment or disassembling any compo-
nent containing fluids. Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
Refer to Special Publication, NENG2500, Caterpillar suitable to collect and contain fluids on Caterpillar
Tools and Shop Products Guide for tools and supplies products.
suitable to collect and contain fluids on Caterpillar
products. Dispose of all fluids according to local regulations and
mandates.
Dispose of all fluids according to local regulations and
mandates.
g00644400
Illustration 2
g00644400
Illustration 1
1. Inspect the condition of the gasket and the
O-ring seals. Replace the gasket and the seals,
1. Use Tool (A) to remove fuel filter (10). if necessary.
6
2. Position the gasket and fuel filter base (9) on the

engine.
3. Install the washers and four bolts (4).
4. Connect tubes (6) and (8) to fuel filter base (9).
5. Install the O-ring seal and crankcase breather (3)

on fuel filter base (9). Align identification mark
(5). Position crankcase breather (3) at 30 5
degrees away from the cylinder head.
6. Install the washer and bolt (1). Tighten the bolt

to a torque of 7 2 Nm (62 18 lb in).
g00612458
7. Install hose (7) on crankcase breather (3) and Illustration 3
tighten clamp (2).
1. Remove fuel outlet line (1) from fuel transfer
8. Install fuel filter (10). pump (3). Immediately cap all openings or plug
all openings in order to prevent contamination.
i01153675 2. Cut nylon strap (2) that fastens the wiring

harness to the unit injector hydraulic pump.
Fuel Transfer Pump - Remove
SMCS Code: 1256-011
Removal Procedure
NOTICE

component life.
NOTICE
Care must be taken to ensure that fluids are contained g00612496
during performance of inspection, maintenance, test- Illustration 4
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 3. Remove the bolts, clip (4) and fuel transfer pump
ing any compartment or disassembling any compo- (3) from the unit injector hydraulic pump.
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar

products.

mandates.
g00612507
Illustration 5
7
4. Remove O-ring seal (5) from the unit injector 1. Clean all components and the mating surfaces.
hydraulic pump. Inspect O-ring seal (5) for Inspect all components. If any component is worn
wear or damage. If the O-ring seal is worn or or damaged, use a new part for replacement.
damaged, use a new part for replacement. Install the elbows for the fuel inlet port and the
fuel outlet port on the fuel transfer pump.
2. Install the O-ring seal (6).
g00612518
Illustration 6
5. Remove the elbows for the fuel inlet port and the
g00612507
fuel outlet port from the fuel transfer pump. Illustration 8
6. Remove O-ring seal (6) from the elbow. Inspect 3. Install O-ring seal (5) on the unit injector
O-ring seal (6) for wear or damage. If the O-ring hydraulic pump.
seal is worn or damaged, use a new part for
replacement.
i01153818
Fuel Transfer Pump - Install

SMCS Code: 1256-012
Installation Procedure
NOTICE
g00612496
Contaminants may cause rapid wear and shortened Illustration 9
component life.
4. Position fuel transfer pump (3) on the unit injector
hydraulic pump.
5. Install the bolts and clip (4). Tighten the bolts for
the fuel transfer pump to a torque of 25 3 Nm
(18 2 lb ft).
g00612518
Illustration 7
8
g00612458 g00618383
Illustration 10 Illustration 12
6. Install fuel outlet line (1). Tighten the connectors 2. Remove O-ring seal (2) from fuel pressure
for the fuel inlet port and the fuel outlet port to a regulator (1).
torque of 17.5 2 Nm (13 1.5 lb ft).
7. Secure the wiring harness to the fuel transfer

pump with a nylon strap.
i01161376
Fuel Pressure Regulator -

Remove and Install
SMCS Code: 1715-010
Removal Procedure
g00618383
Illustration 13
1. Ensure that the orifice in fuel pressure regulator

(1) is open and clean. Install a new O-ring seal
(2) on fuel pressure regulator (1).
g00618385
Illustration 11
1. Remove fuel pressure regulator (1) from the rear

of the cylinder head.
g00618385
Illustration 14
2. Install fuel pressure regulator (1) in the rear of

the cylinder head at a 10 degree angle from the
horizontal centerline.
9
i01205071
Unit Injector - Remove

SMCS Code: 1290-011
Removal Procedure
Table 2
Required Tools
A 1U-7587 Pry Bar 1
g00644457
Start By: Illustration 16
a. Remove the rocker arms and the pushrods. 2. Remove unit injector (2) by hand, when possible.
Refer to Disassembly and Assembly, Rocker Twist unit injector (2).
Shaft and Pushrod - Remove.
3. Use Tool (A) to loosen unit injector (2), if
necessary. Remove unit injector (2) from the
NOTICE
cylinder head.

component life.
NOTICE
during performance of inspection, maintenance, test-
collect the fluid with suitable containers before open-

Tools and Shop Products Guide for tools and supplies g00644459
Illustration 17
products.
4. Ensure that two O-ring seals (3) and (4) are on
Dispose of all fluids according to local regulations and unit injector (2).
mandates.
g00644454
Illustration 15
1. Disconnect wiring harness (1) from the unit

injector.
10
i01205271
Unit Injector - Install

SMCS Code: 1290-012
Table 3
Required Tools
164-5927 Wire Brush 1
9U-6862 Tapered Brush 1 g00644454
A Illustration 19
4C-5552 Large Bore Brush 1
9U-6102 Reamer 1 6. Install a new weather pack connector on wiring
harness (1). Connect wiring harness (1) to the
B 173-1530 Injector Seating Tool 1 unit injector.
End By:
NOTICE
a. Install the rocker arms and the pushrods. Refer
to Disassembly and Assembly, Rocker Shaft
and Pushrod - Install.
component life.
i01496518
1. Use Tool (A) to clean the sleeve of the unit
injector. Unit Injector Sleeve - Remove
SMCS Code: 1713-011
Removal Procedure
Table 4
Required Tools
Part
Tool Part Description Qty
Number
A 143-2099 Unit Injector Tool Group 1
Start By:
g00644459
Illustration 18
a. Remove the unit injector. Refer to Disassembly
and Assembly, Unit Injector - Remove.
2. Install new O-ring seals (3) and (4).
3. Lubricate the O-ring seals with clean engine oil. NOTICE

4. Position unit injector (2) in the cylinder head.
5. Use Tool (B) to properly seat unit injector (2). component life.
Refer to the Tool Operating Manual, NEHS0738,
Using the 173-1530 Injector Seating Tool on
3114, 3116, and 3126 MUI or 3116 3126 HEUI
2-Valve Engines for the proper procedure.
11
NOTICE NOTICE
Care must be taken to ensure that fluids are contained Keep all parts clean from contaminants.
ing, adjusting and repair of the product. Be prepared to Contaminants may cause rapid wear and shortened
collect the fluid with suitable containers before open- component life.

products.

mandates.
g00627676
Illustration 21
1. Inspect the injector sleeve for pitting and for

carbon tracking. Used injector sleeves do not
need to be reamed unless the seated area
is pitted or eroded. Ream the used injector
sleeves if the seated area has excessive carbon
deposits. Ream the sleeve, if necessary. Refer to
Tool Operating Manual, NEHS0675, Using the
143 - 2099 Sleeve Replacement Tool Group on
g00627676
Illustration 20 3114, 3116, and 3126 Engines. Use Tool (A) to
ream injector sleeves.
1. Use Tool (A) to remove unit injector sleeve (1)
from the cylinder head. Refer to Tool Operating New injector sleeves should not be reamed.
Manual, NEHS0675, Using the 143-2099 Refer to Tool Operating Manual, NEHS0738,
Sleeve Replacement Tool Group on 3114, 3116, Using the 173 -1530 Injector Seating Tool
and 3126 Engines for the correct procedure. Group on 3114, 3116, and 3126 Engines for
the remaining steps on installing new injector
sleeves.
i01345407
Unit Injector Sleeve - Install End By:
SMCS Code: 1713-012 a. Install the unit injector. Refer to Disassembly and
Assembly, Unit Injector-Install.
Table 5
Required Tools
Part
Number
Injector Sleeve
A 143-2099 1
Replacement Tool Group
12
i01180574 3. Use Tool (A) and an extension in order to remove

the injection actuation pressure control valve
Injection Actuation Pressure from the unit injector hydraulic pump.
Control Valve - Remove
i01180668
SMCS Code: 5051-011
Injection Actuation Pressure
Removal Procedure Control Valve - Disassemble
Table 6 SMCS Code: 5051-015
Required Tools
Tool Part Number Part Description Qty Disassembly Procedure
A 5P-0333 Crowfoot Socket 1 Start By:
NOTICE a. Remove the injection actuation pressure control

Keep all parts clean from contaminants. valve. Refer to Disassembly and Assembly,
Contaminants may cause rapid wear and shortened Remove.
component life.
NOTICE

component life.
g00644654
Illustration 22
1. Disconnect wiring harness plug (2) from injection

actuation pressure control valve (1).
g00632173
2. Remove nut (3), the spacer, and the solenoid Illustration 24
valve from injection actuation pressure control (1) O-ring seal
valve (1). (2) Nut
(3) Backup ring
(4) O-ring seal
(5) Solenoid valve
(6) Spacer
1. Remove O-ring seals (1) and (4), and backup

ring (3) from the injection actuation pressure
control valve. Inspect the components of the
injection actuation pressure control valve for
wear or damage. If any part is worn or damaged,
use a new part for replacement.
g00644655
Illustration 23
13
i01180694
NOTICE
Injection Actuation Pressure Keep all parts clean from contaminants.
Control Valve - Assemble
SMCS Code: 5051-016 component life.
Assembly Procedure
NOTICE

component life.
1. Clean the injection actuation pressure control

valve and the components for the injection
actuation pressure control valve.
g00644655
Illustration 26
1. Use Tool (A) in order to install the injection

actuation pressure control valve on the unit
injector hydraulic pump. Tighten the injection
actuation pressure control valve to a torque of
50 5 Nm (37 4 lb ft).
g00632173
Illustration 25
(1) O-ring seal
(2) Nut
(3) Backup ring
(4) O-ring seal
(5) Solenoid valve
(6) Spacer
2. Install new O-ring seals (1) and (4), and backup

ring (3) on the injection actuation pressure Illustration 27 g00644654
control valve. Lubricate the O-ring seals with
clean engine oil. 2. Install the solenoid valve, the spacer, and nut (3)
on the injection actuation pressure control valve
i01180663 (1). Tighten nut (3) to a torque of 5.5 1.5 Nm
(49 13 lb in).
3. Reconnect wiring harness plug (2) to the
Control Valve - Install injection actuation pressure control valve.
SMCS Code: 5051-012
Table 7
Required Tools
A 5P-0333 Crowfoot Wrench 1
14
i01205391
Unit Injector Hydraulic Pump -

Remove
SMCS Code: 1714-011
Removal Procedure
Start By:
a. Remove the fuel transfer pump. Refer to

Disassembly and Assembly, Fuel Transfer Pump
- Remove.
g00644692
Illustration 28
b. Remove the injection actuation pressure control
valve. Refer to Disassembly and Assembly, 1. Disconnect tubes (4) and (6) from unit injector
Injection Actuation Pressure Control Valve - hydraulic pump (1). Cap the tubes immediately.
Remove.
2. Remove three bolts (5) from unit injector hydraulic
NOTICE pump (1). Remove unit injector hydraulic pump
Keep all parts clean from contaminants. (1).
Contaminants may cause rapid wear and shortened 3. Remove oil inlet port (2) and oil outlet port (3)
component life. from unit injector hydraulic pump (1).
NOTICE

products.
g00644693
Dispose of all fluids according to local regulations and Illustration 29
mandates.
4. Remove bolt (8) and the washer from gear (9).
Remove O-ring seal (7).
Hot oil and components can cause personal in-

jury.
Do not allow hot oil or components to contact skin.

15
i01205479 5. Install the washers and three bolts (5).

Unit Injector Hydraulic Pump 6. Install new O-ring seals on tubes (4) and (6) and
- Install install the tubes in unit injector hydraulic pump
(1).
SMCS Code: 1714-012
End By:
Installation Procedure a. Install the injection actuation pressure control
valve. Refer to Disassembly and Assembly,
NOTICE Injection Actuation Pressure Control Valve -
Keep all parts clean from contaminants. Install.
Contaminants may cause rapid wear and shortened b. Install the fuel transfer pump. Refer to
component life. Disassembly and Assembly, Fuel Transfer Pump
- Install.
i01160174
Turbocharger - Remove
SMCS Code: 1052-011
Removal Procedure
NOTICE

Illustration 30 g00644693 component life.
1. Install gear (9) with the washer and bolt (8).

Tighten the bolt to a torque of 110 14 Nm NOTICE
(80 10 lb ft). Care must be taken to ensure that fluids are contained
2. Install new O-ring seal (7) and lubricate the seal ing, adjusting and repair of the product. Be prepared to
with clean engine oil. collect the fluid with suitable containers before open-

products.

mandates.
g00644692
Illustration 31
3. Install oil inlet port (2) in unit injector hydraulic

pump (1). Tighten the port to a torque of
26 3 Nm (19 2 lb ft).
4. Install oil outlet port (3) in unit injector hydraulic

pump (1). Tighten the port to a torque of
17 2 Nm (13 1 lb ft).
16
i01160562
Turbocharger - Disassemble
SMCS Code: 1052-015
Disassembly Procedure
NOTICE

component life.
NOTICE
g00617515
Illustration 32 nent containing fluids.
1. Remove bolts (1) and the gasket. Remove bolts Refer to Special Publication, NENG2500, Caterpillar
(3) and tube assembly (2) from the turbocharger. Tools and Shop Products Guide for tools and supplies
products.

mandates.
g00617565
Illustration 33
2. Remove the bolts and the gasket in order to

disconnect oil supply tube assembly (5) from the
turbocharger.
g00617691
Illustration 34
3. Remove four nuts (4), turbocharger (6) and the
gasket from the exhaust manifold.
17
g00617944 g00617944
1. Place alignment marks on the two housings and

the cartridge assembly for the correct alignment
during assembly.
2. Remove line (3) from compressor housing (6).
3. Remove clip (4) on waste gate (7).
4. Remove bolts (1) and waste gate (7) from turbine

housing (5). Remove turbine housing (5).
5. Remove bolts (2) from compressor housing (6).

Remove compressor housing (6).
g00617691
6. Inspect cartridge assembly (8) for wear or Illustration 37
damage. If cartridge assembly (8) is worn or
damaged, use a new part for replacement. 1. Position compressor housing (6) on cartridge
assembly (8) and align the marks on the
Note: The cartridge for the turbocharger is not components. Install bolts (2) that fasten
serviced. Replace the cartridge for the turbocharger compressor housing (6) to cartridge assembly
as an assembly. Contact your local Caterpillar dealer (8).
for more information on the cartridge assembly.
2. Position turbine housing (5) on cartridge
assembly (8) and align the marks on the
i01161232 components. Install bolts (1) that fasten turbine
housing (5) to cartridge assembly (8).
Turbocharger - Assemble
3. Install clip (4) on waste gate (7).
SMCS Code: 1052-016
4. Install line (3) on compressor housing (6).
Assembly Procedure
i01317027
NOTICE
Keep all parts clean from contaminants. Turbocharger - Install
Contaminants may cause rapid wear and shortened SMCS Code: 1052-012
component life.
NOTICE

component life.
18
Note: For information on the reusability of 4. Inspect the gaskets for oil supply tube assembly
components of the turbocharger, refer to Guideline (5) and tube assembly (2). If the gaskets are worn
For Reusable Parts And Salvage Operations, or damaged, use a new part for replacement.
SEBF8018, Turbochargers. For information on
the salvage of components of the turbocharger, 5. Position tube assembly (2) and the gasket
refer to Guideline For Reusable Parts And Salvage on turbocharger (6). Install bolts (1) on the
Operations, SEBF8071, Procedures to Salvage turbocharger and install bolts (3) on the cylinder
Turbocharger Components. block.
1. Inspect the turbocharger gasket for wear or 6. Install the gasket for oil supply tube assembly
damage. If the turbocharger gasket is worn or (5) and connect oil supply tube assembly (5) to
damaged, use a new part for replacement. turbocharger (6).
2. Apply 5P-3931 Anti-Seize Compound on

i01160570
the threads of the mounting studs for the
turbocharger. Exhaust Manifold - Remove
and Install
SMCS Code: 1059-010
Removal Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly

and Assembly, Turbocharger - Remove.
g00617565
Illustration 38
3. Position the turbocharger gasket and

turbocharger (6) on the exhaust manifold. Install
nuts (4) and tighten nuts (4) to a torque of
54 5 Nm (40 4 lb ft).
g00617696
Illustration 40
1. Remove bolts (1), locks (3), exhaust manifold

(2), and the gaskets from the cylinder head
assembly.
2. Disassemble exhaust manifold (2) into three

pieces.
3. Remove mounting studs (4) from exhaust

manifold (2), if necessary.
1. Inspect the condition of the gasket. Replace the
g00617515 gasket, if necessary.
Illustration 39
19
End By:
a. Install the turbocharger. Refer to Disassembly

and Assembly, Turbocharger - Install.
i01205762
Air Inlet Heater - Remove and

Install
SMCS Code: 1090-010
Removal Procedure
g00617696
Illustration 41
2. Apply 5P-3931 Anti-Seize Compound to the

threads of mounting studs (4).
3. Install mounting studs (4). Tighten mounting

studs (4) to a torque of 35 5 Nm (26 4 lb ft).
4. Install new exhaust manifold gaskets.
5. Apply a thin coat of 2P-2333 High Temperature

Sealer to the male ends of exhaust manifold (2).
Coat the inside of the female ends of exhaust
manifold (2) with clean engine oil. Assemble
exhaust manifold (2) and remove the excess Illustration 43 g00644927
sealer from the joints.
1. Disconnect the hoses from air inlet elbows (5).
threads of bolts (1). Position the gaskets and 2. Disconnect wire (1) from the air inlet heater.
exhaust manifold (2) on the cylinder head
assembly. Install locks (3) and bolts (1). 3. Remove nut (4) that secures the ground strap
to the air inlet heater.
4. Remove eight bolts (3) and the washers. Remove

air inlet elbows (5) and air inlet heater (2).
g00617739
Illustration 42
7. Tighten bolts (1) in a numerical sequence to a

torque of 4 1 Nm (35 9 lb in).
8. Tighten bolts (1) in a numerical sequence to a

torque of 45 5 Nm (33 4 lb ft). g00644927
Illustration 44
9. Bend the locking tab over the flat of each bolt
head. 1. Clean the face of air inlet heater (2) with solvent.
Apply 4C-9500 Quick Cure Primer to the face.
The primer must dry for three to five minutes.
20
2. Apply 1U-8846 Sealant to the face of air inlet Installation Procedure

heater (2). The air inlet heater (2) and air inlet
elbows (5) must be installed within ten minutes
of application of the sealant.
3. Install the washers and eight bolts (3).
4. Connect the ground strap to air inlet heater (2)

with nut (4).
5. Connect wire assembly (1) to air inlet heater

(2). Tighten the nut to a torque of 13 1 Nm
(10 1 lb ft).
i01176781
g00629847
Illustration 46
Air Inlet Heater Solenoid -
Remove and Install 1. Position air inlet heater solenoid (3) on the
engine.
SMCS Code: 1090-010-OD
2. Install two bolts (2) in air inlet heater solenoid (3).
Removal Procedure 3. Connect two wires (1) to air inlet heater solenoid
(3).
i01161352
Air Inlet Cover - Remove and

Install
SMCS Code: 1087-010-CH
Removal Procedure
Start By:
g00629847
Illustration 45 a. Remove the air inlet heater. Refer to Disassembly
and Assembly, Air Inlet Heater - Remove and
Note: The air inlet heater solenoid is located just Install.
above the turbocharger on the air inlet manifold.
b. Remove the fuel filter base. Refer to Disassembly
1. Disconnect two wires (1) from air inlet heater and Assembly, Fuel Filter Base - Remove and
solenoid (3). Install.
2. Remove two bolts (2) and remove air inlet heater

solenoid (3) from the engine.
g00618364
Illustration 47
21
1. Disconnect plug (2) for the boost sensor. Start By:
2. Remove four bolts and mounting bracket (1) for a. Remove the cylinder head assembly. Refer to
the fuel filter base. Disassembly and Assembly, Cylinder Head -
Remove.
3. Remove four bolts and air inlet cover (3).
NOTICE
Installation Procedure Keep all parts clean from contaminants.

component life.
Note: For information on the reusability of the inlet

valves, the exhaust valves and the springs, refer
to Guideline For Reusable Parts And Salvage
Operations, SEBF8002, Valves, Valve Springs,
Valve Rotators, and Locks, Guideline For Reusable
Parts And Salvage Operations, SEBF8034, Valve
and Valve Spring Specifications, and Guideline For
Reusable Parts And Salvage Operations, SEBF8162,
Procedure to Measure and Salvage Cylinder Head
Assemblies and Related Components.
g00618364
Illustration 48
1. Inspect the gasket for air inlet cover (3). Replace

the gasket, if necessary.
2. Position air inlet cover (3), mounting bracket (1)

for fuel filter base, and the wiring clip on the
cylinder head. Install eight bolts.
3. Connect plug (2) for the boost sensor.
End By:
a. Install the fuel filter base. Refer to Disassembly

and Assembly, Fuel Filter Base - Remove and
Install.
b. Install the air inlet heater. Refer to Disassembly

Install.
g00653424
Illustration 49
i01488867
Inlet and Exhaust Valves - Note: The following components of the exhaust
valves are different from the components of the inlet
Remove and Install valves: spring retainer (3), valve spring (1), and
valve (5).
SMCS Code: 1105-010
Removal Procedure
Table 8
Required Tools
Part
Number
A 5S-1330 Valve Spring Compressor 1
22
g00676566
Illustration 50
1. Use Tool (A) to compress valve spring (1).

Remove retainer lock (2).
2. Remove Tool (A).

g00653424
Illustration 51
3. Remove spring retainer (3). Remove valve spring
(1).
1. Lubricate valve (5) with clean engine oil. Install
4. Remove valve seal (4) and valve (5). valve (5) in the cylinder head assembly. Install
new valve seal (4) against the valve guide.
5. Repeat Steps 1 through 4 in order to remove the
remaining inlet valves and exhaust valves. 2. Place the following items on the valve stem:
valve spring (1) and spring retainer (3).
Table 9
The valve keepers can be thrown from the valve
Required Tools
when the valve spring compressor is released. En-
Part sure that the valve keepers are properly installed
Number on the valve stem. To help prevent personal injury,
keep away from the front of the valve keepers and
valve springs during the installation of the valves.
NOTICE Note: A small amount of grease can be used to hold

Keep all parts clean from contaminants. the retainer locks in position during installation.
component life.
Note: For information on the reusability of the inlet

valves, the exhaust valves and the springs, refer
Operations, SEBF8002, Valves, Valve Springs,
Valve Rotators, and Locks, Guideline For Reusable
Parts And Salvage Operations, SEBF8034, Valve
and Valve Spring Specifications, and Guideline For
Reusable Parts And Salvage Operations, SEBF8162,
Procedure to Measure and Salvage Cylinder Head
Assemblies and Related Components.
g00676566
Illustration 52
3. Use Tool (A) to compress valve spring (1). Install

retainer lock (2).
23
4. Repeat Steps 1 through 3 in order to install the

remaining inlet valves and exhaust valves.
End By:
a. Install the cylinder head assembly. Refer to

Disassembly and Assembly, Cylinder Head -
Install.
i01496529
Inlet and Exhaust Valve Guides

- Remove and Install
SMCS Code: 1104-010
Removal Procedure
Table 10
Required Tools g00745735
Illustration 53
Part Typical example
Number
A 1U-7793 Valve Guide Driver(1) 1 1. Use Tool (A) to remove the inlet valve guides
(1)
from the cylinder head assembly. Use Tool (A)
Part of 1U-6685 Valve Guide Tool Kit
to remove the exhaust valve guides from the
Start By: cylinder head assembly.
a. Remove the inlet valves and the exhaust valves. Installation Procedure
Refer to Disassembly and Assembly, Inlet and
Exhaust Valves - Remove and Install. Table 11
Required Tools
NOTICE
Part
Keep all parts clean from contaminants. Tool
Number
Part Description Qty
Contaminants may cause rapid wear and shortened A 1U-7793 Valve Guide Driver(1) 1
component life. B 1U-7792 Guide Collar(1) 1
(1) Part of 1U-6685 Valve Guide Tool Kit
Note: For information on the reusability of the valve
guides, refer to Guideline For Reusable Parts And
NOTICE
Salvage Operations, SEBF8218, Specifications
for Cylinder Head Assemblies 3114, 3116, and
3126 Engines and Guideline For Reusable Parts
And Salvage Operations, SEBF8162, Procedure to
component life.
Measure and Salvage Cylinder Head Assemblies
and Related Components.
guides, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8218, Specifications
for Cylinder Head Assemblies 3114, 3116, and
Measure and Salvage Cylinder Head Assemblies
24
4. Use Tool (A) and Tool (B) to install exhaust valve

guide (2). Install the exhaust valve guide until the
protrusion is 23.0 0.5 mm (0.90 0.02 inch)
above the cylinder head assembly.
End By:
a. Install the inlet valves and the exhaust valves.

Exhaust Valves - Remove and Install.
i01414262
Inlet and Exhaust Valve Seat

Inserts - Remove and Install
SMCS Code: 1103-010
Removal Procedure
g00745782 Table 12
Illustration 54
Typical example Required Tools
1. Position inlet valve guide (1) and tap on the top Part
Number
of inlet valve guide (1). This is done in order to
start inlet valve guide (1) into the cylinder head A(1) 6V-4194 Valve Seat Extractor 1
assembly.
B(1) 6V-4193 Valve Seat Extractor 1
2. Use Tool (A) and Tool (B) to install inlet valve C(1) 6V-4804 Handle 1
guide (1). Install inlet valve guides (1) until the
protrusion is 23.0 0.5 mm (0.90 0.02 inch) D(1) 6V-4192 Shaft 1
above the cylinder head assembly. E(1) 6V-4199 Lifting Bracket 1
(1) Part of the 6V-4805 Valve Seat Extractor Tool Group
Start By:
a. Remove the inlet and exhaust valves. Refer to

Disassembly and Assembly, Inlet and Exhaust
Valves - Remove and Install.
NOTICE

component life.

seats, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8218, Specifications for
Cylinder Head Asseblies 3114, 3116, and 3126
Engines.
g00775866
Illustration 55
3. Position exhaust valve guide (2) and tap on the

top of exhaust valve guide (2). This is done in
order to start the exhaust valve guide into the
cylinder head assembly.
25
3. Install Tool (E) on the cylinder head under

Tool (C). Hold Tool (D) while you turn Tool (C).
Remove valve seat (1).
Table 13
Required Tools
Part
Number
Guide and Insert Tool
A 1U-6685 1
Group
g00615519
Illustration 56
NOTICE

component life.

seats, refer to Guideline For Reusable Parts And
Cylinder Head Assemblies 3114, 3116, and 3126
Engines.
1. Cool the valve seat inserts for easier installation.
g00656459
Illustration 57
Note: Replace Tool (A) with Tool (B) for the removal
of the inlet valve seat insert.
1. Install Tool (A) in the exhaust valve seat insert.
2. Install Tool (C) and Tool (D) in Tool (A). Hand

tighten Tool (D). Tool (A) will expand below the
edge of valve seat insert (1).
g00656469
Illustration 59
2. Turn Tool (A) upside-down and use Tool (A) and

a press to install the valve seat inserts in the
3. After the valve seat inserts are installed, grind

the inserts to the final specification. Refer to
Guideline for Reusable Parts and Salvage
Operation, SEBF8218 for the specifications.
g00656462
Illustration 58
26
End By:
a. Install the inlet valves and exhaust valves.

i01156939
Engine Oil Filter Base -

Remove
SMCS Code: 1306-011
Removal Procedure Illustration 60 g00614994
Table 14
1. Remove oil filter assembly (1) with Tool (A).
Required Tools
Part
Number
A 2P-8250 Strap Wrench Assembly 1
NOTICE

component life.
NOTICE
Illustration 61
collect the fluid with suitable containers before open- 2. Disconnect tube (2) from the elbow assembly.
nent containing fluids. 3. Remove the bolts that hold engine oil filter base
(3) to the cylinder block. Remove engine oil filter
Refer to Special Publication, NENG2500, Caterpillar base (3).
suitable to collect and contain fluids on Caterpillar i01522331
products.
mandates.
Disassemble
SMCS Code: 1306-015
Start By:
a. Remove the engine oil filter base. Refer to

Disassembly and Assembly, Engine Oil Filter
Base - Remove.
27
i01522336

Assemble
SMCS Code: 1306-016
Assembly Procedure
g00528968
Illustration 62
1. Remove two plugs (1) and (2) from oil filter base
(3).
g00528969
Illustration 64
1. Install O-ring seals (4) onto plugs (1) and (2).

Install valves(6) and springs (5).
g00528969
Illustration 63
2. Remove springs (5) and valves (6). Remove

O-ring seals (4) from plugs (1) and (2). Inspect
the parts for wear or damage. If the parts
are worn or damaged, use new parts for
replacement.
g00528968
Illustration 65
2. Install two plugs (1) and (2) onto oil filter base (3).
End By:
a. Install the engine oil filter base. Refer to

Base - Install.
28
i01522339 3. Install oil filter assembly (1) with Tool (A). Follow
the instructions with the oil filter assembly for the
Engine Oil Filter Base - Install correct installation.
SMCS Code: 1306-012
i01177007
Installation Procedure Engine Oil Filter Bypass Valve

Table 15 - Remove and Install
Required Tools
SMCS Code: 1308-010-BV
Part
Number
Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
component life.
NOTICE

products.

mandates.
g00614997
Illustration 66
1. Position the gasket and engine oil filter base

(3) over the engine oil cooler. Install the bolts
that hold engine oil filter base (3) to the cylinder
block.
2. Connect tube (2) to engine oil filter base (3).
g00630032
Illustration 68
g00614994
Illustration 67
29
1. Inspect the condition of the O-ring seal. Replace

the seal, if necessary.
2. Install bypass valve (3) and valve spring (2) in

the engine oil filter base.
3. Install plug (1) in the engine oil filter base.
i01176960
Engine Oil Cooler Bypass

Valve - Remove and Install
g00629985
SMCS Code: 1314-010
Illustration 69
1. Remove plug (1) and the O-ring seal from the Removal Procedure
engine oil filter base.
NOTICE
2. Remove valve spring (2) and bypass valve (3) Keep all parts clean from contaminants.
from the engine oil filter base.
component life.
NOTICE NOTICE
Keep all parts clean from contaminants. Care must be taken to ensure that fluids are contained
Contaminants may cause rapid wear and shortened ing, adjusting and repair of the product. Be prepared to
component life. collect the fluid with suitable containers before open-

products.

mandates.
g00630032
Illustration 70
g00629979
Illustration 72
g00629985
Illustration 71
30
g00629985 g00629979
1. Remove plug (1) and the O-ring seal from the 1. Inspect the condition of the O-ring seal. Replace
engine oil cooler. the seal, if necessary.
2. Remove valve spring (2) and bypass valve (3) 2. Install bypass valve (3) and valve spring (2) in
from the engine oil cooler. the engine oil cooler.
Installation Procedure 3. Install plug (1) in the engine oil cooler.
NOTICE i01156915
Engine Oil Cooler - Remove
component life. SMCS Code: 1378-011
Removal Procedure
Start By:

Base - Remove.
g00629985
Illustration 74
31
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 cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
g00614985
Illustration 77
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing 2. Remove O-ring seals (2) from the cylinder block.
burns.
Cooling System Coolant Additive contains alkali. i01156926

Avoid contact with skin and eyes.
Engine Oil Cooler - Install
NOTICE SMCS Code: 1378-012
component life.
NOTICE
NOTICE
Care must be taken to ensure that fluids are contained Contaminants may cause rapid wear and shortened
during performance of inspection, maintenance, test- component life.

products.

mandates.
g00614985
Illustration 78
1. Inspect the condition of O-ring seals (2). Replace

O-ring seals (2), if necessary. Install O-ring seals
(2) in the cylinder block.
g00614981
Illustration 76
1. Remove engine oil cooler (1).

32
NOTICE

products.
g00614981 Dispose of all fluids according to local regulations and

Illustration 79
mandates.
2. Put the gasket and engine oil cooler (1) in the
cylinder block. Note: For information on the reusability of the engine
oil pump, refer to Guideline For Reusable Parts And
End By: Salvage Operations, SEBF8167, Reconditioning
Procedures 3114 and 3116 Engines.
Base - Install.
i01286670
Engine Oil Pump - Remove

SMCS Code: 1304-011
Removal Procedure
Start By:
g00614391
a. Remove the engine oil pan. Refer to Disassembly Illustration 80
and Assembly, Engine Oil Pan - Remove and
Install. 1. Remove two bolts (1) and bolt (2).
NOTICE 2. Remove the engine oil pump.

3. Remove the O-ring seal that is located between
Contaminants may cause rapid wear and shortened the cylinder block and the outlet elbow.
component life.
33
i01286652
Engine Oil Pump - Disassemble

SMCS Code: 1304-015
Table 16
Required Tools
Part
Number
5P-7311 Chain Puller 1
g00614664
A 7S-7786 Puller Leg 2 Illustration 81
5F-7345 Screw 1 1. Remove the two bolts, oil pickup tube (2), and
the gasket from the engine oil pump. Remove
Start By: one bolt and outlet elbow (1) from the engine
oil pump.
a. Remove the engine oil pump. Refer to
Disassembly and Assembly, Engine Oil Pump -
Remove.
NOTICE

component life.
NOTICE
ing, adjusting and repair of the product. Be prepared to g00614677
collect the fluid with suitable containers before open- Illustration 82
nent containing fluids. 2. Remove bolt (3), washer (4), and idler gear (5)
from the engine oil pump.
products.

mandates.
Note: For information on the reusability of the engine

Salvage Operations, SEBF8167, Reconditioning
g00614683
Illustration 83
3. Remove the bearing from idler gear (5) with Tool

(A).
4. Remove shaft (6) of engine oil pump from oil

pump body assembly (7).
34
5. Use Tool (A) to remove drive gear (8).
g00614696
Illustration 86
g00614689
Illustration 84
8. Remove the following items from oil pump body
6. Remove four bolts (10). Separate oil pump body assembly (7): bolt and washer, spring (14), and
(9) from oil pump body assembly (7). oil pressure relief plunger (13)
i01286632
Engine Oil Pump - Assemble

SMCS Code: 1304-016
Assembly Procedure
NOTICE

component life.
g00614694
Illustration 85
Note: For information on the reusability of the engine

NOTICE
Before removing the drive shaft from the pump hous-
Salvage Operations, SEBF8167, Reconditioning
ing, be sure that no burrs exist on the drive shaft. If
the drive shaft has burrs on it, the bores in the pump
housing may be scratched.
1. Ensure that all of the parts of the engine oil pump
are thoroughly clean prior to assembly.
7. Remove shaft assembly (11) and shaft assembly
(12) from oil pump body (9). Note: Lubricate all internal parts of the engine oil
pump with clean engine oil.
35
g00614696 g00614683
2. Install oil pressure relief plunger (13) and spring 6. Press drive gear (8) on shaft assembly (11)
(14) in oil pump body assembly (7). Install the until drive gear (8) is flush with the end of shaft
washer and the bolt. assembly (11).
7. Install oil pump shaft (6). Install the bearing

in idler gear (5). Install the bearing so the
distance between the hub bolt face of idler
gear (5) and the bearing is 0.75 0.25 mm
(0.030 0.010 inch).
g00614694
Illustration 88
g00614677
Illustration 91
8. Install idler gear (5) on oil pump shaft (6). Install

washer (4) and bolt (3). Tighten bolt (3) to
70 15 Nm (52 11 lb ft).
g00614689
Illustration 89
3. Install shaft assembly (12) in oil pump body (9).
5. Position oil pump body (9) on oil pump body

assembly (7) and install bolts (10).
g00614664
Illustration 92
36
9. Check the condition of the gasket that is used in End By:

oil pickup tube (2). If the gasket is damaged,
replace the gasket. Install the gasket and oil a. Install the engine oil pan. Refer to Disassembly
pickup tube (2). and Assembly, Engine Oil Pan - Remove and
Install.
10. Check the condition of the O-ring seal that is
used in outlet elbow (1). If the O-ring seal is
i01155966
damaged, replace the O-ring seal. Install the
O-ring seal and outlet elbow (1). Water Pump - Remove
End By: SMCS Code: 1361-011
a. Install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install. Removal Procedure
Start By:
i01156435
a. Remove the belt tensioner. Refer to Disassembly
Engine Oil Pump - Install and Assembly, Belt Tensioner - Remove and
Install.
SMCS Code: 1304-012
NOTICE and alkali.
Contaminants may cause rapid wear and shortened and under pressure. The radiator and all lines
component life. to heaters or the engine contain hot coolant or
Note: Ensure that the mounting surfaces for the
engine oil pump are thoroughly clean. Remove cooling system pressure cap slowly to
1. Inspect the condition of the O-ring seal. Replace cooling system pressure cap is cool enough to
the seal, if necessary. touch with your bare hand.
2. Install the O-ring seal. Position the engine oil Do not attempt to tighten hose connections when
pump on the cylinder block. the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

NOTICE

component life.
g00614391
Illustration 93
3. Install two bolts (1) and bolt (2).

37
i01156239
NOTICE
Care must be taken to ensure that fluids are contained Water Pump - Disassemble
SMCS Code: 1361-015
ing any compartment or disassembling any compo- Disassembly Procedure
Table 17
Refer to Special Publication, NENG2500, Caterpillar Required Tools
suitable to collect and contain fluids on Caterpillar Part
products. Number
A 1P-0510 Driver Group 1
mandates. B 1P-0520 Driver Group 1
1. Drain the coolant from the cooling system into a Start By:
suitable container for storage or disposal.
a. Remove the water pump. Refer to Disassembly
and Assembly, Water Pump - Remove.
NOTICE

g00614170
products.
Illustration 94
2. Remove water pump V-belt (1). mandates.
3. Loosen hose clamps (4) and remove hose (3).
4. Disconnect hose (2) from the water pump elbow.
g00614231
Illustration 96
1. Remove two O-ring seals (1) from the rear cover

g00614173 of the water pump. Remove four bolts (2) and the
Illustration 95
washers. Remove the rear cover and the gasket.
5. Remove four bolts (6) that hold water pump (5) to
the front of the engine. Remove water pump (5).
6. Remove the O-ring seals from water pump (5),

if necessary.
38
5. Remove seal (5) from the water pump housing

with the handle from Tool (B) and a press.
g00614234
Illustration 97
2. Position the water pump in a press. Use spacer Illustration 100

g00614261
plates to level the water pump.
6. Remove the shaft and the bearing from pulley
3. Push the shaft and pulley (3) out of impeller (4) (3) with a press.
with a suitable drive plate from Tool (A) and a
press. Remove the impeller.
i01275986
Water Pump - Assemble

SMCS Code: 1361-016
Assembly Procedure
Table 18
Required Tools
Part
Number
A 5P-9722 Seal Driver 1
g00614238
Illustration 98
NOTICE
Note: Do not allow the shaft and the pulley to fall to Keep all parts clean from contaminants.
the floor when the shaft and the pulley are removed.
4. Continue to push the shaft and pulley (3) out of component life.
seal (5) and the water pump housing.
g00614283
g00614253 Illustration 101
Illustration 99
39
1. Install the shaft and the bearing into pulley (3) 4. Install impeller (4) on the shaft of the water
with a press. Install the shaft until the shaft is pump with a press. Install the impeller until the
flush with the end of pulley (3). distance between the impeller and the machined
surface of the water pump is 0.75 0.25 mm
2. Press the shaft, the bearing, and pulley (3) as a (0.030 0.010 inch).
unit into the water pump housing. The distance
between the front of pulley (3) and the machined
surface of the water pump housing must be
103.8 0.3 mm (4.09 0.01 inch).
Note: For information on the reusability of pulley

(3), refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8046, Cast Iron and
Steel Pulleys.
g00614231
Illustration 104
5. Install a new gasket between the rear cover of

the water pump and the water pump housing.
Position the gasket and the cover on the water
pump housing. Install four bolts (2) and the
washers.
6. Install two new O-ring seals (1) in the rear cover.

g00614294
Illustration 102
End By:
3. Install seal (5) in the water pump housing with
Tool (A). a. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install.
i01156113
Water Pump - Install

SMCS Code: 1361-012
NOTICE

component life.
g00614288
Illustration 103
40
5. Connect hose (3) to water pump (5) and to the

water temperature regulator housing. Install two
clamps (4).
6. Install hose (2) to the water pump elbow.
7. Install V-belt (1) and adjust V-belt (1). Refer to

the Specifications Module, Belt Tension Chart.
8. Fill the cooling system with coolant to the correct

level. Refer to the Operation and Maintenance
Manual for the correct filling procedure.
End By:
g00614182
Illustration 105 a. Install the belt tensioner. Refer to Disassembly
and Assembly, Belt Tensioner - Remove and
1. Clean surface (7). Install.
2. Inspect the condition of the O-ring seals. Replace
the seals, if necessary. i01162614
Water Temperature Regulator

Housing - Remove and Install
SMCS Code: 1393-010
Removal Procedure

and alkali.

g00614173
Illustration 106 and under pressure. The radiator and all lines
3. Install the O-ring seal on water pump (5). steam. Any contact can cause severe burns.
4. Position water pump (5) on the front of the Remove cooling system pressure cap slowly to
engine. Install four bolts (6). relieve pressure only when engine is stopped and

the coolant is hot, the hose can come off causing
burns.

NOTICE

g00614170
Illustration 107 component life.
41
NOTICE

products.
Dispose of all fluids according to local regulations and g00619513

Illustration 109
mandates.
1. Position a new gasket and water temperature
1. Drain the coolant from the cooling system into a regulator housing (2) on the cylinder block.
2. Install three bolts (1).

i01181083
Water Temperature Regulator -

Remove and Install
SMCS Code: 1355-010
Illustration 108
g00619513 Removal Procedure
2. Remove three bolts (1) from water temperature
regulator housing (2).
3. Remove water temperature regulator housing and alkali.
(2). Remove the gasket from water temperature
regulator housing (2). At operating temperature, engine coolant is hot
Installation Procedure steam. Any contact can cause severe burns.
NOTICE Remove cooling system pressure cap slowly to
Keep all parts clean from contaminants. relieve pressure only when engine is stopped and
Contaminants may cause rapid wear and shortened touch with your bare hand.
component life.
burns.

42
3. Remove water temperature regulators (4) from

NOTICE water temperature regulator housing (3). Remove
Keep all parts clean from contaminants. the gasket from water temperature regulator
housing (3).
component life. Installation Procedure
NOTICE NOTICE

products.

mandates.
1. Drain the coolant from the cooling system into a

g00613961
Illustration 112
1. Place water temperature regulators (4) in water

temperature regulator housing (3).
g00613949
Illustration 110
2. Remove bolts (1) and pipe (2) from water

g00613949
Illustration 113
2. Install a new gasket and pipe (2) in water

3. Install bolts (1).

g00613961
Illustration 111
43
i01181076 3. In order to install the front engine lifting bracket,

refer to Disassembly and Assembly, Fan Drive -
Engine Lifting Bracket - Install.
Remove and Install
i01180175
SMCS Code: 1122-010
Engine Support (Front) -
Removal Procedure Remove and Install
Start By: SMCS Code: 1154-010-FR
a. Remove the fan drive in order to remove the front
engine lifting bracket. Refer to Disassembly and Removal Procedure
Assembly, Fan Drive - Remove.
g00631943
Illustration 116
g00632253
Illustration 114
1. Attach a suitable lifting device to the engine and
slightly lift the engine.
1. Remove four bolts (4) and the washers from rear
engine lifting bracket (5).
2. Remove six bolts (1) and the washers from
engine support (2).
2. Remove rear engine lifting bracket (5) from the
engine.
3. Remove engine support (2) from the engine.
Installation Procedure Installation Procedure
g00632253
Illustration 115 g00631943
Illustration 117
1. Position rear engine lifting bracket (5) on the

1. Clean the surface of the engine and the surface
engine.
of engine support (2).
2. Install the washers and four bolts (4) that hold
2. Position engine support (2) on the engine and
rear engine lifting bracket (5).
install six bolts (1).
44
i01286611 i01286597
Flywheel - Remove Flywheel - Install

SMCS Code: 1156-011 SMCS Code: 1156-012
Removal Procedure Installation Procedure

Table 19 Table 20
Required Tools Required Tools
Part Part
Tool Part Description Qty Tool Part Description Qty
Number Number
A 138-7573 Link Bracket 2 A 138-7573 Link Bracket 2
Note: For information on the reusability of the Note: For information on the reusability of the
flywheel on 3116 engines, refer to Guideline For flywheel on 3116 engines, refer to Guideline For
Reusable Parts And Salvage Operations, SEBF8207, Reusable Parts And Salvage Operations, SEBF8207,
Flywheel Specifications for 3116 Engines. Flywheel Specifications for 3116 Engines.
1. Support the engine with blocks or a suitable Note: Drill and tap the new flywheel ring gear if the
lifting device. outer bolt holes of the flywheel are used . Use the
flywheel as a template and drill twelve holes to a
2. Install Tool (A) on the flywheel. Fasten a suitable diameter of 8.2 mm (0.32 inch). Thread the holes
lifting device to the flywheel. with a tap.
1. Heat the flywheel ring gear to a maximum

temperature of 204 C (400 F). Do not use a
torch to heat the flywheel ring gear. Install the
flywheel ring gear on the flywheel. Position the
flywheel ring gear with the part number toward
the crankshaft. Allow the flywheel ring gear to
cool. Use a soft hammer in order to seat the
flywheel ring gear against the shoulder of the
flywheel.
g00613482
Illustration 118
3. Remove top bolt (1) and the washers. Install a

guide bolt that is longer than top bolt (1). Remove
seven remaining bolts (1) and the washers.
4. Remove flywheel (2) from the guide bolt. The

weight of flywheel (2) is 23 kg (50 lb).
5. Inspect the flywheel ring gear. Replace the ring

g00613482
gear, if necessary. Place the flywheel on a wood Illustration 119
block. Use a hammer and a punch in order to
remove the flywheel ring gear. 2. Install Tool (A) on flywheel (2). Fasten a suitable
lifting device to flywheel (2).
3. Place flywheel (2) in the original position on the

guide bolt. Align the arrows on flywheel (2) and
the crankshaft.
45
4. Apply 9S-3263 Thread Lock Compound to the

threads of eight bolts (1).
5. Install seven bolts (1) and the washers. Remove

the guide bolt and install remaining bolt (1) and
the washer. Tighten the bolts evenly to a torque
of 120 20 Nm (90 15 lb ft).
6. Check the flywheel runout. Refer to Testing

and Adjusting, Basic Block for the correct
procedure.
i01406721
Crankshaft Rear Seal - Remove Illustration 120 g00613243
SMCS Code: 1161-011 Note: Do not damage the flange on the crankshaft
when the crankshaft rear seal is removed.
Removal Procedure
Note: Tool (B) is equipped with three screw tips. Use
Table 21 the screw tips with Tool (B) to remove crankshaft
Required Tools rear seal (1).
Part 2. Carefully remove crankshaft rear seal (1) by

Tool Number Part Description Qty alternating the position of Tool (B) from hole to
A 1U-8145 Drill Bit 1 hole. This will allow crankshaft rear seal (1) to
be removed evenly without damage to the rear
B 1U-7600 Slide Hammer Puller 1 flange surface of the crankshaft.
Start By: Note: New engines from the factory do not have
a wear sleeve. Engines with seals that have been
a. Remove the flywheel. Refer to Disassembly and replaced will be equipped with a wear sleeve. If
Assembly, Flywheel - Remove. the crankshaft of the engine is equipped with a
wear sleeve, refer to Disassembly and Assembly,
Crankshaft Wear Sleeve (Rear) - Remove in order
NOTICE to remove the wear sleeve.
Contaminants may cause rapid wear and shortened i01509332

component life.
Crankshaft Rear Seal - Install
during performance of inspection, maintenance, test- Installation Procedure
collect the fluid with suitable containers before open- Table 22
Required Tools
Part
Refer to Special Publication, NENG2500, Caterpillar Tool Number Part Description Qty
A(1) 132-8772 Seal Locator 1
products. B(1) 1U-7596 Bolt 2
C(1) 1U-7597 Sleeve Ring 1
mandates. D(1) 1U-7594 Seal Installer 1
E(1) 9S-8858 Nut 1
1. Use Tool (A) to drill three evenly spaced holes in (1) Part of the 1U-7598 Seal Installer
the crankshaft rear seal.
46
NOTICE

component life.
Note: Replacement rear seals are supplied with a

wear sleeve. This wear sleeve must be installed
with the rear seal. New engines from the factory do
not have a wear sleeve. Do not install the rear seal
if any of the following conditions exist:
The crankshaft rear seal has been separated g00614109

from the wear sleeve. Illustration 122
Typical example
The rear seal group appears to be damaged.
4. Position Tool (D) over Tool (A) and Tool (C).
The crankshaft rear seal has been lubricated. The Install Tool (E). Tighten Tool (E) in order to install
seal is designed to be installed dry. the crankshaft rear seal and the crankshaft wear
sleeve.
1. Ensure that the rear of the crankshaft is
thoroughly clean and dry prior to the installation 5. Remove Tool (E), Tool (D), and Tool (C). Turn
of the crankshaft rear seal. over Tool (C). Install Tool (C), Tool (D), and Tool
(E). Tighten Tool (E) in order to complete the
installation of the crankshaft rear seal and the
crankshaft wear sleeve.
6. Remove Tool (E) and Tool (D). Check Tool (C)

and Tool (A). The faces of Tool (C) and Tool (A)
will be flush if the crankshaft rear seal and the
crankshaft wear sleeve are properly installed.
Refer to the Specifications Module for more
information.
7. Remove Tool (C), Tool (B), and Tool (A).
End By:
g00613561
Illustration 121 a. Install the flywheel. Refer to Disassembly and
Assembly, Flywheel - Install.
2. Fasten Tool (A) to the rear of the crankshaft with
Tool (B). Hand tighten Tool (B).
i01216259
3. Position the crankshaft rear seal and crankshaft
rear sleeve (1) on Tool (A). Position Tool (C) on Crankshaft Rear Seal Carrier -
Tool (A). Remove and Install
SMCS Code: 1161-010-C3
Removal Procedure
Start By:
a. Remove the flywheel housing. Refer to

Disassembly and Assembly, Flywheel Housing
- Remove and Install.
47
2. Apply 4C-9500 Quick Cure Primer to the joint

NOTICE face of crankshaft rear seal carrier (3). Allow the
Keep all parts clean from contaminants. primer to air dry for three to five minutes.
Contaminants may cause rapid wear and shortened Note: 1U-8846 Sealant is used on the joint face of
component life. the crankshaft rear seal carrier. Do not allow the
sealant to get into the oil passage in the mounting
face of the cylinder block.
3. Apply 1U-8846 Sealant to the joint face of

crankshaft rear seal carrier (3). Spread the
sealant uniformly. Crankshaft rear seal carrier
(3) must be installed within ten minutes of
application of the sealant.
4. Position crankshaft rear seal carrier (3) on the

dowels in the rear of the cylinder block. Use a
soft faced hammer to position crankshaft rear
seal carrier (3) against the cylinder block, if
necessary.
g00613081
Illustration 123
1. Remove bolts (2) for the engine oil pan and

carefully lower the engine oil pan away from the
cylinder block.
2. Remove eight bolts (1) and the washers that hold

the crankshaft rear seal carrier to the cylinder
block.
3. Carefully pry the crankshaft rear seal carrier off

of the two dowels in the cylinder block.
Installation Procedure Illustration 125

g00613081
NOTICE 5. Apply 9S-3263 Thread Lock Compound on the

Keep all parts clean from contaminants. threads of eight bolts (1). Install eight bolts (1)
that hold the crankshaft rear seal carrier (3) to
Contaminants may cause rapid wear and shortened the cylinder block.
component life.
6. Install a new gasket on the engine oil pan. Install
the engine oil pan on the cylinder block. Install
bolts (2).
End By:
a. Install the flywheel housing. Refer to Disassembly

and Assembly, Flywheel Housing - Remove and
Install.
g00613107
Illustration 124
1. Clean the joint face of crankshaft rear seal

carrier (3) and cylinder block (4) with 8T-9011
Component Cleaner.
48
i01406916 1. Fasten Tool (A) and a hoist to flywheel housing

(1).
Flywheel Housing - Remove
and Install 2. Remove twelve bolts (2) and bolt (3) that fastens
the flywheel housing to the cylinder block.
SMCS Code: 1157-010
3. Remove flywheel housing (1). The weight of
flywheel housing (1) is approximately 32 kg
Removal Procedure (70 lb).
Table 23
Required Tools
Part Table 24
Tool Number Part Description Qty Required Tools
A 138-7573 Link Bracket 2 Part
Tool Number Part Description Qty
Start By: A 138-7573 Link Bracket 2
a. Remove the flywheel. Refer to Disassembly and

Assembly, Flywheel - Remove. NOTICE
NOTICE
component life.
component life.
NOTICE

products.

mandates.
g00740507
Illustration 127
Correct installation of O-ring seal (3). Do not install the O-ring seal
in location (4).
Note: On wet flywheel housings that have rear seal

carriers, ensure that the 8C-3091 O-Ring Seal is
installed properly. Improper installation will result in
leakage of torque converter oil between the flywheel
housing and the cylinder block.
Note: Ensure that the mating surface of the flywheel

housing and the mounting face of the cylinder block
g00650171 are thoroughly clean.
Illustration 126
49
1. Apply 1U-8846 Sealant to the entire mounting

face of the flywheel housing prior to installation. NOTICE

products.

mandates.
g00650171
Illustration 128
2. Fasten Tool (A) and a hoist to flywheel housing

(1). Position flywheel housing (1) on the cylinder
block. The weight of flywheel housing (1) is
approximately 32 kg (70 lb).
3. Install twelve bolts (2) and one bolt (3) that

fastens the flywheel housing to the cylinder
block. Refer to the Specification, Flywheel
Housing for the torque specification.
4. Remove Tool (A) and the hoist from flywheel

housing (1).
g00691836
Illustration 129
5. Check the flywheel housing runout. Refer to
the Systems Operation/Testing and Adjusting, 1. Remove eight bolts (2), crankshaft vibration
Flywheel and Flywheel Housing. damper (3), and two spacers from the crankshaft
pulley.
End By:
Note: For information on the reusability of the
a. Install the flywheel. Refer to Disassembly and vibration damper on 3114 and 3116 engines, refer
Assembly, Flywheel - Install. to Guideline For Reusable Parts And Salvage
Operations, SEBF8220, Specifications for Damper
i01309362 Inspection 3114 and 3116 Engines.
Vibration Damper and Pulley - 2. Loosen the tension on water pump drive belt (1).
Remove the belt from the crankshaft pulley.
Remove and Install
SMCS Code: 1205-010
Removal Procedure
NOTICE

component life.
g00691831
Illustration 130
3. Remove four bolts (4) and the washers.

50
4. Remove crankshaft pulley (5). Note: Check the alignment marks on the rubber
vibration dampers for proper alignment. The rubber
Note: For information on the reusability of the vibration damper should be replaced if the rubber
crankshaft pulley, refer to Guideline For Reusable vibration damper is out of alignment. Refer to
Parts And Salvage Operations, SEBF8046, Cast Specifications, Vibration Damper.
Iron and Steel Pulleys.
3. Install two spacers and crankshaft vibration
damper (1). Tighten eight bolts (2) to a torque of
Installation Procedure 55 10 Nm (40 7 lb ft).
NOTICE Note: For information on the reusability of the
Keep all parts clean from contaminants. vibration damper on 3114 and 3116 engines, refer
Contaminants may cause rapid wear and shortened Operations, SEBF8220, Specifications for Damper
component life. Inspection 3114 and 3116 Engines.
4. Adjust the tension of water pump drive belt

(3). Refer to the Specifications Module, Belt
Tension Chart. Also, refer to the Operation and
Maintenance Manual, Belt - Inspect.
i01153831
Crankshaft Front Seal -

Remove
SMCS Code: 1160-011
g00691831 Removal Procedure

Illustration 131
Table 25
1. Position crankshaft pulley (5) on the crankshaft.
Required Tools
Install four bolts (4) and tighten the bolts to a
torque of 160 30 Nm (118 22 lb ft). Part
A 1U-7600 Slide Hammer Puller 1
crankshaft pulley, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8046, Cast B 1U-8145 Drill Bit 1
Iron and Steel Pulleys.
Start By:
a. Remove the vibration damper and the pulley.

Refer to Disassembly and Assembly, Vibration
Damper and Pulley - Remove and Install.
NOTICE

component life.
g00691836
Illustration 132
2. Install water pump drive belt (3).

51
g00612597 g00612634
Note: Do not damage the flange of the crankshaft

during the removal of the seal.
1. Use Tool (B) and carefully drill three evenly

spaced holes in crankshaft front seal (1).
2. Alternate between the drilled holes and use Tool

(A) to remove crankshaft front seal (1).
i01153847
Crankshaft Front Seal - Install

SMCS Code: 1160-012 Illustration 135 g00612636
Installation Procedure Note: Refer to the Specifications Module,

Crankshaft Seals for information on the distance
Table 26 between the following items: the front face of the
Required Tools crankshaft front seal and the front face of the front
housing.
Part
Tool Number Part Description Qty 1. Position installation sleeve (2). Use Tool (A) to
A 1U-7430 Front Seal Installer 1 install crankshaft front seal (1).
Note: The crankshaft seal is designed to be installed

NOTICE dry.
2. Remove installation sleeve (2) from the crankshaft
Contaminants may cause rapid wear and shortened front seal. Ensure that the seal surface of the
component life. crankshaft pulley is thoroughly clean and dry.
Ensure that the seal surface of the crankshaft
pulley is in good condition.
Note: Ensure that the flange of the crankshaft and
the front housing are thoroughly clean before you
End By:
install the crankshaft front seal.
a. Install the vibration damper and the pulley.
52
i01176651
Front Cover - Remove

SMCS Code: 1166-011
Removal Procedure
g00746413
Illustration 137
1. Install a new gasket (3) on the front cover (2).
g00629709
Illustration 136
Note: It is not necessary to remove the vibration

damper and the crankshaft pulley in order to
remove the front cover.
1. Remove bolts (1) from front cover (2).
2. Remove front cover (2) and the gasket from the

front of the engine.
g00629709
Illustration 138
i01423951
2. Install the gasket and front cover (2) on the front
Front Cover - Install of the engine.
SMCS Code: 1166-012 3. Install bolts (1) in front cover (2).
NOTICE

component life.
53
i01494480 3. Identify the type of idler gear on the engine.

Remove three bolts (1) that hold the idler gear
Gear Group (Front) - Remove to the block.
SMCS Code: 1206-011 4. Remove idler shaft (3) and camshaft idler gear
(2). Separate idler gear (2) from idler shaft
Removal Procedure (3) and remove the sleeve bearing from the
camshaft idler gear.
Table 27
Required Tools
5. Use Tool (A) and a press to remove the bearing.
Tool Part Part Description Qty

Number i01496449
A 1P-0520 Driver Group 1 Gear Group (Front) - Install

Start By: SMCS Code: 1206-012
a. Remove the crankshaft vibration damper. Refer to Installation Procedure

Disassembly and Assembly, Vibration Damper
and Pulley - Remove and Install. Table 28
Required Tools
b. Remove the crankshaft front seal. Refer to
Disassembly and Assembly, Crankshaft Front Part Part Description Qty
Tools
Seal - Remove. Number
c. Remove the camshaft. Refer to Disassembly and
Assembly, Camshaft - Remove.
Note: For information on reusability of the camshaft
d. Remove the front housing. Refer to Disassembly idler gear, refer to Guideline For Reusable Parts
and Assembly, Housing (Front) - Remove. And Salvage Operations, SEBF8045, Timing Gears
for All Engines.
idler gear, refer to Guideline For Reusable Parts
And Salvage Operations, SEBF8045, Timing Gears
for All Engines.
1. Place the engine at the Top Center position. The

timing marks should be in line with the crankshaft
gear.
g00677884
Illustration 139
2. Identify the location of timing marks (4) and (5)

on the camshaft idler gear. Identify the location
of timing mark (6) on the crankshaft drive gear.
54
g00643979
Illustration 140
Type 1
1. Use Tool (A) and a suitable press to install the

sleeve bearing in the camshaft idler gear.
2. Install the bearing sleeve to a depth of

0.40 0.25 mm (0.016 0.010 inch) below the
front face of the gear.
3. Place the idler shaft (3) on the cylinder block.

Install three bolts (1) that hold the idler shaft to
the cylinder block. Tighten the bolts to a torque
of 70 15 Nm (51 11 lb ft).
4. Install camshaft idler gear (2) on idler shaft (3).

The timing marks should face outward.
5. Align the timing marks on camshaft idler gear

(2) with the timing marks on the crankshaft drive
gear.
55
g00644057
Illustration 141
Type 2
1. Use Tool (A) and a suitable press and install the

sleeve bearing in the camshaft idler gear.
2. Install plate (4) on the back of idler shaft (3).

Position idler gear assembly on the cylinder
block. Install the three bolts that hold the idler
gear to the engine block. Tighten the bolts to a
torque of 70 15 Nm (51 11 lb ft).

The timing marks should face outward.
4. Align the timing marks on camshaft idler gear

(2) with the timing marks on the crankshaft drive
gear.
56
g00644128
Illustration 142
Type 3
1. Position idler shaft (3) on the cylinder block. End By:

Install the shortest bolt in the recessed hole in
idler shaft (3). This bolt will hold the shaft in a. Install the front housing. Refer to Disassembly
position on the cylinder block. and Assembly, Housing (Front) - Install.
2. Install camshaft idler gear (2) on idler shaft (3). b. Install the camshaft. Refer to Disassembly and
The timing marks should face outward. Assembly, Camshaft - Install.
3. Align the timing marks on idler gear (2) with the c. Install the crankshaft front seal. Refer to
timing marks on the camshaft drive gear. Disassembly and Assembly, Crankshaft Front
Seal - Install.
4. Position plate (4) over the gear and install the
remaining bolts (1). Tighten three bolts (1) to a d. Install the crankshaft vibration damper and
torque of 70 15 Nm (51 11 lb ft). pulley. Refer to Disassembly and Assembly,
Vibration Damper and Pulley -Remove and
Install.
57
i01305434
Housing (Front) - Remove

SMCS Code: 1151-011
Removal Procedure
Start By:
a. Remove the crankshaft vibration damper. Refer to

and Pulley - Remove and Install.

Disassembly and Assembly, Crankshaft Front
Seal - Remove.

g00691386
NOTICE Illustration 144
during performance of inspection, maintenance, test- 4. Remove 18 bolts (3) that fasten front housing (4)
ing, adjusting and repair of the product. Be prepared to to the cylinder block and to the engine oil pan.
collect the fluid with suitable containers before open- Remove front housing (4). Clean the sealant from
ing any compartment or disassembling any compo- front housing (4) and the cylinder block.
i01305311
Tools and Shop Products Guide for tools and supplies Housing (Front) - Install
products. SMCS Code: 1151-012

mandates.
1. Remove any external components, if equipped.
g00691429
Illustration 143
2. Remove five bolts (1) and remove front engine

support. g00691386
Illustration 145
3. Remove two bolts (2) and belt tightener (5).

1. Clean the joint face on front housing (4 ) with
8T-9011 Component Cleaner.
58
2. Apply 4C-9500 Quick Cure Primer to the joint i01158735

face. Allow the primer to dry for at least three to
five minutes. Camshaft Idler Gear - Remove
Note: Do not allow the 1U-8846 Sealant to seal the
and Install
main oil passage on front housing (4). SMCS Code: 1206-010
3. Apply 1U-8846 Sealant to the joint face. Spread
the sealant uniformly. The front housing must Removal Procedure
be installed within ten minutes of applying the
Table 29
sealant.
Required Tools
4. Position the front housing on the cylinder block.
Part
Number
5. Install bolts (3) that fasten the front housing to
the cylinder block and the engine oil pan. A 1P-0520 Driver Group 1
Start By:
a. Remove the front housing. Refer to Disassembly

and Assembly, Housing (Front) - Remove.
NOTICE

component life.
NOTICE
Illustration 146
g00691429 Care must be taken to ensure that fluids are contained
6. Position belt tightener (5) and install two bolts (2). ing, adjusting and repair of the product. Be prepared to
7. Position the front engine support and install five ing any compartment or disassembling any compo-
bolts (1). nent containing fluids.
8. Install any external components, if equipped. Refer to Special Publication, NENG2500, Caterpillar
End By: suitable to collect and contain fluids on Caterpillar
products.
a. Install the camshaft. Refer to Disassembly and
Assembly, Camshaft - Install. Dispose of all fluids according to local regulations and
mandates.
b. Install the crankshaft front seal. Refer to
Seal - Install.
c. Install the crankshaft vibration damper. Refer to

59
g00616240
Illustration 149
5. Use Tool (A) and a press to remove the bearing

from camshaft idler gear (2).
g00616185
Illustration 147
Table 30
1. Rotate the crankshaft until the number one piston Required Tools
is at the top center position. Timing mark (4)
for camshaft idler gear (2) should be in line Part
Number
with timing mark (5) for crankshaft drive gear
(6). Identify the location of timing mark (4) for A 1P-0520 Driver Group 1
camshaft idler gear (2) and timing mark (5) for
crankshaft drive gear (6).
NOTICE
2. Remove the two bolts that fasten plate (1) to idler Keep all parts clean from contaminants.
shaft (3). Remove plate (1).
component life.
g00616226
Illustration 148
3. Slide camshaft idler gear (2) from idler shaft (3). g00616240
Illustration 150
4. Remove the bolt and idler shaft (3) from the 1. Use Tool (A) and a press to install the
cylinder block. bearing in camshaft idler gear (2). Install the
bearing until the bearing is 0.40 0.25 mm
(0.016 0.010 inch) below the front face of
camshaft idler gear (2).
60
i01152168
Valve Mechanism Cover -

Remove and Install
SMCS Code: 1107-010
Removal Procedure
NOTICE

g00616246
component life.
Illustration 151
2. Ensure that oil supply passages (7) in the NOTICE

cylinder block and idler shaft (3) are free of Care must be taken to ensure that fluids are contained
contaminants. Position idler shaft (3) on the during performance of inspection, maintenance, test-
cylinder block. Install the bolt that holds idler ing, adjusting and repair of the product. Be prepared to
shaft (3) to the cylinder block. Tighten the bolt to collect the fluid with suitable containers before open-
a torque of 70 15 Nm (51 11 lb ft). ing any compartment or disassembling any compo-

products.

mandates.
g00616185
Illustration 152
3. Install camshaft idler gear (2) on idler shaft (3). g00611536

Ensure that timing mark (4) for camshaft idler Illustration 153
gear (2) is facing outward. Align the identified
timing mark (4) for camshaft idler gear (2) with 1. Remove breather assembly (2) from valve
the identified timing mark (5) for crankshaft drive mechanism cover (1).
gear (6).
2. Remove the bolts that hold valve mechanism
4. Position plate (1) and install two bolts. Tighten the cover (1) to valve mechanism cover base (3).
bolts to a torque of 70 15 Nm (51 11 lb ft).
3. Remove the seal from the valve mechanism
End By: cover.
a. Install the front housing. Refer to Disassembly

and Assembly, Housing (Front) - Install.
61
Installation Procedure i01152050
NOTICE
Rocker Shaft and Pushrod -
Keep all parts clean from contaminants. Remove
Contaminants may cause rapid wear and shortened SMCS Code: 1102-011; 1208-011
component life.
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to

Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
NOTICE

component life.
g00611536
Illustration 154 NOTICE

products.

mandates.
g00611545
Illustration 155
Bolt tightening sequence for the valve mechanism cover 1. Put identification marks on each rocker arm in
order to identify the proper location in the engine
(A) Rear
(B) Front for installation.
1. Position valve mechanism cover (1) and the seal

on valve mechanism cover base (3). Cut the seal
to length. Apply 4C-9612 Silicone Sealant on
both sides of the seal joint.
2. Install the bolts. Tighten the bolts in a numerical

sequence to a torque of 9 Nm (80 lb in).
Note: Inspect the O-ring seal of the breather

assembly. Replace the O-ring seal, if necessary.
3. Position breather assembly (2) on valve

mechanism cover (1). Tighten the bolt for
breather assembly (2) to a torque of 7 2 Nm g00611428
Illustration 156
(62 18 lb in).
2. Loosen all rocker arm adjustment screws (4) in
order to release the tension on the rocker shaft.
62
3. Remove two bolts (1), eleven bolts (2), and

rocker shaft (3).
g00744197
Illustration 158
Illustration 157
g00611430 1. Remove support bracket (1) from rocker shaft
assembly (4).
4. Remove inlet valve bridges (5) and pushrods (6).
2. Remove valve rocker arms (2) and unit injector
rocker arm (3) from rocker shaft assembly (4).
i01415176
Note: Do not force the rocker arms from the
Rocker Shaft - Disassemble rocker shaft assembly. If necessary, use a piece of
6V-0083 Emery Polishing Paper to lightly buff the
SMCS Code: 1102-015 surface of the shaft to aid in removal .
Disassembly Procedure 3. Check the adjustment screws on valve rocker

arms (2) and unit injector rocker arm (3) for
Start By: damage.
a. Remove the rocker shaft and the pushrods. Refer 4. Inspect rocker shaft assembly (4) for scratches
to Disassembly and Assembly, Rocker Shaft and cracks.
and Pushrod - Remove.
NOTICE

component life.
Note: For information on reusability of components

of the rocker shaft, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8267, Rocker
Arms and Rocker Arm Shafts for 3114 and 3116
Engines.
g00630277
Illustration 159
5. Inspect bearing (5) on unit injector rocker arm (3).

The bore in the rocker arm is 24.808 0.20 mm
(0.9767 0.0079 inch). Refer to Specification,
Valve Rocker Arm and lifters. Replace the
bearing, if necessary.
6. Ensure that button (6) on unit injector rocker

arm (3) is not damaged. Also ensure that the
retaining ring for button (6) is in place.
63
i01418849 4. Lubricate rocker shaft assembly (4) with clean

engine oil.
Rocker Shaft - Assemble
5. Install valve rocker arms (2) and unit injector
SMCS Code: 1102-016 rocker arm (3) on rocker shaft assembly (4).
Assembly Procedure 6. Install support bracket (1) on rocker shaft

assembly (4).
NOTICE End By:
a. Install the rocker shaft and the pushrods. Refer
Contaminants may cause rapid wear and shortened to Disassembly and Assembly, Rocker Shaft
component life. and Pushrod - Install.
Note: For information on reusability of components i01496456

of the rocker shaft, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8267, Rocker Rocker Shaft and Pushrod -
Arms and Rocker Arm Shafts for 3114 and 3116
Engines. Install
SMCS Code: 1102-012; 1208-012
Table 31
Required Tools
Part
Number
A 146-2597 Holder - Pushrod 1
NOTICE
g00630277
Illustration 160
1. Install button (6) and the retaining ring, if component life.
necessary.
2. Place clean engine oil on a new bearing (5) prior Note: For information on reusability of components
to installation. of the rocker shaft, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8267, Rocker
3. Ensure that the oil hole in bearing (5) is aligned Arms and Rocker Arm Shafts for 3114 and 3116
with the oil hole in the rocker arm. Hone the Engines.
bearing, if necessary. Refer to the Specifications
Module for the correct dimensions. 1. Install the pushrods in the engine. The base of
the pushrod should be in the seat of the pushrod
lifter.
g00744197
Illustration 161
64
d. Remove the water temperature regulator housing.

Refer to Disassembly and Assembly, Water
Temperature Regulator Housing - Remove and
Install.
e. Remove the inlet manifold. Refer to Disassembly

and Assembly, Inlet Manifold - Remove.
f. Remove the exhaust manifold. Refer to

Disassembly and Assembly, Exhaust Manifold
NOTICE
g00629575
Illustration 162
component life.
2. Position the rocker shaft assembly (2) in the
engine. Line up the pushrods with the rocker
arms. NOTICE
3. Install four bolts (1) in rocker shaft assembly during performance of inspection, maintenance, test-
(2). Tighten the bolts to a torque of 33 7 Nm ing, adjusting and repair of the product. Be prepared to
(24 5 lb ft). collect the fluid with suitable containers before open-
4. Remove Tool (A) from the pushrods. nent containing fluids.
5. Adjust the valve lash on all of the adjustment Refer to Special Publication, NENG2500, Caterpillar
screws. Refer to the Testing and Adjusting Tools and Shop Products Guide for tools and supplies
Module, Air Inlet and Exhaust Sytem for the suitable to collect and contain fluids on Caterpillar
correct procedure. products.
6. Repeat the procedure for the remaining rocker Dispose of all fluids according to local regulations and
shaft assemblies. mandates.
End By:
a. Install the valve mechanism cover. Refer to cylinder head, refer to Guideline For Reusable Parts
Disassembly and Assembly, Valve Mechanism And Salvage Operations, SEBF8218, Specifications
Cover - Remove and Install. for Cylinder Head Assemblies 3114, 3116, and
i01496461 Measure and Salvage Cylinder Head Assemblies
Cylinder Head - Remove
SMCS Code: 1100-011
Removal Procedure
Start By:
a. Remove the fuel filter base. Refer to Disassembly

Install.
b. Remove the governor. Refer to Disassembly and

Assembly, Governor - Remove.
g00611341
c. Remove the unit injectors. Refer to Disassembly Illustration 163
and Assembly, Unit Injector - Remove. Typical example
65
1. Attach a suitable lifting device to the cylinder

head.
g00611342
Illustration 166
g00654709 2. Install a new cylinder head gasket (3).

Illustration 164
2. Remove bolts (1) and (2) that hold the cylinder

head to the cylinder block. Carefully remove
the cylinder head from the cylinder block. The
cylinder head for the 3116 engine weighs
approximately 85 kg (187 lb).
g00746424
Illustration 167
Note: To avoid damage to the cylinder head gasket,

use guide bolts of an appropriate size to install the
cylinder head.
g00611342 3. Attach a suitable lifting device to the cylinder
Illustration 165
head. Position the cylinder head assembly onto
3. Remove cylinder head gasket (3). the dowels in the cylinder block. Lower the
cylinder head onto the cylinder block.
i01529885
Cylinder Head - Install

SMCS Code: 1100-012
NOTICE

component life.
g00748574
Illustration 168
1. Thoroughly clean the mating surfaces of the
cylinder head and the cylinder block. 4. Inspect the condition of cylinder head bolts (1)
and (2). Replace cylinder head bolts (1) and (2),
if necessary.
66
5. Lubricate cylinder head bolts (1) and (2) with f. Install the fuel filter base. Refer to Disassembly
clean engine oil. Install cylinder head bolts (1) and Assembly, Fuel Filter Base - Remove and
and (2). Follow Step 6 for the correct tightening Install.
procedure.
i01151741
Lifter Group - Remove and

Install
SMCS Code: 1209-010
Removal Procedure
Start By:

g00794320 Install.
Illustration 169
b. Remove the rocker arms and pushrods. Refer to

6. Tighten the cylinder head bolts according to the Disassembly and Assembly, Rocker Shaft and
following procedure:
Pushrod - Remove.
a. Tighten bolt (1) through bolt (14) in a numerical c. Remove the unit injector hydraulic pump. Refer
sequence to a torque of 150 15 Nm
to Disassembly and Assembly, Unit Injector
(110 11 lb ft).
Hydraulic Pump - Remove.
b. Tighten bolt (1) through bolt (14) again
d. Remove the air compressor. Refer to Disassembly
in a numerical sequence to a torque of
and Assembly, Air Compressor - Remove and
435 20 Nm (320 15 lb ft). Install.
c. Tighten bolt (1) through bolt (14) again
e. Remove the electronic control module (ECM).
in a numerical sequence to a torque of Refer to Disassembly and Assembly, Electronic
435 20 Nm (320 15 lb ft).
Control Module - Remove and Install.
d. Tighten bolt (15) through bolt (20) in a
numerical sequence to a torque of 55 7 Nm NOTICE
(41 5 lb ft). Keep all parts clean from contaminants.
End By: Contaminants may cause rapid wear and shortened

component life.
a. Install the exhaust manifold. Refer to Disassembly
and Assembly, Exhaust Manifold - Remove and
NOTICE
Install.
b. Install the inlet manifold. Refer to Disassembly
and Assembly, Inlet Manifold - Install.
c. Install the water temperature regulator housing.
Temperature Regulator Housing- Remove and
Install.
d. Install the unit injectors. Refer to Disassembly
products.
and Assembly, Unit Injector - Install.
e. Install the governor. Refer to Disassembly and
mandates.
Assembly, Governor - Install.
67
Note: Ensure that the sleeves of the side covers

remain in the side covers.
5. Remove four bolts (6) and the dowels that hold

the lifter arms (7) and the lifter shaft (8) to each
side cover. Remove gasket (9).
NOTICE

component life.
g00611180
Illustration 170
1. Remove bolt (1) that holds the bracket for the

engine speed/timing sensor to the timing gear
housing. Remove two engine speed/timing
sensors (3) and the bracket from the timing gear
housing.
2. Cut the straps that hold the wiring harness to

side cover (2) of the cylinder block.
3. Remove the bolts that hold side cover (2) to the

cylinder block.
g00611184
Illustration 173
1. Install gasket (9).
2. Install lifter arms (7) on lifter shaft (8).
3. Position lifter shaft (8) and the dowels on the

side cover. Ensure that the oil holes in the lifter
shaft are facing the side cover. Apply 9S-3263
Thread Lock Compound on the threads of bolts
(6) that hold lifter shaft (8) to the side cover.
Install bolts (6). Tighten bolts (6) to a torque of
g00611182 13 3 Nm (10 2 lb ft). Tighten the two center
Illustration 171
bolts. Then tighten the end bolts.
4. Remove the bolts and side covers (4) and (5) 4. Lubricate the lifters with clean engine oil.
from the cylinder block.
5. Ensure that the cylinder block and the sealing
surfaces of the side cover are thoroughly clean.
Apply 1U-8846 Sealant to the sealing surfaces
of the side cover. The side covers must be
installed on the cylinder block within 10 minutes
of applying the sealant.
g00611184
Illustration 172
68
d. Install the rocker arms and pushrods. Refer to

Disassembly and Assembly, Rocker Shaft and
Pushrod - Install.
e. Install the fuel filter base. Refer to Disassembly

Install.
i01151060
Camshaft - Remove
SMCS Code: 1210-011
g00611182
Illustration 174 Removal Procedure
Start By:
a. Remove the rocker arms and the push rods.

Refer to Disassembly and Assembly, Rocker
b. Remove the unit injector hydraulic pump. Refer

c. Remove the side cover. Refer to Disassembly

and Assembly, Lifter Group - Remove and
Install.
g00611180
Illustration 175
d. Remove the front cover. Refer to Disassembly
and Assembly, Front Cover - Remove.
6. Position the gaskets and side covers (2), (4), and
(5) on the cylinder block. Install the bolts and
clips that hold the side covers in position. NOTICE
7. Install two engine speed/timing sensors (3) and
the bracket to the timing gear housing. Install Contaminants may cause rapid wear and shortened
bolt (1). component life.
8. Secure the two plugs of the wiring harness to

the engine speed/timing sensors in the timing NOTICE
gear housing. Use new straps to hold the wiring Care must be taken to ensure that fluids are contained
harness to the side covers of the cylinder block. during performance of inspection, maintenance, test-
End By: collect the fluid with suitable containers before open-
a. Install the electronic control module (ECM). nent containing fluids.
Refer to Disassembly and Assembly, Electronic
Control Module - Remove and Install. Refer to Special Publication, NENG2500, Caterpillar
b. Install the air compressor. Refer to Disassembly suitable to collect and contain fluids on Caterpillar
and Assembly, Air Compressor - Remove and products.
Install.
c. Install the unit injector hydraulic pump. Refer mandates.
Hydraulic Pump - Install. Note: The air compressor was removed in order to
accommodate the engine repair stand.
69
1. Turn the crankshaft to top center compression i01494499

stroke for the No. 1 piston. Install the timing
bolt in the flywheel. This is for timing during Camshaft - Install
installation.
SMCS Code: 1210-012
2. Ensure that the timing marks on the following
gears are aligned: the camshaft drive gear, the Installation Procedure
idler gear, and the crankshaft gear.
NOTICE
Note: It is not necessary to remove the cylinder Keep all parts clean from contaminants.
head for removal of the camshaft.
3. Wire the valve lifters away from the camshaft. component life.
Note: For information on reusability of the camshaft,

refer to Guideline For Reusable Parts And Salvage
Operations, SEBF8097, Camshaft Measurement,
Guideline For Reusable Parts And Salvage
Operations, SEBF8146, Visual Inspection of
Camshafts, and Guideline For Reusable Parts And
Measurement of Camshafts in 3114/3116 Engines.
For information on reusability of the camshaft
gear, refer to Guideline For Reusable Parts And
Salvage Operations, SEBF8045, Timing Gears for
All Engines.
1. Lubricate the camshaft and the camshaft

bearings with clean engine oil.
g00611074
Illustration 176
4. Remove two bolts (3) and camshaft retainer plate

(2) from camshaft gear (1).
g00654762
Illustration 178
2. Carefully install camshaft (4) and camshaft gear

(1) in the engine.
NOTICE
When installing the camshaft, make sure the num-
ber one cylinder is at top center of the compression
g00611082 stroke with the timing bolt installed in the flywheel. The
Illustration 177
camshaft timing is very important. The timing mark
5. Remove camshaft (4) from the cylinder block. on the camshaft drive gear must line up with the tim-
ing mark on the idler gear. Refer to the Specifications
Manual for more information.
70
g00677700 g00611152
Typical example
NOTICE
3. Ensure that timing mark (5) on the camshaft gear Do not allow the camshaft to fall to the floor when
is aligned with timing mark (6) on the idler gear. pressing it from the drive gear. Also make sure that
the camshaft lobes do not catch on the press plates.
4. Install camshaft retainer plate (2) and two bolts
(3).
2. Place the camshaft and camshaft gear (1) in a
End By: suitable press. Press the camshaft from camshaft
gear (1).
a. Install the front cover. Refer to Disassembly and
Assembly, Front Cover - Install. Installation Procedure
b. Install the side cover. Refer to Disassembly and 1. Heat the camshaft gear to a maximum
Assembly, Lifter Group - Remove and Install. temperature of 315 C (600 F).
c. Install the governor. Refer to Disassembly and 2. Align the key in the camshaft with the groove
Assembly, Governor - Install. (keyway) in the camshaft gear.
3. Install the camshaft gear on the end of the

i01151709
camshaft.
Camshaft Gear - Remove and
End By:
Install
SMCS Code: 1210-010-GE Assembly, Camshaft - Install.
Removal Procedure i01199837
Start By: Camshaft Bearings - Remove

a. Remove the camshaft. Refer to Disassembly and and Install
SMCS Code: 1211-010
1. Wrap the camshaft with a protective covering in
order to prevent damage to the camshaft. Removal Procedure
Table 32
Required Tools
Part
Camshaft Bearing Tool
A 8S-2241 1
Group
71
Start By:
NOTICE
a. Remove the camshaft. Refer to Disassembly and Keep all parts clean from contaminants.
NOTICE component life.

component life.
NOTICE

products.

mandates.
Note: Note the oil hole orientation in each camshaft

bearing prior to removal for assembly purposes.
g00610640
Illustration 182
Rear view of engine
g00610631
Illustration 181
1. Install Tool (A). Use Tool (A) to remove the

camshaft bearings from the cylinder block.
Table 33
Required Tools
Part
Camshaft Bearing Tool
A 8S-2241 1
Group
72
i01150906
Engine Oil Pan - Remove and

Install
SMCS Code: 1302-010
Removal Procedure

jury.
NOTICE

component life.
NOTICE
g00610642 ing, adjusting and repair of the product. Be prepared to
Illustration 183
Front view of engine collect the fluid with suitable containers before open-
1. Use Tool (A) to install all of the camshaft bearings nent containing fluids.
except for the front bearing. Locate oil hole (1) in
each bearing so that oil hole (1) is located at the Refer to Special Publication, NENG2500, Caterpillar
top of the bore. Refer to Illustration 182. Tools and Shop Products Guide for tools and supplies
2. Use Tool (A) to install the front camshaft bearing. products.
Align oil hole (1) in the front camshaft bearing
with the oil hole in the cylinder block. Locate joint Dispose of all fluids according to local regulations and
(2) in the front camshaft bearing in the proper mandates.
position. Refer to Illustration 183. Refer to the
Specifications for more information. 1. Drain the engine oil into a suitable container for
storage or disposal.
End By:

Assembly, Camshaft - Install.
g00610543
Illustration 184
Typical example
73
Note: Do not pry or gouge the sealing surface of

the engine oil pan. If the engine oil pan is difficult to
remove, tap the engine oil pan with a rubber mallet.
2. Remove the bolts for the engine oil pan. Remove

engine oil pan (1).
g00610550
Illustration 186
Typical example
g00610550
Illustration 185
Typical example
3. Remove gasket (2) from the engine oil pan.
4. Remove the drain plug and the O-ring seal from

the engine oil pan.
g00610543
Keep all parts clean from contaminants. Typical example
Contaminants may cause rapid wear and shortened 4. Place new gasket (2) and engine oil pan (1) on
component life. the cylinder block.
1. Install the drain plug and the O-ring seal on

the engine oil pan. Tighten the drain plug to
25 5 Nm (18 4 lb ft).

gasket, if necessary.
3. Clean the mating surface of the engine oil pan

and the cylinder block.
Note: Apply 1U-8846 Sealant to the four places

at the tee joints of the following items: the timing
gear housing to the cylinder block and the flywheel
housing (seal carrier) to the cylinder block. Use
approximately 0.5 mm (0.02 inch) of sealant at each
of the four places. Do not apply liquid gasket on the
gasket for the engine oil pan. Do not apply liquid
gasket to the gasket surface of the engine oil pan.
g00610574
Illustration 188
5. Install the bolts for the engine oil pan. Tighten

the bolts (X). Tighten the bolts to a torque of
31 3 Nm (23 2 lb ft).
74
6. Start at position (Z) and tighten the remaining

bolts in a counterclockwise direction. Tighten
the remaining bolts to a torque of 31 3 Nm
(23 2 lb ft).
7. Start at position (Z) and tighten the bolts again in

a counterclockwise direction. Tighten the bolts to
a torque of 31 3 Nm (23 2 lb ft).
8. Fill the engine with oil to the correct level. Refer

to the Operation and Maintenance Manual for the
correct filling procedure.
i01150877
g00610526
Illustration 189
Piston Cooling Jets - Remove
and Install 1. Remove bolt (1) and piston cooling jet (2) from
each cylinder.
SMCS Code: 1331-010
Removal Procedure
NOTICE
Start By: Keep all parts clean from contaminants.
a. Remove the engine oil pump. Refer to Contaminants may cause rapid wear and shortened
Disassembly and Assembly, Engine Oil Pump - component life.
Remove.
NOTICE

component life.
NOTICE
nent containing fluids. Illustration 190
g00610526
Refer to Special Publication, NENG2500, Caterpillar 1. Position piston cooling jet (2) in the cylinder
Tools and Shop Products Guide for tools and supplies block. Ensure that piston cooling jet (2) is seated
suitable to collect and contain fluids on Caterpillar properly. Hold piston cooling jet (2) and install
products. bolt (1) in each cylinder. Tighten the bolt to a
mandates. End By:

and Assembly, Engine Oil Pump - Install.
75
i01286292 Guideline For Reusable Parts And Salvage

Pistons and Connecting Rods Connecting Rods
- Remove
SMCS Code: 1225-011 Operations, SEBF8064, Salvage of Non-Serrated
Connecting Rods
Removal Procedure Note: For information on reusability of the piston
pins, refer to the following list.
Start By:
a. Remove the cylinder head. Refer to Disassembly Operations, SEBF8051, Piston Pins and Retaining
and Assembly, Cylinder Head - Remove. Rings
b. Remove the engine balancer shaft on the Guideline For Reusable Parts And Salvage
3114 engines only. Refer to Disassembly and Operations, SEBF8303, Procedure to Inspect
Assembly, Engine Balancer Shaft - Remove and Piston Pins
Install.
Note: For information on reusability of the rod eye
c. Remove the engine oil pump. Refer to bushing, refer to the following list.
Remove. Guideline For Reusable Parts And Salvage
Operations, SEBF8242, Verification of Connecting
d. Remove the piston cooling jets. Refer to Rod Eye Bushing Retention Using 5P-8639
Disassembly and Assembly, Piston Cooling Jets Connecting Rod Bushing Press Group
NOTICE Operations, SEBF8274, Using Rod Eye Bushing
Keep all parts clean from contaminants. Installation and Removal Tools
Contaminants may cause rapid wear and shortened Note: For information on reusability of the cylinder
component life. block and salvage procedures, refer to the following
list.
Note: For information on reusability of the pistons,
refer to the following list.
Operations, SEBF8192, Specifications and
Salvage for Cylinder Blocks on 3114, 3116, 3126
Guideline For Reusable Parts And Salvage Engines
Operations, SEBF8049, Pistons
Guideline For Reusable Parts And Salvage Operations, SEBF8261, Installing a 7C-6208
Operations, SEBF8228, Procedure to Clean and Cylinder Sleeve in 3114, 3116 Engines and a
Inspect One and Two-Piece Pistons in 3114/3116 107-7604 Cylinder Sleeve in 3126 Engines
Engines
Special Instruction, SEHS8869, Cylinder Block
Guideline For Reusable Parts And Salvage Salvage Procedure Using Belzona Ceramic R
Operations, SEBF8290, Visual Inspection of Metal
Two-Piece Pistons
Special Instruction, GMG00981, Using 1P-3537
Tool Operating Manual, NEHS0775, Using the Dial Bore Gauge Group to Check Cylinder Bore
186-0137 Piston Ring Gauge on Steel Crown, Size
Two-Piece Pistons used in 3126 Engines
Note: For information on reusability of the connecting

Special Instruction, SMHS7606, Use of 1P-4000
Line Boring Tool Group
rods, refer to the following list.
Special Instruction, SEHS8841, Using the
Guideline For Reusable Parts And Salvage Ironstitch Procedure for Casting Salvage
Operations, SEBF8206, Specifications for
Connecting Rods on 3116 Engines
Special Instruction, SEHS8919, Salvage Weld
Procedure for Cast Iron Cylinder Blocks
76

Operations, SEBF8076, Specifications to Salvage
Cylinder Block Contact Surfaces
g00610272
Illustration 193
4. Push the piston and connecting rod away

Illustration 191
g00610269 from the crankshaft. Remove the upper half of
connecting rod bearing (4) from connecting rod
1. Inspect the connecting rod and connecting (3).
rod cap (2) for the proper identification mark.
The connecting rod and connecting rod cap 5. Remove the piston and connecting rod (3) from
(2) should have an etched number on the side the cylinder block.
that is toward the right side of the engine. The
number should match the cylinder number. Mark 6. Repeat Steps 1 through 5 for the remaining
the connecting rod and connecting rod cap (2), pistons and connecting rods.
if necessary.
i01336888
Pistons and Connecting Rods

- Disassemble
SMCS Code: 1225-015
Table 34
Required Tools
Part
g00610272
Illustration 192
A 1U-6683 Piston Ring Expander 1
2. Remove connecting rod cap nuts (1), bolts (5), B 1P-1861 Retaining Ring Pliers 1
and connecting rod cap (2).
Start By:
3. Remove the lower half of bearing (4) from
connecting rod cap (2). a. Remove the pistons and the connecting rods.
Refer to Disassembly and Assembly, Pistons
NOTICE and Connecting Rods - Remove.
Install short pieces of rubber hose over both connect-
ing rod bolts in order to protect the crankshaft from the NOTICE
threaded portion of the connecting rod bolts. Keep all parts clean from contaminants.

component life.
77
Note: For information on reusability of the pistons, 1. Use Tool (B) to remove retaining ring (2). Remove
refer to the following list. piston pin (4) and separate piston (1) from
connecting rod (3).

Two-Piece Pistons

186-0137 Piston Ring Gauge on Steel Crown,

Guideline For Reusable Parts And Salvage g00610428

Operations, SEBF8063, Visual Inspection of Illustration 195
Connecting Rods
2. Use Tool (A) to remove piston ring (5).
Operations, SEBF8064, Salvage of Non-Serrated
i01150791
Connecting Rods
Note: For information on reusability of the piston

pins, refer to the following list. - Assemble
Guideline For Reusable Parts And Salvage SMCS Code: 1225-016
Operations, SEBF8051, Piston Pins and Retaining
Rings Assembly Procedure
Guideline For Reusable Parts And Salvage Table 35
Operations, SEBF8303, Procedure to Inspect
Required Tools
Piston Pins
Part
Note: For information on reusability of the rod eye Tool Number Part Description Qty
bushing, refer to the following list. 1U-6683
A Ring Expander 1

Operations, SEBF8242, Verification of Connecting NOTICE
Rod Eye Bushing Retention Using 5P-8639 Keep all parts clean from contaminants.
Connecting Rod Bushing Press Group
Guideline For Reusable Parts And Salvage component life.
Operations, SEBF8274, Using Rod Eye Bushing
Installation and Removal Tools
NOTICE
Verify correct assembly of the pistons and the con-
necting rods. Ensure that the etched numbers on the
rod and the rod cap are in the correct positions. The
etched number on the rod and the rod cap correspond
to the cylinder in which it should be installed.
g00610426
Illustration 194
78
g00610428 g00610503
1. Check the clearance between the ends of piston 6. The piston is a two-piece assembly. This piston
rings (5). Refer to the Specifications Manual, consists of piston crown (7) and piston skirt (8).
Pistons and Rings topic. Inspect bearing (9) in the piston crown (7). The
piston crown must be replaced if the piston
Note: The oil ring must be installed over the spring crown is worn or damaged. Bearing (9) is not
with the end gap 180 degrees from the oil ring serviced.
spring joint.
2. Install the oil control piston ring with Tool (A).

The ends of the spring should be rotated 180
degrees from the ring end gap.
3. Install the intermediate piston ring with the side

marked UP-2 toward the top of the piston. Use
Tool (A) in order to install the ring.
4. Install the top piston ring with the side marked

UP-1 toward the top of the piston. Use Tool (A)
in order to install the ring.
g00610426
Illustration 199
7. Position piston (1) on connecting rod (3). Coat

pin (4) with clean engine oil and install pin (4).
Ensure that the retainer rings are in the grooves
of piston (1).
End By:
a. Install the pistons and the connecting rods.

Refer to Disassembly and Assembly, Piston and
Connecting Rods - Install.
g00610498
Illustration 197
5. Replace rod bearing (6) by pressing a new

bearing into the connecting rod. Refer to Special
Instruction, SEHS7295 for the correct tooling and
the correct installation procedure.
79
i01459773 Guideline For Reusable Parts And Salvage

Pistons and Connecting Rods Rod Eye Bushing Retention Using 5P-8639
- Install Connecting Rod Bushing Press Group
SMCS Code: 1225-012 Guideline For Reusable Parts And Salvage

Installation and Removal Tools
Table 36
Required Tools
Part
A 173-5529 Piston Ring Compressor 1
NOTICE

component life.
g00678193
Illustration 200
refer to the following list. 1. Install the bolts (5) and the upper half of
connecting rod bearing (4). Ensure that the
bearing tab engages with the slot in connecting
Guideline For Reusable Parts And Salvage rod (3).

Two-Piece Pistons

Two-Piece Pistons used in 3126 and 3126B
Engines


Operations, SEBF8063, Visual Inspection of g00678195
Illustration 201
Connecting Rods
2. Install the lower half of connecting rod bearing
Guideline For Reusable Parts And Salvage (4). Ensure that the bearing tab engages with the
slot in connecting rod cap (2).
Connecting Rods
3. Place clean engine oil on the following items: the
pistons, the piston rings, the cylinder bore, the
upper half of the connecting rod bearing, and
the lower half of the connecting rod bearing.
Rings NOTICE
Guideline For Reusable Parts And Salvage ing rod bolts in order to protect the crankshaft from the
Operations, SEBF8303, Procedure to Inspect threaded portion of the connecting rod bolts.
Piston Pins

bushing, refer to the following list.
80
9. Remove the hoses that were installed in Step 4

from the connecting rod bolts.
g00746584
Illustration 202
4. Install short pieces of rubber hose (6) over both Illustration 204 g00678200
connecting rod bolts.
10. Install connecting rod bearing cap (2) on the
connecting rod (3). Ensure that the number on
connecting rod bearing cap (2) matches the
number on the connecting rod (3). Ensure that
the numbers are on the same side.
11. Lubricate connecting rod cap bolts with

4C-5593 Anti-Seize Compound.
g00634923
Illustration 203
Note: Each piston ring end gap must be positioned

120 degrees from each other.
5. Install Tool (A) in order to compress the piston

rings.
6. With the number one crankshaft throw at the Illustration 205

g00610272
bottom center, install the piston and connecting
rod in the engine. Ensure that the proper piston
NOTICE
and connecting rod are in the corresponding
Loose connecting rod nuts can result in the separation
cylinder with the bearing retainer notch toward
of the rod cap and result in major engine damage.
the right side of the engine.
Note: The etched number on the connecting rod 12. Install connecting rod cap nuts (1). Tighten nuts
must be on the right side of the engine in the (1) to a torque of 54 7 Nm (40 5 lb ft).
corresponding cylinder.
7. Line up the piston and the connecting rod with

the crankshaft. Use a soft hammer and tap the
piston into the cylinder bore until Tool (A) comes
off of the piston.
8. Use a soft hammer in order to tap the piston into

the cylinder bore while you guide connecting rod
(3) onto the crankshaft.
81
Start By:

Remove.
NOTICE

component life.
g00678202
Illustration 206
13. Place index mark (7) on the connecting rod.

Place index mark (9) on connecting rod cap
nut (1). Index marks (7) and (9) mark the initial
position of the nut. Place index mark (8) on
connecting rod cap nut (1). Index mark (8)
should be 60 5 degrees counterclockwise
from index mark (9). Tighten each nut (1) for
an additional 60 5 degrees (1/6 turn). Index
mark (8) should be lined up with index mark (7).
Repeat the procedure for the other connecting
g00610152
rod cap nut. Illustration 207
14. Repeat Steps 1 through 13 for the remaining 1. Remove bolts (1) that hold crankshaft main
pistons and connecting rods. bearing cap (2). Remove crankshaft main
bearing cap (2).
End By:
2. Remove the lower half of the crankshaft main
a. Install the piston cooling jets. Refer to bearing from crankshaft main bearing cap (2).
Disassembly and Assembly, Piston Cooling Jets
b. Install the engine oil pump. Refer to Disassembly

c. Install the cylinder head. Refer to Disassembly

and Assembly, Cylinder Head - Install.
i01150114
Crankshaft Main Bearings -

Remove
g00516920
SMCS Code: 1203-011 Illustration 208
Typical example
Removal Procedure
NOTICE
Table 37 If the crankshaft is turned in the wrong direction, the
Required Tools tab of the crankshaft main bearing will be pushed be-
tween the crankshaft and the cylinder block. this can
Part cause damage to either or both the crankshaft and the
Tool Number Part Description Qty cylinder block.
A 2P-5518 Bearing Tool 1
3. Use the following steps in order to remove the
upper half of crankshaft main bearings:
82
a. Turn the crankshaft until Tool (A) can be

installed in the crankshaft journal. Install Tool
(A).
b. Turn the crankshaft in order to remove the

upper half of the crankshaft main bearing. In
order to get the tab out first, the crankshaft
must be turned in the correct direction.
c. Check the condition of the crankshaft main

bearings. Refer to the Guideline For Reusable
Parts, SEBF8009, Main and Connecting
Rod Bearings or refer to the Guideline
For Reusable Parts, SEBF0531, Main and
Connecting Rod Bearings. g00516920
Illustration 209
i01496477 1. Use Tool (A) and install the upper halves of the
crankshaft main bearings in the cylinder block.
Crankshaft Main Bearings - Do not put oil on the back of the crankshaft main
Install bearing.
SMCS Code: 1203-012
Table 38
Required Tools
Part
A 2P-5518 Main Bearing Tool 1
B 8T-5096 Dial Indicator Group 1
g00610152
2. Install the lower halves of the crankshaft main
Contaminants may cause rapid wear and shortened bearings in crankshaft main bearing caps (2).
component life. Do not put oil on the back of the crankshaft main
bearing.
Note: Place clean engine oil on the crankshaft main
bearings prior to assembly. Ensure that the tabs on NOTICE
the back side of the crankshaft main bearings fit in Crankshaft main bearing caps should be installed with
the grooves of the crankshaft main bearing caps the part number toward the right side of the engine.
and the cylinder block. Crankshaft main bearing caps are to be identified by
stamped numbers 1 through 7 located on the bottom
surface. The thrust plate is used on the center crank-
shaft main bearing only.
3. Place crankshaft main bearing caps (2) in

position on the cylinder block. Place clean
engine oil or Molylube on the bolt threads and
on the washer face. Install bolts (1).
4. Tighten bolts (1) to a torque of 54 7 Nm

(40 5 lb ft). Tighten each bolt (1) for an
additional 90 5 degrees (1/4 turn).
83
g00517003 g00609979
5. Check the end play of the crankshaft with Tool 1. Fasten lifting slings and a hoist to each end of
(B). The end play must be 0.07 mm (0.003 inch) the crankshaft. Refer to Illustration 212.
to 0.32 mm (0.013 inch).
End By:

i01197475
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure g00609985

Illustration 213
Start By:
2. Remove bolts (2), the washers, and main bearing
a. Remove the cylinder head. Refer to Disassembly caps (3). Carefully remove crankshaft (1) from
and Assembly, Cylinder Head - Remove. the cylinder block. The weight of the crankshaft
is approximately 62 kg (137 lb).
b. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove. 3. Remove the main bearings from the cylinder
block. Remove the main bearings from the main
c. Remove the camshaft idler gear. Refer to bearing caps.
Disassembly and Assembly, Camshaft Idler
Gear - Remove and Install.
d. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, Pistons and
Connecting Rods - Remove.
NOTICE

component life.
84
i01516597 2. Install Tool (B) between Tool (A) and the

crankshaft wear sleeve. Turn Tool (B) until the
Crankshaft Wear Sleeve (Rear) edge of Tool (B) makes a crease in the crankshaft
- Remove wear sleeve. Make a crease in the crankshaft
wear sleeve at two other locations around the
(If Equipped) crankshaft wear sleeve until the crankshaft wear
sleeve is loose.
SMCS Code: 1161-011-ZV
3. Remove Tool (B), Tool (A), and the crankshaft
Removal Procedure wear sleeve from the end of the crankshaft.
Table 39
i01216629
Required Tools
Part
Crankshaft Wear Sleeve (Rear)
Tool Number Part Description Qty - Install
A 4C-4869 Distorter Ring 1
B 5P-7312 Seal Distorter 1
Start By:
Table 40
a. Remove the crankshaft rear seal. Refer to Required Tools
Disassembly and Assembly, Crankshaft Rear
Seal - Remove. Part
NOTICE A(1) 132-8772 Seal Locator 1

Keep all parts clean from contaminants. B(1) 1U-7596 Bolt 2
Contaminants may cause rapid wear and shortened C(1) 1U-7597 Sleeve Ring 1
component life. D(1) 1U-7594 Seal Installer 1
E(1) 9S-8858 Nut 1
(1) Part of the 1U-7598 Seal Installer
NOTICE

component life.

thoroughly clean and dry prior to the installation
of the crankshaft rear seal.
g00614029
Illustration 214
Note: Wear sleeves are not installed at the factory.

The wear sleeve is included with the replacement
rear seal.
1. Install Tool (A) in the bore of the crankshaft rear

sleeve.
85
End By:
a. Install the flywheel. Refer to Disassembly and

i01150032
Crankshaft - Install
SMCS Code: 1202-012
Table 41
g00613561
Illustration 215
Required Tools
2. Fasten Tool (A) to the rear of the crankshaft with Part

Tool (B). Hand tighten Tool (B). Tool Number Part Description Qty
A 8T-5096 Dial Indicator Group 1
rear sleeve (1) on Tool (A). Position Tool (C) on
Tool (A). NOTICE

component life.
NOTICE
Ensure that the crankshaft main bearing tabs engage
with the grooves in the block and the crankshaft main
bearing cap.
1. Check the condition of the main bearings.

Refer to Main and Connecting Rod Bearings,
SEBF8009 and refer to Engine Bearings and
g00614109 Crankshafts, SEBD0531.
Illustration 216
Note: The number six main bearing is the thrust

bearing.
Install Tool (E). Tighten Tool (E) in order to install
the crankshaft rear seal and the crankshaft wear
2. Clean the bearing surfaces in the cylinder block
sleeve.
for the main bearings. Apply clean engine oil on
the upper main bearing. Do not put engine oil on
5. Remove Tool (E), Tool (D), and Tool (C). Turn
the back side of the bearing surfaces. Install the
over Tool (C). Install Tool (C), Tool (D), and Tool
upper main bearing in the cylinder block. Ensure
that the tab on the back side of the bearing
engages with the groove in the cylinder block.

will be flush if the crankshaft rear seal and the
information.

86
6. Install bolts (2) and the washers for main

bearing caps (3). Tighten bolts (2) to a torque of
54 7 Nm (40 5 lb ft).
7. Turn bolts (2) for an additional 90 5 degrees

(1/4 turn).
g00610100
Illustration 217
3. Put clean engine oil on the journals of the

crankshaft bearing. Fasten lifting straps and
a hoist to crankshaft (1). Carefully install the
crankshaft in the cylinder block.
g00610119
Illustration 219
4. Clean the bearing surface of the main bearing
caps. Install the lower main bearing in the 8. Check the end play of crankshaft (1) with Tool
crankshaft main bearing caps. Ensure that the (A). The end play must be 0.07 mm (0.003 inch)
tab on the back side of the bearing engages to 0.32 mm (0.013 inch).
with the groove in the main bearing cap. Apply
clean engine oil on the lower main bearing. End By:
Do not put engine oil on the back side of the
bearing surfaces. a. Install the pistons and connecting rods. Refer
5. Install crankshaft main bearing caps with the Connecting Rods - Install.
part numbers toward the right hand side of
the cylinder block. Ensure that crankshaft main b. Install the camshaft idler gear. Refer to
bearing caps have numbers 1 through 7. The Disassembly and Assembly, Camshaft Idler
numbers should start at the front of the engine. Gear - Remove and Install.
Place clean engine oil or Molylube on the bolt
threads and the washers. c. Install the front housing. Refer to Disassembly
Note: When the bolts for the rear main bearing cap
are tightened, slide the main bearing cap as far d. Install the cylinder head. Refer to Disassembly
forward as possible until the cap is against the and Assembly, Cylinder Head - Install.
bolts. Hold the main bearing cap in this position
and tighten the bolts.
i01177454
Crankshaft Gear - Remove and

Install
SMCS Code: 1204-010-GE
Removal Procedure
Start By:
a. Remove the front gear group. Refer to

Disassembly and Assembly, Gear Group (Front)
- Remove.
g00609985
Illustration 218
87
NOTICE

component life.

All Engines.
1. Place alignment marks on the crankshaft gear

and on the crankshaft. The alignment marks will
g00630476
ensure that the camshaft gear is aligned properly Illustration 221
during installation.
1. Heat crankshaft gear (1) to a temperature of
316 C (600 F) for installation.
2. Align the timing marks on the crankshaft and on

crankshaft gear (1). Install crankshaft gear (1)
on crankshaft (2).
Note: Ensure that crankshaft gear (1) is flush against

the shoulder of crankshaft. If the gear is not flush
damage to the gear may occur.
End By:
a. Install the front gear group. Refer to Disassembly

and Assembly, Gear Group (Front) - Install.
g00630476
Illustration 220
i01410976
2. Heat crankshaft gear (1). Remove the gear from
crankshaft (2). Bearing Clearance - Check
Installation Procedure SMCS Code: 1203-535; 1219-535
NOTICE Measurement Procedure

Table 42
Contaminants may cause rapid wear and shortened Required Tools
component life.
Part
A - Plastigage -
All Engines. NOTICE

component life.
Note: Caterpillar does not recommend the checking

of the actual bearing clearances particularly on
small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each
Caterpillar engine bearing is quality checked for
specific wall thickness.
88
Note: The measurements should be within 3. Carefully remove the cap, but do not remove
specifications and the correct bearings should Tool (A). Measure the width of Tool (A) while Tool
be used. If the crankshaft journals and the bores (A) is in the bearing cap or on the crankshaft
for the block and the rods were measured during journal. Refer to Illustration 222.
disassembly, no further checks are necessary.
However, if the technician still wants to measure 4. Remove all of Tool (A) before you install the
the bearing clearances, Tool (A) is an acceptable bearing cap.
method. Tool (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm Note: When Tool (A) is used, the readings can
(0.004 inch). sometimes be unclear. For example, all parts of
Tool (A) are not the same width. Measure the major
NOTICE width in order to ensure that the parts are within
Lead wire, shim stock or a dial bore gauge can dam- the specification range. Refer to Specifications,
age the bearing surfaces. Crankshaft for the correct clearances.
i01200681
The technician must be very careful to use Tool (A)
correctly. The following points must be remembered: Ether Atomizer - Remove and
Ensure that the backs of the bearings and the Install
bores are clean and dry.
SMCS Code: 1456-010
Ensure that the bearing locking tabs are properly
seated in the tab grooves. Removal Procedure
The crankshaft must be free of oil at the contact
points of Tool (A).
1. Put a piece of Tool (A) on the crown of the

bearing that is in the cap.
Note: Do not allow Tool (A) to extend over the edge

of the bearing.
2. Use the correct torque-turn specifications in

order to install the bearing cap. Do not use an
impact wrench. Be careful not to dislodge the
bearing when the cap is installed.
Note: Do not turn the crankshaft when Tool (A) is g00642608

Illustration 223
installed.
NOTICE

component life.
1. Remove ether atomizer (1) from the top of the

air inlet manifold.
g00473227
Illustration 222
Typical example
89
g00618473
Illustration 226
g00642608
Illustration 224
2. Remove bolt (2) and idler pulley (3).
Note: Install the ether atomizer so that the direction
of the spray is parallel to the air inlet heater, If
i01161563
equipped. The ether atomizer has an indicator in
order to show the direction of the spray. Idler Pulley - Disassemble
Note: The ether atomizer has two ports that are SMCS Code: 1358-015
separated by 180 degrees. The two ports must be
aimed parallel to the length of the block.
1. Install ether atomizer (1). The minimum torque for
Table 43
the ether atomizer is 2.8 Nm (25 lb in).
Required Tools
i01161409 Part
Number
Idler Pulley - Remove A 1P-0510 Driver Group 1
SMCS Code: 1358-011 B 1P-1855 Retaining Ring Pliers 1
Removal Procedure Start By:
a. Remove the idler pulley. Refer to Disassembly

and Assembly, Idler Pulley - Remove.
g00618468
Illustration 225
1. Remove cover (1) from the idler pulley. Cover (1)

will be damaged during removal. Illustration 227
g00618635
1. Remove spacer (1) and bolt (5) from idler pulley

(4).
2. Remove retaining rings (2) from each side of

idler pulley (4) with Tool (B).
90
3. Remove bearings (3) from each side of idler i01161430

pulley (4) with Tool (A).
Idler Pulley - Install
i01161599 SMCS Code: 1358-012
Idler Pulley - Assemble
SMCS Code: 1358-016
Assembly Procedure
Table 44
Required Tools
Part
Number
g00618473
Illustration 229
1. Position idler pulley (3). Install bolt (2) and tighten

bolt (2) to a torque of 55 10 Nm (40 7 lb ft).
g00618635
Illustration 228
1. Install one retaining ring (2) in idler pulley (4).
2. Install two bearings (3) in idler pulley (4) with

Tool (A). Install the remaining retaining ring (2).
3. Install spacer (1) and bolt (5) in idler pulley (4). g00618468
Illustration 230
End By:
2. Install a new cover (1) on idler pulley (3).
a. Install the idler pulley. Refer to Disassembly and
Assembly, Idler Pulley - Install.
91
i01160976 1. Position belt tensioner (2) on the cylinder block.

Install four bolts (1).
Belt Tensioner - Remove and
Install 2. Install the drive belt. Use a breaker bar to place
the original amount of tension on the drive belt.
SMCS Code: 1358-010
i01162446
Removal Procedure Belt Tightener - Remove
SMCS Code: 1358-011
Removal Procedure
g00614167
Illustration 231
1. Use a breaker bar to release the tension on belt

tensioner (2). Remove the drive belt.
2. Remove four bolts (1) and belt tensioner (2). g00619355

Illustration 233
Installation Procedure 1. Remove two bolts (1) that hold water pump belt
tightener (3) to the timing gear housing.
2. Remove V-belt (2) from the pulley of water pump

belt tightener (3). Remove water pump belt
tightener (3).
i01162490
Belt Tightener - Disassemble

SMCS Code: 1358-015
Table 45
Required Tools
Part
Number
A 1P-1855 Retaining Ring Pliers 1
g00614167 B 1P-0510 Driver Group 1
Illustration 232
92
Start By:
a. Remove the water pump belt tightener. Refer to

Disassembly and Assembly, Belt Tightener -
Remove.
g00619412
Illustration 236
1. Check the condition of shaft (4) in idler plate

assembly (5). Replace idler plate assembly (5) if
shaft (4) is worn.
g00619391
Illustration 234
1. Use Tool (A) to remove retaining ring (1). Remove

pulley (2) from the idler plate assembly.
g00619393
Illustration 237
2. Thoroughly clean the following components: the

bearing bore in the pulley, the outside bearing
g00619393 bore of the pulley, and the outside diameter of
Illustration 235
two bearings (3). Apply 9S-3263 Thread Lock
2. Remove two bearings (3) from pulley (2) with a Compound in the bearing bore of the pulley
press and Tool (B). and on the outside diameter of two bearings
(3). Install two bearings (3) in the pulley with
Tool (B). Ensure that bearings (3) are centered
i01162522 in the pulley.
Belt Tightener - Assemble
SMCS Code: 1358-016
Assembly Procedure
Table 46
Required Tools
Part
Number
B 1P-0510 Driver Group 1
93
2. Install two bolts (1) that hold water pump belt

3. Adjust the tension of V-belt (2). Refer to Operation

and Maintenance Manual, Belt Tension Chart.
i01148551
Fan Drive - Remove

SMCS Code: 1359-011
Removal Procedure
g00619391
Illustration 238 Start By:
3. Install pulley (2) on the idler plate assembly. a. Remove the alternator. Refer to Disassembly and
Install retaining ring (1) with Tool (A) in order to Assembly, Alternator - Remove and Install.
hold pulley (2) to the idler plate assembly.
End By:
a. Install the water pump belt tightener. Refer to

Install.
i01162480
Belt Tightener - Install

SMCS Code: 1358-012

g00609660
g00609661
Illustration 241
1. Remove two bolts (2) and remove alternator

bracket (1).
2. If equipped, remove three bolts (3), the washers,

Illustration 239
g00619355 and the nuts. Remove refrigerant compressor (4).
1. Position water pump belt tightener (3) and install 3. Remove six bolts (5) and the washers. Remove
V-belt (2) on the pulley of water pump belt fan drive (6) and front lifting group (7) from the
tightener (3). cylinder head assembly.
94
i01309851
Fan Drive - Disassemble

SMCS Code: 1359-015
Disassembly Procedures
Start By:
a. Remove the fan drive. Refer to Disassembly and

Assembly, Fan Drive Remove.
NOTICE

component life.
NOTICE
g00693987
Illustration 242
Tools and Shop Products Guide for tools and supplies 1. Remove six bolts (1) and the fan drive pulley.
products. 2. Remove three bolts (6) and the washers from
the bearing retainer (2).
mandates. Note: Access to bolts (6) can be made by rotating
the fan drive shaft.
3. Remove fan drive shaft (5) from fan support (3).
4. Remove two bolts (9) and remove thrust plate (4).
5. Remove rolling bearing (8) and bearing retainer

(2 ) from fan drive shaft (5). Remove O-ring seal
(7) from the bearing retainer.
i01309920
Fan Drive - Assemble

SMCS Code: 1359-016
Fan Drive Assembly

NOTICE

component life.
95
5. Install fan drive shaft (5) in fan support (3). Install

NOTICE the three washers and bolts (6) that hold the
Care must be taken to ensure that fluids are contained unit together.
ing, adjusting and repair of the product. Be prepared to Note: Rotate the fan drive shaft in order to access
collect the fluid with suitable containers before open- the mounting bolt holes.
nent containing fluids. 6. Fill the bearing cavity in the fan drive with 30 g
(1 oz) of 2S-3230 Bearing Lubricant.
Tools and Shop Products Guide for tools and supplies End By:
products. a. Install the Fan Drive. Refer to Disassembly and
Assembly, Fan Drive Install.
mandates.
i01148567
Fan Drive - Install

SMCS Code: 1359-012
g00609660
Illustration 244
g00693987
Illustration 243
1. Check the condition of O-ring seal (7) that is

used in retainer (2). Check the condition of
the roller bearing (8). If the components are
damaged use new parts for replacement.
2. Install roller bearing (8) in bearing retainer (2).

Install the roller bearing so the lip seal is facing
g00609661
toward the retainer for the roller bearing (2). Illustration 245
3. Install O-ring seal (7) in bearing retainer (2). 1. Position fan drive (6) and front lifting group (7)
Install bearing retainer (2) and the roller bearing on the cylinder head assembly. Install six bolts
(8) as a unit on the fan drive shaft (5). Seat the (5) and the washers.
bearing inner race against the fan drive shaft.
2. If equipped, position refrigerant compressor (4).
4. Use two bolts (9) and install thrust plate (4). Install three bolts (3), the washers, and the nuts.
96
3. Position alternator bracket (1). Install two bolts 1. Loosen the screw (3) until wiring harness
(2). connector (1) can be disconnected. Disconnect
wiring harness (1) from electronic control module
End By: (2).
a. Install the alternator. Refer to Disassembly and 2. Remove four bolts (4). Remove the electronic
Assembly, Alternator - Remove and Install. control module from the engine.
i01309287 Installation Procedure

Engine Control Module -
Remove and Install
SMCS Code: 1901-010
Removal Procedure
NOTICE

component life.
g00693487
Illustration 247
NOTICE
Care must be taken to ensure that fluids are contained 1. Position electronic control module (2) on the
during performance of inspection, maintenance, test- engine and install four bolts (4).
collect the fluid with suitable containers before open- 2. Connect wiring harness (1) to control module (2).
ing any compartment or disassembling any compo- Install screws (4) and tighten screws to a torque
nent containing fluids. of 0.9 Nm (8 lb in).
Refer to Special Publication, NENG2500, Caterpillar i01148408

suitable to collect and contain fluids on Caterpillar Alternator - Remove and Install
products.
SMCS Code: 1405-010
mandates.
Removal Procedure
Table 47
Required Tools
Part
A 1U-7117 Breaker Bar 1
g00693487
Illustration 246
97
1. Position alternator (3) on the mounting bracket.

Install bolts (2).
2. Use Tool (A) to install drive belt (4) on the drive

pulley of the alternator.
Note: Adjust the tension on the drive belt if the

engine is not equipped with a belt tensioner. Refer
correct adjusting procedure.
3. Connect wires (1) to the alternator. Use the index

marks to correctly connect the wires. Tighten the
mounting bolt for the ground wire to a torque
g00609523
of 6.2 0.6 Nm (54 5 lb in). Tighten the
Illustration 248 mounting bolt for the battery wire to a torque of
Typical Example 11.3 2.3 Nm (100 20 lb in).
Note: Release the tension on the belt at the belt

tightener, if the engine is not equipped with a belt i01012803
tensioner.
Electric Starting Motor -
1. Use tool (A) to release the tension on belt Remove and Install
tensioner (5).
SMCS Code: 1453-010
2. Remove drive belt (4) from the drive pulley on
alternator (3).
Removal Procedure
3. Place an index mark on all electrical wires (1)
1. Place an index mark on all of the electrical wires
that are connected to the alternator. Disconnect
that are connected to the electric starting motor.
electrical wires (1) from the alternator.
Disconnect the electrical wires from the electric
starting motor.
4. Remove two bolts (2).
5. Remove alternator (3) from the mounting bracket.
Table 48
Required Tools
Part
g00519372
Illustration 250
Typical example
2. Fasten a suitable lifting device to the electric

starting motor.
3. Remove three bolts (1).
4. Remove the electric starting motor and the

gasket from the flywheel housing. The weight of
the electric starting motor is 29 kg (65 lb).
g00609523
Illustration 249
Typical example
98
NOTICE
1. Inspect the condition of the gasket. Replace the Keep all parts clean from contaminants.
2. Install the gasket on the electric starting motor. component life.
NOTICE

products.
g00519372
Illustration 251 Dispose of all fluids according to local regulations and
Typical example mandates.
3. Fasten a suitable lifting device to the electric 1. Remove the air pressure from the air tank and
starting motor. drain the coolant from the cooling system.
4. Place the electric starting motor in the flywheel
housing. Install three bolts (1).
5. Connect all of the electrical wires to the electric

starting motor by using the index marks.
i01331969
Air Compressor - Remove and

Install
SMCS Code: 1803-010
Removal Procedure
Table 49
Required Tools
Part
g00609682
Illustration 252
A 138-7573 Link Bracket 1
2. Disconnect water hose (1) and water hose (3)
from the air compressor.
3. Disconnect air hose (2) and oil hose (4) from the
Do not disconnect the air lines until the air pres- air compressor.
sure in the system is at zero. If hose is disconnect-
ed under pressure it can cause personal injury. 4. Install Tool (A) and a proper lifting device to the
air compressor. The weight of the air compressor
99
5. Remove the mounting bracket for a Midland a. Remove bolts (9) that fasten the mounting
EL-740 air compressor by using the following bracket to the air compressor.
procedure:
b. Remove bolts (10) that fasten the mounting
bracket to the cylinder block. Remove the
mounting bracket for the air compressor.
g00609684
Illustration 253
a. Remove bolt (8) and the clip for the oil hose
g00705313
from the bracket for the air compressor. Illustration 255
b. Remove two bolts (5) and bolt (6) that fastens 7. Use two technicians to support air compressor
the bracket for the air compressor to the (12). Remove bolts (11), air compressor (12),
cylinder block. Remove bolt (7) and the and the gasket from the timing gear housing.
spacer between the air compressor and the
bracket for the air compressor. Remove the
bracket for the air compressor.
Table 50
6. Remove the mounting bracket for a Bendix Tu-Flo
550 and Bendix Tu-Flo 750 air compressors by Required Tools
using the following procedure: Part
NOTICE

component life.
g00705242
Illustration 254
Typical example
100
g00705313 g00609684
1. Install Tool (A) and a proper lifting device to the a. Position the bracket for the air compressor
air compressor. The weight of the air compressor and install bolts (5) and (6). Install the spacer
is approximately 23 kg (51 lb). and bolt (7). Hand tighten all bolts.
2. Inspect the condition of the gasket. Replace the NOTICE

gasket, if necessary. Install the gasket between A loose compressor bracket can lead to a broken front
air compressor (12) and the timing gear housing. cover and can cause damage to the front gear train of
the engine.
3. Position air compressor (12) in the front housing.
Ensure that the drive gear engages correctly
with the gear in the front housing. b. Tighten bolt (7) to a torque of 50 10 Nm
(37 7 lb ft). Tighten bolt (5) to a torque of
4. Apply 9S-3263 Thread Lock Compound to the 55 10 Nm (40 7 lb ft). Tighten bolt (6) to
threads of two bolts (11). Install two bolts (11). a torque of 28 7 Nm (21 5 lb ft). Remove
Tighten bolts (11) to a torque of 100 20 Nm the lifting device and Tool (A).
(75 15 lb ft).
6. Install the mounting bracket for Bendix Tu-Flo
5. Install the mounting bracket for a Midland EL-740 550 and Bendix Tu-Flo 750 air compressors by
air compressor by using the following procedure: using the following procedure:
101
7. Connect oil hose assembly (4) to the air

compressor. Connect the clip that holds the hose
assembly to the air compressor. Tighten bolt (8)
that holds the clip to a torque of 28 7 Nm
(21 5 lb ft).
8. Connect water hose (1) and (3) to the air

compressor.
9. Connect air hose (2) to the air compressor.

i01517187
Air Compressor Drive Gear -

Remove
Illustration 258 g00705242 SMCS Code: 1803-011-GE
Typical example
Removal Procedure
a. Position the bracket for the air compressor
and install bolts (9) and bolts (10) finger tight. Table 51
Required Tools
NOTICE Tool Part Number Part Description Qty
A loose compressor bracket can lead to a broken front
cover and can cause damage to the front gear train of Air Compressor
A 132-5451 1
the engine. Gear Holder
Start By:
b. Tighten bolts (9) to a torque of 55 10 Nm
(40 7 lb ft). Tighten bolts (10) to a torque of
55 10 Nm (40 7 lb ft). Remove the lifting a. Remove the air compressor. Refer to Disassembly
device and Tool (A).
Install.
NOTICE

component life.
g00609682
Illustration 260
Typical example
102
1. Mount air compressor (1) in a bench vise. 4. Install air compressor drive gear (4) on the air
compressor crankshaft.
2. Install tool (A) on the air compressor drive gear.
5. Install washer (3) and nut (2).
3. Remove nut (2) and washer (3).
4. Remove air compressor drive gear (4).
7. Tighten nut (2) to a torque of 165 10 Nm
(120 7 lb ft).
i01517157
Air Compressor Drive Gear - 8. Place a driver which is slightly larger than the nut
over the nut and tap the driver with a hammer.
Install
9. Tighten the nut again to a torque of 165 10 Nm
SMCS Code: 1803-012-GE (120 7 lb ft).
Installation Procedure End By:
Table 52 a. Install the air compressor. Refer to Disassembly

Required Tools Install.
A 132-5451 Air Compressor Gear 1
Holder
NOTICE

component life.
g00609907
Illustration 261
Typical example
1. Use 138-8440 Component Cleaner in order to

clean the inside diameter of gear (4) and the
outside diameter of the drive shaft for the air
compressor.
2. Lubricate washer (3) and the threads on the

drive shaft with clean engine oil.
3. Mount air compressor (1) in a bench vise.

103
Index Section
Index
A Crankshaft Front Seal - Install ............................... 51
Installation Procedure ........................................ 51
Air Compressor - Remove and Install.................... 98 Crankshaft Front Seal - Remove ........................... 50
Installation Procedure ........................................ 99 Removal Procedure ........................................... 50
Removal Procedure ........................................... 98 Crankshaft Gear - Remove and Install .................. 86
Air Compressor Drive Gear - Install..................... 102 Installation Procedure ........................................ 87
Installation Procedure ...................................... 102 Removal Procedure ........................................... 86
Air Compressor Drive Gear - Remove................. 101 Crankshaft Main Bearings - Install......................... 82
Removal Procedure ......................................... 101 Installation Procedure ........................................ 82
Air Inlet Cover - Remove and Install ...................... 20 Crankshaft Main Bearings - Remove..................... 81
Removal Procedure ........................................... 20 Crankshaft Rear Seal - Install................................ 45
Air Inlet Heater - Remove and Install..................... 19 Installation Procedure ........................................ 45
Installation Procedure ........................................ 19 Crankshaft Rear Seal - Remove............................ 45
Removal Procedure ........................................... 19 Removal Procedure ........................................... 45
Air Inlet Heater Solenoid - Remove and Install...... 20 Crankshaft Rear Seal Carrier - Remove and
Installation Procedure ........................................ 20 Install ................................................................... 46
Removal Procedure ........................................... 20 Installation Procedure ........................................ 47
Alternator - Remove and Install ............................. 96 Removal Procedure ........................................... 46
Installation Procedure ........................................ 97 Crankshaft Wear Sleeve (Rear) - Install ................ 84
Equipped) ............................................................ 84
B Removal Procedure ........................................... 84
Cylinder Head - Install ........................................... 65
Bearing Clearance - Check ................................... 87 Installation Procedure ........................................ 65
Measurement Procedure ................................... 87 Cylinder Head - Remove ....................................... 64
Belt Tensioner - Remove and Install ...................... 91 Removal Procedure ........................................... 64
Removal Procedure ........................................... 91
Belt Tightener - Assemble ..................................... 92 D
Assembly Procedure.......................................... 92
Belt Tightener - Disassemble ................................ 91 Disassembly and Assembly Section........................ 5
Disassembly Procedure ..................................... 91
Belt Tightener - Install............................................ 93
Installation Procedure ........................................ 93 E
Belt Tightener - Remove........................................ 91
Removal Procedure ........................................... 91 Electric Starting Motor - Remove and Install ......... 97
C Engine Control Module - Remove and Install ........ 96
Camshaft - Install................................................... 69 Removal Procedure ........................................... 96
Installation Procedure ........................................ 69 Engine Lifting Bracket - Remove and Install.......... 43
Camshaft - Remove............................................... 68 Installation Procedure ........................................ 43
Camshaft Bearings - Remove and Install .............. 70 Engine Oil Cooler - Install...................................... 31
Installation Procedure ........................................ 71 Installation Procedure ........................................ 31
Removal Procedure ........................................... 70 Engine Oil Cooler - Remove .................................. 30
Camshaft Gear - Remove and Install .................... 70 Removal Procedure ........................................... 30
Installation Procedure ........................................ 70 Engine Oil Cooler Bypass Valve - Remove and
Removal Procedure ........................................... 70 Install ................................................................... 29
Camshaft Idler Gear - Remove and Install ............ 58 Installation Procedure ........................................ 30
Removal Procedure ........................................... 58 Engine Oil Filter Base - Assemble......................... 27
Crankshaft - Install................................................. 85 Assembly Procedure.......................................... 27
Installation Procedure ........................................ 85 Engine Oil Filter Base - Disassemble .................... 26
Crankshaft - Remove............................................. 83 Disassembly Procedure ..................................... 26
Removal Procedure ........................................... 83 Engine Oil Filter Base - Install ............................... 28
104
Index Section
Engine Oil Filter Base - Remove ........................... 26 G

Engine Oil Filter Bypass Valve - Remove and Gear Group (Front) - Install ................................... 53
Install ................................................................... 28 Installation Procedure ........................................ 53
Installation Procedure ........................................ 29 Gear Group (Front) - Remove ............................... 53
Engine Oil Pan - Remove and Install ..................... 72
Removal Procedure ........................................... 72 H
Engine Oil Pump - Assemble................................. 34
Assembly Procedure.......................................... 34 Housing (Front) - Install ......................................... 57
Engine Oil Pump - Disassemble............................ 33 Installation Procedure ........................................ 57
Disassembly Procedure ..................................... 33 Housing (Front) - Remove ..................................... 57
Engine Oil Pump - Install ....................................... 36 Removal Procedure ........................................... 57
Engine Oil Pump - Remove ................................... 32
Removal Procedure ........................................... 32 I
Engine Support (Front) - Remove and Install ........ 43
Installation Procedure ........................................ 43 Idler Pulley - Assemble .......................................... 90
Removal Procedure ........................................... 43 Assembly Procedure.......................................... 90
Ether Atomizer - Remove and Install ..................... 88 Idler Pulley - Disassemble ..................................... 89
Installation Procedure ........................................ 89 Disassembly Procedure ..................................... 89
Removal Procedure ........................................... 88 Idler Pulley - Install ................................................ 90
Exhaust Manifold - Remove and Install ................. 18 Installation Procedure ........................................ 90
Installation Procedure ........................................ 18 Idler Pulley - Remove ............................................ 89
Important Safety Information ................................... 2
F Assemble ............................................................. 13
Fan Drive - Assemble ............................................ 94 Injection Actuation Pressure Control Valve -
Fan Drive Assembly ........................................... 94 Disassemble ........................................................ 12
Fan Drive - Disassemble ....................................... 94 Disassembly Procedure ..................................... 12
Disassembly Procedures ................................... 94 Injection Actuation Pressure Control Valve -
Fan Drive - Install................................................... 95 Install ................................................................... 13
Fan Drive - Remove............................................... 93 Injection Actuation Pressure Control Valve -
Removal Procedure ........................................... 93 Remove ............................................................... 12
Flywheel - Install.................................................... 44 Removal Procedure ........................................... 12
Installation Procedure ........................................ 44 Inlet and Exhaust Valve Guides - Remove and
Flywheel - Remove................................................ 44 Install ................................................................... 23
Flywheel Housing - Remove and Install ................ 48 Removal Procedure ........................................... 23
Installation Procedure ........................................ 48 Inlet and Exhaust Valve Seat Inserts - Remove and
Front Cover - Install ............................................... 52 Installation Procedure ........................................ 25
Front Cover - Remove ........................................... 52 Inlet and Exhaust Valves - Remove and Install ..... 21
Fuel Filter Base - Remove and Install ..................... 5 Removal Procedure ........................................... 21
Installation Procedure .......................................... 5
Removal Procedure ............................................. 5
Fuel Pressure Regulator - Remove and Install........ 8 L
Removal Procedure ............................................. 8 Lifter Group - Remove and Install.......................... 66
Fuel Transfer Pump - Install..................................... 7 Installation Procedure ........................................ 67
Installation Procedure .......................................... 7 Removal Procedure ........................................... 66
Fuel Transfer Pump - Remove ................................. 6
105
Index Section
P Vibration Damper and Pulley - Remove and

Install ................................................................... 49
Piston Cooling Jets - Remove and Install .............. 74 Installation Procedure ........................................ 50
Pistons and Connecting Rods - Assemble ............ 77
Assembly Procedure.......................................... 77 W
Disassembly Procedure ..................................... 76 Water Pump - Assemble........................................ 38
Pistons and Connecting Rods - Install................... 79 Assembly Procedure.......................................... 38
Installation Procedure ........................................ 79 Water Pump - Disassemble ................................... 37
Pistons and Connecting Rods - Remove............... 75 Disassembly Procedure ..................................... 37
Removal Procedure ........................................... 75 Water Pump - Install .............................................. 39
Water Pump - Remove .......................................... 36
R Removal Procedure ........................................... 36
Water Temperature Regulator - Remove and
Rocker Shaft - Assemble ....................................... 63 Install ................................................................... 41
Assembly Procedure.......................................... 63 Installation Procedure ........................................ 42
Rocker Shaft - Disassemble .................................. 62 Removal Procedure ........................................... 41
Disassembly Procedure ..................................... 62 Water Temperature Regulator Housing - Remove and
Rocker Shaft and Pushrod - Install ........................ 63 Install ................................................................... 40
Rocker Shaft and Pushrod - Remove .................... 61 Removal Procedure ........................................... 40
Table of Contents..................................................... 3
Turbocharger - Assemble ...................................... 17
Turbocharger - Disassemble.................................. 16
Turbocharger - Install............................................. 17
Turbocharger - Remove ......................................... 15
Unit Injector - Install............................................... 10

Unit Injector - Remove ............................................. 9
Unit Injector Hydraulic Pump - Remove................. 14
Unit Injector Sleeve - Install ................................... 11
Unit Injector Sleeve - Remove ............................... 10
Valve Mechanism Cover - Remove and Install ...... 60

106
Index Section
107
Index Section
2001 Caterpillar
All Rights Reserved Printed in U.S.A.
SENR3130-07
April 2000
Specifications
Torque Specifications
i01097883


this publication.


death.
3
Table of Contents
Table of Contents
Specifications Section
General Torque Information .................................. 4
Standard Torque for Metric Fasteners .................. 4
Standard Torque for Inch Fasteners ...................... 5
Standard Torque for O-Ring Face Seal Fittings and
37 Degree Flared Fittings ................................... 5
O-Ring Face Seal Fittings ..................................... 6
Fitting Installation .................................................. 6
Torques for Flared and O-Ring Fittings ................. 8
Air Conditioning Fittings ........................................ 9
Tapered Pipe Thread Fittings ................................ 9
Tightening Other Fittings ...................................... 10
Standard Torque for Worm Drive Band Hose
Clamps ................................................................ 10
Standard Torque for Constant Torque Hose
Clamps ................................................................ 11
Index Section
Index ..................................................................... 12
4
Specifications Section Table 2

Metric Taperlock Studs
i01252954 Thread Size

Standard Torque
Metric
General Torque Information M6 8 3 Nm (6 2 lb ft)
SMCS Code: 7553 M8 17 5 Nm (13 4 lb ft)
M10 35 5 Nm (26 4 lb ft)
M12 65 10 Nm (48 7 lb ft)
Mismatched or incorrect fasteners can result in M16 110 20 Nm (80 15 lb ft)
damage or malfunction, or personal injury.
M20 170 30 Nm (125 22 lb ft)
Take care to avoid mixing metric dimensioned fas- M24 400 60 Nm (300 44 lb ft)
teners and inch dimensioned fasteners.
M30 750 80 Nm (550 60 lb ft)
Exceptions to these torques are given in the Service M36 1200 150 Nm (880 110 lb ft)
Manual, if necessary.
Prior to installation of any hardware, ensure that

components are in near new condition. Bolts and
threads must not be worn or damaged. Threads
must not have burrs or nicks. Hardware must be
free of rust and corrosion. Clean the hardware with
a noncorrosive cleaner. Do not lubricate the fastener
threads except for the rust preventive. The rust
preventive should be applied by the supplier of that
component for purposes of shipping and storage.
Other applications for lubricating components may
also be specified in the Service Manual.
i00621350
Standard Torque for Metric

Fasteners
SMCS Code: 7553
Table 1
Metric Nuts and Bolts
Thread Size
Standard Torque
Metric
M6 12 3 Nm (9 2 lb ft)
M8 28 7 Nm (21 5 lb ft)
M10 55 10 Nm (41 7 lb ft)
M12 100 20 Nm (75 15 lb ft)
M14 160 30 Nm (120 22 lb ft)
M16 240 40 Nm (175 30 lb ft)
M20 460 60 Nm (340 44 lb ft)
M24 800 100 Nm (590 75 lb ft)
M30 1600 200 Nm (1180 150 lb ft)
M36 2700 300 Nm (2000 220 lb ft)
5
i00621349 i00642843
Standard Torque for Inch Standard Torque for O-Ring

Fasteners Face Seal Fittings and 37
SMCS Code: 7553
Degree Flared Fittings
Table 3 SMCS Code: 7553
Inch Nuts and Bolts
Thread Size
Standard Torque
Inch
1/4 12 3 Nm (9 2 lb ft)
5/16 25 6 Nm (18 4 lb ft)
3/8 47 9 Nm (35 7 lb ft)
7/16 70 15 Nm (50 11 lb ft)
1/2 105 20 Nm (75 15 lb ft)
9/16 160 30 Nm (120 22 lb ft)
5/8 215 40 Nm (160 30 lb ft)
3/4 370 50 Nm (275 37 lb ft)
7/8 620 80 Nm (460 60 lb ft)
1 900 100 Nm (660 75 lb ft)
1 1/8 1300 150 Nm (960 110 lb ft)
g00287842
1 1/4 1800 200 Nm (1320 150 lb ft) Illustration 1
1 3/8 2400 300 Nm (1780 220 lb ft) (A) O-ring face seal. (B) 37 degree flare. (C) O-ring plug with a
hexagon head. (1) O-ring seal. (2) Hexagon head.
1 1/2 3100 350 Nm (2280 260 lb ft)
Table 4
Inch Taperlock Studs
Thread Size
Standard Torque
Inch
1/4 8 3 Nm (6 2 lb ft)
5/16 17 5 Nm (13 4 lb ft)
3/8 35 5 Nm (26 4 lb ft)
7/16 45 10 Nm (33 7 lb ft)
1/2 65 10 Nm (48 7 lb ft)
5/8 110 20 Nm (80 15 lb ft)
3/4 170 30 Nm (125 22 lb ft)
7/8 260 40 Nm (190 30 lb ft)
1 400 60 Nm (300 44 lb ft)
1 1/8 525 60 Nm (390 44 lb ft)
1 1/4 750 80 Nm (550 60 lb ft)
1 3/8 950 125 Nm (700 90 lb ft)
1 1/2 1200 150 Nm (880 110 lb ft)
6
Table 5 i00643194
Ferrous Straight Thread O-Ring Fitting

Torques for Mating with Ferrous Materials
O-Ring Face Seal Fittings
Outer Diameter SMCS Code: 7553
Thread Size Standard
of the Nominal
Inch Torque
Tube
3.18 mm 5.0 1.5 Nm
5/16 - 24
(.125 inch) (4 1 lb ft)
4.76 mm 12 2 Nm
3/8 - 24
(.188 inch) (9 1 lb ft)
6.35 mm 22 2 Nm
7/16 - 20
(.250 inch) (16 1 lb ft)
7.94 mm 30 3 Nm
1/2 - 20
(.312 inch) (22 2 lb ft)
9.52 mm 48 5 Nm
9/16 - 18
(.375 inch) (35 4 lb ft)
12.70 mm 82 8 Nm g00287959
3/4 - 16 Illustration 2
(.500 inch) (60 6 lb ft)
O-ring face seal fittings
15.88 mm 143 15 Nm (1) O-ring face seal fitting. (2) O-ring groove. (3) Nut for the O-ring
7/8 - 14
(.625 inch) (105 11 lb ft) face seal. (4) O-ring seal. (5) Straight thread O-ring fitting.
19.05 mm 190 20 Nm Table 6

1 1/16 - 12
(.750 inch) (140 15 lb ft)
Ferrous Straight Thread O-Ring Fitting
22.22 mm 250 25 Nm
1 3/16 - 12 Thread Size
(.875 inch) (185 18 lb ft) Standard Torque
Inch
25.40 mm 300 30 Nm
1 5/16 - 12 9/16 - 18 25 3 Nm (18 2 lb ft)
(1.000 inch) (220 22 lb ft)
31.75 mm 350 30 Nm 11/16 - 16 37 4 Nm (27 3 lb ft)
1 5/8 - 12
(1.250 inch) (260 22 lb ft)
13/16 - 16 54 5 Nm (40 4 lb ft)
38.10 mm 430 40 Nm
1 7/8 - 12 1 - 14 86 8 Nm (65 6 lb ft)
(1.500 inch) (320 30 lb ft)
50.80 mm 450 45 Nm 1 13/16 - 12 125 15 Nm (90 11 lb ft)
2 1/2 - 12
(2.000 inch) (330 33 lb ft) 1 7/16 - 12 165 15 Nm (120 11 lb ft)
1 11/16 - 12 200 20 Nm (150 15 lb ft)
Note: Use 50 percent of the torque values from
Table 5 when the fitting, the plug or the port material 2 - 12 225 20 Nm (165 15 lb ft)
is nonferrous.
i00643197
Fitting Installation
SMCS Code: 7553
Note: The tightening sequence of the fasteners that

attach a tube assembly or hose assembly to the
machine is very critical to the proper function of the
machine. The sealing surfaces of the tube assembly
or hose assembly should be secured squarely.
The sealing surfaces of the tube assembly or hose
assembly should be tightened to the serviced
component (control valve, cylinder, hydraulic motor,
etc). Perform this procedure prior to the final
tightening of any clamps or clips that are used
in order to fasten the tube assembly or the hose
assembly to the machine.
7
Installation of the Hydraulic Line

1. For a metal tube to hose installation, install the
tube and tighten all bolts finger tight at the rigid
end.
2. Install the hose and tighten all bolts finger tight.
3. Put the hose in a position so that the hose does

not make contact with the machine or with
another hose.
4. Tighten the bolts on both connections to the

specified torque.
5. Start the engine.
6. Move the implement control levers to all of the

positions.
7. Look at the hose during movement of the

implement. Ensure that the hose is not in contact Illustration 3 g00288144
with the machine or with other hoses. Elbow body assembly
(1) End of the fitting body that connects to the tube. (2) Fitting
8. Shut off the engine. body. (3) Locknut. (4) Backup washer. (5) O-ring seal. (6) End of
the fitting that goes into the other part.
9. If necessary, put the hose in a new position so
that the hose will not make contact when the 1. Put locknut (3), backup washer (4) and O-ring
machine implement is moved. seal (5) as far back on fitting body (2) as
possible. Hold these components in this position.
Assembly of the Fittings with Turn the fitting into the part that is used for the
fitting. Turn the fitting until backup washer (4)
Straight Threads and O-Ring Seals contacts the surface of the part that is used for
backup washer (4).
This type of fitting is used in many applications.
The tube end of the fitting will be different in 2. To put the fitting assembly in the correct position,
design so that the fitting can be used in many turn fitting body (2) outward to a maximum of
different applications. However, the same installation 360 degrees. Tighten locknut (3) to the torque
procedure for the fitting can be used. If the tube that is shown in the correct chart for the fitting
end of the fitting body and the illustration (elbow or that is used.
straight body) match, it is necessary to assemble
the sleeve on the tube before connecting the tube Note: If the fitting is a connector (straight fitting), the
to the end. hex on the body takes the place of the locknut. To
install this type of fitting, tighten the hex against the
face of the part for the hex.
8
i00644796 Table 7
Torques for Flared and O-Ring Nuts for 37 Degree Flared Fittings
Fittings Outer Diameter

of the Nominal
Inch Torque
Tube
SMCS Code: 7553
3.18 mm 5.0 1.5 Nm
5/16
The torques that are shown in Table 7 and in Table (.125 inch) (4 1 lb ft)
8 should be used on the nut of the following fittings: 4.76 mm 11 2 Nm
37 degree flared fittings, 45 degree flared fittings, 3/8
(.188 inch) (8 1 lb ft)
inverted flared fittings, O-ring plugs for a recessed
drive, O-ring fittings for the air conditioning, 6.35 mm 16 4 Nm
7/16
and swivel nuts. The torques should be used (.250 inch) (12 3 lb ft)
for applications that allow the following working 7.94 mm 20 5 Nm
pressures: 7750 to 34,450 kPa (1125 to 5000 psi). 1/2
(.312 inch) (15 4 lb ft)
The torque depends on the size of the fitting and
the type of the fitting. 9.52 mm 25 5 Nm
9/16
(.375 inch) (18 4 lb ft)
37 Degree Flared Fittings 9.52 mm 35 5 Nm

5/8
(.375 inch) (26 4 lb ft)
12.70 mm 50 7 Nm
3/4
(.500 inch) (37 5 lb ft)
15.88 mm 65 7 Nm
7/8
(.625 inch) (48 5 lb ft)
19.05 mm 100 10 Nm
1 1/16
(.750 inch) (75 7 lb ft)
g00288204 22.22 mm 120 10 Nm
Illustration 4
1 3/16
(1) 37 degree flared fitting. (2) Swivel nuts.
(.875 inch) (90 7 lb ft)
25.40 mm 135 15 Nm
1 5/16
(1.000 inch) (100 11 lb ft)
31.75 mm 180 15 Nm
1 5/8
(1.250 inch) (135 11 lb ft)
38.10 mm 225 15 Nm
1 7/8
(1.500 inch) (165 11 lb ft)
50.80 mm 320 30 Nm
2 1/2
(2.000 inch) (240 22 lb ft)

Table 7 when the fitting, the plug or the port material
is nonferrous.
45 Degree Flared and 45 Degree

Inverted Flare Fittings
g00288205
Illustration 5
(1) 45 degree inverted flared fittings. (2) 45 degree flared fittings.
9
Table 8 Table 9
45 Degree Flared Fittings and 45 Degree Air Conditioning Fittings
Inverted Flare Fittings
45 Degree Flare Fitting
O-Ring Fitting End
Outer Diameter End
of the Nominal
Inch Torque Steel Aluminum
Tube Thread
Standard Tubes Tubes
Size
3.18 mm 5.0 1.5 Nm Torque Standard Standard
5/16 Inch
(.125 inch) (4 1 lb ft) Torque Torque
4.76 mm 8.0 1.5 Nm 14 4 Nm 30 3 Nm 23 3 Nm
3/8 5/8 - 18
(.188 inch) (6 1 lb ft) (10 3 lb ft) (22 2 lb ft) (17 2 lb ft)
6.35 mm 11 2 Nm 27 4 Nm 52 5 Nm 33 4 Nm
7/16 3/4 - 16
7.94 mm 17 3 Nm 40 4 Nm 60 7 Nm 38 4 Nm
1/2 7/8 - 14
9.52 mm 30 3 Nm 45 5 Nm 75 8 Nm 50 5 Nm
5/8 1 1/16 - 14
11.11 mm 30 3 Nm
11/16
(.438 inch) (22 2 lb ft)
i00644809
12.70 mm 38 4 Nm
(.500 inch)
3/4
(28 3 lb ft) Tapered Pipe Thread Fittings
15.88 mm 50 5 Nm
(.625 inch)
7/8
(37 4 lb ft)
SMCS Code: 7553
19.05 mm 90 8 Nm Table 10
1 1/16
(.750 inch) (65 6 lb ft) Tapered Pipe Thread Fittings
22.22 mm 100 10 Nm Standard Torque
1 1/4
(.875 inch) (75 7 lb ft) Thread Size
of the Pipe Threads with
Threads without
Inch 5P-3413 Pipe
Pipe Sealant
i00644800 Sealant
1/16 - 27 10 Nm (7 lb ft) 10 Nm (7 lb ft)
Air Conditioning Fittings
1/8 - 27 16 Nm (12 lb ft) 16 Nm (12 lb ft)
SMCS Code: 7553
1/4 - 18 20 Nm (15 lb ft) 25 Nm (18 lb ft)
3/8 - 18 35 Nm (26 lb ft) 45 Nm (33 lb ft)
1/2 - 14 45 Nm (33 lb ft) 60 Nm (44 lb ft)
3/4 - 14 60 Nm (44 lb ft) 75 Nm (55 lb ft)
1 - 11 1/2 75 Nm (55 lb ft) 90 Nm (65 lb ft)
1 1/4 - 11 1/2 90 Nm (65 lb ft) 110 Nm (80 lb ft)
g00288301
Illustration 6
1 1/2 - 11 1/2 110 Nm (80 lb ft) 130 Nm (95 lb ft)
(1) O-ring seal. (2) 45 degree flare fitting.
2 - 11 1/2 130 Nm (95 lb ft) 160 Nm (120 lb ft)

Table 10 when the fitting, the plug or the port
material is nonferrous.
10
i00645384 Put the nut and the sleeve over the tube. The head
of the sleeve or the shoulder end of the sleeve
Tightening Other Fittings should be next to the nut. Push the tube into the
counterbore of the fitting body as far as possible.
SMCS Code: 7553 Turn the nut clockwise until the sleeve holds the
tube and until the sleeve prevents the tube from
Hi Duty Tube Fittings (Shear Sleeve) moving. Tighten the nut for an additional 1 1/4 turns.
The sleeve should be seated and the sleeve should
give a locking action. When it is necessary to
assemble the tube fitting again, put the sleeve over
the tube and tighten the nut until a sudden increase
in torque is felt. Next, tighten the fitting for an
additional 1/6 to 1/3 turn in order to seat the sleeve.
Flex Fittings
g00288323
Illustration 7
After the tube has been put through the nut and
after the tube makes contact against the tube
shoulder in the fitting body, turn the nut with a
wrench until a small decrease in torque is felt. The
small decrease in torque indicates that the sleeve
has been broken off of the nut. Hold the tube in
order to prevent the tube from turning. Tighten the Illustration 10
g00288326
nut for an additional 1 1/2 turns.
Put the nut and the sleeve over the tubing and push
Hi Seal Fittings the tube into the counterbore of the fitting body
as far as possible. Tighten the nut until the nut is
against the hex part of the fitting body.
i01206505
Standard Torque for Worm

Drive Band Hose Clamps
g00288324
Illustration 8 SMCS Code: 7553
Put the nut and the sleeve over the tubing so that
the end of the sleeve that is short and heavy is
facing the end of the tubing. Put the tube end
against the counterbore in the body of the fitting and
tighten the nut until the nut is over the last thread
on the body. The remainder of the space is used
whenever the fitting is removed and installed again.
g00280501
Illustration 11
Tube Fittings that are Not Flared
g00288325
Illustration 9
11
Table 11
Initial Installation Torque
Width of Clamp
On New Hose
7.9 mm (0.31 inch) 0.9 0.2 Nm (8 2 lb in)
13.5 mm (0.53 inch) 4.5 0.5 Nm (40 4 lb in)
15.9 mm (0.63 inch) 7.5 0.5 Nm (65 4 lb in)
Reassembly or Retightening
Width of Clamp
Torque
7.9 mm (0.31 inch) 0.7 0.2 Nm (6 2 lb in)
13.5 mm (0.53 inch) 3.0 0.5 Nm (27 4 lb in)
15.9 mm (0.63 inch) 4.5 0.5 Nm (40 4 lb in)
i01206414
Standard Torque for Constant

Torque Hose Clamps
SMCS Code: 7553
Use a constant torque hose clamp in place of any

standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
hose clamp. Due to extreme temperature changes,
the hose will heat set. Heat setting can cause hose
clamps to loosen. Loose hose clamps can result
in leaks. There have been reports of component
failures that have been caused by hose clamps that
have loosened. The constant torque hose clamp will
help prevent these failures.
g00279591
Illustration 12
Use a torque wrench for proper installation of the

constant torque hose clamps. The constant torque
hose clamp is installed correctly under the following
conditions:
Screw tip (1) extends 6.35 mm (0.25 inch) (X)

beyond the housing.
The belleville washers are collapsed nearly

flat after screw (2) is tightened to a torque of
11 1 Nm (98 9 lb in).
Index
A
Air Conditioning Fittings......................................... 9
Fitting Installation................................................... 6
Assembly of the Fittings with Straight Threads and
O-Ring Seals.................................................... 7
Installation of the Hydraulic Line ........................ 7
General Torque Information................................... 4
Important Safety Information ................................. 2
O-Ring Face Seal Fittings ..................................... 6
Specifications Section ........................................... 4

Standard Torque for Constant Torque Hose
Clamps................................................................. 11
Standard Torque for Inch Fasteners ...................... 5
Standard Torque for Metric Fasteners ................... 4
Standard Torque for O-Ring Face Seal Fittings and
37 Degree Flared Fittings .................................... 5
Standard Torque for Worm Drive Band Hose
Clamps................................................................. 10
Table of Contents................................................... 3
Tapered Pipe Thread Fittings ................................ 9
Tightening Other Fittings ....................................... 10
Flex Fittings........................................................ 10
Hi Duty Tube Fittings (Shear Sleeve) ................. 10
Hi Seal Fittings................................................... 10
Tube Fittings that are Not Flared........................ 10
Torques for Flared and O-Ring Fittings ................. 8
37 Degree Flared Fittings .................................. 8
45 Degree Flared and 45 Degree Inverted Flare
Fittings.............................................................. 8
2000 Caterpillar
RENR1270-06
March 2001
Specifications
3126B and 3126E Truck Engines
BKD1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Atmospheric Pressure Sensor (If Equipped) ........

Inlet Air Temperature Sensor ................................
36
36
Speed and Timing Sensor ................................... 37
Electronic Control Wiring Group ........................... 37
Specifications Section Air Inlet Heater ...................................................... 37
Air Compressor (Midland Air Compressors) ......... 38
Engine Design ....................................................... 4
Air Compressor (Bendix Tu-Flo Air
Fuel Transfer Pump (Fuel Transfer Pump and High
Compressors) ..................................................... 38
Pressure Oil Pump) ............................................... 4
Fuel Filter Lines ...................................................... 5
Fuel Filter Base ...................................................... 5 Index Section
Injection Actuation Pressure Control Valve ............. 6
Unit Injector ............................................................. 6 Index ..................................................................... 40
Valve Rocker Arms, Lifters, and Bridges ............... 7
Valve Mechanism Cover ........................................ 7
Cylinder Head Valves .............................................. 7
Cylinder Head ........................................................ 9
Turbocharger ........................................................ 11
Air Inlet Elbow ....................................................... 12
Exhaust Manifold ................................................. 12
Exhaust Elbow ..................................................... 12
Exhaust Brake ...................................................... 13
Camshaft ............................................................. 13
Engine Oil Filter Base .......................................... 14
Engine Oil Cooler Bypass Valve ........................... 14
Engine Oil Pump .................................................. 15
Engine Oil Pan ..................................................... 15
Crankcase Breather ............................................. 16
Water Temperature Regulator .............................. 16
Water Pump ......................................................... 17
Cylinder Block Cover Group ................................ 18
Cylinder Block ...................................................... 18
Crankshaft ........................................................... 20
Crankshaft Seals ................................................. 20
Rear Seal Carrier (If Equipped) ............................ 21
Vibration Damper ................................................. 22
Connecting Rod Bearing Journal ......................... 22
Main Bearing Journal ............................................ 22
Connecting Rod ................................................... 22
Piston and Rings .................................................. 23
Piston and Rings .................................................. 24
Piston Cooling Jet ................................................. 26
Front Housing and Covers ................................... 27
Gear Group (Front) ............................................... 28
Flywheel ............................................................... 29
Flywheel Housing ................................................ 29
Engine to Transmission Adapter (If Equipped) ..... 30
Crankshaft Pulley ................................................. 30
Belt Tension Chart ............................................... 30
Belt Tensioner (If Equipped) ................................. 31
Belt Tightener ...................................................... 31
Refrigerant Compressor ....................................... 32
Fan Drive ............................................................. 32
Alternator and Regulator ...................................... 33
Electric Starting Motor ......................................... 33
Coolant Temperature Sensor ............................... 35
Injection Actuation Pressure Sensor ..................... 35
Engine Oil Pressure Sensor (If Equipped) ............ 35
Engine Oil Temperature Sensor (If Equipped) ...... 36
Boost Pressure Sensor ......................................... 36
4
Specifications Section i01147139
Fuel Transfer Pump

i01146230 (Fuel Transfer Pump and High
Engine Design Pressure Oil Pump)
SMCS Code: 1201 SMCS Code: 1256
g00290846 g00608597
Cylinder And Valve Location
(A) Exhaust valve.
(1) Tighten the bolt to the following
torque. .................. 110 14 Nm (80 10 lb ft)
(B) Inlet valve.
(2) Injection actuation pressure control valve
Bore ............................................ 110 mm (4.3 inch) (IAPCV)
Stroke .......................................... 127 mm (5.0 inch) (3) Tighten the inlet of the oil pump to the following
3 torque. ........................ 26 3 Nm (19 2 lb ft)
Displacement .................................. 7.25 L (442 in )
(4) Tighten the outlet of the oil pump to the following
Number of cylinders ............................................... 6 torque. ........................ 23 2 Nm (17 1 lb ft)
Cylinder arrangement ..................................... In-line (5) Tighten the outlet of the fuel pump to the
following torque. ......... 18 2 Nm (13 1 lb ft)
Valves per cylinder ................................................. 3
(6) Tighten the inlet of the fuel pump to the following
In order to check the engine valve lash setting, torque. ........................ 18 2 Nm (13 1 lb ft)
the engine must be cold and the engine must be
stopped. Engine valve lash settings
Inlet .................................. 0.38 mm (0.015 inch)
Exhaust ............................ 0.64 mm (0.025 inch)
Type of combustion .......................... Direct Injection
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4
The crankshaft rotation is viewed from the

flywheel end of the engine. Crankshaft
rotation .......................................... counterclockwise
Note: The front end of the engine is opposite of

the flywheel end of the engine. The left side of the g00617095
Illustration 3
engine and the right side of the engine are viewed
from the flywheel end of the engine. The number
one cylinder is the front cylinder. (7) Tighten the nut on the tube assembly to the
5
(8) Tighten the locknut at the cylinder head to the i00867319

Fuel Filter Base
(9) Connection of tube assembly to pump outlet
SMCS Code: 1261; 1262
Tighten the nut on the tube assembly to the
Tighten the locknut at the pump outlet to the
following torque. ...... 23 2 Nm (17 1.5 lb ft)
i00665415
Fuel Filter Lines

SMCS Code: 1274
g00322250
Illustration 5
Typical example
(1) Put 4C-9507 Retaining Compound on the

tapered end of the stud to the following
distance. ............. 7.6 1.5 mm (.30 .06 inch)
(2) Distance from the sealing surface of the filter

base to the end of the stud ....... 24.6 1.3 mm
(.97 .05 inch)
g00291745
Illustration 4
Typical example (3) Sealing surface of the stud
Left side of engine
Note: Do not damage this surface.
Note: Refer to the System Operation, Testing and
(4) Torque for stud .. 68 7 Nm (50.15 5.16 lb ft)
Adjusting, Fuel Pressure for the correct method of
inspecting fuel pressure.
(1) Tube assembly (fuel filter to fuel gallery)
(2) Tube assembly (fuel transfer pump to fuel filter)
(3) Fuel outlet port
(4) The fuel pressure regulator valve maintains

minimum fuel system pressure.
Minimum pressure at low idle .. 400 kPa (58 psi)
(5) The position for the fuel pressure regulator valve

is 10 Degrees from horizontal.
6
i00665959 i01146244
Injection Actuation Pressure Unit Injector

Control Valve SMCS Code: 1290
SMCS Code: 5051
g00291832
Illustration 6
(1) Install the injection actuation pressure control

valve. Tighten the valve to the following
torque. ........................ 50 5 Nm (37 4 lb ft)
(2) Tighten the nut to the following

torque. ................. 5.5 1.5 Nm (49 13 lb in)
(3) Spacer
g00616863
Illustration 7
(1) Lubricate the bore slightly. Use the lubricant

that is being sealed.
(2) Tighten bolt (2) to the following

torque. ......................... 6 1 Nm (53 9 lb in)
(3) Position oil deflector (3).
(4) Tighten bolt (4) to the following

torque. ................... 12 3 Nm (106 26 lb in)
7
i01510477 (5) The lifter group must be installed with the oil
holes in the shaft, as shown.
Valve Rocker Arms, Lifters,
and Bridges (6) Apply 9S-3263 Thread Lock Compound.
Tighten the bolts that are shown above
SMCS Code: 1102; 1121; 1209 in a numerical sequence to the following
torque. ........................ 13 3 Nm (10 2 lb ft)
i00666014
Valve Mechanism Cover

SMCS Code: 1107
g00291835
Illustration 10
Typical example
Tighten the bolts in a numerical sequence to the

following torque. ................. 12 3 Nm (9 2 lb ft)
g00291845
Illustration 8
i01146333
(1) Valve rocker arm assembly Cylinder Head Valves

Bore in the rocker arm for the shaft
(new) ................................... 21.548 0.013 mm SMCS Code: 1105
(0.8483 0.0005 inch)
Diameter of the rocker arm shaft
(new) ................................... 21.500 0.013 mm
(0.8465 0.0005 inch)
(2) Tighten the locknut to the following

torque. ........................ 30 7 Nm (22 5 lb ft)
(3) Valve lash

Inlet valves ...................... 0.38 mm (0.015 inch)
Exhaust valves ................ 0.64 mm (0.025 inch)
(4) Lifter assembly

Bore in the lifter arm for the shaft
(new) ................................... 15.670 0.013 mm
(0.6169 0.0005 inch)
Diameter of shaft (new) ...... 15.620 0.018 mm
(0.6150 0.0007 inch)
g00291847 g00291915
View A-A
8
Note: The inlet and exhaust valve stems must be Exhaust valve .............. 9.408 mm (0.3704 inch)
coated with engine oil prior to installation in the
cylinder head. After installation into the cylinder head, the valve
guide bore is the following value.
Note: The tips of the inlet and exhaust valves must
be coated with 8T-2998 Lubricant. The lubricant Diameter of the valve guide bore (new)
must be applied after assembly of the retainer.
Inlet valve ............................. 8.072 0.013 mm
(1) Exhaust valve (0.3178 0.0005 inch)
Exhaust valve ....................... 9.515 0.013 mm
(2) Inlet valve (0.3746 0.0005 inch)
(3) 137-6718 Spring for exhaust valve The valve guide can be reused. The valve guide
bore must not be larger than the following value.
Free length .................... 92.08 mm (3.625 inch)
Assembled length ......... 80.27 mm (3.160 inch) Maximum diameter of a valve guide bore (worn)
Load at assembled length ............... 662 33 N
(148 7 lb) Inlet valve .................... 8.080 mm (0.3181 inch)
Minimum operating length ................. 66.27 mm Exhaust valve .............. 9.538 mm (0.3755 inch)
(2.609 inch)
Load at minimum operating length .. 1445 58 N (7) Diameter of the valve head
(325 13 lb)
Inlet valve ............................... 40.00 0.13 mm
(1.575 0.005 inch)
(4) 140-6188 Spring for inlet valve Exhaust valve ......................... 43.00 0.13 mm
Free length ........................ 67.5 mm (2.66 inch) (1.693 0.005 inch)
Assembled length ............. 60.4 mm (2.38 inch)
Load at assembled length ............... 303 18 N (8) Angle of the valve faces
(68 4 lb)
Inlet valve ........................ 29.75 0.25 degrees
Minimum operating length ................... 46.4 mm
Exhaust valve ....................... 45 0.25 degrees
(1.83 inch)
Load at minimum operating length .. 899 36 N
(202 8 lb)
(5) Height to the top of the valve guides

Inlet valves ............................. 23.00 0.50 mm
(0.906 0.020 inch)
Exhaust valves ....................... 17.80 0.50 mm
(0.701 0.020 inch)
Diameter of valve guide ................... 12.065 mm
(0.4750 inch)
Note: Install the valve guide from the spring side of

the cylinder head.
g00291916
Note: Assemble the valve guide. Seat the seal Illustration 12
against the top of the valve guide.
(9) Diameter of the valve seat inserts
(6) Valve stem diameter (new) Inlet valve ........................... 42.000 0.013 mm
Inlet valves ........................... 8.000 0.008 mm (1.6535 0.0005 inch)
(0.3150 0.0003 inch) Exhaust valve ..................... 46.000 0.013 mm
Exhaust valve ....................... 9.441 0.010 mm (1.8110 0.0005 inch)
(0.3717 0.0004 inch)
Diameter of the bore in cylinder head for the valve
The cylinder head valves can be reused if the seat insert
minimum dimensions for the valve stems are met.
Bore diameter
Minimum diameter of a valve stem (worn) Inlet valve ........................... 41.931 0.013 mm
Inlet valve .................... 7.965 mm (0.3136 inch) (1.6508 0.0005 inch)
9
Exhaust valve ..................... 45.931 0.013 mm i01329325

(1.8083 0.0005 inch)
Cylinder Head
Note: The valve seat insert must be shrunk by
reduced temperature before the valve seat insert SMCS Code: 1100
is installed in the head.
(10) Angle of the valve seat inserts

Inlet valve ........................ 30.25 0.25 degrees
Exhaust valve .................... 44.5 0.25 degrees
(11) Depth of the bore in the head for the valve seat
insert ..... 10.00 0.05 mm (0.394 0.002 inch)
(12) Outside diameter of the seating face of the

valve seat insert
Inlet valve .................. 37.351 mm (1.4705 inch)
Exhaust valve ............ 40.800 mm (1.6063 inch)
g00619066
Illustration 13
Note: Do not reuse the valve seat inserts if the
outside diameter of the valve seat insert is larger (1) Large bolts
than the specified value.
(2) Small bolts
(13) The valve lips can be reused if the minimum
dimensions for the valve lips are met. Use the following procedure to install bolts (1) and
(2):
Inlet valve ........................ 2.04 mm (0.080 inch)
Exhaust valve .................. 1.63 mm (0.064 inch) 1. Apply engine oil to the threads of the bolts.
(14) Distance from the head of the valve to the 2. Tighten the large bolts (1) in a numerical
cylinder head face. The valve must be closed. sequence.
Inlet valve Tighten the bolts to the following
Maximum permissible distance ........... 1.71 mm torque. .................. 150 15 Nm (110 11 lb ft)
(0.067 inch)
Minimum permissible distance ............ 1.09 mm 3. Tighten the large bolts (1) in a numerical
(0.043 inch) sequence.
Exhaust valve Tighten the bolts to the following

torque. .................. 435 20 Nm (320 15 lb ft)
Maximum permissible distance ........... 1.71 mm
(0.067 inch) 4. Tighten the large bolts (1) again in a numerical
Minimum permissible distance ............ 1.09 mm sequence.
(0.043 inch)
Tighten the bolts to the following
torque. .................. 435 20 Nm (320 15 lb ft)
5. Tighten the small bolts (2) in a numerical

sequence.

torque. .......................... 55 7 Nm (41 5 lb ft)
10
g00292446
Illustration 14
Front and rear views of the cylinder head
(3) The installation depth of the cup plug is

measured from the face of the cylinder
head to the top edge of the plug. Depth of
installation ................................. 1.25 0.25 mm
(0.049 0.010 inch)
(4) Apply 9S-3263 Thread Lock Compound to

the first three threads of the plugs. Tighten the
plugs to the following torque. ...... 184 18 Nm
(136 13 lb ft)
g00616924
Illustration 15
(5) Height of new cylinder head ..... 158 0.15 mm Cross section view of the cylinder head
(6.220 0.006 inch) The view is rotated 15.5 degrees in a counterclockwise direction.
(6) Apply 9S-3263 Thread Lock Compound to the

cylinder head at location (A).
g00703447
Illustration 16
Location Of The Socket Setscrew (Orifice)
11
(7) Tighten a new 154-8025 Socket Setscrew Note: The 3E-8017 Locknut has a special thread
(orifice) that has the dry Loctite to a torque of form that is identifiable from a standard thread. This
47 9 Nm (35 7 lb ft). thread form is called a Spiralock thread.
The new 154-8025 Socket Setscrew and the The 136-0612 Turbocharger and 136-0613
former 142-7290 Socket Setscrew (orifice) may be Turbocharger is secured to the exhaust manifold
reused. Apply 154-9731 Thread Lock Compound with the 9X-6620 Locknut. Tighten the 9X-6620
to the threads of the socket setscrew (orifice). Locknut to the following torque. ............. 70 5 Nm
Tighten the socket setscrew (orifice) to a torque of (50 4 lb ft)
47 9 Nm (35 7 lb ft).
Note: The 9X-6620 Locknut is a locknut with a
standard thread form.
i01498172
Turbocharger (2) Exhaust inlet
SMCS Code: 1052 (3) Exhaust outlet
(4) Air inlet
(5) Waste gate
Opening pressure of the wastegate .... 148 3 kPa

(21.5 0.5 psi)
End play for a new shaft .............. .102 0.025 mm

(.0040 .0010 inch)
Maximum permissible end play for a worn

shaft ......................................... 0.20 mm (.008 inch)
Use the following procedure to install the band

g00777391 clamps to hold the cartridge to the compressor
Illustration 17
Typical example of turbocharger with a wastegate housing:
1. Tighten the clamps to a torque of 14 1.1 Nm

(125 10 lb in).
2. Tap lightly around the circumference of the

clamp.
3. Tighten the clamps again. Tighten the clamps to

a torque of 14 1.1 Nm (125 10 lb in).
Note: Put clean engine oil in the oil inlet of the

turbocharger after assembly or before installation.
This will provide lubrication during start-up and
during storage.
g00777400
Illustration 18
Typical example of turbocharger without a wastegate
(1) Stud
Apply 5P-3931 Anti-Seize Compound to the studs.
The 136-0610 Turbocharger and the 136-0611

Turbocharger are secured to the exhaust manifold
with the 3E-8017 Locknut. Tighten the 3E-8017
Locknut to the following torque. ............. 54 5 Nm
(40 4 lb ft)
12
i01498928
Air Inlet Elbow

SMCS Code: 1071
g00291084
Illustration 20
Three-piece exhaust manifold
Typical example

threads of bolts (1 through 12).
4. Tighten bolts (1 through 12 ) in a numerical

sequence.

g00777818
Illustration 19 torque. ........................... 4 1 Nm (35 9 lb in)
(1) Air Inlet Elbow 5. Tighten bolts (1 through 12 ) in a numerical

sequence.
Apply 1U-8846 Liquid Gasket to the face of
the elbow and spread the sealant uniformly. The Tighten the bolts to the following
elbow must be assembled and the elbow must be torque. .......................... 45 5 Nm (33 4 lb ft)
tightened within ten minutes.
6. Lock the tabs and bend the tabs (13) over the
(2) Tighten the bolts to the following flat of the bolt heads.
torque. ........................ 28 7 Nm (21 5 lb ft)
7. Tighten the studs (14) to a torque of 35 5 Nm
(26 4 lb ft).
i01515581
Exhaust Manifold i00873446
SMCS Code: 1059 Exhaust Elbow

NOTICE SMCS Code: 1061
Excessive use of sealant can cause damage to com-
ponents.
To avoid component damage use only the amount of

sealant necessary for the application.
Use the following procedure during assembly of the

three-piece exhaust manifold to the cylinder block.
1. Apply clean engine oil to the inside diameter of

the female ends of the exhaust manifold.
2. Apply 2P-2333 High Temperature Sealer to the

outside diameter of the male ends of the exhaust
g00443065
manifold. Do not apply the sealer at the tip of Illustration 21
the male ends. Remove any excess sealer from
the assembled joint. (1) Tighten the nut for the clamp to the following
torque. .......................... 12 4 Nm (9 3 lb ft)
13
i00880497 (3) Diameter of the camshaft

journals ............................... 65.126 0.013 mm
Exhaust Brake (2.5640 0.0005 inch)
SMCS Code: 1093 (4) Inlet lobe
(5) Exhaust lobe
(6) Distance between the shoulder of the camshaft

and the shoulder of the gear
Total distance ................................. 4.83 0.05 mm

(0.190 0.002 inch)
g00449163
Illustration 22
(1) Tighten the clamps that hold the exhaust

brake to the exhaust pipe to the following
torque. ................... 8.5 0.5 Nm (75 4 lb in)
i00663394
Camshaft Illustration 24
g00291256
SMCS Code: 1210 (7) Camshaft lobe lift
Specified camshaft lobe lift (7)

Exhaust lobe .................. 7.707 mm (.3034 inch)
Inlet lobe ........................ 7.970 mm (.3138 inch)
To find the lobe lift, use the procedure that follows:
1. Measure the camshaft lobe height (8).
2. Measure the base circle (9).
3. Subtract the base circle that is found in Step 2

from the lobe height that is found in Step 1. The
difference is the actual camshaft lobe lift (7).
g00291257
Illustration 23
Maximum permissible difference between actual
(1) Heat the gear for installation. Do not use a torch. lobe lift and the specified lobe lift of a new
camshaft ............................... 0.10 mm (.004 inch)
Maximum temperature ................. 316C (600F)
(2) The following dimensions are located in the area

that is shown above.
New thrust washer thickness ... 4.70 0.03 mm
(0.185 0.0012 inch)
End play of a new camshaft .... 0.13 0.08 mm
(0.005 0.0031 inch)
Maximum permissible end play of a worn
camshaft .......................... 0.46 mm (0.018 inch)
14
i00664110 i00667186
Engine Oil Filter Base Engine Oil Cooler Bypass

SMCS Code: 1306
Valve
SMCS Code: 1314
g00292073
Illustration 26
Typical example
(1) The oil cooler bypass valve will open at the

following pressure. ....................... 125 30 kPa
g00291396
Illustration 25 (18 4.5 psi)
(1) The 9L-9188 Spring is located in the filter 9L-9188 Spring specifications for the oil cooler
bypass valve: bypass valve
Outside diameter ............... 11.2 mm (0.44 inch) Outside diameter ................. 11.2 mm (.44 inch)
Free length ........................ 57.9 mm (2.28 inch) Free length ........................ 57.9 mm (2.28 inch)
Assembled length ............. 43.2 mm (1.70 inch) Assembled length ............. 43.2 mm (1.70 inch)
Load at assembled length ............. 15.6 1.3 N Load at assembled length ............. 15.6 1.3 N
(3.50 0.30 lb) (3.50 0.30 lb)
(2) The oil filter bypass valve must open at the

following pressure. ....................... 125 30 kPa
(18 4.5 psi)
(3) Put 9S-3263 Thread Lock Compound on the

last 7.5 1.5 mm (0.30 0.06 inch) of the
threads at the base end of the stud.
Tighten the stud to the following torque. .. 68 7 Nm

(50 5 lb ft)
(4) Put clean engine oil on the filter seal. Tighten

the filter until the seal contacts the base. After
the seal contacts the base, rotate the filter by
270 degrees.
15
i00669541 Load at assembled length ........... 51.99 1.9 N

(12 0.4 lb)
Engine Oil Pump
(5) Relief valve plunger
SMCS Code: 1304
Diameter of the plunger ..... 17.000 0.013 mm
(.6693 .0005 inch)
Bore in the pump body for the
plunger ............................... 17.100 0.025 mm
(.6732 .0010 inch)
i00880101
Engine Oil Pan

SMCS Code: 1302
g00292581
Illustration 27
Section view through pump gears
Typical example
g00448568
Illustration 28 g00292582 Illustration 29
The section view is of the bypass valve that is located in the pump
assembly. (1) Tighten the drain plug to the following
torque. ........................ 50 5 Nm (37 4 lb ft)
(1) Distance between the front face of the gear and
the housing ............................. 43.00 0.25 mm Apply 1U-8846 Liquid Gasket to four areas on the
(1.693 .010 inch) sealing surface of the oil pan. The areas are marked
location (Y). The areas are at the corners of the oil
(2) Length of the gears ................ 33.00 0.03 mm pan in the following locations:
(1.299 0.001 inch)
connecting joint of the front housing and the front
Depth of the bores for the gears .. 33.13 0.02 mm of the cylinder block
(1.304 0.001 inch)
connecting joint of the flywheel housing and the
(3) Diameter of the gear shafts .. 15.600 0.005 mm rear of the cylinder block
(.6142 .0002 inch)
Use the following procedure to tighten the bolts for
Bores in the pump bodies for the gear the oil pan.
shafts ...... 15.641 0.008 mm (.6158 .0003 inch)
Tighten four bolts (X).
(4) 105-1805 Spring for relief valve
Start with bolt (Z) and tighten all remaining bolts in
Outside diameter ................. 13.0 mm (.51 inch) a counterclockwise sequence.
Free length .................... 64.98 mm (2.558 inch)
Assembled length ............. 54.5 mm (2.15 inch) Tighten the bolts to the following
torque. .............................. 31 3 Nm (23 2 lb ft)
16
Start again with bolt (Z) and tighten all remaining i00663196
bolts in a counterclockwise sequence.
Water Temperature Regulator
torque. .............................. 31 3 Nm (23 2 lb ft) SMCS Code: 1355
Part No.: 119-3075
i00873547 S/N: BKD1-Up
Crankcase Breather Part No.: 119-3075

S/N: 1AJ1-Up
SMCS Code: 1317
Part No.: 119-3075
S/N: 8YL1-Up
Part No.: 119-3075
S/N: CKM1-Up
S/N: CRP1-Up
Part No.: 119-3075
S/N: 7AS1-Up
Part No.: 119-3075
S/N: 8SZ1-Up
Part No.: 119-3075
S/N: 9SZ1-Up
g00330803
Illustration 30
Typical example
(1) Tighten the bolt that holds the breather cap to

the following torque. .. 7 2 Nm (62 18 lb in)
g00291249
Illustration 31
Fully open temperature of the water temperature

regulator ............................................... 94C (201F)
(1) Air vent valve
(2) Closed dimension of the water temperature

regulator ....... 30.5 0.5 mm (1.20 0.02 inch)
(3) Minimum stroke of the water temperature

regulator at fully open temperature ..... 8.75 mm
(0.345 inch)
17
i00663555 i00669873
Water Temperature Regulator Water Pump

Part No.: 115-4223
S/N: BKD1-Up
Part No.: 115-4223
S/N: 1AJ1-Up
Part No.: 115-4223
S/N: 8YL1-Up
Part No.: 115-4223
S/N: CKM1-Up
S/N: CRP1-Up
Part No.: 115-4223
S/N: 7AS1-Up
Part No.: 115-4223
S/N: 8SZ1-Up
Part No.: 115-4223
S/N: 9SZ1-Up
g00292733
Illustration 33
The impeller cover is not shown.
(1) Clearance between the impeller and the

housing ....... 0.75 0.25 mm (.030 .010 inch)
(2) Seal
g00291249
Illustration 32 (3) Height of seal ......................... 12.83 0.13 mm
(.505 .005 inch)
Fully open temperature of the water temperature
regulator ............................................... 97C (206F) (4) The filter should not extend beyond the surface
of the housing.
(1) Air vent valve
(5) Dimension from the front face of the pulley to
(2) Closed dimension of the water temperature the face of the housing ............ 103.8 0.3 mm
regulator ....... 30.5 0.5 mm (1.20 0.02 inch) (4.09 .01 inch)
(3) Minimum stroke of the water temperature
(.315 inch)
18
i01147399 Clean the face of the cover with solvent. Apply

1U-8846 Liquid Gasket to the cover. Spread
Cylinder Block Cover Group uniformly on the face of the cover and around
the bolt holes. The cover must be installed and
SMCS Code: 1201 tightened within ten minutes.
(6) Sleeve (7) extends from the face of cylinder

block (1). Distance ....................... 5.0 0.5 mm
(0.20 0.02 inch)
(7) Six sleeves marked location (X).
(8) Side cover
g00619081
Illustration 34
Left side view of engine
g00448150
Illustration 36
Typical example of side cover
Tighten bolts (1 through 8) in a numerical sequence.

torque. .............................. 28 7 Nm (21 5 lb ft)
g00471794
Illustration 35 i01513281
View A-A
Cylinder Block
(1) Cylinder block
SMCS Code: 1201
(2) Gasket
Gasket (2) has a bead on one surface. Install the

gasket so that the bead is facing side cover (8).
(3) Length of two bolts ........... 40.0 mm (1.58 inch)
(4) Length of the bolts marked location

(Y). ..................................... 20.0 mm (0.79 inch)
Length of the ten remaining bolts for the three side

covers ...................................... 30.0 mm (1.18 inch)
(5) Cover
g00292819
Illustration 37
19
(1) The installation depth of the cup plug is

measured from the block face to the top edge
of the plug. Distance ................ 1.25 0.25 mm
(.049 .010 inch)
(2) The dowels extend past the top face of the

cylinder block. Distance .................. 14 2 mm
(.55 .080 inch)
(3) The two large dowels extend past the rear face
of the cylinder block. Distance .. 12.0 0.5 mm
(.47 .02 inch)
(4) The dowels extend past the front face of the

cylinder block. Distance .............. 8.0 0.5 mm
(.31 .02 inch)
g00292821
Illustration 39
(7) Diameter of cylinder bore .. 110.025 0.025 mm

g00292820 (4.3317 0.0010 inch)
Illustration 38
View A-A
(8) Distance from the centerline of the crankshaft
(5) Bore diameters in the cylinder block for bore to the top surface of the cylinder
all camshaft bearings except the front block .. 322.00 0.17 mm (12.677 0.007 inch)
bearing ............................... 69.000 0.038 mm
(2.7165 .0015 inch) (9) Front camshaft bearing joint location
(6) Locate the bearing oil hole for all camshaft (10) Bore diameter in the cylinder block for the front
bearings at the top of the bore. The front camshaft bearing ............... 70.000 0.025 mm
camshaft bearing is not located at the top of (2.7559 .0010 inch)
the bore.
(11) Front camshaft bearing oil hole
Note: The front camshaft bearing is installed with

the bearing oil hole (11) in alignment with the oil
hole in the cylinder block and the bearing joint (9)
in the position that is shown.

torque. ...................... 70 10 Nm (50 7 lb ft)
(13) Bearing cap

Width of the main bearing
cap ................................... 159.995 0.020 mm
(6.2990 .0008 inch)
Width of the cylinder block for the main
bearing ............................. 160.000 0.018 mm
(6.2992 .0007 inch)
20
(14) Distance from the centerline of the crankshaft (1) Heat the gear for installation. Do not use a
bore to the pan rail ..... 110.00 mm (4.331 inch) torch. ............................................ 316C (600F)
(15) Location of the sequence number for the (2) Crankshaft end play ................. 0.07 to 0.32 mm
bearing cap (0.003 to 0.013 inch)
(16) Main bearing cap bolts

i00664274
Install the bearing caps with the sequence number

to the right. The order is 1 through 7 (front to rear).
Crankshaft Seals
SMCS Code: 1160; 1161
1. Apply 4C-5593 Anti-Seize Compound to the bolt
threads (16) and face of the washers. Note: Refer to Disassembly and Assembly for the
complete procedure for removing and installing the
2. Tighten bolts (16) on each bearing cap. crankshaft seal groups.
Tighten to the following torque. ......... 54 7 Nm
(40 5 lb ft)
3. Tighten bolts (16) on each bearing cap again.
Tighten the bolts by another one quarter of a

turn. ............................................ 90 5 degrees
(17) Bore in the cylinder block for the seven main

bearings ............................. 95.000 0.013 mm
(3.7402 0.0005 inch)
Note: Additional information on reconditioning

procedures can be ordered. Refer to the following
documents: Illustration 41
g00291469

Operations, SEBF8277, Specifications and Salvage
for Cylinder Blocks on 3126 Engines

Operations, SEBF8268, Installing a 107-7604
Cylinder Sleeve in 3126 Engines
i01147402
Crankshaft
SMCS Code: 1202
g00291470
Illustration 42
Rear crankshaft seal groups
The single lip seal is used for dry applications (A).
The double lip seal is used for wet applications (B).
(1) Carrier housing and flywheel housing
(2) Rear seal
Install the rear seal. Make sure that the rear face of
the seal (2) is 15.4 0.5 mm (0.61 0.020 inch)
from the blocks rear face (4).
g00293038
Illustration 40
21
Note: The original rear seal runs directly on the i00873707

crankshaft flange. The original seal assembly does
not contain a wear sleeve. The Service Rear seal Rear Seal Carrier
group contains a wear sleeve (7). (If Equipped)
SMCS Code: 1161
g00291471
Illustration 43
Front crankshaft seal
(3) Front seal
Install the front seal. Make sure that the front face of
the seal (3) is 2.5 0.5 mm (0.0984 0.0197 inch)
from the front housing (5).
g00443494
Illustration 44
(4) Rear face of block
(1) Apply 1U-8846 Liquid Gasket to the joint face
(5) Front housing
of the seal carrier. Spread the liquid gasket
uniformly on the joint face. The seal carrier must
(6) Pulley
be assembled and tightened to the cylinder
block within ten minutes.
(7) Wear sleeves
Do not remove the wear sleeves from the seal
threads of the eight bolts.
group.
(8) Shipping sleeve for the front seal
Install the front seal (3) in the housing. Remove the

shipping sleeve (8). Install the pulley (6).
22
i01161520 Clearance between bearing and new

journal .. 0.053 to 0.155 mm (0.0021 to 0.0061 inch)
Vibration Damper
SMCS Code: 1205 i01135346
Main Bearing Journal

SMCS Code: 1202; 1203
Table 2
Diameter Of Crankshaft Journal (Bearing

Surface) For Main Bearings
90.000 0.020 mm
Original Size Journal
(3.5433 0.0008 inch)
Undersize Journal 89.750 0.020 mm

0.25 mm (0.010 inch) (3.5335 0.0008 inch)

0.50 mm (0.020 inch) (3.5236 0.0008 inch)
Clearance between bearing and new

journal .. 0.071 to 0.173 mm (0.0028 to 0.0068 inch)
g00618602
Rubber vibration damper
Connecting Rod
(1) Damper assembly
SMCS Code: 1218
Note: The dash marks on the front of the damper
assembly must be in alignment with each other. A
new damper assembly will be needed if the dash
marks are not in alignment.
Maximum permissible face runout of the damper

assembly at location (A) ................ 0.00 to 2.03 mm
(0.000 to 0.080 inch)
i01135341
Connecting Rod Bearing

Journal
SMCS Code: 1202; 1219; 1225
Table 1
Diameter Of Crankshaft Journal (Bearing Surface)

For Connecting Rod Bearings
70.000 0.020 mm
Original Size Journal
(2.7559 0.0008 inch)

0.25 mm (0.010 inch) (2.7461 0.0008 inch)

0.50 mm (0.020 inch) (2.7362 0.0008 inch) g00293050
Illustration 46
23
Note: The connecting rod must be heated for the i01147404

installation of the piston pin bearing. Do not use
a torch. Piston and Rings
The connecting rod may be heated from SMCS Code: 1214; 1215
175 to 260C (347 to 500F) for the installation of
the piston pin bearing. Two-Piece Articulated Piston
Length (A) is the maximum distance for heating the
connecting rod . ............. 75 5 mm (3.0 .2 inch)
The bearing joint (B) must be at 12.0 5 degrees

above the centerline.
(1) Bore size

Bore in the connecting rod for the piston pin
bearing ............................... 43.191 0.013 mm
(1.7004 .0005 inch)
Bore in the bearing for the piston
pin ....................................... 40.028 0.008 mm
(1.5759 0.0003 inch)
g00293184
Illustration 47
(2) Distance between the center of the
bearings ...................... 200.00 mm (7.874 inch)
(3) Location for the etched cylinder numbers on the

rod and the cap after assembly
Note: Etch the cylinder number on the connecting

rod and the cap in this location (3). Mark the
connecting rod and the cap with a number 1
through 6. Mark the numbers on the same side of
the connecting rod as the bearing retainer notch.
(4) Connecting rod bolts
(5) Bore in the connecting rod for the

g00293185
bearing for the crankshaft connecting rod Illustration 48
journal ................................. 75.000 0.013 mm
(2.9527 .0005 inch) (1) Crown assembly
Tighten the connecting rod bolts. Use the (2) Connecting rod
instructions that follow:
Note: Install the rod and piston group in the engine
1. Before installing the connecting rod bolts (4), with the part number to the rear of the engine.
lubricate the bolt threads and the seating faces The rear of the engine is the flywheel end of the
of the caps with engine oil. engine. Lubricate the rod and piston group with
clean engine oil before you insert the rod and piston
2. Install the connecting rod bolts (4). group into the block.
Tighten each nut to the following Top Ring and Intermediate Ring
torque. .......................... 54 7 Nm (40 5 lb ft)
(3) The top ring has the mark UP-1.
3. Put an alignment mark on the cap and the nut.
Install the piston ring with the side marked UP-1
4. Tighten each nut for an additional 60 5 toward the top of the piston. The colored stripe
degrees (1/6 of a turn). faces to the right of the ring end gap.
The ends of the piston ring have a clearance when

the piston ring is installed in a cylinder with a
specific bore size.
24
Cylinder bore size ............. 110.03 mm (4.332 inch) Clearance ..... 0.45 0.15 mm (0.018 0.006 inch)
Clearance ..................................... 0.550 0.10 mm The oil control piston ring has an increase in
(0.0217 0.0039 inch) clearance for each 0.03 mm (0.001 inch) increase
in the cylinder liner bore.
The piston ring has an increase in clearance for
each 0.03 mm (0.001 inch) increase in the cylinder Increase ................................. 0.09 mm (0.004 inch)
liner bore.
After the piston rings have been installed, rotate the
Increase ................................. 0.09 mm (0.004 inch) piston rings so that the end gaps are 120 degrees
from each other.
(4) The intermediate ring has the mark UP-2.
(6) Piston skirt
toward the top of the piston. The colored stripe Lubricate the entire piston in zone (A) prior to
faces to the right of the piston ring end gap. assembly into the cylinder block. Use clean engine
oil.
Thickness of the new piston ring ... 2.98 0.01 mm
(0.1173 0.0004 inch) Piston Pin Bore
The ends of the piston ring have a clearance when (7) Piston pin
specific bore size. Piston pin bore diameter that is in the crown
assembly ............................ 40.031 0.007 mm
Cylinder bore size ............. 110.03 mm (4.332 inch) (1.5760 0.0003 inch)
Piston pin bore diameter that is in the piston
Clearance ................................... 0.825 0.125 mm skirt ..................................... 40.020 0.005 mm
(0.0325 0.0049 inch) (1.5756 0.0002 inch)
Piston pin diameter ............ 40.000 0.005 mm
The intermediate piston ring has an increase in (1.5748 0.0002 inch)
clearance for each 0.03 mm (.001 inch) increase Length of piston pin ............... 89.95 0.15 mm
in the cylinder liner bore. (3.541 0.006 inch)
Increase ................................. 0.09 mm (0.004 inch) Thoroughly lubricate the piston pin with clean
engine oil prior to assembly.
Oil Control Ring
i01228514
(5) The oil control piston ring has a spring that is
installed with the ring. The gap in the spring Piston and Rings
should be a distance of 180 degrees from the
ring end gap when the oil control piston ring is SMCS Code: 1214; 1215
assembled. The light green colored portion of
the spring must be visible at the ring end gap.
One-Piece Aluminum Piston
Width of the groove in a new piston for the oil
control piston ring ...................... 4.041 0.013 mm
(0.1591 0.0005 inch)
Thickness of the new piston ring .. 3.985 0.010 mm

(0.1569 0.0004 inch)
Clearance between the oil groove and the oil control

piston ring ................................... 0.033 0.079 mm
(0.0013 0.0031 inch)
The ends of the oil control piston ring have a

clearance when the ring is installed in a cylinder
with a specific bore size.
g00293184
Illustration 49
Cylinder bore size ............. 110.03 mm (4.332 inch)
25
Thickness of the new piston ring ... 2.98 0.01 mm

(0.1173 0.0004 inch)

specific bore size.
Clearance ................................... 0.825 0.125 mm

(0.0325 0.0049 inch)
The intermediate piston ring has an increase in

clearance for each 0.03 mm (0.001 inch) increase
g00656758
in the cylinder liner bore.
Illustration 50
Increase ................................. 0.09 mm (0.004 inch)
(1) Piston body assembly
Lubricate the entire piston in zone (A) prior to Oil Control Ring
assembly into the cylinder block. Use clean engine
oil. (5) The oil control piston ring has a spring that is
installed with the ring. The gap in the spring
(2) Connecting rod should be a distance of 180 degrees from the
ring end gap when the oil control piston ring is
Note: Assemble the rod and piston group with the assembled. The light green colored portion of
marking front on the piston body in the opposite the spring must be visible at the ring end gap.
direction of the part number on the rod assembly.
Install the rod and piston group in the engine with Thickness of the new piston ring .. 3.985 0.010 mm
the part number on the rod assembly to the rear of (0.1569 0.0004 inch)
the engine. The rear of the engine is the flywheel
end of the engine. Lubricate the rod and piston The ends of the oil control piston ring have a
group with clean engine oil before you insert the clearance when the ring is installed in a cylinder
rod and piston group into the block. with a specific bore size.

Top Ring and Intermediate Ring
Clearance ..... 0.45 0.15 mm (0.018 0.006 inch)
(3) The top ring has the mark UP-1.
The oil control piston ring has an increase in
Install the piston ring with the side marked UP-1 clearance for each 0.03 mm (0.001 inch) increase
toward the top of the piston. The colored stripe in the cylinder liner bore.
faces to the right of the ring end gap.
Increase ................................. 0.09 mm (0.004 inch)
the piston ring is installed in a cylinder with a After the piston rings have been installed, rotate the
specific bore size. piston rings so that the end gaps are 120 degrees
from each other.
Clearance ..... 0.40 0.10 mm (0.016 0.004 inch) Piston Pin Bore
The piston ring has an increase in clearance for (6) Piston pin
each 0.03 mm (0.001 inch) increase in the cylinder Piston pin diameter ............ 40.000 0.005 mm
liner bore. (1.5748 0.0002 inch)
Length of piston pin ............... 89.95 0.15 mm
Increase ................................. 0.09 mm (0.004 inch) (3.541 0.006 inch)
(4) The intermediate ring has the mark UP-2. Thoroughly lubricate the piston pin with clean
toward the top of the piston. The colored stripe
faces to the right of the piston ring end gap.
26
i01228425 i01234648
Piston Cooling Jet Piston Cooling Jet

One-Piece Aluminum Piston Two-Piece Articulated Piston
g00657849 g00657849
(1) Piston cooling jet (1) Piston cooling jet
The piston cooling jets must be checked for the The piston cooling jets must be checked for the
location of the stream of oil. Insert a drill rod with a location of the stream of oil. Insert a drill rod with a
diameter of 1.90 mm (0.075 inch) into the orifice. diameter of 1.90 mm (0.075 inch) into the orifice.
This drill rod simulates the stream of oil under This drill rod simulates the stream of oil under
normal operating pressure. The drill rod must normal operating pressure. The drill rod must
pass through a circle with a diameter of 5.0 mm pass through a circle with a diameter of 5.0 mm
(0.20 inch) at point (A). (0.20 inch) at point (A).
Use the following dimensions in order to locate Use the following dimensions in order to locate
point (A). point (A).
Dimension (B) .................... 17.0 mm (0.67 inch) Dimension (B) .................... 26.5 mm (1.04 inch)
Dimension (C) ................... 33.0 mm (1.30 inch) Dimension (C) ................... 34.0 mm (1.34 inch)
Dimension (D) ................... 50.0 mm (1.97 inch) Dimension (D) ................... 50.0 mm (1.97 inch)
27
i01358291 Apply 1U-8846 Liquid Gasket to the front housing

sealing surfaces before assembling the front
Front Housing and Covers housing to the cylinder block. The front housing
must be assembled and tightened to the cylinder
SMCS Code: 1162; 1166 block within ten minutes.
(1) Cylinder Block
(2) Front housing
(3) Bolts (X) ............................. 50.0 mm (1.97 inch)
(4) Bolts (Y) ............................... 20.0 mm (.79 inch)
(5) Front housing cover

serrations of the studs before installation.
g00716820
Illustration 53
g00293311
Illustration 54
28
i00673287
Gear Group (Front)

SMCS Code: 1206
g00293531
Illustration 55
(1) Camshaft idler gear (3) Tighten the bolts of the camshaft idler gear to
the following torque. ....................... 70 15 Nm
Distance between the front of the bearing face and (50 11 lb ft)
the front of the gear face (B) ......... 0.40 0.25 mm
(.016 .010 inch) (4) Align the timing marks on the camshaft idler
gear (1) with the holes on the camshaft and the
Diameter of new shaft (A) .......... 80.00 0.013 mm crankshaft gears (2) and (5).
(3.1496 .0005 inch)
(5) Crankshaft gear
(2) Camshaft gear
(6) Oil pump drive gear
29
(7) Apply 9S-3263 Thread Lock Compound to the 1. Install the flywheel ring gear. Face the part
threads of the oil pump idler gear bolt. Tighten number on the ring gear (2) toward the engine
the bolt to the following torque. ..... 70 15 Nm block. The flywheel ring gear must be installed
(50 11 lb ft) against the shoulder (4). The flywheel ring gear
can be heated for installation. Do not use a torch.
(8) Oil pump idler gear
Maximum temperature ................... 204C (400F)
The distance between the rear of the bearing face
and the rear of the gear face (C). .. 0.75 0.25 mm 2. Press the spring pin (3) into the crankshaft before
(.030 .010 inch) assembling the flywheel to the crankshaft. Check
the distance from the face of the crankshaft to
Diameter of new shaft (D) ........ 28.644 0.013 mm the end of the pin (3).
(1.1277 .0005 inch)
Distance ............. 11.0 1.0 mm (.43 .04 inch)
i00672569
3. Tighten the bolts (1) that hold the flywheel to the
Flywheel crankshaft.
SMCS Code: 1156 Tighten to the following torque. ..... 120 20 Nm

(90 15 lb ft)
i00672686
Flywheel Housing
SMCS Code: 1157
g00293373
Illustration 57
Mounting face for the block
Note: Refer to Systems Operation, Testing and

Adjusting for the correct method of inspecting the
flywheel housing.
g00293319
Illustration 56
Note: Apply 1U-8846 Liquid Gasket to all of the
Note: Refer to System Operation, Testing and sealing surfaces of the flywheel housing . The
Adjusting for the correct method of inspecting the flywheel housing must be assembled and tightened
flywheel. to the block within ten minutes.
(1) Bolt
(2) Ring gear
(3) Spring pin
(4) Shoulder
The following instructions should be used during

installation of the ring gear:
30
i01329788 i00670847
Engine to Transmission Crankshaft Pulley

Adapter SMCS Code: 1205
(If Equipped)
SMCS Code: 1001
g00293042
Illustration 59
(1) Tighten the bolts to the following

torque. ................ 200 25 Nm (150 18 lb ft)
i01211708
Belt Tension Chart

Illustration 58 g00293519 SMCS Code: 1357
(1) Crankshaft Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
(2) Flywheel assembly
(3) Hub
(4) Flex plate

torque. .................. 120 20 Nm (90 15 lb ft)
31
Table 3
Belt Tension Chart
Borroughs Gauge
Gauge Reading
Numbers
Belt
Belt Width Number Number of
Size Belt Tension Belt Tension
of the Old the New
Initial(1) Used(2)
Gauge Gauge
3/8 10.72 mm (0.422 inch) 623 22 N (140 5 lb) 400 22 N (90 5 lb) BT-33-95 BT-33-97
1/2 13.89 mm (0.547 Inch) 712 22 N (160 5 lb) 445 44 N (100 10 lb) BT-33-95 BT-33-97
5V 15.88 mm (0.626 Inch) 712 22 N (160 5 lb) 445 44 N (100 10 lb) BT-33-72 BT-33-72C
11/16 17.48 mm (0.688 Inch) 712 22 N (160 5 lb) 445 44 N (100 10 lb) BT-33-72 BT-33-72C
8K 27.82 mm (1.095 inch) 800 22 N (180 5 lb) 489 44 N (110 10 lb) ------ BT-33-109
6PK 20.94 mm (0.824 Inch) 667 22 N (150 5 lb) 467 44 N (105 10 lb) ------ BT-33-109
Measure the tension of the belt that is farthest from the engine.
(1) Belt Tension Initial is for a new belt.
(2) Belt Tension Used is used for a belt that has operated for 30 minutes or more of operation at the rated speed.
i00675918 i00670033
Belt Tensioner Belt Tightener

(If Equipped) SMCS Code: 1358
SMCS Code: 1358
g00294094
Illustration 60
(1) Minimum travel ................................. 71 degrees
(2) The torque for the spring is 14.1 1.7 Nm

g00292814
(10 1 lb ft) at 25 degrees from the released Illustration 61
position.
(1) Distance from the back of the plate assembly to
the middle of the pulley ............. 26.0 0.3 mm
(1.02 .012 inch)
(2) Distance from the back of the plate assembly to

the back of the pulley ................ 16.0 0.3 mm
(.63 .01 inch)
(3) Plate assembly

32
(4) Pulley i00670126
(5) Apply 9S-3263 Thread Lock Compound to the Fan Drive

pulley bore before assembly.
SMCS Code: 1359
i00677590
Refrigerant Compressor
SMCS Code: 1802
g00294494
Illustration 62
g00292816
Illustration 63
Use the following procedure to install the refrigerant
compressor: (1) Use the grease fitting to fill the bearing cavity
with 30 grams (1.05 ounces) of 2S-3230
1. Install all bolts hand tight. Grease Cartridge lubricant. Apply the grease
to the bearing cavity after installing fan drive
2. Tighten the top bolt (A). bearings.
Tighten the bolt to the following (2) Bracket

torque. ........................ 55 10 Nm (40 7 lb ft)
(3) Bearing assembly
3. Tighten the two lower bolts (D).
(4) Bolt
torque. ........................ 55 10 Nm (40 7 lb ft) (5) Bolt
4. Tighten the remaining two bolts (B) and (C). (6) Support
Tighten the bolts to the following Assembly procedure for the bracket
torque. ........................ 55 10 Nm (40 7 lb ft)
1. Tighten bolt (4) by hand into the housing.
33
2. Tighten bolt (5) by hand into the bracket (2). (1) Tighten the shaft nut to the following
torque. ...................... 102 7 Nm (75 5 lb ft)
3. Tighten bolts (4) and (5).
(2) Tighten the screw to the following
Tighten the bolts to the following torque. ................... 6.2 0.6 Nm (55 5 lb in)
torque. ........................ 55 10 Nm (40 7 lb ft)
torque. ............. 11.3 2.3 Nm (100 20 lb in)
i00668315
Alternator and Regulator (4) Regulator

Voltage setting ............................. No adjustment
SMCS Code: 1405; 1410 Permissible voltage range .......... 13.5 to 14.5 V
i01161319
Electric Starting Motor

SMCS Code: 1453
Part No.: 6V-4238
S/N: BKD1-Up
Part No.: 6V-4238
S/N: 1AJ1-Up
Part No.: 6V-4238
S/N: 8YL1-Up
g00292354
Illustration 64
Part No.: 6V-4238
S/N: CKM1-Up
S/N: CRP1-Up
Part No.: 6V-4238
S/N: 7AS1-Up
Part No.: 6V-4238
S/N: 8SZ1-Up
Part No.: 6V-4238
S/N: 9SZ1-Up
g00292355
Illustration 65
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output.
6T-1395 Alternator
Polarity ..................................... Negative ground
Rotation ...................................... Either direction
The minimum full load current at 5000 rpm is the

following value. .......................................... 107 Amp g00282688
Illustration 66
Typical example
The minimum full load current at 1500 rpm is the
following value. ............................................ 45 Amp
Output voltage ...................................... 14.0 0.5 V

34
i01161323

SMCS Code: 1453
Part No.: 103-0875
S/N: BKD1-Up
Part No.: 103-0875
S/N: 1AJ1-Up
Part No.: 103-0875
S/N: 8YL1-Up
Part No.: 103-0875
g00489813 S/N: CKM1-Up
Illustration 67
Typical solenoid connections
S/N: CRP1-Up
When the electric starting motor is viewed from Part No.: 103-0875
the drive end, the motor rotates in the following S/N: 7AS1-Up
direction. ................................................... Clockwise
Part No.: 103-0875
No load conditions at 25C (77F) S/N: 8SZ1-Up
Speed ..................................... 7018 1517 rpm Part No.: 103-0875
Current ................................... 125.5 27.5 amp S/N: 9SZ1-Up
Voltage ......................................................... 11 V
(1) Tighten the nut on the battery terminal to the

following torque. ... 30.5 3.5 Nm (22 3 lb ft)
(2) Tighten the ground terminal to the following

torque. .................. 30.5 3.5 Nm (22 3 lb ft)

torque. ............... 2.25 0.25 Nm (20 2 lb in)
(4) Tighten the nut on the switch terminal to the

following torque. ....................... 2.25 0.25 Nm
(20 2 lb in)
g00282688
(5) Tighten the nut on the motor terminal to the Illustration 68
following torque. ........ 8 3 Nm (71 27 lb in) Typical example
(6) Tighten the nut on the motor frame terminal to

Solenoid
Current draw at 12 V and 25C (77F)

Pull-in windings ............................... 89 5 amp
Hold-in windings ............ 23 2 amp maximum
g00282689
Illustration 69
Typical solenoid connections
35
When the electric starting motor is viewed from (2) Plug

the drive end, the motor rotates in the following
i01147852

No load conditions at 25 C (77 F) Injection Actuation Pressure
Speed ....................................... 3628 413 rpm Sensor
Current ........................................... 84 16 amp
Voltage ......................................................... 23 V SMCS Code: 1925
(1) Tighten the nut on the battery terminal to the
(2) Tighten the ground terminal to the following

torque. .................. 30.5 3.5 Nm (22 3 lb ft)

torque. ............... 2.25 0.25 Nm (20 2 lb in)
(4) Tighten the nut on the switch terminal to the

(20 2 lb in)
(5) Tighten the nut on the motor terminal to the

g00294225
following torque. ... 14.7 3.4 Nm (11 3 lb ft) Illustration 71
Typical example
(6) Tighten the nut on the motor frame terminal to
the following torque. .. 8 3 Nm (71 27 lb in) (1) Sensor assembly
Solenoid Tighten the sensor assembly to the following

torque. ........................... 10 2 Nm (90 18 lb in)
Current draw at 20 V and 25C (77F)
(2) Plug
Pull-in windings ............................... 36 2 amp
Hold-in windings ................ 6.75 amp maximum
i00675120
i00675104 Engine Oil Pressure Sensor

Coolant Temperature Sensor (If Equipped)
g00293958 g00293960
Typical example Typical example
(1) Sensor assembly (1) Sensor assembly
Tighten the sensor assembly to the following Tighten the sensor assembly to the following
torque. .............................. 20 5 Nm (15 4 lb ft) torque. ........................... 10 2 Nm (90 18 lb in)
36
(2) Port fitting i01161328
Atmospheric Pressure Sensor

i00676593
(If Equipped)
Engine Oil Temperature Sensor
SMCS Code: 1923
(If Equipped)
SMCS Code: 1929
g00293963
Illustration 75
Typical example
g00294228
Illustration 73
(1) Sensor assembly
(1) Sensor assembly
Tighten the sensor assembly to the following
torque. ........................... 10 2 Nm (90 18 lb in)
torque. ........................... 10 2 Nm (90 18 lb in)
(2) Plug
i00675169
i01331712
Boost Pressure Sensor Inlet Air Temperature Sensor
SMCS Code: 1917
SMCS Code: 1921
g00293962
Illustration 76
Typical example
(1) Pin for the signal circuit
(1) Sensor assembly
(2) Pin for the ground circuit
torque. ........................... 10 2 Nm (90 18 lb in) (3) Tighten the sensor assembly to the following
torque: ........................ 20 5 Nm (15 4 lb ft)
(2) Port fitting
37
i00677047 (4) Tighten the nut to the following

torque. ......................... 8 1 Nm (71 9 lb in)
Speed and Timing Sensor
(5) The wire assembly connects the magnetic
SMCS Code: 1907; 1912 switch assembly to the air inlet heater.
(6) Air inlet heater
(7) The ground strap for the air inlet heater

connects to the engine block.
(8) Engine Control Module (ECM)

torque. ......................... 6 1 Nm (53 9 lb in)
i01147860
Air Inlet Heater

g00295489
Illustration 77
SMCS Code: 1090
(1) Bracket
(2) Sensor
(3) Flange
Seat both sensors to the sensors flanges before

tightening the bolt to the bracket.
The sensors must be replaced as a pair.
i01329489
Electronic Control Wiring

g00292365
Group Illustration 79
Section view of the air inlet heater
SMCS Code: 1408
(1) Air inlet heater
(2) Tighten the nuts to the following

torque. ......................... 8 1 Nm (71 9 lb in)
Note: During assembly of the air inlet heater to

the inlet manifold and the air inlet elbow, clean
the air inlet heaters joint faces with solvent. Apply
4C-9500 Quick Cure Primer to the joint faces. Allow
the primer to air dry for a minimum of three to five
minutes. Apply 1U-8846 Liquid Gasket to the joint
face and spread the gasket maker uniformly. The
heater must be assembled and tightened within ten
minutes.
g00703522
Illustration 78
(1) Magnetic switch assembly

torque. ................... 6.0 0.5 Nm (53 4 lb in)
(3) Air inlet elbow

38
i01343836 4. Tighten two bolts (C) to a torque of 55 10 Nm

(40 7 lb ft).
Air Compressor
(Midland Air Compressors) 5. Tighten one bolt (D) to a torque of 28 7 Nm
(21 5 lb ft).
SMCS Code: 1803
i01328911
Air Compressor
(Bendix Tu-Flo Air
Compressors)
SMCS Code: 1803
g00709958
Illustration 80
(1) Air compressor
(2) Nut
Perform the following steps in order to properly

tighten the nut:
g00292298
Illustration 81
1. Tighten the nut to a torque of 165 10 Nm
(120 7 lb ft). (1) Air compressor
2. Use a soft faced hammer and a 1U-7962 Socket (2) Nut
(Impact) and tap the gear one time. Tighten the
nut to a torque of 165 10 Nm (120 7 lb ft). Perform the following steps in order to properly
tighten the nut:
3. Use a soft faced hammer and a 1U-7962 Socket
(Impact) and tap the gear one time. Tighten the 1. Tighten the nut to a torque of 165 10 Nm
nut to a torque of 165 10 Nm (120 7 lb ft). (120 7 lb ft).
(3) Gear 2. Use a soft faced hammer and a 1U-7962 Socket
(Impact) and tap the gear one time. Tighten the
(4) Bolt nut to a torque of 165 10 Nm (120 7 lb ft).
Tighten the bolt that holds the air compressor 3. Use a soft faced hammer and a 1U-7962 Socket
line on engines that are equipped with this (Impact) and tap the gear one time. Tighten the
hose assembly. Tighten the bolt to the following nut to a torque of 165 10 Nm (120 7 lb ft).
torque. .............................. 30 7 Nm (22 5 lb ft)
(3) Gear
Use the following procedure to mount the air
compressor. (4) Bolt
1. Install two bolts (A) and tighten the bolts to a Tighten the bolt that holds the air compressor
torque of 100 20 Nm (75 15 lb ft). line on engines that are equipped with this
hose assembly. Tighten the bolt to the following
2. Install the following four bolts finger tight: (B), torque. .............................. 30 7 Nm (22 5 lb ft)
(C), and (D).
Use the following procedure to mount the air
3. Tighten one bolt (B) to a torque of 50 10 Nm compressor.
(37 7 lb ft).
39
1. Install two bolts (A) and tighten the bolts to a

2. Install the four bolts (B) and (C) finger tight.
3. Tighten two bolts (B) to a torque of 55 10 Nm

(40 7 lb ft).
4. Tighten two bolts (C) to a torque of 55 10 Nm

(40 7 lb ft).
40
Index Section
Index
A Fuel Filter Lines ....................................................... 5
Fuel Transfer Pump (Fuel Transfer Pump and High
Air Compressor (Bendix Tu-Flo Air Compressors).. 38 Pressure Oil Pump) ............................................... 4
Air Compressor (Midland Air Compressors).......... 38
Air Inlet Elbow........................................................ 12
Air Inlet Heater....................................................... 37 G
Alternator and Regulator ....................................... 33
Atmospheric Pressure Sensor (If Equipped) ......... 36 Gear Group (Front)................................................ 28
B I
Belt Tension Chart ................................................. 30 Important Safety Information ................................... 2

Belt Tensioner (If Equipped) .................................. 31 Injection Actuation Pressure Control Valve ............. 6
Belt Tightener ........................................................ 31 Injection Actuation Pressure Sensor ..................... 35
Boost Pressure Sensor.......................................... 36 Inlet Air Temperature Sensor................................. 36
C M
Camshaft ............................................................... 13 Main Bearing Journal ............................................ 22

Connecting Rod..................................................... 22
Connecting Rod Bearing Journal .......................... 22
Coolant Temperature Sensor................................. 35 P
Crankcase Breather............................................... 16
Crankshaft ............................................................ 20 Piston and Rings ............................................. 2324
Crankshaft Pulley .................................................. 30 One-Piece Aluminum Piston .............................. 24
Crankshaft Seals ................................................... 20 Two-Piece Articulated Piston ............................. 23
Cylinder Block........................................................ 18 Piston Cooling Jet.................................................. 26
Cylinder Block Cover Group .................................. 18 One-Piece Aluminum Piston .............................. 26
Cylinder Head.......................................................... 9 Two-Piece Articulated Piston ............................. 26
Cylinder Head Valves .............................................. 7
R
E
Rear Seal Carrier (If Equipped) ............................. 21
Electric Starting Motor ..................................... 3334 Refrigerant Compressor ........................................ 32
Electronic Control Wiring Group............................ 37
Engine Design ......................................................... 4
Engine Oil Cooler Bypass Valve ............................ 14 S
Engine Oil Filter Base............................................ 14
Engine Oil Pan....................................................... 15 Specifications Section ............................................. 4
Engine Oil Pressure Sensor (If Equipped)............. 35 Speed and Timing Sensor ..................................... 37
Engine Oil Pump.................................................... 15
Engine Oil Temperature Sensor (If Equipped)....... 36
Engine to Transmission Adapter (If Equipped) ...... 30 T
Exhaust Brake ....................................................... 13
Exhaust Elbow....................................................... 12 Table of Contents..................................................... 3
Exhaust Manifold ................................................... 12 Turbocharger ......................................................... 11
F U
Fan Drive ............................................................... 32 Unit Injector ............................................................. 6

Flywheel ................................................................ 29
Flywheel Housing .................................................. 29
Front Housing and Covers..................................... 27
Fuel Filter Base ....................................................... 5
41
Index Section
Valve Mechanism Cover .......................................... 7

Valve Rocker Arms, Lifters, and Bridges ................. 7
Vibration Damper................................................... 22
Water Pump........................................................... 17
Water Temperature Regulator ......................... 1617
42
Index Section
43
Index Section
2001 Caterpillar
RENR1271-05
March 2001
Systems Operation
Testing and Adjusting
BKD1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Electrical System

Battery - Test ....................................................... 113
Belt Tension Chart .............................................. 113
Charging System - Test ...................................... 114
Systems Operation Section Electric Starting System - Test ............................ 116
Engine Oil Pressure Sensor - Test ...................... 117
Engine Design ....................................................... 4
Pinion Clearance - Adjust ................................... 117
General Information ................................................ 4
General Information .............................................. 14
Glossary of Electronic Control Terms ................... 16 Index Section
Electronic Control System Components ............... 19
Fuel System ......................................................... 23 Index ................................................................... 119
Air Inlet and Exhaust System ............................... 52
Lubrication System .............................................. 58
Cooling System .................................................... 60
Basic Engine ......................................................... 63
Electrical System ................................................. 65
Testing and Adjusting Section

Fuel System
Fuel System - Inspect ........................................... 70
Air in Fuel - Test .................................................... 71
Engine Speed - Check .......................................... 72
Finding Top Center Position for No. 1 Piston ........ 73
Fuel Quality - Test ................................................. 74
Fuel System - Prime ............................................. 75
Fuel System Pressure - Test ................................. 75
Gear Group (Front) - Time .................................... 77
Unit Injector - Test ................................................. 78
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 79
Turbocharger - Inspect .......................................... 81
Inlet Manifold Pressure - Test ............................... 84
Exhaust Temperature - Test .................................. 85
Aftercooler - Test ................................................... 86
Engine Crankcase Pressure (Blowby) - Test ........ 89
Compression - Test ............................................... 89
Engine Valve Lash - Inspect/Adjust ...................... 89
Lubrication System
Engine Oil Pressure - Test .................................... 93
Engine Oil Pump - Inspect .................................... 96
Excessive Bearing Wear - Inspect ........................ 96
Excessive Engine Oil Consumption - Inspect ....... 96
Increased Engine Oil Temperature - Inspect ........ 96
Cooling System
Cooling System - Check (Overheating) ................ 98
Cooling System - Inspect .................................... 100
Cooling System - Test ......................................... 101
Water Temperature Regulator - Test ................... 105
Water Pump - Test .............................................. 106
Basic Engine
Piston Ring Groove - Inspect .............................. 107
Connecting Rod Bearings - Inspect .................... 107
Main Bearings - Inspect ...................................... 107
Cylinder Block - Inspect ...................................... 107
Flywheel - Inspect ............................................... 108
Flywheel Housing - Inspect ................................. 109
Vibration Damper - Check ................................... 111
4
Systems Operation Section
Systems Operation Section i01503933
General Information
i01147099
SMCS Code: 1000
Engine Design
Advantages of a Dedicated PTO
SMCS Code: 1000
The ECM provides several options in order to
enhance vehicles that require control of the engine
speed for vocational applications. The vocational
applications include the following applications:
cement mixers, refuse packers, bulk haulers, utility
trucks, fire trucks, and applications that require
the control of the engine rpm for the operation of
specialized equipment.
There are eleven dedicated PTO parameters. The

dedicated PTO has ten inputs and one output. The
features of the dedicated PTO provide a significant
increase in the capability of the engine and of the
usage of the engine.
g00290846
Illustration 1
The electronically controlled 3126B engine and the
3126E engine eliminates the need for the following
(A) Exhaust valve. items: mechanical control cables, air cylinders,
(B) Inlet valve. electric solenoids, and linkages and connections.
The dedicated PTO provides a simple installation.
Bore ............................................ 110 mm (4.3 inch) The Cruise Control switches that are in the cab and
the circuit for the accelerator pedal position are left
Stroke .......................................... 127 mm (5.0 inch) unaffected.
Displacement .................................. 7.25 L (442 in 3 ) Features of the Dedicated PTO

Number of cylinders ............................................... 6 There are several features of the dedicated PTO:
Cylinder arrangement ..................................... In-line The dedicated PTO reduces the alteration of the
cab wiring or the dedicated PTO eliminates the
Valves per cylinder ................................................. 3 alteration of the cab wiring.
In order to check the engine valve lash setting, The dedicated PTO has multiple speed control by
the engine must be cold and the engine must be using the PTO Engine RPM Set Speed Input A
stopped. Engine valve lash settings and PTO Engine RPM Set Speed Input B.
Inlet .................................. 0.38 mm (0.015 inch)
Exhaust ............................ 0.64 mm (0.025 inch) The dedicated PTO has two speed controls that
require the PTO On/Off circuit.
The dedicated PTO has an accelerator position
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4 sensor that is remote. This sensor enables the
system to control engine rpm with variable
The crankshaft rotation is viewed from the speeds from a remote location.
rotation .......................................... counterclockwise The dedicated PTO has reduced engine noise
levels during PTO operation. The reduced engine
Note: The front end of the engine is opposite the noise levels are compared to a mechanical
flywheel end of the engine. The left side of the engine PTO.
from the flywheel end of the engine. The number
one cylinder is the front cylinder.
5
Customer Programmable Parameter PTO Shutdown Time The PTO Shutdown Time
Options is a programmable time. If the engine is in PTO
mode, then the PTO Shutdown Time will shut
There are many customer programmable parameter down the engine when the time limit expires.
options:
PTO Activates Cooling Fan The PTO Activates
PTO Configuration The PTO Configuration Cooling Fan can be programmed so that the
determines the input/output configuration that is cooling fan will operate during PTO operation.
used for the Dedicated PTO operation.
Input 4 Input 4 provides a parameter for a
PTO Top Engine Limit The PTO Top Engine Torque Limit Switch when torque limiting is desired
Limit provides a parameter in order to limit the for temporary protection of equipment. This is
engine rpm during PTO operation. regardless of the position of the PTO On/Off switch.
MAR98 or later Personality Modules
PTO Engine RPM Set Speed The PTO Engine
RPM Set Speed provides a set point for the engine Input 5 Input 5 provides a parameter for an
rpm for the PTO. Ignore Brake/Clutch Switch when mobile use of
the vehicle is desired with a set engine rpm. The
PTO Engine RPM Set Speed A This provides brake and the clutch are not required in order to
a programmable engine speed set point that disengage the engine rpm set speed. MAR98 or
is actuated by a dedicated switch circuit. The later Personality Modules
dedicated switch circuit is Input 7. JUL99 or later
Personality Modules Input 7 Input 7 can be programmed to PTO
Engine RPM Set Speed Input A in order to provide
PTO Engine RPM Set Speed B This provides a a dedicated circuit for the PTO operation at a
second programmable engine speed set point that programmed speed when the PTO On/Off Switch is
is actuated by a second dedicated switch circuit. ON. JUL99 or later Personality Modules
The dedicated switch circuit is Input 19. JUL99 or
later Personality Modules Input 19 Input 19 is programmable to PTO
Engine RPM Set Speed Input B in order to provide
PTO to Set Speed The PTO to Set Speed a second dedicated circuit for the operation at a
function requires only one circuit (PTO On/Off programmed speed when PTO Engine RPM Set
Switch) to provide two speed controls. The PTO Speed Input A is OFF and the PTO On/Off switch
to Set Speed function provides three-speed is ON. JUL99 or later Personality Modules
controls by using the PTO On/Off Switch and the
Set/Resume Switch. Additional Features of the Dedicated PTO
PTO Cab Throttle RPM Limit The PTO Cab The engine exhaust brake that is controlled by
Throttle RPM Limit provides a parameter in order the ECM is disabled when the PTO On/Off circuit
to limit the rpm from the accelerator pedal position is in the ON position.
sensor in the cab during PTO operation. The PTO
Cab Throttle RPM Limit can be used in order to When the PTO On/Off switch is in the ON position,
exceed the programmed PTO Top Engine Limit the Idle Shutdown feature is disabled.
with the accelerator pedal that is in the cab.
Two terminal connector and wiring is standard on
Torque Limit The torque limit reduces the all GM applications. Two terminal connector and
engine torque during PTO operation. The torque wiring is standard for the PTO On/Off Switch. Two
limit will also reduce the engine torque when terminal connector and wiring is standard for the
the Torque Limit Switch is in the ON position for PTO Interlock Switches.
temporary protection of equipment.
The PTO Shutdown Timer reduces driver abuse.
PTO Vehicle Speed Limit The PTO Vehicle Driver abuse is placing the truck in PTO mode in
Speed Limit determines the operating range of the order to disable the idle shutdown time.
vehicle speed during PTO operation.
Idle/PTO RPM Ramp Rate The Idle/PTO RPM

Ramp Rate determines the rate of acceleration
and deceleration.
Idle/PTO Bump RPM The Idle/PTO Bump RPM

determines the amount of change in the engine rpm
when the Set/Resume Switch is toggled.
6
Definition of Power Take-Off (PTO)

The dedicated PTO is an engine rpm control that
is initiated through an On/Off circuit. The circuit
is connected to Input 1 (terminal 56) of the ECM
Vehicle Harness Connector J1/P1. Engine rpm
control that is initiated through the Cruise Control
On/Off switch is referred to as Extended Idle.
Engine rpm control that is initiated through the Fast
Idle Enable Switch is referred to as Fast Idle.
The Four Programmable PTO

Configurations
Off The functions for the dedicated PTO are not
available.
Cab Switches The cruise control Set/Resume

switch and the Accelerator Pedal are used to control
the engine rpm. A dedicated PTO On/Off switch is
required. Refer to Illustration 2.
Remote Switches The Set/Resume switch for the

remote PTO is used to control the engine rpm. The
remote switches ignore all of the cab controls. An
On/Off switch for the dedicated PTO is required.
Refer to Illustration 3.
Remote Throttle The remote throttle is used

in order to control the engine rpm. The remote
throttle will ignore all of the cab controls. An On/Off
switch for the dedicated PTO is required. Refer to
Illustration 4.
7
g00625394
Illustration 2
PTO configuration for cab switches
(1) Cruise Control Set/Resume Switch (2) PTO On/Off Switch (3) PTO Switch On Lamp
g00625393
Illustration 3
PTO configuration for remote switches
(4) PTO Switch On Lamp (6) PTO On/Off Switch
(5) PTO Set/Resume Switch (7) PTO Switch On Lamp
8
g00625391
Illustration 4
PTO configuration for remote throttle
(8) PTO Switch On Lamp (10) PTO Set/Resume Switch (12) Remote Throttle for the PTO
(9) PTO On/Off Switch (11) PTO Switch On Lamp
One Speed Control with One Circuit Variable Speed Control That uses an
Input for the Remote Accelerator Position
One speed control with one circuit provides an
optional PTO Set Speed for applications that require Sensor
only one speed above low idle. The following
The following components are required: PTO On/Off
components are required: PTO On/Off Switch, PTO
Interlock Switches, and PTO Switch On Lamp(s). Switch, PTO Interlock Switches, Cruise Control
Switch or Remote Set/Resume Switch, and Remote
Hand Accelerator or an Accelerator Pedal Assembly
Two Speed Control with Three Circuits that is equipped with a Accelerator Position Sensor
that is supplied by Caterpillar.
The two speed control with three circuits has two set
speeds above low idle. The two set speeds that are
above the low idle engine rpm are the PTO to Set
Multiple Speed Control That Uses
Speed and the PTO Top Engine Limit. The following Dedicated Switch Inputs
components are required: PTO On/Off Switch,
PTO Interlock Switches, Cruise Control or Remote This function can be used in conjunction with other
Set/Resume Switch, and PTO Switch On Lamp(s). features that are used to control engine speed. The
function is available for the three configurations for
the PTO. The following components are required:
PTO On/Off Switch, PTO Interlock Switches, and
switch for the PTO Engine RPM Set Speed Input
A. The switch for the PTO Engine RPM Set Speed
Input B can be used in addition to the switch for
the PTO Engine RPM Set Speed Input A.
9
Engine RPM Control That Uses Switches Recommended Information for

Instead of a Control That Uses An Operator of the PTO
Accelerator Position Sensor
Ensure that the operator understands the operation
This function uses switches in order to control of the engine and the components for the PTO
engine rpm. Switches are also recommended if operation. Ensure that the operator understands the
the operator of the PTO will be frequently varying operation before attempting to install the switches
the engine rpm. Switches are recommended if the before the parameters are programmed. The
operator of the PTO will not have a free hand or a installation questionnaire will make the installation
free foot in order to operate the accelerator. easier to understand. The installation questionnaire
will help the installer understand the options that
Differences Between Fast Idle and are needed.
Dedicated PTO Operation Question (1) through question (8) should be
asked before starting the installation procedure.
The following differences are between the fast idle The remaining questions may be asked after the
and the dedicated PTO: installation is completed. This will help to fine tune
the programming and other system components.
Fast Idle is intended for cab control of the engine Refer to the information for programmable
speed. The dedicated PTO can be set up for parameters that is found in Programmable
control in the cab or for remote control of engine Parameters Available Ranges, Options, and
speed during PTO operation. Default Settings. For more information, refer to
Special Publication, LEXT0023, Programming CAT
Fast Idle requires a single momentary switch to Electronic Truck Engines. Also refer to Special
select the programmed engine speed(s). The Publication, LEBT9390, Electrical and Electronic
dedicated PTO can be as simple as a single Application and Installation Guide.
two-position switch. The two positions are the ON
position and the OFF position. The dedicated PTO Complete the following information once the
can also require combinations of two-position installation is complete:
switches and momentary switches.
Programmed Parameter Information Sheet for the
The dedicated PTO provides several options: Operator of the PTO
programmable engine rpm limits, set points,
bump rates, ramp rates, and programmable
torque limit. These features are not available for
Instructions for the Operator of the PTO
Fast Idle control.
Diagrams for Switches and Components that are
used for the Installation of the PTO
The ramp rate for Fast Idle rpm is fixed and this
rate can not be adjusted. The information that is recorded should be explained
to the operator of the PTO. The information that is
Fast Idle requires a momentary switch. Fast Idle recorded should be left in the cab glove box. This
can not be used with a typical PTO system that will allow the operator of the PTO to review the
requires two-position switches. The momentary configuration of the truck and the PTO. This will
switch can not be operated hydraulically. The allow the service technician to troubleshoot any
momentary switch can not be operated by air. suspected problems that relate to the installation.
The momentary switch can not be a position limit
switch that is integrated into the PTO operation.
Installation Questionnaire
Fast Idle Operation That Has One or Two
Refer to the 3126B and 3126E Truck Engine
Speed Control with One Circuit Electronic PTO Installation and Applications Service
Manual, PTO Parameters - Program for the
This function provides an optional set speed(s) for installation and programming that is based on the
applications that require only one or two speeds information on the Questionnaire Response.
above low idle.
A momentary Fast Idle Enable Switch and a Fast

Idle Enabled Lamp are required.
10
Table 1
Questions Response
Determine the location of the controls inside the cab for the
PTO.
Determine the location of the controls outside the cab for
the PTO.
Determine if control of the engine rpm is required from both
the cab and outside of the cab.
Determine if the operator of the PTO will be continually
varying engine rpm.
Determine if a hand accelerator or a foot accelerator will
be used.
Determine the maximum PTO operation vehicle speed.
Determine if the PTO will require the use of the clutch and
the service brakes. Determine that the engine rpm must be
maintained when the clutch and service brakes are used.
Determine the maximum torque of the equipment when the
PTO On/Off circuit is ON.
Determine the necessity of a torque limit when the PTO
On/Off circuit is in the OFF position.
Example Determine that a torque limit is needed in order to
reduce the torque for the driveline.
Determine if one or more fixed engine rpm above low idle is
required.
Determine the first engine rpm.
Determine the second engine rpm.
Determine the necessity in order for the engine to accelerate
to the first engine rpm when the PTO On/Off switch is turned
to the ON position.
Determine the operating speed points.
Determine the maximum operating engine rpm for the
equipment.
Determine if the accelerator pedal rpm should be limited. This
will occur only if the control of the engine rpm is from the cab.
Determine the acceleration rate that is required in order
for the engine to reach the set point for the engine rpm.
Determine the rate of deceleration that is required in order for
the engine to decelerate from the set point for the engine rpm.
Ask the following question ONLY if the vehicle uses the
Caterpillar Engine Control Module (ECM) to turn the engine
cooling fan ON. If necessary, contact the OEM of the vehicle
for more information.
Determine the minor fluctuations in engine rpm that are
caused by the engine cooling fan that is cycling ON and OFF.
Determine if this will cause a pump problem or other system
problems.
Programmed Parameter Table 2

Information Sheet for the Operator Selected Engine Rating
of the PTO Rating Number
ECM Identification Parameters
Use the following table to fill in the programmed
parameters once the installation is complete. Vehicle ID
Otherwise, print a copy of the engine configuration
Truck Manufacturer Parameters
by using the Electronic Technician.
(continued)
11
(Table 2, contd) (Table 2, contd)

Truck Manufacturer Input Number 4 (Torque
JUL99 and newer Limit Switch)
Personality Modules MAR98 and newer
Personality Modules
Vehicle Speed Parameters
Input Number 5 (Ignore
Vehicle Speed Limit Brake/Clutch Switch)
Cruise Control Parameters MAR98 and newer
Personality Modules
Low Cruise Control Speed
Set Limit Input Number 7 (PTO
Engine Set Speed Input
High Cruise Control A)
Speed Set Limit JUL99 and newer
Personality Modules
Cruise/Idle/PTO Switch
Configuration Input Number 19 (PTO
Idle Parameters B)
Idle Vehicle Speed Limit JUL99 and newer
Personality Modules
Idle RPM Limit
Idle/PTO RPM Ramp Rate
(rpm/sec)
Idle/PTO Bump RPM
Fast Idle RPM 1
Fast Idle RPM 2
Dedicated PTO Parameters
PTO Configuration
PTO Top Engine Limit
PTO Engine RPM Set
Speed
PTO Engine RPM Set
Speed A
JUL99 and newer
Personality Modules
PTO Engine RPM Set
Speed B
JUL99 and newer
Personality Modules
PTO to Set Speed
PTO Cab Throttle RPM
Limit
PTO Vehicle Speed Limit
Torque Limit
PTO Shutdown Time
PTO Activates Cooling
Fan
Engine and Gear Parameters
Top Engine Limit
Low Idle Engine RPM
Transmission Style
Input Selections
(continued)
12
Instructions for the Operator of the

PTO
Table 3
Question Response
The following interlocks must be set before the engine can be
operated for PTO purposes.
For example, the parking brake must be engaged and the
transmission must be placed in the neutral position.
Determine the location of the PTO On/Off switch. Determine
the labeling of the switch.
Determine the maximum vehicle speed while the PTO is in
operation.
NOTE: Exceeding the maximum vehicle speed will cause
the engine to exit the PTO set speed. The engine will then
return to low idle.
Determine if the PTO is set up to allow the use of the clutch
and service brakes with an engine rpm set speed. Determine
the PTO mode vehicle speed limit that is required for the
operation of the PTO.
If the answer is yes, then determine the location of the
switch that allows this operation. Determine the labeling of
the switch.
Determine if only one or two engine rpm above low idle are
necessary.
Determine if the installation is configured for engine
acceleration to increase to a desired engine rpm. This should
happen when the PTO On/Off switch is turned to the ON
position.
Determine the necessity that involves the cooling fan that
runs constantly when the control that is for the cooling fan
is active.
Determine the location of the PTO Switch On Lamp.
Determine the labeling of the switch.
Determine the programming of the PTO Shutdown Timer.
Determine the programming of the PTO Torque Limit.
Truck Installation Diagram for The 1. Locate the following items and create a sketch
Switches and The Components of these items: switches, sensors, and lamps.
Electronic PTO Installation and Applications
Follow the steps below once the installation is
complete: Service Manual, The Four Programmable
PTO Configurations for the installation and
programming that is based on the information on
the Questionnaire Response.
2. Provide a copy of the appropriate diagrams from

this manual that illustrate the specific installation
to the vehicle owner.
13
g00720254
Illustration 5
(1) Torque limit switch (7) PTO Switch On lamp
(2) Ignore/Normal Brake/Clutch switch (8) On/Off Switch for the PTO Engine RPM
(3) PTO On/Off switch Set Speed A
(4) PTO switch ON lamp (9) On/Off Switch for the PTO Engine RPM
(5) PTO Set/RPM Increase/Decrease Switch Set Speed B
(6) PTO Accelerator Assembly
14
i01517325
General Information
SMCS Code: 1000
g00608514
Illustration 6
Right side view
(1) Lifting eye (6) Belt tensioner
(2) Engine crankcase breather (7) Water drain plug
(3) Turbocharger (8) Crankshaft vibration damper
(4) Oil filler (9) Oil filter
(5) Water temperature regulator housing (10) Jacket water pump
15
g00608515
Illustration 7
Left side view
(11) Oil filler (14) Fuel priming pump (if equipped) (17) Air compressor
(12) Lifting eye (15) Oil level gauge (typical example) (18) Cylinder head grounding stud
(13) Fuel filter (16) Electronic Control Module (ECM) (19) Oil drain plug
The 3126B and 3126E engines are in-line six The engine has built-in diagnostics in order to
cylinder arrangements. The firing order of the ensure that all of the components are operating
engine is 1-5-3-6-2-4. The engines rotation is properly. In the event of a system component
counterclockwise when the engine is viewed from failure, the operator will be alerted to the condition
the flywheel end of the engine. The engine utilizes via the check engine light that is located on the
a turbocharger and an air-to-air aftercooler. The dashboard. An electronic service tool can be used
engines have a bore of 110 mm (4.3 inch) and a to read the numerical code of the faulty component
stroke of 127 mm (5.0 inch). The displacement is or condition. Also, the cruise control switches can
7.25 L (442 in 3 ). be used to flash the code on the check engine light.
Intermittent faults are logged and stored in memory.
The hydraulic electronic unit injector system (HEUI)
eliminates many of the mechanical components Starting The Engine
that are used in a pump-and-line system. The
HEUI also provides increased control of the timing
The engines ECM will automatically provide the
and increased control of the fuel air mixture. The correct amount of fuel in order to start the engine.
timing advance is achieved by precise control of
Do not hold the throttle down while the engine
the unit injector timing. Engine rpm is controlled by
is cranking. If the engine fails to start in twenty
adjusting the injection duration. A special pulse seconds, release the starting switch. Allow the
wheel provides information to the Electronic Control
starting motor to cool for two minutes before the
Module (ECM) for detection of cylinder position and
starting motor is used again.
engine rpm.
16
Boost Pressure Sensor The boost pressure sensor

NOTICE measures inlet manifold air pressure. The boost
Excessive ether (starting fluid) can cause piston and pressure sensor sends a signal to the Electronic
ring damage. Use ether for cold weather starting pur- Control Module (ECM).
poses only.
Bypass Circuit A bypass circuit is a circuit that is
used as a substitute circuit for an existing circuit. A
Cold Mode Operation bypass circuit is typically used as a test circuit.
Starting the engine and operation in cold weather is Calibration Calibration is an electronic adjustment
dependent on the type of fuel that is used, the oil of a sensor signal.
viscosity, and other optional starting aids. For more
information, refer to the Operation and Maintenance Coolant Temperature Sensor The coolant
Manual, Cold Weather Operation topic (Operation temperature sensor measures the engine coolant
Section). temperature. The sensor sends a signal to the
electronic control module (ECM). The engines
coolant temperature is used in Cold Mode
i00664947 operation. Coolant temperature is also used in order
to optimize engine performance.
Glossary of Electronic Control
Terms Cruise Control Range The cruise control range
establishes the vehicle speed range for the
SMCS Code: 1900 operation of cruise control. The range is usually
limited to the speed range that is anticipated on
Accelerator Pedal Position Sensor The accelerator the open road.
pedal position sensor is an electronic sensor
that is connected to the accelerator pedal. The Code See the Diagnostic Code.
accelerator pedal position sensor sends a Pulse
Width Modulated Signal to the ECM. Customer Specified Parameters A customer
specified parameter is a parameter that can be
After Market Device An after market device is changed. A customer specified parameters value
a device or an accessory that is installed by the is set by the customer. These parameters are
customer after the vehicle is delivered. protected by customer passwords.
Air-To-Air Aftercooler (ATAAC) An air-to-air CAT Data Link The data link is an electrical
aftercooler is a device that is used on turbocharged connection that is used to communicate with other
engines in order to cool inlet air that has undergone microprocessor based devices. The microprocessor
compression. The inlet air is cooled after the inlet based devices are compatible with the proposed
air passes through the turbocharger. The inlet air American Trucking Association and the SAE
is passed through an aftercooler (heat exchanger) Standard. These devices include trip recorders,
that uses ambient air for cooling. The inlet air that electronic dashboards, and maintenance systems.
has been cooled advances to the inlet manifold. The data link is also the communication medium that
is used for programming with the electronic service
American Wire Gauge (AWG) AWG is a measure tool. The data link is also used for troubleshooting
of the diameter of electrical wire. AWG is also with the electronic service tool.
a measure of the current carrying capacity of
electrical wire. When the AWG number is smaller, Desired RPM The desired rpm is input to the
the diameter of the wire is larger. When the AWG electronic governor within the ECM. The electronic
number is larger, the diameter of the wire is smaller. governor uses the signal from the Accelerator Pedal
Position Sensor, the Engine Speed Sensor, the
Atmospheric Pressure Sensor The atmospheric Cruise Control, and the Customer Parameters in
pressure sensor measures barometric pressure. order to determine desired rpm.
The sensor sends a signal to the electronic control
module (ECM). The signal is used in engine control Diagnostic Code A diagnostic code is sometimes
and in engine operation. called a fault code. A diagnostic code is an
indication of a problem or event in the electrical
Before Top Center (BTC) BTC is the 180 degrees engine systems.
of crankshaft rotation before the piston reaches
the top center position in the normal direction of
rotation.
17
Diagnostic Lamp A diagnostic lamp is sometimes Harness The harness is the bundle of wiring
called the check engine light. The diagnostic lamp that connects all the components of the electrical
is used to warn the operator of the presence of an engine system.
active diagnostic code.
Hertz (Hz) Hz is the measure of frequency in
Direct Current (DC) Direct current is the type of cycles per second.
current that flows consistently in only one direction.
High Pressure Oil Manifold The high pressure
Duty Cycle See Pulse Width Modulation. oil manifold is an oil gallery that is added to the
cylinder head in order to supply the unit injectors
Electronic Control Analyzer And Programmer with high pressure oil.
(ECAP) The ECAP is a Caterpillar electronic
service tool. The ECAP is used for programming and High Pressure Oil Pump The high pressure oil
for diagnosing various types of electronic controls. pump is an axial piston pump that is driven by
gears. The high pressure oil pump is used to raise
Electronic Control Module (ECM) The ECM is the engine oil pressure in order to activate the unit
the engines control computer. The ECM provides injectors. The amount of oil pressure that is required
power to the electronics. The ECM monitors data to activate the unit injectors is called the actuation
that is input from the engines sensors. The ECM pressure.
acts as a governor in order to control engine rpm.
Hydraulic Electronic Unit Injector (HEUI) System
Electronic Engine Control The electronic engine The HEUI is a fuel system that uses a hydraulically
control is a complete electronic system. The actuated, electronically controlled unit injector. The
electronic engine control monitors the engine system combines the pumping, electronic fuel
operation under all conditions. The electronic metering and injecting elements in a single unit.
engine control also controls the engine operation
under all conditions. Injection Actuation Pressure Control Valve (IAP
Control Valve) The injection actuation pressure
Electronic Technician (ET) The ET is a Caterpillar control valve is a variable valve. The valve is used
electronic service tool that is used for diagnosing to maintain the proper oil pressure in the engine
and programming a variety of electronic controls. high pressure oil gallery. The valve is controlled by
the ECM.
Estimated Dynamic Timing Estimated dynamic
timing is the ECMs estimate of actual injection Injection Actuation Pressure (IAP) Sensor The
timing. injection actuation pressure sensor is a sensor that
measures hydraulic oil pressure. The sensor also
Exhaust Brake Enable Signal The exhaust brake sends a signal to the electronic control module
enable signal interfaces the ECM to the engine (ECM).
retarder. This prevents the operation of the exhaust
brake under unsafe engine operating conditions. Inlet Air Temperature Sensor The inlet air
temperature sensor is a sensor that measures the
Failure Mode Identifier (FMI) The FMI describes inlet air temperature. The sensor also sends a signal
the type of failure that was experienced by the to the electronic control module (ECM).
component. The codes for the FMI were adopted
from the standard practices of SAE (J1587 Open Circuit An open circuit is a broken electrical
diagnostics). wire connection. The signal or the supply voltage
cannot reach the intended destination.
Flash Memory See the Personality Module.
Original Equipment Manufacturer (OEM) An OEM
Fuel Ratio Control (FRC) The FRC is a limit that is the manufacturer of a vehicle that utilizes a
is based on the control of the fuel to air ratio. The Caterpillar engine.
FRC is used for emission control. When the ECM
senses a higher turbocharger outlet pressure, the Parameter A parameter is a programmable value
ECM increases the limit for the FRC in order to allow which affects the characteristics or the behavior of
more fuel into the cylinders. the engine and/or vehicle.
Fuel Position The fuel position is a signal within Parameter Identifier (PID) A PID is a numerical
the ECM. The signal is from the electronic governor. code that contains two digits or three digits. A
The signal goes to the fuel injection control. The numerical code is assigned to each component.
signal is based on the desired engine speed, the The numerical code identifies data via the data link
FRC, the rated position, and the actual engine to the ECM.
speed.
18
Password A password is a group of numeric Rated Fuel Position (Rated Fuel Pos on ECAP)
characters or alphanumeric characters. A password The rated fuel position indicates the maximum
is designed to restrict the changing of information allowable fuel position (longest injection pulse). The
in the ECM. The electrical engine systems require rated fuel position will produce rated power for this
correct customer passwords in order to change engine configuration.
customer specified parameters. The electrical
engine systems require correct factory passwords Reference Voltage The reference voltage is a
in order to clear certain logged events. Factory regulated voltage that is used by the sensor in order
passwords are also required in order to change to generate a signal voltage.
certain engine specifications.
Sensor A sensor is used to detect a change in
Personality Module The personality module is the pressure, in the temperature, or in mechanical
the module in the ECM which contains all the movement. When any of these changes are
instructions (software) for the ECM and performance detected, a sensor converts the change into an
maps for a specific horsepower family. Updates and electrical signal.
rerates are accomplished by electronically flashing
in new data. The updates and rerates are flashed in Service Program Module (SPM) The SPM is a
using an electronic service tool. software program on a computer chip that was
programmed at the factory. The computer chip
Power Take-Off (PTO) The PTO is operated with is designed to adapt an ECAP for a particular
the cruise control switches or dedicated PTO inputs. application.
This mode of operation permits setting constant
engine rpm when the vehicle is not moving or when Short Circuit A short circuit is an electrical circuit
the vehicle is moving at slow speeds. that is mistakenly connected to an undesirable
point. For example, an electrical contact is made
Progressive Shifting Progressive shifting is with the frame whenever an exposed wire rubs
upshifting through the lower gears quickly. Shifts against a vehicles frame.
are made above peak torque but below rated rpm.
Needlessly operating the engine in the higher rpm Signal A signal is a voltage or a wave that is
ranges before shifting to the next gear wastes fuel. used to transmit information that is typically from a
Also, this mode of operation fails to take advantage sensor to the ECM.
of the torque rise of the engine.
Speed Burp A speed burp is a sudden brief
Pulse Width Modulation (PWM) A PWM is a digital change in engine rpm.
type of electronic signal that corresponds to a
measured variable. The length of the pulse (signal) Speed-timing Sensor The speed-timing sensor is
is controlled by the measured variable. The variable a sensor that provides a Pulse Width Modulated
is quantified by a certain ratio. This ratio is the signal to the ECM. The ECM interprets this signal as
percent of on-time that is divided by the percent the crankshaft position and the engine speed.
of off-time. A PWM signal is generated by the
Throttle Position Sensor. Subsystem A subsystem is a part of the engine
system that relates to a particular function.
Supply Voltage Supply voltage is a constant

voltage that is supplied to a component in order
to provide electrical power for operation. Supply
voltage may be generated by the ECM. Supply
voltage may also be the battery voltage of the
vehicle that is supplied by the vehicle wiring.
T Harness This harness is a test harness that

is designed to permit normal circuit operation and
the measurement of the voltage simultaneously.
Typically, the harness is inserted between the two
ends of a connector.
g00284479
Illustration 8 Throttle Position Throttle position is the ECMs
Example Of Pulse Width Modulation interpretation of the signal from the accelerator
pedal position sensor. The throttle position may be
used as part of a power take-off control.
19
Total Tattletale The total tattletale is the total

number of changes to all system parameters.
Transducer A transducer is a device that converts

a mechanical signal to an electrical signal.
Vehicle Speed Sensor A vehicle speed sensor is

an electromagnetic pickup that measures vehicle
speed from the rotation of gear teeth in the drive
train of the vehicle.
i01269186
Electronic Control System

Components
SMCS Code: 1900
g00292549
Illustration 9
Electronic Control System Components (left side view)
(1) Grommet for injector harness. (2) Injection actuation pressure sensor. (3) Air inlet heater. (4) Inlet air temperature sensor. (5) Atmospheric
pressure sensor (if equipped). (6) Boost pressure sensor. (7) Engine harness connector J2/P2. (8) Engine ground stud connection. (9) Vehicle
harness connector J1/P1. (10) Oil temperature sensor (if equipped). (11) Injection actuation pressure control valve. (12) Engine speed-timing
sensors. (13) Coolant temperature sensor. (14) Oil pressure sensor (if equipped). (15) Electronic Control Module (ECM).
20
g00292594
Illustration 10
Electronic Control System Components (top view)
(1) Grommet for injector harness. (2) Injection actuation pressure sensor. (3) Air inlet heater. (4) Inlet air temperature sensor. (5) Atmospheric
pressure sensor (if equipped). (6) Boost pressure sensor. (8) Engine ground stud connection. (11) Injection actuation pressure control valve.
(16) Relay of air inlet heater.
The electronic control system is integrally designed An input component is one that sends an electrical
into the engines fuel system and the engines air signal to the ECM of the system. The signal that is
inlet and exhaust system in order to electronically sent varies in either of the following ways:
control the fuel delivery and the injection timing. The
electronic control system provides increased timing voltage
control and fuel air ratio control in comparison to
conventional mechanical engines. Injection timing frequency
is achieved by the precise control of the injector
firing time. Engine rpm is controlled by adjusting the pulse width
injection duration. The Electronic Control Module
(ECM) energizes the unit injector solenoids in order The variation of the signal is in response to a
to start the injection of fuel. Also, the Electronic change in some specific system of the vehicle.
Control Module (ECM) de-energizes the unit injector Some specific examples of an input component
solenoids in order to stop the injection of fuel. are the engine speed-timing sensors, the coolant
temperature sensor, and the cruise control switches.
Refer to Systems Operation/Testing And Adjusting, The ECM interprets the signal from the input
HEUI Injector Operation for a complete explanation component as information about the condition,
of the fuel injection process. environment, or operation of the vehicle.
The engine uses the following three types of

electronic components:
input component
control component
output component
21
A control component (ECM) receives the input Table 4

signals from the input components. Electronic Electrical Connectors And Functions
circuits inside the control component evaluate the
signals from the input components. These electronic J/P No. Function
circuits also supply electrical energy to the output
ECM Connector (70 pin, OEM Harness
components of the system. The electrical energy J1/P1
Connector)
that is supplied to the output components is based
on predetermined combinations of input signal ECM Connector (70 pin, Engine Harness
J2/P2
values. Connector)
Coolant Temperature Sensor Connector
An output component is one that is operated by J100/P100
(2 pin)
a control module. The output component receives
electrical energy from the control group. The output Inlet Manifold Air Temperature Sensor
J103/P103
component uses that electrical energy in one of Connector (2 Pin)
two ways. The output component can use that J200/P200 Boost Pressure Sensor Connector (3 pin)
electrical energy in order to perform work. The
output component can use that electrical energy in Atmospheric Pressure Sensor Connector
J203/P203
(3 pin)
order to provide information.
Injection Actuation Pressure Sensor
J204/P204
As an example, a moving solenoid plunger will Connector (3 pin)
perform work. By performing work, the component
J300/P300 Unit Injector Connector (12 pin)
has functioned in order to regulate the vehicle.
J301/P301 No. 1 Unit Injector Connector (2 pin)
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 J305/P305 No. 5 Unit Injector Connector (2 pin)
advantages:
improvement in performance J400/P400 Engine Timing Calibration Probe (2 pin)
Top Camshaft Engine Speed-Timing
improvement in fuel consumption J401/P401
Sensor Connector (2 pin)
reduction in emissions levels J402/P402
Bottom Camshaft Engine Speed-Timing
Accelerator Pedal Position Connector (3
J403/P403
pin)
Injection Actuation Pressure Control
J500/P500
Valve Connector (2 pin)
Relay Of Air Inlet Heater Connector (2
J501/P501
pin)
Lamp Of Air Inlet Heater Connector (2
J648/P648
pin)
Table 5
Diagnostic Flash Codes
Flash
PID-FMI Description of Code
Code
1-11 72 Cylinder 1 Fault
(continued)
22

Diagnostic Flash Codes Diagnostic Flash Codes
Flash Flash
PID-FMI Description of Code PID-FMI Description of Code
Code Code
22-13 42 Check Timing Sensor Calibration Coolant Temperature Sensor Open
110-03 27
Circuit
30-08 29 Invalid PTO Throttle Signal
Coolant Temperature Sensor Short
30-13 29 PTO Throttle Sensor Calibration 110-04 27
Circuit
41-03 21 8 Volt Supply Above Normal 110-11 61 Very High Coolant Temperature
41-04 21 8 Volt Supply Below Normal 111-01 62 Low Coolant Level Warning
Injection Actuation Pressure Control 111-02 12 Coolant Level Sensor Fault
42-11 18
Valve Driver Fault
111-11 62 Very Low Coolant Level
43-02 71 Ignition Keyswitch Fault
Injection Actuation Pressure Out of
Loss of Engine RPM Signal on 164-00 17
Range
64-02 34 Engine Speed and Timing Sensor
Number 2 Injection Actuation Pressure Sensor
164-02 15
Erratic
No Pattern on Engine Speed and
64-11 34
Timing Sensor Number 2 Injection Actuation Pressure Open
164-03 15
Circuit
70-05 49 Air Inlet Heater Open Circuit
Injection Actuation Pressure Short
70-06 49 Air Inlet Heater Short Circuit 164-04 15
Circuit
71-00 01 Idle Shutdown Override 164-11 39 Injection Actuation Pressure System
71-01 47 Idle Shutdown Occurrence Intermittent Battery Power to the
168-02 51
71-14 47 PTO Shutdown Occurrence ECM
84-00 41 Vehicle Overspeed Warning 190-00 35 Engine Overspeed Warning
84-01 31 Loss of Vehicle Speed Signal Loss of RPM Signal on Engine

190-02 34
Speed and Timing Sensor Number 1
84-02 36 Invalid Vehicle Speed Signal
No Pattern on Engine Speed and
190-11 34
84-08 36 Vehicle Speed Out of Range Timing Sensor Number 1
84-10 36 Vehicle Speed Rate of Change 231-11 58 J1939 Data Link Fault
91-08 32 Invalid Throttle Signal 232-03 21 5 Volt Supply Above Normal
91-13 28 Throttle Sensor Calibration 232-04 21 5 Volt Supply Below Normal
100-03 24 Open Circuit of Oil Pressure Sensor 246-11 00 Service Brake Switch Number 1 Fault
100-04 24 Short Circuit of Oil Pressure Sensor 247-11 00 Service Brake Switch Number 2 Fault
100-11 46 Very Low Oil Pressure 252-11 59 Incorrect Engine Software
102-03 25 Boost Pressure Sensor Open Circuit Check Customer or System
253-02 59
Parameters
102-04 25 Boost Pressure Sensor Short Circuit
Inlet Manifold Air Temperature
105-03 38
Sensor Open Circuit i01477589
105-04 38
Sensor Short Circuit
Fuel System
Atmospheric Pressure Sensor Open SMCS Code: 1250
108-03 26
Circuit
Atmospheric Pressure Sensor Short
108-04 26
Circuit
110-00 61 High Coolant Temperature Warning
(continued)
23
Introduction
g00457847
Illustration 11
HEUI Component Diagram
(1) Hydraulic pump. (2) Oil flow to engine. (3) Oil filter. (4) Engine oil pump. (5) Oil cooler. (6) IAP sensor. (7) Injectors. (8) Fuel supply rail.
(9) Fuel pressure regulator. (10) IAP control valve. (11) Fuel filter. (12) Fuel tank. (13) Back of cam gear. (14) Speed-timing sensors. (15)
ECM. (16) Boost pressure sensor. (17) Accelerator pedal. (18) Accelerator pedal position sensor. (19) Batteries. (20) Coolant temperature
sensor. (21) Data link. (22) Exhaust brake relay. (23) Inlet air temperature sensor. (24) Transmission relay. (25) Vehicle speed sensor. (26)
Inlet air heater relay. (27) Inlet air heater lamp. (28) Fast idle lamp. (29) Check engine lamp. (30) Speedometer and tachometer. (31) Cruise
ON/OFF switch and Cruise SET/RESUME switch. (32) PTO ON/OFF switch and SET/RESUME switch. (33) Service brake switches. (34)
Neutral and clutch switches. (35) Fuel transfer pump.
24
The operation of the Hydraulic Electronic Unit The HEUI uses engine lubrication oil that is
Injector (HEUI) fuel system is completely different pressurized from 6 MPa (870 psi) to 24 MPa
from any other type of fuel system that is actuated (3500 psi) in order to pump fuel from the injector.
mechanically. The HEUI fuel system is completely The HEUI operates in the same way as a hydraulic
free of adjustment. Adjustments to the components cylinder in order to multiply the force of the high
that are mechanical can not be made. Changes pressure oil. By multiplying the force of the high
in performance are made by installing different pressure oil, the HEUI can produce injection
software in Electronic Control Module (ECM) (15). pressures that are very high. This multiplication of
pressure is achieved by applying the force of the
This fuel system consists of six basic components: high pressure oil to a piston. The piston is larger
than the plunger by approximately six times. The
Hydraulic Electronic Unit Injector (HEUI) (7) piston that is powered by engine lubrication oil
under high pressure pushes on the plunger. This
Electronic Control Module (ECM) (15) engine lubrication oil under high pressure is called
the actuation pressure of the oil. The actuation
Hydraulic Pump (1) pressure of the oil generates the injection pressure
that is delivered by the unit injector. Injection
Injection Actuation Pressure Control Valve (10) pressure is greater than actuation pressure of the
oil by approximately six times.
Fuel Transfer Pump (35)
Low actuation pressure of the oil results in low
Injection Actuation Pressure Sensor (6) injection pressure of the fuel. During conditions
of low speed such as idle and start, low injection
Note: The components of the HEUI fuel system are pressure is utilized.
not serviceable. These fuel system components
must not be disassembled. Disassembly will High actuation pressure of the oil results in high
damage the components. If the components have injection pressure of the fuel. During conditions of
been disassembled, Caterpillar may not allow high speed such as high idle and acceleration, high
a warranty claim or Caterpillar may reduce the injection pressure is utilized.
warranty claim.
There are many other operating conditions when the
injection pressure is between the minimum and the
Component Description maximum. Regardless of the speed of the engine,
the HEUI fuel system provides infinite control of
Hydraulic Electronic Unit Injector injection pressure.
The HEUI fuel system utilizes a hydraulically
actuated electronically controlled unit injector (7).
Electronic Control Module (ECM)
Electronic Control Module (ECM) (15) is located on
All fuel systems for diesel engines use a plunger
the left side of the engine. The ECM is a powerful
and barrel in order to pump fuel under high pressure
into the combustion chamber. This fuel is pumped computer that provides total electronic control of
engine performance. The ECM uses data from
into the combustion chamber in precise amounts in
engine performance that is gathered by several
order to control engine performance. The HEUI uses
engine oil under high pressure in order to power the sensors. Then, the ECM uses this data in order
to make adjustments to the fuel delivery, injection
plunger. All other fuel systems use a fuel injection
pressure and injection timing. The ECM contains
pump camshaft lobe in order to power the plunger.
Because the HEUI is much different, a technician programmed performance maps (software) in order
to define horsepower, torque curves and rpm. This
must use different troubleshooting methods.
software is commonly called the personality module.
Some engines use Electronic Control Modules

(ECM) (15) with a replaceable computer chip.
The software has already been installed in the
replaceable computer chip. The 3126B and 3126E
diesel truck engines do not have a replaceable
personality module. The 3126B and 3126E diesel
truck engines personality module are a permanent
part of the ECM. The 3126B and 3126E diesel truck
engines personality module can be reprogrammed
by using the feature of flash programming of the
Caterpillar Electronic Technician (ET).
25
ECM (15) logs faults of engine performance. Also, Fuel transfer pump (35) is a single piston pump
the ECM is capable of running several diagnostic that is spring loaded. The pump is operated by
tests automatically when the ECM is used with an off-center bearing on the back of the hydraulic
an electronic service tool such as the ET or the pump shaft. There are two check valves in the fuel
Electronic Control Analyzer Programmer (ECAP). transfer pump. The inlet check valve opens in order
to allow fuel from the tank into the pump. The inlet
Hydraulic Pump check valve closes in order to prevent fuel leakage
back to the fuel tank. The outlet check valve opens
Hydraulic pump (1) (high pressure oil pump) in order to supply fuel to the fuel supply passage.
is located at the left front corner of the engine. The fuel supply passage is located in the cylinder
The hydraulic pump is a piston pump that has a head. The fuel supply passage supplies fuel to
fixed displacement. The hydraulic pump uses an injectors (7). The outlet check valve closes in order
axial piston. The hydraulic pump uses a portion to prevent pressurized fuel leakage back through
of the engine lubrication oil. The hydraulic pump the pump.
pressurizes the engine lubrication oil to the injection
actuation pressure that is required in order to power Injection Actuation Pressure Sensor
the HEUI injectors. (IAP)
Injection Actuation Pressure Control IAP Sensor (6) is installed in the high pressure oil
Valve (IAP Control Valve) manifold. The high pressure oil manifold supplies
actuation oil in order to power the unit injectors. The
Injection actuation pressure control valve (10) (IAP IAP Sensor monitors injection actuation pressure.
Control Valve) is located on the side of hydraulic The IAP Sensor sends a continuous voltage signal
pump (1). Under most conditions, the pump is back to ECM (15). The ECM interprets the signal.
producing excess oil flow. The IAP Control Valve The ECM is aware of the injection actuation pressure
discharges excess pump flow to the drain in at all times.
order to control injection actuation pressure to the
desired level. The IAP Control Valve is a valve of
high precision that controls the actual actuation
pressure. The performance maps of ECM (15)
contain a desired actuation pressure for every
engine operating condition. The ECM sends a
control current to the IAP Control Valve. The control
current should make the actual actuation pressure
equal to the desired actuation pressure.
IAP Control Valve (10) is an actuator. The IAP

Control Valve converts an electrical signal from
ECM (15) to the mechanical control of a spool valve
in order to control pump outlet pressure.
Fuel Transfer Pump

Fuel transfer pump (35) is mounted on the back of
hydraulic pump (1). The fuel transfer pump is used
in order to draw fuel from fuel tank (12). Also, the
fuel transfer pump is used in order to pressurize
the fuel to 450 kPa (65 psi). The pressurized fuel is
supplied to injectors (7).
26
HEUI Fuel System Operation

Low Pressure Fuel System
g00458217
Illustration 12
(8) Fuel supply line. (9) Fuel pressure regulator. (11) Fuel filter. (12) Fuel tank. (35) Fuel transfer pump.
27
The low pressure fuel system serves three functions. Fuel pressure regulator (9) consists of an orifice
The low pressure fuel system supplies fuel for and a spring loaded check valve. The orifice is a
combustion to injectors (7). Also, the low pressure flow restriction that pressurizes the supply fuel.
fuel system supplies excess fuel flow in order to The spring loaded check valve opens at 35 kPa
cool the unit injectors and the low pressure fuel (5 psi) in order to allow the fuel which has flowed
system supplies excess fuel flow in order to remove through the orifice to return to fuel tank (12). When
air from the system. the engine is off and no fuel pressure is present,
the spring loaded check valve closes. The spring
The low pressure fuel system consists of four basic loaded check valve closes in order to prevent the
components: fuel in the cylinder head from draining back to the
fuel tank.
Fuel tank (12)
Fuel filter (11)
Fuel transfer pump (35)
Fuel pressure regulator (9)
Fuel transfer pump (35) is mounted on the back of
hydraulic pump (1). The fuel transfer pump pushes
pressurized fuel out of the outlet port and the fuel
transfer pump draws new fuel into the inlet port.
Fuel is drawn from fuel tank (12) and flows through

two micron fuel filter (11).
Fuel flows from fuel filter (11) to the inlet side of

fuel transfer pump (35). An inlet check valve in the
inlet port of the fuel transfer pump opens in order
to allow the flow of fuel into the pump. After the
fuel flow has stopped, the inlet check valve closes
in order to prevent fuel flow out of the inlet port.
Fuel flows from the inlet port in the pump to the
outlet port, which also has a check valve. The outlet
check valve opens in order to allow pressurized fuel
flow out of the pump. The outlet check valve closes
in order to prevent pressurized fuel leakage back
through the pump.
Fuel flows from the outlet port of fuel transfer pump

(35) to the fuel supply passage in the cylinder head.
The fuel supply passage is a drilled hole which
begins at the front of the cylinder head. The fuel
supply passage extends to the back of the cylinder
head. This passage connects with each unit injector
bore in order to supply fuel to unit injectors (7). Fuel
from the transfer pump flows through the cylinder
head to all of the unit injectors. Excess fuel flows out
of the back of the cylinder head. After the excess
flows out of the back of the cylinder head, the fuel
flows into fuel pressure regulator (9).
28
Injection Actuation System

Actuation Oil Flow
g00458284
Illustration 13
Flow Path of the Injection Actuation Oil
(1) Hydraulic pump. (2) Oil flow to engine. (3) Oil filter. (4) Engine oil pump. (5) Oil cooler. (7) Injectors.
29
The injection actuation system serves two functions. The high pressure oil passage connects with each
The injection actuation system supplies high unit injector bore in order to supply high pressure
pressure oil in order to power HEUI injectors (7). actuation oil to unit injectors (7). Actuation oil that is
Also, the injection actuation system controls the under high pressure flows from hydraulic pump (1)
injection pressure that is produced by the unit through the cylinder head to all of the injectors. Oil
injectors by changing the actuation pressure of the is contained in the high pressure oil passage until
oil. the oil is used by the unit injectors. Oil that has been
exhausted by the unit injectors is expelled under
The injection actuation system consists of five basic the valve covers. This oil returns to the crankcase
components: through oil drain holes in the cylinder head.
Engine oil pump (4)

Engine oil filter (3)
Hydraulic pump (1)
Injection actuation pressure control valve (IAP
Control Valve) (10)
Injection actuation pressure sensor (IAP Sensor)

(6)
Oil from engine oil pump (4) supplies the needs

of the engine lubrication system. Also, oil from the
engine oil pump supplies the needs of hydraulic
pump (1) for the fuel system. The capacity of
the engine oil pump has been increased in order
to meet the additional flow requirement that is
necessary.
Oil that is drawn from the sump is pressurized

to the lubrication system oil pressure by engine
oil pump (4). Oil flows from the engine oil pump
through engine oil cooler (5), through engine oil
filter (3), and then to the main oil gallery. A separate
circuit from the main oil gallery directs a portion
of the lubrication oil in order to supply hydraulic
pump (1). A steel tube on the left side of the engine
connects the main oil gallery with the inlet port of
the hydraulic pump.
Oil flows into the inlet port of hydraulic pump (1)

and the oil fills the pump reservoir. The pump
reservoir provides oil to the hydraulic pump during
start-up. Also, the pump reservoir provides oil to
the hydraulic pump until the engine oil pump can
increase pressure.
The pump reservoir also provides makeup oil to

the high pressure oil passage in the cylinder head.
When the engine is off and the engine cools down,
the oil shrinks. A check valve in the pump allows
oil to be drawn from the pump reservoir in order to
keep the high pressure oil passage full.
Oil from the pump reservoir is pressurized in

hydraulic pump (1) and the oil is pushed out of the
outlet port of the pump under high pressure. Oil then
flows from the outlet port of the hydraulic pump to
the high pressure oil passage in the cylinder head.
30
Actuation Oil Pressure Control
g00458648
Illustration 14
Injection Actuation Oil Pressure Control
(1) Hydraulic pump. (2) Oil flow to engine. (3) Oil filter. (4) Engine oil pump. (5) Oil cooler. (6) IAP sensor. (7) Injectors. (8) Fuel supply rail. (9)
Fuel pressure regulator. (10) IAP control valve. (12) Fuel tank. (15) ECM.
31
Hydraulic pump (1) is a fixed displacement axial ECM (15) selects the desired actuation pressure.
piston pump. The pump is designed in order to The desired actuation pressure is based on both the
generate adequate flow under the conditions that sensor input and the performance maps. The ECM
are the most demanding. sends a control current to IAP Control Valve (10)
in order to change the actual actuation pressure.
Under most operating conditions, hydraulic pump The IAP Control Valve reacts to the electrical
(1) is producing excess flow. This excess flow must current from the ECM in order to change the actual
be discharged to a drain in order to control the actuation pressure. The actual actuation pressure
systems pressure. IAP Control Valve (10) regulates is changed when the IAP Control Valve discharges
system pressure by discharging the precise amount pump flow to the drain. The IAP Control Valve
of oil to the drain. This discharging of oil is required acts as an electrically controlled relief valve. IAP
in order to maintain the desired actuation pressure. Sensor (6) monitors the actual actuation pressure
in the high pressure oil passage. The IAP Sensor
There are two types of actuation pressure: reports the actual actuation pressure to the ECM by
sending a signal voltage to the ECM.
Desired actuation pressure
The injection actuation pressure control system
Actual actuation pressure operates in a cycle. ECM (15) selects the desired
actuation pressure. Then, the ECM sends an
Desired actuation pressure is the injection actuation electrical current to IAP Control Valve (10) that
pressure that is required by the system for optimum should produce that pressure. The IAP Control
engine performance. The desired actuation Valve reacts to the electrical current from the ECM
pressure is established by the performance maps by changing the pressure relief setting, which
in ECM (15). The ECM selects the desired actuation changes the actual actuation pressure. IAP Sensor
pressure. The ECM bases the selection on the (6) monitors the actual actuation pressure and the
signal inputs from many sensors. Some of the IAP Sensor sends a signal voltage back to the ECM.
sensors that are supplying signal inputs to the ECM The ECM interprets the signal voltage from the IAP
are accelerator pedal position sensor (18), boost Sensor in order to calculate the actual actuation
pressure sensor (16), speed-timing sensors (14), pressure. Then, the ECM compares the actual
and coolant temperature sensor (20). The desired actuation pressure to the desired actuation pressure
actuation pressure is constantly changing due in order to adjust the electrical current to the IAP
to changing engine speed and due to changing Control Valve. The IAP Control Valve responds to the
engine load. The desired actuation pressure is only change in electrical current by changing the actual
constant under steady state conditions (steady actuation pressure. This process is repeated 67
engine speed and load). times per second. This cycle of constant repetition
is called a closed loop control system.
Actual actuation pressure is the actual system
pressure of the actuation oil that is powering Most of the high pressure oil flow from hydraulic
the injectors (7). IAP Control Valve (10) is pump (1) is used in order to power unit injectors
constantly changing the amount of pump flow (7). Excess flow is the amount of pump flow that is
that is discharged to the drain. The pump flow not required in order to meet the desired actuation
is discharged to the drain in order to match the pressure. The excess flow is returned to the drain
actual actuation pressure to the desired actuation through IAP Control Valve (10). Excess flow from the
pressure. IAP Control Valve flows upward through a U-shaped
tube in the pump reservoir. The excess flow travels
Three components operate together in order to through a drilled passage to the front of the pump.
control injection actuation pressure: Drain oil flows out of the front of the pump over the
pump drive gear and flows down the engine front
ECM (15) gear train to sump.
IAP Control Valve (10)

IAP Sensor (6)
32
Operation of the Injection Actuation

Pressure Control Valve
g00295335
Illustration 15
Injection Actuation Pressure Control Valve
(1) Drain port. (2) Valve body. (3) Control orifice. (4) Spool chamber. (5) Armature. (6) Valve spool. (7) Spool spring. (8) Reduced pressure oil.
(9) Poppet. (10) Push pin. (11) Solenoid.
The IAP Control Valve is an electrically controlled Solenoid (11)

pilot operated pressure control valve. The Injection
Actuation Pressure Control Valve is used in order to The IAP Control Valve operates by using a
maintain selected actuation system pressure. The variable electrical current from the ECM in order
selected actuation system pressure is maintained to create a magnetic field in the solenoid (11).
regardless of engine speed, pump flow, and This magnetic field acts on armature (5) and the
variable oil demand of the unit injectors. The IAP magnetic field generates a mechanical force. This
Control Valve consists of six basic components: mechanical force pushes armature (5) to the left.
The mechanical force travels through push pin (10)
Armature (5) to poppet (9).
Valve spool (6)

Spool spring (7)
Poppet (9)
Push pin (10)
33
The magnetic force that is holding poppet (9)

closed is opposed by reduced hydraulic pressure
inside the spool chamber. The reduced hydraulic
pressure inside the spool chamber is trying to
open poppet (9). This reduced hydraulic pressure
increases until the reduced hydraulic pressure
overcomes the mechanical force of solenoid (11).
When the reduced hydraulic pressure overcomes
the mechanical force of solenoid (11), poppet (9)
opens. The open poppet allows a flow path to
drain for some of the reduced pressure oil (8).
Discharging part of reduced pressure oil (8) to drain
lowers the hydraulic pressure. When the hydraulic
pressure of reduced pressure oil (8) decreases
below the magnetic force on poppet (9), the poppet
closes again.
Valve Operation for ENGINE OFF
g00295336
Illustration 16
Operation of the Injection Actuation Pressure Control Valve (Engine Off)
(1) Pump outlet pressure (none). (2)Current from ECM (none). (3) Closed drain port. (4) Poppet (open).
When the engine is off, there is no pump outlet

pressure (1) from the pump and there is no current
to the solenoid from the ECM (2). The spool spring
pushes the spool valve completely to the left. When
the spool spring pushes the spool valve completely
to the left, drain port (3) is completely blocked.
34
Valve Operation for ENGINE CRANKING
g00295337
Illustration 17
Operation of the Injection Actuation Pressure Control Valve (Engine Cranking)
(1) Present pump outlet pressure. (2) Current from the ECM. (3) Drain port (blocked position). (4) Poppet (closed position).
During engine start-up, approximately 6 MPa Note: If the engine is already warm, the pressure
(870 psi) of injection actuation pressure is required that is required to start the engine may be higher
in order to activate the unit injector. This low than 6 MPa (870 psi). The values for the desired
injection actuation pressure generates a low fuel actuation pressures are stored in the performance
injection pressure of about 35 MPa (5000 psi). This maps of the ECM. The values for desired actuation
low fuel injection pressure aids cold starting. pressures vary with engine temperature.
In order to start the engine quickly, the injection

actuation pressure must rise quickly. Because the
hydraulic pump is being turned at engine cranking
speed, pump flow is very low. The ECM sends
a strong current (2) to the IAP Control Valve in
order to keep the spool closed. With the spool in
the closed position, all of the flow to drain port
(3) is blocked. The flow to drain port (3) remains
blocked until the actual actuation pressure of 6 MPa
(870 psi) is reached. The unit injectors are not fired
until the 6 MPa (870 psi) actual actuation pressure
is reached.
35
Once the unit injectors begin to operate, the ECM

controls the current to the IAP Control Valve.
The ECM and the IAP Control Valve maintain the
actual actuation pressure at 6 MPa (870 psi) until
the engine starts. The ECM monitors the actual
actuation pressure through the IAP Sensor that
is located in the high pressure oil manifold. The
ECM establishes desired actuation pressure by
monitoring several electrical input signals and the
ECM sends a predetermined current to the IAP
Control Valve. The ECM also compares the desired
actuation pressure to the actual actuation pressure
in the high pressure oil passage. The ECM adjusts
the current levels to the IAP Control Valve in order
to make the actual actuation pressure equal to the
desired actuation pressure.
Oil Flow for ENGINE CRANKING
Pump outlet pressure (1) enters the end of the

valve body and pump outlet pressure acts against
the valve spool. The pump outlet pressure tries to
push the valve spool to the right (open). A small
amount of oil also flows through the center of the
spool, through the spool control orifice and into the
spool spring chamber. The current from the ECM (2)
causes the solenoid to generate a magnetic field
which pushes the armature to the left. The armature
exerts a force on the push pin and the poppet
which holds the poppet closed. The poppet is the
only path to the drain for the oil in the spool spring
chamber. Pump outlet pressure (1) flows through
the spool control orifice and into the spool spring
chamber. This flow of pump outlet pressure allows
spring chamber pressure to build up. Because the
spring chamber path to the drain is blocked by the
poppet, the pressure in the spring chamber is equal
to pump outlet pressure (1).
The combination of spool spring force and spring

chamber pressure hold the spool to the left. When
the spool is held to the left, the drain ports are
closed. All pump flow is directed to the high
pressure oil manifold until an actual actuation
pressure of 6 MPa (870 psi) is reached.
36
Valve Operation for RUNNING ENGINE
g00295338
Illustration 18
Operation of the Injection Actuation Pressure Control Valve (Running Engine)
(1)Pump outlet pressure. (2)Current from ECM. (3) Drain port (open). (4) Poppet (open). (5) Reduced pressure oil.
Once the engine starts, the ECM controls the The magnetic force that is applied to the poppet
current (2) to the IAP Control Valve in order to holds the poppet closed. When the poppet is
maintain the desired actuation pressure. The IAP closed, the pressure in the spool spring chamber
Sensor monitors the actual actuation pressure in increases. When the pressure in the spool spring
the high pressure oil passage in the cylinder head. chamber exceeds the magnetic force that is holding
The ECM compares the actual actuation pressure the poppet closed, the poppet (4) will move to the
to the desired actuation pressure 67 times per right. When the poppet (4) moves to the right, some
second. When these pressures do not match, the of the pressure oil in the spool spring chamber
ECM adjusts the current levels (2) to the IAP Control escapes to the drain. This causes the pressure in
Valve in order to make the actual injection actuation the spring chamber to drop. When the pressure
pressure equal to the desired injection actuation in the spring chamber drops, the poppet closes.
pressure. When the poppet closes, the pressure again begins
to increase and the cycle is repeated. This process
The amount of current that is sent to the solenoid controls the reduced pressure oil (5) in the spool
regulates the amount of magnetic force that is spring cavity. The reduced pressure oil (5) in the
trying to hold the poppet closed. The solenoid, spool spring cavity acts on the spool. The reduced
the armature and the push pin simulate a variable pressure oil (5) in the spool spring cavity tries to
spring that is electronically controlled. Increased move the spool to the left. When the spool is moved
current results in increased force. Decreased to the left, the drain port (3) is blocked.
current results in decreased force.
37
The combined force of the mechanical spring and Components of the HEUI Injector
reduced pressure oil in the spool spring chamber
try to move the spool to the left in order to block the The HEUI injector serves four functions. The HEUI
drain port (3). When the drain port is blocked, pump injector pressurizes supply fuel from 450 kPa
outlet pressure (1) rises and the increased pump (65 psi) to 162 MPa (23500 psi). The HEUI injector
outlet pressure moves the spool to the right (open). functions as an atomizer by pumping high pressure
fuel through orifice holes in the unit injector tip.
Because the mechanical spring has a fixed spring The HEUI injector delivers the correct amount of
rate, the reduced pressure oil (5) in the spool must atomized fuel into the combustion chamber and the
be adjusted in order to control pump outlet pressure HEUI injector disperses the atomized fuel evenly
(1). The reduced pressure oil (5) in the spool can throughout the combustion chamber.
be raised in order to control pump outlet pressure
(1) or the reduced pressure oil (5) in the spool can
be lowered in order to control pump outlet pressure
(1). The reduced pressure oil (5) is controlled by
the amount of electrical current from the ECM (2).
Most of the time, the poppet and the spool operate
in a partially open position. The poppet and the
spool are completely open or completely closed
only during the following conditions:
Acceleration
Deceleration
Rapidly changing engine loads
Oil Flow for RUNNING ENGINE
When pump outlet pressure (1) enters the end of

the valve body, a small amount of oil flows into the
spool spring chamber through the control orifice
in the spool. The pressure in the spool spring
chamber is controlled by adjusting the force on
the poppet (4). Adjusting the force on the poppet
(4) allows the poppet to drain off some of the oil in
the spool spring chamber. The force on the poppet
is controlled by the strength of the magnetic field
that is produced from the electrical current from the
ECM (2). The spool responds to pressure changes
in the spool spring chamber. The spool changes
positions in order to balance the force on the spool.
The spool tries to make the force on the right side
of the spool equal to the force on the left side of the
spool. The spool position dictates the amount of the
surface area of the drain ports (3) that is open.
The open area of the drain port controls the amount

of oil that is drained off from the pump outlet. The
oil is drained off from the pump outlet in order
to maintain the desired actuation pressure. The
process of responding to pressure changes on
either side of the spool occurs so rapidly that the
spool is held in a partially open position and pump
outlet pressure (1) is closely controlled. The IAP
Control Valve allows infinitely variable control of
pump outlet pressure (1) between 6 MPa (870 psi)
and 24 MPa (3500 psi).
38
g00295359
Illustration 19
Components of the HEUI Injector
(1) Solenoid. (2) Armature. (3) Upper poppet seat. (4) Poppet valve. (5) Lower poppet seat. (6) Intensifier piston. (7) Plunger. (8) Plunger
cavity. (9) Barrel. (10) Nozzle assembly.
The HEUI injector consists of five basic components: Barrel (9)

Solenoid (1) Nozzle assembly (10)
Poppet valve (4)
Intensifier piston (6) and plunger (7)
39
Solenoid Barrel
The solenoid (1) is an electromagnet. When the The barrel (9) is the cylinder that holds plunger (7).
solenoid is energized, the solenoid creates a very The plunger moves inside the barrel. The plunger
strong magnetic field. This magnetic field attracts and barrel together act as a pump. Both the
the armature (2) which is connected to the poppet plunger and the barrel are precision components
valve (4) by an armature screw. When the armature that have a working clearance of only 0.0025 mm
moves toward the solenoid, the armature lifts the (.00010 inch). These tight clearances are required in
poppet valve off the poppet valves lower seat (5). order to produce injection pressures over 162 MPa
Energizing the solenoid and lifting the poppet valve (23500 psi) without excessive leakage.
off the poppet valves lower seat is the beginning of
the fuel injection process. Note: A small amount of controlled leakage is
required in order to lubricate the plunger which
Poppet Valve prevents wear.
The poppet valve (4) has two positions which are The barrel (9) also contains the PRIME spill port.
opened and closed. In the closed position, the
poppet is held on the lower poppet seat (5) by a The PRIME spill port is a small hole with a high
spring. The closed lower poppet seat prevents high precision tolerance. The PRIME spill port is
pressure actuation oil from entering the unit injector. machined through the side of barrel (9) into plunger
The open upper poppet seat (3) vents oil in the (7). This port momentarily vents fuel injection
cavity that is above the intensifier piston (6) to the pressure during the downward stroke of the plunger.
atmosphere. The oil is vented to the atmosphere
through the upper portion of the unit injector. In the
open position, the solenoid (1) is energized and the
poppet valve is lifted off the poppet valves lower
seat. When the poppet valve is lifted off the poppet
valves lower seat, the lower poppet seat opens
allowing high pressure actuation oil to enter the
unit injector. When the high pressure actuation oil
enters the unit injector, the high pressure actuation
oil pushes on the top of intensifier piston (6). The
upper poppet seat (3) of poppet valve (4) closes
and upper poppet seat (3) of poppet valve (4)
blocks the path to the drain. Blocking the path to
the drain prevents the leakage of high pressure
actuation oil from the unit injector.
Intensifier Piston
The surface area of intensifier piston (6) is six times
larger than the surface area of plunger (7). This
larger surface area provides a multiplication of
force. This multiplication of force allows 24 MPa
(3500 psi) of actuation oil to produce 162 MPa
(23500 psi) of fuel injection pressure. When poppet
valve (4) moves away from lower poppet seat (5),
high pressure actuation oil enters the unit injector.
When the high pressure actuation oil enters the unit
injector, the high pressure actuation oil pushes on
the top of intensifier piston (6). Pressure rises on
top of the intensifier piston and the pressure pushes
down on intensifier piston (6) and plunger (7). The
downward movement of the plunger pressurizes the
fuel in plunger cavity (8). The pressurized fuel in
the plunger cavity causes nozzle assembly (10) to
open. When the nozzle assembly opens, the fuel
delivery into the combustion chamber begins. A
large O-ring around the intensifier piston separates
the oil above the intensifier piston from the fuel
below the intensifier piston.
40
Nozzle Assembly
g00295360
Illustration 20
Nozzle Assembly
(1) Inlet fill check ball. (2) Case. (3) Check. (4) Tip. (5) Tip orifice holes.
The nozzle assembly is similar to all other unit

injectors nozzle assemblies. Fuel that has been
pressurized to the injection pressure flows from the
plunger cavity through a passage in the nozzle to
the nozzle tip (4). Fuel flow out of the tip is stopped
by check (3), which covers the tip orifice holes
(5) in the end of the tip (4). The force of a spring
holds the check down in the closed position. This
prevents the leakage of fuel out of tip (4) and this
prevents the leakage of combustion gas into the
unit injector when the cylinder fires.
41
When the injection pressure increases to

approximately 28 MPa (4000 psi), the hydraulic
force that is pushing on check (3) becomes greater
than the spring force that is holding the check
down. When the spring force is overcome by the
hydraulic force, the check moves away from tip (4).
When the check moves away from the tip, the check
is in the open position. The amount of pressure that
is required to open the check is called the Valve
Opening Pressure (VOP). The fuel flows out of tip
orifice holes (5) in the end of the tip and the fuel
flows into the combustion chamber. The check
remains open and fuel continues to flow out of the
tip until fuel injection pressure drops below 28 MPa
(4000 psi). When the pressure drops, the check
closes and fuel injection is stopped. The amount of
pressure that allows the check to close is called the
Valve Closing Pressure (VCP).
Note: Valve Opening Pressures (VOP) and Valve

Closing Pressures (VCP) vary among applications
and horsepower ratings in order to meet exhaust
emission standards. The above values were used
as illustrations only.
The inlet fill check ball (1) unseats during upward

travel of the plunger in order to allow the plunger
cavity to refill. The inlet fill check ball seats during
the downward stroke of the plunger and the inlet
fill check ball seals during the downward stroke of
the plunger. The inlet fill check ball seals during the
downward stroke of the plunger in order to prevent
fuel injection pressure leakage into the fuel supply.
Operation of the HEUI Fuel Injector

There are five stages of injection with the HEUI
injector:
Pre-injection
Pilot injection
Delay
Main injection
End of injection
42
Pre-Injection
g00295361
Illustration 21
HEUI Injector (Pre-Injection)
(1) Upper poppet seat (open). (2) Closed lower poppet seat. (A) Drain (atmosphere). (B) Fuel supply pressure. (C) Actuation oil pressure. (D)
Moving parts.
43
All of the internal components have been returned to

the spring loaded position during the pre-injection.
The solenoid is not energized and the lower poppet
seat (2) is closed. When the lower poppet seat is
closed, the lower poppet seat blocks high pressure
actuation oil from entering the unit injector. The
plunger and the intensifier piston are at the top
of the bore and the plunger cavity is full of fuel.
Fuel pressure in the plunger cavity is equal to the
fuel supply pressure. The fuel supply pressure is
approximately 450 kPa (65 psi).
44
Pilot Injection
g00295362
Illustration 22
HEUI Injector (Pilot Injection)
(1) Upper poppet seat (closed position). (2) Lower poppet seat (open). (A) Drain (atmosphere). (B) Fuel supply pressure. (C) Actuation oil
pressure. (D) Moving parts. (E) Injection pressure. (F) Fuel flow. (G) Mechanical movement.
45
When the ECM activates the unit injector, the ECM The PRIME feature produces a small pilot injection
sends a current to the unit injector solenoid. The that is followed by a brief delay. The brief delay
current causes the solenoid to produce a strong gives the pilot injection the time that is required
magnetic field which creates a pull on the armature. to start burning. The main injection follows the
The armature is mechanically connected to the pilot injection and the main injection is delivered
poppet valve by a screw. The magnetic pull of into the flame front that was established by the
the solenoid overcomes the spring tension that is pilot injection. The main injection is immediately
holding the poppet valve closed. When the poppet ignited. The main injection burns smoothly and the
valve opens, the poppet moves away from the lower main injection burns completely. This complete
poppet seat. combustion significantly reduces particulate
emission (soot) and NOx. This complete combustion
When the poppet valve opens, the upper poppet also reduces combustion noise from the engine
seat (1) blocks the path to the drain and the lower up to 50 percent. This reduction of combustion
poppet seat (2) opens the poppet chamber to noise from the engine results in noticeably quieter
incoming high pressure actuation oil. High pressure engine operation. The actual operation of PRIME is
oil flows around the poppet. The high pressure described in the following information.
oil flows through a passage onto the top of the
intensifier piston. High pressure oil acts on the top
of the intensifier piston. The piston and the plunger
are pushed down by the high pressure oil. The
downward movement of the plunger pressurizes
the fuel in the plunger cavity and nozzle assembly.
When the pressure reaches Valve Opening Pressure
(VOP) of approximately 28 MPa (4000 psi), the
check lifts up from the seat in the tip. When the
check lifts up from the seat in the tip, injection
begins.
Pre-Injection Metering (PRIME)
The 3126B and 3126E diesel engines fuel

system has a unique feature that is called PRIME.
PRe-Injection MEtering (PRIME) is a feature that
offers a significant benefit in lower emissions.
Also, PRIME offers a significant benefit in reducing
combustion noise. While other fuel systems deliver
a single large quantity of fuel into the combustion
chamber, PRIME injectors break the delivery into two
separate quantities. The first quantity is a small pilot
injection which is followed by a short delay. Then,
the injector delivers a large main injection. The pilot
injection is not intended to produce power. The pilot
injection is intended to establish a flame front. The
pilot injection will help the larger main injection burn
more completely and the pilot injection will help the
larger main injection burn in a controlled manner.
Under certain engine operating conditions, when

fuel is delivered in one large injection, the fuel tends
to explode rather than burn in a controlled manner.
This results in engine knock. When fuel explodes
rather than burns in a controlled manner, engine
knock and excess NOx emissions result.
46
Injection Delay
g00295363
Illustration 23
HEUI Injector Delay
47
The plunger continues moving downward and the

plunger continues to inject fuel into the combustion
chamber. Until the PRIME groove in the plunger
lines up with the PRIME spill port in the barrel, the
plunger continues to inject fuel into the combustion
chamber. When the groove in the plunger aligns
with the spill port, high pressure fuel under the
plunger can flow upward. The high pressure fuel
flows through three holes in the bottom of the
plunger. Then, the high pressure fuel flows out of
the groove of the plunger and the spill port and the
fuel flows back into the fuel supply passage. This
loss of high pressure fuel causes injection pressure
to drop below Valve Closing Pressure (VCP). The
spring force overcomes the hydraulic force of the
reduced injection pressure. When the spring force
overcomes the hydraulic force of the reduced
injection pressure, the check closes and fuel
injection stops. This is the end of the pilot injection
and the start of the short injection delay period.
48
Main Injection
g00295364
Illustration 24
HEUI Injector (Main Injection)
49
While the solenoid is energized, the poppet valve

remains open. While the poppet valve is open, high
pressure oil continues to flow. The flow of the high
pressure oil pushes downward on the intensifier
piston and the plunger. The injection pressure
fluctuates between 34 MPa (5000 psi) and 162 MPa
(23500 psi). The injection pressure depends on
the engines requirements. Injection continues
until either the solenoid is de-energized or the
intensifier piston hits the bottom of the bore. When
the solenoid is de-energized, the poppet spring is
allowed to close the poppet valve. When the poppet
valve closes, high pressure oil is shut off.
50
End of Injection
g00295365
Illustration 25
HEUI Injector (End Of Injection)
(1) Upper poppet seat (open). (2) Lower poppet seat (closed position). (A) Drain (atmosphere). (B) Fuel supply pressure. (C) Actuation oil
pressure. (D) Moving parts. (F) Fuel flow. (G) Mechanical movement.
51
The end of the injection cycle begins when the ECM Fuel Heater And Water Separator
stops the current to the unit injector solenoid. The
magnetic field of the solenoid breaks down and the
(If Equipped)
magnetic field is unable to overcome the spring
force of the poppet. The poppet returns to the
lower poppet seat which closes the poppet valve.
When the poppet valve closes, high pressure oil is
stopped from entering the unit injector. As the lower
poppet seat closes, the upper poppet seat opens
to the drain. When the upper poppet seat opens to
the drain, the actuation pressure of the oil drops off.
Fuel injection pressure under the plunger exerts

an upward force on the plunger and the intensifier
piston. As the pressure of the actuation oil above
the intensifier piston drops off, the downward force
on the intensifier piston drops off. The upward force
of the fuel injection pressure under the plunger
suddenly becomes greater than the downward
force on the intensifier piston. The downward motion
of the intensifier piston and the plunger stops.
The exhaust oil on top of the intensifier piston can

flow to the drain through the open upper poppet
seat. Then, the oil flows through a vent hole to the g00291751
Illustration 26
rocker arm compartment under the valve cover. (1) Fuel filter. (2) Fuel inlet. (3) Fuel outlet. (4) Fuel heater and
water separator. (5) Drain valve.
When the downward travel of the plunger stops,
fuel flow also stops. While the check is still open, Some engines may have a combination of a fuel
the remaining fuel pressure pushes a small amount heater and a water separator. The fuel heater is
of fuel out of the orifice holes. This causes a large controlled by a thermostat that is located in the
pressure drop which lowers injection pressure base of the unit. The thermostat is preset. When the
below Valve Closing Pressure (VCP). Spring tension fuel temperature is below 4C (40F), the thermostat
on the check now reseats the check into the tip and will turn on the heater. When the fuel temperature is
injection stops. 15C (60F), the thermostat will turn off the heater.
When the check closes, injection stops. When Water that has been separated from the fuel can be
injection stops, the fill cycle starts. The area above drained from the unit by lifting up on drain valve (5).
the intensifier piston cavity is open to atmospheric
pressure through the upper poppet seat. Pressure
drops very rapidly in the cavity above the intensifier
piston to near zero. The return spring of the plunger
pushes up on the plunger and the intensifier piston.
As the plunger and the intensifier piston move
upward, oil is forced around the upper poppet seat.
After the oil is forced around the upper poppet seat,
the oil is forced out of a vent hole.
As the plunger rises, pressure in the plunger cavity

also drops to near zero. The fuel supply pressure is
450 kPa (65 psi). Fuel supply pressure unseats the
plunger fill check in order to fill the plunger cavity
with fuel. When the intensifier piston is pushed to
the top of the bore, the fill cycle ends. When the
fill cycle ends, the plunger cavity is full and the
inlet fill check ball is reseated. Pressure above the
intensifier piston and the poppet chamber is zero.
The fuel injection cycle is complete and the unit
injector is ready to begin again. The unit injector is
now back in the pre-injection cycle.
52
i01515218 Aftercooler core (2) is a separate cooler core.

Aftercooler core (2) is installed in front of the core
Air Inlet and Exhaust System (standard) of the engine radiator on the machine.
Air that is ambient temperature is moved across
SMCS Code: 1050 the aftercooler core by the engine fan. This cools
the turbocharged inlet air.
From aftercooler core (2), the air is forced into the

cylinder head in order to fill the inlet ports. Air flow
from the inlet port into the cylinder is controlled by
the inlet valves.
g00787037
Illustration 27
Airflow Schematic
(1) Air line. (2) Aftercooler core. (3) Air inlet elbow. (4) Exhaust
outlet from turbocharger. (5) Turbine side of turbocharger. (6)
Compressor side of turbocharger. (7) Air cleaner.
The components of the air inlet and exhaust system Illustration 28 g00294192
control the quality of the air that is available for Air Inlet And Exhaust System
combustion. These components also control the
(2) Aftercooler core. (4) Exhaust outlet. (5) Turbine side of
amount of the air that is available for combustion. turbocharger. (6) Compressor side of turbocharger. (7) Exhaust
The components of the air inlet and exhaust system manifold. (8) Exhaust valve. (9) Inlet valve. (10) Air inlet.
are listed below:
There are two inlet valves and one exhaust valve
Air cleaner for each cylinder. Inlet valves open when the
piston moves down on the inlet stroke. When the
Turbocharger inlet valves open, cooled compressed air from
the inlet port is pulled into the cylinder. The inlet
Aftercooler valves close and the piston begins to move up on
the compression stroke. The air in the cylinder is
Cylinder head compressed. When the piston is near the top of the
compression stroke, fuel is injected into the cylinder.
Valves and valve system components The fuel mixes with the air and combustion starts.
During the power stroke, the combustion force
Piston and cylinder pushes the piston downward. After the power stroke
is complete, the piston moves upward. This upward
Exhaust manifold movement is the exhaust stroke. During the exhaust
stroke, the exhaust valve opens, and the exhaust
Inlet air is pulled through the air cleaner. The inlet air gases are pushed through the exhaust port into the
is then compressed and heated by the compressor exhaust manifold. After the piston completes the
wheel of turbocharger (6) to about 150C (300F). exhaust stroke, the exhaust valves close and the
The inlet air is then pushed through air-to-air cycle starts again. The complete cycle consists of
aftercooler core (2) and the inlet air is moved to air four stages:
inlet elbow (3). The temperature of the inlet air at
air inlet elbow (3) is about 43C (110F). Cooling Inlet stroke
of the inlet air increases the combustion efficiency.
Increased combustion efficiency helps to lower fuel Compression stroke
consumption. Also, increased combustion efficiency
helps to increase horsepower output. Power stroke
Exhaust stroke
53
Exhaust gases from exhaust manifold (7) enter the When the load on the engine increases, more fuel
turbine side of turbocharger (5) in order to turn the is injected into the cylinders. The combustion of
turbine wheel. The turbine wheel is connected to a this additional fuel produces more exhaust gases.
shaft which drives the compressor wheel. Exhaust The additional exhaust gases cause the turbine
gases from the turbocharger pass through the and the compressor wheels of the turbocharger to
exhaust outlet pipe, the muffler and the exhaust turn faster. As the compressor wheel turns faster,
stack. 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
Turbocharger efficiency.
g00294194
Illustration 30
Turbocharger With Waste Gate
(12) Actuating lever. (13) Canister. (14) Line (boost pressure).
When the engine is operating under conditions

g00294193
of low boost, a spring pushes on a diaphragm in
Illustration 29 canister (13). This action moves actuating lever (12)
Turbocharger in order to close the valve of the waste gate. Closing
(1) Air inlet. (2) Compressor housing. (3) Compressor wheel. (4) the valve of the waste gate allows the turbocharger
Bearing. (5) Oil Inlet port. (6) Bearing. (7) Turbine housing. (8) to operate at maximum performance.
Turbine wheel. (9) Exhaust outlet. (10) Oil outlet port. (11) Exhaust
inlet.
As the boost pressure increases against the
diaphragm in canister (13), the valve of the waste
The turbocharger is installed on the center section gate is opened. When the valve of the waste gate
of the exhaust manifold. All the exhaust gases is opened, the rpm of the turbocharger is limited
from the engine go through the turbocharger. The by bypassing a portion of the exhaust gases. The
compressor side of the turbocharger is connected exhaust gases are bypassed through line (14)
to the aftercooler by a pipe. around the turbine wheel of the turbocharger.
The exhaust gases go into turbine housing (7) Note: The turbocharger with a waste gate is preset
through exhaust inlet (11). The exhaust gases then at the factory and no adjustment can be made.
push the blades of turbine wheel (8). The turbine
wheel is connected by a shaft to compressor wheel Bearings (4) and (6) for the turbocharger use
(3). engine oil under pressure for lubrication. The oil
comes in through oil inlet port (5). The oil then goes
Clean air from the air cleaners is pulled through through passages in the center section in order to
compressor housing air inlet (1) by the rotation of lubricate the bearings. Oil from the turbocharger
compressor wheel (3). The action of the compressor goes out through oil outlet port (10) in the bottom
wheel blades causes a compression of the inlet air. of the center section. The oil then goes back to the
This compression gives the engine more power by engine lubrication system.
allowing the engine to burn more air and more fuel
during combustion.
54
Valve System Components Air Inlet Heater

The engines are equipped with an electric heater
that is located behind the air inlet elbow. The
electric heater has two functions:
Aid in starting
Aid in white smoke cleanup during start-up
Under the proper conditions, the Electronic Control
Module (ECM) turns on the electric heater. The
following conditions are evaluated prior to activating
the electric heater:
Jacket water coolant temperature

Inlet manifold temperature
Ignition switch position
Duration of time
The system is capable of delivering heat for 30
seconds prior to start-up and during cranking of the
engine. After the engine has started, the system is
capable of delivering heat constantly for 7 minutes,
or the system can cycle the heat for 13 minutes.
During the heating cycle, the heat is on for ten
g00294195 seconds and the heat is off for ten seconds.
Illustration 31
Valve System Components
If the air inlet heater malfunctions, the engine will
(1) Rocker arms. (2) Bridge. (3) Spring. (4) Pushrods. (5) Exhaust
valve. (6) Inlet valves. (7) Lifter. (8) Camshaft lobe. still start and the engine will still run. There may be
a concern regarding the amount of white smoke that
The valve system components control the flow of is present. Also, there may be a concern regarding
inlet air into the cylinders during engine operation. the need for an alternative starting aid.
The valve system components also control the flow
of exhaust gases out of the cylinders during engine System Components
operation.
The system of the air inlet heater consists of the
The crankshaft gear drives the camshaft gear following basic components:
through an idler gear. The camshaft must be
timed to the crankshaft in order to get the correct Relay of the air inlet heater
relation between the piston movement and the valve
movement. Heater element
The camshaft has two camshaft lobes for each Coolant temperature sensor
cylinder. The lobes operate the inlet and exhaust
valves. As the camshaft turns, lobes on the camshaft Inlet manifold temperature sensor
cause lifters (7) to move pushrods (4) up and down.
Upward movement of the pushrods against rocker Electronic Control Module (ECM)
arms (1) results in downward movement (opening)
of valves (5) and (6). Indicator lamp
Each cylinder has two inlet valves and one exhaust
valve. Valve springs (3) close the valves when the
lifters move down.
55
During engine cranking, when the sum of the

coolant temperature plus the inlet air temperature
is less than 25C (109F), the ECM will turn on the
heater. The heater will remain on during engine
cranking. If the engine fails to start, the ECM reverts
to preheat. Reverting to preheat will activate the
heater for another 30 seconds.
Running of the engine

After the engine has started, the same combination
of inlet air temperature and coolant temperature will
determine the state of the heater.
This mode of operation uses a continuous strategy.

The heater will remain on for a maximum of 7
minutes after starting.
Mode of Post Heat

If the same conditions still exist after the continuous
Illustration 32 g00294196 strategy ends, the ECM will activate the intermittent
Location Of Components
strategy. The heater is cycled for a maximum of 13
minutes. During this cycle, the heater is turned on
(1) Relay of the air inlet heater. (2) Inlet manifold temperature
sensor. (3) Ground strap (heater to engine). (4) Air inlet heater. (5)
for 10 seconds and the heater is turned off for 10
Coolant temperature sensor. (6) Electronic Control Module (ECM). seconds. After the 13 minute time limit, the heater
is shut off.
The relay for the air inlet heater (1) is located on the
mounting bracket for the fuel filter. The relay turns When one of the temperature sensors fails, the
the 12 V heater ON and OFF in response to signals system will operate in the following manner:
from the ECM (6).
Coolant temperature sensor
The air inlet heater (4) is a component of the air
inlet cover. The heater element has a ground strap When the coolant temperature sensor has an open
(3) that must be connected to the engine. circuit or a short circuit, the coolant temperature
sensor has failed. During this condition, the heater
There are five conditions that would cause the air will be activated when the inlet air temperature is
inlet heater to be activated: less than 10C (50F).
Powerup Inlet air temperature sensor

Regardless of temperature, the heater and the lamp When the inlet air temperature sensor has an open
of the heater should come on for two seconds when circuit or a short circuit, the inlet air temperature
the ECM is first powered (lamp check). sensor has failed. During this condition, the heater
will be activated when the coolant temperature is
Mode of Preheat less than 40C (104F).
When the sum of the coolant temperature plus the Under the proper condition, the heater will
inlet air temperature is less than 25C (109F), the be reactivated. When the sum of the coolant
ECM will turn on the heater and the lamp for 30 temperature and the inlet air temperature has
seconds. This is a cycle of preheat. dropped below 25C (109F), the heater will be
reactivated. This condition could exist after a warm
The ECM will then turn off the heater and the lamp. engine has cooled and the operator attempts to
When the operator attempts to start the engine prior start the engine.
to the completion of preheat, the ECM proceeds
into the mode of cranking for heater control. When the sum of the coolant temperature and the
inlet air temperature does not attain 35C (127F),
Mode of cranking the heater will be activated. The heater can be
activated no longer than 20 minutes (maximum).
The ECM will turn off the heater after the 20 minute
time limit.
56
For additional information on the air inlet heater refer

to Troubleshooting, Air Inlet Heater Circuit - Test.
g00786279
Illustration 33
Schematic Of Air Inlet Heater (Typical Example)
(1) Battery. (2) Fuse panel. (3) Lamp of air inlet heater. (4) Electronic Control Module. (5) Engine ground. (6) Air inlet heater. (7) Relay of
air inlet heater.
57
g00787054
Illustration 34
Flow Chart Of Controller Of Air Inlet Heater
58
i01486056
Lubrication System
SMCS Code: 1300
g00292659
Illustration 35
Lubrication System Schematic
(1) Hydraulic pump. (2) High pressure relief valve. (3) Passage to the rocker arms. (4) High pressure oil line. (5) Injection actuation pressure
control valve. (6) High pressure oil manifold. (7) Oil supply line for hydraulic pump. (8) Piston cooling jets. (9) Cylinder head gallery. (10) Passage
to pushrod lifters. (11) Main bearings. (12) Camshaft bearing. (13) Passage to engine oil pan. (14) Main oil gallery. (15) Turbocharger oil supply
line. (16) Passage to front housing. (17) Passage to oil pump idler gear bearing. (18) Oil filter bypass valve. (19) Passage to camshaft idler gear
bearing. (20) Passage. (21) Engine oil filter. (22) Oil cooler bypass valve. (23) Engine oil cooler. (24) Engine oil pump. (25) Oil pump bypass
valve. (26) Auxiliary engine oil filter (if equipped). (27) Engine oil pan.
59
Engine oil pump (24) is mounted to the bottom of The passage in front housing (16) sends the oil flow
the cylinder block inside the engine oil pan (27). in two directions. At the upper end of the passage,
The engine oil pump (24) pulls oil from engine oil is directed back into the block and up to cylinder
oil pan (27). The engine oil pump pushes the oil head gallery (9) through passage (3) to the rocker
through the passage to the engine oil cooler (23). arm mechanism. A passage (17) sends oil to the oil
Oil then flows through engine oil filter (21). The pump idler gear bearing.
filtered oil then enters the turbocharger oil supply
line (15) and main oil gallery (14). Oil from the front main bearing enters a passage
(19) to the camshaft idler gear bearing. Oil
passages in the crankshaft send oil from all the
main bearings (11) through the connecting rods to
the connecting rod bearings.
The passages send oil from the camshaft bearing

(12) to an oil passage in the side covers. The oil
then enters a hole in the shafts to pushrod lifters
(10). The oil lubricates the bearings of the lifter.
Note: Engines that are equipped with an auxiliary oil

filter (26) will receive oil at a port. The filtered oil will
be returned to engine oil pan (27).
The hydraulic pump (1) is a gear-driven axial piston

g00292660
Illustration 36 pump. The hydraulic pump raises the engine oil
Right Side View Of Engine pressure from the typical operating oil pressure to
(15) Turbocharger oil supply line. (18) Oil filter bypass valve. (21) the actuation pressure that is required by the unit
Engine oil filter. (22) Oil cooler bypass valve. (23) Oil cooler. (28) injectors. The injection actuation pressure control
Turbocharger oil return tube. valve (5) electronically controls the output pressure
of the hydraulic pump (1).
The oil circuit consists of a low pressure circuit

and a high pressure circuit. The low pressure
circuit typically operates at a pressure of 240 kPa
(35 psi) to 480 kPa (70 psi). The low pressure circuit
provides engine oil that has been filtered to the
hydraulic pump (1). Also, the low pressure circuit
provides engine oil that has been filtered to the
lubricating system of the engine. Oil is drawn from
the engine oil pan (27). Oil is supplied through the
engine oil cooler (23) and engine oil filter (21) to
both the engine and the hydraulic pump (1).
g00292662
The high pressure oil system provides actuation
Illustration 37 oil to the unit injector. The high pressure circuit
Left Side View Of Engine operates in a pressure range typically between
(1) Hydraulic pump. (4) Oil supply line (high pressure). (6) Oil 4 MPa (581 psi) and 23 MPa (3350 psi). This high
manifold (high pressure). (7) Oil supply line (hydraulic pump). pressure oil flows through a line into the cylinder
head. The cylinder head stores the oil at actuation
The main oil gallery (14) distributes oil to main pressure. The oil is ready to actuate the unit injector.
bearings (11), piston cooling jets (8), and camshaft Oil is discharged from the unit injector under the
bearing (12). Oil from main oil gallery (14) exits the valve cover so that no return lines are required.
front of the block. The oil then enters a groove that
is cast in front housing (16). After the lubrication oils work is done, the lubrication
oil returns to the engine oil pan.
Oil enters the crankshaft through holes in the
bearing surfaces (journals) for the main bearing The oil pump bypass valve (25) limits the pressure
(11). Passages connect the bearing surface of the oil that is coming from the engine oil pump
(journal) for the main bearing (11) with the bearing (24). The engine oil pump (24) can pump more than
surface (journal) for the connecting rod. enough oil into the system. When there is more than
enough oil, the oil pressure increases. When the oil
pressure increases, the oil pump bypass valve (25)
will open. This allows the oil that is not needed to go
back to the suction side of the engine oil pump (24).
60
The bypass valves (22) and (18) will open when Crankshaft main bearings
the engine is cold (starting conditions). Opening
the bypass valves achieves immediate lubrication Turbocharger cartridge
of all components. Immediate lubrication is critical
when cold oil with high viscosity causes a restriction An oil cooling chamber is formed by the lip that is
to the oil flow through engine oil cooler (23) and forged at the top of the skirt of the piston and the
engine oil filter (21). The engine oil pump (24) sends cavity that is behind the ring grooves in the crown.
the cold oil through the bypass valves around the Oil flow for the piston cooling jet enters the cooling
engine oil cooler (23) and engine oil filter (21) to the chamber through a drilled passage in the skirt. Oil
turbocharger oil supply line (15) and the main oil flow from the piston cooling jet returns to the engine
gallery (14) in the cylinder block. oil pan (27) through the clearance gap between the
crown and the skirt. Four holes that are drilled from
When the oil gets warm, the pressure difference the piston oil ring groove to the interior of the piston
in the bypass valves decreases and the bypass drain excess oil from the oil ring.
valves close. After the bypass valves close, there
is a normal flow of oil through the engine oil cooler
and the engine oil filter.
The bypass valves will also open when there is a

restriction in the engine oil cooler (23) or engine
oil filter (21). This design allows the engine to be
lubricated even though engine oil cooler (23) or
engine oil filter (21) are restricted.
The engine oil cooler bypass valve is also activated

by pressure. If the oil pressure differential across
the engine oil cooler reaches 125 30 kPa
(18 4.5 psi), the valve will open. Opening the valve
allows the oil flow to bypass the engine oil cooler
g00292663
(23). Illustration 38
Front Left Side View Of Engine
The main oil flow now reaches the main engine oil (29) Breather. (30) Hose. (31) Valve cover.
filter (21). When the oil pressure differential across
the oil filter bypass valve (18) reaches 125 30 kPa Breather (29) allows engine blowby to escape from
(18 4.5 psi), the valve opens in order to allow the crankcase. The engine blowby is discharged
the oil flow to go around the oil filter (21). The through hose (30) into the atmosphere. This
oil flow continues in order to lubricate the engine prevents pressure from building up that could cause
components. When the oil is cold, an oil pressure seals or gaskets to leak.
difference in the bypass valve also causes the valve
to open. This bypass valve then provides immediate
lubrication to all the engine components when cold i00665400
oil with high viscosity causes a restriction to the oil
flow through the engine oil filter (21). The bypass Cooling System
valve will also open when there is a restriction in the
engine oil filter (21). This design allows the engine SMCS Code: 1350
to be lubricated even though engine oil filter (21)
is restricted. This engine has a pressure type cooling system that
is equipped with a shunt line.
Note: Refer to Specifications, Engine Oil Filter
Base. A pressure type cooling system offers two
advantages:
Filtered oil flows through the main oil gallery (14) in
the cylinder block. Oil is supplied from the main oil The cooling system can operate safely at a
gallery (14) to the following components: temperature that is higher than the normal boiling
point of water.
Piston cooling jets (8)
The cooling system prevents cavitation in the
water pump.
Valve mechanism
Camshaft bearing (12)
61
Cavitation is the sudden formation of low pressure

bubbles in liquids by mechanical forces. The
formation of air or steam pockets is more difficult
within a pressure type cooling system.
The shunt line prevents cavitation by the water

pump. The shunt line provides a constant flow of
coolant to the water pump.
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.
g00293081
Illustration 40
Water Lines Group
g00293080
Illustration 39 (1) Cylinder head. (2) Water temperature regulator housing. (5)
Cooling System Schematic Bypass hose. (9) Water pump. (10) Outlet to radiator. (11) Water
temperature regulator. (12) Air vent valve in thermostat.
(1) Cylinder head. (2) Water temperature regulator housing. (3)
Expansion tank. (4) Shunt line (expansion tank to water pump).
(5) Bypass hose. (6) Radiator. (7) Cylinder block. (8) Oil cooler. From the cylinder block, the coolant flows into
(9) Water pump. passages in the cylinder head. The passages send
the flow around the unit injector sleeves and the
Water pump (9) is located on the right side of the inlet and the exhaust passages. The coolant now
cylinder block. The water pump is belt driven from enters water temperature regulator housing (2) at
the crankshaft pulley. Coolant can enter the water the front right side of the cylinder head.
pump in three places:
Water temperature regulator (11) controls the
the inlet at the bottom of the water pump direction of flow. When the coolant temperature
is below the normal operating temperature,
the bypass hose (5) into the top of the water the water temperature regulator is closed. The
pump coolant is directed through bypass hose (5) and
into the top inlet of the water pump. When the
the shunt line (4) into the top of the water pump coolant temperature reaches the normal operating
temperature, water temperature regulator (11)
Coolant from the bottom of the radiator is pulled into opens. When the water temperature regulator is
the bottom inlet of the pump by impeller rotation. open, the bypass is closed. Most of the coolant
The coolant exits the back of the pump directly into goes through outlet (10) to the radiator for cooling.
the oil cooler cavity of the block. The remainder flows through bypass hose (5) and
into the water pump.
All of the coolant passes through the core of
the oil cooler and the coolant enters the internal Note: Some coolant systems may contain two water
water manifold of the cylinder block. The manifold temperature regulators.
disperses the coolant to water jackets around the
cylinder walls.
62
The shunt line (4) extends from the top of the water If the engine is equipped with an air compressor,
pump to an expansion tank. The shunt line must coolant is supplied from the water temperature
be routed properly in order to avoid trapping any regulator housing to air compressor (3) through
air. By providing a constant flow of coolant to the coolant supply line (1). The coolant is circulated
water pump, the shunt line keeps the water pump through the air compressor and the coolant is
from cavitation. returned to the cooling system through coolant
return line (2) into the cylinder head.
Note: Water temperature regulator (11) is an
important part of the cooling system. The water
temperature regulator divides coolant flow between
Coolant Conditioner (If Equipped)
the radiator and the bypass in order to maintain
Some conditions of operation can cause pitting.
the normal operating temperature. If the water
This pitting is caused by corrosion or by cavitation
temperature regulator is not installed in the system, erosion. A corrosion inhibitor is a chemical that
there is no mechanical control, and most of the
provides a reduction in pitting. The addition of a
coolant will travel the path of least resistance
corrosion inhibitor can keep this type of damage
through the bypass. This will cause the engine to to a minimum.
overheat in hot weather and the engine will not
reach normal operating temperature in cold weather.
The coolant conditioner element is a spin-on
element that is similar to the fuel filter and to the
Note: Air vent valve (12) will allow the air to escape
oil filter elements. The coolant conditioner element
past the water temperature regulator from the
attaches to the coolant conditioner base that is
cooling system while the radiator is being filled. mounted on the front of the engine. Coolant flows
During normal operation, the air vent valve will be
from the water pump to the coolant conditioner base
closed in order to prevent coolant flow past the
and back to the cylinder block. Coolant constantly
water temperature regulator. flows through the coolant conditioner element when
the valves are in the OPEN position.
Coolant For Air Compressor (If
The element has a specific amount of inhibitor
Equipped) for acceptable cooling system protection. As the
coolant flows through the element, the corrosion
inhibitor goes into the solution. The corrosion
inhibitor is a dry solution, so the inhibitor dissolves.
The corrosion inhibitor then mixes to the correct
concentration. Two basic types of elements are
used for the cooling system. The two elements
are the precharge elements and the maintenance
elements. Each type of element has a specific
use. The elements must be used correctly in order
to get the necessary concentration for cooling
system protection. The elements also contain a
filter. The elements should remain in the system so
that coolant will flow through after the conditioner
material is dissolved.
The precharge element contains more than the

normal amount of inhibitor. The precharge element
is used when a system is first filled with new
coolant. This element must add enough inhibitor in
order to bring the complete cooling system up to
the correct concentration.
g00293082
Illustration 41
Coolant Lines For Air Compressor
(1) Coolant supply line. (2) Coolant return line. (3) Air compressor.
63
The maintenance elements have a normal amount One-Piece Pistons

of inhibitor. The maintenance elements are installed
at the first change interval. A sufficient amount of The one-piece aluminum pistons have an iron band
inhibitor is provided by the maintenance elements for the compression ring. This helps to reduce wear
in order to maintain the corrosion protection at an on the compression ring groove. The one-piece
acceptable level. After the first change interval, piston has three rings:
only maintenance elements are installed. In order
to provide the cooling system with protection, Compression ring
maintenance elements are installed at specific
intervals. Intermediate ring
i01388618
Oil ring
Basic Engine All of the rings are located above the piston pin
bore. The compression ring is a Keystone ring.
SMCS Code: 1200 Keystone rings have a tapered shape. The action of
the ring in the piston groove that is tapered helps
prevent seizure of the rings. Seizure of the rings is
Cylinder Block And Head caused by deposits of carbon. The intermediate
ring is rectangular with a sharp lower edge. The
The cylinder block has seven main bearings. The oil ring is a standard type of ring or a conventional
main bearing caps are fastened to the cylinder type of ring. Oil returns to the crankcase through
block with two bolts per cap. holes in the oil ring groove.
Removal of the oil pan allows access to the Oil from the piston cooling jets sprays the underside
crankshaft, the main bearing caps, the piston of the pistons. The spray lubricates the pistons
cooling jets, and the oil pump. and the spray cools the pistons. The spray also
improves the pistons life and the spray also
The camshaft is accessible through the covers improves the rings life.
on the left side of the cylinder block. These side
covers support the pushrod lifters. The camshaft is The connecting rod has a taper on the pin bore
supported by bearings that are pressed into the end. This taper gives the connecting rod and the
cylinder block. There are seven camshaft bearings. piston more strength. The additional strength is
concentrated in the areas with the most load. Two
The cylinder head is separated from the cylinder bolts hold the connecting rod cap to the connecting
block by a nonasbestos fiber gasket with a steel rod. This design keeps the connecting rod width
backing. Coolant flows out of the cylinder block to a minimum, so that the connecting rod can be
through gasket openings and into the cylinder removed through the cylinder.
head. This gasket also seals the oil supply and
drain passages between the cylinder block and the
Two-Piece Pistons
cylinder head.
The two-piece articulated piston consists of an
The air inlet ports are on the left side of the
alloy forged steel crown that is connected to an
cylinder head, while the exhaust ports are located
aluminum skirt by the piston pin. The two-piece
on the right side of the cylinder head. There are articulated piston has three rings:
two inlet valves and one exhaust valve for each
cylinder. Replaceable valve guides are pressed
into the cylinder head. The hydraulically actuated Compression ring
electronically controlled unit injector is located
between the three valves. Fuel is injected directly Intermediate ring
into the cylinders at very high pressure. A pushrod
valve system controls the valves. Oil ring
All of the rings are located above the piston pin
Piston, Rings And Connecting bore. The compression ring is a Keystone ring.
Keystone rings have a tapered shape. The action of
Rods the ring in the piston groove that is tapered helps
prevent seizure of the rings. Seizure of the rings is
One-piece aluminum pistons are used in most
caused by deposits of carbon. The intermediate
applications. Engines with higher cylinder pressures
require two-piece pistons. Refer to the Parts Manual ring is rectangular with a sharp lower edge. The
oil ring is a standard type of ring or a conventional
in order to obtain information about the type of
type of ring. Oil returns to the crankcase through
pistons that are used in a specific engine.
holes in the oil ring groove.
64
Oil from the piston cooling jets sprays the underside

of the pistons. The spray lubricates the pistons
and the spray cools the pistons. The spray also
improves the pistons life and the spray also
improves the rings life.
The connecting rod has a taper on the pin bore

end. This taper gives the connecting rod and the
piston more strength. The additional strength is
concentrated in the areas with the most load. Two
bolts hold the connecting rod cap to the connecting
rod. This design keeps the connecting rod width
to a minimum, so that the connecting rod can be
removed through the cylinder.
g00293227
Illustration 42
Crankshaft Schematic Of Oil Passages In Crankshaft
(1) Oil gallery
The crankshaft changes the combustion forces (2) Main bearings
in the cylinder into usable rotating torque which (3) Connecting rod bearings
powers the equipment. A vibration damper is used
at the front of the crankshaft to reduce torsional Pressure oil is supplied to all main bearings through
vibrations (twist on the crankshaft) that can cause drilled holes in the webs of the cylinder block.
damage to the engine. The oil then flows through drilled holes in the
crankshaft in order to provide oil to the connecting
The crankshaft drives a group of gears on the front rod bearings. The crankshaft is held in place by
of the engine. The gear group drives the following seven main bearings. A thrust bearing next to the
devices: rear main bearing controls the end play of the
crankshaft.
Oil pump
Camshaft Vibration Damper
Hydraulic oil pump The force from combustion in the cylinders will
cause the crankshaft to twist. This is called torsional
Gear-driven air compressor vibration. If the vibration is too great, the crankshaft
will be damaged. The vibration damper limits the
Power steering pump torsional vibrations to an acceptable amount in
order to prevent damage to the crankshaft.
In addition, belt pulleys on the front of the crankshaft
drive the following components:
Radiator fan
Water pump
Alternator
Refrigerant compressor
Hydrodynamic seals are used at both ends of the
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
seal is located in the front housing. The rear seal is
installed in the flywheel housing.
65
Rubber Vibration Damper (If Equipped) The viscous vibration damper is installed on the
front of crankshaft (1). The viscous vibration damper
has a weight (2) in a case (3). The space between
the weight and the case is filled with a viscous fluid.
The weight moves in the case in order to limit the
torsional vibration.
Camshaft
The camshaft is located in the upper left side of the
cylinder block. The camshaft is driven by gears at
the front of the engine. Seven bearings support the
camshaft. A thrust plate is mounted between the
camshaft drive gear and a shoulder of the camshaft
in order to control the end play of the camshaft.
The camshaft is driven by an idler gear which

is driven by the crankshaft gear. The camshaft
rotates in the same direction as the crankshaft. The
crankshaft rotates in the counterclockwise direction
when the engine is viewed from the flywheel end
of the engine. There are timing marks on the
g00293231 crankshaft gear, the idler gear, and the camshaft
Illustration 43
Rubber Vibration Damper gear in order to ensure the correct camshaft timing
(1) Crankshaft. (2) Ring. (3 ) Rubber ring. (4) Hub. (5) Alignment
to the crankshaft for proper valve operation.
marks.
As the camshaft turns, each lobe moves a lifter
The rubber vibration damper is installed on the assembly. There are two lifter assemblies for each
front of crankshaft (1). The hub (4) and ring (2) are cylinder. Each lifter assembly moves a pushrod.
isolated by a rubber ring (3). The rubber vibration Each pushrod moves a valve (exhaust) or a set of
damper has alignment marks (5) on the hub and valves (inlet). The camshaft must be in time with the
the ring. These marks give an indication of the crankshaft. The relation of the camshaft lobes to
condition of the rubber vibration damper. the crankshaft position causes the valves in each
cylinder to operate at the correct time.
Viscous Vibration Damper (If Equipped)
i01478239
Electrical System
SMCS Code: 1400; 1550; 1900
Grounding Practices
Proper grounding for the vehicle electrical system
and the engine electrical systems is necessary for
proper vehicle performance and reliability. Improper
grounding will result in unreliable electrical circuit
paths and uncontrolled electrical circuit paths.
Uncontrolled engine electrical circuit paths can

result in damage to main bearings, crankshaft
bearing journal surfaces, and aluminum
components.
Uncontrolled electrical circuit paths can cause

electrical noise which may degrade the vehicle and
Illustration 44
g00293230 radio performance.
Cross Section Of Viscous Vibration Damper
(1) Crankshaft. (2) Weight. (3) Case.
66
To ensure proper functioning of the vehicle and Ground wires or ground straps should be combined
engine electrical systems, an engine-to-frame at ground studs that are only for ground use. The
ground strap with a direct path to the battery must engine grounds should be inspected after every
be used. This may be provided by a starting motor 20125 km (12,500 miles) or every 250 hours. All of
ground, by a frame to starting motor ground, or by the grounds should be tight and free of corrosion.
a direct frame to engine ground. An engine-to-frame
ground strap must be used in order to connect the The engine alternator should be battery ground with
grounding stud of the engine to the frame of the a wire size that is capable of managing the full
vehicle and to the negative battery post. charging current of the alternator.
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.
Engine Electrical System

The electrical system has three separate circuits:
Charging circuit
g00769833
Illustration 45
Grounding Stud To Battery Ground () Starting circuit
Low amperage circuit
Some of the electrical system components are used
in more than one circuit. The following components
are used in each of the three circuits:
Battery
Circuit breaker
Ammeter
Battery cables
The charging circuit is in operation when the engine
is running. An alternator generates electricity for the
charging circuit. A voltage regulator in the circuit
controls the electrical output in order to keep the
battery at full charge.
Illustration 46
g00769834 NOTICE
Alternate Grounding Stud To Battery Ground ()
The disconnect switch, if equipped, must be in the ON
position in order to let the electrical system function.
The engine must have a wire ground to the battery. There will be damage to some of the charging circuit
components if the engine is running with the discon-
nect switch in the OFF position.
67
If the vehicle has a disconnect switch, the starting The alternator converts mechanical energy and
circuit can operate only after the disconnect switch magnetic energy into alternating current (AC)
is put in the ON position. and voltage. This process is done by rotating an
electromagnetic field (rotor) that is direct current
The starting circuit is in operation only when the (DC) inside a three-phase stator. The alternating
start switch is activated. current and the voltage that is generated by the
stator are changed to direct current. This change is
Both the low amperage circuit and the charging accomplished by a system that uses three-phase,
circuit are connected to the same side of the full-wave, rectified outputs. The three-phase,
ammeter. The starting circuit is connected to the full-wave, rectified outputs have been converted by
opposite side of the ammeter. six rectifier diodes that are made of silicon. The
alternator also has a diode trio. A diode trio is an
NOTICE assembly that is made up of three exciter diodes.
Never operate the alternator without the battery in the The diode trio rectifies field current that is needed
circuit. Making or breaking an alternator connection to start the charging process. Direct current flows
with heavy load on the circuit can cause damage to to the alternator output terminal.
the regulator.
A solid-state regulator is installed in the back of the
alternator. Two brushes conduct the current through
two slip rings to the field coil on the rotor.
Charging System Components
Also, a capacitor is mounted in the back of the
Alternator alternator. The capacitor protects the rectifier from
high voltages. The capacitor also suppresses radio
noise sources.
The voltage regulator is a solid-state electronic

switch that controls the alternator output. The
voltage regulator limits the alternator voltage to a
preset value by controlling the field current. The
voltage regulator feels the voltage in the system. The
voltage regulator switches ON and 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 voltage output.
Note: Refer to Service Manual, SENR3862 for

detailed service information for the Delco Remy 27
SI Series Alternator.
Note: If the alternator is connected to an engine

component, the ground strap must connect that
engine component to the frame or to the battery
ground.
g00293544
Illustration 47
Alternator Components (Typical Example) Starting System Components
(1) Brush holder. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end
frame. (6) Fan assembly. (7) Slip rings. (8) Rectifier.
Starting Solenoid
The alternator has three-phase, full-wave, rectified
A solenoid is a magnetic switch that does two basic
output. The alternator uses brushes to generate
operations:
electricity.
The alternator is an electrical component and a The solenoid closes the high current starting
motor circuit with a low current start switch circuit.
mechanical component that is driven by a belt from
engine rotation. The alternator is used to charge
the storage battery during engine operation. The The solenoid engages the starting motor pinion
with the ring gear.
alternator is cooled by a fan that is a part of the
alternator. The fan pulls air through holes in the
back of the alternator. The air exits the front of the
alternator and the air cools the alternator in the
process.
68
Starting Motor
g00285112
Illustration 48
Typical Solenoid g00293548
Illustration 49
Starting Motor (Typical Example)
The solenoid has windings (one set or two sets)
(1) Brush assembly. (2) Field windings. (3) Solenoid. (4) Clutch.
around a hollow cylinder. A plunger with a spring (5) Pinion. (6) Armature.
loaded device is inside of the cylinder. The plunger
can move forward and backward. When the start The starting motor is used to turn the engine
switch is closed and electricity is sent through the flywheel at a rate that will allow the engine to start
windings, a magnetic field is created. The magnetic running.
field pulls the plunger forward in the cylinder. This
moves the shift lever in order to engage the pinion Note: Some starting motors have ground straps
drive gear with the ring gear. The front end of the that connect the starting motor to the frame, but
plunger then makes contact across the battery many of these starting motors are not grounded to
and the motor terminals of the solenoid. After the the engine. These starting motors have electrical
contact is made, the starting motor begins to turn insulation systems. For this reason, the ground
the flywheel of the engine. strap that connects the starting motor to the frame
may not be an acceptable engine ground. Starting
When the start switch is opened, current no longer motors that were installed as original equipment are
flows through the windings. The spring now pushes grounded to the engine. These starting motors have
the plunger back to the original position. At the a ground wire from the starting motor to the negative
same time, the spring moves the pinion gear away terminal of the battery. When a starting motor must
from the flywheel. be changed, consult an authorized dealer for the
proper grounding practices for that starting motor.
When two sets of solenoid windings are used, the
windings are called the hold-in winding and the The starting motor has a solenoid. When the ignition
pull-in winding. Both sets of windings have the switch is turned to the START position, the starting
same number of turns around the cylinder, but the motor solenoid will be activated electrically. The
pull-in winding uses a wire with a larger diameter. solenoid plunger will now move a mechanical
The wire with a larger diameter produces a greater linkage. The mechanical linkage will push the
magnetic field. When the start switch is closed, starting motor pinion in order to engage with the
part of the current flows from the battery through flywheel ring gear. The starter motor pinion will
the hold-in windings. The rest of the current flows engage with the ring gear before the electric
through the pull-in windings to the motor terminal. contacts in the solenoid close the circuit between
The current then flows through the motor to ground. the battery and the starting motor. When the circuit
The solenoid is fully activated when the connection between the battery and the starting motor is
across the battery and the motor terminal is complete, the pinion will turn the engine flywheel. A
complete. When the solenoid is fully activated, the clutch gives protection for the starting motor so that
current is shut off through the pull-in windings. At the engine cannot turn the starting motor too fast.
this point, only the smaller hold-in windings are in
operation. The hold-in windings operate for the
duration of time that is required in order to start the
engine. The solenoid will now draw less current
from the battery, and the heat that is generated by
the solenoid will be kept at an acceptable level.
69
When the ignition switch is released from the START

position, the starting motor solenoid is deactivated.
The starting motor solenoid is deactivated when
current no longer flows through the windings. The
spring now pushes the plunger back to the original
position of the plunger. At the same time, the spring
moves the pinion gear away from the flywheel ring
gear.
70
Testing and Adjusting 4. Operate the hand priming pump (if equipped).
If excessive resistance is felt, inspect the fuel
Section pressure regulating valve (3). Make sure that the
pressure regulator (3) is installed correctly, and
make sure that the pressure regulator functions
correctly.
Fuel System
5. Install a new fuel filter (6).
i01334705 6. Cut the old filter open with the 4C-5084 Oil Filter
Fuel System - Inspect Cutter. Inspect the filter for excess contamination.
Determine the source of the contamination. Make
SMCS Code: 1250-040 the necessary repairs.
7. Service the primary fuel filter (if equipped).

Initial Inspection Of The Fuel
System 8. Operate the hand priming pump (if equipped). If
uneven resistance is felt, test for air in the fuel.
A problem with the components that send fuel to Refer to Testing and Adjusting, Air in Fuel - Test
the engine can cause low fuel pressure. This can for more information.
decrease engine performance.
9. Remove any air that may be in the fuel system.
Refer to Testing and Adjusting, Fuel System -
Prime.
Start Up Procedure
Note: Refer to Operation and Maintenance Manual,
Engine Starting in the Operation Section.
After work has been done on the fuel system,

consider the following precautions before you start
the engine. Make sure that you use this starting
procedure to start the engine only after the fuel
system has been worked on:
g00296730
Illustration 50 1. Disconnect the air inlet system from the
Fuel System turbocharger.
(1) Tube assembly (fuel filter to fuel supply passage)
(2) Tube assembly (fuel transfer pump to fuel filter)
(3) Pressure regulator
(4) Tube assembly (tank return line)
(5) Fuel inlet port (fuel transfer pump) Be careful when placing the steel plate against
(6) Fuel filter the opening on the turbocharger air inlet. To avoid
(7) Tube assembly
crushed fingers, do not position fingers between
the steel plate and the opening on the turbocharg-
1. Check the fuel level in the fuel tank. Inspect the
er air inlet. Due to excessive suction, the plate can
cap for the fuel tank. Ensure that the vent in the
be forcefully pulled against the opening on the tur-
fuel cap is not filled with dirt.
bocharger air inlet.
2. Check all fuel lines for fuel leakage. The fuel lines
must be free from restrictions and faulty bends. 2. Another person will need to help as a
Verify that the fuel return line is not collapsed. precautionary step. This person should be ready
to use the steel plate to cover the turbocharger
3. Clean the screen inside the inlet fitting of the fuel air inlet if a problem occurs.
transfer pump.
Note: Make sure that the steel plate is large enough
to cover the entire turbocharger air inlet.
3. Start the engine.

71
Immediately place the steel plate against the i01459442

opening on the turbocharger air inlet, if the
engine operates in one of the following ways: Air in Fuel - Test
The engine runs too fast. SMCS Code: 1280-081
The engine runs out of control. This procedure checks for air in the fuel. This
procedure also assists in finding the source of the
Covering the opening will stop the air supply to air.
the engine, so the engine will stop.
1. Examine the fuel system for leaks. Ensure that
the fuel line fittings are properly tightened. Check
Inspection With The Engine the fuel level in the fuel tank. Air can enter the
Running fuel system on the suction side between the fuel
transfer pump and the fuel tank.
Either too much fuel for combustion or not enough
fuel for combustion can be the cause of a problem 2. Install a 2P-8278 Fuel Flow Tube (Sight Gauge)
in the fuel system. Finding the source of the problem in the fuel return line. When possible, install the
can be difficult, especially when you have smoke sight gauge in a straight section of the fuel line
that rises from the exhaust. Therefore, work is often that is at least 304.8 mm (12 inches) long. Do not
done on the fuel system when the problem is really install the sight gauge near the following devices
with some other part of the engine. that create turbulence:
When noticeable smoke rises from the exhaust, this Elbows

problem can be caused by a damaged unit injector.
This unusual smoke can also be caused by one or Relief valves
more of the reasons that follow:
Check valves
not enough air for good combustion
Observe the fuel flow during engine cranking.
an overload at high altitude Look for air bubbles in the fuel. If there is no fuel
in the sight gauge, prime the fuel system. Refer
oil leakage into combustion chamber to Testing and Adjusting, Fuel System - Prime
for more information. If the engine starts, check
altitude for air in the fuel at varying engine speeds.
When possible, operate the engine under the
air inlet and exhaust leaks conditions which have been suspect of air in the
fuel.
Note: Refer to Troubleshooting for more information
on the fuel system.
Checking The Operation Of

Individual Cylinders
Low temperature at an exhaust manifold port is
an indication of no fuel to the cylinder. This can
possibly be an indication of an injector with a
defect. An extra high temperature at an exhaust
manifold port can be an indication of too much fuel
to the cylinder. High temperatures may also be
caused by an injector with a defect.
Refer to Testing And Adjusting, Exhaust

Temperature - Test for the procedure for checking
the temperatures in the exhaust manifold port.
72
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not

use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the
fuel lines between the fuel tank and the fuel
transfer pump. Repair any leaks that are found.
Check the fuel pressure in order to ensure that
the fuel transfer pump is operating properly. For
information about checking the fuel pressure, see
Testing and Adjusting, Fuel System Pressure
- Test.
5. If the source of the air is not found, disconnect

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

combustion gases may be leaking into the
fuel system. Also, if the O-rings on the injector
sleeves are worn, missing, or damaged,
Illustration 51 g00578151 combustion gases may leak into the fuel system.
2P-8278 Fuel Flow Tube (Sight Gauge)
(1) A steady stream of small bubbles with a diameter of i01287795
approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
Engine Speed - Check
are also acceptable if there is two seconds to three seconds
intervals between bubbles. SMCS Code: 1000
(3) Excessive air bubbles in the fuel are not acceptable.
Table 6
3. If excessive air is seen in the sight gauge in the Tools Needed
fuel return line, install a second sight gauge at
Part Part Name Quantity
the inlet to the fuel transfer pump. If a second
Number
sight gauge is not available, move the sight
gauge from the fuel return line and install the 1U-6602 Photo-Tachometer(1) 1
sight gauge at the inlet to the fuel transfer pump. or or
Observe the fuel flow during engine cranking. 9U-7400 Multitach Tool Group
Look for air bubbles in the fuel. If the engine (1) This unit is a hand-held service tool.
starts, check for air in the fuel at varying engine
speeds. Note: The Electronic Service Tools can also be used.
If excessive air is not seen at the inlet to the fuel You can observe the engine rpm, which is displayed
transfer pump, the air is entering the system after on the status screen of the electronic service tool.
the fuel transfer pump. Proceed to Step 6.
If excessive air is seen at the inlet to the fuel

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. g00286276
Illustration 52
9U-7400 Multitach Tool Group
73
The 9U-7400 Multitach Tool Group can measure

engine rpm from a magnetic pickup. This magnetic
pickup is located in the flywheel housing. The
multitach also uses the ability to measure engine
rpm from visual engine parts that are rotating.
Note: Refer to Special Instruction, NEHS0605 that

is with the 9U-7400 Multitach Tool Group. This
manual gives instructions for the test procedure.
The 1U-6602 Photo-Tachometer is a phototach for

general use. This tachometer can only register the
basic input frequency on any rotating part that is
visible. The basic input frequency is 1 pulse per
revolution per piece of reflective tape. g00677920
Illustration 54
Note: Refer to Special Instruction, SEHS8854 that is Timing Hole Location (Typical Example)
with this group. This manual provides instructions (3) Flywheel housing. (4) Plug.
for using this tool.
Note: The measurement of engine rpm can be set

with the Electronic Service Tool. Refer to Electronic
Troubleshooting.
i01277944
Finding Top Center Position

for No. 1 Piston
SMCS Code: 1105-531
Table 7
g00677919
Tools Needed Illustration 55
Timing Hole Location (Typical Example)
Part Number Part Name Quantity
(3) Flywheel housing. (4) Plug.
8T-0292 Bolt 1
Note: The hole (2) can be in one of two positions:
The right front face of the flywheel housing

(Illustration 54)
the left front face of the flywheel housing

(Illustration 55)
1. Remove the plug (4) from timing hole (2) from

the front side of the flywheel housing (3).
Note: Turn the engine with the four large bolts on

the front of the crankshaft. Do not use the eight
small bolts on the front of the crankshaft pulley.
g00677921 2. Put top center bolt (1) through timing hole (2) in
Illustration 53
Top Center Bolt Location (Typical Example) the flywheel housing (3).
(1) Top center bolt. (2) Timing hole. (3) Flywheel housing.
Turn the flywheel in the direction of normal
engine rotation. Turn the flywheel until the timing
bolt engages with the hole in the flywheel.
74
Note: If the flywheel is turned beyond the point of 1. Determine if water and/or contaminants are
engagement, the flywheel must be turned in the present in the fuel. Check the water separator (if
direction that is opposite of normal engine rotation. equipped). If a water separator is not present,
Turn the flywheel by approximately 30 degrees. proceed to Step 2. Drain the water separator, if
Then turn the flywheel in the direction of normal necessary. A full fuel tank minimizes the potential
engine rotation until the timing bolt engages with for overnight condensation.
the threaded hole. When the No. 1 piston is at the
top center position, this procedure will remove the Note: A water separator can appear to be full of fuel
play from the gears. when the water separator is actually full of water.
3. Remove the valve cover. 2. Determine if contaminants are present in the

fuel. Remove a sample of fuel from the bottom
The inlet valves and the exhaust valve for the No. of the fuel tank. Visually inspect the fuel sample
1 cylinder are fully closed under two conditions: for contaminants. The color of the fuel is not
necessarily an indication of fuel quality. However,
No. 1 piston is on the compression stroke. fuel that is black, brown, and/or similar to sludge
can be an indication of the growth of bacteria or
The rocker arms can be moved by hand. oil contamination. In cold temperatures, cloudy
fuel indicates that the fuel may not be suitable
If the rocker arms cannot be moved and the for operating conditions. The following methods
valves are slightly open, the No. 1 piston is on can be used to prevent wax from clogging the
the exhaust stroke. fuel filter:
Note: Refer to Testing And Adjusting, Crankshaft Fuel heaters

Positions for Valve Lash Setting.
Blending fuel with additives
4. After the timing bolt has been installed in
the flywheel, complete these procedures, as Utilizing fuel with a low cloud point such as
required: kerosene
a. Find the cylinders that need to be checked Refer to Operation and Maintenance Manual,
for the stroke position of the crankshaft. Fuel Recommendations for more information.
b. Find the cylinders that need to be adjusted 3. Check fuel API with a 9U-7840 Fluid and Fuel
for the stroke position of the crankshaft. Calibration Gp for low power complaints. The
acceptable range of the fuel API is 30 to 45
5. When the actual stroke position is identified and when the API is measured at 15 C (60 F), but
the other stroke position is needed, remove the there is a significant difference in energy within
timing bolt from the flywheel. this range. Refer to Tool Operating Manual,
NEHS0607 for API correction factors when a low
6. Turn the flywheel by 360 degrees in the direction power problem is present and API is high.
of normal engine rotation.
Note: A correction factor that is greater than 1.000
Note: The timing hole is used during the procedure may be the cause of low power and/or poor fuel
to set the valve lash. consumption.
4. If fuel quality is still suspected as a possible

i01370330
cause to problems regarding engine
Fuel Quality - Test performance, disconnect the fuel inlet line, and
temporarily operate the engine from a separate
SMCS Code: 1280-081 source of fuel that is known to be good. This
will determine if the problem is caused by fuel
This test checks for problems regarding fuel quality. quality. If fuel quality is determined to be the
Refer to Diesel Fuels and Your Engine, SEBD0717 problem, drain the fuel system and replace the
for additional details. fuel filters. Engine performance can be affected
by the following characteristics :
Use the following procedure to test for problems
regarding fuel quality: Cetane number of the fuel
Air in the fuel
75
Other fuel characteristics 4. Push the plunger and tighten the plunger in a
counterclockwise direction. Tighten the plunger
by hand.
i01334752
Fuel System - Prime 5. Turn the red selector lever knob back to the RUN
position.
SMCS Code: 1258-548
6. After you pressurize the fuel system, promptly
crank the engine.
Note: Use the engine starting procedure. Refer

Fuel leaked or spilled onto hot surfaces or elec- to Operation and Maintenance Manual, Engine
trical components can cause a fire. To help pre- Starting in the Operation Section.
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately. i01504979
Fuel System Pressure - Test

If the engines fuel system is run dry, fill the fuel
tank. Then prime the fuel system in order to remove SMCS Code: 1250-081; 1256-081
any air bubbles from the system.
Table 8
NOTICE Tools Needed

Do not loosen fuel lines at the fuel manifold. The Part Number Part Name Quantity
engine components may be damaged and/or loss of
priming pressure may occur when the fuel lines are Engine Pressure Test 1
1U-5470
loosened. Group
3Y-2888 Connector 1
3J-1907 O-Ring Seal 1
Note: Both the 5P-2720 Probe Adapter and the

5P-2718 Pressure Probe can be used with these
tools. Use these additional tools to allow the future
installation of pressure probes.
Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. Clean up fuel
spills immediately.
g00296544
Illustration 56
NOTICE
Follow these steps in order to prime the fuel system:
1. Locate the red selector lever knob for the fuel
priming pump.
component life.
2. Turn the red selector lever knob away from the
fuel filter base by 90 degrees.
This position is the PRIME position.
3. Operate the priming pumps plunger in order

to fill the final fuel filter. Continue until you feel
resistance.
Note: You may need to pump the priming pump

for 25 times or more in order to fill the fuel filter.
Furthermore, you may need up to 75 pump strokes
to fill the fuel supply passage.
76
NOTICE

products.

Illustration 58
mandates.
Fuel Return Line (Typical Example)
(1) Fuel supply passage. (2) Tube assembly (CPU to fuel supply
The 1U-5470 Engine Pressure Test Group can be passage). (3) Pressure regulator. (4) Tube assembly (fuel transfer
used in order to check the engines fuel pressures. pump to fuel filter).
g00284796 g00296503
1U-5470 Engine Pressure Test Group Fuel Pressure Test (Typical Example)
(1) Pressure indicators. (2) Zero adjustment screw. (3) Pressure (5) Fuel filter base. (6) Fuel pressure tap (unfiltered tap). (7) Fuel
indicator. (4) Pressure tap. (5) Pressure indicator. pressure tap (filtered tap).
This tool group has a gauge that is used to register During both normal operating conditions and load
the pressure in the fuel manifolds. The Special conditions, the fuel pressure should register the
Instruction, SEHS8907 is with the tool group. following range:
400 to 525 kPa (58 to 76 psi)

At low idle, the fuel pressure at the fuel filters inlet
should be at the following amount:
400 to 435 kPa (58 to 63 psi)

The fuel pressure to fuel supply passage (1) should
be the same amount, if you subtract the change in
pressure (delta P) across the filter.
With a new filter, the pressure drop across the fuel

filter typically registers the following amount:
35 kPa (5 psi)
77
As abrasive particles collect in the fuel filter, the i01334974

pressure differential across the filter will increase.
When a filter becomes plugged, fuel supply Gear Group (Front) - Time
pressure may drop as low as 69 kPa (10 psi)
before a significant power loss is detected by the SMCS Code: 1206-531
operator. Low fuel pressure will cause cavitation
and internal damage to the unit injectors. The
pressure differential across the fuel filter should
not exceed 69 kPa (10 psi).
Pressure regulator (3) is mounted directly in the

cylinder head. The regulator is located at the fuel
return port toward the rear end of the fuel supply
passage (1). The orifice maintains fuel pressure at
low engine rpm.
To check the unfiltered fuel pressure, follow this

procedure:
1. Remove the plug from fuel pressure tap (6).
2. Install the connector, the seal, and the 1U-5470

Engine Pressure Test Group to fuel pressure tap
(6).
This will obtain the fuel transfer pump pressure.
To check the fuel pressure in the fuel supply

passage (1), follow these steps:
1. Remove the plug from fuel pressure tap (7).
2. Install the adapter, the seal, and the 1U-5470 g00632109

Illustration 60
Engine Pressure Test Group to fuel pressure tap
(7). Front Gear Group
(1) Camshaft gear and timing reference gear
3. Operate the engine. (2) Timing marks
(3) Idler gear
(4) Crankshaft gear
Note: Make sure that the fuel filter is clean before
you check the fuel pressure. A restricted fuel filter Correct fuel injection timing and correct valve
causes lower fuel pressure at fuel pressure tap (7) mechanism operation is determined by the timing
than the fuel pressure at fuel pressure tap (6). reference gear and the alignment of the front gear
group. The timing reference gear is located on the
camshaft gear. The timing reference gear is used
to measure 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).
Check the teeth on the timing reference gear. 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, RENR1367, PC-32:
Engine Speed/Timing Calibration.
78
i01280287 6. Remove the suspect unit injector and check the

unit injector for signs of exposure to coolant.
Unit Injector - Test Exposure to coolant will cause rust to form on
the injector. If the unit injector shows signs of
SMCS Code: 1290-081 exposure to coolant, remove the injector sleeve
and inspect the injector sleeve. Replace the
This procedure assists in identifying the cause for injector sleeve if the injector sleeve is damaged.
an injector misfiring. Perform this procedure only Check the unit injector for an excessive brown
after performing the Cylinder Cutout Test. Refer to discoloration that extends beyond the injector
Troubleshooting, Injector Solenoids Circuits Test tip. If excessive discoloration is found, check
for more information. the quality of the fuel. Refer to Testing and
Adjusting, Fuel Quality - Test. Replace the seals
1. Check for air in the fuel, if this procedure has not on the injector and reinstall the injector. Refer
already been performed. Refer to Testing and to Disassembly and Assembly Manual, Unit
Adjusting, Air in Fuel - Test. Injector - Install. Also refer to Disassembly and
Assembly Manual, Unit Injector Sleeve - Install.
Inspect the injector for deposits of soot that are
above the surface of the seat of the injector.
Electrical shock hazard. The electronic unit injec- Deposits of soot indicate combustion gas
tor system uses 90-120 volts. leakage. The source of the leak should be found,
and the source of the leak should be remedied.
The injector will not need to be replaced if
2. Remove the valve cover and look for broken combustion gas leakage was the problem.
parts. Repair any broken parts or replace any
broken parts that are found. Inspect all wiring for 7. If the problem is not resolved, replace the
the solenoids. Look for loose connections. Also suspect injector with a new injector. In order to
look for frayed wires or broken wires. Ensure verify that the new injector is working properly,
that the connector for the unit injector solenoid perform the Cylinder Cutout Test. Use the
is properly connected. Perform a pull test on Caterpillar Electronic Technician (ET).
each of the wires.
3. Look for signs of fuel leakage. Investigate the

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

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

are tightened to the proper torque. In order to
check the torque, loosen the bolts that hold
the unit injector. Tighten the bolts to the proper
torque. Refer to either the Disassembly and
Assembly Manual , Unit Injector - Install or the
Specifications Manual , Unit Injector - Install for
the proper tightening procedure.
79
Air Inlet and Exhaust

System Hot engine components can cause injury from
burns. Before performing maintenance on the
i01503753
engine, allow the engine and the components to
cool.
- Inspect
SMCS Code: 1050-040 Making contact with a running engine can cause
burns from hot parts and can cause injury from
Air Inlet Restriction rotating parts.
There will be a reduction in the performance of the When working on an engine that is running, avoid
engine if there is a restriction in the air inlet system contact with hot parts and rotating parts.
or the exhaust system.
Table 9
4. Use the differential pressure gauge of the
1U-5470 Engine Pressure Group.
Required Tools
Part
Part Name Quantity
Number
1U-5470 Engine Pressure Group 1
g00678913
Illustration 62
Typical example
(1) Turbocharger
(2) Air Inlet Piping
(3) Test location
g00293196 (4) Air cleaner
Illustration 61
1U-5470 Engine Pressure Group
a. Connect the vacuum port of the differential
Refer to Special Instruction, SEHS8907, Using pressure gauge to test location (3). Test
the 1U-5470 Engine Pressure Group for the location (3) can be located anywhere along
instructions that are needed to use the 1U-5470 air inlet piping (2) after engine air cleaner (4)
Engine Pressure Group. but before turbocharger (1).
1. Inspect the engine air cleaner inlet and ducting b. Leave the pressure port of the differential
in order to ensure that the passageway is not pressure gauge open to the atmosphere.
blocked or collapsed.
c. Start the engine. Run the engine in the
2. Inspect the engine air cleaner element. Replace no-load condition at high idle.
a dirty engine air cleaner element with a clean
engine air cleaner element. d. Record the value.
3. Check for dirt tracks on the clean side of the e. Multiply the value from Step 4.d by 1.8.
engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the f. Compare the result from Step 4.e to the
engine air cleaner element and/or the seal for appropriate values that follow.
the engine air cleaner element.
80
The air flow through a used engine air cleaner

may have a restriction. The air flow through a
plugged engine air cleaner will be restricted to
some magnitude. In either case, the restriction must
not be more than the following amount:
Maximum restriction .... 6.2 kPa (25 inch of H2O)
The air flow through a new engine air cleaner

element must not have a restriction of more than
the following amount:
Maximum restriction .... 3.7 kPa (15 inch of H2O)
Exhaust Restriction g00293196

Illustration 63
Refer to Special Instruction, SEHS8907, Using

The muffler and converter will become extrem-
the 1U-5470 Engine Pressure Group for the
ly hot during engine operation. A hot muffler
instructions that are needed to use the 1U-5470
and converter can cause serious burns. Allow
Engine Pressure Group.
adaquate cooling time before working on or near
the muffler and converter.
Excessive idling can cause the catalytic

converter/muffler to plug. A plugged catalytic Hot engine components can cause injury from
converter/muffler will lead to an increase in burns. Before performing maintenance on the
exhaust back pressure. Operating the engine in engine, allow the engine and the components to
extremely cold conditions may cause the catalytic cool.
converter/muffler to plug. One indication of a
plugged catalytic converter/muffler is poor engine
response.
Making contact with a running engine can cause
If the engine is operated at low idle or at low load
for 24 or more consecutive hours, the engine should burns from hot parts and can cause injury from
rotating parts.
be run at rated conditions for five to fifteen minutes.
Running the engine at rated conditions should clean
out the catalytic converter/muffler. When working on an engine that is running, avoid
contact with hot parts and rotating parts.
Exhaust Back Pressure

Back pressure is the difference in the pressure
between the exhaust and the atmospheric air.
Table 10
Tools Needed
Part
Part Name Quantity
Number
g00780838
Illustration 64
(A) Catalytic converter/muffler
(B) 152 mm (6 inches)
(C) 305 mm (12 inches)
(D) Turbocharger or Exhaust Manifold
(1) Preferred Test Location
(2) Optional Test Location
81
The location of the back pressure tap is important 1. Connect the pressure port of the differential
in order to obtain an accurate back pressure pressure gauge to test location. The test location
reading. The test location should be located on a should be located on a straight length of exhaust
straight length of exhaust pipe. This back pressure pipe. This back pressure tap should be located
tap should be located as close as possible to the as close as possible to the turbocharger or the
turbocharger or the exhaust manifold. The tap exhaust manifold.
should be located at least 305 mm (12 inches)
downstream of a bend. The tap should have 2. Leave the vacuum port of the differential pressure
152 mm (6 inches) before a bend. If a continuous gauge open to the atmosphere.
straight length of exhaust that is 457 mm (18 inches)
is not available, the tap should be located as close 3. Start the engine. Run the engine in the no-load
as possible to the neutral axis on an elbow. condition at high idle until the engine reaches
normal operating temperature.
If the exhaust is not equipped with a back pressure
tap, the following procedure may be use in order 4. Record the value.
to install a pressure tap.
5. Multiply the value from Step 4 by 1.8.
1. Mark the position for the pressure tap.
6. Compare the result from Step 5 to the value that
2. Weld or braze a 1/8 inch NPT half coupling to follows.
the exhaust pipe.
Back pressure from the exhaust must not be more
3. Drill a 3.18 mm (0.125 inch) hole through the wall than the following amount:
of the exhaust inside the half coupling.
Maximum back pressure for engines without a
4. Remove any burrs from the inside of the exhaust Catalytic converter/muffler ................... 10.0 kPa
pipe. (40 inch of H2O)
Maximum back pressure for engines with a
Use the differential pressure gauge of the 1U-5470
Catalytic converter/muffler ................... 14.9 kPa
Engine Pressure Group in order to measure back
(60 inch of H2O)
pressure from the exhaust. Use the following
procedure in order to measure back pressure from
If the maximum back pressure is within the allowable
the exhaust:
limits, refer to Troubleshooting, Low/Power/Poor or
No Response to Throttle.
If the back pressure exceeds 14.9 kPa

(60 inch of H2O), replace the catalytic
converter/muffler.
i01388605
Turbocharger - Inspect
SMCS Code: 1052-040
Disconnect batteries before performance of any

service work.
g00678914 Hot engine components can cause injury from

Illustration 65
Typical example burns. Before performing maintenance on the
(1) Catalytic converter/muffler
(2) Test location cool.
(3) Exhaust piping
(4) Turbocharger
82
Inspection of the Compressor and

the Compressor Housing
Personal injury can result from rotating and mov-
ing parts. Remove air piping from the compressor inlet.
Stay clear of all rotating and moving parts. 1. Inspect the compressor wheel for damage from a
foreign object. If there is damage, determine the
Never attempt adjustments while the machine is source of the foreign object. As required, clean
moving or the engine is running unless otherwise the inlet system and repair the intake system.
specified. Replace the turbocharger. If there is no damage,
go to Step 3.
The machine must be parked on a level surface
and the engine stopped. 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,
NOTICE go to Step 3.
3. Turn the rotating assembly by hand. While you
Contaminants may cause rapid wear and shortened turn the assembly, push the assembly sideways .
component life. The assembly should turn freely. The compressor
wheel should not rub the compressor housing.
Replace the turbocharger if the compressor
NOTICE wheel rubs the compressor wheel housing. If
Care must be taken to ensure that fluids are contained there is no rubbing or scraping, go to Step 4.
ing, adjusting and repair of the product. Be prepared to 4. Inspect the compressor and the compressor
collect the fluid with suitable containers before open- wheel housing for oil leakage. An oil leak from
ing any compartment or disassembling any compo- the compressor may deposit oil in the aftercooler.
nent containing fluids. Drain and clean the aftercooler if you find oil in
the aftercooler.
Tools and Shop Products Guide for tools and supplies a. Check the oil level in the crankcase. If the oil
suitable to collect and contain fluids on Caterpillar level is too high, adjust the oil level.
products.
b. Inspect the air cleaner element for restriction.
Dispose of all fluids according to local regulations and If restriction is found, correct the problem.
mandates.
c. Inspect the engine crankcase breather. Clean
Before you begin inspection of the turbocharger, the engine crankcase breather or replace
be sure that the inlet air restriction is within the the engine crankcase breather if the engine
specifications for your engine. Be sure that the crankcase breather is plugged.
exhaust system restriction is within the specifications
for your engine. Refer to Systems Operation/Testing d. Remove the turbocharger oil drain line.
and Adjusting, Air Inlet and Exhaust System - Inspect the drain opening. Inspect the oil
Inspect. drain line. Inspect the area between the
bearings of the rotating assembly shaft. Look
The condition of the turbocharger will have definite for oil sludge. Inspect the oil drain hole for
effects on engine performance. Use the following oil sludge. Inspect the oil drain line for oil
inspections and procedures to determine the sludge in the drain line. If necessary, clean
condition of the turbocharger. the rotating assembly shaft. If necessary,
clean the oil drain hole. If necessary, clean
Inspection of the Compressor and the Compressor the oil drain line.
Housing
e. If Steps 4.a through 4.d did not reveal the
Inspection of the Turbine Wheel and the Turbine source of the oil leakage, the turbocharger has
Housing internal damage. Replace the turbocharger.
Inspection of the Wastegate

83
Inspection of the Turbine Wheel e. If Steps 4.a through 4.d did not reveal the
source of the oil leakage, the turbocharger has
and the Turbine Housing internal damage. Replace the turbocharger.
Remove the air piping from the turbine outlet casing.
1. Inspect the turbine for damage by a foreign
object. If there is damage, determine the source The turbocharger senses boost pressure which
of the foreign object. Replace the turbocharger. actuates the wastegate valve. The wastegate valve
If there is no damage, go to Step 2. controls the amount of exhaust gas that is allowed
to bypass the turbine side of the turbocharger.
2. Inspect the turbine wheel for buildup of carbon Regulating the amount of exhaust gas that enters the
and other foreign material. Inspect the turbine turbocharger regulates the rpm of the turbocharger.
housing for buildup of carbon and foreign
material. Clean the turbine wheel and clean the
turbine housing if you find buildup of carbon or
foreign material. If there is no buildup of carbon
or foreign material, go to Step 3.
3. Turn the rotating assembly by hand. While you

turn the assembly, push the assembly sideways.
The assembly should turn freely. The turbine
wheel should not rub the turbine wheel housing.
Replace the turbocharger if the turbine wheel
rubs the turbine wheel housing. If there is no
rubbing or scraping, go to Step 4.
4. Inspect the turbine and the turbine wheel

housing for oil leakage. Inspect the turbine and
the turbine wheel housing for oil coking. Some oil
coking may be cleaned. Heavy oil coking may
require replacement of the turbocharger. If the oil
is coming from the turbocharger center housing
go to Step 4.a. Otherwise go to Inspection of
the Wastegate. g00295815
Illustration 66
a. Remove the turbocharger oil drain line. Typical Example

Inspect the drain opening. Inspect the area (1) Actuating Rod
between the bearings of the rotating assembly (2) Canister
(3) Line
shaft. Look for oil sludge. Inspect the oil drain
hole for oil sludge. Inspect the oil drain line
When the engine operates in conditions of low boost
for oil sludge. If necessary, clean the rotating
(lug), a spring presses against a diaphragm in
assembly shaft. If necessary, clean the drain
canister (2). This moves actuating rod (1) in order to
opening. If necessary, clean the drain line.
close the wastegate valve. Then, the turbocharger
can operate at maximum performance.
b. If crankcase pressure is high, or if the oil
drain is restricted, pressure in the center
As the boost pressure increases against the
housing may be greater than the pressure of
diaphragm in canister (2), the wastegate valve
the turbine housing. Oil flow may be forced in
opens. The rpm of the turbocharger becomes
the wrong direction and the oil may not drain.
limited. This limitation occurs because a portion of
Check the crankcase pressure and correct
the exhaust gases bypass the turbine wheel of the
any problems.
turbocharger.
c. If the oil drain line is damaged, replace the
The following levels of boost pressure indicate a
oil drain line.
problem with the wastegate valve:
d. Check the routing of the oil drain line.
Eliminate any sharp restrictive bends. Make Too high at full load conditions
sure that the oil drain line is not too close to
the engine exhaust manifold. Too low at all lug conditions
The Technical Marketing Information (TMI) provides
the correct pressure for the inlet manifold.
84
To check the operation of the wastegate valve, High idle rpm

verify the correct pressure for the wastegate valve.
This can be accomplished by referring to the letter Height above sea level for engine operation
designation that is stamped on the actuating lever
of the wastegate valve. This letter designation Inlet air restriction
indicates a corresponding amount of pressure.
Exhaust system restriction
Note: Refer to Table 11 for the letter designation
and the corresponding amounts of pressure. NOTICE
If the high idle rpm or the engine rating is higher than
Remove the air line, and slowly apply the given in the Technical Marketing Information (TMI)
corresponding amount of pressure to the canister. for the height above sea level at which the engine is
DO NOT EXCEED 200 kPa (29 psi). operated, there can be damage to engine or to tur-
bocharger parts. Damage will result when increased
When the external supply of air that is connected heat and/or friction due to the higher engine output
to line (3) reaches the corresponding pressure for goes beyond the engine cooling and lubrication
the wastegate valve, the actuating lever should systems abilities.
move by 0.50 0.25 mm (0.020 0.010 inch). If
the actuating lever does NOT move by this amount,
replace the turbines housing assembly of the
i01388608
turbocharger. This housing assembly includes the
wastegate valve. If necessary, replace the complete
turbocharger.
Inlet Manifold Pressure - Test
SMCS Code: 1058-081
Note: The housing assembly for the wastegate
turbine is preset at the factory and no adjustments The efficiency of an engine can be checked by
can be made. making a comparison of the pressure in the inlet
Table 11
manifold with the information given in the TMI
(Technical Marketing Information). The information
Amount Of Pressure That Is Required To is also listed on the Fuel Setting And Related
Check The Wastegate Valve Information Microfiche. This test is used when there
Letter is a decrease of horsepower from the engine, yet
kPa psig there is no real sign of a problem with the engine.
Designation
B 156 (23) The correct pressure for the inlet manifold is listed
C 153 (22) in the TMI (Technical Marketing Information). The
correct pressure is also on the Fuel Setting And
D 124 (18) Related Information Microfiche. Development of
E 130 (19) this information is performed under the following
conditions:
F 135 (20)
G 180 (26) 96 kPa (28.8 in Hg) dry barometric pressure
H 144 (21) 25 C (77 F) outside air temperature
J 188 (27)
35 API rated fuel
M 200 (29)
V 161 (23) Any change from these conditions can change the
pressure in the inlet manifold. The outside air may
W 164 (24) have a higher temperature and a lower barometric
pressure than the values that are given above.
The boost pressure controls the maximum rpm of the This will cause a lower inlet manifold pressure
turbocharger, because the boost pressure controls measurement than the pressure in the TMI. Outside
the position of the wastegate. The following factors air that has both a lower temperature and a higher
also affect the maximum rpm of the turbocharger: barometric pressure will cause a higher inlet
manifold pressure measurement.
Engine rating
Horsepower demand on the engine
85
A difference in fuel density will change horsepower 1. Remove plug (1) from the air inlet cover.
(stall speed) and boost. If the fuel is rated above
35 API, the pressure in the inlet manifold can be 2. Connect the 1U-5470 Engine Pressure Test
less than the pressure that appears in the TMI. Group to the air inlet cover at the pressure test
If the fuel is rated below 35 API, the pressure in location.
the inlet manifold can be more than the pressure
that appears in the TMI. BE SURE THAT THE Note: A tee fitting or some other plumbing
AIR INLET OR THE EXHAUST DOES NOT HAVE component will be necessary to allow the boost
A RESTRICTION WHEN YOU ARE MAKING A pressure sensor to be connected with a test
CHECK OF THE PRESSURE. location.
Note: The electronic service tool may be used to 3. Record the value.
check the pressure in the inlet manifold.
4. Compare the value that was recorded in Step 3
Table 12 to the pressure that is given in the TMI (Technical
Tools Needed Marketing Information). The correct pressure
is also given in the Fuel Setting And Related
Part Number Part Description Qty Information Microfiche.
1U-5470 Engine Pressure Test Group 1
i01281586
Exhaust Temperature - Test

SMCS Code: 1088-081
Table 13
Tools Needed
Part
Part Name Quantity
Number
123-6700 Laser Infrared Thermometer 1
When the engine runs at low idle, the temperature of

g00293196 an exhaust manifold port can indicate the condition
Illustration 67
of a unit injector:
1U-5470 Engine Pressure Test Group
A low temperature indicates that no fuel is flowing
Refer to Special Instruction, SEHS8907, Using to the cylinder. An inoperative unit injector pump
the 1U-5470 Engine Pressure Test Group for the could cause this low temperature.
instructions that are needed to use the 1U-5470
Engine Pressure Test Group. A very high temperature can indicate that too much
fuel is flowing to the cylinder. A malfunctioning unit
injector could cause this very high temperature.
Use the 123-6700 Infrared Thermometer to check

this exhaust temperature. You can find operating
instructions and maintenance instructions inside the
Operators Manual, NEHS0630, 123-6700 Infrared
Thermometer II with Laser Sighting.
g00295555
Illustration 68
Pressure Test Location
(1) Plug
Use the following procedure in order to measure the

inlet manifold pressure:
86
i01281711 The use of winter fronts or shutters is discouraged

with air-to-air aftercooled systems. Winter fronts can
Aftercooler - Test only be used on certain truck models. On these
trucks, tests have shown that the engine jacket
SMCS Code: 1063-081 water will overheat before the inlet manifold air
temperature is excessive. These trucks use sensors
Table 14
and indicators that are installed in order to indicate
Tools Needed engine operating conditions before excessive inlet
manifold air temperatures are reached. Check with
Part
Part Name Quantity the truck manufacturer about the use of both winter
Number
fronts and shutters.
FT-1984 Aftercooler Testing Group 1 Inlet Manifold Pressure
FT-1438 Aftercooler (Dynamometer 1 Normal inlet manifold pressure with high exhaust
Test)
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
Visual Inspection cleaning procedure.
Inspect the following parts at each oil change:
Low inlet manifold pressure and high exhaust
manifold temperature can be caused by any of the
Air lines following conditions:
Hoses Plugged air cleaner Clean the air cleaner or
replace the air cleaner, as required. Refer to the
Gasket joints Operation and Maintenance Manual, Engine Air
Cleaner Element - Clean/Replace.
Blockage in the air lines Blockage in the air lines

Pressurized air can cause personal injury. When between the air cleaner and the turbocharger must
pressurized air is used for cleaning, wear a protec- be removed.
tive face shield, protective clothing, and protective
shoes. Aftercooler core leakage Aftercooler core leakage
should be pressure tested. Refer to Aftercooler
Core Leakage topic for the testing procedure.
Ensure that the constant torque hose clamps are
tightened to the correct torque. Check the truck Leakage of the induction system Any leakage from
manufacturers specifications for the correct torque. the pressure side of the induction system should
Check the welded joints for cracks. Ensure that be repaired.
the brackets are tightened in the correct positions.
Ensure that the brackets are in good condition. Use Inlet manifold leak An inlet manifold leak can be
compressed air to clean any debris or any dust caused by the following conditions: loose fittings
from the aftercooler core assembly. Inspect the and plugs, missing fittings and plugs, damaged
cooler core fins for the following conditions: fittings and plugs, and leaking inlet manifold gasket.
Damage
Debris
Corrosion
Use a stainless steel brush to remove any corrosion.
Ensure that you use soap and water.
Note: When parts of the air-to-air aftercooler

system are repaired, a leak test is recommended.
When parts of the air-to-air aftercooler system are
replaced, a leak test is recommended.
87
Aftercooler Core Leakage A large leak of the aftercooler core can often be
found by making a visual inspection. To check for
smaller leaks, use the following procedure:
1. Disconnect the air pipes from the inlet and outlet

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

cooler core 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
being pressurized.
NOTICE
Do not use more than 240 kPa (35 psi) of air pressure
or damage to the aftercooler core can be the result.
g00295702
Illustration 69
FT-1984 Aftercooler Testing Group
3. Install the regulator and valve assembly (1) on
the outlet side of the aftercooler core assembly.
(1) Regulator and valve assembly
(2) Nipple
Also, attach the air supply.
(3) Relief valve
(4) Tee 4. Open the air valve and pressurize the aftercooler
(5) Coupler to 205 kPa (30 psi). Shut off the air supply.
(6) Aftercooler
(7) Dust plug
(8) Dust plug 5. Inspect all connection points for air leakage.
(9) Chain
6. The aftercooler systems pressure should not
A low power problem in the engine can be the result drop more than 35 kPa (5 psi) in 15 seconds.
of aftercooler leakage. Aftercooler system leakage
can result in the following problems: 7. If the pressure drop is more than the specified
amount, use a solution of soap and water to
Low power check all areas for leakage. Look for air bubbles
that will identify possible leaks. Replace the
Low boost pressure aftercooler core, or repair the aftercooler core,
as needed.
Black smoke
High exhaust temperature
To help prevent personal injury when the tooling is
NOTICE removed, relieve all pressure in the system slowly
Remove all air leaks from the system to prevent engine by using an air regulator and a valve assembly.
damage. In some operating conditions, the engine can
pull a manifold vacuum for short periods of time. A 8. After the testing, remove the FT-1984 Aftercooler
leak in the aftercooler or air lines can let dirt and other Testing Group. Reconnect the air pipes on both
foreign material into the engine and cause rapid wear sides of the aftercooler core assembly.
and/or damage to engine parts.
88
Air System Restriction Turbocharger Failure
Personal injury can result from air pressure.
Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less

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

aftercooler core. Internally flush the air-to-air
aftercooler core with a solvent that removes oil
and other foreign substances. Shake the air-to-air
aftercooler core in order to eliminate any trapped
debris. Wash the aftercooler with hot, soapy water.
Thoroughly rinse the aftercooler with clean water
and blow dry the aftercooler with compressed air.
Illustration 70
g00581364 Blow dry the assembly in the reverse direction of
normal air flow. To make sure that the whole system
Pressure measurements should be taken at the inlet is clean, carefully inspect the system.
manifold (1) and at the turbocharger outlet (2).
NOTICE
Use the differential pressure gauge of the 1U-5470 Do not use caustic cleaners to clean the air-to-air af-
Engine Pressure Group. Use the following procedure tercooler core.
in order to measure the restriction of the aftercooler:
Caustic cleaners will attack the internal metals of the
1. Connect the vacuum port of the differential core and cause leakage.
pressure gauge to port (1).
2. Connect the pressure port of the differential Dynamometer Test

In hot ambient temperatures, chassis dynamometer
3. Record the value. tests for models with an air-to-air aftercooler can
add a greater heat load to the jacket water cooling
The air lines and the cooler core must be inspected system. Therefore, the jacket water cooling systems
for internal restriction when both of the following temperature must be monitored. The following
conditions are met: measurements may also need a power correction
factor:
Air flow is at a maximum level.
Inlet air temperature
Total air pressure drop of the charged system
exceeds 16.9 kPa (5 in Hg). Fuel API rating
If a restriction is discovered, proceed with the Fuel temperature
following tasks, as required:
Barometric pressure
Clean
With dynamometer tests for engines, use the
Repair FT-1438 Aftercooler (Dynamometer Test). This tool
provides a water cooled aftercooler in order to
Replacement control the inlet air temperature to 43 C (110 F).
89
i01281928 i01120286
Engine Crankcase Pressure Compression - Test

(Blowby) - Test SMCS Code: 1215
SMCS Code: 1215; 1317 An engine that runs roughly can have a leak at the
Table 15
valves. An engine that runs roughly can also have
valves that need an adjustment. Remove the head
Tools Needed and inspect the valves and valve seats. This is
Part necessary to find those small defects that would
Part Name Quantity not normally cause problems. Repairs of these
Number
problems are normally performed when you are
8T-2700 Blowby/Air Flow Indicator 1 reconditioning the engine.
Damaged pistons or damaged rings can cause

i01510447
too much pressure in the crankcase. This condition
will cause the engine to run rough. There will be Engine Valve Lash -
more than the normal amount of fumes (blowby)
rising from the crankcase breather. The breather Inspect/Adjust
can then become restricted in a very short time.
This condition can cause oil leakage at gaskets and SMCS Code: 1102-025
seals that would not normally have leakage. Blowby
can also be caused by worn valve guides or by a
failed turbocharger seal.
To prevent possible injury, do not use the starter
Note: The electronic service tool can be used to to turn the flywheel.
measure crankcase pressure.
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

injectors.
Disconnect electronic fuel injector enable circuit

connector to prevent personal injury.
Do not come in contact with the fuel injector ter-

g00286269
minals while the engine is running.
Illustration 71
8T-2700 Blowby/Air Flow Indicator
Note: Valve lash is measured between the rocker
The 8T-2700 Blowby/Air Flow Indicator is used arm and the bridge for the inlet valves. Valve lash
to check the amount of blowby. Refer to Special is measured between the rocker arm and the valve
Instruction, SEHS8712, Using the 8T-2700 stem for the exhaust valve. All of the clearance
Blowby/Air Flow Indicator for the test procedure measurements and the adjustments must be made
for checking the blowby. with the engine stopped. The valves must be FULLY
CLOSED.
Valve Lash Check

An adjustment is NOT NECESSARY if the
measurement of the valve lash is in the acceptable
range. Adjust the valve lash while the engine is
stopped. The range is specified in Table 16.
90
Table 16 Valve Lash and Valve Bridge

Check for Valve Lash Adjustment
Valves Acceptable Range for Valve Lash
Inlet 0.38 0.08 mm (0.015 0.003 inch)
Exhaust 0.64 0.08 mm (0.025 0.003 inch)
If the measurement is not within this range

adjustment is necessary. See Testing And Adjusting,
Valve Lash And Valve Bridge Adjustment.
g00750123
Illustration 73
(1) Exhaust rocker arm. (2) Inlet valve bridge. (3) Inlet rocker arm.
Illustration 72
g00290846 (4) Rocker arm adjustment screw locknut for the exhaust rocker
arm. (5) Rocker arm adjustment screw for the exhaust rocker arm.
Cylinder and Valve Location (6) Rocker arm adjustment screw locknut for the inlet rocker arm.
(A) Exhaust valves. (B) Inlet valves. (7) Rocker arm adjustment screw for the inlet rocker arm.
Valve Mechanism
g00295786
Illustration 74
View A-A
(1) Exhaust rocker arm. (2) Inlet valve bridge. (4) Rocker arm
adjustment screw locknut for the exhaust rocker arm. (5) Rocker
arm adjustment screw for the exhaust rocker arm.
91
Table 17 b. With the feeler gauge between exhaust rocker

Valve Lash
arm (1) and the exhaust valve stem, turn
rocker arm adjustment screw for the exhaust
Valves Dimension of Gauge rocker arm (5) in a clockwise direction.
Continue turning the adjustment screw until
Inlet 0.38 mm (0.015 inch)
the valve lash reaches the specifications in
Exhaust 0.64 mm (0.025 inch) Table 17.
Adjust the valve lash while the engine is stopped. c. After each adjustment, tighten the rocker arm
Use the following procedure to adjust the valves: adjustment screw locknut for the exhaust
rocker arm (4) to a torque of 30 7 Nm
1. Put the No. 1 piston at the top center position. (22 5 lb ft). Then, check the adjustment
again.
Note: See Testing and Adjusting, Finding The Top
Center Position for No. 1 Piston for further details. 5. Remove the top center bolt, and turn the flywheel
by 360 degrees in the direction of the engines
2. With No. 1 piston at the top center position of rotation. This will position the No. 1 piston at the
the correct stroke, an adjustment can be made top center on the opposite stroke. Install the top
to the valves. center bolt in the flywheel.
Before any adjustments are made, lightly tap 6. Make an adjustment to the valve lash on the inlet
each rocker arm at the top of the adjustment valves 3, 5,and 6.
screw. Use a soft mallet to ensure that the lifter
roller seats against the camshafts base circle. a. Loosen the rocker arm adjustment screw
locknut for the inlet rocker arm (6).
3. Make an adjustment to the valve lash on the inlet
valves for cylinders 1, 2, and 4. Insert an appropriate feeler gauge between
inlet rocker arm (3) and inlet valve bridge (2).
a. Loosen the rocker arm adjustment screw If the clearance is insufficient for the feeler
locknut for the inlet rocker arm (6). gauge, turn rocker arm adjustment screw for
the inlet rocker arm (7) in a counterclockwise
Insert an appropriate feeler gauge between direction. This increases the valve lash.
inlet rocker arm (3) and inlet valve bridge (2).
If the clearance is insufficient for the feeler b. With the feeler gauge between inlet rocker
gauge, turn rocker arm adjustment screw for arm (3) and inlet valve bridge (2), turn rocker
the inlet rocker arm (7) in a counterclockwise arm adjustment screw for the inlet rocker arm
direction. This increases the valve lash. (7) in a clockwise direction. Continue turning
the adjustment screw until the valve lash
b. With the feeler gauge between inlet rocker reaches the specifications in Table 17.
arm (3) and inlet valve bridge (2), turn rocker
arm adjustment screw for the inlet rocker arm c. After each adjustment, tighten the rocker arm
(7) in a clockwise direction. Continue turning adjustment screw locknut for the inlet rocker
the adjustment screw until the valve lash arm (6) to a torque of 30 7 Nm (22 5 lb ft).
reaches the specifications in Table 17. Then, check the adjustment again.
c. After each adjustment, tighten the rocker arm 7. Make an adjustment to the valve lash on the
adjustment screw locknut for the inlet rocker exhaust valves 2, 4, and 6.
arm (6) to a torque of 30 7 Nm (22 5 lb ft).
Then, check the adjustment again. a. Loosen the rocker arm adjustment screw
locknut for the exhaust rocker arm (4).
4. Make an adjustment to the valve lash on the
exhaust valves 1, 3, and 5. Insert an appropriate feeler gauge between
exhaust rocker arm (1) and the exhaust valve
a. Loosen the rocker arm adjustment screw stem. If the clearance is insufficient for the
locknut for the exhaust rocker arm (4). feeler gauge, turn rocker arm adjustment
screw for the exhaust rocker arm (5) in a
Insert an appropriate feeler gauge between counterclockwise direction. This increases the
exhaust rocker arm (1) and the exhaust valve valve lash.
stem. If the clearance is insufficient for the
feeler gauge, turn rocker arm adjustment
screw for the exhaust rocker arm (5) in a
counterclockwise direction. This increases the
valve lash.
92
b. With the feeler gauge between exhaust rocker

arm (1) and the exhaust valve stem, turn
rocker arm adjustment screw for the exhaust
rocker arm (5) in a clockwise direction.
Continue turning the adjustment screw until
the valve lash reaches the specifications in
Table 17.
c. After each adjustment, tighten the rocker arm

adjustment screw locknut for the exhaust
rocker arm (4) to a torque of 30 7 Nm
(22 5 lb ft). Then, check the adjustment
again.
8. Remove the top center bolt from the flywheel

after all valve lash adjustments have been made.
93
Lubrication System
i01282269
Engine Oil Pressure - Test

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

Engine parts that are hot, or parts that are moving, Illustration 75
can cause personal injury. 1U-5470 Engine Pressure Group
The 1U-5470 Engine Pressure Group measures the

NOTICE oil pressure in the system. This engine tool group
Keep all parts clean from contaminants. can read the oil pressure inside the oil manifold.
Contaminants may cause rapid wear and shortened Note: Refer to Special Instruction, SEHS8907,
component life. Using the 1U-5470 Engine Pressure Group for
more information on using the 1U-5470 Engine
Pressure Group.
NOTICE
Care must be taken to ensure that fluids are contained Note: The engine oil pressure can also be measured
during performance of inspection, maintenance, test- by using an electronic service tool. Refer to
ing, adjusting and repair of the product. Be prepared to Troubleshooting for information on the use of the
collect the fluid with suitable containers before open- electronic technician.

products.

mandates.
Table 18
Tools Needed
g00680246
Illustration 76
Oil Gallery Plug
8J-7844 Adapter Fitting 1 (1) Plug.
3K-0360 O-Ring Seal 1
1. Install the 1U-5470 Engine Pressure Group into
4M-5317 Terminal Bushing oil gallery plug (1).
or or 1
5P-2720 Probe Adapter Note: Engine oil pressure to the camshaft and main
bearings should be checked on each side of the
cylinder block at oil gallery plug (1).
2. Start the engine. Run the engine with SAE

10W30 or SAE 15W40 oil. The information in the
engine oil pressure graph is invalid for other oil
viscosities. Refer to Operation and Maintenance
Manual, Engine Oil for the recommendations
of engine oil.
94
Note: Allow the engine to reach operating 6. Compare the recorded engine oil pressure with
temperature before you perform the pressure test. the oil pressure indicators on the instrument
panel and the engine oil pressure that is
Note: The engine oil temperature should not exceed displayed on the electronic service tool.
115C (239F).
7. An engine oil pressure indicator that has a
3. Record the value of the engine oil pressure when defect or an engine oil pressure sensor that
the engine has reached operating temperature. has a defect can give a false indication of a
low oil pressure or a high oil pressure. If there
4. Locate the point that intersects the lines for is a notable difference between the engine oil
the engine rpm and for the oil pressure on the pressure readings make necessary repairs.
engine oil pressure graph.
8. If the engine oil pressure is determined to be low,
refer to Reasons for Low Engine Oil Pressure.
9. If the engine oil pressure is determined to be

high, refer to Reason for High Engine Oil
Pressure.
Reasons for Low Engine Oil

Pressure
NOTICE

component life.
NOTICE

g00293198 suitable to collect and contain fluids on Caterpillar
Illustration 77
Engine Oil Pressure Graph products.
5. The results must fall within the ACCEPTABLE Dispose of all fluids according to local regulations and
range on the chart. A problem exists when the mandates.
results fall within the NOT ACCEPTABLE range
on the chart. The problem needs to be corrected. Engine oil level is low. Refer to Step 1.
Engine failure or a reduction in engine life can
be the result if engine operation is continued with Engine oil is contaminated. Refer to Step 2.
oil manifold pressure outside this range.
The engine oil bypass valves are open. Refer to
Note: A record of engine oil pressure can be used Step 3.
as an indication of possible engine problems or
damage. A possible problem could exist if the The engine lubrication system is open. Refer to
oil pressure suddenly increases or decreases Step 4.
70 kPa (10 psi) and the oil pressure is in the
ACCEPTABLE range. The engine should be The oil suction tube has a leak or a restricted inlet
inspected and the problem should be corrected. screen. Refer to Step 5.
The engine oil pump is faulty. Refer to Step 6.

95
Engine Bearings have excessive clearance. Refer 5. The inlet screen of the oil suction tube for the
to Step 7. engine oil pump can have a restriction. This
restriction will cause cavitation and a loss of
1. Check the engine oil level in the crankcase. engine oil pressure. Check the inlet screen on
The oil level can possibly be too far below the the oil pickup tube and remove any material that
oil pump supply tube. This will cause the oil may be restricting engine oil flow. Low engine oil
pump not to have the ability to supply enough pressure may also be the result of the oil pickup
lubrication to the engine components. If the tube that is drawing in air. Check the joints of the
engine oil level is low add engine oil in order oil pickup tube for cracks or a damaged O-ring
to obtain the correct engine oil level. Refer to seal. Remove the engine oil pan in order to gain
Operation and Maintenance Manual, Engine Oil access to the oil pickup tube and the oil screen.
for the recommendations of engine oil. Refer to Disassembly and Assembly, Engine Oil
Pan - Remove and Install for more information.
2. Engine oil that is contaminated with fuel or
coolant will cause low engine oil pressure. 6. Check the following problems that may occur
High engine oil level in the crankcase can be to the engine oil pump.
an indication of contamination. Determine the
reason for contamination of the engine oil and a. Air leakage in the supply side of the oil
make the necessary repairs. Replace the engine pump will also cause cavitation and loss of
oil with the approved grade of engine oil. Also oil pressure. Check the supply side of the
replace the engine oil filter. Refer to Operation oil pump and make necessary repairs. For
and Maintenance Manual, Engine Oil for the information on the repair of the engine oil
recommendations of engine oil. pump, refer to Disassembly and Assembly,
Engine Oil Pump - Remove.
NOTICE
Caterpillar oil filters are built to Caterpillar speci- b. Oil pump gears that have too much wear will
fications. Use of an oil filter not recommended by cause a reduction in oil pressure. Repair the
Caterpillar could result in severe engine damage to engine oil pump. For information on the repair
the engine bearings, crankshaft, etc., as a result of of the engine oil pump, refer to Disassembly
the larger waste particles from unfiltered oil entering and Assembly, Engine Oil Pump - Remove.
the engine lubricating system. Only use oil filters
recommended by Caterpillar. 7. Excessive clearance at engine bearings will
cause low engine oil pressure. Check the
engine components that have excessive bearing
3. If the engine oil bypass valves are held in the clearance and make the necessary repairs.
open position, a reduction in the oil pressure
can be the result. This may be due to debris in Reason for High Engine Oil
the engine oil. If the engine oil bypass valves
are stuck in the open position, remove each Pressure
engine oil bypass valve and clean each bypass
valve in order to correct this problem. You must NOTICE
also clean each bypass valve bore. Install Keep all parts clean from contaminants.
new engine oil filters. For information on the
repair of the engine oil bypass valves, refer to Contaminants may cause rapid wear and shortened
Disassembly and Assembly, Engine Oil Filter component life.
Base - Disassemble.
4. An oil line or an oil passage that is open, NOTICE

broken, or disconnected will cause low engine Care must be taken to ensure that fluids are contained
oil pressure. An open lubrication system could during performance of inspection, maintenance, test-
be caused by a piston cooling jet that is missing ing, adjusting and repair of the product. Be prepared to
or damaged. collect the fluid with suitable containers before open-
Note: The piston cooling jets direct engine oil nent containing fluids.
toward the bottom of the piston in order to cool the
piston. This also provides lubrication for the piston Refer to Special Publication, NENG2500, Caterpillar
pin. Breakage, a restriction, or incorrect installation Tools and Shop Products Guide for tools and supplies
of the piston cooling jets will cause seizure of the suitable to collect and contain fluids on Caterpillar
piston. products.

mandates.
96
Engine oil pressure will be high if the engine oil i01282970

bypass valves become stuck in the closed position
and the engine oil flow is restricted. Foreign matter Excessive Engine Oil
in the engine oil system could be the cause for the
restriction of the oil flow and the movement of the
Consumption - Inspect
engine oil bypass valves. If the engine oil bypass SMCS Code: 1348-040
valves are stuck in the closed position, remove
each bypass valve and clean each bypass valve in
order to correct this problem. You must also clean Oil Leakage On Outside Of Engine
each bypass valve bore. Install new engine oil
filters. New engine oil filters will prevent more debris Check for leakage at the seals at each end of the
from causing this problem. For information on the crankshaft. Look for leakage at the oil pan gasket
repair of the engine oil filter bypass valve, refer to and all lubrication system connections. Look for any
Disassembly and Assembly, Engine Oil Filter Base oil that may be leaking from the crankcase breather.
- Disassemble. This can be caused by combustion gas leakage
around the pistons. A dirty crankcase breather
will cause high pressure in the crankcase. A dirty
NOTICE
crankcase breather will cause the gaskets and the
Caterpillar oil filters are built to Caterpillar speci-
seals to leak.
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of Oil Leakage Into Combustion Area
the larger waste particles from unfiltered oil entering Of Cylinders
recommended by Caterpillar. Oil leakage into the combustion area of the cylinders
can be the cause of blue smoke. There are four
possible ways for oil leakage into the combustion
i01378651 area of the cylinders:
Engine Oil Pump - Inspect Oil leakage between worn valve guides and valve
stems
SMCS Code: 1304-040
If any part of the engine oil pump is worn enough

Worn components or damaged components
(pistons, piston rings, or dirty oil return holes)
in order to affect the performance of the engine oil
pump, the engine oil pump must be replaced. Refer
to the Specifications Module, Engine Oil Pump
Incorrect installation of the compression ring
and/or the intermediate ring
topic for clearances.
Oil leakage past the seal rings in the impeller end
i01126690 of the turbocharger shaft
Excessive Bearing Wear - Excessive oil consumption can also be the result if
oil with the wrong viscosity is used. Oil with a thin
Inspect viscosity can be caused by fuel leakage into the
crankcase or by increased engine temperature.
SMCS Code: 1203-040; 1211-040; 1219-040
When some components of the engine show i01283115

bearing wear in a short time, the cause can be a
restriction in an oil passage. Increased Engine Oil
An engine oil pressure indicator may show that there
Temperature - Inspect
is enough oil pressure, but a component is worn SMCS Code: 1348-040
due to a lack of lubrication. In such a case, look at
the passage for the oil supply to the component. A When the engine is at operating temperature
restriction in an oil supply passage will not allow and you are using SAE 10W30 oil, the maximum
enough lubrication to reach a component. This will
oil temperature is 115 C (239 F). This is the
result in early wear. temperature of the oil after passing through the oil
cooler.
97
Look for a restriction in the oil passages of the oil

cooler. The oil temperature may be higher than
normal when the engine is operating. In such
a case, the oil cooler may have a restriction. A
restriction in the oil cooler will not cause low oil
pressure in the engine.
Determine if the oil cooler bypass valve is held in

the open position. This condition will allow the oil to
pass through the valve instead of the oil cooler. The
oil temperature will increase.
98
Cooling System 4. Check for air in the cooling system. Air can
enter the cooling system in different ways. The
following items are some of the most common
i01389751 causes for air in the cooling system:
Cooling System - Check Filling the cooling system incorrectly

(Overheating) Combustion gas leakage into the cooling
SMCS Code: 1350-535 system
Above normal coolant temperatures can be caused Loose hose clamp

by many conditions. Use the following procedure
to determine the cause of above normal coolant Combustion gas can get into the system through
temperatures: the following conditions: inside cracks, damaged
cylinder head, and damaged cylinder head
gasket. A loose hose clamp can allow air into the
cooling system during the cooldown period. Air
in the cooling system causes a reduction in the
Personal injury can result from escaping fluid un- cooling capacity of the coolant.
der pressure.
5. Check the fan drive system. A fan drive system
If a pressure indication is shown on the indicator, that is not turning at the correct speed can cause
push the release valve in order to relieve pressure improper air speed across the radiator core. The
before removing any hose from the radiator. lack of proper air flow across the radiator core
can cause the coolant not to cool to the proper
temperature differential.
1. Check the coolant level in the cooling system.
Refer to Operation and Maintenance Manual,
6. Check the water temperature gauge. A water
Cooling System Coolant Level - Check. If
temperature gauge which does not work correctly
the coolant level is too low, air will get into the
will not show the correct temperature. Refer to
cooling system. Air in the cooling system will
Testing and Adjusting, Cooling System - Test.
cause a reduction in coolant flow and bubbles in
the coolant. Air bubbles cause a reduction in the
7. Check the sending unit. In some conditions, the
cooling of engine parts.
temperature sensor in the engine sends signals
to a sending unit. The sending unit converts
2. Check the quality of the coolant. The coolant
these signals to an electrical impulse which is
should have the following properties:
used by a mounted gauge. If the sending unit
malfunctions, the gauge can show an incorrect
Color that is similar to new coolant reading. Also if the electric wire breaks or if the
electric wire shorts out, the gauge can show an
Odor that is similar to new coolant incorrect reading.
Free from dirt and debris 8. Check the radiator.
If the coolant does not have these properties,
a. Check the radiator for a restriction to coolant
drain the system and flush the system. Refill
flow. Check the radiator for debris, for dirt, or
the cooling system with the correct mixture of
for deposits on the inside of the radiator core.
water, antifreeze, and coolant conditioner. Refer
Debris, dirt, or deposits will restrict the flow of
to Operation and Maintenance Manual, General
coolant through the radiator.
Coolant Information.
b. Check for debris or for damage between
3. Check the coolant mixture of antifreeze and
the fins of the radiator core. Debris between
water. The mixture should be approximately 50
the fins of the radiator core restricts air flow
percent water and 50 percent antifreeze with
through the radiator core. Refer to Testing and
3 to 6 percent coolant conditioner. Refer to
Adjusting, Cooling System - Inspect.
Operation and Maintenance Manual, General
Coolant Information. If the coolant mixture is
incorrect, drain the cooling system and flush the
cooling system. Refill the cooling system with the
correct mixture of water, antifreeze, and coolant
conditioner.
99
c. Check for missing radiator baffles or for 12. Check the cooling system hoses and clamps.
damaged radiator baffles. Radiator baffles Damaged hoses with leaks can normally be
prevent recirculation of air around the sides seen. Hoses that have no visual leaks can soften
of the radiator. A missing radiator baffle during operation. The soft areas of the hose can
or a damaged radiator baffle raises the become kinked or crushed during operation.
temperature of the air that goes through the These areas of the hose can cause a restriction
radiator. in the coolant flow. Hoses can become soft.
Also, hoses can get cracks after a period of
d. Ensure that the radiator size is according time. The inside of a hose can deteriorate, and
to the OEM specifications. An undersized the loose particles of the hose can cause a
radiator does not have enough area for the restriction of the coolant flow. Refer to Operation
effective release of heat. This may cause and Maintenance Manual, Hoses and Clamps -
the engine to run at a temperature that is Inspect/Replace.
higher than normal. The normal temperature
is dependent on the ambient temperature. 13. Check for a restriction in the air inlet system.
A restriction of the air that is coming into the
9. Check the filler cap. A pressure drop in the engine can cause high cylinder temperatures.
radiator can cause the boiling point to be lower. High cylinder temperatures can cause higher
This can cause the cooling system to boil. Refer than normal temperatures in the cooling system.
to Testing and Adjusting, Cooling System - Test. Refer to Testing and Adjusting, Air Inlet and
Exhaust System - Inspect.
10. Check the fan and/or the fan shroud.
a. If the measured restriction is higher than the
a. Ensure that the fan is installed correctly. maximum permissible restriction, remove the
Improper installation of the fan can cause foreign material from the engine air cleaner
engine overheating. element or install a new engine air cleaner
element. Refer to Operation and Maintenance
b. The fan must be large enough to send air Manual, Engine Air Cleaner Element -
through most of the area of the radiator Clean/Replace.
core. Ensure that the size of the fan and the
position of the fan are according to the OEM b. Check the air inlet system for a restriction
specifications. again.
c. The fan shroud and the radiator baffling must c. If the measured restriction is still higher than
be the proper size. The fan shroud and the the maximum permissible restriction, check
radiator baffling must be positioned correctly. the air inlet piping for a restriction.
The size of the fan shroud and the position
of the fan shroud should meet the OEM 14. Check for a restriction in the exhaust system.
specifications. The size of the radiator baffling A restriction of the air that is coming out of the
and the position of the radiator baffling should engine can cause high cylinder temperatures.
meet the OEM specifications.
a. Make a visual inspection of the exhaust
11. Check for loose drive belts. system. Check for damage to exhaust
piping. Also, check for a damaged muffler.
a. A loose fan drive belt will cause a reduction If no damage is found, check the exhaust
in the air flow across the radiator. Check the system for a restriction. Refer to Testing and
fan drive belt for proper belt tension. Adjust Adjusting, Air Inlet and Exhaust System -
the tension of the fan drive belt, if necessary. Inspect.
Belt - Inspect. b. If the measured restriction is higher than the
maximum permissible restriction, there is a
b. A loose water pump drive belt will cause a restriction in the exhaust system. Repair the
reduction in coolant flow through the radiator. exhaust system, as required.
Check the water pump drive belt for proper
belt tension. Adjust the tension of the water c. Ensure that the exhaust gas is not being
pump drive belt, if necessary. Refer to drawn into the cooling air inlet.
Operation and Maintenance Manual, Belt -
Inspect.
100
15. Check the shunt line. The shunt line must be i01390078
submerged in the expansion tank. A restriction
of the shunt line from the radiator top tank to the Cooling System - Inspect
engine water pump inlet will cause a reduction
in water pump efficiency. A reduction in water SMCS Code: 1350-040
pump efficiency will result in low coolant flow
and overheating. Cooling systems that are not regularly inspected are
the cause for increased engine temperatures. Make
16. Check the water temperature regulator. A water a visual inspection of the cooling system before any
temperature regulator that does not open, or tests are performed.
a water temperature regulator that only opens
part of the way can cause overheating. Refer
to Testing and Adjusting, Water Temperature
Regulator - Test. Personal injury can result from escaping fluid un-
der pressure.
17. Check the water pump. A water pump with
a damaged impeller does not pump enough If a pressure indication is shown on the indicator,
coolant for correct engine cooling. Remove push the release valve in order to relieve pressure
the water pump and check for damage to the before removing any hose from the radiator.
impeller. Refer to Testing and Adjusting, Water
Pump - Test.
18. Check the air flow through the engine Refer to Operation and Maintenance Manual,
compartment. The air flow through the radiator Cooling System Coolant Level - Check.
comes out of the engine compartment. Ensure
that the filters, the air conditioner, and similar 2. Check the quality of the coolant. The coolant
items are not installed in a way that prevents the should have the following properties:
free flow of air through the engine compartment.
Color that is similar to new coolant
19. Check the aftercooler. A restriction of air flow
through the air to air aftercooler (if equipped) Odor that is similar to new coolant
can cause overheating. Check for debris or
deposits which would prevent the free flow of Free from dirt and debris
air through the aftercooler. Refer to Testing and
Adjusting, Aftercooler - Test. If the coolant does not have these properties,
20. Consider high outside temperatures. When the cooling system with the correct mixture of
outside temperatures are too high for the rating water, antifreeze, and coolant conditioner. Refer
of the cooling system, there is not enough of a to Operation and Maintenance Manual, General
temperature difference between the outside air Coolant Information.
and coolant temperatures.
3. Look for leaks in the system.
21. Consider high altitude operation. The cooling
capacity of the cooling system goes down as Note: A small amount of coolant leakage across
the engine is operated at higher altitudes. A the surface of the water pump seals is normal.
pressurized cooling system that is large enough This leakage is required in order to provide
to keep the coolant from boiling must be used. lubrication for this type of seal. A hole is provided
in the water pump housing in order to allow this
22. The engine may be running in the lug condition. coolant/seal lubricant to drain from the pump
When the load that is applied to the engine is housing. Intermittent leakage of small amounts of
too large, the engine will run in the lug condition. coolant from this hole is not an indication of water
When the engine is running in the lug condition, pump seal failure.
engine rpm does not increase with an increase
of fuel. This lower engine rpm causes a reduction 4. Ensure that the airflow through the radiator does
in air flow through the radiator. This lower engine not have a restriction. Look for bent core fins
rpm also causes a reduction in coolant flow between the folded cores of the radiator. Also,
through the system. This combination of less air look for debris between the folded cores of the
and less coolant flow during high input of fuel radiator.
will cause above normal heating.
5. Inspect the drive belts for the fan.
101
6. Check for damage to the fan blades.
7. Look for air or combustion gas in the cooling

system.
and alkali.
8. Inspect the filler cap, and check the surface that
seals the filler cap. This surface must be clean.
i01517089 steam. Any contact can cause severe burns.
Cooling System - Test Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
SMCS Code: 1350-040; 1350-081 enough to touch with your bare hand.
This engine has a pressure type cooling system. A Cooling System Conditioner contains alkali. Avoid
pressure type cooling system has two advantages. contact with skin and eyes.
The cooling system can be operated in a safe
manner at a temperature higher than the normal
boiling point (steam) of water. The coolant level must be to the correct level in
order to check the coolant system. The engine must
This type of system prevents cavitation in the water be cold and the engine must not be running.
pump. Cavitation is the forming of low pressure
bubbles in liquids that are caused by mechanical After the engine is cool, loosen the pressure cap
forces. The formation of an air pocket or a steam in order to relieve the pressure out of the cooling
pocket in this type of cooling system is difficult. system. Then remove the pressure cap.
The level of the coolant should not be more than

13 mm (0.5 inch) from the bottom of the filler pipe.
If the cooling system is equipped with a sight glass,
the coolant should be to the proper level in the
sight glass.
Test Tools For Cooling System

Table 19
Tools Needed
Part
Part Name Quantity
Number
g00286266 4C-6500 Digital Thermometer 1

Illustration 78
Boiling point of water 8T-2700 Blowby/Air Flow Indicator 1
9S-8140 Pressurizing Pump 1
Remember that temperature and pressure work
together. When a diagnosis is made of a cooling 9U-7400 Multitach Tool Group
system problem, temperature and pressure must or or 1
1U-6602 Photo-Tachometer
be checked. Cooling system pressure will have an
effect on the cooling system temperature. For an 1U-7297 Coolant/Battery Tester 1
example, refer to Illustration 78. This will show the
1U-7298 Coolant/Battery Tester 1
effect of pressure on the boiling point (steam) of
water. This will also show the effect of height above
sea level.

rotating parts.
When working on an engine that is running, avoid

102
g00286267 g00286276
4C-6500 Digital Thermometer 9U-7400 Multitach Tool Group
The 4C-6500 Digital Thermometer is used in the The 9U-7400 Multitach Tool Group is used to
diagnosis of overheating conditions and in the check the fan speed. Refer to Operating Manual,
diagnosis of overcooling conditions. This group can NEHS0605, 9U-7400 Multitach Tool Group for
be used to check temperatures in several different the testing procedure.
parts of the cooling system. Refer to Operating
Manual, NEHS0554, 4C-6500 Digital Thermometer The 9U-7400 Multitach Tool Group can measure
Group for the testing procedure. engine rpm from a magnetic pickup. This magnetic
pickup is located in the flywheel housing. The
magnetic pickup also uses the ability to measure
engine rpm from visual engine parts that are
rotating.
g00286269
Illustration 80
The 8T-2700 Blowby/Air Flow Indicator is used to

g00296064
check the air flow through the radiator core. Refer to Illustration 82
Special Instruction, SEHS8712, Using the 8T-2700 1U-6602 Photo-Tachometer
Blowby/Air Flow Indicator for the test procedure
for checking blowby. The 1U-6602 Photo-Tachometer is a
photo-tachometer that is held by hand for
general use. The 1U-6602 Photo-Tachometer is
a phototach, so this tachometer only registers
basic input frequency on any visible, rotating
part. The basic input frequency equals one
revolution per piece of reflective tape. The 1U-6602
Photo-Tachometer does not replace the 9U-7400
Multitach Tool Group.
103
Making the Correct Antifreeze

Mixtures
Adding pure antifreeze as a makeup solution for
the cooling system top-off is an unacceptable
practice. Adding pure antifreeze increases the
concentration of antifreeze in the cooling system.
This increases the concentration of the dissolved
solids and the undissolved chemical inhibitors
in the cooling system. Add the antifreeze and
water mixture to the same freeze protection as
your cooling system. The following chart assists
in determining the concentration of antifreeze to
use. Refer to Operation and Maintenance Manual,
Illustration 83 g00286369 General Coolant Information.
9S-8140 Pressurizing Pump
Table 20
The 9S-8140 Pressurizing Pump is used to test the Antifreeze Concentrations

filler caps. This pressurizing pump is also used to Temperature Concentration
pressure test the cooling system for leaks.
30% antifreeze and
Protection to 15 C (5 F)
70% water
Protection to 23 C 40% antifreeze and
(10 F) 60% water
(34 F) 50% water
(60 F) 40% water
Checking the Filler Cap

Table 21
g00439083 Tools Needed

Illustration 84
1U-7297 Coolant/Battery Tester or 1U-7298 Coolant/Battery Part
Part Name Quantity
Tester Number
Check the coolant frequently in cold weather for
the proper glycol concentration. Use either the
1U-7297 Coolant/Battery Tester or the 1U-7298 One cause for a pressure loss in the cooling system
Coolant/Battery Tester in order to ensure adequate can be a damaged seal on the radiator filler cap.
freeze protection. The testers are identical except
for the temperature scale. The testers give
immediate, accurate readings. The testers can be
used for antifreeze/coolants that contain ethylene
or propylene glycol.
g00296067
Illustration 85
Typical schematic of filler cap
(1) Sealing surface of both filler cap and radiator
104
Testing The Radiator And Cooling

System For Leaks
and alkali. Table 22
Tools Needed
and under pressure. The radiator and all lines Part
Part Name Quantity
to heaters or the engine contain hot coolant or Number
steam. Any contact can cause severe burns. 9S-8140 Pressurizing Pump 1
Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool Use the following procedure in order to check the
enough to touch with your bare hand. cooling system for leaks:
Cooling System Conditioner contains alkali. Avoid

contact with skin and eyes.
To check for the amount of pressure that opens the and alkali.
filler cap, use the following procedure:
1. After the engine cools, carefully loosen the filler and under pressure. The radiator and all lines
cap. Slowly release the pressure from the cooling to heaters or the engine contain hot coolant or
system. Then, remove the filler cap. steam. Any contact can cause severe burns.
Carefully inspect the filler cap. Look for any Remove filler cap slowly to relieve pressure only
damage to the seals and to the sealing surface. when engine is stopped and radiator cap is cool
Inspect the following components for any foreign enough to touch with your bare hand.
substances:
Filler cap contact with skin and eyes.
Seal 1. After the engine is cool, loosen the filler cap

slowly and allow pressure out of the cooling
Surface for seal system. Then remove the filler cap from the
radiator.
Remove any deposits that are found on these
items, and remove any material that is found on 2. Ensure that the coolant level is above the top of
these items. the radiator core.
2. Install the filler cap on the 9S-8140 Pressurizing 3. Install the 9S-8140 Pressurizing Pump onto the
Pump. radiator.
3. Look at the gauge for the exact pressure that 4. Take the pressure reading on the gauge to
opens the filler cap. 20 kPa (3 psi) more than the pressure on the
filler cap.
4. Compare the gauges reading with the opening
pressure that is listed on the filler cap. 5. Check the radiator for leakage on the outside.
5. If the filler cap is damaged, replace the filler cap. 6. Check all connection points for leakage, and
check the hoses for leakage.
The cooling system does not have leakage only if

the following conditions exist:.
You do NOT observe any outside leakage.

The reading remains steady after five minutes.
The inside of the cooling system has leakage only if
the following conditions exist:
105
The reading on the gauge goes down.

Make any repairs, as required.
Test For The Water Temperature

Gauge
Table 23
Tools Needed
Part
Part Name Quantity
Number
g00296551
4C-6500 Illustration 86
Digital Thermometer
or or 1 Test Location
2F-7112 Thermometer (1) Plug. (2) Water temperature regulator housing.
Remove the plug from one of ports (1). Install one

of the following thermometers in the open port:
Personal injury can result from escaping fluid un- The 4C-6500 Digital Thermometer
der pressure.
The 2F-7112 Thermometer
If a pressure indication is shown on the indicator,
push the release valve in order to relieve pressure A temperature indicator of known accuracy can
before removing any hose from the radiator. also be used to make this check.
Start the engine. Run the engine until the

temperature reaches the desired range according
to the test thermometer. If necessary, place a
Making contact with a running engine can cause cover over part of the radiator in order to cause a
burns from hot parts and can cause injury from restriction of the air flow. The reading on the water
rotating parts. temperature indicator should agree with the test
thermometer within the tolerance range of the water
When working on an engine that is running, avoid temperature indicator.
i01283699
Check the accuracy of the water temperature
indicator or water temperature sensor if you find Water Temperature Regulator
either of the following conditions:
- Test
The engine runs at a temperature that is too hot,
but a normal temperature is indicated. A loss of SMCS Code: 1355-081; 1355-081-ON
coolant is found.
The engine runs at a normal temperature, but a

hot temperature is indicated. No loss of coolant Personal injury can result from escaping fluid un-
is found. der pressure.
Coolant temperature can also be read on the display If a pressure indication is shown on the indicator,
screens of the Electronic Service Tool (ET or ECAP). push the release valve in order to relieve pressure
before removing any hose from the radiator.
Note: An option is available for both single

regulators and dual regulators. For dual regulators,
both of these types of regulators must be installed.
You must install both of these types of regulators, or
the engines performance will be adversely affected.
106
1. Remove the water temperature regulator(s) from

the engine.
2. Heat water in a pan until the temperature is 97 C

(207 F). Stir the water in the pan. This allows the
temperature to radiate throughout the pan.
3. Hang the water temperature regulator(s) in the

pan 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 minutes. g00296313
Illustration 87
5. After ten minutes, remove the water temperature Pressure test ports for the water pump
regulator(s). The water temperature regulator(s) (1) Port (alternate heater supply). (2) Port (engine diagnosis). (3)
should have opened. Perform an immediate Port (heater return line).
check of the distance for the openings on the
water temperature regulator(s).
Refer to the Specifications, Water Temperature Making contact with a running engine can cause
Regulator for more information about the burns from hot parts and can cause injury from
minimum distance for openings on the water rotating parts.
temperature regulator(s).
If the distance is less than the amount listed contact with hot parts and rotating parts.
in the manual, replace the water temperature
regulator.
The pressure rise is the difference between inlet
pressure and outlet pressure. The pressure rise
i01490824
indicates if the water pump operates correctly. Port
Water Pump - Test (1) and Port (2) represent the water pump outlet
pressure. Port (3) represents the water pump inlet
SMCS Code: 1361-040; 1361-081 pressure.
Table 24 To measure the pressure rise, compare inlet

pressure with outlet pressure. Calculate the
Tools Needed difference between the pressure of the inlet port
Part and the outlet ports. The pressure rise must add
Part Name Quantity
Number up to a minimum of 80 kPa (12 psi) under both of
the following conditions:
6V-7775 Air Pressure Gauge 1
8J-7844 Adapter Fitting 1 The engine is at operating temperature.
3K-0360 O-Ring Seal 1
The engine operates at full load condition.
5P-2725 Probe Seal Adapter 1
5P-2718 Pressure Probe(1) 1
5P-4487 Adapter 1
5P-2720 Probe Adapter 1
5P-2718 Pressure Probe(1) 1
(1) If port (1) is used, two tools are required.
107
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
i01432013 Line Boring Tool Group. The 1P-4000 Line Boring
Tool Group is used in order to check the alignment
Piston Ring Groove - Inspect of the main bearing bores. The 1P-3537 Dial
Bore Gauge Group can be used to check the
SMCS Code: 1214-040 size of the bore. Refer to Special Instruction,
GMG00981, 1P-3537 Dial Bore Gauge Group for
The 186-0190 Piston Ring Groove Gauge Gp is the instructions that are needed to use the 1P-3537
available to check the top ring groove in the piston. Dial Bore Gauge Group.
Refer to the instruction card with the tool for the
correct use of the 186-0190 Piston Ring Groove
Gauge Gp. i01160522
Cylinder Block - Inspect

i01284815
SMCS Code: 1201-040
Connecting Rod Bearings -
Table 25
Inspect
Tools Needed
SMCS Code: 1219-040 Part
Part Name Quantity
Number
The connecting rod bearings fit tightly in the bore
in the rod. If the bearing joints are fretted, check 1P-3537 Dial Bore Gauge Group 1
the bore size. This can be an indication of wear
because of a loose fit.
Connecting rod bearings are available with 0.25 mm

(0.010 inch) and 0.50 mm (0.020 inch) smaller
inside diameter than the original size bearings.
These bearings are for crankshafts that have been
ground.
i01284843
Main Bearings - Inspect

SMCS Code: 1203-040
g00285686
Illustration 88
Main bearings are available with 0.25 mm
(0.010 inch) and a 0.50 mm (0.020 inch) smaller 1P-3537 Dial Bore Gauge Group
These bearings are for crankshafts that have been If the main bearing caps are installed without
ground. bearings, the bore in the block for the main bearings
can be checked. Tighten the nuts on the bearing
Main bearings are also available with a larger caps to the torque that is given in Specifications,
outside diameter than the original size bearings. Cylinder Block. Alignment error in the bores must
These bearings are used for the cylinder blocks not be more than 0.08 mm (0.003 inch).
with the main bearing bore that is made larger than
the bores original size. The size that is available The 1P-3537 Dial Bore Gauge Group can be used
has a 0.50 mm (0.020 inch) outside diameter that is to check the size of the bore. Refer to Special
larger than the original size bearings. Instruction, GMG00981, 1P-3537 Dial Bore Gauge
Group for the instructions that are needed to use
the 1P-3537 Dial Bore Gauge Group.
108
i01284996 Bore Runout (radial eccentricity) of

Flywheel - Inspect the Flywheel
SMCS Code: 1156-040
Table 26
Tools Needed
Part
Part Name Quantity
Number
8T-5096 Dial Indicator 1
Face Runout (axial eccentricity) of

the Flywheel
g00286054
Illustration 90
Checking bore runout of the flywheel
(1) 7H-1945 Holding Rod
(3) 7H-1942 Dial Indicator
(4) 7H-1940 Universal Attachment
1. Install 7H-1942 Dial Indicator (3). Make an

adjustment of 7H-1940 Universal Attachment
(4) so the dial indicator makes contact on the
flywheel.
2. Set the dial indicator to read 0.0 mm (0.00 inch).

g00286049
Illustration 89 3. Turn the flywheel at intervals of 90 degrees and
Checking face runout of the flywheel read the dial indicator.
1. Refer to Illustration 89 and install the dial 4. Take the measurements at all four points. The
indicator. Always put a force on the crankshaft difference between the lower measurements and
in the same direction before the dial indicator the higher measurements that are performed at
is read. This will remove any crankshaft end all four points must not be more than 0.15 mm
clearance. (0.006 inch), which is the maximum permissible
face runout (radial eccentricity) of the flywheel.
3. Turn the flywheel at intervals of 90 degrees and

read the dial indicator.
4. Take the measurements at all four points. The

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 (axial eccentricity) of the flywheel.
109
If you use any other method except the method that

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

of the dial indicator will contact the face of the
flywheel housing.
2. Put a force on the crankshaft toward the rear

before the dial indicator is read at each point.
g00286058
Illustration 91
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).
i01340595 g00285932
Illustration 93
Flywheel Housing - Inspect Checking face runout of the flywheel housing
SMCS Code: 1157-040 3. Turn the flywheel while the dial indicator is set at
0.0 mm (0.00 inch) at location (A). Read the dial
Table 27 indicator at locations (B), (C) and (D).
Tools Needed
4. The difference between the lower measurements
Part and the higher measurements that are performed
Part Name Quantity
Number at all four points must not be more than 0.30 mm
8T-5096 Dial Indicator 1 (0.012 inch), which is the maximum permissible
face runout (axial eccentricity) of the flywheel
housing.
Face Runout (Axial Eccentricity) of
the Flywheel Housing Bore Runout (Radial Eccentricity)
of the Flywheel Housing
g00285931
Illustration 92
8T-5096 Dial Indicator g00285934
Illustration 94
8T-5096 Dial Indicator
110
1. Fasten a dial indicator to the flywheel so the anvil 6. Turn the flywheel counterclockwise in order to
of the dial indicator will contact the bore of the put the dial indicator at position (C). Write the
flywheel housing. measurement in the chart.
7. Turn the flywheel counterclockwise in order to

put the dial indicator at position (D). Write the
measurement in the chart.
8. Add the lines together in each column.
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.
g00285932
Illustration 95
Checking bore runout of the flywheel housing
g00285936
Illustration 96
g00286046
Illustration 97
2. While the dial indicator is in the position at
location (C) adjust the dial indicator to 0.0 mm Graph for total eccentricity
(0.00 inch). Push the crankshaft upward against (1) Total vertical eccentricity
the top of the bearing. Refer to Illustration 96. (2) Total horizontal eccentricity
(3) Acceptable value
Write the measurement for bearing clearance on (4) Unacceptable value
line 1 in column (C).
10. Find the intersection of the eccentricity lines
Note: Write the measurements for the dial indicator (vertical and horizontal) in Illustration 97.
with the correct notations. This notation is necessary
for making the calculations in the chart correctly. 11. If the point of the intersection is in the
ACCEPTABLE range, the bore is in alignment.
3. Divide the measurement from Step 2 by two. If the point of intersection is in the NOT
Write this number on line 1 in columns (B) and ACCEPTABLE range, the flywheel housing must
(D). be changed.
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).

put the dial indicator at position (B). Write the
measurements in the chart.
111
i01388616 If the alignment marks are not aligned, the

rubber portion of the rubber vibration damper has
Vibration Damper - Check separated from the hub and/or from the ring. When
the alignment marks are not aligned, replace the
SMCS Code: 1205-535 rubber vibration damper.
Rubber Vibration Damper (If A used rubber vibration damper can have a
visual wobble of the outer ring. When the vibration
Equipped) damper rotates, this wobble consists of movement
from the front to the rear. This does not call for a
replacement, because some wobble of the outer
ring is typical. Use the following procedure to make
sure that the wobble of the outer ring is acceptable:
1. Install a dial indicator, a contact point, or other

parts that are required to hold the dial indication
stationary.
Note: The contact point must be perpendicular (90

degree angle) to the face of the outer ring of the
rubber vibration damper. The contact point must
make contact near to the center of the outer ring.
2. Push on the front end of the crankshaft in order

to prevent any end play. End play would be
free movement on the centerline. You must keep
pressure on the crankshaft, until you complete
the measurements.
3. Set the dial indicator to a reading of 0.0 mm

Illustration 98
g00295949 (0.00 inch).
Rubber vibration damper
4. Turn the crankshaft by 360 degrees and watch
(1) Crankshaft
(2) Hub
the dial indicator. A total indicator reading
(3) Rubber of 0.00 to 2.03 mm (0.000 to 0.080 inch) is
(4) Ring acceptable.
(5) Alignment marks
Damage to the vibration damper or failure of the

vibration damper will increase vibrations. This will
result in damage to the crankshaft.
If any of the following problems with the rubber

vibration damper exist, replace the rubber vibration
damper:
Damaged
Bent
Worn bolt holes with loose fit for bolts
Crankshaft failure due to torsional forces
The rubber vibration damper displays alignment
marks on the hub and on the ring. These marks
indicate the condition of the rubber vibration
damper.
112
Viscous Vibration Damper
g00295962
Illustration 99
Viscous Vibration Damper
(1) Crankshaft
(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.
If any of the following problems with the viscous

vibration damper exist, replace the viscous vibration
damper:
Leaking
Damaged
Bent
Worn bolt holes with loose fit for bolts
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.
113
Electrical System Use the 4C-4911 Battery Load Tester in order

to test a battery that does not maintain a charge
when the battery is active. The 4C-4911 Battery
i01286207 Load Tester is a portable unit in a metal case. The
4C-4911 Battery Load Tester can be used under
Battery - Test field conditions and under high temperatures. The
tester can be used to load test all 6, 8, and 12
SMCS Code: 1401-081 Volt batteries. This tester has two heavy-duty load
cables that can easily be fastened to the battery
Most of the tests of the electrical system can be terminals. A load adjustment knob is located on the
done on the engine. The wiring insulation must be top of the tester. The load adjustment knob permits
in good condition. The wire and cable connections the current that is being drawn from the battery
must be clean, and both components must be tight. to be adjusted to a maximum of 1000 amperes.
The tester is cooled by an internal fan that is
automatically activated when a load is applied.
Never disconnect any charging unit circuit or bat- The tester has a built-in LCD. The LCD is a digital
tery circuit cable from the battery when the charg- voltmeter. The LCD is a digital meter that will
ing unit is operated. A spark can cause an explo- also display the amperage. The digital voltmeter
sion from the flammable vapor mixture of hydro- accurately measures the battery voltage at the
gen and oxygen that is released from the elec- battery through wires for tracing. These wires are
trolyte through the battery outlets. Injury to per- buried inside the load cables. The digital meter,
sonnel can be the result. that displays the amperage, accurately displays the
current that is being drawn from the battery which
is being tested.
The battery circuit is an electrical load on the
charging unit. The load is variable because of the Note: Refer to Operating Manual , SEHS9249 for
condition of the charge in the battery. detailed instruction on the use of the 4C-4911
Battery Load Tester. See Special Instruction,
NOTICE SEHS7633, Battery Test Procedure for the correct
The charging unit will be damaged if the connections procedures to use when you test the battery. This
between the battery and the charging unit are broken publication also contains the specifications to use
while the battery is being charged. Damage occurs when you test the battery.
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage i01286614
will damage the charging unit, the regulator, and other
electrical components. Belt Tension Chart
SMCS Code: 1357
Note: Do not use the belt tension chart for belts with
g00283565
Illustration 100
4C-4911 Battery Load Tester
114
Table 28
Belt Tension Chart
Borroughs Gauge
Gauge Reading
Numbers
Belt
of the Old the New
Initial(1) Used(2)
Gauge Gauge
i01380929 Test Tools For The Charging

Charging System - Test System
SMCS Code: 1406-081 Table 29
Tools Needed
The condition of charge in the battery at each
regular inspection will show if the charging system Part
Part Name Quantity
is operating correctly. An adjustment is necessary Number
when the battery is constantly in a low condition 8T-0900 Ammeter 1
of charge or a large amount of water is needed.
A large amount of water would be more than one 6V-7070 Digital Multimeter 1
ounce of water per cell per week or per every 100
service hours.
8T-0900 Ammeter
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 the
system. Off-engine testing or bench testing will give
a test of the charging unit and voltage regulator
operation. This testing will give an indication of
needed repair. After repairs are made, perform
a test in order to prove that the units have been
repaired to the original condition of operation.
g00296441
Illustration 101
8T-0900 Ammeter
115
The 8T-0900 Ammeter is completely portable. The 6V-7070 Digital Multimeter is a hand-held
This ammeter is a self-contained instrument that service tool with a digital display, that is completely
measures electrical currents without breaking the portable. This multimeter is built with extra protection
circuit and without disturbing the conductors against damage in field applications. The multimeter
insulation. is equipped with 7 functions and 29 ranges. The
6V-7070 Digital Multimeter has an instant ohms
The ammeter contains a digital display that is used indicator. This indicator permits checking continuity
to monitor current directly within a range between 1 for a fast inspection of the circuits. The multimeter
ampere and 1200 amperes. If an optional 6V-6014 can also be used for troubleshooting capacitors
Cable is connected between this ammeter and a that have small values.
digital multimeter, current readings can be viewed
directly from the display of the multimeter. This can Note: Refer to Special Instruction, SEHS7734 for
be accomplished under only one condition: complete information for the use of the 6V-7070
Digital Multimeter.
the readings are less than 1 ammeter.
A lever opens the ammeters jaws over a conductor.
Alternator Regulator
The conductors diameter can not be larger than
The charging rate of the alternator should be
19 mm (0.75 inch). checked when an alternator is charging the battery
too much. The charging rate of the alternator should
The spring loaded jaws close around the conductor
be checked when an alternator is not charging the
for measuring the current. A trigger switch controls battery enough.
the ammeter. The trigger switch can be locked into
the ON position or into the OFF position.
No adjustment can be made in order to change the
rate of charge on the alternator regulators. If the
After the trigger has been working and the trigger is
rate of charge is not correct, a replacement of the
turned to the OFF position, the reading appears in
regulator is necessary.
the digital display for five seconds. This accurately
measures currents in areas with a limited access.
See Special Instruction, REHS0354, Charging
For example, these areas include areas that are
System Troubleshooting for the correct procedures
beyond the operators sight. For DC operation, an to use to test the charging system. This publication
ammeter contains a zero control, and batteries
also contains the specifications to use when you
inside the handle supply the power.
test the charging system.
Note: Refer to Special Instruction, SEHS8420
for more information about using the 8T-0900
Ammeter.
6V-7070 Digital Multimeter
g00283566
Illustration 102
116
Tightening The Alternator Pulley Table 30
Nut Tools Needed

Part Number Part Name QTY
6V-7070 Digital Multimeter 1
g00283566
Illustration 104
g00283568
Illustration 103 The 6V-7070 Digital Multimeter is a hand-held
Tools For Tightening The Alternator Pulley Nut service tool with a digital display, that is completely
(1) 8T-9293 Torque Wrench. (2) 8S-1588 Adapter (1/2 inch portable. This multimeter is built with extra protection
female to 3/8 inch male). (3) 2P-8267 Socket Assembly. (4) against damage in field applications. The multimeter
8H-8517 Combination Wrench (1-1/8 inch). (5) 8T-5314 Socket. is equipped with 7 functions and 29 ranges. The
Tighten the nut that holds the pulley with the tools indicator. This indicator permits checking continuity
shown. Refer to the Specifications module for the for a fast inspection of the circuits. The multimeter
torque. can also be used for troubleshooting capacitors
that have small values.
i01382658
Note: Refer to Special Instruction, SEHS7734 for
Electric Starting System - Test complete information for the use of the 6V-7070
Digital Multimeter.
SMCS Code: 1450-081
Use the multimeter in the DCV range to find starting
Most of the tests of the electrical system can be system components which do not function.
done on the engine. The wiring insulation must be
in good condition. The wire and cable connections Move the start control switch in order to activate the
must be clean, and both components must be tight. starting solenoids. The starting solenoids operation
The battery must be fully charged. If the on-engine can be heard as the pinions of the starting motors
test shows a defect in a component, remove the are engaged with the ring gear on the engine
component for more testing. flywheel.
The starting system consists of the following If a solenoid for a starting motor will not operate,
components: it is possible that the current from the battery did
not reach the solenoid. Fasten one lead of the
Keyswitch multimeter to the terminal connection for the battery
cable on the solenoid. Touch the other lead to a
Starting motor solenoid good ground. A zero reading indicates that there
is a broken circuit from the battery. More testing is
Starting motor necessary when there is a voltage reading on the
multimeter.
117
The solenoid operation also closes the electric

circuit to the motor. Connect one lead of the
multimeter to the terminal connection of the solenoid
that is fastened to the motor. Touch the other lead
to a good ground. Activate the starting solenoid
and look at the multimeter. A reading of the battery
voltage shows that the problem is in the motor. The
motor must be removed for further testing. A zero
reading on the multimeter shows that the solenoid
contacts do not close. This is an indication of the
need for repair to the solenoid or an adjustment to
be made to the pinion clearance for the starting
motor.
Perform a test. Fasten one multimeter lead to the g00283572

terminal connection for the small wire at the solenoid Illustration 105
and fasten the other lead to the ground. Look at Connection for checking pinion clearance
the multimeter and activate the starting solenoid. A Typical example
voltage reading shows that the problem is in the (1) Ground terminal
solenoid. A zero reading indicates that the problem (2) Switch terminal
is in the start switch or the wires for the start switch. (3) Connector to the motor
Fasten one multimeter lead to the start switch at the 1. Install the solenoid without connector (3) from the
terminal connection for the wire from the battery. MOTOR connections (terminal) on the solenoid
Fasten the other lead to a good ground. A zero to the motor.
reading indicates a broken circuit from the battery.
Make a check of the circuit breaker and wiring. If 2. Connect a battery, that has the same voltage as
there is a voltage reading, the problem is in the start the solenoid, to the SW terminal (2).
switch or in the wires for the start switch.
3. Connect the other side of the battery to
Starting motors that operate too slowly can have an connector (3).
overload because of too much friction in the engine
that is being started. Slow operation of the starting 4. For a moment, connect a wire from the solenoid
motors can also be caused by a short circuit, loose connection (terminal), which is marked MOTOR,
connections and/or dirt in the motors. to the ground connection (terminal). The pinion
will shift to the crank position and the pinion will
stay there until the battery is disconnected.
i01335899
Engine Oil Pressure Sensor -

Test
SMCS Code: 1924-081
Refer to the Troubleshooting, RENR1367, PC-42:

Engine Oil Pressure Sensor Open Or Short Circuit
Test for information on checking the engine oil
pressure sensor.
i01285864
Pinion Clearance - Adjust Illustration 106 g00283574
SMCS Code: 1454-025 Typical example

(4) Shaft nut
(5) Pinion
Electric Starting Motor (6) Pinion clearance
When the solenoid is installed, make an adjustment 5. Push the pinion toward the end with the
of the pinion clearance. The adjustment can be commutator in order to remove free movement.
made with the starting motor removed.
6. Pinion clearance (6) must be 9.1 mm (0.36 inch).
118
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.
119
Index Section
Index
A Electrical System........................................... 65, 113
Charging System Components .......................... 67
Aftercooler - Test ................................................... 86 Engine Electrical System ................................... 66
Aftercooler Core Leakage .................................. 87 Grounding Practices .......................................... 65
Air System Restriction ....................................... 88 Starting System Components ............................ 67
Dynamometer Test............................................. 88 Electronic Control System Components................ 19
Turbocharger Failure .......................................... 88 Engine Crankcase Pressure (Blowby) - Test ......... 89
Visual Inspection................................................ 86 Engine Design ......................................................... 4
Air in Fuel - Test..................................................... 71 Engine Oil Pressure - Test..................................... 93
Air Inlet and Exhaust System .......................... 52, 79 Measuring Engine Oil Pressure ......................... 93
Air Inlet Heater ................................................... 54 Reason for High Engine Oil Pressure ................ 95
Turbocharger...................................................... 53 Reasons for Low Engine Oil Pressure ............... 94
Valve System Components................................ 54 Engine Oil Pressure Sensor - Test ...................... 117
Air Inlet and Exhaust System - Inspect.................. 79 Engine Oil Pump - Inspect..................................... 96
Air Inlet Restriction............................................. 79 Engine Speed - Check........................................... 72
Exhaust Back Pressure...................................... 80 Engine Valve Lash - Inspect/Adjust ....................... 89
Exhaust Restriction............................................ 80 Valve Lash and Valve Bridge Adjustment .......... 90
Valve Lash Check .............................................. 89
Excessive Bearing Wear - Inspect......................... 96
B Excessive Engine Oil Consumption - Inspect ........ 96
Oil Leakage Into Combustion Area Of
Basic Engine.................................................. 63, 107 Cylinders .......................................................... 96
Camshaft............................................................ 65 Oil Leakage On Outside Of Engine.................... 96
Crankshaft.......................................................... 64 Exhaust Temperature - Test................................... 85
Cylinder Block And Head ................................... 63
Piston, Rings And Connecting Rods.................. 63
Vibration Damper ............................................... 64 F
Battery - Test ....................................................... 113
Belt Tension Chart ............................................... 113 Finding Top Center Position for No. 1 Piston ......... 73
Flywheel - Inspect................................................ 108
Bore Runout (radial eccentricity) of the
C Flywheel ......................................................... 108
Face Runout (axial eccentricity) of the
Charging System - Test ....................................... 114 Flywheel ......................................................... 108
Alternator Regulator......................................... 115 Flywheel Housing - Inspect ................................. 109
Test Tools For The Charging System ............... 114 Bore Runout (Radial Eccentricity) of the Flywheel
Tightening The Alternator Pulley Nut ............... 116 Housing .......................................................... 109
Compression - Test................................................ 89 Face Runout (Axial Eccentricity) of the Flywheel
Connecting Rod Bearings - Inspect..................... 107 Housing .......................................................... 109
Cooling System ............................................... 60, 98 Fuel Quality - Test.................................................. 74
Coolant Conditioner (If Equipped)...................... 62 Fuel System..................................................... 23, 70
Coolant For Air Compressor (If Equipped)......... 62 Component Description ..................................... 24
Cooling System - Check (Overheating) ................. 98 Components of the HEUI Injector ...................... 37
Cooling System - Inspect..................................... 100 Fuel Heater And Water Separator (If Equipped).. 51
Cooling System - Test.......................................... 101 HEUI Fuel System Operation............................. 26
Checking the Filler Cap.................................... 103 Introduction ........................................................ 23
Making the Correct Antifreeze Mixtures........... 103 Operation of the HEUI Fuel Injector................... 41
Test For The Water Temperature Gauge ......... 105 Fuel System - Inspect............................................ 70
Test Tools For Cooling System ........................ 101 Checking The Operation Of Individual
Testing The Radiator And Cooling System For Cylinders .......................................................... 71
Leaks.............................................................. 104 Initial Inspection Of The Fuel System ................ 70
Cylinder Block - Inspect....................................... 107 Inspection With The Engine Running................. 71
Start Up Procedure ............................................ 70
Fuel System - Prime.............................................. 75
E Fuel System Pressure - Test ................................. 75
Electric Starting System - Test ............................ 116

G
Gear Group (Front) - Time..................................... 77

General Information........................................... 4, 14 V
Advantages of a Dedicated PTO.......................... 4
Cold Mode Operation......................................... 16 Vibration Damper - Check ................................... 111
Definition of Power Take-Off (PTO)...................... 6 Rubber Vibration Damper (If Equipped)........... 111
Installation Questionnaire .................................... 9 Viscous Vibration Damper ............................... 112
Instructions for the Operator of the PTO ............ 12
Operator of the PTO......................................... 10 W
Recommended Information for Operator of the
PTO.................................................................... 9 Water Pump - Test ............................................... 106
Starting The Engine ........................................... 15 Water Temperature Regulator - Test.................... 105
Truck Installation Diagram for The Switches and
The Components.............................................. 12
Glossary of Electronic Control Terms .................... 16

Increased Engine Oil Temperature - Inspect ......... 96
Inlet Manifold Pressure - Test ................................ 84
Lubrication System .......................................... 58, 93
Main Bearings - Inspect....................................... 107
Pinion Clearance - Adjust .................................... 117

Electric Starting Motor ..................................... 117
Piston Ring Groove - Inspect............................... 107
Systems Operation Section ..................................... 4
Testing and Adjusting Section ............................... 70
Turbocharger - Inspect........................................... 81
Inspection of the Compressor and the Compressor
Housing ............................................................ 82
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 83
Inspection of the Wastegate .............................. 83
Unit Injector - Test.................................................. 78
2001 Caterpillar
RENR1369-06
March 2001
Disassembly and
Assembly
BKD1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Vibration Damper and Pulley - Remove and Install

............................................................................. 58
Disassembly and Assembly Section Front Cover - Remove ........................................... 60
Fuel Filter Base - Remove ..................................... 5
Fuel Filter Base - Install ......................................... 6
Camshaft Idler Gear - Remove and Install ............ 62
Fuel Pressure Regulator - Remove and Install ....... 8
Valve Mechanism Cover Base - Remove and
Unit Injector - Remove ............................................ 9
Install ................................................................... 66
Unit Injector - Install .............................................. 12
Unit Injector Sleeve - Remove .............................. 16
Rocker Shaft - Disassemble ................................ 68
Unit Injector Sleeve - Install .................................. 17
Rocker Shaft - Assemble ..................................... 69
Remove ............................................................... 17
Disassemble ....................................................... 18
Camshaft - Remove .............................................. 74
Assemble ............................................................ 18
Install ................................................................... 19
Camshaft Bearings - Remove and Install ............ 77
Unit Injector Hydraulic Pump - Remove ................ 19
Air Inlet Heater - Remove and Install ................... 25
Air Inlet Heater Solenoid - Remove and Install .... 27
Air Inlet Cover - Remove and Install ..................... 27
Install ................................................................... 29
Install ................................................................... 31
Atmospheric Pressure Sensor - Remove and
Install ................................................................... 92
Coolant Temperature Sensor - Remove and
Install ................................................................... 93
Engine Oil Pressure Sensor - Remove and Install
............................................................................. 94
Engine Oil Temperature Sensor - Remove and Install
............................................................................. 95
Injection Actuation Pressure Sensor - Remove and
Install ................................................................... 96
Speed/Timing Sensor - Remove and Install ........ 97
Boost Pressure Sensor - Remove and Install ....... 98
Inlet Air Temperature Sensor - Remove and
Install ................................................................... 99
............................................................................. 43
Idler Pulley - Remove .......................................... 100
Flywheel - Remove ............................................... 44
Idler Pulley - Disassemble .................................. 100
Idler Pulley - Assemble ....................................... 101
Crankshaft Rear Seal - Remove ........................... 45
Idler Pulley - Install ............................................. 101
Belt Tensioner - Remove and Install ................... 102
Belt Tightener - Remove ..................................... 102
Equipped) ............................................................ 47
Belt Tightener - Disassemble .............................. 103
Crankshaft Wear Sleeve (Rear) - Install ............... 47
Belt Tightener - Assemble .................................. 103
Belt Tightener - Install ......................................... 104
Install ................................................................... 48
Fan Drive - Remove ........................................... 104
Flywheel Housing - Remove and Install ............... 49
Fan Drive - Install ................................................ 105
Rear Power Take-Off (RPTO) - Disassemble ........ 51
Engine Control Module - Remove and Install ..... 105
Rear Power Take-Off (RPTO) - Assemble ............ 54
Alternator - Remove and Install ......................... 106
Electric Starting Motor - Remove and Install ..... 106
4
Table of Contents
Air Compressor - Remove and Install ................ 107

Index Section
Index ................................................................... 113
5
Disassembly and Assembly

Section
i01405963
Fuel Filter Base - Remove

SMCS Code: 1262-011
Removal Procedure
Table 1
Required Tools
NOTICE
Keep all parts clean from contaminants. Illustration 1 g00612695
Contaminants may cause rapid wear and shortened 1. Use Tool (A) and remove fuel filter (1).
component life.
NOTICE

products.
g00612699
Illustration 2
mandates.
2. Disconnect tube assembly (2) and tube assembly
(4) from fuel filter base (5). Immediately cap all
openings or plug all openings in order to prevent
contamination.
3. Remove bolts (3) that hold fuel filter base (5) to

the mounting bracket. Remove fuel filter base (5).
6
i01405970 3. Install fuel filter (1). Refer to the Operation and

Maintenance Manual, Fuel System Secondary
Fuel Filter Base - Install Filter - Replace topic for more information.
SMCS Code: 1262-012 4. Prime the fuel system. Refer to the Operation
and Maintenance Manual, Fuel System - Prime
Installation Procedure topic for more information.
NOTICE i01153675
Fuel Transfer Pump - Remove
Removal Procedure
NOTICE

component life.
NOTICE
g00612699
Illustration 3 ing any compartment or disassembling any compo-
1. Position fuel filter base (5) on the mounting
bracket. Install bolts (3). Refer to Special Publication, NENG2500, Caterpillar
2. Connect tube assembly (2) and tube assembly suitable to collect and contain fluids on Caterpillar
(4) to the fuel filter base. products.

mandates.
g00612458
Illustration 5
1. Remove fuel outlet line (1) from fuel transfer

g00612695 pump (3). Immediately cap all openings or plug
Illustration 4
all openings in order to prevent contamination.
7
2. Cut nylon strap (2) that fastens the wiring 6. Remove O-ring seal (6) from the elbow. Inspect
harness to the unit injector hydraulic pump. O-ring seal (6) for wear or damage. If the O-ring
seal is worn or damaged, use a new part for
replacement.
i01153818

SMCS Code: 1256-012
NOTICE
g00612496
Illustration 6 Contaminants may cause rapid wear and shortened
component life.
3. Remove the bolts, clip (4) and fuel transfer pump
(3) from the unit injector hydraulic pump.
g00612518
Illustration 9
g00612507
Illustration 7
1. Clean all components and the mating surfaces.
4. Remove O-ring seal (5) from the unit injector Inspect all components. If any component is worn
hydraulic pump. Inspect O-ring seal (5) for or damaged, use a new part for replacement.
wear or damage. If the O-ring seal is worn or Install the elbows for the fuel inlet port and the
damaged, use a new part for replacement. fuel outlet port on the fuel transfer pump.
2. Install the O-ring seal (6).
g00612518
Illustration 8
g00612507
Illustration 10
5. Remove the elbows for the fuel inlet port and the
fuel outlet port from the fuel transfer pump.
3. Install O-ring seal (5) on the unit injector
hydraulic pump.
8
i01161376
Fuel Pressure Regulator -

Remove and Install
SMCS Code: 1715-010
Removal Procedure
g00612496
Illustration 11
4. Position fuel transfer pump (3) on the unit injector

hydraulic pump.
5. Install the bolts and clip (4). Tighten the bolts for
the fuel transfer pump to a torque of 25 3 Nm
(18 2 lb ft).
g00618385
Illustration 13
1. Remove fuel pressure regulator (1) from the rear

of the cylinder head.
g00612458
Illustration 12
6. Install fuel outlet line (1). Tighten the connectors

for the fuel inlet port and the fuel outlet port to a
torque of 17.5 2 Nm (13 1.5 lb ft). g00618383
Illustration 14
7. Secure the wiring harness to the fuel transfer
pump with a nylon strap. 2. Remove O-ring seal (2) from fuel pressure
regulator (1).
9
NOTICE

component life.
NOTICE
g00618383
Illustration 15 Refer to Special Publication, NENG2500, Caterpillar
1. Ensure that the orifice in fuel pressure regulator suitable to collect and contain fluids on Caterpillar
(1) is open and clean. Install a new O-ring seal products.
(2) on fuel pressure regulator (1).
mandates.
Table 3
Tools For Cleaning Carbon Deposits From
The Injector Sleeve Bores
Part Number Part QTY
Description
4C-5027 Tap Wrench 1
4C-6161 Tube Brush 1
4C-6774 Vacuum Gun Kit 1
g00618385 8T-7765 Hand Pad 1

Illustration 16
1U-5512 Cut & Polish Roll 1
2. Install fuel pressure regulator (1) in the rear of 9U-6102 Reamer 1
the cylinder head at a 10 degree angle from the
horizontal centerline. 9U-6862 Tapered Brush 1
Table 4
i01501703
Tools For Evacuating Fuel From The Cylinders
Unit Injector - Remove
Part Number Part Qty
SMCS Code: 1290-011 Description
4C-4057 Tube 1
Removal Procedure 1U-5718 Vacuum Pump 1
Table 2 1U-5814 Bottle Assembly 1
Required Tools
Part
Number
A 1U-7587 Pry Bar 1
Start By:

10
Removal Of The Injector 1. Remove oil drain plugs (8) at each end of the
cylinder head.
g00778847
Illustration 19
(2) Wiring Harness Connection
(3) Clamp
(9) Injection Actuation Pressure Sensor
(10) Shoulder Bolt
(11) Socket Head Bolt
2. Remove the Injection Actuation Pressure Sensor

(9).
3. Allow the engine oil to drain from the ports in the

cylinder head before the injector is removed.
g00293685
Illustration 17 4. Remove the harness connector (2) away from
(1) 128-6601 Solenoid Assembly the injector solenoids.
(2) Harness Connector
(3) Clamp
(4) O-Ring Seals
5. Remove the Shoulder Bolt (10) and the Socket
(5) 9Y-9025 Sleeve Head Bolt (11) from the clamp (3).
(6) Angled Seat
(7) 137-5621 Tip Assembly
g00294212
Illustration 20
g00777907
Illustration 18
(8) Oil Drain Plug
11
Steps For Cleaning The Carbon Deposits
g00778868
Illustration 23
(14) Metal Seal
Cleanliness is very important in the area around the

sleeve and the sleeve bore when you are reinstalling
the injector. This injector has a metal seal between
the bottom of the injectors case and a seat in the
cylinder head. Unlike the former designs which
were seated against a brass sleeve, this injector
seats in the cylinder head. Clean the carbon from
the seat area that is inside of the cylinder head.
g00778851 Also clean the carbon from the end of the injector if
Illustration 21 the injector should be reinstalled.
(12) Do not pry here.
(13) Tool (A) should be placed at this location in order to gently The fine grade of the Scotch Brite material is
remove the injector. preferred. Scotch Brite is available from the Tools
And Shop Products Guide as the 1U-5512 Cut &
6. Place Tool (A) under the clamp (13) on the Polish Roll and as the 8T-7765 Hand Pad.
flywheel side of the injector.
If the sleeve of the injector has been removed from
7. Use Tool (A) to remove the injector. the engine, use a 9U-6102 Reamer to remove
carbon deposits from the angled surface.
Note: Do not use the 9U-6102 Reamer in order to

remove metal from the sleeve. Use the 9U-6102
Reamer in order to remove carbon only.
If the sleeve of the injector is installed in the engine,

use the 4C-6161 Tube Brush to clean the carbon
deposits from the inside of the sleeve.
If you choose to clean the angled seat on the

injector with a wire brush, the wire brush should not
contact the tip of the injector. Failure of the tip and
major engine damage may result.
g00294208
Illustration 22 Note: Using power tools in order to rotate the
(4) O-Ring Seals material should not be necessary. The carbon in
the sleeve is more removable than the carbon at
8. Remove the O-Ring seals (4) from the injector. locations that are exposed to higher temperatures.
9. Repeat Step 4 through Step 8 for the remainder The following procedure is the preferred method of
of the injectors. cleaning the sleeve bore.
1. Place a 38 mm (1.5 inch) square piece of Scotch

Brite material on the end of a 9U-6862 Tapered
Brush.
12
2. Twist the 9U-6862 Tapered Brush with the

4C-5027 Tap Wrench against the lower surface
of the sleeve bore.
3. The surface should be cleaned until the surface

is smooth and shiny. The entire sleeve bore
should be cleaned in order to remove any loose
carbon particles.
Note: A 4C-6774 Vacuum Gun Kit is available in

order to clean the loose material from the sleeve
bore.
Evacuation Of Fuel And Oil From The

Cylinder
Evacuate as much fuel and oil as possible from
the cylinder before installation of the injector. Use
the 1U-5718 Vacuum Pump, 1U-5814 Bottle
Assembly, and the 4C-4057 Tube to evacuate the
fuel. Several evacuations may be necessary. g00777907
Illustration 24
i01501732 1. Install oil drain plugs (8).

Unit Injector - Install
SMCS Code: 1290-012
Table 5
Required Tools
Part
Number
A 149-2955 Seal Protector 1
B 149-2956 Seal Installer 1
g00779451
Illustration 25
C 152-1057 Fuel Injector Installer 1
2. Install Injection Actuation Pressure Sensor (9).
NOTICE

component life.
NOTICE
The correct procedures and tooling specifications
must always be used. Failure to follow any of the
procedures may result in damage, malfunction, or
possible engine failure.
13
g00778880
Illustration 26
This is an illustration of the 154-8016 Fuel Injector Seals.
(14) Metal Seal (17) 9X-7557 O-Ring Seal (20) 109-3207 O-Ring Seal
(15) 133-3715 Backup Ring (18) 148-2903 O-Ring Seal
(16) 150-4105 Backup Ring (19) 149-5240 Backup Ring
14
Note: Proper installation of the injector is very

important. Damage to the upper high pressure seals
can cause excessive oil leakage under the valve
cover. This may cause the engine not to start due
to a low actuation pressure. Damage to the lower
high pressure seals may allow high pressure oil to
leak into the fuel supply passage. This will result in
excessive oil consumption.
g00638512
Illustration 27
(A) 149-2955 Seal Protector
g00621566
Illustration 29
(X) 8T-2396 Bolts.
g00638506
Illustration 28 (Y) 159-0288 Deflector.
(B) 149-2956 Seal Installer
Note: Some of these engines were built without the
159-0288 Deflector. During the installation of the
NOTICE
unit injectors, the deflectors should be installed. Six
The correct procedures and tooling specifications
159-0288 Deflectors and six 8T-2396 Bolts are
must always be used. Failure to follow any of the
required for each engine. These new deflectors and
procedures may result in damage, malfunction, or
bolts replace the former 6V-8653 Bolts.
possible engine failure.
Note: Install the upper seal pack first. Then install

the middle seal pack. Finally, install the bottom
O-Ring Seal.
3. Both the 149-2955 Seal Protector (A) and the

149-2956 Seal Installer (B) should be used
when you are installing the upper high pressure
seals.
Note: New seals should be installed after each

removal of the injector from the engine.
4. Lubricate the O-Ring seals and the sleeve bore

g00294210
of the injector sparingly with clean engine oil. Illustration 30
15
7. Insert the harness connectors (2) back into the

injectors solenoids. Ensure that the clips are
snapped back into the proper position.
8. Check the system for leaks by using the following

procedure.
Check the Fuel System for Leaks

1. Visually inspect the components of the injector
for oil leaks around the outside diameter.
g00312124
Illustration 31
(C) 152-1057 Fuel Injector Installer
5. Carefully install the injector into the injector bore.

If access permits you to seat the injector, push
the injector straight down on top of the injectors
solenoid by hand until the injector is firmly
seated in the injector bore. Pushing hard enough
to compress the injectors seals may be difficult.
If the injector can not be seated by hand, use a
152-1057 Fuel Injector Installer (C).
g00778891
Illustration 33
Note: Do NOT pry on the top of the injector with
another tool. Do NOT strike the injector with a 2. Disconnect the injector wiring harness with
hammer. Damage to the injector will result. Damage the 12-pin connector (20). The harness is
to the injector that is due to improper installation is located between the hydraulic pump and the
not a warrantable failure. cylinder head. Disconnect the Injection Actuation
Pressure Sensors connector. This will cause the
oil pressure to raise to about 2500 psi.
3. Crank the engine in order to allow the actuation

pressure to rise. Cranking the engine also purges
the air from the system.
4. Visually check for oil leaks in the area that is

between the outside diameter of the injector and
the cylinder block.
Note: A small amount of seepage from the injectors

vent hole during cranking is normal. A large steady
flow from one injector that is greater than the flow
g00778888 from the other injectors may indicate a problem with
Illustration 32
that injector.
(2) Wiring Harness Connection
(3) Clamp
(10) Shoulder Bolt
5. If no leaks are found, connect the injector wiring
(11) Socket Head Bolt harness (20) and the Injection Actuation Pressure
Sensor.
Note: Do not use the shoulder bolt and the socket
head bolt in order to seat the injector. If a side load 6. Start the engine.
is placed on the bolts, the bolts may fail.
7. Check for oil leaks while the engine is running
6. After the injector is seated, position the clamp at idle.
(2) and tighten the Shoulder Bolt (10) to a torque
of 6 Nm (50 lb in). Then tighten the Socket Head 8. If no leaks are found, install the ET or other
Bolt (11) to a torque of 12 Nm (9 lb ft). electronic service.
16
9. Test the actuation pressure. Increase the

actuation pressure to the maximum pressure
(approximately 3300 psi).
10. If no leaks are found, check the crankcase oil

level. Supply the proper amount of oil to the
crankcase.
End By:
a. Install the valve mechanism cover. Refer to

g00616609
i01155473 Illustration 34
Unit Injector Sleeve - Remove

SMCS Code: 1713-011
Removal Procedure
Table 6
Required Tools
Part
Number
A 151-4832 Injector Sleeve Tool 1
g00616610
Start By: Illustration 35
(1) Nut
a. Remove the unit injectors. Refer to Disassembly (2) Washer
(3) Bearing
and Assembly, Unit Injector - Remove. (4) Washer
(5) Sleeve
(6) Threaded rod assembly
NOTICE (7) Unit injector sleeve
Keep all parts clean from contaminants. (X) Threaded part of the rod assembly
(Y) Expandable part of the rod assembly
component life.
NOTICE

products. g00616556
Illustration 36

mandates.
17
1. Install threaded rod assembly (5) in the unit

injector sleeve. Seat expandable part of
rod assembly (Y) in the unit injector sleeve.
Rotate threaded part of rod assembly (X) in a
counterclockwise direction while expandable
part of the rod assembly (Y) is held in position.
g00616586
Illustration 37 Illustration 38 g00614968
2. Install the remaining parts of Tool (A) on threaded 1. Install two new O-rings (2) on unit injector sleeve
rod assembly (5). (1).
3. Tighten nut (1) in order to remove unit injector 2. Place unit injector sleeve (1) on Tool (A).
sleeve (7) from the cylinder head.
3. Lubricate the new O-rings with clean engine
i01156694 oil and position the unit injector sleeve in the
cylinder head.
Unit Injector Sleeve - Install
4. Install unit injector sleeve (1) in the cylinder head
SMCS Code: 1713-012 with a hammer.
End By:
Table 7 a. Install the unit injectors. Refer to Disassembly
Required Tools
Part
Tool Part Description Qty i01405993
Number
A 150-3152 Sleeve Installer 1 Injection Actuation Pressure
Control Valve - Remove
NOTICE
Keep all parts clean from contaminants. SMCS Code: 5051-011
Contaminants may cause rapid wear and shortened Removal Procedure

component life.
Table 8
Required Tools
NOTICE

component life.
18
i01405996
NOTICE
Care must be taken to ensure that fluids are contained Injection Actuation Pressure
during performance of inspection, maintenance, test- Control Valve - Disassemble
collect the fluid with suitable containers before open- SMCS Code: 5051-015
products.

mandates.
g00762956
Illustration 40
(4) Solenoid valve
(5) Spacer
(6) Nut
1. Remove O-ring seals (3) and (2), and backup

ring (1) from the injection actuation pressure
g00762946
control valve. Inspect the components of the
Illustration 39 injection actuation pressure control valve for
wear or damage. If any part is worn or damaged,
1. Disconnect wiring harness plug (2) from injection use a new part for replacement.
actuation pressure control valve (1).
2. Remove nut (3), spacer (5), and solenoid valve i01405998

(4) from injection actuation pressure control valve
(1). Injection Actuation Pressure
Control Valve - Assemble
3. Use Tool (A) and an extension in order to remove
the injection actuation pressure control valve SMCS Code: 5051-016
from the unit injector hydraulic pump.
Assembly Procedure
NOTICE

component life.
19
g00763009 g00762946
(4) Solenoid valve
(5) Spacer 1. Use Tool (A) in order to install the injection
(6) Nut actuation pressure control valve on the unit
injector hydraulic pump. Tighten the injection
1. Clean the injection actuation pressure control actuation pressure control valve (1) to a torque
valve and the components for the injection of 50 5 Nm (37 4 lb ft).
2. Install solenoid valve (4), spacer (5), and nut (3)
2. Install new O-ring seals (3) and (2), and backup on the injection actuation pressure control valve
ring (1) on the injection actuation pressure (1). Tighten nut (3) to a torque of 5.5 1.5 Nm
control valve. Lubricate the O-ring seals with (49 13 lb in).
clean engine oil.
3. Reconnect wiring harness plug (2) to the
injection actuation pressure control valve (1).
i01406008
Injection Actuation Pressure i01477891

Control Valve - Install Unit Injector Hydraulic Pump -
SMCS Code: 5051-012 Remove
Installation Procedure SMCS Code: 1714-011
Table 9 Removal Procedure

Required Tools
Table 10
Required Tools
Part
Number
NOTICE A 5P-0327 Crowfoot Wrench 1
B 180-0186 Removal Tool 1
component life.
NOTICE

component life.
20
NOTICE

products.

mandates.
Note: If the engine is equipped with a 151-0858

Tube then proceed to 1. If the engine is equipped
with a 175-3236 Hose Assembly then go to 3.
g00706904
Illustration 44
(Type II) 175-3236 Hose Assembly
g00616113
Illustration 43
(Type I) 151-0858 Tube
g00769688
Illustration 45
1. Use Tool (A) in order to remove tube (1) and fuel
line (2).
3. Insert Tool (B) on the hose side of the rubber
2. Disconnect electrical plugs (3) and (4). Proceed boot on hose assembly (7). Push the rubber
to Step 5. boot toward the fitting in order to remove hose
assembly (7). Use Tool (A) to remove fuel line (2).
Note: If Tool (B) is not available, screwdrivers

that are medium sized may be used. Insert the
screwdrivers on each side of the rubber boot and
move the rubber boot toward the fitting. This will
allow the removal of hose assembly (7).
4. Disconnect electrical plug (4).

21
5. Remove return line (6) from the engine block i01335912

and fitting (5).
Unit Injector Hydraulic Pump
- Install
SMCS Code: 1714-012
Table 11
Required Tools
Part
Number
NOTICE

component life.
g00706976
Illustration 46
6. Cut nylon strap (9) that fastens the wiring

harness to unit injector hydraulic pump (8).
7. Remove three bolts (10) and remove unit injector

hydraulic pump (8) from the timing gear housing.
g00706978
Illustration 48
1. Position drive gear (14) on the unit injector

hydraulic pump. Install bolt (12) and washer (13)
on the unit injector hydraulic pump. Tighten bolt
(12) to a torque of 110 14 Nm (81 10 lb ft).
g00706978 2. Lubricate O-ring seal (11) with clean engine

Illustration 47
oil. Install the O-ring seal on the unit injector
hydraulic pump.
8. Remove O-ring seal (11) from unit injector
hydraulic pump (8). Inspect the O-ring seal for
wear or damage. If the O-ring seal is worn or
damaged, use a new part for replacement.
9. Remove bolt (12) and washer (13). Remove drive

gear (14). Inspect the drive gear for wear or
damage. Replacethe drive gear, if necessary.
22
6. Secure the wiring harness to the unit injector

hydraulic pump with a nylon strap. Connect
electrical plugs (3) and (4).
Note: Use the following steps in order to convert the

engine from the 151-0858 Tube to the 175-3236
Hose Assembly.
7. Remove the connectors for the 151-0858 Tube

that are located in the unit injector hydraulic
pump and the cylinder head.
8. Position the 153-4906 O-Ring Seal on the

threaded end of each 179-7002 Adapter. Install
the adapters in the unit injector hydraulic pump
and the cylinder head.
Note: When you replace the 151-0858 Tube with

175-3236 Hose Assembly the fuel supply line
must be replaced in order to provide the necessary
clearance.
g00706976
Illustration 49
Note: The following steps are for engines that are
3. Position unit injector hydraulic pump (8) on the equipped with the 175-3236 Hose Assembly.
timing gear housing. Install three bolts (10) and
tighten three bolts (10) to a torque of 28 7 Nm
(20 5 lb ft).
Note: If the engine is equipped with a 175-3236

Hose Assembly then go to Step 9. If the engine
is equipped with a 151-0858 Tube then proceed
with Step 4. If you are converting the engine from
151-0858 Tube to 175-3236 Hose Assembly then
go to Step 7.
g00706904
Illustration 51
9. Install return line (6) and fitting (5).
10. Reconnect electrical plug (4).
NOTICE
If the hose is not correctly connected the hose will
come loose when the engine is started and the en-
gine oil will come out of the hose. Engine damage can
g00616113
Illustration 50 result.
4. Install return line (6) and fitting (5).
5. Install tube (1) and fuel line (2).

23
NOTICE
Leakage of the high pressure engine oil lines can re-
sult in failure of the engine fuel system.
11. Install hose assembly (7) and lock the hose

assembly in position. Apply pressure in order to
snap the hose assembly into the quick coupling
for each of the ends.
Note: Be sure to check the connection by pulling

back on the hose.
i01160174
SMCS Code: 1052-011
NOTICE 1. Remove bolts (1) and the gasket. Remove bolts

Keep all parts clean from contaminants. (3) and tube assembly (2) from the turbocharger.
component life.
NOTICE

suitable to collect and contain fluids on Caterpillar g00617565
Illustration 53
products.
2. Remove the bolts and the gasket in order to
disconnect oil supply tube assembly (5) from the
mandates.
turbocharger.
3. Remove four nuts (4), turbocharger (6) and the

gasket from the exhaust manifold.
24
i01334762
Turbocharger - Install
SMCS Code: 1052-012
NOTICE

component life.
1. Inspect the turbocharger gasket for wear or

damage. If the turbocharger gasket is worn or
damaged, use a new part for replacement.
2. Apply 5P-3931 Anti-Seize Compound on

the threads of the mounting studs for the
turbocharger. Illustration 55 g00617515
5. Inspect the gaskets for oil supply tube assembly

(5) and tube assembly (2). If the gaskets are worn
or damaged, use a new part for replacement.
6. Position tube assembly (2) and the gasket

on turbocharger (6). Install bolts (1) on the
turbocharger and install bolts (3) on the cylinder
block.
7. Install the gasket for oil supply tube assembly

(5) and connect oil supply tube assembly (5) to
turbocharger (6).
g00617565
3. Position the turbocharger gasket and Exhaust Manifold - Remove

turbocharger (6) on the exhaust manifold. Install and Install
nuts (4) that fasten turbocharger (6) to the
exhaust manifold. SMCS Code: 1059-010
4. Tighten the locknuts that fasten the turbocharger
to the exhaust manifold. Removal Procedure
Tighten the 3E-8017 Locknut with the Spiralock Start By:
thread to the following torque: .......... 54 5 Nm
(40 4 lb ft) a. Remove the turbocharger. Refer to Disassembly
Tighten the standard 9X-6620 Locknut to the
following torque: .......... 70 5 Nm (50 4 lb ft)
25

threads of bolts (1). Position the gaskets and
exhaust manifold (2) on the cylinder head
assembly. Install locks (3) and bolts (1).
g00617696
Illustration 56
1. Remove bolts (1), locks (3), exhaust manifold

(2), and the gaskets from the cylinder head
assembly. Illustration 58 g00617739
2. Disassemble exhaust manifold (2) into three 7. Tighten bolts (1) in a numerical sequence to a
pieces. torque of 4 1 Nm (35 9 lb in).
3. Remove mounting studs (4) from exhaust 8. Tighten bolts (1) in a numerical sequence to a
manifold (2), if necessary. torque of 45 5 Nm (33 4 lb ft).
Installation Procedure 9. Bend the locking tab over the flat of each bolt
head.
gasket, if necessary. End By:

and Assembly, Turbocharger - Install.
i01340727
Air Inlet Heater - Remove and

Install
SMCS Code: 1090-010
Removal Procedure
g00617696
Illustration 57

threads of mounting studs (4).
3. Install mounting studs (4). Tighten mounting

studs (4) to a torque of 35 5 Nm (26 4 lb ft).
4. Install new exhaust manifold gaskets.
5. Apply a thin coat of 2P-2333 High Temperature

Sealer to the male ends of exhaust manifold (2).
Coat the inside of the female ends of exhaust
g00618197
manifold (2) with clean engine oil. Assemble Illustration 59
exhaust manifold (2) and remove the excess
sealer from the joints. 1. Remove oil level gauge (1).
26
2. Disconnect plug (2) from the air temperature

sensor.
g00618201
Illustration 62
g00618201 3. Position air inlet heater (8) and air inlet elbow
Illustration 60
(6) on the air inlet cover.
3. Disconnect wire (3) from the solenoid of the air
inlet heater.
4. Remove ground strap (5) from the air inlet cover.
5. Remove hose (7) from air inlet elbow (6).
6. Remove eight bolts (4). Remove air inlet elbow

(6) and the air inlet heater.
g00709111
Illustration 63
4. Position oil level gauge (1) and install eight bolts

(4).
5. Connect ground strap (5) to the air inlet cover.
6. Connect wire (3) to the solenoid of the air inlet

heater. Tighten the nut to a torque of 6 0.5 Nm
(53 4 lb in).
Illustration 61
g00618206 7. Connect plug (2) to the air temperature sensor.
1. Clean the joint face on air inlet heater (8) with 8. Install hose (7) on air inlet elbow (6).
solvent. Apply 4C-9500 Quick Cure Primer on
the joint face. Allow the primer to air dry for a
minimum of three to five minutes.
2. Apply 1U-8846 Sealant to the joint face of

air inlet heater (8) and on the joint face of air
inlet elbow (6). Air inlet heater (8) and air inlet
elbow (6) must be installed within ten minutes of
application of the sealant.
27
i01161333 i01161352
Air Inlet Heater Solenoid - Air Inlet Cover - Remove and

Remove and Install Install
SMCS Code: 1090-010-OD SMCS Code: 1087-010-CH
Removal Procedure Removal Procedure

Start By:
a. Remove the air inlet heater. Refer to Disassembly

Install.

Install.
g00618344
Illustration 64
1. Remove nut (1) in order to disconnect the wire

assembly from air inlet heater solenoid (3).
Disconnect plug (2) from the wiring harness.
2. Remove two bolts (4) and remove air inlet heater

solenoid (3).

g00618364
1. Disconnect plug (2) for the boost sensor.
2. Remove four bolts and mounting bracket (1) for

the fuel filter base.
3. Remove four bolts and air inlet cover (3).
g00618344
Illustration 65
1. Position air inlet heater solenoid (3) and install

two bolts (4).
2. Connect plug (2) to the wiring harness. Install

the wire assembly to air inlet heater solenoid
(3). Tighten nut (1) to a torque of 6.0 0.5 Nm
(53 4 lb in).
g00618364
Illustration 67
1. Inspect the gasket for air inlet cover (3). Replace

the gasket, if necessary.
28
2. Position air inlet cover (3), mounting bracket (1)

for fuel filter base, and the wiring clip on the
cylinder head. Install eight bolts.
3. Connect plug (2) for the boost sensor.
End By:

Install.
b. Install the air inlet heater. Refer to Disassembly

Install. g00617268
Illustration 68
i01160097 Note: The following components of the exhaust are

different from the components of the inlet: spring
Inlet and Exhaust Valves - retainer (5), valve spring (4), and valve (2).
Remove and Install
1. Use Tool (A) to compress valve spring (4).
SMCS Code: 1105-010 Remove retainer lock (6) and spring retainer (5).
2. Remove Tool (A). Remove valve spring (4) and

Removal Procedure washer (3).
Table 12
3. Remove valve seal (1) and valve (2).
Required Tools
Part 4. Repeat Steps 1 through 3 in order to remove the
Tool Part Description Qty remaining inlet valves and exhaust valves.
Number
Start By: Table 13
Required Tools
a. Remove the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head - Part
Remove. Number
NOTICE
NOTICE
Contaminants may cause rapid wear and shortened Keep all parts clean from contaminants.
component life.
component life.
29
i01157075
Inlet and Exhaust Valve Guides

SMCS Code: 1104-010
Removal Procedure
Table 14
Required Tools
Part
Number
g00617268
Illustration 69 A 1U-7793 Valve Guide Driver 1
1. Lubricate valve (2) with clean engine oil. Install B 9U-6895 Valve Guide Driver 1
valve (2) in the cylinder head assembly. Install
new valve seal (1) against the valve guide. Start By:
2. Place the following items on the valve stem: a. Remove the inlet and exhaust valves. Refer to
washer (3), valve spring (4), and spring retainer Disassembly and Assembly, Inlet and Exhaust
(5). Valves - Remove and Install.
NOTICE
when the valve spring compressor is released. En- Contaminants may cause rapid wear and shortened
sure that the valve keepers are properly installed component life.
on the valve stem. To help prevent personal injury,
Note: A small amount of grease can be used to hold

the retainer locks in position during installation.
3. Use Tool (A) to compress valve spring (4). Install

retainer lock (6).

End By:
g00615075
Illustration 70
a. Install the cylinder head assembly. Refer to
Disassembly and Assembly, Cylinder Head -
Install. 1. Use Tool (A) to remove the inlet valve guides
from the cylinder head assembly. Use Tool (B)
to remove the exhaust valve guides from the
30
Table 15
Required Tools
Part
Number
A 1U-7793 Valve Guide Driver 1
B 9U-6895 Valve Guide Driver 1
C 1U-7792 Guide Collar 1
D 149-4008 Guide Collar 1
NOTICE

component life.
g00615087
Illustration 72
3. Position exhaust valve guide (2) and tap on the

top of exhaust alve guide (2). This is done in
order to start the exhaust valve guide into the
4. Use Tool (B) and Tool (D) to install exhaust valve

guide (2). Install exhaust valve guide (2) until the
End By:
a. Install the inlet and exhaust valves. Refer to

g00615080
Illustration 71
1. Position inlet valve guide (1) and tap on the top

of inlet vave guide (1). This is done in order to
start inlet valve guide (1) into the cylinder head
assembly.
2. Use Tool (A) and Tool (C) to install inlet valve

guide (1). Install inlet valve guides (1) until the
31
i01157654

SMCS Code: 1103-010
Removal Procedure
Table 16
Required Tools
Part
Number
A(1) 6V-4194 Valve Seat Extractor 1
B(1) 6V-4193 Valve Seat Extractor 1
C(1) 6V-4804 Handle 1
D(1) 6V-4192 Shaft 1
E(1) 6V-4199 Lifting Bracket 1 Illustration 74 g00615525
(1) Part of the 6V-4805 Valve Seat Extractor Tool Group
Note: Replace Tool (A) with Tool (B) for the removal
Start By: of the inlet valve seat insert.
a. Remove the inlet and exhaust valves. Refer to 1. Install Tool (A) in the exhaust valve seat insert.
Valves - Remove and Install. 2. Install Tool (C) and Tool (D) in Tool (A). Hand
tighten Tool (D). Tool (A) will expand below the
NOTICE edge of valve seat insert (1).

component life.
g00615519
Illustration 73
g00615542
Illustration 75
3. Install Tool (E) on the cylinder head under

Tool (C). Hold Tool (D) while you turn Tool (C).
Remove valve seat (1).
32
Table 17 Engine Oil Filter Base -

Required Tools Remove
Part
Tool Part Description Qty SMCS Code: 1306-011
Number
A 149-6115 Valve Seat Installer 1
Removal Procedure
B 7N-1819 Valve Guide 1
Table 18
Required Tools
NOTICE
Keep all parts clean from contaminants. Part
Number
component life.
NOTICE

component life.
NOTICE

products.

g00615567
Illustration 76 mandates.
1. Turn Tool (A) upside-down and use Tool (A) and

a press to install the valve seat inserts in the
End By:

g00614994
Illustration 77

33
g00614997 g00615003
2. Disconnect tube (2) from the elbow assembly. 1. Remove plugs (2) from engine oil filter base (1).
3. Remove the bolts that hold engine oil filter base

(3) to the cylinder block. Remove engine oil filter
base (3).
i01156967

Disassemble
SMCS Code: 1306-015
g00615004
Illustration 80
Start By:
a. Remove the engine oil filter base. Refer to 2. Remove valve springs (4) and valves (3) from
Disassembly and Assembly, Engine Oil Filter engine oil filter base (1). Remove O-ring seals
(5) from plugs (2).
Base - Remove.
NOTICE i01156991
Contaminants may cause rapid wear and shortened Assemble
component life.
SMCS Code: 1306-016
NOTICE
Care must be taken to ensure that fluids are contained Assembly Procedure
ing, adjusting and repair of the product. Be prepared to NOTICE
collect the fluid with suitable containers before open- Keep all parts clean from contaminants.
nent containing fluids. Contaminants may cause rapid wear and shortened
component life.
suitable to collect and contain fluids on Caterpillar 1. Inspect the condition of the O-ring seals.
products. Replace the O-ring seals, if necessary. The
contact surfaces of the O-ring seals must be
Dispose of all fluids according to local regulations and clean and dry.
mandates.
34
NOTICE

component life.
g00615004
Illustration 81
2. Install O-ring seals (5) on plugs (2). Apply clean

engine oil on O-ring seals (5).
g00614997
Illustration 83
1. Position the gasket and engine oil filter base

(3) over the engine oil cooler. Install the bolts
that hold engine oil filter base (3) to the cylinder
block. Tighten the bolts to a torque of 28 7 Nm
(21 5 lb ft).
2. Connect tube (2) to engine oil filter base (3).
g00615003
Illustration 82
3. Apply clean engine oil on valves (3). Install

valves (3), springs (4), and plugs (2) in engine
oil filter base (1).
End By:

Base - Install.
g00614994
Illustration 84
i01156954
3. Install oil filter assembly (1) with Tool (A). Follow
Engine Oil Filter Base - Install the instructions with the oil filter assembly for the
correct installation.
SMCS Code: 1306-012
Table 19
Required Tools
Part
Number
35
i01336679 i01336717
Engine Oil Pump - Remove Engine Oil Pump - Disassemble

Removal Procedure Disassembly Procedure

Start By: Table 20
Required Tools
a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and Part
Install. Number
5P-7311 Chain Puller 1
NOTICE A 7S-7786 Puller Leg 2
5F-7345 Screw 1
component life. Start By:
NOTICE a. Remove the engine oil pump. Refer to

Care must be taken to ensure that fluids are contained Disassembly and Assembly, Engine Oil Pump -
during performance of inspection, maintenance, test- Remove.
collect the fluid with suitable containers before open- NOTICE
ing any compartment or disassembling any compo- Keep all parts clean from contaminants.
Refer to Special Publication, NENG2500, Caterpillar component life.
products. NOTICE
Dispose of all fluids according to local regulations and during performance of inspection, maintenance, test-
mandates. ing, adjusting and repair of the product. Be prepared to

products.

mandates.
g00614391
Illustration 85
1. Remove two bolts (1) and bolt (2).
2. Remove the engine oil pump.
3. Remove the O-ring seal that is located between

the cylinder block and the outlet elbow.
g00614664
Illustration 86
36
1. Remove the two bolts, oil pickup tube (2), and

the gasket from the engine oil pump. Remove
one bolt and outlet elbow (1) from the engine
oil pump.
g00614689
Illustration 89
6. Remove four bolts (10). Separate oil pump body

(9) from oil pump body assembly (7).
g00614677
Illustration 87
2. Remove bolt (3), washer (4), and idler gear (5)

from the engine oil pump.
g00614694
Illustration 90
NOTICE
Before removing the drive shaft from the pump hous-
g00614683
Illustration 88 ing, be sure that no burrs exist on the drive shaft. If
3. Remove the bearing from idler gear (5) with Tool housing may be scratched.
(A).
4. Remove shaft (6) of engine oil pump from oil 7. Remove shaft assembly (11) and shaft assembly
pump body assembly (7). (12) from oil pump body (9).
5. Use Tool (A) to remove drive gear (8).
g00614696
Illustration 91
37
8. Remove the following items from oil pump body

assembly (7): bolt and washer, spring (14), and
oil pressure relief valve (13)
i01336699

SMCS Code: 1304-016
Assembly Procedure
NOTICE
Keep all parts clean from contaminants. Illustration 94 g00614689
Contaminants may cause rapid wear and shortened 3. Install shaft assembly (12) in oil pump body (9).
component life.
1. Ensure that all of the parts of the engine oil pump
are thoroughly clean prior to assembly. 5. Position oil pump body (9) on oil pump body
assembly (7) and install bolts (10).
Note: Lubricate all internal parts of the engine oil
g00614683
Illustration 95
Illustration 92
g00614696 6. Press drive gear (8) on shaft assembly (11)
until drive gear (8) is flush with the end of shaft
2. Install oil pressure relief valve (13) and spring assembly (11).
(14) in oil pump body (7). Install the washer and
the bolt. 7. Install oil pump shaft (6). Install the bearing
in idler gear (5). Install the bearing so the
distance between the hub bolt face of idler
gear (5) and the bearing is 0.75 0.25 mm
(0.030 0.010 inch).
g00614694
Illustration 93
38
i01156435
Engine Oil Pump - Install

SMCS Code: 1304-012
NOTICE

component life.
g00614677
Illustration 96 Note: Ensure that the mounting surfaces for the
engine oil pump are thoroughly clean.
8. Install idler gear (5) on oil pump shaft (6). Install
washer (4) and bolt (3). Tighten bolt (3) to 1. Inspect the condition of the O-ring seal. Replace
70 15 Nm (52 11 lb ft). the seal, if necessary.
2. Install the O-ring seal. Position the engine oil

pump on the cylinder block.
g00614664
Illustration 97
9. Check the condition of the gasket that is used in

oil pickup tube (2). If the gasket is damaged, Illustration 98
g00614391
replace the gasket. Install the gasket and oil
pickup tube (2). 3. Install two bolts (1) and bolt (2).
10. Check the condition of the O-ring seal that is End By:
used in outlet elbow (1). If the O-ring seal is
damaged, replace the O-ring seal. Install the a. Install the engine oil pan. Refer to Disassembly
O-ring seal and outlet elbow (1). and Assembly, Engine Oil Pan - Remove and
Install.
End By:

39
i01155966
Water Pump - Remove

SMCS Code: 1361-011
Removal Procedure
Start By:

Install.
g00614170
Illustration 99
Personal injury can result from hot coolant, steam 2. Remove water pump V-belt (1).
and alkali.
3. Loosen hose clamps (4) and remove hose (3).
and under pressure. The radiator and all lines 4. Disconnect hose (2) from the water pump elbow.


burns.

g00614173
Illustration 100
NOTICE
Keep all parts clean from contaminants. 5. Remove four bolts (6) that hold water pump (5) to
the front of the engine. Remove water pump (5).
component life. 6. Remove the O-ring seals from water pump (5),
if necessary.
NOTICE
Care must be taken to ensure that fluids are contained i01156239
ing, adjusting and repair of the product. Be prepared to Water Pump - Disassemble
ing any compartment or disassembling any compo- SMCS Code: 1361-015
Tools and Shop Products Guide for tools and supplies Table 21
suitable to collect and contain fluids on Caterpillar Required Tools
products.
Part
Dispose of all fluids according to local regulations and Number
mandates. A 1P-0510 Driver Group 1
40
Start By: 3. Push the shaft and pulley (3) out of impeller (4)
with a suitable drive plate from Tool (A) and a
a. Remove the water pump. Refer to Disassembly press. Remove the impeller.
NOTICE

products.
g00614238
Illustration 103
mandates.
Note: Do not allow the shaft and the pulley to fall to
the floor when the shaft and the pulley are removed.
4. Continue to push the shaft and pulley (3) out of

seal (5) and the water pump housing.
g00614231
Illustration 101
1. Remove two O-ring seals (1) from the rear cover

of the water pump. Remove four bolts (2) and the
washers. Remove the rear cover and the gasket. Illustration 104
g00614253
5. Remove seal (5) from the water pump housing

with the handle from Tool (B) and a press.
g00614234
Illustration 102
2. Position the water pump in a press. Use spacer

plates to level the water pump. Illustration 105 g00614261
41
6. Remove the shaft and the bearing from pulley

(3) with a press.
i01275986

SMCS Code: 1361-016
Assembly Procedure
Table 22
Required Tools
Part g00614294
Tool Part Description Qty Illustration 107
Number
A 5P-9722 Seal Driver 1 3. Install seal (5) in the water pump housing with
Tool (A).
NOTICE

component life.
g00614283
Illustration 106
1. Install the shaft and the bearing into pulley (3)

with a press. Install the shaft until the shaft is
flush with the end of pulley (3).
2. Press the shaft, the bearing, and pulley (3) as a g00614288

unit into the water pump housing. The distance Illustration 108
between the front of pulley (3) and the machined
surface of the water pump housing must be 4. Install impeller (4) on the shaft of the water
103.8 0.3 mm (4.09 0.01 inch). pump with a press. Install the impeller until the
distance between the impeller and the machined
Note: For information on the reusability of pulley surface of the water pump is 0.75 0.25 mm
(3), refer to Guideline For Reusable Parts And (0.030 0.010 inch).
Salvage Operations, SEBF8046, Cast Iron and
Steel Pulleys.
42
1. Clean surface (7).

the seals, if necessary.
g00614231
Illustration 109
5. Install a new gasket between the rear cover of

the water pump and the water pump housing.
Position the gasket and the cover on the water Illustration 111 g00614173
pump housing. Install four bolts (2) and the
washers. 3. Install the O-ring seal on water pump (5).
6. Install two new O-ring seals (1) in the rear cover. 4. Position water pump (5) on the front of the
engine. Install four bolts (6).
End By:
a. Install the water pump. Refer to Disassembly and

i01156113

SMCS Code: 1361-012
NOTICE
Keep all parts clean from contaminants. g00614170
Illustration 112
Contaminants may cause rapid wear and shortened 5. Connect hose (3) to water pump (5) and to the
component life. water temperature regulator housing. Install two
clamps (4).
6. Install hose (2) to the water pump elbow.
7. Install V-belt (1) and adjust V-belt (1). Refer to

the Specifications Module, Belt Tension Chart.

End By:
a. Install the belt tensioner. Refer to Disassembly

Illustration 110 g00614182 Install.
43
i01181083

Remove and Install
SMCS Code: 1355-010
Removal Procedure

and alkali.
g00613949
Illustration 113
2. Remove bolts (1) and pipe (2) from water


burns.

NOTICE g00613961
Keep all parts clean from contaminants. Illustration 114
Contaminants may cause rapid wear and shortened 3. Remove water temperature regulators (4) from
component life. water temperature regulator housing (3). Remove
the gasket from water temperature regulator
housing (3).
NOTICE
Care must be taken to ensure that fluids are contained Installation Procedure
products.

mandates.

44
1. Support the engine with blocks or a suitable

lifting device.
2. Install Tool (A) on the flywheel. Fasten a suitable

lifting device to the flywheel.
g00613961
Illustration 115
1. Place water temperature regulators (4) in water

g00613482
Illustration 117
3. Remove top bolt (1) and the washers. Install a

guide bolt that is longer than top bolt (1). Remove
seven remaining bolts (1) and the washers.
4. Remove flywheel (2) from the guide bolt. The

weight of flywheel (2) is 23 kg (50 lb).

gear, if necessary. Place the flywheel on a wood
remove the flywheel ring gear.
g00613949
Illustration 116
i01287254
2. Install a new gasket and pipe (2) in water
temperature regulator housing (3). Flywheel - Install
3. Install bolts (1). SMCS Code: 1156-012
4. Fill the cooling system with coolant to the correct Installation Procedure
Manual for the correct filling procedure. Table 24
Required Tools
i01336741 Part
Number
Flywheel - Remove
SMCS Code: 1156-011
Note: Drill and tap the new flywheel ring gear if the
Removal Procedure outer bolt holes of the flywheel are used . Use the
flywheel as a template and drill twelve holes to a
Table 23 diameter of 8.2 mm (0.32 inch). Thread the holes
Required Tools with a tap.
Part
Number
45
1. Heat the flywheel ring gear to a maximum Start By:

temperature of 204 C (400 F). Do not use a
torch to heat the flywheel ring gear. Install the a. Remove the flywheel. Refer to Disassembly and
flywheel ring gear on the flywheel. Position the Assembly, Flywheel - Remove.
flywheel ring gear with the part number toward
the crankshaft. Allow the flywheel ring gear to NOTICE
cool. Use a soft hammer in order to seat the Keep all parts clean from contaminants.
flywheel ring gear against the shoulder of the
flywheel. Contaminants may cause rapid wear and shortened
component life.
NOTICE

g00613482 products.
Illustration 118
2. Install Tool (A) on flywheel (2). Fasten a suitable mandates.
lifting device to flywheel (2).
3. Place flywheel (2) in the original position on the 1. Use Tool (A) to drill three evenly spaced holes in
guide bolt. Align the arrows on flywheel (2) and the crankshaft rear seal.
the crankshaft.

threads of eight bolts (1).
5. Install seven bolts (1) and the washers. Remove

the guide bolt and install remaining bolt (1) and
the washer. Tighten the bolts evenly to a torque
of 120 20 Nm (90 15 lb ft).
6. Check the flywheel runout. Refer to Testing and

Adjusting, Flywheel - Inspect for the correct
procedure.
g00613243
Crankshaft Rear Seal - Remove Note: Do not damage the flange on the crankshaft
when the crankshaft rear seal is removed.
SMCS Code: 1161-011
Note: Tool (B) is equipped with three screw tips. Use
Removal Procedure the screw tips with Tool (B) to remove crankshaft
rear seal (1).
Table 25
2. Carefully remove crankshaft rear seal (1) by
Required Tools
alternating the position of Tool (B) from hole to
Part hole. This will allow crankshaft rear seal (1) to
Tool Number Part Description Qty be removed evenly without damage to the rear
flange surface of the crankshaft.
A 1U-8145 Drill Bit 1
B 1U-7600 Slide Hammer Puller 1
46
Note: New engines from the factory do not have

a wear sleeve. Engines with seals that have been
replaced will be equipped with a wear sleeve. If
the crankshaft of the engine is equipped with a
wear sleeve, refer to Disassembly and Assembly,
Crankshaft Wear Sleeve (Rear) - Remove in order
to remove the wear sleeve.
i01509332
Crankshaft Rear Seal - Install

SMCS Code: 1161-012
g00613561
Table 26 2. Fasten Tool (A) to the rear of the crankshaft with

Required Tools Tool (B). Hand tighten Tool (B).
Part 3. Position the crankshaft rear seal and crankshaft

Tool Number Part Description Qty rear sleeve (1) on Tool (A). Position Tool (C) on
A(1) 132-8772 Seal Locator 1 Tool (A).
B(1) 1U-7596 Bolt 2
D(1) 1U-7594 Seal Installer 1
E(1) 9S-8858 Nut 1
NOTICE

component life.
g00614109
Illustration 121
Note: Replacement rear seals are supplied with a Typical example
wear sleeve. This wear sleeve must be installed
with the rear seal. New engines from the factory do 4. Position Tool (D) over Tool (A) and Tool (C).
not have a wear sleeve. Do not install the rear seal Install Tool (E). Tighten Tool (E) in order to install
if any of the following conditions exist: the crankshaft rear seal and the crankshaft wear
sleeve.
The crankshaft rear seal has been separated
from the wear sleeve. 5. Remove Tool (E), Tool (D), and Tool (C). Turn
The rear seal group appears to be damaged. (E). Tighten Tool (E) in order to complete the
The crankshaft rear seal has been lubricated. The crankshaft wear sleeve.
seal is designed to be installed dry.
1. Ensure that the rear of the crankshaft is and Tool (A). The faces of Tool (C) and Tool (A)
thoroughly clean and dry prior to the installation will be flush if the crankshaft rear seal and the
of the crankshaft rear seal. crankshaft wear sleeve are properly installed.
information.

47
End By: 2. Install Tool (B) between Tool (A) and the
crankshaft wear sleeve. Turn Tool (B) until the
a. Install the flywheel. Refer to Disassembly and edge of Tool (B) makes a crease in the crankshaft
Assembly, Flywheel - Install. wear sleeve. Make a crease in the crankshaft
wear sleeve at two other locations around the
crankshaft wear sleeve until the crankshaft wear
i01516597
sleeve is loose.
Crankshaft Wear Sleeve (Rear) 3. Remove Tool (B), Tool (A), and the crankshaft
- Remove wear sleeve from the end of the crankshaft.
(If Equipped)
i01216629
Crankshaft Wear Sleeve (Rear)
Removal Procedure - Install
Table 27 SMCS Code: 1161-012-ZV
Required Tools
Part Installation Procedure
Table 28
A 4C-4869 Distorter Ring 1
Required Tools
B 5P-7312 Seal Distorter 1
Part
Start By:
A(1) 132-8772 Seal Locator 1
a. Remove the crankshaft rear seal. Refer to B(1) 1U-7596 Bolt 2
Seal - Remove.
D(1) 1U-7594 Seal Installer 1
NOTICE E(1) 9S-8858 Nut 1
component life. NOTICE

component life.

thoroughly clean and dry prior to the installation
of the crankshaft rear seal.
g00614029
Illustration 122
Note: Wear sleeves are not installed at the factory.

The wear sleeve is included with the replacement
rear seal.
1. Install Tool (A) in the bore of the crankshaft rear

sleeve.
g00613561
Illustration 123
48
2. Fasten Tool (A) to the rear of the crankshaft with i01216259

Tool (B). Hand tighten Tool (B).
Crankshaft Rear Seal Carrier -
rear sleeve (1) on Tool (A). Position Tool (C) on
Remove and Install
Tool (A). SMCS Code: 1161-010-C3
Removal Procedure
Start By:

NOTICE

component life.
g00614109
Illustration 124

Install Tool (E). Tighten Tool (E) in order to install
the crankshaft rear seal and the crankshaft wear
sleeve.
5. Remove Tool (E), Tool (D), and Tool (C). Turn


will be flush if the crankshaft rear seal and the Illustration 125
g00613081
Refer to the Specifications Module for more 1. Remove bolts (2) for the engine oil pan and
information. carefully lower the engine oil pan away from the
cylinder block.
2. Remove eight bolts (1) and the washers that hold
End By: the crankshaft rear seal carrier to the cylinder
block.
Assembly, Flywheel - Install. 3. Carefully pry the crankshaft rear seal carrier off
of the two dowels in the cylinder block.
NOTICE

component life.
49
6. Install a new gasket on the engine oil pan. Install

the engine oil pan on the cylinder block. Install
bolts (2).
End By:
a. Install the flywheel housing. Refer to Disassembly

Install.
i01216263

g00613107
and Install
Illustration 126
SMCS Code: 1157-010
1. Clean the joint face of crankshaft rear seal
carrier (3) and cylinder block (4) with 8T-9011
Component Cleaner. Removal Procedure
Table 29
face of crankshaft rear seal carrier (3). Allow the Required Tools
primer to air dry for three to five minutes. Part
Note: 1U-8846 Sealant is used on the joint face of
the crankshaft rear seal carrier. Do not allow the A 138-7573 Link Bracket 2
sealant to get into the oil passage in the mounting
face of the cylinder block. Start By:
3. Apply 1U-8846 Sealant to the joint face of a. Remove the flywheel. Refer to Disassembly and
crankshaft rear seal carrier (3). Spread the Assembly, Flywheel - Remove.
sealant uniformly. Crankshaft rear seal carrier
(3) must be installed within ten minutes of
application of the sealant. NOTICE
4. Position crankshaft rear seal carrier (3) on the
dowels in the rear of the cylinder block. Use a Contaminants may cause rapid wear and shortened
soft faced hammer to position crankshaft rear component life.
seal carrier (3) against the cylinder block, if
necessary.
NOTICE

products.

mandates.
g00613081
Illustration 127
5. Apply 9S-3263 Thread Lock Compound on the

threads of eight bolts (1). Install eight bolts (1)
that hold the crankshaft rear seal carrier (3) to
the cylinder block.
50
Note: Ensure that the mating surface of the flywheel

housing and the mounting face of the cylinder block
are thoroughly clean. Inspect the gasket of the
engine oil pan for damage. Replace the gasket, if
necessary.
1. Apply 1U-8846 Sealant to the entire mounting

face of the flywheel housing prior to installation.
g00650171
Illustration 128
1. Fasten Tool (A) and a hoist to flywheel housing

(1).
2. Remove twelve bolts (2) and bolt (3) that fastens

the flywheel housing to the cylinder block.
g00650171
Illustration 130
g00612738
Illustration 129
3. Remove four bolts (4) that fasten the engine oil g00612738
Illustration 131
pan to flywheel housing (1). Remove flywheel
housing (1). The weight of flywheel housing (1) 2. Fasten Tool (A) and a hoist to flywheel housing
is approximately 25 kg (55 lb). (1). Position flywheel housing (1) on the cylinder
block. The weight of flywheel housing (1) is
Installation Procedure approximately 25 kg (55 lb). Install four bolts (4)
that fasten the engine oil pan to flywheel housing
Table 30 (1).
Required Tools 3. Install twelve bolts (2) and one bolt (3) that
Part fastens the flywheel housing to the cylinder
Tool Number Part Description Qty block.
4. Remove Tool (A) and the hoist from flywheel
housing (1).
NOTICE
Keep all parts clean from contaminants. 5. Check the flywheel housing runout. Refer to
the Systems Operation/Testing and Adjusting,
Contaminants may cause rapid wear and shortened Flywheel and Flywheel Housing.
component life.
51
End By:

i01446717
Rear Power Take-Off (RPTO) -

Disassemble
SMCS Code: 1165-011-RE
Removal Procedure
Table 31
Required Tools
Part
Number
A 6V-8004(1) Guide Bolt 2
C 1P-0510 Driver Group 1
D 156-7100 Puller Group 1
(1) Cut off the head of 6V-8004 Bolt and chamfer edges.
Start By:
a. Remove the flywheel.
NOTICE

component life.
52
g00757656
Illustration 132
53
(1) Dowel (10) Adapter Assembly (19) Bolt

(2) Thrust Washer (11) Lip Seal (20) Gasket
(3) Sleeve Bearing (12) Bolt (21) Cover
(4) Dowel (13) Seal (22) Seal
(5) Gear Assembly (14) Gear Assembly (23) Cover
(6) Sleeve Bearing (15) Gear Assembly (24) Bolt
(7) Thrust Washer (16) Sleeve Bearing (25) Bolt
(8) Dowel (17) Shaft (26) Housing for Rear Power Take-Off
(9) Seal (18) Bolt
g00759600 g00760232
1. Install Tool (A) in the crankshaft. 4. Remove bolts (18) and (19), idler shaft (17) and
idler gear (15).
2. Remove bolts (24), washers, crankshaft rear seal
(23) and seal (22). Refer to Illustration 132. Note: Inspect the condition of the bearing. If
necessary, remove bearing (16) from the gear with
3. Remove bolts (25), washers , cover (21) and Tool (B). Bearing relief groove (U) must line up with
gasket (20). Inspect the condition of the gasket. the relief groove (V) in gear (15) within two degrees.
Replace the gasket, if necessary. Remove Bearing (16) must not extend beyond either face
crankshaft gear (14) from the crankshaft. of gear.
5. Remove bolts (12), cover (10), and PTO shaft (5).
6. Remove thrust washer (2).
Note: Inspect the condition of bearing (3). If

necessary, remove bearing (3) with Tool (D). Refer to
Disassembly and Assembly, Rear Power Take-Off
(RPTO) - Assemble for installation of bearing.
g00759678
Illustration 134
54
i01446735

Assemble
Table 32
Required Tools
Part
Number
6V-8004
A (1) Guide Bolt 2

C 1P-0510 Driver Group 1
(1) Cut off the head of 6V-8004 Bolt and chamfer edges.
NOTICE

component life.
55
g00757656
Illustration 136
(1) Dowel (10) Adapter Assembly (19) Bolt
(2) Thrust Washer (11) Lip Seal (20) Gasket
(3) Sleeve Bearing (12) Bolt (21) Cover
(4) Dowel (13) Seal (22) Seal
(5) Gear Assembly (14) Gear Assembly (23) Cover
(6) Sleeve Bearing (15) Gear Assembly (24) Bolt
(7) Thrust Washer (16) Sleeve Bearing (25) Bolt
(8) Dowel (17) Shaft (26) Housing for Rear Power Take-Off
(9) Seal (18) Bolt
56
g00759921
Illustration 138
(D) The flat side of Adapter Assembly (10)
(X) location of bearing joint
(Y) height of bearing
(Z) height of dowel
4. Place adapter assembly (10) on the work surface.

g00759999
Illustration 137 The outside face should be down. Install bearing
(XX) location of bearing joint (6) in adapter assembly (10) with Tool (B).
(YY) height of bearing
(ZZ) height of dowel Note: The split in the bearing should be located
at angle (X), which is 45 10 degrees from
1. Use Tool (B) to install bearing (3) in the housing the centerline in the adapter assembly (10). The
for the Rear Power Take-Off (26). bearing should extend beyond the surface of the
adapter assembly (10) by a distance (Y) which is
Note: The bearing joint is located at an angle (XX) 3.1 .5 mm (0.12 0.02 inch).
that is 15 3 degrees from the horizontal centerline.
The oil hole in the bearing must align with the oil 5. Install dowels (8) and thrust washer (7) in
gallery in the housing for the RPTO. The bearing adapter assembly (10). Refer to Illustration 136.
should extend beyond the surface of the housing
for the RPTO by a distance (YY) of 3.1 .5 mm Note: The dowels should extend beyond the surface
(0.12 0.02 inch). of the adapter assembly (10) by a distance of
3.5 .2 mm (0.14 0.01 inch).
2. Install dowels (1) in the RPTO housing (26).
6. Install O-ring seal (9) on adapter assembly (10).
Note: The dowels should extend beyond the surface
of the RPTO housing by a distance 3.5 .2 mm 7. Turn over adapter assembly (10). Use Tool (C) to
(0.14 0.01 inch). install lip type seal (11). Lubricate lip type seal
(11) lightly with the lubricant that is being sealed.
3. Install thrust washer (2) into RPTO housing (26).
Note: Lip seal (11) should be installed to a depth
of 2.5 .5 mm (0.1 0.02 inch).
57
10. Install idler gear (15) on idler shaft (17). Install

the shaft and gear assembly in the flywheel
housing. Start with the bolt that is marked T.
Tighten bolts (18) and (19) in a clockwise
position to a torque of 100 Nm (74 lb ft). Again
tighten bolts to a torque of 175 Nm (130 lb ft).
g00759811
Illustration 139
Note: Ensure that flat side (10B) of cover (10) is

against the flywheel housing. This will ensure that
oil passage (10A) is located toward the flywheel
housing.
g00759821
Illustration 142
8. Install PTO shaft (5) and adapter assembly (10)
into RPTO housing (26) and install bolts (12). 11. Install Tool (A) in the crankshaft. Install gasket
(13) and crankshaft gear (14).
12. Install the gasket (20), cover (21), bolts (25)

and washers.
13. Install O-ring (22), crankshaft rear seal (23), and

bolts (24).
End By:
a. Install the flywheel.
g00760157
Illustration 140
g00760159
Illustration 141
9. Install bearing (16) in gear (15) with Tool (B).
Note: Bearing relief groove (U) must line up with the

relief groove (V) in gear (15) within two degrees.
Bearing (16) must not extend beyond either face
of gear.
58

Vibration Damper and Pulley -
Remove and Install
SMCS Code: 1205-010
Removal Procedure
g00612684
Illustration 145
1. Position crankshaft pulley (5) on the crankshaft.

Install four bolts (4) and tighten the bolts to a
2. Install water pump drive belt (3).
Note: Check the alignment marks on the rubber

vibration dampers for proper alignment. The rubber
vibration damper should be replaced if the rubber
vibration damper is out of alignment. Refer to
Specifications, Vibration Damper.
g00612677
Illustration 143
1. Remove eight bolts (2), crankshaft vibration

damper (1), and two spacers from the crankshaft
pulley.
g00612684 g00612677
2. Loosen the tension on water pump drive belt (3). 3. Install two spacers and crankshaft vibration
Remove the belt from the crankshaft pulley. damper (1). Tighten eight bolts (2) to a torque of
55 10 Nm (40 7 lb ft).
3. Remove four bolts (4) and the washer.
4. Adjust the tension of water pump drive belt
4. Remove crankshaft pulley (5). (3). Refer to the Specifications Module, Belt
Tension Chart. Also, refer to the Operation and
Maintenance Manual, Belt - Inspect.
59
i01153831 i01153847
Crankshaft Front Seal - Crankshaft Front Seal - Install

Remove SMCS Code: 1160-012
SMCS Code: 1160-011
Removal Procedure Table 34
Table 33 Required Tools

Required Tools Part
Part
Tool Number Part Description Qty A 1U-7430 Front Seal Installer 1
A 1U-7600 Slide Hammer Puller 1
B 1U-8145 Drill Bit 1 NOTICE
Start By: Contaminants may cause rapid wear and shortened

component life.
Damper and Pulley - Remove and Install. Note: Ensure that the flange of the crankshaft and
the front housing are thoroughly clean before you
install the crankshaft front seal.
NOTICE

component life.
g00612634
Illustration 148
g00612597
Illustration 147
Note: Do not damage the flange of the crankshaft

during the removal of the seal.
1. Use Tool (B) and carefully drill three evenly

spaced holes in crankshaft front seal (1).
2. Alternate between the drilled holes and use Tool

(A) to remove crankshaft front seal (1).
g00612636
Illustration 149
Note: Refer to the Specifications Module,

Crankshaft Seals for information on the distance
between the following items: the front face of the
crankshaft front seal and the front face of the front
housing.
60
1. Position installation sleeve (2). Use Tool (A) to

install crankshaft front seal (1).
Note: The crankshaft seal is designed to be installed

dry.
2. Remove installation sleeve (2) from the crankshaft

front seal. Ensure that the seal surface of the
crankshaft pulley is thoroughly clean and dry.
Ensure that the seal surface of the crankshaft
pulley is in good condition.
End By:

i01153795
Front Cover - Remove g00612568

Illustration 150
SMCS Code: 1166-011
Note: The front pulley was removed and the damper
was removed for better photographic illustration.
Removal Procedure The air compressor was removed in order to
Start By:
1. Remove the bolts and front cover (1) from the
a. Remove the fan drive. Refer to Disassembly and front housing.
i01153809
NOTICE
Keep all parts clean from contaminants. Front Cover - Install
Contaminants may cause rapid wear and shortened SMCS Code: 1166-012
component life.
NOTICE
Care must be taken to ensure that fluids are contained NOTICE
during performance of inspection, maintenance, test- Keep all parts clean from contaminants.
collect the fluid with suitable containers before open- Contaminants may cause rapid wear and shortened
ing any compartment or disassembling any compo- component life.
Refer to Special Publication, NENG2500, Caterpillar Note: The rear face of the cover and the front face
Tools and Shop Products Guide for tools and supplies of the housing must be clean.
products. 1. Inspect the condition of the housing cover
gasket. Replace the gasket, if necessary.
mandates.
61
NOTICE

products.

mandates.
1. Remove any external components, if equipped.
g00612568
Illustration 151
2. Install the housing cover gasket.
3. Position front cover (1) on the front housing.

Install the bolts on front cover (1).
End By:
a. Install the fan drive. Refer to Disassembly and

Assembly, Fan Drive - Install.
g00615717
Illustration 152
i01153309
Housing (Front) - Remove 2. Remove five bolts (1) and remove front engine
support.
SMCS Code: 1151-011
Removal Procedure
Start By:
a. Remove the crankshaft vibration damper. Refer to


Seal - Remove.

g00612359
Illustration 153
3. Remove two bolts (2) and belt tightener (3).

62
4. Remove the bolts that fasten front housing (4)

to the cylinder block and to the engine oil pan.
Remove front housing (4). Clean the sealant from
front housing (4) and the cylinder block.
i01336821
Housing (Front) - Install

SMCS Code: 1151-012
g00615717
Illustration 155
7. Position the front engine support and install five

bolts (1).
8. Install any external components, if equipped.
End By:


Seal - Install.
c. Install the crankshaft vibration damper. Refer to

g00612359
Illustration 154
i01158735
1. Clean the joint face on front housing (4) with
8T-9011 Component Cleaner. Camshaft Idler Gear - Remove
and Install
face. Allow the primer to dry for at least three to
SMCS Code: 1206-010
five minutes.
Note: Do not allow the 1U-8846 Sealant to seal the Removal Procedure
main oil passage on front housing (4).
Table 35
3. Apply 1U-8846 Sealant to the joint face. Spread Required Tools
the sealant uniformly. Front housing (4) must
be installed within ten minutes of applying the Part
Number
sealant.
4. Position front housing (4) on the cylinder block.
Start By:
5. Install the bolts that fasten front housing (4) to
the cylinder block and the engine oil pan.
a. Remove the front housing. Refer to Disassembly
6. Position belt tightener (3) and install two bolts (2).
63
NOTICE

component life.
NOTICE
nent containing fluids. g00616226
Illustration 157
Tools and Shop Products Guide for tools and supplies 3. Slide camshaft idler gear (2) from idler shaft (3).
products. 4. Remove the bolt and idler shaft (3) from the
cylinder block.
mandates.
g00616240
Illustration 158
5. Use Tool (A) and a press to remove the bearing

from camshaft idler gear (2).
Table 36
g00616185 Required Tools

Illustration 156
Part
1. Rotate the crankshaft until the number one piston Number
is at the top center position. Timing mark (4)
for camshaft idler gear (2) should be in line
with timing mark (5) for crankshaft drive gear
(6). Identify the location of timing mark (4) for NOTICE
camshaft idler gear (2) and timing mark (5) for Keep all parts clean from contaminants.
crankshaft drive gear (6).
2. Remove the two bolts that fasten plate (1) to idler component life.
shaft (3). Remove plate (1).
64
g00616240
Illustration 159
1. Use Tool (A) and a press to install the

bearing in camshaft idler gear (2). Install the
bearing until the bearing is 0.40 0.25 mm
(0.016 0.010 inch) below the front face of
camshaft idler gear (2). g00616185
Illustration 161

Ensure that timing mark (4) for camshaft idler
gear (2) is facing outward. Align the identified
timing mark (4) for camshaft idler gear (2) with
the identified timing mark (5) for crankshaft drive
gear (6).
4. Position plate (1) and install two bolts. Tighten the

End By:
a. Install the front housing. Refer to Disassembly

Illustration 160 g00616246 and Assembly, Housing (Front) - Install.
2. Ensure that oil supply passages (7) in the i01516145

cylinder block and idler shaft (3) are free of
contaminants. Position idler shaft (3) on the Valve Mechanism Cover -
cylinder block. Install the bolt that holds idler
shaft (3) to the cylinder block. Tighten the bolt to Remove and Install
SMCS Code: 1107-010
Removal Procedure
NOTICE

component life.
65
NOTICE

products.

Illustration 163
mandates.
g00786705
Illustration 164
g00611536
Illustration 162 Bolt tightening sequence for the valve mechanism cover
(A) Rear
1. Remove breather assembly (2) from valve (B) Front
mechanism cover (1).
1. Position valve mechanism cover (1) and the seal
2. Remove the bolts that hold valve mechanism on valve mechanism cover base (3). Cut the seal
cover (1) to valve mechanism cover base (3). to length. Apply 4C-9612 Silicone Sealant on
both sides of the seal joint.
3. Remove the seal from the valve mechanism
cover. 2. Install the bolts. Tighten the bolts in a
numerical sequence to a torque of 12 3 Nm
Installation Procedure (106 27 lb in).
NOTICE Note: Inspect the O-ring seal of the breather

Keep all parts clean from contaminants. assembly. Replace the O-ring seal, if necessary.
Contaminants may cause rapid wear and shortened 3. Position breather assembly (2) on valve
component life. mechanism cover (1). Tighten the bolt for
breather assembly (2) to a torque of 7 2 Nm
(62 18 lb in).
66
i01516146
Valve Mechanism Cover Base -

Remove and Install
SMCS Code: 1120-010
Removal Procedure
Start By:

NOTICE

component life.
g00611577
Illustration 166
NOTICE
2. Disconnect wiring harness plugs (2) from each
Care must be taken to ensure that fluids are contained of the unit injectors.

products.

mandates.
g00611578
Illustration 167
3. Remove the bolts and base (3) of the valve

mechanism cover from the cylinder head.
g00611576
Illustration 165
1. Disconnect plug (1) from the wiring harness.

67
g00611576
Illustration 170
g00611578
Illustration 168
4. Connect plug (1) to the wiring harness.
1. Ensure that the mating surface of base (3) of the
valve mechanism cover and the cylinder head End By:
are thoroughly clean.
a. Install the valve mechanism cover. Refer to
2. Position base (3) of the valve mechanism cover Disassembly and Assembly, Valve Mechanism
on the cylinder head. Install the bolts and tighten Cover - Remove and Install.
the bolts in a numerical sequence to a torque of
12 3 Nm (106 27 lb in).
i01152050

Remove
SMCS Code: 1102-011; 1208-011
Removal Procedure
Start By:

NOTICE

component life.
g00611577
Illustration 169
3. Connect wiring harness plugs (2) to each of the

unit injectors.
68
i01152099
NOTICE
Care must be taken to ensure that fluids are contained Rocker Shaft - Disassemble
SMCS Code: 1102-015
ing any compartment or disassembling any compo- Disassembly Procedure
Table 37
suitable to collect and contain fluids on Caterpillar Part
products. Tool Number Part Description Qty
mandates.
Start By:
1. Put identification marks on each rocker arm in a. Remove the rocker shaft. Refer to Disassembly
order to identify the proper location in the engine and Assembly, Rocker shaft and pushrod -
for installation. Remove.
NOTICE

component life.
NOTICE
g00611428 nent containing fluids.
Illustration 171

2. Loosen all rocker arm adjustment screws (4) in
order to release the tension on the rocker shaft.
products.
3. Remove two bolts (1), eleven bolts (2), and
rocker shaft (3).
mandates.
g00611430
Illustration 172
g00611468
4. Remove inlet valve bridges (5) and pushrods (6). Illustration 173
69
Note: Place an identification mark on each of the

components of the rocker shaft for installation
purposes.
1. Remove retaining ring (1) with Tool (A).
2. Remove stand (2), inlet rocker arm (3), exhaust

rocker arm (4), stand (5), and spring (6) from the
rocker shaft.
3. Inspect all of the components of the rocker shaft

for wear and damage. Replace the components
of the rocker shaft, if necessary.
g00611468
Rocker Shaft - Assemble 2. Install spring (6), stand (5), exhaust rocker arm
(4), inlet rocker arm (3), and stand (2) on the
SMCS Code: 1102-016 rocker shaft.
Assembly Procedure 3. Install retaining ring (1) with Tool (A).
Table 38 End By:

Required Tools
a. Install the rocker shaft. Refer to Disassembly and
Part Assembly, Rocker Shaft and Pushrod - Install.
A 1P-1855 Retaining Ring Pliers 1 i01152077
NOTICE
Keep all parts clean from contaminants. Install
Contaminants may cause rapid wear and shortened SMCS Code: 1102-012; 1208-012
component life.
NOTICE
Care must be taken to ensure that fluids are contained NOTICE
during performance of inspection, maintenance, test- Keep all parts clean from contaminants.
collect the fluid with suitable containers before open- Contaminants may cause rapid wear and shortened
ing any compartment or disassembling any compo- component life.

products.

mandates.
1. Lubricate all of the components of the rocker

shaft with clean engine oil.
g00611430
Illustration 175
1. Apply 8T-2998 Lubricant to both ends of

pushrods (6).
70
Note: Ensure that the pushrods are installed c. Remove the water temperature regulator housing.
correctly in the socket of the tappets. Refer to Disassembly and Assembly, Water
2. Lubricate pushrods (6) with clean engine oil. Install.
Install pushrods (6) and valve bridges (5).
d. Remove the unit injectors. Refer to Disassembly
and Assembly, Unit Injector - Remove.
e. Remove the air inlet cover. Refer to Disassembly

and Assembly, Air Inlet Cover - Remove and
Install.
f. Remove the exhaust manifold. Refer to

Disassembly and Assembly, Exhaust Manifold
NOTICE
g00611428
3. Position rocker shaft (3). Install bolts (1) and (2).
Finger tighten bolts (1) and (2). Tighten bolts NOTICE
(2) to a torque of 100 20 Nm (74 15 lb ft). Care must be taken to ensure that fluids are contained
Tighten bolts (1) to a torque of 28 7 Nm during performance of inspection, maintenance, test-
(21 5 lb ft). ing, adjusting and repair of the product. Be prepared to
4. Apply 8T-2998 Lubricant to each of the button ing any compartment or disassembling any compo-
faces of the rocker arms. nent containing fluids.
5. Adjust the valve lash of the rocker arm. Refer to Refer to Special Publication, NENG2500, Caterpillar
the Systems Operation/Testing and Adjusting. Tools and Shop Products Guide for tools and supplies
End By: products.
a. Install the valve mechanism cover. Refer to Dispose of all fluids according to local regulations and
Disassembly and Assembly, Valve Mechanism mandates.
i01459879
Cylinder Head - Remove

SMCS Code: 1100-011
Removal Procedure
Start By:
a. Remove the fan drive. Refer to Disassembly and

g00746424
Illustration 177
1. Attach a suitable lifting device to the cylinder
Install.
head.
71
g00611336 g00611342
2. Remove bolts (1), bolts (2) and washers that hold 2. Install a new cylinder head gasket (3).
the cylinder head to the cylinder block. Carefully
remove the cylinder head from the cylinder
block. The cylinder head weighs approximately
85 kg (187 lb).
g00746424
Illustration 181

g00611342
Illustration 179 cylinder head.
3. Remove cylinder head gasket (3). 3. Attach a suitable lifting device to the cylinder
head. Position the cylinder head assembly onto
the dowels in the cylinder block. Lower the
i01174189
cylinder head onto the cylinder block.
SMCS Code: 1100-012
NOTICE

component life.

cylinder head and the cylinder block. Illustration 182 g00611336
Typical example
72
4. Inspect the condition of cylinder head bolts (1) e. Install the fuel filter base. Refer to Disassembly
and (2). Replace cylinder head bolts (1) and (2), and Assembly, Fuel Filter Base - Remove and
if necessary. Install.
5. Lubricate cylinder head bolts (1) and (2) with f. Install the fan drive. Refer to Disassembly and
clean engine oil. Install cylinder head bolts (1) Assembly, Fan Drive - Install.
and (2). Follow Step 6 for the correct tightening
procedure.
i01151741

Install
SMCS Code: 1209-010
Removal Procedure
Start By:

Install.
g00611358
Illustration 183
b. Remove the rocker arms and pushrods. Refer to
Disassembly and Assembly, Rocker Shaft and
6. Tighten the cylinder head bolts according to the
Pushrod - Remove.
c. Remove the unit injector hydraulic pump. Refer
a. Tighten bolt (1) through bolt (14) in a numerical
(110 11 lb ft).
d. Remove the air compressor. Refer to Disassembly
in a numerical sequence to a torque of Install.
435 20 Nm (320 15 lb ft).
e. Remove the electronic control module (ECM).
c. Tighten bolt (1) through bolt (14) again Refer to Disassembly and Assembly, Electronic
Control Module - Remove and Install.
435 20 Nm (320 15 lb ft).
d. Tighten bolt (15) through bolt (20) in a NOTICE

numerical sequence to a torque of 55 7 Nm Keep all parts clean from contaminants.
(41 5 lb ft).
End By: component life.
a. Install the exhaust manifold. Refer to Disassembly

and Assembly, Exhaust Manifold - Remove and
Install.
b. Install the air inlet cover. Refer to Disassembly

and Assembly, Air Inlet Cover - Remove and
Install.
c. Install the unit injectors. Refer to Disassembly

d. Install the water temperature regulator housing.

Install.
73
NOTICE

products.

Illustration 186
mandates.
Note: Ensure that the sleeves of the side covers
remain in the side covers.
5. Remove four bolts (6) and the dowels that hold

the lifter arms (7) and the lifter shaft (8) to each
side cover. Remove gasket (9).
NOTICE

component life.
g00611180
Illustration 184
1. Remove bolt (1) that holds the bracket for the

engine speed/timing sensor to the timing gear
housing. Remove two engine speed/timing
sensors (3) and the bracket from the timing gear
housing.
2. Cut the straps that hold the wiring harness to

side cover (2) of the cylinder block.
3. Remove the bolts that hold side cover (2) to the

cylinder block.
g00611184
Illustration 187
1. Install gasket (9).
2. Install lifter arms (7) on lifter shaft (8).
3. Position lifter shaft (8) and the dowels on the

side cover. Ensure that the oil holes in the lifter
shaft are facing the side cover. Apply 9S-3263
Thread Lock Compound on the threads of bolts
(6) that hold lifter shaft (8) to the side cover.
Install bolts (6). Tighten bolts (6) to a torque of
g00611182 13 3 Nm (10 2 lb ft). Tighten the two center
Illustration 185
bolts. Then tighten the end bolts.
4. Remove the bolts and side covers (4) and (5)
4. Lubricate the lifters with clean engine oil.
from the cylinder block.
74
5. Ensure that the cylinder block and the sealing c. Install the unit injector hydraulic pump. Refer
surfaces of the side cover are thoroughly clean. to Disassembly and Assembly, Unit Injector
Apply 1U-8846 Sealant to the sealing surfaces Hydraulic Pump - Install.
of the side cover. The side covers must be
installed on the cylinder block within 10 minutes d. Install the rocker arms and pushrods. Refer to
of applying the sealant. Disassembly and Assembly, Rocker Shaft and
Pushrod - Install.
e. Install the fuel filter base. Refer to Disassembly

Install.
i01151060
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
g00611182 Start By:
Illustration 188

b. Remove the unit injector hydraulic pump. Refer

c. Remove the side cover. Refer to Disassembly

Install.
d. Remove the front cover. Refer to Disassembly

g00611180
Illustration 189
6. Position the gaskets and side covers (2), (4), and NOTICE
(5) on the cylinder block. Install the bolts and Keep all parts clean from contaminants.
clips that hold the side covers in position.
7. Install two engine speed/timing sensors (3) and component life.
the bracket to the timing gear housing. Install
bolt (1). NOTICE
8. Secure the two plugs of the wiring harness to during performance of inspection, maintenance, test-
the engine speed/timing sensors in the timing ing, adjusting and repair of the product. Be prepared to
gear housing. Use new straps to hold the wiring collect the fluid with suitable containers before open-
harness to the side covers of the cylinder block. ing any compartment or disassembling any compo-
End By:
a. Install the electronic control module (ECM). Tools and Shop Products Guide for tools and supplies
Refer to Disassembly and Assembly, Electronic suitable to collect and contain fluids on Caterpillar
Control Module - Remove and Install. products.
b. Install the air compressor. Refer to Disassembly Dispose of all fluids according to local regulations and
and Assembly, Air Compressor - Remove and mandates.
Install.
75
Note: The air compressor was removed in order to i01253696

Camshaft - Install
1. Turn the crankshaft to top center compression
stroke for the No. 1 piston. Install the timing SMCS Code: 1210-012
bolt in the flywheel. This is for timing during
installation. Installation Procedure
2. Ensure that the timing marks on the following NOTICE
gears are aligned: the camshaft drive gear, the Care must be taken to ensure that fluids are contained
idler gear, and the crankshaft gear. during performance of inspection, maintenance, test-
Note: It is not necessary to remove the cylinder collect the fluid with suitable containers before open-
head for removal of the camshaft. ing any compartment or disassembling any compo-
3. Wire the valve lifters away from the camshaft.
products.

mandates.
NOTICE

component life.
g00611074
Illustration 190
4. Remove two bolts (3) and camshaft retainer plate

(2) from camshaft gear (1).
g00611082
Illustration 192
Typical example
Note: The air compressor was removed in order to

1. Carefully install camshaft (4) in the engine.
NOTICE
Illustration 191 g00611082 ber one cylinder is at top center of the compression
stroke with the timing bolt installed in the flywheel. The
5. Remove camshaft (4) from the cylinder block. camshaft timing is very important. The timing mark
on the camshaft drive gear must line up with the tim-
76
2. Ensure that the timing marks on the following 1. Wrap the camshaft with a protective covering in
gears are aligned: the camshaft drive gear, the order to prevent damage to the camshaft.
g00611152
Illustration 194
NOTICE
Do not allow the camshaft to fall to the floor when
pressing it from the drive gear. Also make sure that
g00611074
Illustration 193 2. Place the camshaft and camshaft gear (1) in a
Typical example suitable press. Press the camshaft from camshaft
gear (1).
3. Install camshaft retainer plate (2) and two bolts
(3) on camshaft gear (1).
End By:
1. Heat the camshaft gear to a maximum
temperature of 315 C (600 F).
Assembly, Front Cover - Install.
2. Align the key in the camshaft with the groove
(keyway) in the camshaft gear.
b. Install the side cover. Refer to Disassembly and
Assembly, Lifter Group - Remove and Install.
3. Install the camshaft gear on the end of the
camshaft.
c. Install the unit injector hydraulic pump. Refer
End By:
Hydraulic Pump - Install.
d. Install the rocker arms and the push rods. Refer a. Install the camshaft. Refer to Disassembly and
i01151709

Install
Removal Procedure
Start By:
a. Remove the camshaft. Refer to Disassembly and

77
i01199837
Camshaft Bearings - Remove

and Install
SMCS Code: 1211-010
Removal Procedure
Table 39
Required Tools
Part
g00610631
Camshaft Bearing Tool Illustration 195
A 8S-2241 1
Group
1. Install Tool (A). Use Tool (A) to remove the
camshaft bearings from the cylinder block.
Start By:
a. Remove the camshaft. Refer to Disassembly and Installation Procedure

Table 40
NOTICE Required Tools

Keep all parts clean from contaminants. Part
component life. Camshaft Bearing Tool
A 8S-2241 1
Group
NOTICE NOTICE

products.

mandates.
Note: Note the oil hole orientation in each camshaft

bearing prior to removal for assembly purposes.
78
1. Use Tool (A) to install all of the camshaft bearings

except for the front bearing. Locate oil hole (1) in
each bearing so that oil hole (1) is located at the
top of the bore. Refer to Illustration 196.
2. Use Tool (A) to install the front camshaft bearing.

Align oil hole (1) in the front camshaft bearing
with the oil hole in the cylinder block. Locate joint
(2) in the front camshaft bearing in the proper
position. Refer to Illustration 197. Refer to the
Specifications for more information.
End By:

i01150906

Install
SMCS Code: 1302-010
Removal Procedure
g00610640
Illustration 196
Rear view of engine
jury.
NOTICE

component life.
NOTICE

products.

mandates.
g00610642
Illustration 197
Front view of engine
1. Drain the engine oil into a suitable container for
storage or disposal.
79

Note: Apply 1U-8846 Sealant to the four places

at the tee joints of the following items: the timing
gear housing to the cylinder block and the flywheel
housing (seal carrier) to the cylinder block. Use
approximately 0.5 mm (0.02 inch) of sealant at each
of the four places. Do not apply liquid gasket on the
gasket for the engine oil pan. Do not apply liquid
gasket to the gasket surface of the engine oil pan.
g00610543
Illustration 198
Typical example
Note: Do not pry or gouge the sealing surface of

the engine oil pan. If the engine oil pan is difficult to
remove, tap the engine oil pan with a rubber mallet.
2. Remove the bolts for the engine oil pan. Remove

engine oil pan (1).
g00610550
Illustration 200
Typical example
g00610550
Illustration 199
Typical example
3. Remove gasket (2) from the engine oil pan.

g00610543
Illustration 201
4. Remove the drain plug and the O-ring seal from Typical example
the engine oil pan.
4. Place new gasket (2) and engine oil pan (1) on
Installation Procedure the cylinder block.
NOTICE

component life.
1. Install the drain plug and the O-ring seal on

the engine oil pan. Tighten the drain plug to
25 5 Nm (18 4 lb ft).

80
NOTICE

component life.
NOTICE

products.
Illustration 202 g00610574 Dispose of all fluids according to local regulations and
mandates.
5. Install the bolts for the engine oil pan. Tighten
the bolts (X). Tighten the bolts to a torque of
31 3 Nm (23 2 lb ft).
6. Start at position (Z) and tighten the remaining

bolts in a counterclockwise direction. Tighten
the remaining bolts to a torque of 31 3 Nm
(23 2 lb ft).
7. Start at position (Z) and tighten the bolts again in

a counterclockwise direction. Tighten the bolts to
8. Fill the engine with oil to the correct level. Refer

g00610526
correct filling procedure. Illustration 203
1. Remove bolt (1) and piston cooling jet (2) from

i01150877 each cylinder.
and Install Installation Procedure
SMCS Code: 1331-010 NOTICE
Removal Procedure Contaminants may cause rapid wear and shortened
component life.
Start By:

Remove.
81

Two-Piece Pistons

Engines


g00610526
Connecting Rods
Illustration 204
1. Position piston cooling jet (2) in the cylinder Operations, SEBF8064, Salvage of Non-Serrated
block. Ensure that piston cooling jet (2) is seated Connecting Rods
properly. Hold piston cooling jet (2) and install
bolt (1) in each cylinder. Tighten the bolt to a Note: For information on reusability of the piston
torque of 28 7 Nm (21 5 lb ft). pins, refer to the following list.
End By: Guideline For Reusable Parts And Salvage
a. Install the engine oil pump. Refer to Disassembly Rings
i01287371
Piston Pins
- Remove bushing, refer to the following list.
SMCS Code: 1225-011
Removal Procedure Rod Eye Bushing Retention Using 5P-8639
Start By:
a. Remove the cylinder head. Refer to Disassembly Operations, SEBF8274, Using Rod Eye Bushing
and Assembly, Cylinder Head - Remove. Installation and Removal Tools
b. Remove the engine oil pump. Refer to

Remove.
c. Remove the piston cooling jets. Refer to

NOTICE

component life.
g00610269
Illustration 205

82
1. Inspect the connecting rod and connecting i01336888

The connecting rod and connecting rod cap Pistons and Connecting Rods
(2) should have an etched number on the side
- Disassemble
number should match the cylinder number. Mark SMCS Code: 1225-015
the connecting rod and connecting rod cap (2),
if necessary.
2. Remove connecting rod cap nuts (1), bolts (5),
Table 41
and connecting rod cap (2).
Required Tools
NOTICE Part
Install short pieces of rubber hose over both connect- Tool Number Part Description Qty
ing rod bolts in order to protect the crankshaft from the
A 1U-6683 Piston Ring Expander 1
threaded portion of the connecting rod bolts.
B 1P-1861 Retaining Ring Pliers 1
Start By:
a. Remove the pistons and the connecting rods.

Refer to Disassembly and Assembly, Pistons
and Connecting Rods - Remove.
NOTICE

component life.
g00610272
Illustration 206 Note: For information on reusability of the pistons,
3. Remove the lower half of bearing (4) from
connecting rod cap (2). Guideline For Reusable Parts And Salvage
4. Push the piston and connecting rod away
from the crankshaft. Remove the upper half of Guideline For Reusable Parts And Salvage
connecting rod bearing (4) from connecting rod Operations, SEBF8290, Visual Inspection of
(3). Two-Piece Pistons
5. Remove the piston and connecting rod (3) from Tool Operating Manual, NEHS0775, Using the
the cylinder block. 186-0137 Piston Ring Gauge on Steel Crown,
6. Repeat Steps 1 through 5 for the remaining
pistons and connecting rods. Note: For information on reusability of the connecting

Connecting Rods

Connecting Rods

83
Guideline For Reusable Parts And Salvage i01337585

Rings Pistons and Connecting Rods
- Assemble
Operations, SEBF8303, Procedure to Inspect SMCS Code: 1225-016
Piston Pins
Note: For information on reusability of the rod eye Assembly Procedure

bushing, refer to the following list.
Table 42
Guideline For Reusable Parts And Salvage Required Tools

Part
Rod Eye Bushing Retention Using 5P-8639 Tool Number Part Description Qty
A 1U-6683 Ring Expander 1
Installation and Removal Tools NOTICE

component life.
NOTICE
g00610426
Illustration 207
1. Use Tool (B) to remove retaining ring (2). Remove

piston pin (4) and separate piston (1) from
connecting rod (3).
g00610428
Illustration 209
1. Check the clearance between the ends of piston

rings (5). Refer to the Specifications Manual,
Pistons and Rings topic.
Note: The oil ring must be installed over the spring

with the end gap 180 degrees from the oil ring
g00610428
Illustration 208 spring joint.
2. Use Tool (A) to remove piston ring (5). 2. Install the oil control piston ring with Tool (A).
The ends of the spring should be rotated 180
degrees from the ring end gap.

84

g00610426
Illustration 212
NOTICE
g00610498
Illustration 210 An improperly installed retainer ring could cause the
piston and connecting rod to come apart during en-
5. Replace rod bearing (6) by pressing a new gine operation. This action can result in a broken Pis-
bearing into the connecting rod. Refer to Special ton Skirt and major engine damage.
Instruction, SEHS7295 for the correct tooling and
the correct installation procedure.
7. Position piston (1) on connecting rod (3). Coat
pin (4) with clean engine oil and install pin (4).
Ensure that the retainer rings are in the grooves
of piston (1).
End By:

i01459773

Illustration 211
g00610503 - Install
6. The piston is a two-piece assembly. This piston SMCS Code: 1225-012
consists of piston crown (7) and piston skirt (8).
Inspect bearing (9) in the piston crown (7). The Installation Procedure
piston crown must be replaced if the piston
crown is worn or damaged. Bearing (9) is not Table 43
serviced. Required Tools
Part
A 173-5529 Piston Ring Compressor 1
NOTICE

component life.
85



Two-Piece Pistons

Engines
g00678193
Note: For information on reusability of the connecting Illustration 213
1. Install the bolts (5) and the upper half of
Guideline For Reusable Parts And Salvage connecting rod bearing (4). Ensure that the
Operations, SEBF8063, Visual Inspection of bearing tab engages with the slot in connecting
Connecting Rods rod (3).

Connecting Rods


Rings

Piston Pins g00678195
Illustration 214
bushing, refer to the following list. 2. Install the lower half of connecting rod bearing
(4). Ensure that the bearing tab engages with the
slot in connecting rod cap (2).
Rod Eye Bushing Retention Using 5P-8639 3. Place clean engine oil on the following items: the
Connecting Rod Bushing Press Group pistons, the piston rings, the cylinder bore, the
upper half of the connecting rod bearing, and
the lower half of the connecting rod bearing.
Installation and Removal Tools NOTICE
ing rod bolts in order to protect the crankshaft from the
threaded portion of the connecting rod bolts.
86
9. Remove the hoses that were installed in Step 4

from the connecting rod bolts.
g00746584
Illustration 215
4. Install short pieces of rubber hose (6) over both Illustration 217 g00678200
connecting rod bolts.
10. Install connecting rod bearing cap (2) on the
connecting rod (3). Ensure that the number on
number on the connecting rod (3). Ensure that
the numbers are on the same side.
11. Lubricate connecting rod cap bolts with

g00634923
Illustration 216
Note: Each piston ring end gap must be positioned

120 degrees from each other.
5. Install Tool (A) in order to compress the piston

rings.
6. With the number one crankshaft throw at the Illustration 218

g00610272
bottom center, install the piston and connecting
rod in the engine. Ensure that the proper piston
NOTICE
Loose connecting rod nuts can result in the separation
of the rod cap and result in major engine damage.
Note: The etched number on the connecting rod 12. Install connecting rod cap nuts (1). Tighten nuts
must be on the right side of the engine in the (1) to a torque of 54 7 Nm (40 5 lb ft).
corresponding cylinder.
7. Line up the piston and the connecting rod with

off of the piston.
8. Use a soft hammer in order to tap the piston into

the cylinder bore while you guide connecting rod
(3) onto the crankshaft.
87
Start By:

Remove.
NOTICE

component life.
g00678202
Illustration 219
13. Place index mark (7) on the connecting rod.

Place index mark (9) on connecting rod cap
nut (1). Index marks (7) and (9) mark the initial
position of the nut. Place index mark (8) on
connecting rod cap nut (1). Index mark (8)
should be 60 5 degrees counterclockwise
from index mark (9). Tighten each nut (1) for
an additional 60 5 degrees (1/6 turn). Index
mark (8) should be lined up with index mark (7).
Repeat the procedure for the other connecting
g00610152
rod cap nut. Illustration 220
14. Repeat Steps 1 through 13 for the remaining 1. Remove bolts (1) that hold crankshaft main
pistons and connecting rods. bearing cap (2). Remove crankshaft main
bearing cap (2).
End By:
a. Install the piston cooling jets. Refer to bearing from crankshaft main bearing cap (2).
b. Install the engine oil pump. Refer to Disassembly

c. Install the cylinder head. Refer to Disassembly

i01150114

Remove
g00516920
SMCS Code: 1203-011 Illustration 221
Typical example
Removal Procedure
NOTICE
Table 44 If the crankshaft is turned in the wrong direction, the
Required Tools tab of the crankshaft main bearing will be pushed be-
Part cause damage to either or both the crankshaft and the
Tool Number Part Description Qty cylinder block.
upper half of crankshaft main bearings:
88

(A).


Parts, SEBF8009, Main and Connecting
Connecting Rod Bearings. g00516920
Illustration 222
i01496477 1. Use Tool (A) and install the upper halves of the
crankshaft main bearings in the cylinder block.
Crankshaft Main Bearings - Do not put oil on the back of the crankshaft main
Install bearing.
SMCS Code: 1203-012
Table 45
Required Tools
Part
A 2P-5518 Main Bearing Tool 1
g00610152
2. Install the lower halves of the crankshaft main
Contaminants may cause rapid wear and shortened bearings in crankshaft main bearing caps (2).
component life. Do not put oil on the back of the crankshaft main
bearing.
bearings prior to assembly. Ensure that the tabs on NOTICE
the back side of the crankshaft main bearings fit in Crankshaft main bearing caps should be installed with
the grooves of the crankshaft main bearing caps the part number toward the right side of the engine.
and the cylinder block. Crankshaft main bearing caps are to be identified by

on the washer face. Install bolts (1).
4. Tighten bolts (1) to a torque of 54 7 Nm

(40 5 lb ft). Tighten each bolt (1) for an
additional 90 5 degrees (1/4 turn).
89
g00517003 g00609979
5. Check the end play of the crankshaft with Tool 1. Fasten lifting slings and a hoist to each end of
(B). The end play must be 0.07 mm (0.003 inch) the crankshaft. Refer to Illustration 225.
to 0.32 mm (0.013 inch).
End By:

i01197475
Crankshaft - Remove
SMCS Code: 1202-011

Illustration 226
Start By:
2. Remove bolts (2), the washers, and main bearing
a. Remove the cylinder head. Refer to Disassembly caps (3). Carefully remove crankshaft (1) from
and Assembly, Cylinder Head - Remove. the cylinder block. The weight of the crankshaft
b. Remove the front housing. Refer to Disassembly
and Assembly, Housing (Front) - Remove. 3. Remove the main bearings from the cylinder
block. Remove the main bearings from the main
c. Remove the camshaft idler gear. Refer to bearing caps.
i01150032
d. Remove the pistons and connecting rods. Refer

Connecting Rods - Remove. SMCS Code: 1202-012
NOTICE Installation Procedure

Table 46
Required Tools
component life.
Part
90
5. Install crankshaft main bearing caps with the

NOTICE part numbers toward the right hand side of
Keep all parts clean from contaminants. the cylinder block. Ensure that crankshaft main
bearing caps have numbers 1 through 7. The
Contaminants may cause rapid wear and shortened numbers should start at the front of the engine.
component life. Place clean engine oil or Molylube on the bolt
threads and the washers.
NOTICE Note: When the bolts for the rear main bearing cap
Ensure that the crankshaft main bearing tabs engage are tightened, slide the main bearing cap as far
with the grooves in the block and the crankshaft main forward as possible until the cap is against the
bearing cap. bolts. Hold the main bearing cap in this position
and tighten the bolts.
1. Check the condition of the main bearings.
Refer to Main and Connecting Rod Bearings,
SEBF8009 and refer to Engine Bearings and
Crankshafts, SEBD0531.
Note: The number six main bearing is the thrust

bearing.
2. Clean the bearing surfaces in the cylinder block

for the main bearings. Apply clean engine oil on
the upper main bearing. Do not put engine oil on
the back side of the bearing surfaces. Install the
upper main bearing in the cylinder block. Ensure
that the tab on the back side of the bearing
engages with the groove in the cylinder block. Illustration 228
g00609985
6. Install bolts (2) and the washers for main

bearing caps (3). Tighten bolts (2) to a torque of
54 7 Nm (40 5 lb ft).
7. Turn bolts (2) for an additional 90 5 degrees

(1/4 turn).
g00610100
Illustration 227
3. Put clean engine oil on the journals of the

crankshaft bearing. Fasten lifting straps and
a hoist to crankshaft (1). Carefully install the
crankshaft in the cylinder block.
4. Clean the bearing surface of the main bearing Illustration 229

g00610119
caps. Install the lower main bearing in the
crankshaft main bearing caps. Ensure that the 8. Check the end play of crankshaft (1) with Tool
tab on the back side of the bearing engages (A). The end play must be 0.07 mm (0.003 inch)
with the groove in the main bearing cap. Apply to 0.32 mm (0.013 inch).
clean engine oil on the lower main bearing.
Do not put engine oil on the back side of the
bearing surfaces.
91
End By:
a. Install the pistons and connecting rods. Refer

b. Install the camshaft idler gear. Refer to

c. Install the front housing. Refer to Disassembly

d. Install the cylinder head. Refer to Disassembly

and Assembly, Cylinder Head - Install. g00645876
Illustration 230
i01207228 1. Use Tool (A) in order to remove crankshaft gear

(1) from crankshaft (2).
Install Installation Procedure
NOTICE
Removal Procedure
Table 47 component life.
Required Tools
Part 1. Position the woodruff key in the crankshaft.
8B-7551 Bearing Puller 1
8B-7549 Puller Leg 2
3H-0465 Push-Puller Plate 4
A 1B-4207 Full Nut 2
8B-7560 Step Plate 1
1P-0820 Hydraulic Puller 1
9U-6600 Hand Hydraulic Pump 1
Start By:
g00645882
a. Remove the crankshaft. Refer to Disassembly Illustration 231
and Assembly, Crankshaft - Remove.
NOTICE
Keep all parts clean from contaminants. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
Contaminants may cause rapid wear and shortened contact the skin.
component life.
2. Heat crankshaft gear (1) to a maximum
temperature of 316 C (600 F). Install crankshaft
gear (1) on the crankshaft.
End By:
a. Install the crankshaft. Refer to Disassembly and

Assembly, Crankshaft - Install.
92
i01410976 Note: Do not allow Tool (A) to extend over the edge
of the bearing.
Bearing Clearance - Check
SMCS Code: 1203-535; 1219-535 order to install the bearing cap. Do not use an
Measurement Procedure bearing when the cap is installed.
Table 48 Note: Do not turn the crankshaft when Tool (A) is

Required Tools installed.
Part
A - Plastigage -
NOTICE

component life.

small engines. This is because of the possibility of g00473227
Illustration 232
obtaining inaccurate results and the possibility of Typical example
Caterpillar engine bearing is quality checked for 3. Carefully remove the cap, but do not remove
specific wall thickness. Tool (A). Measure the width of Tool (A) while Tool
(A) is in the bearing cap or on the crankshaft
Note: The measurements should be within journal. Refer to Illustration 232.
specifications and the correct bearings should
be used. If the crankshaft journals and the bores 4. Remove all of Tool (A) before you install the
for the block and the rods were measured during bearing cap.
However, if the technician still wants to measure Note: When Tool (A) is used, the readings can
the bearing clearances, Tool (A) is an acceptable sometimes be unclear. For example, all parts of
method. Tool (A) is less accurate on journals with Tool (A) are not the same width. Measure the major
small diameters if clearances are less than 0.10 mm width in order to ensure that the parts are within
(0.004 inch). the specification range. Refer to Specifications,
Crankshaft for the correct clearances.
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
i01481332
age the bearing surfaces.
The technician must be very careful to use Tool (A) - Remove and Install
correctly. The following points must be remembered:
SMCS Code: 1923-010
Ensure that the backs of the bearings and the
Removal Procedure
seated in the tab grooves. NOTICE
points of Tool (A). Contaminants may cause rapid wear and shortened
component life.
93
NOTICE

products.

Illustration 234
mandates.
(1) Atmospheric pressure sensor
1. Install atmospheric pressure sensor (1). Tighten

the atmospheric pressure sensor to a torque of
10 2 Nm (90 18 lb in).
2. Connect the plug for atmospheric pressure

sensor (1).
i01479483
Coolant Temperature Sensor -

Remove and Install
g00772510 SMCS Code: 1906-010
Illustration 233
(1) Atmospheric pressure sensor
Removal Procedure
1. Disconnect the plug for atmospheric pressure
sensor (1). NOTICE
2. Remove atmospheric pressure sensor (1).
component life.
NOTICE NOTICE
Keep all parts clean from contaminants. Care must be taken to ensure that fluids are contained
Contaminants may cause rapid wear and shortened ing, adjusting and repair of the product. Be prepared to
component life. collect the fluid with suitable containers before open-

products.

mandates.
94
i01479715

Remove and Install
SMCS Code: 1924-010
Removal Procedure
NOTICE

g00770396
component life.
Illustration 235
(1) Coolant temperature sensor
(2) Electrical connection for coolant temperature sensor NOTICE
1. Disconnect plug (2) from coolant temperature during performance of inspection, maintenance, test-
sensor (1). ing, adjusting and repair of the product. Be prepared to
2. Remove coolant temperature sensor (1). ing any compartment or disassembling any compo-
NOTICE suitable to collect and contain fluids on Caterpillar
Keep all parts clean from contaminants. products.
Contaminants may cause rapid wear and shortened Dispose of all fluids according to local regulations and
component life. mandates.
g00770396 g00770526
(1) Coolant temperature sensor (1) Electrical connection for engine oil pressure sensor
(2) Electrical connection for coolant temperature sensor (2) Engine oil pressure sensor
1. Install coolant temperature sensor (1). Tighten 1. Disconnect plug (1) from engine oil pressure
the coolant temperature sensor to a torque of sensor (2).
20 5 Nm (15 4 lb ft).
2. Remove engine oil pressure sensor (2).
2. Connect plug (2) to coolant temperature
sensor(1).
95
NOTICE
NOTICE Care must be taken to ensure that fluids are contained
Keep all parts clean from contaminants. during performance of inspection, maintenance, test-
Contaminants may cause rapid wear and shortened collect the fluid with suitable containers before open-
component life. ing any compartment or disassembling any compo-

products.

mandates.
g00770526
Illustration 238
(1) Electrical connection for engine oil pressure sensor
(2) Engine oil pressure sensor
1. Install engine oil pressure sensor (2). Tighten

the engine oil pressure sensor to a torque of
10 2 Nm (90 18 lb in).
2. Connect plug (1) to engine oil pressure sensor

(2).
i01481086
Engine Oil Temperature Sensor

- Remove and Install Illustration 239
g00771060
(1) Engine oil temperature sensor

SMCS Code: 1929-010 (2) Electrical connection for engine oil temperature sensor
Removal Procedure 1. Disconnect plug (2) for engine oil temperature

sensor (1).
NOTICE
Keep all parts clean from contaminants. 2. Remove engine oil temperature sensor (1).
Contaminants may cause rapid wear and shortened Installation Procedure

component life.
NOTICE

component life.
96
NOTICE

products.

mandates.
g00771060
Illustration 240
(1) Engine oil temperature sensor
(2) Electrical connection for engine oil temperature sensor
1. Install engine oil temperature sensor (1). Tighten

the engine oil temperature sensor to a torque of
10 2 Nm (90 18 lb in).
2. Connect plug (2) for engine oil temperature

sensor (1).
g00770496
Illustration 241
(1) Electrical connection for injection actuation pressure sensor
i01479662
(2) Injection actuation pressure sensor
Injection Actuation Pressure 1. Disconnect plug (1) from injection actuation
Sensor - Remove and Install pressure sensor (2).
SMCS Code: 1925-010 2. Remove injection actuation pressure sensor (2).

NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
97
g00770496
Illustration 242
(1) Electrical connection for injection actuation pressure sensor
(2) Injection actuation pressure sensor
1. Install injection actuation pressure sensor (2).

Tighten the injection actuation pressure sensor
to a torque of 10 2 Nm (90 18 lb in). g00771142
Illustration 243
2. Connect plug (1) to injection actuation pressure (1) Speed/timing sensors
(2) Bolt
sensor (2). (3) Electrical connections for speed/timing sensors
i01481228 1. Disconnect plugs (3) for speed/timing sensors

(1).
Speed/Timing Sensor -
2. Remove bolt (2) that fastens the speed/timing
Remove and Install sensors to the engine.
SMCS Code: 1907-010; 1912-010
3. Remove speed/timing sensors (1).

NOTICE
NOTICE
component life.
component life.
NOTICE Note: The speed/timing sensors must be replaced

Care must be taken to ensure that fluids are contained as a pair.

products.

mandates.
98
NOTICE

products.

mandates.
g00771142
Illustration 244
(1) Speed/timing sensors
(2) Bolt
(3) Electrical connections for speed/timing sensors
1. Position speed/timing sensors (1) on the engine.
Note: Ensure that the speed/timing sensors are

seated on the sensor flanges before you tighten the
bolt on the bracket.
2. Install bolt (2) that fastens the speed/timing

sensors on the engine.
3. Connect plugs (3) for speed/timing sensors (1).
i01481057 g00771041
Illustration 245
Boost Pressure Sensor - (1) Boost pressure sensor

(2) Electrical connection for boost pressure sensor
Remove and Install
1. Disconnect plug (2) for boost pressure sensor
SMCS Code: 1917-010 (1).
2. Remove boost pressure sensor (1).

Removal Procedure
NOTICE
component life.
component life.
99
NOTICE

products.

mandates.
g00771041
Illustration 246
(1) Boost pressure sensor
(2) Electrical connection for boost pressure sensor
1. Install boost pressure sensor (1). Tighten the

boost pressure sensor to a torque of 10 2 Nm
(90 18 lb in).
2. Connect plug (2) for boost pressure sensor (1).

g00771192
Illustration 247
i01481365
Typical example
Inlet Air Temperature Sensor - (1) Inlet air temperature sensor
(2) Electrical connection for inlet air temperature sensor
Remove and Install
1. Disconnect plug (2) for inlet air temperature
SMCS Code: 1921-010 sensor (1).
Removal Procedure 2. Remove inlet air temperature sensor (1).

NOTICE
component life.
component life.
100
g00771192 g00618473
Typical example
(1) Inlet air temperature sensor 2. Remove bolt (2) and idler pulley (3).
(2) Electrical connection for inlet air temperature sensor
i01161563
1. Install inlet air temperature sensor (1). Tighten
the inlet air temperature sensor to a torque of Idler Pulley - Disassemble
20 5 Nm (15 4 lb ft).
SMCS Code: 1358-015
2. Connect plug (2) for inlet air temperature sensor
(1).
i01161409 Table 49
Required Tools
Idler Pulley - Remove
Part
SMCS Code: 1358-011 Number
Removal Procedure B 1P-1855 Retaining Ring Pliers 1
Start By:
a. Remove the idler pulley. Refer to Disassembly

and Assembly, Idler Pulley - Remove.
g00618468
Illustration 249
1. Remove cover (1) from the idler pulley. Cover (1)

will be damaged during removal.
g00618635
Illustration 251
1. Remove spacer (1) and bolt (5) from idler pulley

(4).
101
2. Remove retaining rings (2) from each side of i01161430

idler pulley (4) with Tool (B).
Idler Pulley - Install
3. Remove bearings (3) from each side of idler
pulley (4) with Tool (A). SMCS Code: 1358-012
i01161599
Idler Pulley - Assemble
SMCS Code: 1358-016
Assembly Procedure
Table 50
Required Tools
Part
Number
g00618473
Illustration 253
1. Position idler pulley (3). Install bolt (2) and tighten

bolt (2) to a torque of 55 10 Nm (40 7 lb ft).
g00618635
Illustration 252
1. Install one retaining ring (2) in idler pulley (4).
2. Install two bearings (3) in idler pulley (4) with g00618468

Tool (A). Install the remaining retaining ring (2). Illustration 254
3. Install spacer (1) and bolt (5) in idler pulley (4). 2. Install a new cover (1) on idler pulley (3).
End By:
a. Install the idler pulley. Refer to Disassembly and

Assembly, Idler Pulley - Install.
102
i01160976 1. Position belt tensioner (2) on the cylinder block.

Install four bolts (1).
Install 2. Install the drive belt. Use a breaker bar to place
the original amount of tension on the drive belt.
SMCS Code: 1358-010
i01162446
Removal Procedure Belt Tightener - Remove
SMCS Code: 1358-011
Removal Procedure
g00614167
Illustration 255

tensioner (2). Remove the drive belt.
2. Remove four bolts (1) and belt tensioner (2). g00619355

Illustration 257
Installation Procedure 1. Remove two bolts (1) that hold water pump belt
2. Remove V-belt (2) from the pulley of water pump

belt tightener (3). Remove water pump belt
tightener (3).
g00614167
Illustration 256
103
i01162490 i01162522
Belt Tightener - Disassemble Belt Tightener - Assemble

Disassembly Procedure Assembly Procedure

Table 51 Table 52
Required Tools Required Tools
Part Part
Tool Part Description Qty Tool Part Description Qty
Number Number
A 1P-1855 Retaining Ring Pliers 1 A 1P-1855 Retaining Ring Pliers 1
B 1P-0510 Driver Group 1 B 1P-0510 Driver Group 1
Start By:
a. Remove the water pump belt tightener. Refer to

Remove.
g00619412
Illustration 260
1. Check the condition of shaft (4) in idler plate

assembly (5). Replace idler plate assembly (5) if
shaft (4) is worn.
g00619391
Illustration 258
1. Use Tool (A) to remove retaining ring (1). Remove

pulley (2) from the idler plate assembly.
g00619393
Illustration 261
2. Thoroughly clean the following components: the

bearing bore in the pulley, the outside bearing
bore of the pulley, and the outside diameter of
g00619393
Illustration 259 two bearings (3). Apply 9S-3263 Thread Lock
Compound in the bearing bore of the pulley
2. Remove two bearings (3) from pulley (2) with a and on the outside diameter of two bearings
press and Tool (B). (3). Install two bearings (3) in the pulley with
Tool (B). Ensure that bearings (3) are centered
in the pulley.
104
2. Install two bolts (1) that hold water pump belt

3. Adjust the tension of V-belt (2). Refer to Operation

and Maintenance Manual, Belt Tension Chart.
i01148551
Fan Drive - Remove

SMCS Code: 1359-011
Removal Procedure
g00619391
Illustration 262 Start By:
3. Install pulley (2) on the idler plate assembly. a. Remove the alternator. Refer to Disassembly and
Install retaining ring (1) with Tool (A) in order to Assembly, Alternator - Remove and Install.
hold pulley (2) to the idler plate assembly.
End By:
a. Install the water pump belt tightener. Refer to

Install.
i01162480
Belt Tightener - Install

SMCS Code: 1358-012

g00609660
g00609661
Illustration 265
1. Remove two bolts (2) and remove alternator

bracket (1).
2. If equipped, remove three bolts (3), the washers,

Illustration 263
g00619355 and the nuts. Remove refrigerant compressor (4).
1. Position water pump belt tightener (3) and install 3. Remove six bolts (5) and the washers. Remove
V-belt (2) on the pulley of water pump belt fan drive (6) and front lifting group (7) from the
tightener (3). cylinder head assembly.
105
i01148567 i01377485
Fan Drive - Install Engine Control Module -

SMCS Code: 1359-012
Remove and Install
SMCS Code: 1901-010
Removal Procedure
g00609660
Illustration 266
g00609591
Illustration 268
1. Loosen screw (1) until wiring harness (4) can

be disconnected. Disconnect wiring harness (4)
from engine control module (2).
2. Remove four bolts (3). Remove the engine

control module from the engine.
g00609661
Illustration 267
1. Position fan drive (6) and front lifting group (7)

on the cylinder head assembly. Install six bolts
(5) and the washers.
2. If equipped, position refrigerant compressor (4).

Install three bolts (3), the washers, and the nuts.
3. Position alternator bracket (1). Install two bolts

(2).
g00609591
Illustration 269
End By:
1. Position engine control module (2) on the engine
a. Install the alternator. Refer to Disassembly and and install four bolts (3).
Assembly, Alternator - Remove and Install.
2. Connect wiring harness (4) to engine control
module (2). Tighten screw (1) to a torque of
6 1 Nm (53 9 lb in).
106
i01148408
Alternator - Remove and Install

SMCS Code: 1405-010
Removal Procedure
Table 53
Required Tools
Part
g00609523
Illustration 271
Typical example
1. Position alternator (3) on the mounting bracket.

Install bolts (2).
2. Use Tool (A) to install drive belt (4) on the drive

pulley of the alternator.
Note: Adjust the tension on the drive belt if the

engine is not equipped with a belt tensioner. Refer
correct adjusting procedure.
g00609523 3. Connect wires (1) to the alternator. Use the index

Illustration 270 marks to correctly connect the wires. Tighten the
Typical Example mounting bolt for the ground wire to a torque
of 6.2 0.6 Nm (54 5 lb in). Tighten the
Note: Release the tension on the belt at the belt mounting bolt for the battery wire to a torque of
tightener, if the engine is not equipped with a belt 11.3 2.3 Nm (100 20 lb in).
tensioner.
1. Use tool (A) to release the tension on belt i01012803

tensioner (5).
2. Remove drive belt (4) from the drive pulley on Remove and Install
alternator (3).
SMCS Code: 1453-010
3. Place an index mark on all electrical wires (1)
electrical wires (1) from the alternator.
Removal Procedure
4. Remove two bolts (2).
Disconnect the electrical wires from the electric
5. Remove alternator (3) from the mounting bracket.
starting motor.
Table 54
Required Tools
Part
107
i01331969

Install
SMCS Code: 1803-010
Removal Procedure
Table 55
Required Tools
Part
g00519372
Illustration 272 A 138-7573 Link Bracket 1
Typical example

starting motor.
Do not disconnect the air lines until the air pres-
3. Remove three bolts (1). sure in the system is at zero. If hose is disconnect-
ed under pressure it can cause personal injury.
the electric starting motor is 29 kg (65 lb). NOTICE
Installation Procedure Contaminants may cause rapid wear and shortened
component life.
NOTICE
2. Install the gasket on the electric starting motor. Care must be taken to ensure that fluids are contained

products.

mandates.
g00519372 1. Remove the air pressure from the air tank and
Illustration 273
drain the coolant from the cooling system.
Typical example

starting motor.


108
a. Remove bolt (8) and the clip for the oil hose
from the bracket for the air compressor.
b. Remove two bolts (5) and bolt (6) that fastens

the bracket for the air compressor to the
cylinder block. Remove bolt (7) and the
spacer between the air compressor and the
bracket for the air compressor. Remove the
bracket for the air compressor.
6. Remove the mounting bracket for a Bendix Tu-Flo

550 and Bendix Tu-Flo 750 air compressors by
using the following procedure:
g00609682
Illustration 274
2. Disconnect water hose (1) and water hose (3)

from the air compressor.
3. Disconnect air hose (2) and oil hose (4) from the
air compressor.
4. Install Tool (A) and a proper lifting device to the

air compressor. The weight of the air compressor
5. Remove the mounting bracket for a Midland

EL-740 air compressor by using the following Illustration 276
g00705242
procedure: Typical example
a. Remove bolts (9) that fasten the mounting

bracket to the air compressor.
b. Remove bolts (10) that fasten the mounting

bracket to the cylinder block. Remove the
mounting bracket for the air compressor.
g00609684
Illustration 275
109
g00705313 g00705313
7. Use two technicians to support air compressor 1. Install Tool (A) and a proper lifting device to the
(12). Remove bolts (11), air compressor (12), air compressor. The weight of the air compressor
and the gasket from the timing gear housing. is approximately 23 kg (51 lb).

Installation Procedure gasket, if necessary. Install the gasket between
Table 56 air compressor (12) and the timing gear housing.
Required Tools 3. Position air compressor (12) in the front housing.
Part Ensure that the drive gear engages correctly
Tool Number Part Description Qty with the gear in the front housing.
threads of two bolts (11). Install two bolts (11).
NOTICE Tighten bolts (11) to a torque of 100 20 Nm
Keep all parts clean from contaminants. (75 15 lb ft).
Contaminants may cause rapid wear and shortened 5. Install the mounting bracket for a Midland EL-740
component life. air compressor by using the following procedure:
110
g00609684 g00705242
Typical example
a. Position the bracket for the air compressor
and install bolts (5) and (6). Install the spacer a. Position the bracket for the air compressor
and bolt (7). Hand tighten all bolts. and install bolts (9) and bolts (10) finger tight.
NOTICE NOTICE
A loose compressor bracket can lead to a broken front A loose compressor bracket can lead to a broken front
cover and can cause damage to the front gear train of cover and can cause damage to the front gear train of
the engine. the engine.
b. Tighten bolt (7) to a torque of 50 10 Nm b. Tighten bolts (9) to a torque of 55 10 Nm

(37 7 lb ft). Tighten bolt (5) to a torque of (40 7 lb ft). Tighten bolts (10) to a torque of
55 10 Nm (40 7 lb ft). Tighten bolt (6) to 55 10 Nm (40 7 lb ft). Remove the lifting
a torque of 28 7 Nm (21 5 lb ft). Remove device and Tool (A).
the lifting device and Tool (A).
6. Install the mounting bracket for Bendix Tu-Flo

550 and Bendix Tu-Flo 750 air compressors by
using the following procedure:
g00609682
Illustration 281
111
7. Connect oil hose assembly (4) to the air 1. Mount air compressor (1) in a bench vise.
compressor. Connect the clip that holds the hose
assembly to the air compressor. Tighten bolt (8) 2. Install tool (A) on the air compressor drive gear.
that holds the clip to a torque of 28 7 Nm
(21 5 lb ft). 3. Remove nut (2) and washer (3).
8. Connect water hose (1) and (3) to the air 4. Remove air compressor drive gear (4).
compressor.
i01517157
9. Connect air hose (2) to the air compressor.

level. Refer to the Operation and Maintenance Install
i01517187
Table 58
Remove Required Tools
SMCS Code: 1803-011-GE Tool Part Number Part Description Qty
A 132-5451 Air Compressor Gear 1
Removal Procedure Holder
Table 57
Required Tools NOTICE
Air Compressor Contaminants may cause rapid wear and shortened
A 132-5451 1 component life.
Gear Holder
Start By:
a. Remove the air compressor. Refer to Disassembly

Install.
NOTICE

component life.
g00609907
Illustration 283
Typical example
1. Use 138-8440 Component Cleaner in order to

clean the inside diameter of gear (4) and the
outside diameter of the drive shaft for the air
compressor.
2. Lubricate washer (3) and the threads on the

drive shaft with clean engine oil.

g00609907
Illustration 282 4. Install air compressor drive gear (4) on the air
Typical example compressor crankshaft.
112
5. Install washer (3) and nut (2).

(120 7 lb ft).
8. Place a driver which is slightly larger than the nut

over the nut and tap the driver with a hammer.
9. Tighten the nut again to a torque of 165 10 Nm

(120 7 lb ft).
End By:
a. Install the air compressor. Refer to Disassembly

Install.
113
Index Section
Index
A Camshaft Idler Gear - Remove and Install ............ 62
Air Compressor - Remove and Install.................. 107 Removal Procedure ........................................... 62
Installation Procedure ...................................... 109 Coolant Temperature Sensor - Remove and
Removal Procedure ......................................... 107 Install ................................................................... 93
Air Compressor Drive Gear - Install..................... 111 Installation Procedure ........................................ 94
Air Compressor Drive Gear - Remove................. 111 Crankshaft - Install................................................. 89
Air Inlet Cover - Remove and Install ...................... 27 Crankshaft - Remove............................................. 89
Removal Procedure ........................................... 27 Crankshaft Front Seal - Install ............................... 59
Air Inlet Heater - Remove and Install..................... 25 Installation Procedure ........................................ 59
Installation Procedure ........................................ 26 Crankshaft Front Seal - Remove ........................... 59
Air Inlet Heater Solenoid - Remove and Install...... 27 Crankshaft Gear - Remove and Install .................. 91
Alternator - Remove and Install ........................... 106 Crankshaft Main Bearings - Install......................... 88
Installation Procedure ...................................... 106 Installation Procedure ........................................ 88
Removal Procedure ......................................... 106 Crankshaft Main Bearings - Remove..................... 87
Atmospheric Pressure Sensor - Remove and Removal Procedure ........................................... 87
Install ................................................................... 92 Crankshaft Rear Seal - Install................................ 46
Removal Procedure ........................................... 92 Crankshaft Rear Seal - Remove............................ 45
B Install ................................................................... 48
Bearing Clearance - Check ................................... 92 Removal Procedure ........................................... 48
Measurement Procedure ................................... 92 Crankshaft Wear Sleeve (Rear) - Install ................ 47
Belt Tensioner - Remove and Install .................... 102 Installation Procedure ........................................ 47
Installation Procedure ...................................... 102 Crankshaft Wear Sleeve (Rear) - Remove (If
Removal Procedure ......................................... 102 Equipped) ............................................................ 47
Belt Tightener - Assemble ................................... 103 Removal Procedure ........................................... 47
Assembly Procedure........................................ 103 Cylinder Head - Install ........................................... 71
Belt Tightener - Disassemble .............................. 103 Installation Procedure ........................................ 71
Disassembly Procedure ................................... 103 Cylinder Head - Remove ....................................... 70
Belt Tightener - Install.......................................... 104 Removal Procedure ........................................... 70
Installation Procedure ...................................... 104
Belt Tightener - Remove...................................... 102
Removal Procedure ......................................... 102 D
Boost Pressure Sensor - Remove and Install........ 98
Installation Procedure ........................................ 98 Disassembly and Assembly Section........................ 5
E
C
Electric Starting Motor - Remove and Install ....... 106
Camshaft - Install................................................... 75 Installation Procedure ...................................... 107
Installation Procedure ........................................ 75 Removal Procedure ......................................... 106
Camshaft - Remove............................................... 74 Engine Control Module - Remove and Install ...... 105
Removal Procedure ........................................... 74 Installation Procedure ...................................... 105
Camshaft Bearings - Remove and Install .............. 77 Removal Procedure ......................................... 105
Installation Procedure ........................................ 77 Engine Oil Filter Base - Assemble......................... 33
Removal Procedure ........................................... 77 Assembly Procedure.......................................... 33
Camshaft Gear - Remove and Install .................... 76 Engine Oil Filter Base - Disassemble .................... 33
Installation Procedure ........................................ 76 Disassembly Procedure ..................................... 33
Removal Procedure ........................................... 76 Engine Oil Filter Base - Install ............................... 34
114
Index Section
Engine Oil Filter Base - Remove ........................... 32 I

Engine Oil Pan - Remove and Install ..................... 78 Idler Pulley - Assemble ........................................ 101
Installation Procedure ........................................ 79 Assembly Procedure........................................ 101
Removal Procedure ........................................... 78 Idler Pulley - Disassemble ................................... 100
Engine Oil Pressure Sensor - Remove and Install.. 94 Disassembly Procedure ................................... 100
Installation Procedure ........................................ 95 Idler Pulley - Install .............................................. 101
Removal Procedure ........................................... 94 Installation Procedure ...................................... 101
Engine Oil Pump - Assemble................................. 37 Idler Pulley - Remove .......................................... 100
Assembly Procedure.......................................... 37 Removal Procedure ......................................... 100
Engine Oil Pump - Disassemble............................ 35 Important Safety Information ................................... 2
Disassembly Procedure ..................................... 35 Injection Actuation Pressure Control Valve -
Engine Oil Pump - Install ....................................... 38 Assemble ............................................................. 18
Installation Procedure ........................................ 38 Assembly Procedure.......................................... 18
Engine Oil Pump - Remove ................................... 35 Injection Actuation Pressure Control Valve -
Removal Procedure ........................................... 35 Disassemble ........................................................ 18
Engine Oil Temperature Sensor - Remove and Disassembly Procedure ..................................... 18
Install ................................................................... 95 Injection Actuation Pressure Control Valve -
Exhaust Manifold - Remove and Install ................. 24 Injection Actuation Pressure Control Valve -
Installation Procedure ........................................ 25 Remove ............................................................... 17
Injection Actuation Pressure Sensor - Remove and
Install ................................................................... 96
F Installation Procedure ........................................ 96
Fan Drive - Install................................................. 105 Inlet Air Temperature Sensor - Remove and
Installation Procedure ...................................... 105 Install ................................................................... 99
Fan Drive - Remove............................................. 104 Installation Procedure ........................................ 99
Removal Procedure ......................................... 104 Removal Procedure ........................................... 99
Flywheel - Install.................................................... 44 Inlet and Exhaust Valve Guides - Remove and
Flywheel - Remove................................................ 44 Installation Procedure ........................................ 30
Flywheel Housing - Remove and Install ................ 49 Inlet and Exhaust Valve Seat Inserts - Remove and
Front Cover - Install ............................................... 60 Removal Procedure ........................................... 31
Installation Procedure ........................................ 60 Inlet and Exhaust Valves - Remove and Install ..... 28
Front Cover - Remove ........................................... 60 Installation Procedure ........................................ 28
Fuel Filter Base - Install........................................... 6
Fuel Filter Base - Remove....................................... 5 L
Fuel Pressure Regulator - Remove and Install........ 8 Lifter Group - Remove and Install.......................... 72
Installation Procedure .......................................... 9 Installation Procedure ........................................ 73
Removal Procedure ............................................. 8 Removal Procedure ........................................... 72
Fuel Transfer Pump - Install..................................... 7
Fuel Transfer Pump - Remove ................................. 6 P
Piston Cooling Jets - Remove and Install .............. 80
H Removal Procedure ........................................... 80
Housing (Front) - Install ......................................... 62 Assembly Procedure.......................................... 83
Installation Procedure ........................................ 62 Pistons and Connecting Rods - Disassemble ....... 82
Housing (Front) - Remove ..................................... 61 Disassembly Procedure ..................................... 82
115
Index Section
Pistons and Connecting Rods - Install................... 84 Vibration Damper and Pulley - Remove and
Pistons and Connecting Rods - Remove............... 81 Installation Procedure ........................................ 58
R W
Rear Power Take-Off (RPTO) - Assemble ............. 54 Water Pump - Assemble........................................ 41

Installation Procedure ........................................ 54 Assembly Procedure.......................................... 41
Rear Power Take-Off (RPTO) - Disassemble ........ 51 Water Pump - Disassemble ................................... 39
Removal Procedure ........................................... 51 Disassembly Procedure ..................................... 39
Rocker Shaft - Assemble ....................................... 69 Water Pump - Install .............................................. 42
Rocker Shaft - Disassemble .................................. 68 Water Pump - Remove .......................................... 39
Disassembly Procedure ..................................... 68 Removal Procedure ........................................... 39
Rocker Shaft and Pushrod - Install ........................ 69 Water Temperature Regulator - Remove and
Rocker Shaft and Pushrod - Remove .................... 67 Installation Procedure ........................................ 43
Speed/Timing Sensor - Remove and Install .......... 97

Unit Injector - Install............................................... 12

Unit Injector - Remove ............................................. 9
Unit Injector Hydraulic Pump - Remove................. 19
Unit Injector Sleeve - Install ................................... 17
Unit Injector Sleeve - Remove ............................... 16

Install ................................................................... 66
2001 Caterpillar
RENR1282-03
May 2001
Service Manual
Electronic PTO Installation and
Applications
BKD1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents
Switches ................................................................. 4
Component Installation ........................................... 8

Programmable Parameters ................................... 40
Troubleshooting Section
Troubleshooting with a Diagnostic Code
0030-08 Invalid PTO Throttle Signal (29) .............. 44
0030-13 PTO Throttle Sensor Calibration (29) ..... 44
0071-14 PTO Shutdown Timer Occurrence (47) .. 44
Diagnostic Functional Tests

PTO Shutdown Timer - Test .................................. 46
PTO Switch Circuit - Test ...................................... 48
PTO Switch ON Lamp Circuit - Test ...................... 57
Remote PTO Accelerator Position Sensor Circuit -
Test ..................................................................... 61

PTO Parameters - Program .................................. 70
PTO Configurations - Test ..................................... 72
Index Section
Index ................................................................... 115
4
Switches
i01219566
SMCS Code: 1011-ZS
General Information
Switch Electrical Specifications
SMCS Code: 1000; 1165
The plating that is on the switch should not corrode
This manual explains the different options and and the plating should not oxidize. Gold plated
applications for the installation of the electronics for contacts are recommended. All switches should be
the PTO. Different switches and components are an environmentally sealed unit. All switches should
shown in different applications in this manual. be protected according to the requirements of the
application.
Once the installation is complete, ensure that the
operator of the PTO understands the operation of Normally, the applied voltage to the switches will not
the PTO. Fully explain the different applications and exceed 11.5 Volts. The normal current draw through
components of the installation. Ensure that the Truck the switches will not exceed 0.0065 Amp (6.5 mA).
Installation Diagram is completed and ensure that
the Truck Installation Diagram is explained to the The chatter (momentary opening and closing) of
operator of the PTO. the contacts should not exceed a duration of 0.1
seconds (100 milliseconds). The switches should
This manual has been created in different sections. not open and the switches should not close due to
The Specifications section explains the selection of a vibration or shock. Closure of an installed switch
the different components that may be needed for must short the circuit. The input will short to the
the installation. Schematics and configurations for Input Sensor Common 1 (terminal 18) or to the Input
the switches and components are provided. The Sensor Common 2 (terminal 3) of the ECM Vehicle
schematics and configurations are for the different Harness Connector J1/P1.
installations.
The Systems Operation section explains the Voltage Thresholds (Measurement at the
operation of the PTO once the switches and ECM)
components have been installed. More detail is
given on the different types of installations. Voltage Input of Less Than 0.9 Volts When the
switch contacts close, the voltage that is across the
The Testing and Adjusting section explains the following items must be less than 0.9 Volts between
operation of the system once the system has been the respective control input and the sensor common
installed. All of the different types of installation connection: difference of the ground potential, drop
arrangements are explained in full operation. A in switch voltage, and drop in voltage for the wiring
diagram of the position of the tachometer, the harness.
switches, and the accelerator pedal is given for
each step for a quick reference. Voltage Input Equal To or Greater Than 4.0 Volts
When the switch contacts open, the following items
Finally, the Troubleshooting section explains the must not result in an effective resistance of less than
diagnostics and the correction of any problems 5,000 Ohms from the respective control input to the
with the installation. For more information on sensor common connection: the pin to pin leakage
troubleshooting, always refer to the Troubleshooting paths in connectors, harnesses, and switches.
Guide for your engine.
Note: The following terminals are designated as
the Sensor Common connection J1/P1: Terminal 3
(Input Sensor Common 2) and terminal 18 (Input
Sensor Common 1). OEM installed switches that are
input into the ECM must not be connected to the
vehicle or to the cab ground. The OEM installed
switches must be grounded to the Sensor Common
by using a dedicated return line to ECM Vehicle
Harness Connector P1.
5
Selecting a Switch Type Electrical Specifications for the

The type of switch that is required depends on
Remote Accelerator Pedal Position
the type of application that is required. The Cruise Sensor
Control Set/Resume or the RPM Increase/RPM
Decrease Switch is typically a three-position
momentary switch. A spring is used in order to
return the switch to the OFF position.
The PTO On/Off Switch can be an On/Off or a

two-position switch. The switch can be actuated by
one of the following operations:
Manual
Air
Hydraulic
g00622029
The Interlock Switches for the PTO are typically Illustration 2
actuated by air. The Interlock Switches for the 161-8906 Accelerator Pedal Position Sensor
PTO are also in the normally closed position. The
switches are connected into the air lines for the The 161-8906 Position Sensor is required. The
Parking Brake or connected to the air lines for sensor is supplied with a Deutsch HD connector.
the Transmission. All switches may be controlled The Deutsch part number is HD16-3-96S. The
hydraulically or the switches may be limit switches. Caterpillar part number is 8T-8731 Connector Plug.
All switches that are located outside the cab should The connecting harness will require a Deutsch HD
be environmentally sealed and protected. receptacle connection. The Deutsch part number
is HD14-3-96P. The Caterpillar part number is
Switches That Are Available from 8T-8732 .
Caterpillar Note: The 161-8906 Position Sensor can not be
powered by the 8 Volt power supply from the ECM.
A 112-4073 Pressure Switch Assembly is available. The 161-8906 Position Sensor must be connected
The switch has the following features: single pole, and powered by 12/24 Volt battery voltage.
single throw, and actuated by air.
Mounting the Accelerator Pedal Position
Sensor
g00621900
Illustration 1
Schematic for the 112-4073 Pressure Switch Assembly
The actuation pressure for the switch is the following value: Illustration 3 g00638606
330 kPa (48 psi)
107-2281 Mounting Block
The handle is not included.
6
The 161-8906 Position Sensor can be attached to Specifications for the Harness
either an accelerator pedal assembly or a 107-2281
Mounting Block. The PTO Accelerator Assembly The harness should be protected from the
does not include the handle. A mechanical linkage environment by using a conduit that is plastic or
can also be used in the application. Contact the by other means. All of the wire for the harness
vehicle OEM in order to obtain information on the should be 18 AWG or the wire should be larger.
part number for the accelerator pedal assembly. The wire for the harness should be SAE J1128. The
wire for the harness should be SXL or GXL. Use
an equivalent wire for the harness if one of the
types is not available. The acceptable range for
wire insulation outside diameter is 2.26 to 3.33 mm
(0.089 to 0.131 inch). All ring terminals and all
splices that are connected to the harness must be
sealed. All ring terminals and all splices that are
routed to the engine ECM must be sealed. Seal the
terminals and splices with Raychem ES2000 shrink
tubing or the equivalent in order to seal the ring
terminals and the splices.
g00638604
Illustration 4
Williams Controls, Inc. Pedal assembly
Table 1
Williams Controls, Inc. Part Numbers for
Pedal Assemblies
Supplier Part Number Pedal Angle
350415 28 degrees
350416 35 degrees
350417 45 degrees
Note: The 161-8906 Position Sensor provides a

Pulse Width Modulated signal to the ECM that is
constant frequency. The duty cycle varies with the
position of the accelerator pedal. The ECM Remote
Throttle input cannot be used with a vernier control
cable assembly or as an input for the throttle switch.
The ECM Remote Throttle input must receive the
correct PWM signal during any of the following
conditions: The ECM is in the ON position., The
PTO Configuration is programmed to Remote
Throttle., and A diagnostic code is the result.
7
Table 2
Components for the 70 Terminal Connector for the ECM
Vendor and Vendor Part
Description Usage Caterpillar Part Number
Number
70 Terminal Connector Vehicle Harness for the OEM AMP/776241-1 160-7689
The AMP terminal is a Number 16 and Number 18 AMP/776093-1 126-1766
gold socket contact that is AWG SXL Wire
stamped and formed. Number 14, Number 16, and
Number 18 AWG GXL wire
The Deutsch terminal is a Number 14 AWG SXL wire Deutsch-0462-209-1631 126-1768
gold socket contact that is and Number 14 AWG GXL
machined for field service. wire
The Deutsch terminal is a Number 16 and Number 18 Deutsch-0462-201-1631 9X-3402
Gold Socket Contact that is AWG SXL wire
machined for field service. Number 16 and Number 18
AWG GXL wire
Sealing Plug for Number 14 Unused Connector Slots PEI Genesis-225-0093-000 9G-3695
AWG to Number 18 AWG
Sealing Plug for Number 14 Unused Connector Slots Deutsch-114017 8T-8737
AWG to 18 AWG
Hand Crimp Tool The tool crimps the following Deutsch-HDT-48-00 1U-5804
wire: Number 14, Number
16, and Number 18 AWG
Terminal Removal Tool SXL and GXL Wire AMP 776106 151-6320
g00622240
Illustration 5
(1) Contact Pin
(2) Machined socket contact
(3) Stamped and forged socket contact
(4) Sealing plug
Table 3
Components with 2-Pin Connector for
GM Vehicles Only
Description Packard Part Number
Metra-Pack 150 Series 1 205 2644
Female 2-Pin Connector
Metra-Pack 150 Series 1 216 2343
Male 2-Pin Connector
8
i01486701
Component Installation
SMCS Code: 1000; 1900
g00627397
Illustration 6
Left side view of 3126B engine
(1) Vehicle harness connector J1/P1 (5) Side view of vehicle harness connector
(2) Engine harness connector J2/P2 P1
(3) Engine Control Module (ECM) (6) Harness side of vehicle harness
(4) ECM side of vehicle harness connector connector P1
P1
9
Considerations for the Installation Engine Shutdown Switch

If an engine shutdown switch is desired, then the
switch should be connected to a Normally Closed
Relay. Refer to Schematics 7 and 8 for an example.
The switches labeled PTO Interlock in the
The actual location of the switch should be readily
schematics are redundant and should be added
accessible to the operator of the PTO during PTO
to ensure the engine is put in PTO mode only
operation.
when the vehicle and operator are prepared for
safe PTO operation. The interlocks must pre-
vent operation of the engine PTO until the PTO
operator is expecting it and is prepared. These
switch(es) may be (parking brake switch or other
switches) available as an interlock and are re-
quired for the application.
NOTICE
It is the installer and the vehicle owners responsibil-
ity to determine the necessary interlocks for the the
PTO system and to provide the PTO operator with the
operating instructions. Failure to do so may cause ve-
hicle/equipment damage.
PTO Switch On Lamp

The PTO Switch On lamp should be installed in the
cab. If the PTO operating station is outside of the
cab, a lamp should also be installed at the operating
station. This lamp will provide an indication to the
driver/PTO operator when the PTO On/Off circuit
is ON. Refer to the appropriate diagrams for the
application. If the PTO Configuration is programmed
to Cab Switches, then refer to Illustrations 12 and
13. If the PTO Configuration is programmed to
Remote Switches, then refer to Illustrations 14 and
15. If the PTO Configuration is programmed to
Remote Throttle, then refer to Illustrations 16 and 17.
The PTO Configuration is Programmed

to Remote Switches or to Remote
Throttle
The components that follow are ignored when
the PTO On/Off circuit is in the ON position. The
configuration of the PTO must also be programmed
to Remote Switches or to Remote Throttle:
accelerator pedal position sensor for the cab, clutch
switch, service brake switch, and cruise control
switches. A PTO Switch On lamp is recommended
in both the cab and at the remote station in order
to indicate when the PTO On/Off circuit is ON. The
Parking Brake Switch and/or a Transmission Neutral
Switch causes the engine to return to the low idle
rpm. The engine will return to the low idle rpm if
someone tries to move the vehicle and the operator
of the PTO is at the remote location. The Idle/PTO
Vehicle Speed Limit should also be programmed to
the minimum 1 km/h (1 mph) in order to cause the
engine to return to low idle if the vehicle is moved.
10
Schematics for the Engine Shutdown Switch
g00627399
Illustration 7
Schematic for the engine shutdown switch for a full feature system
11
g00627401
Illustration 8
Schematic for the engine shutdown switch for a GM (basic) system
PTO Interlocks for Transmission Driven

PTO
Any PTO Configuration
Vehicles that use a transmission driven PTO require

an additional Parking Brake Interlock Switch for the
PTO On/Off circuit. The interlock will prevent PTO
operation if the Parking Brake is not set.
12
g00716284
Illustration 9
Schematic for the PTO interlock for transmission driven PTO
Installation of Fast Idle

Configuration
Fast Idle Configuration
Illustrations 10 and 11 show the location of the
components as well as the wiring diagram for the
fast idle. Fast idle operation is not an integral part
of PTO operation. Fast idle operation provides
another method that controls the engine speed that
is similar to PTO operation.
13
g00627568
Illustration 10
Fast idle configuration
(A) Fast idle switch (D) Harness side of the vehicle harness (40) Input 18 (fast idle enable switch)
(B) Fast idle enabled lamp connector P1
(C) ECM side of the vehicle harness (5) AP sensor/switch sensor common
connector P1 (31) Output 9 (fast idle enabled lamp)
g00627571
Illustration 11
Fast idle schematic
Installation for Three PTO The information in this section provides details on
the installation of the necessary components that
Configurations are required for the various options for the PTO
The PTO configuration provides three programmable configuration.
options:
Cab switches
Remote switches
Remote throttle
14
Cab Switches PTO Configuration

No splicing into the existing cab wiring is necessary.
The Cruise Control Set/Resume Switch is used
for PTO Operation, Cruise Control, and Extended
Idle. The function of the Set position and Resume
position is determined by the programming of
the following parameters: PTO Engine RPM Set
Speed, Cruise/Idle/PTO Switch Configuration,
and Idle/PTO Bump RPM
The Set position becomes the RPM increase

position and the Resume position becomes the
RPM decrease position if the PTO Engine RPM Set
Speed is programmed above 0 rpm. If the PTO
Engine RPM Set Speed is programmed to 0 rpm,
then the Set position can provide either the ACCEL
or the DECEL function and the Resume position can
provide either the DECEL function or the ACCEL
function. A programmable bump rpm is determined
by the Idle/PTO Bump RPM parameter.
Note: A Neutral Switch (Input 12, J1/P1 terminal-62)

is required for PTO operation if the PTO
Configuration is programmed to Cab Switches
and the Transmission Style is programmed to
one of the following options: Automatic Option 3,
Automatic Option 4, AT/MT/HT Option 3, and
AT/MT/HT Option 4.
15
g00627573
Illustration 12
Configuration of the cab switches
(A) Set/Resume switch (E) Harness side of the vehicle harness
(B) PTO On/Off switch connector P1
(C) PTO Switch On lamp (3) Input sensor common 2
(D) ECM side of the vehicle harness (30) Output 1 (PTO switch On lamp)
connector P1 (56) Input 1 (PTO On/Off switch)
16
g00716285
Illustration 13
Schematic for cab switches
Remote Switches PTO Configuration The Set position becomes the RPM increase
The Cruise Control Set/Resume switch that is RPM decrease position if the PTO Engine RPM Set
in the cab is not used. Remote switches PTO Speed is programmed above 0 rpm. If the PTO
configuration requires the installation of a remote Engine RPM Set Speed is programmed to 0 rpm,
set switch and the installation of a remote resume then the Set position can provide either the ACCEL
switch. While the PTO is in operation, all of the cab or the DECEL function and the Resume position can
controls will be ignored. provide either the DECEL function or the ACCEL
The function of the Set position and Resume by the Idle/PTO Bump RPM parameter.
position is determined by the programming of the
PTO Engine RPM Set Speed, Cruise/Idle/PTO
Switch Configuration, and the Idle/PTO Bump
RPM parameters.
17
g00772914
Illustration 14
Configuration of the remote switches
(A) PTO On/Off Switch (C) PTO Switch On lamp (3) Input sensor common 2
(B) The PTO Set/Resume switch may (D) PTO Switch On lamp (30) Output 1 (PTO switch On lamp)
be located in the cab or in a remote (E) ECM side of the vehicle harness (56) Input 1 (PTO On/Off switch)
location. The operation of the PTO connector J1 (58) Input 2 (PTO set switch)
Set/Resume switch is dependent upon (F) Harness side of the vehicle harness (60) Input 3 (PTO resume switch)
the programming. connector P1
18
g00716287
Illustration 15
Schematic for remote switches
Remote Throttle PTO Configuration

The ECM monitors the Remote Accelerator Position
Sensor when the PTO On/Off switch and the PTO
Interlock switches are closed. The PTO Set switch
can be used to set engine rpm and the PTO
Resume switch is available to resume a previously
set RPM. The switch will go to the ACCEL position
or the switch will go to the DECEL position from
the current set speed if the PTO Set switch is held
in position or the PTO Resume switch is held in
position. This is based on the programming for the
customer specified parameter.
19
g00772929
Illustration 16
Configuration for remote throttle
(A) PTO Switch On lamp (D) PTO Switch On lamp (3) Input sensor common 2
(B) PTO On/Off switch (E) PTO Accelerator Assembly (30) Output 1 (remote PTO switch On lamp)
(C) The PTO Set/Resume switch may (F) ECM side of the vehicle harness (56) Input 1 (PTO On/Off switch)
be located in the cab or in a remote connector P1 (58) Input 2 (PTO Set switch)
location. The operation of the PTO (G) Harness side of the vehicle harness (60) Input 3 (PTO Resume switch)
Set/Resume switch is dependent upon connector P1 (68) Input 8 (remote accelerator)
the programming.
20
g00772947
Illustration 17
Schematic for remote throttle
Cab Switches with Torque Limiting and Cab Switches with Ignore Brake/Clutch Switch
Ignore Brake/Clutch Switch
The Ignore Brake/Clutch switch is intended for
Cab Switches with Torque Limiting applications that require mobile use of the vehicle
with a set engine rpm. The PTO will disengage if the
The Cab Switches PTO configuration is used in brake is depressed or if the clutch is depressed.
Illustrations 18 and 19. The illustrations also include The Ignore Brake/Clutch switch prevents the
the ability to use a programmed Torque Limit when clutch or the brake from disengaging the PTO set
the PTO On/Off switch is in either the ON or the speed. This is useful for the following applications:
OFF position (MAR98 or later Personality Modules). fire truck, cement pavement, and curb pouring
The Torque Limit is used when the Torque Limit has operations. In order to enable this feature, Input
a programmed value and the PTO On/Off switch 5 must be programmed to Ignore Brake/Clutch
is in the ON position. The illustrations show the Switch. The default is None.
connection of a second switch in order to provide
the Torque Limit under certain conditions. The
Torque Limit is operational when driving the vehicle
and the PTO On/Off switch is in the OFF position.
For example, this is useful when the transmission
provides deep reduction gears that require reduced
torque levels for the driveline. This feature should
only be used for temporary protection of the
equipment. To enable this feature, Input 4 must be
programmed to Torque Limit Switch. The default is
None.
21
g00627602
Illustration 18
Configuration for cab switches with torque limiting and ignore brake/clutch switch
(A) Set/Resume switch (G) Harness side of the vehicle harness
(D) Torque limit switch (7) Input 4 (torque limit switch)
(E) Ignore/Normal Brake/Clutch switch (30) Output 1 (PTO Switch On lamp)
(F) ECM side of the vehicle harness (47) Input 5 (Brake/Clutch disable switch)
22
g00772957
Illustration 19
Schematic for cab switches with torque limiting and ignore brake/clutch switch
23
Remote Switches with Torque Limiting

and Ignore Brake/Clutch Switch
Remote Switches with Torque Limiting
The Remote Switches PTO Configuration is used in

Illustration 20 and in Illustration 21. The illustrations
also show the ability to use a programmed Torque
Limit when the PTO On/Off switch is in the ON
or OFF position (MAR98 or later Personality
Modules). The Torque Limit is used when the Torque
Limit has a programmed value and the PTO On/Off
switch is in the ON position. The diagrams illustrate
the connection of a second switch in order to
provide the Torque Limit under certain conditions.
The Torque Limit is operational when driving and
the PTO On/Off switch is in the OFF position.
None.
Remote Switches with Ignore Brake/Clutch

Switch
The Ignore Brake/Clutch switch is not required

for the remote switches PTO configuration. If
the remote switches PTO configuration is used
in conjunction with extended idle or fast idle, an
Ignore Brake/Clutch switch can be installed. The
Ignore Brake/Clutch switch will prevent the clutch
or the Brake from disengaging an extended idle
speed or fast idle speed.
24
g00627604
Illustration 20
Configuration for remote switches with torque limiting and ignore brake/clutch switch
25
(A) PTO Switch On lamp (F) Ignore/Normal Brake/CLutch switch (7) Input 4 (torque limit switch)
(B) PTO On/Off switch (cab or remote (G) ECM side of the vehicle harness (30) Output 1 (Remote PTO Switch On lamp)
location) connector P1 (47) Input 5 (Brake/Clutch disable switch)
(C) PTO Set/Resume switch (H) Harness side of the vehicle harness (56) Input 1 (PTO On/Off switch)
(D) PTO Switch On lamp connector P1 (58) Input 2 (PTO Set switch)
(E) Torque limit switch (3) Input sensor common 2 (60) Input 3 (PTO Resume switch)
g00772960
Illustration 21
Schematic for remote switches with torque limiting and ignore brake/clutch switch
Idle Shutdown is Disabled with the PTO

Switch ON
The ECM will disable the Idle Shutdown Timer
when the circuit for the PTO On/Off switch is in
the ON position. This will prevent shutdowns that
are unwanted when the PTO mode is active. The
PTO Shutdown Timer can be used to shut down
the engine. This shutdown can be used if the
driver/operator is using the PTO mode in order to
prevent idle shutdown. The PTO Shutdown Timer
will shut down the engine but the PTO Shutdown
Timer will not disable the ECM.
Note: It is critical that the operator of the PTO

knows the arrangement. The operator must fully
understand the setup of the PTO system. It is also
critical that the operator of the PTO understands the
operation of the system.
26
Multiple Speed PTO Operation That Uses

The PTO Engine RPM Set Speed Input
A and The PTO Engine RPM Set Speed
Input B
The multiple speed PTO operation that uses the
PTO Engine RPM Set Speed Input A and the PTO
Engine RPM Set Speed Input B is available for use
with all three PTO configurations. The engine will
operate at the PTO Engine RPM Set Speed A that
is programmed when the PTO Engine RPM Set
Speed Input A switch (Input 7) and the PTO On/Off
switch are ON. The engine will operate at the PTO
Engine RPM Set Speed B when the PTO Engine
RPM Set Speed Input B switch (Input 19) and the
PTO On/Off switch are ON. The PTO Engine RPM
Set Speed B will not operate unless the PTO Engine
RPM Set Speed A is OFF. The PTO Engine RPM Set
Speed Input A and the PTO Engine RPM Set Speed
Input B have priority over all of the other features
that are used to control the engine speed during
PTO operation. The exception is any circumstance
that causes the PTO operation to be disabled. The
Multiple Speed PTO Operation that uses the PTO
Engine RPM Set Speed Input A and the PTO Engine
RPM Set Speed Input B requires JUL99 or newer
Personality Modules.
27
g00628458
Illustration 22
Illustration 22 shows the configuration for the multiple speed PTO operation by using the PTO Engine RPM Set Speed Input A and the
PTO Engine RPM Set Speed Input B.
(A) Set/Resume switch (G) Harness side of the vehicle harness
(D) PTO Set Speed B On/Off switch (23) Input 19 (PTO Set Speed B switch)
(E) PTO Set Speed A On/Off switch (30) Output 1 (PTO Switch On lamp)
(F) ECM side of the vehicle harness (46) Input 7 (PTO Set Speed A switch)
28
g00628460
Illustration 23
Illustration 23 shows the schematic for the multiple speed PTO operation that uses the PTO Engine RPM Set Speed Input A and the PTO
Engine RPM Set Speed Input B.
29
Systems Operation Section Customer Programmable Parameter

Options
i01503933 There are many customer programmable parameter
options:
General Information
PTO Configuration The PTO Configuration
SMCS Code: 1000; 1165 determines the input/output configuration that is
Advantages of a Dedicated PTO
PTO Top Engine Limit The PTO Top Engine
The ECM provides several options in order to Limit provides a parameter in order to limit the
enhance vehicles that require control of the engine engine rpm during PTO operation.
speed for vocational applications. The vocational
applications include the following applications: PTO Engine RPM Set Speed The PTO Engine
cement mixers, refuse packers, bulk haulers, utility RPM Set Speed provides a set point for the engine
trucks, fire trucks, and applications that require rpm for the PTO.
the control of the engine rpm for the operation of
specialized equipment. PTO Engine RPM Set Speed A This provides
a programmable engine speed set point that
There are eleven dedicated PTO parameters. The is actuated by a dedicated switch circuit. The
dedicated PTO has ten inputs and one output. The dedicated switch circuit is Input 7. JUL99 or later
features of the dedicated PTO provide a significant Personality Modules
increase in the capability of the engine and of the
usage of the engine. PTO Engine RPM Set Speed B This provides a
second programmable engine speed set point that
The electronically controlled 3126B engine and the is actuated by a second dedicated switch circuit.
3126E engine eliminates the need for the following The dedicated switch circuit is Input 19. JUL99 or
items: mechanical control cables, air cylinders, later Personality Modules
electric solenoids, and linkages and connections.
The dedicated PTO provides a simple installation. PTO to Set Speed The PTO to Set Speed
The Cruise Control switches that are in the cab and function requires only one circuit (PTO On/Off
the circuit for the accelerator pedal position are left Switch) to provide two speed controls. The PTO
unaffected. to Set Speed function provides three-speed
controls by using the PTO On/Off Switch and the
Features of the Dedicated PTO Set/Resume Switch.
There are several features of the dedicated PTO: PTO Cab Throttle RPM Limit The PTO Cab
Throttle RPM Limit provides a parameter in order
The dedicated PTO reduces the alteration of the to limit the rpm from the accelerator pedal position
cab wiring or the dedicated PTO eliminates the sensor in the cab during PTO operation. The PTO
alteration of the cab wiring. Cab Throttle RPM Limit can be used in order to
exceed the programmed PTO Top Engine Limit
The dedicated PTO has multiple speed control by with the accelerator pedal that is in the cab.
using the PTO Engine RPM Set Speed Input A
and PTO Engine RPM Set Speed Input B. Torque Limit The torque limit reduces the
engine torque during PTO operation. The torque
The dedicated PTO has two speed controls that limit will also reduce the engine torque when
require the PTO On/Off circuit. the Torque Limit Switch is in the ON position for
temporary protection of equipment.
The dedicated PTO has an accelerator position
sensor that is remote. This sensor enables the PTO Vehicle Speed Limit The PTO Vehicle
system to control engine rpm with variable Speed Limit determines the operating range of the
speeds from a remote location. vehicle speed during PTO operation.
The dedicated PTO has reduced engine noise Idle/PTO RPM Ramp Rate The Idle/PTO RPM
levels during PTO operation. The reduced engine Ramp Rate determines the rate of acceleration
noise levels are compared to a mechanical and deceleration.
engine PTO.
Idle/PTO Bump RPM The Idle/PTO Bump RPM
determines the amount of change in the engine rpm
30
PTO Shutdown Time The PTO Shutdown Time Definition of Power Take-Off (PTO)
is a programmable time. If the engine is in PTO
mode, then the PTO Shutdown Time will shut The dedicated PTO is an engine rpm control that
down the engine when the time limit expires. is initiated through an On/Off circuit. The circuit
PTO Activates Cooling Fan The PTO Activates Vehicle Harness Connector J1/P1. Engine rpm
Cooling Fan can be programmed so that the control that is initiated through the Cruise Control
cooling fan will operate during PTO operation. On/Off switch is referred to as Extended Idle.
Input 4 Input 4 provides a parameter for a Idle Enable Switch is referred to as Fast Idle.
Torque Limit Switch when torque limiting is desired
for temporary protection of equipment. This is The Four Programmable PTO
regardless of the position of the PTO On/Off switch.
MAR98 or later Personality Modules Configurations
Input 5 Input 5 provides a parameter for an Off The functions for the dedicated PTO are not
Ignore Brake/Clutch Switch when mobile use of available.
brake and the clutch are not required in order to Cab Switches The cruise control Set/Resume
disengage the engine rpm set speed. MAR98 or switch and the Accelerator Pedal are used to control
later Personality Modules the engine rpm. A dedicated PTO On/Off switch is
Input 7 Input 7 can be programmed to PTO
Engine RPM Set Speed Input A in order to provide Remote Switches The Set/Resume switch for the
a dedicated circuit for the PTO operation at a remote PTO is used to control the engine rpm. The
programmed speed when the PTO On/Off Switch is remote switches ignore all of the cab controls. An
ON. JUL99 or later Personality Modules On/Off switch for the dedicated PTO is required.
Input 19 Input 19 is programmable to PTO
Engine RPM Set Speed Input B in order to provide Remote Throttle The remote throttle is used
a second dedicated circuit for the operation at a in order to control the engine rpm. The remote
programmed speed when PTO Engine RPM Set throttle will ignore all of the cab controls. An On/Off
Speed Input A is OFF and the PTO On/Off switch switch for the dedicated PTO is required. Refer to
is ON. JUL99 or later Personality Modules Illustration 26.
Additional Features of the Dedicated PTO

The engine exhaust brake that is controlled by
the ECM is disabled when the PTO On/Off circuit
is in the ON position.
When the PTO On/Off switch is in the ON position,

the Idle Shutdown feature is disabled.
Two terminal connector and wiring is standard on

all GM applications. Two terminal connector and
wiring is standard for the PTO On/Off Switch. Two
terminal connector and wiring is standard for the
PTO Interlock Switches.

Driver abuse is placing the truck in PTO mode in
order to disable the idle shutdown time.
31
g00625394
Illustration 24
PTO configuration for cab switches
g00625393
Illustration 25
PTO configuration for remote switches
32
g00625391
Illustration 26
PTO configuration for remote throttle
One Speed Control with One Circuit Variable Speed Control That uses an
Two Speed Control with Three Circuits that is equipped with a Accelerator Position Sensor
Speed and the PTO Top Engine Limit. The following Dedicated Switch Inputs
components are required: PTO On/Off Switch,
PTO Interlock Switches, Cruise Control or Remote This function can be used in conjunction with other
Set/Resume Switch, and PTO Switch On Lamp(s). features that are used to control engine speed. The
switch for the PTO Engine RPM Set Speed Input
A. The switch for the PTO Engine RPM Set Speed
Input B can be used in addition to the switch for
the PTO Engine RPM Set Speed Input A.
33
Engine RPM Control That Uses Switches Recommended Information for

Instead of a Control That Uses An Operator of the PTO
Accelerator Position Sensor
This function uses switches in order to control of the engine and the components for the PTO
engine rpm. Switches are also recommended if operation. Ensure that the operator understands the
the operator of the PTO will be frequently varying operation before attempting to install the switches
the engine rpm. Switches are recommended if the before the parameters are programmed. The
operator of the PTO will not have a free hand or a installation questionnaire will make the installation
free foot in order to operate the accelerator. easier to understand. The installation questionnaire
Differences Between Fast Idle and are needed.
Dedicated PTO Operation Question (1) through question (8) should be
The following differences are between the fast idle The remaining questions may be asked after the
and the dedicated PTO: installation is completed. This will help to fine tune
Fast Idle is intended for cab control of the engine Refer to the information for programmable
speed. The dedicated PTO can be set up for parameters that is found in Programmable
control in the cab or for remote control of engine Parameters Available Ranges, Options, and
speed during PTO operation. Default Settings. For more information, refer to
Fast Idle requires a single momentary switch to Electronic Truck Engines. Also refer to Special
select the programmed engine speed(s). The Publication, LEBT9390, Electrical and Electronic
dedicated PTO can be as simple as a single Application and Installation Guide.
two-position switch. The two positions are the ON
position and the OFF position. The dedicated PTO Complete the following information once the
can also require combinations of two-position installation is complete:
switches and momentary switches.
The dedicated PTO provides several options: Operator of the PTO
programmable engine rpm limits, set points,
bump rates, ramp rates, and programmable
torque limit. These features are not available for
Fast Idle control.
The ramp rate for Fast Idle rpm is fixed and this
rate can not be adjusted. The information that is recorded should be explained
Fast Idle requires a momentary switch. Fast Idle recorded should be left in the cab glove box. This
can not be used with a typical PTO system that will allow the operator of the PTO to review the
requires two-position switches. The momentary configuration of the truck and the PTO. This will
switch can not be operated hydraulically. The allow the service technician to troubleshoot any
momentary switch can not be operated by air. suspected problems that relate to the installation.
The momentary switch can not be a position limit
switch that is integrated into the PTO operation.
Installation Questionnaire
Fast Idle Operation That Has One or Two
Speed Control with One Circuit Electronic PTO Installation and Applications Service
Manual, PTO Parameters - Program for the
This function provides an optional set speed(s) for installation and programming that is based on the
applications that require only one or two speeds information on the Questionnaire Response.
above low idle.
A momentary Fast Idle Enable Switch and a Fast

Idle Enabled Lamp are required.
34
Table 4
Questions Response
PTO.
the PTO.
varying engine rpm.
be used.
required.
to the ON position.
equipment.
problems.

(continued)
35

Truck Manufacturer Input Number 4 (Torque
JUL99 and newer Limit Switch)
Personality Modules MAR98 and newer
Personality Modules
Input Number 5 (Ignore
Vehicle Speed Limit Brake/Clutch Switch)
Cruise Control Parameters MAR98 and newer
Personality Modules
Set Limit Input Number 7 (PTO
High Cruise Control A)
Speed Set Limit JUL99 and newer
Personality Modules
Configuration Input Number 19 (PTO
Idle Parameters B)
Idle Vehicle Speed Limit JUL99 and newer
Personality Modules
Idle RPM Limit
(rpm/sec)
Idle/PTO Bump RPM
Fast Idle RPM 1
Fast Idle RPM 2
PTO Configuration
PTO Engine RPM Set
Speed
PTO Engine RPM Set
Speed A
JUL99 and newer
Personality Modules
PTO Engine RPM Set
Speed B
JUL99 and newer
Personality Modules
PTO to Set Speed
PTO Cab Throttle RPM
Limit
Torque Limit
PTO Shutdown Time
Fan
Top Engine Limit
Low Idle Engine RPM
Transmission Style
Input Selections
(continued)
36

PTO
Table 6
Question Response
operation.
return to low idle.
the switch.
necessary.
position.
is active.
Electronic PTO Installation and Applications
complete: Service Manual, The Four Programmable
PTO Configurations for the installation and
programming that is based on the information on
the Questionnaire Response.

37
g00720254
Illustration 27
(1) Torque limit switch (7) PTO Switch On lamp
(2) Ignore/Normal Brake/Clutch switch (8) On/Off Switch for the PTO Engine RPM
(3) PTO On/Off switch Set Speed A
(4) PTO switch ON lamp (9) On/Off Switch for the PTO Engine RPM
(5) PTO Set/RPM Increase/Decrease Switch Set Speed B
(6) PTO Accelerator Assembly
38
i01517325
General Information
SMCS Code: 1000; 1165
g00608514
Illustration 28
Right side view
(1) Lifting eye (6) Belt tensioner
(2) Engine crankcase breather (7) Water drain plug
(3) Turbocharger (8) Crankshaft vibration damper
(4) Oil filler (9) Oil filter
(5) Water temperature regulator housing (10) Jacket water pump
39
g00608515
Illustration 29
Left side view
(11) Oil filler (14) Fuel priming pump (if equipped) (17) Air compressor
(12) Lifting eye (15) Oil level gauge (typical example) (18) Cylinder head grounding stud
(13) Fuel filter (16) Electronic Control Module (ECM) (19) Oil drain plug
The 3126B and 3126E engines are in-line six The engine has built-in diagnostics in order to
cylinder arrangements. The firing order of the ensure that all of the components are operating
engine is 1-5-3-6-2-4. The engines rotation is properly. In the event of a system component
counterclockwise when the engine is viewed from failure, the operator will be alerted to the condition
the flywheel end of the engine. The engine utilizes via the check engine light that is located on the
a turbocharger and an air-to-air aftercooler. The dashboard. An electronic service tool can be used
engines have a bore of 110 mm (4.3 inch) and a to read the numerical code of the faulty component
stroke of 127 mm (5.0 inch). The displacement is or condition. Also, the cruise control switches can
7.25 L (442 in 3 ). be used to flash the code on the check engine light.
Intermittent faults are logged and stored in memory.
The hydraulic electronic unit injector system (HEUI)
eliminates many of the mechanical components Starting The Engine
that are used in a pump-and-line system. The
HEUI also provides increased control of the timing
The engines ECM will automatically provide the
and increased control of the fuel air mixture. The correct amount of fuel in order to start the engine.
timing advance is achieved by precise control of
Do not hold the throttle down while the engine
the unit injector timing. Engine rpm is controlled by
is cranking. If the engine fails to start in twenty
adjusting the injection duration. A special pulse seconds, release the starting switch. Allow the
wheel provides information to the Electronic Control
starting motor to cool for two minutes before the
Module (ECM) for detection of cylinder position and
starting motor is used again.
engine rpm.
40
Fast Idle Engine RPM Limit The Fast Idle RPM

NOTICE Limit is the maximum RPM Set Speed that uses the
Excessive ether (starting fluid) can cause piston and Fast Idle Enable Switch. The programmable range
ring damage. Use ether for cold weather starting pur- is 700 rpm to the TEL in one rpm increments. The
poses only. operator can override the programmed Fast Idle
RPM. Depress the accelerator pedal and toggle the
Fast Idle Enable Switch when the engine is at the
Cold Mode Operation desired rpm. This rpm would then be the Fast Idle
RPM until the engine is shut down.
Starting the engine and operation in cold weather is
dependent on the type of fuel that is used, the oil
viscosity, and other optional starting aids. For more
information, refer to the Operation and Maintenance
Manual, Cold Weather Operation topic (Operation
Section).
i01487853
Programmable Parameters
SMCS Code: 1000
Understanding Programmable
Engine RPM Limits
There are four programmable engine rpm limits that
are available.
Top Engine Limit (TEL) The TEL is used while

the vehicle is being driven on the road. The TEL
determines the maximum rpm when the PTO On/Off
Switch is in the OFF position.
Idle RPM Limit The Idle RPM Limit is the

maximum of the engine rpm limit if the engine rpm
is established by using the Cruise Control On/Off
Switch and the Cruise Control Set/Resume Switch.
The programmable range of the Idle RPM Limit is
from 700 rpm to the TEL in one rpm increments.
The minimum programmable Idle RPM Limit is
determined by the programmed Low Idle RPM. The
maximum programmable Idle RPM Limit is limited
by the Top Engine Limit.
PTO Top Engine Limit The PTO Top Engine Limit

is the maximum engine rpm limit when the PTO
On/Off switch is ON. The PTO Top Engine Limit has
a programmable range from 700 rpm to the TEL in
one rpm increments. The minimum programmable
PTO Top Engine Limit is actually determined by
the programmed Low Idle RPM. The maximum
programmable PTO Top Engine Limit is the TEL.
41
Available Ranges, Options,

and Default Settings for the
Table 7
Parameter Available Range or Options Default
Selected Engine Rating
Rating Number Engine Power Dependent -

Vehicle ID 17 Characters are Available. 00000000000000000
Security Access Parameters
Truck Manufacturer GM or Other The value is programmed at the factory.
JUN99 and newer Personality Modules
Vehicle Speed Calibration 2485 to 93206 pulses/km GM: 19884 pulses/km
(4000 to 150000 pulses/mile) (32000 pulses/mile)
Other: The value is not programmed.
Vehicle Speed Limit GM: 48 to 121 km/h (30 to 75 mph) GM: 121 (75)
Other: 48 to 204 km/h (30 to 127 mph) Other: 204 (127)
VSL Protection GM: 1700 rpm GM: 1700 rpm
Other: 1700 to the TEL Other: TEL
Tachometer Calibration 12.0 to 500.0 GM: 17.5
pulse/revolution Other: 134.0
Soft Vehicle Speed Limit NO or YES NO
Low Speed Range Axle Ratio 0.00 to 19.99 0.00
MAR98 and newer Personality Modules
High Speed Range Axle Ratio 0.00 to 9.99 0.00
Cruise Control Parameters
Low Cruise Control Speed Set Limit GM: 48 to 121 km/h (30 to 75 mph) GM: 48 km/h (30 mph)
Other: 24 to 204 km/h (15 to 127 mph) Other: 204 km/h (127 mph)
High Cruise Control Speed Set Limit GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
Engine Retarder Mode Coast, Latch, or Manual Manual
Cruise/Idle/PTO Switch Configuration Set/Accel or Set/Decel GM: Set/Decel
Other: Set/Accel
SoftCruise Control YES or NO GM: NO
Other: YES
Idle Parameters
Idle Vehicle Speed Limit 2 to 24 (1 to 15) 2 km/h (1 mph)
km/h (mph)
Idle RPM Limit 700 to TEL TEL
Idle/PTO RPM Ramp Rate 5 to 1000 50 rpm/sec
rpm/sec
Idle/PTO Bump RPM 5 to 500 rpm 20 rpm
Fast Idle RPM 1 700 rpm to TEL 1000 rpm
0 rpm is OFF.
(continued)
42
(Table 7, contd)
PTO Configuration OFF, Cab Switches, Remote OFF
Switches, Remote Throttle
PTO Top Engine Limit 700 rpm to TEL TEL
PTO Engine RPM Set Speed Low Idle to PTO TEL 0 rpm
0 rpm is OFF.
PTO Engine RPM Set Speed A Low Idle to PTO TEL 0 RPM
JUL99 and newer Personality Modules
PTO Engine RPM Set Speed B Low Idle to PTO TEL 0 RPM
PTO to Set Speed YES or NO NO
PTO Cab Throttle RPM Limit TEL, Low Idle, PTO TEL TEL
PTO Vehicle Speed Limit 2 to 204 km/h (1 to 127 mph) 2 km/h (1 mph)
Torque Limit 135 Nm (100 lb ft) To Rated Torque 2712 Nm (2000 lb ft)
PTO Shutdown Time 3 to 1440 minutes 0
0 rpm is OFF.
PTO Activates Cooling Fan Normal, Continuous Normal
Lower Gears Engine RPM Limit 1500 rpm to TEL TEL
Lower Gears Turn Off Speed 2 to 24 km/h (1 to 15 mph) 2 km/h (1 mph)
Intermediate Gears Engine RPM Limit 1500 rpm to TEL TEL
Intermediate Gears Turn Off Speed 16 to 80 km/h (10 to 50 mph) 16 km/h (10 mph)
Gear Down Protection RPM Limit 1700 rpm to TEL TEL
Gear Down Protection Turn On Speed GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
Top Engine Limit Dependent upon the Engine and the Dependent upon the Engine and the
Rating Rating
Low Idle Engine RPM 700 to 800 rpm 700 rpm
Idle Quality Calibration Decrease 1, 2, 3, or 4 Nominal
MAR98 and newer Personality Modules Increase 1, 2, 4, or 4
Nominal
Transmission Style GM: Unavailable GM: Unavailable
Other: Manual, Automatic Option 1, Other: Manual
Automatic Option 2, Automatic Option
3, Automatic Option 4, AT/MT/HT
Option 1, AT/MT/HT Option 2,
AT/MT/HT Option 3, AT/MT/HT
Option 4
AT/MT/HT Part Throttle Shift Speed Default, Medium, High Default
Timer Parameters
Idle Shutdown Time 3 to 1440 minutes 0
0 minutes is OFF.
Allow Idle Shutdown Override YES or NO YES
(continued)
43
(Table 7, contd)
A/C Switch Fan On Time 0 to 600 seconds 0
0 seconds is OFF.
Fan with Engine Brake On YES or NO NO
Engine Monitoring Parameters
Engine Monitoring Mode GM: OFF, Warning, Derate Warning
Other: OFF, Warning, Derate,
Shutdown
Coolant Level Sensor NO, 4-Pin NO
Engine Oil Pressure Sensor Installed, Not Installed Not Installed
JUN98 and newer Personality Modules
Maintenance Indicator Parameters
Maintenance Indicator Mode OFF, Man.-Distance, Man.-Hour, OFF
Auto-Distance, Auto-Hour
PM1 Interval (1) 8047 to 56350 Kilometers 24140 Kilometers (15000 Miles)
(5000 to 35000 Miles) 250 Hours
100 to 750 Hours
Engine Oil Capacity 19 to 57 L (20 to 60 qt) GM: 21 L (22 qt)
Other: 31 L (33 qt)
Trip Parameters
Dash - PM1 Reset YES or NO NO
Dash - Customer Parameters YES or NO NO
Theft Deterrent System Control YES, NO, Auto-Enable NO
Theft Deterrent Password Four Characters 0000
Input Selections
Input number 4 NONE, Torque Limit Switch NONE
Input number 5 NONE, Ignore Brake/Clutch Switch NONE
Input number 6 NONE, Two Speed Axle Switch NONE
Input number 7 NONE, Diagnostic Enable, PTO NONE
JUL99 and newer Personality Modules Engine RPM Set Speed Input A
Input number 19 NONE, PTO Engine RPM Set Speed NONE
JUL99 and newer Personality Modules Input B
Output Selections
Output 9 GM: Unavailable(2) GM: Unavailable
Other: Wait to Start lamp, Fast Idle Other: Fast Idle Lamp
Lamp
Fan Control Type On/Off, NONE NONE
Passwords
Customer Password 1 8 characters are available.
Customer Password 2 8 characters are available.
Data Link Paramters
Powertrain Data Link NONE, J1939 GM: J1939
Other: NONE
(1) (Refer to the Operation and Maintenance Manual, Maintenance Schedule.)
(2) This is used only for the Fast Idle Lamp.
44
Troubleshooting Section i01368633
0030-13 PTO Throttle Sensor

Calibration (29)
Troubleshooting with a
SMCS Code: 1913-038; 1913
Diagnostic Code
Conditions Which Generate This Code:
i01368614
The PTO Configuration is a Customer Parameter.
0030-08 Invalid PTO Throttle The PTO Configuration is programmed to Remote
Throttle. The duty cycle of the PTO Accelerator
Signal (29) signal is less than 5 percent or more than 95
percent.
SMCS Code: 1913-038; 1913
System Response:
Electronic System Response The ECM returns the
The PTO Configuration is a Customer Parameter. engine to low idle when the problem is detected.
The PTO Configuration is programmed to Remote
Throttle. The ECM is not receiving a correct PTO Service Tool Display or Lamps The Service Tool
accelerator signal. will indicate 0 percent Throttle Position for the PTO
Accelerator Sensor Status parameter while the
Note: If the PTO Configuration is programmed to Diagnostic Code is Active.
Remote Throttle, the ECM must receive a proper
signal from the Remote Accelerator Position Sensor Engine Response The engine will remain at low
at all times. The remote throttle signal must be idle while the Diagnostic Code is Active.
present even when the PTO ON/OFF Switch is in
the OFF position. Troubleshooting:
System Response: Note: The Remote Accelerator Pedal Position
Sensor can not be calibrated.
engine to low idle when the problem is detected. Perform the following diagnostic procedure:
Service Tool Display or Lamps The Service Tool Test
will indicate 0 percent Throttle Position for the PTO
Accelerator Sensor Status parameter while the Results:
Diagnostic Code is Active.
OK STOP.
Engine Response The engine will remain at low
idle while the Diagnostic Code is Active.
i01225477
Troubleshooting:
0071-14 PTO Shutdown Timer
The diagnostic code is probably caused by an Occurrence (47)
open circuit in the Accelerator Pedal Position Signal
circuit or an open circuit in the 12 volt sensor supply SMCS Code: 1900
voltage circuit. An abnormal change in the signal
frequency can also cause this code. Conditions Which Generate This Code:
Perform the following diagnostic procedure: The timer for the PTO has expired and the engine
Remote PTO Accelerator Position Sensor Circuit - has shut down.
Test
Note: This code represents an event. This code
Results: does not represent an Electronic System fault.
OK STOP. System Response:
Electronic System Response The ECM remains

powered after the engine shutdown.
45
Service Tool Display or Lamps Customer

Passwords are required to clear this diagnostic
code.
Engine Response The engine is shut down.
Troubleshooting:
Perform the following diagnostic procedure: Idle

Shutdown Timer - Test
Results:
OK STOP.
46
Diagnostic Functional B. Access the Customer Parameters on the

Electronic Service Tool. Access the following
Tests display screens in order:
Service
i01474068
PTO Shutdown Timer - Test Configuration

a. Record the programmed PTO shutdown time.
SMCS Code: 1900-038
The PTO shutdown Time must be between 3
and 1440 minutes. If the PTO shutdown time
System Operation Description:
is programmed to 0, the timer is disabled.
Use this procedure under the following situation:
C. Start the engine. Allow the engine to warm up
until the coolant temperature is 38 C (100 F).
Use this procedure to determine if the PTO
Shutdown is operating correctly. Allow the engine to operate at the programmed
low idle and turn off any unnecessary accessory
devices.
The following background information is related
to this procedure:
D. Ensure that all unnecessary loads are turned
OFF.
PTO Shutdown Timer
E. Use the following procedure in order to check
A programmable parameter for the PTO Shutdown
the operation of the PTO shutdown:
Timer is provided. This timer will shut down the
engine when all of the following conditions are met:
a. Park the vehicle.
The PTO shutdown time that is programmed has b. Ensure that the PTO configuration is
expired.
programmed to Cab Switches, Remote
Switches or Remote Throttle.
The ECM is programmed to use Dedicated PTO
parameters.
c. Ensure that the status of the PTO on/off switch
is on.
The PTO on/off switch is ON and the ECM is in
the dedicated PTO mode.
d. Observe the status of the PTO Shutdown.
The engine is not in the Cold Mode. Expected Result:
During the last 90 seconds of the PTO Shutdown
Result 1 The status of the parameter for PTO
Timer, the check engine lamp will begin flashing. If
the vehicle is equipped with a PTO switch on lamp, Shutdown indicates COUNTING.
the PTO switch on lamp will begin flashing during
Result 2 The ECM is not reading the proper
the last 90 seconds.
conditions for activation of the timer.
If the PTO shutdown timer is activated and the timer
Results:
stops the engine, the following event code will be
generated.
Result 1 The ECM is reading the proper
conditions for the activation of the PTO shutdown
71-14 PTO Shutdown Timer Occurrence (47) timer. Proceed to Test Step 2.
Note: Fuel rates are not monitored while the PTO
shutdown timer is active. Shutdown will occur Result 2 Proceed to Test Step 3.
regardless of load. Unlike the idle shutdown timer,
the PTO shutdown timer cannot be overridden by
Test Step 2. Verify The Driver Alert
using the clutch pedal or the brake pedal. Function Of The PTO Shutdown.
Test Step 1. Verify Activation Of The PTO A. Connect an Electronic Service Tool to the cab
data link connector.
Shutdown Timer.
B. Use the following procedure in order to activate
A. Connect an Electronic Service Tool to the cab
the PTO shutdown timer:
47
a. Access the Customer Parameters on the Repair: Perform the following diagnostic
Electronic Service Tool. Access the following procedure:
display screens in order:
Troubleshooting, Check Engine Lamp Circuit -
Service Test
Configuration STOP.
b. Record the programmed PTO shutdown time. Test Step 3. Check The State Of The
The PTO shutdown time must be between 3 Related Conditions When The Vehicle Is
and 1440 minutes. If the PTO shutdown time Parked.
A. Check the state of the following related conditions
c. Reprogram the PTO shutdown time to 3 when the vehicle is parked:
minutes for this test.
a. Ensure that the vehicle speed is 0 km/h
C. Observe the following items during the 90 second (0 mph) on the Electronic Service Tool or the
period before the programmed shutdown time: dash display.
check engine lamp b. Ensure that the engine is not in cold mode.
status of the PTO shutdown timer Note: The Electronic Service Tool status screen will
indicate if the cold mode is active.
PTO switch on lamp
c. Ensure that the PTO on/off switch is ON.
During the 90 second period before the
scheduled shutdown, the status should change Expected Result:
from COUNTING to DRIVER ALERT and the
check engine lamp and the PTO switch on lamp Result 1 Vehicle speed is not indicated as 0 km/h
should flash rapidly. (0 mph).
Note: A PTO switch on lamp is an optional feature Result 2 The Electronic Service Tool status screen
and the PTO switch on lamp may not be installed. indicates that the engine is in the cold mode.
D. Reprogram the PTO shutdown timer to the value Result 3 The PTO on/off switch is not ON.
that was recorded earlier for this test.
Results:
Expected Result:
Result 1 Continue by testing the vehicle speed
Result 1 The driver alert function of the PTO circuit.
shutdown operates in the manner that is described
above. Repair: Perform the following diagnostic
procedure: Troubleshooting, Vehicle Speed
Result 2 The PTO switch on lamp did not flash. Circuit - Test
Result 3 The check engine lamp did not flash. STOP.
Results: Result 2 The engine must not be in cold mode

operation while this test procedure is being
Result 1 The PTO shutdown timer is operating performed. Allow the engine to run until the
properly. Clear all diagnostic codes. STOP. coolant temperature exceeds 38 C (100 F).
Troubleshoot and repair any related conditions.
Result 2 The PTO switch on lamp did not flash STOP.
during the driver alert.
Result 3 Continue by testing the circuit for the
Repair: Perform the following diagnostic PTO on/off switch.
procedure: Troubleshooting, PTO Switch ON
Lamp Circuit - Test Repair: Perform the following diagnostic
procedure: Troubleshooting, PTO Switch Circuit -
STOP. Test
Result 3 The check engine lamp did not flash STOP.

during the driver alert.
48
i01474120 PTO interlocks may also be connected in series with

the PTO on/off switch. The Interlocks are intended
PTO Switch Circuit - Test to prevent the PTO on/off circuit from activating
unless certain conditions are met.
SMCS Code: 1165-081-ZS
INPUT 2
The input 2 is used for the PTO set/rpm increase
Use this procedure under the following situation: switch when the PTO Configuration is programmed
to Remote Switches or Remote Throttle.
Use this procedure to determine that the vehicle
wiring and the ECM are functioning properly for the INPUT 3
features of Dedicated PTO.
The input 3 is used for the PTO resume/rpm
The following background information is related decrease switch when the PTO Configuration
to this procedure: is programmed to Remote Switches or Remote
Throttle.
INPUT 1
The PTO Configuration Is Set To Cab Switches.
The input 1 is used for the circuit for the PTO on/off
switch when the PTO Configuration is programmed When the PTO Configuration is programmed to
to Cab Switches, Remote Switches, or Remote Cab Switches and the PTO on/off switch is on, the
Throttle. following circuits can be used to interrupt a set rpm:
When the PTO on/off circuit is on, the ECM will be cruise control set/resume switch
in Dedicated PTO mode.
service brake pedal position switch 1
When the ECM is in the Dedicated PTO mode the
PTO Top Engine Limit (TEL) is activated. The engine service brake pedal position switch 2
may proceed directly to the PTO engine rpm set
speed if the parameter is programmed. If a PTO clutch pedal position switch
switch on lamp is connected to the output 1, the
PTO switch on lamp will turn on whenever the PTO neutral switch
on/off circuit is on.
When the PTO Configuration is programmed to
If the problem is with undetermined PTO kickouts, Cab Switches and the PTO on/off switch is on,
use the following procedure: the cab accelerator pedal position sensor can be
limited to one of the following settings by using the
Operate the vehicle in PTO mode. PTO Cab Throttle RPM Limit parameter:
After the kickout, review the Electronic Service low idle
Tool status parameter. The Electronic Service Tool
kickout status parameter indicates the cause. This PTO Top Engine Limit
must be performed before the ignition key switch
is turned OFF. It is important to remember that the top engine limit
parameter will only indicate the last kickout since
the ECM has been powered by the Ignition Key The PTO Configuration Is Set To Remote
Switch Input. Switches or Remote Throttle.
This parameter is blank when the ECM is first When the PTO Configuration is programmed to
powered up. If this parameter is blank, No Remote Switches or Remote Throttle and the
Occurrence is indicated. This parameter remains PTO on/off switch is on, the following circuits are
blank until the ECM detects the use of the PTO ignored:
mode. Also, this parameter remains blank until the
ECM detects the disengagement of PTO mode. service brake pedal position switch 1
Refer to Table 8 in order to interpret the status
screen kickout status parameter. service brake pedal position switch 2
The following kickout status parameter is available: clutch pedal position switch
PTO kickout neutral switch
49
cab accelerator pedal position sensor

cab cruise control set/resume switch
A remote accelerator pedal position sensor
is connected to the input 8 when the PTO
Configuration is programmed to Remote Throttle.
Note: The wiring for your particular application may

be slightly different. The circuits for the sensor
common are used interchangeably by the OEM
of the vehicle. The following circuits are common
within the ECM:
The Input Sensor Common 1 is terminal 18.

The AP Sensor/Switch Sensor Common is
terminal 5.
Table 8
Table For The PTO Kickout Status Screen On The Electronic Service Tool
Electronic Service Tool Meaning or Possible Cause Troubleshooting
Intermittent engine speed signal or lost Refer to Troubleshooting, Speed/Timing
No Engine Speed
engine speed signal. Circuit - Test.
The PTO On/Off switch is turned OFF or the Proceed with the test procedure.
Switch Turned Off
switch circuit has an open circuit condition.
The service brake pedal is depressed or Refer to Troubleshooting, Service Brake
Brake the service brke switch circuit has an open Pedal Position Switch 1 Circuit - Test.
circuit condition.
The clutch pedal is depressed or the Refer to Troubleshooting, Cutch Pedal
clutch pedal switch circuit has an open Position Switch Circuit - Test.
Clutch
circuit condition. Also, the switch could be
incorrectly adjusted.
The Vehicle speed has exceeded the PTO Refer to Troubleshooting, Vehicle Speed
Vehicle Speed Limit Vehicle Speed Limit or the vehicle speed Circuit - Test if a problem with the signal
signal is erratic or intermittent. exists.
The transmission is not in neutral or the Refer to Troubleshooting, Neutral Switch
Neutral transmission neutral switch circuit has an Circuit - Test.
open circuit condition.
The PTO has not been enabled since the Operate the vehicle in the PTO mode in
No Occurrence
ECM has been powered up. order to create the problem again.
50
g00644420
Illustration 30
This illustration is for the schematic for cab switches for PTO configuration.
g00644427
Illustration 31
This illustration is for the schematic for remote switches for PTO configuration.
51
g00644448
Illustration 32
This illustration is for the schematic for remote throttle for PTO configuration.
Test Step 1. Check The Programming Of B. Check the cab glove box for any information
The Dedicated PTO Customer Parameter. regarding the installation of the PTO. It is
important to understand the location and the
A. Connect an Electronic Service Tool. function of the PTO Interlocks that are used in
the installation.
B. Turn the ignition key switch to the ON position.
C. Contact the installer of the PTO component, if
C. Access the Dedicated PTO Customer necessary.
Parameters on the Electronic Service Tool. Note
the programming of the PTO Configuration D. Determine the schematic that most closely
Parameter. matches the installation. Review the schematics
in this procedure for each of the options for the
Expected Result: specific PTO Configuration of the truck.
The PTO Configuration is programmed to Cab E. Record the PTO Configuration.

Switches, Remote Switches, or Remote Throttle.
Expected Result:
Results:
The requirements for the installation and the
Yes Proceed to Test Step 2. application have been reviewed.
No The Dedicated PTO features are not Results:

programmed for this engine. If PTO operation
is desired, the PTO Configuration must be OK Proceed to Test Step 3.
Switches, or Remote Throttle. STOP.
Test Step 2. Determine The PTO

Installation Setup.
A. From the programming of the PTO Configuration
Parameter, review the truck wiring in order to
determine the method of installation of the wiring.
Talk to the driver about the use of the PTO.
52
Test Step 3. Inspect Electrical Connectors

And Wiring.
g00713728
Illustration 33
Terminal locations for ECM
A. Thoroughly inspect ECM connector J1/P1, terminal 68

the firewall bulkhead connectors, and any
connectors that are used by the PTO. Refer to Illustration 33.
Refer to Troubleshooting, Inspecting Electrical C. Check the ECM connector (allen head screw) for
Connectors for details. the proper torque of 6.0 nm (55 lb in).
B. Perform a 45 N (10 lb) pull test on each of the D. Check the harness and wiring for abrasion and
wires in the ECM connector that are associated pinch points from the sensor to the ECM.
with the connections for the PTO. The following
connections should be tested if the connections Expected Result:
are used:
All connectors, pins and sockets should be
terminal 3 completely coupled and/or inserted and the harness
and wiring should be free of corrosion, abrasion
terminal 5 or pinch points.
terminal 30 Results:
terminal 35 OK Proceed to Test Step 4.

terminal 44 Not OK
terminal 56 Repair: Perform the following diagnostic
procedure:
terminal 58
terminal 60
53
Repair the connectors or wiring and/or replace Test Step 5. Check Status Of The
the connectors or wiring. Ensure that all of the Set/Resume Input On The Electronic
seals are properly in place and ensure that the Service Tool.
connectors are completely coupled.
Note: The set/resume input increases the engine
Verify that the repair eliminates the problem. rpm and the set/resume input decreases the engine
rpm.
STOP.
A. Find the PTO set/resume switch. If the PTO
Test Step 4. Check The PTO On/Off Configuration is programmed to Cab Switches,
Switch Circuit With An Electronic Service the cruise control set/resume switch will be
Tool. used. If the PTO Configuration is programmed
to Remote Switches or Remote Throttle, a
A. Turn the ignition key switch to the ON position. dedicated PTO set/resume switch will be used.
B. For the input 1 (PTO on/off switch), Access The PTO Configuration is programmed to
the Electronic Service Tool status screens that Cab Switches.
display the following status parameters:
Look at the status for the Cruise Control
PTO Config Set/Resume Switch parameter on the Electronic
Service Tool. The parameter is located on the
PTO ON/OFF Switch same status screen as the cruise/idle switch.
C. Verify that each of the PTO interlocks are set. B. While the Electronic Service Tool status screen
Then, while the Electronic Service Tool status for the switch is being monitored, perform the
screen is being monitored turn on the PTO on/off following procedure in order:
switch and turn off the PTO on/off switch.
Put the cruise control set/resume switch in the
An example of a PTO interlock would be a Set position.
parking brake that is intended to allow PTO
engine control under specific conditions. Release the cruise control set/resume switch
from the Set position.
Expected Result:
Result 1 The status of the PTO on/off switch on the Resume position.
Electronic Service Tool changes from OFF to ON
when the PTO on/off switch is turned OFF and ON, Release the cruise control set/resume switch
but the set/resume switch is not operating correctly. from the Resume position.
Result 2 The status of the PTO on/off switch on the The PTO Configuration is programmed to
Electronic Service Tool changes from OFF to ON Remote Switches or Remote Throttle.
when the PTO on/off switch is turned OFF and ON.
However, the remote accelerator is not operating View the status parameter on the Electronic
correctly. Service Tool for the Remote PTO Set Switch
and the Remote PTO Resume Switch.
Result 3 The status of the PTO on/off switch on the
Electronic Service Tool does not change from OFF C. While the Electronic Service Tool status screen
to ON when the PTO on/off switch is turned OFF for the switch is being monitored, perform the
and ON. following procedure in order:
Results: Put the remote PTO set/resume switch in the

Set position.
Result 1 Proceed to Test Step 5.
Release the remote PTO set/resume switch
Result 2 from the Set position.
Repair: Perform the following diagnostic Put the remote PTO set/resume switch in the
procedure: Troubleshooting, Remote PTO Resume position.
Accelerator Position Sensor Circuit - Test
STOP. from the Resume position.

54
Expected Result: Test Step 6. Check The Status Of The

PTO On/Off Switch On The Electronic
When the PTO Configuration is programmed to Service Tool.
Cab Switches, the status parameter for the cruise
control set/resume switch on the Electronic Service
Tool behaves in the following manner:
The status of the cruise control set/resume switch

will display OFF when the set switch is released.

changes from OFF to set switch ON when the
switch is moved to the SET position.

changes from set switch ON to resume switch
ON when the resume switch is moved to the
RESUME position.

Remote Switches or Remote Throttle, the status
parameter for the remote PTO set switch behaves
in the following manner:
The status screen for the remote PTO set switch Illustration 34 g00768799
displays OFF when the remote PTO set switch
ECM breakout T-connector
is released.
A. Turn the ignition key switch to the OFF position.
The status of the remote PTO resume switch
displays OFF when the remote PTO resume
B. Fabricate a jumper wire 100 mm (4 inch) long.
switch is released.
Crimp a Deutsch pin to both ends of the wire.
The status of the remote PTO set switch changes C. Disconnect vehicle harness connector P1 from
from OFF to set switch ON when the remote PTO
set switch is moved to the SET position. the ECM.
D. Connect a 70-Termial breakout T to ECM

The status of the remote PTO resume switch connector J1 and connect P1 to the breakout T.
changes from OFF to resume switch ON when
the remote PTO resume switch is moved to the
E. Connect an Electronic Service Tool to the cab
RESUME position.
Results:
F. Turn the ignition key switch to the ON position.
Yes The set circuit and the resume circuit G. Access the PTO On/Off Switch status on the
are functioning correctly. The PTO Inputs are
Electronic Service Tool.
functioning properly. Continue troubleshooting if
the original condition is not resolved. STOP.
H. While the switch status is being observed on the
Electronic Service Tool install the jumper into the
No (programmed to Cab Switches) The PTO breakout T in order to connect terminal 56 (input
Configuration is programmed to Cab Switches.
1) to terminal 3 (input sensor common #2).
Proceed to Test Step 7.
The input 1 is the PTO on/off switch.
No (programmed to Remote Switches or
Remote Throttle) The PTO Configuration is
programmed to Remote Switches or Remote
Throttle. Proceed to Test Step 8.
Expected Result:
The switch status of the PTO On/Off Switch on

the Electronic Service Tool behaves in the following
manner:
55
The switch status is OFF when the jumper is Test Step 7. Check The Status Of The
removed. Cruise Control Set/Resume Switch On
The Electronic Service Tool.
The switch status changes from OFF to ON when
the jumper is in place.
Results:
Yes The input 1 (PTO on/off switch) of the ECM

is functioning correctly. The problem is in the
switches of the vehicle or the problem is in the
wiring of the vehicle.
Repair: Inspect the wiring. Select one of the

following options:
Repair the wiring or replace the wiring.

Send the vehicle to the OEM dealer for repair.
Verify that the repair eliminates the problem.
STOP.
No The ECM is not reading the switch status Illustration 35 g00768798

change.
Repair: Perform the following diagnostic

procedure: A. Turn the ignition key switch to the OFF position.

1. Temporarily connect a test ECM.
2. Ensure that the PTO Configuration of the test
C. Disconnect vehicle harness connector P1 from
ECM matches the PTO Configuration of the
suspect ECM. the ECM.
D. Connect a 70-termial breakout T to ECM

3. Remove all jumpers and replace all connectors.
connector J1 and connect P1 to the breakout T.
4. Recheck the system for active diagnostic
codes.
5. Repeat the test step.
F. Turn the ignition key switch to the ON position,
6. If the problem is resolved with the test ECM, while the engine is off.
reconnect the suspect ECM.
G. Access the status of the cruise control set/resume
7. If the problem returns with the suspect ECM, switch on the Electronic Service Tool.
replace the ECM.
H. While the switch status is being observed on
8. Verify that the repair eliminates the problem. the Electronic Service Tool install the jumper
into the breakout T in order to connect terminal
35 (Set) to terminal 5 (AP sensor/switch sensor
STOP.
common). Also, while the switch status is being
observed on the Electronic Service Tool remove
the jumper from the breakout T in order to
disconnect terminal 35 (Set) from terminal 5 (AP
sensor/switch sensor common).
56
I. While the switch status is being observed on the 2. Ensure that the PTO Configuration of the test
Electronic Service Tool, install the jumper into the ECM matches the PTO Configuration of the
breakout T. This connects terminal 44 (resume) suspect ECM.
to terminal 5 (AP sensor/switch sensor common).
Also, while the switch status is being observed 3. Remove all jumpers and replace all connectors.
on the Electronic Service Tool, remove the jumper
from the breakout T. This will disconnect terminal 4. Recheck the system for active diagnostic
44 (resume) from terminal 5 (AP sensor/switch codes.
sensor common).
6. If the problem is resolved with the test ECM,
Expected Result: reconnect the suspect ECM.
The switch status of the cruise control set/resume 7. If the problem returns with the suspect ECM,
switch on the Electronic Service Tool behaves in replace the ECM.
the following manner:
8. Verify that the repair eliminates the problem.
The switch status of the cruise control set/resume
switch is OFF when the jumper is removed. STOP.
The switch status of the cruise control set/resume Test Step 8. Check The Status of the
switch changes from OFF to set switch ON Remote PTO Set Switch and the Remote
when the jumper is connected from terminal PTO Resume Switch on the Electronic
35 (Set) to terminal 5 (AP sensor/switch sensor Service Tool.
common).

switch changes from OFF to resume switch
ON when the jumper is connected from terminal
44 (switch resume terminal) to terminal 5 (AP
Results:
Yes The set input and the resume input of the

ECM are functioning correctly. The problem is in
the switches of the vehicle or the problem is in
the wiring of the vehicle.

following options:

g00768769
Illustration 36
ECM Breakout T-connector
STOP.
No The ECM is not reading the switch status B. Fabricate a jumper wire 100 mm (4 inch) long.
change.
procedure:
the ECM.
57
E. Connect an Electronic Service Tool to the cab Results:

Yes The input 2 (Remote PTO Set Switch) and
F. Turn the ignition key switch to the ON position. the input 3 (Remote PTO Resume Switch) of the
G. Access the Remote PTO Set Switch and Remote the switches of the vehicle or the problem is in
PTO Resume Switch status on the Electronic the wiring of the vehicle.
Service Tool.
H. While the status of the Remote PTO Set Switch is following options:
being observed on the Electronic Service Tool,
install the jumper into the breakout T in order to Repair the wiring or replace the wiring.
connect terminal 58 (input 2) to terminal 3 (input
sensor common #2). Also, while the switch status Send the vehicle to the OEM dealer for repair.
is being observed on the Electronic Service Tool
remove the jumper from the breakout T in order Verify that the repair eliminates the problem.
to disconnect terminal 58 (input 2) from terminal
3 (input sensor common #2). STOP.
I. While the status of the Remote PTO Resume No The ECM is not reading the switch status
Switch is being observed on the Electronic change.
Service Tool, install the jumper into the breakout
T in order to connect terminal 60 (input 3) to Repair: Perform the following diagnostic
terminal 3 (input sensor common #2). Also, procedure:
while the switch status is being observed on the
Electronic Service Tool remove the jumper from 1. Temporarily connect a test ECM.
the breakout T in order to disconnect terminal 60
(input 3) from terminal 3 (input sensor common 2. Ensure that the PTO Configuration of the test
#2). ECM matches the PTO Configuration of the
suspect ECM.
The input 2 is the set switch for the PTO and the
input 3 is the resume switch for the PTO. 3. Remove all jumpers and replace all connectors.
Refer to Illustration 36. 4. Recheck the system for Active diagnostic

codes.
Expected Result:
The switch status of the Remote PTO Set Switch on
the Electronic Service Tool behaves in the following 6. If the problem is resolved with the test ECM,
manner: reconnect the suspect ECM.
The switch status of the Remote PTO Set Switch 7. If the problem returns with the suspect ECM,
is OFF when the jumper is removed. replace the ECM.
The switch status of the Remote PTO Set Switch 8. Verify that the repair eliminates the problem.
jumper is connected from terminal 58 (input 2) to STOP.
terminal 3 (input sensor common #2).
i01474436
The switch status of the Remote PTO Resume
Switch on the Electronic Service Tool behaves in
PTO Switch ON Lamp Circuit
- Test
Switch is OFF when the jumper is removed. SMCS Code: 7431-081
The switch status of the Remote PTO Resume System Operation Description:
Switch changes from OFF to resume switch ON
when the jumper is connected from terminal 60 Use this procedure under the following situation:
(input 3) to terminal 3 (input sensor common #2).
Use the following information in order to determine
if the PTO Switch ON Lamp is operating incorrectly.
58
Terminal 30 (Output 1)
Output 1 can be used as a PTO Switch On Lamp

output. If the PTO Configuration is programmed to
Cab switches, Remote Switches, or Remote Throttle,
the Output will turn the lamp ON whenever the PTO
Switch Circuit is turned ON.
Electrical Connection of Lamps
One terminal of the lamp must be connected to

battery voltage through the vehicle wiring. The other
terminal is connected to the ECM at the Vehicle
Harness Connector J1/P1 at terminal 30.
The ECM provides a path to ground in order to turn

the lamp ON.
g00703413
Illustration 37
Schematic for PTO Switch ON Lamp
59
g00668646
Illustration 38
Test Step 1. Inspect Electrical Connectors Not OK

And Wiring.
Repair: Repair the connectors or wiring and/or
A. Thoroughly inspect ECM vehicle harness replace the connectors or wiring. Ensure that all
connector J1/P1, the firewall bulkhead of the seals are properly in place and ensure that
connector, or the PTO Switch ON Lamp. the connectors are completely coupled.
Refer to Troubleshooting, Inspecting Electrical
Connectors for details. STOP.
B. Perform a 45 N (10 lb) pull test on each of the Test Step 2. Check For Normal Operation
wires in the ECM Connector that are associated Of The PTO Switch ON Lamp.
with the PTO Switch ON Lamp.
A. Use the following procedure for the Output 1
Refer to Illustration 38. (PTO Switch ON Lamp).
C. Check the ECM connector (allen head screw) for Connect an Electronic Service Tool. Access
the proper torque of 6.0 Nm (55 lb in). the status screen that displays the PTO
Configuration and the PTO ON/OFF Switch. The
D. Check the harness and wiring for abrasion and PTO Configuration must indicate Cab Switches,
pinch points from the battery to the ECM. Remote Switches, or Remote Throttle. The PTO
Configuration is not programmed to turn the
Expected Result: PTO Switch ON Lamp to the ON position if the
PTO Configuration indicates OFF.
completely coupled and/or inserted and the harness While the PTO Switch ON Lamp and the status
and wiring should be free of corrosion, abrasion of PTO ON/OFF Switch is being watched on
or pinch points. the Electronic Service Tool, turn the PTO On/Off
Switch to the ON position and the OFF position.
Results: The PTO Switch ON Lamp should turn ON when
the PTO On/Off Switch is in the ON position. Also,
OK Proceed to Test Step 2. the PTO Switch ON Lamp should turn Off when
60
Expected Result:
The lamp turns ON and the lamp turns OFF per the
above description.
Results:
Yes The lamp appears to operating correctly

at this time. STOP.
No Proceed to Test Step 3.

Test Step 3. Test The PTO Switch ON
Lamp Circuit.
g00668711
Illustration 39
Vehicle harness connector P1
A. Disconnect ECM vehicle harness connector Result 3 The lamp will stay ON while the ECM
J1/P1. Vehicle Harness Connector is disconnected.
B. Fabricate a jumper wire 100 mm (4 inch) long. Results:

Result 1 The PTO Switch ON Lamp circuit is
C. Insert the jumper into terminal 30 of connector functioning properly. Proceed to test step 4.
P1.
Result 2 The lamp did not turn ON. The
D. Connect the other end of the jumper wire to vehicles lamp circuit is not functioning properly.
terminal 65 (battery) of connector P1. The lamp is probably burned out or there is a
problem in the wiring from the cab to either the
E. Turn the ignition key switch to the ON position. ECM or the +Battery connection. Repair the lamp
circuit or send the vehicle to the OEM dealer for
F. While the lamp is being watched, insert the repairs. STOP.
jumper wire and remove the jumper wire.
Result 3
Expected Result: procedure:
Result 1 The PTO Switch On Lamp turns ON while The circuit between the ECM and the lamp is
the jumper is connected to both sockets. Also, the shorted to chassis ground. Repair the circuit or
PTO Switch On Lamp turns OFF when the jumper is send the vehicle to the OEM dealer for repairs.
removed from one of the sockets.
STOP.
Result 2 The suspect lamp does not turn ON while
the jumper is connected to both sockets.
61
Test Step 4. Check ECM Operation Of The

PTO Switch On Lamp.
g00642533
Illustration 40
A. Disconnect ECM vehicle harness connector Results:

J1/P1.
Yes The ECM is operating correctly. There is a
B. Insert a 70-Terminal breakout T between ECM problem in the vehicle wiring or the lamp. STOP.
vehicle harness connector J1 and ECM vehicle
harness connector P1. No
C. Connect one probe of the voltage test lamp to Repair: Temporarily connect a test ECM. Ensure
terminal 65 (-battery). Connect the other probe of that the PTO Configuration of the test ECM
the voltage test lamp to terminal 52 (unswitched matches the PTO Configuration of the suspect
+battery) of the breakout T. ECM. Check the ECM operation of the PTO Switch
ON Lamp when the test ECM is installed. If the
D. The test lamp should turn ON. If the test lamp problem is resolved with the test ECM, reconnect
does not turn on, either the test lamp is faulty or the suspect ECM. If the problem returns with the
the wiring to the ECM is faulty. Continue with this suspect ECM, replace the ECM.
step if the lamp turns ON.
STOP.
E. Leave the probe of the test lamp connected to
terminal 52 (unswitched +battery).
i01334712
F. Connect the other probe of the test lamp to

terminal 30 (Output 1) of the breakout T.
Remote PTO Accelerator
Position Sensor Circuit - Test
SMCS Code: 1913
G. Connect an Electronic Service Tool. Access the
following display screens in order: System Operation Description:
Diagnostics Use this procedure under the following situation:
Diagnostic Test Use this procedure if any of the following Diagnostic

Codes are indicated:
Special Test
30-08 Invalid PTO Throttle Signal (29)
H. Activate the Special Test for the PTO Switch ON
Lamp. Observe the voltage test lamp. The lamp 30-13 PTO Throttle Sensor Calibration (29)
should turn ON when the test is Active. Also, the
lamp should turn OFF when the test is inactive. Also, use this procedure if the Remote PTO
Accelerator Position Sensor is suspected of
Expected Result: improper operation.
The test lamp turns ON and the test lamp turns OFF Remote PTO Accelerator Position Sensor
per the above description.
62
A Remote PTO Accelerator Position Sensor may The ECM is in PTO mode if the PTO On/Off Switch
be used for PTO purposes. The Remote PTO is ON. This can be checked through an Electronic
Accelerator Position Sensor should be connected to Service Tool Status Screen.
the ECM Connector P1/J1 terminal 68. Before the
ECM will respond to the Remote PTO Accelerator The ECM will not respond to the Remote PTO
Position Sensor, the ECM PTO Configuration must Accelerator Position Sensor when both of the
be programmed to Remote Throttle, and the PTO following conditions are met:
ON/OFF Switch must be in the ON position. Also,
Caterpillar offers the following recommendation: The PTO ON/OFF circuit is switched from the OFF
position to the ON position.
The Remote PTO Accelerator Position Sensor
must be powered from the vehicle battery (+12 V). The ECM reads the PTO Accelerator Position
Sensor above Low Idle.
Therefore, the +12 V version of the Accelerator
Position Sensor must be used for the Remote PTO This prevents the engine from experiencing
Accelerator Position Sensor, and the +8 V version unexpected acceleration or sudden acceleration
for the Cab Accelerator Pedal Position Sensor. when the PTO ON/OFF circuit is turned ON. The
PTO Accelerator Position Sensor must return to Low
The ECM will not respond to the Remote PTO Idle before the ECM will respond. The ECM must
Accelerator Position Sensor if there is a 253-02 also see a transition from the OFF position to the ON
Check Customer or System Parameters (56) Active position in the PTO ON/OFF Switch in order to allow
Diagnostic Code under some conditions. Refer to the other PTO speed control functions to operate. If
Troubleshooting, ECM Memory - Test if there is a the engine is started with the PTO ON/OFF Switch
253-02 Check Customer or System Parameters (56) in the ON position, the accelerator will respond. The
Active Diagnostic Code. response will occur only if the accelerator pedal
is first returned to the low idle position. The other
The Remote Accelerator Pedal Position Sensor is speed control functions will not respond.
used to provide a throttle position signal to the ECM.
Sensor output is a constant frequency signal with
a pulse width that varies with the pedal position.
This output signal is referred to as either a Duty
Cycle or a Pulse Width Modulated signal (PWM)
and this output signal is expressed as a percentage
between 3 and 100 percent.
The Pedal Mounted Accelerator Pedal Position

Sensor is attached directly to the Accelerator Pedal
Assembly and the Pedal Mounted Accelerator Pedal
Position Sensor requires no adjustment.

Sensor will produce a Duty Cycle of 10 to 22
percent at low idle and 75 to 90 percent when the
accelerator pedal is fully depressed. The percent
of duty cycle is translated in the ECM into an
accelerator pedal position of 3 to 100 percent.

Sensor can be replaced separately from the Pedal
Assembly. An incorrectly calibrated Pedal Assembly
can not be adjusted. The entire Pedal Assembly
must be replaced.
If the vehicle is using the ECM Dedicated PTO

functions, the Cab Accelerator Pedal Position
Sensor will be ignored while the engine is in PTO
mode and the PTO Configuration is programmed
to the following setting:
Remote Throttle
63
g00642017
Illustration 41
Schematic for remote accelerator pedal position sensor
64
g00642018
Illustration 42
Test Step 1. Inspect Electrical Connectors E. Check the harness and wiring for abrasion and
And Wiring. pinch points from the Remote PTO Accelerator
Position Sensor to the ECM.
A. Connect an Electronic Service Tool. Verify that
the parameter for the PTO Configuration is Expected Result:
programmed to the Remote Throttle.
B. Thoroughly inspect ECM Vehicle Harness completely coupled and/or inserted and the harness
Connector J1/P1, the firewall bulkhead connector and wiring should be free of corrosion, abrasion
and the Remote PTO Accelerator Pedal Position or pinch points.
Sensor Connector. Refer to Troubleshooting,
Inspecting Electrical Connectors for details. Results:
C. Perform a 45 N (10 lb) pull test on each of the OK Proceed to test step 2.
wires in the ECM Connector that are associated
with the Remote PTO Accelerator Position Not OK
Sensor:
Terminal 68 procedure:
D. Check the ECM Connector (Allen Head Screw)

for the proper torque of 6.0 Nm (55 lb in).
65
Repair the connectors or wiring and/or replace Test Step 3. Check the Supply Voltage
the connectors or wiring. Ensure that all of the for the Remote PTO Accelerator Position
seals are properly in place and ensure that the Sensor.
A. Turn the Ignition Key Switch to the ON position.
B. Measure the voltage at terminal A (+12 V) with
STOP. reference to terminal B (sensor common) at the
connector J406. This connector is for the Remote
Test Step 2. Check for Active Diagnostic PTO Accelerator Position Sensor.
Codes.
Expected Result:
A. Connect an Electronic Service Tool to the Cab
Data Link Connector. The measured voltage is between 11.0 VDC and
13.5 VDC.
B. Turn the Ignition Key Switch to the ON position.
Results:
C. Monitor the Active Diagnostic Code Screen of
the Electronic Service Tool. Check and record OK Proceed to test step 4.
Active Diagnostic Codes.
Not OK The vehicle wiring or the battery is
Note: When the ECM automatically calibrates new causing the problem. Repair the wiring or the
duty cycle values for the low idle throttle position battery. Replace the wiring or the battery. Perform
and the high idle throttle position the ECM assumes the repair that is necessary. Verify that the repair
22 percent duty cycle at low idle and 75 percent has fixed the problem. STOP.
duty cycle at high idle. As a result, you may notice
that the PTO Throttle Position Status reaches 100 Test Step 4. Check The Duty Cycle Of The
percent well before the remote PTO accelerator Accelerator Pedal Position Sensor.
pedal is fully depressed. This is normal. After
some cycling of the accelerator pedal to the high A. Turn the Ignition Key Switch to the ON position.
idle position, the ECM will adjust the calibration
automatically. The ECM will adjust the calibration B. Monitor the Duty Cycle of the PTO Throttle
automatically provided that the high idle stop Sensor on the Electronic Service Tool. Access
position is within the 75 to 90 percent duty cycle the following display screen in order:
range, and the low idle is in the 10 to 22 percent
duty cycle range. During normal operation, you Service
may notice that more movement of the remote PTO
accelerator pedal is required for the PTO Throttle Calibrations
Position status to increase above 3 percent. You
may also observe that the status reaches the 100 Monitor Throttle Position Sensor
percent value prior to the limit of the high idle
position. This is done in order to ensure that the Expected Result:
accelerator reaches these two critical points for
engine operation. The Duty Cycle is between 10 and 22 percent with
the accelerator pedal assembly in the Low Idle
Expected Result: position, and the Duty Cycle is between 75 and 90
percent with the accelerator pedal assembly in the
Result 1 Diagnostic Code 30-08 or 30-13 is Active. High Idle position.
Result 2 There are NO Active Diagnostic Codes that Results:

are related to the Accelerator Pedal Position Sensor
Circuit at this time, but a problem is suspected with Yes The Remote PTO Accelerator Pedal
operation of the Remote PTO Accelerator Pedal Position Sensor is operating correctly. Proceed
Position Sensor Circuit. to test step 5.
Results: No The Remote PTO Accelerator Pedal Position

Sensor Circuit is not operating correctly. Proceed
Result 1 Proceed to test step 3. to test step 6.
Result 2 Proceed to test step 3.

66
Test Step 5. Check The Status Of The B. Remove the signal wire for the Remote PTO
Power Train Data Link With An Electronic Throttle Position Sensor (terminal C) from J406.
Service Tool. This is the Vehicle Harness side of the Connector
for the Accelerator Position Sensor.
A. Start the engine. While the status of the PTO
Throttle Position is being monitored on the C. Install a Breakout T with 3 terminals at the
Electronic Service Tool, depress the remote PTO Connector J406/P406 for the Remote PTO
accelerator pedal and release the remote PTO Accelerator Position Sensor.
accelerator pedal. The Throttle Position status
and the engine should respond to the change in D. Connect the multimeter probes to terminal
the accelerator pedal position. C (ACCELERATOR PEDAL POSITION) and
terminal B (ACCELERATOR/SWITCH SENSOR
B. Go to the System Troubleshooting Settings COMMON) of the Breakout T.
portion of the Electronic Service Tool and turn
OFF the Power Train Data Link. E. While the Duty Cycle is being monitored on the
multimeter, depress the accelerator pedal and
C. While the status of the PTO Throttle Position is release the accelerator pedal.
being monitored on the Electronic Service Tool,
depress the accelerator pedal and release the Expected Result:
accelerator pedal. Also depress the accelerator
pedal and release the accelerator pedal while The Duty Cycle is between 10 and 22 percent with
the engine response is being monitored. the accelerator pedal assembly in the Low Idle
position, and the Duty Cycle is between 75 and 90
Expected Result: percent with the accelerator pedal assembly in the
High Idle position.
The status of the PTO Throttle Position and the
engine should respond to the change in the Results:
accelerator pedal position.
Yes Reinsert the wire (terminal C) into the
Result 1 The PTO Accelerator is functioning Connector for the Remote PTO Accelerator
properly. Position Sensor. The sensor is working correctly.
Proceed to test step 7.
Result 2 The Throttle Response is limited by a
power train data link message. No Leave the PWM Probe Connected to the
Breakout T. Insert the wire (terminal C) into
Results: the Connector for the Remote PTO Accelerator
Position Sensor. The sensor or the Accelerator
Result 1 The Remote PTO Accelerator Pedal Pedal Assembly is faulty. Proceed to test step 8.
Position Sensor is operating correctly. Continue
troubleshooting until the original condition is Test Step 7. Check The Duty Cycle Of The
resolved. STOP. Remote PTO Accelerator Position Sensor
At The ECM.
Result 2 If the engine responds with the Power
Train Data Link in the OFF position, but not with Note: Performing certain steps within this procedure
the Power Train Data Link in the ON position, requires the use of a multimeter that is capable of
a component of the Power Train Data Link is measuring a PWM Duty Cycle.
causing the response problem of the Remote
PTO Accelerator Pedal Position Sensor. Send A. Turn the Ignition Key Switch to the OFF position.
the truck to the vehicle manufacturer in order to
repair the faulty component of the Power Train B. Remove the signal wire for the REMOTE PTO
Data Link. STOP. ACCELERATOR POSITION SENSOR (terminal
68) from the Vehicle Harness side (P1) of ECM
Test Step 6. Check The Duty Cycle Of The Connector P1/J1.
Remote PTO Accelerator Position Sensor
At The Sensor. C. Connect the multimeter probes between the
removed wire and the ECM Sensor Common or
Note: Performing certain steps within this procedure ground.
requires the use of a multimeter that is capable of
measuring a PWM Duty Cycle. D. Turn the Ignition Key Switch to the ON position.
A. Turn the Ignition Key Switch to the OFF position.

67
E. Use the multimeter in order to display the Duty When the sensor is removed from the Accelerator
Cycle output of the Accelerator Pedal Position Assembly the following Diagnostic Codes may
Sensor. While the Duty Cycle output of the be generated:
Remote PTO Accelerator Position Sensor is
being monitored on the multimeter, move the 30-13 PTO Throttle Sensor Calibration (29)
accelerator assembly from the Low Idle position
to the High Idle position. Record the results. This is normal. The Diagnostic Code should
disappear when the sensor is properly
F. Turn the Ignition Key Switch to the OFF position. assembled back into the Accelerator Pedal
Assembly.
G. Insert terminal 68 into the ECM Vehicle Connector
P1/J1 (70 Terminal).
Expected Result:
The Duty Cycle is between 10 and 22 percent with

High Idle position.
Results:
Yes A good signal from the Remote PTO

Accelerator Position Sensor is reaching the ECM.
Verify that the ECM is receiving the proper battery
voltage. If the ECM is receiving the proper battery
voltage, temporarily connect a test ECM and
verify that the problem is resolved. If the problem
disappears with the test ECM, reconnect the
suspect ECM. If the problem returns with the
suspect ECM, replace the ECM. STOP.
No There is a problem with signal wire for the

Remote PTO Accelerator Position Sensor in the
Vehicle Wiring Harness. Proceed to test step 9.
Test Step 8. Remove The Remote PTO

Accelerator Position Sensor From The
Accelerator Pedal Assembly.
B. Remove the Remote PTO Accelerator Position

Sensor from the Accelerator Assembly. Note
sensor orientation in the Accelerator Assembly,
and the sensor pigtail routing prior to sensor
removal. Thoroughly inspect the pigtail for signs
of abrasion.
C. Connect the multimeter that is capable of

measuring a PWM Duty Cycle to terminal C
of the Breakout T.
D. Turn the ignition key switch to the ON position.
E. Display the Duty Cycle output of the Remote PTO

Accelerator Position Sensor while the sensor slot
is released. Use a screwdriver to advance the
sensor slot to the maximum position. Refer to
Illustration 43.
68
g00642019
Illustration 43
(1) Mounting screw holes (3) Sensor housing (5) Accelerator pedal assembly
(2) Sensor slot (4) Mounting surface for sensor (6) Accelerator block assembly
Expected Result: No The Remote PTO Accelerator Position

Sensor is faulty. Check the Accelerator Assembly
When the sensor is removed from the Accelerator in order to ensure that the Accelerator Assembly
Pedal Assembly and the sensor slot is released, the is not causing damage to the sensor. If the
Duty Cycle is 10 percent or less. When the sensor Accelerator Assembly is causing damage to
slot is moved to the maximum position, the Duty the sensor, refer to the OEM dealer for correct
Cycle increases to 90 percent or more. replacement of the Accelerator Assembly. STOP.
Results: Test Step 9. Route The Supply Bypass

Wires To The Accelerator Pedal Position
Yes The Remote PTO Accelerator Position Sensor.
Sensor is working correctly. Clear any diagnostic
codes that were caused by performing this test A. Turn the ignition key switch to the OFF position.
procedure. Refer to the OEM dealer for correct
replacement of the Accelerator Assembly. STOP.
69
B. Remove the signal wire for the remote PTO

accelerator position sensor (terminal 66) from
the ECM Connector P1.
C. Remove terminal C (Accelerator Pedal Position)

from the Accelerator Pedal Position Sensor
Connector.
D. Route new wiring from the ECM to the Remote

PTO Accelerator Position Sensor.
E. Turn the ignition key switch to the ON position.
F. Check the Duty Cycle of the Remote PTO

Accelerator Position Sensor with an Electronic
Service Tool while the accelerator pedal
assembly is being moved over the full range.
Expected Result:

High Idle position.
Results:
Yes The wiring from the ECM to the Accelerator

Pedal Position Sensor appears faulty. Permanently
install new wiring. Verify that the repair eliminates
the problem. STOP.
No Double check the wiring, the ECM Vehicle

Harness Connector J1/P1 and the Sensor
Connector. If a problem still exists, restart the test
procedure. STOP.
70

Section

i01488507
PTO Parameters - Program

SMCS Code: 1000-591
Installation and Programming That

Is Based on The Questionnaire
Response
Table 9
Question Response
The operator of the PTO needs to control the engine rpm. If the operator of the PTO will be operating the PTO from the
Determine the location on the vehicle. cab, then program the PTO configuration to cab switches.
Determine if the operator of the PTO needs to continually Otherwise, consider using the fast idle.
vary the engine rpm. If the operator of the PTO will be outside of the cab, then
Determine if a foot accelerator is necessary. Determine if a program the PTO configuration to either Remote Switches
hand accelerator is necessary. or to Remote Throttle. If the operator of the PTO will be
This determines the programming of the PTO configuration. continually varying the engine rpm by using a foot accelerator
or a hand accelerator, then program the PTO configuration to
remote throttle. Otherwise, program the PTO configuration to
remote switches.
If operation of the PTO in the cab or out side of the cab is
required, then the following components are used for the
control of the PTO in the cab: The Cruise Control On/Off
switch, the Cruise Control Set/Resume switch, the Cab
Accelerator Pedal, or the Fast Idle switch are needed.
The remote PTO configuration should be used for outside
cab control. The PTO configuration should be programmed to
either remote switches or remote throttle.
Determine the maximum vehicle speed for the PTO operation. Program the PTO Vehicle Speed Limit to the value that
Determine if the PTO operation requires the use of the clutch is needed. If the PTO is driven by the transmission and
and the service brakes without changing the engine rpm. a high vehicle speed results, then this parameter can be
This determines the programming of the PTO Vehicle set to avoid a disconnection of the vehicle speed circuit.
Speed Limit. This also determines if an additional switch is Refer to the appropriate diagrams for the application if the
necessary in order to prevent the movement of the brake operation requires feathering out the service brakes or the
pedal and the movement of the clutch from returning the clutch in order to adjust the vehicle speed. A set engine
engine rpm to programmed low idle rpm. rpm is also maintained at the same time. Refer to the PTO
Service Manual, Cab Switches with Torque Limiting and
Ignore Brake/Clutch Switch for more information if the PTO
configuration is programmed to cab switches. When the Fast
Idle Enable Switch is used for the engine speed control for
the PTO operation, program the Idle Vehicle Speed Limit to
this value.
Determine the torque value that is maximum for the Program the parameter for the Torque Limit to this value.
equipment when the circuit for the PTO is ON. NOTE: The programmed torque limit is an estimate. To
This determines the programming of the torque limit. determine actual torque output, test the engine on a
NOTE: Fast idle does not provide this option. dynamometer.
(continued)
71
(Table 9, contd)
Determine if a torque limit is also required for the temporary Refer to the appropriate schematic for the application if the
protection of equipment. This is determined for the instance torque limit is required. This may be required for the instance
when the PTO On/Off Circuit is in the OFF position. when the PTO is OFF. Refer to the PTO Service Manual,
This determines if a Torque Limit switch is necessary. Cab Switches with Torque Limiting and Ignore Brake/Clutch
Switch if the PTO configuration is programmed to cab
switches. If the PTO configuration is programmed to Remote
Switches, then refer to PTO Service Manual, Remote
Switches with Torque Limiting and Ignore Brake/Clutch
Switch.
Determine if one or more fixed engine rpm above low idle is These responses are for a dedicated PTO.
required. If only one rpm above low idle is required, program the PTO
Determine the first engine rpm. Top Engine Limit and PTO Engine RPM Set Speed to the
Determine the second engine rpm. same rpm.
This determines the programming of the PTO Engine RPM If two rpm are desired, then program the PTO Engine RPM
Set Speed and the PTO Top Engine Limit parameters for Set Speed to the first rpm value. Program the PTO Top
a dedicated PTO. Engine Limit to the second rpm.
For Fast Idle, this determines the programming of fast idle Program the PTO to Set Speed to YES if the engine should
engine rpm 1 and fast idle engine rpm 2. accelerate to the first engine rpm point. This occurs when the
Determine that the engine rpm needs to accelerate to the PTO On/Off switch is turned ON.
first engine rpm at the instant when the PTO On/Off switch NOTE: The PTO Engine RPM Set Speed Input A and
is turned ON. the PTO Engine RPM Set Speed Input B is another
This determines the programming of the PTO in relation to option. Refer to PTO Service Manual, Multiple Speed PTO
the Set Speed parameter for a dedicated PTO. This also Operation for more information.
determines if a second switch is required for control of the These responses are for questions that are involved with the
engine rpm. subject of fast idle.
Program the Fast Idle Engine RPM to the desired RPM if only
one rpm above low idle is required and the Switch for Fast
Idle will be used for operation in the cab.
Program the Fast Idle Engine RPM 1 parameter to the first
rpm value if two rpm are desired and the Fast Idle Switch
will be used for operation in the cab. Program the Fast Idle
Engine RPM 2 to the second engine rpm.
Determine if the control for the engine rpm is required from This requires the use of parameters for a Dedicated PTO
both the cab and outside of the cab. that is operated outside of the cab. The accelerator position
Determine the points for operating speed if control for the sensor that is in the cab, the Fast Idle Switch, the Cruise
engine rpm is required in both locations. Control On/Off Switch, and the Cruise Control Set/Resume
Switch are also needed for operation from the cab.
Program the Idle RPM Limit for the use of the Cruise Control
Switches and program the Fast Idle RPM Limits for use
from the cab of the Fast Idle Switch. Program the Dedicated
PTO parameters for operation outside the cab.
Determine the engine rpm that is maximum for the PTO in Program the Top PTO Engine RPM Limit to this rpm.
operating conditions. The answer to this question will determine whether the PTO
Determine if the accelerator pedal should have limited rpm. Cab Throttle RPM Limit should be programmed to Low
This determines the programming of the Top PTO Engine Idle, Top Engine Limit, or PTO Top Engine Limit if the
RPM Limit and the PTO Cab Throttle RPM Limit. PTO Configuration is programmed to the Cab Switches.
NOTE: The accelerator pedal is ignored in the PTO.
NOTE: Fast Idle does not provide accelerator position rpm
limits.
Determine the necessary time in order for the engine to This parameter may be programmed after demonstrating
accelerate and decelerate to the engine rpm set points and some different settings to the customer.
from the engine rpm set points. NOTE: The engine will ramp to the rpm that is programmed if
NOTE: Acceleration rates and deceleration rates are the Fast Idle Switch is used for operation in the cab. This is
measured in rpm/sec. independent of the programmed Idle/PTO Ramp Rate.
This determines the programming of the Idle/PTO Ramp
Rate that is measured in rpm/sec.
72
Programming the Parameters PTO Cab Throttle RPM Limit The PTO Cab
Throttle RPM Limit is used only if the PTO
Programming the parameters requires an Electronic Configuration is programmed to Cab Switches.
Service Tool. Customer Passwords are required to The cab accelerator position sensor is always
change the current settings for the programmable limited to low idle when the PTO On/Off circuit is ON
parameters if the customer passwords have been and the PTO Configuration has been programmed
set. Availability of some of the parameters depends to Remote Switches or Remote Throttle.
on the programming of other parameters. Program
the Parameter for the PTO Configuration before Torque Limit The Torque Limit can be
attempting to program any of the Dedicated PTO programmed to values above the Rated Torque
Parameters. Failure to program the Parameter for of the engine. However, the Rated Torque of the
the PTO Configuration first will cause the remaining engine is the maximum torque of the engine.
Dedicated PTO Parameters to display Unavailable
on the Electronic Service Tool Configuration Screen. Cruise/Idle/PTO Switch Configuration The
Set/Resume switch operates as an RPM
Programming Provisions Increase/RPM Decrease switch when the PTO
On/Off switch is ON and the parameter for the PTO
The following parameters or the operation of Engine RPM Set Speed is programmed. Placing
the following parameters are affected by other the switch in the Set position will signal the ECM to
parameters. increase the engine rpm. Placing the switch in the
Resume position will signal the ECM to decrease
PTO Configuration The Parameter for the PTO the engine rpm.
Configuration must be programmed first in order
to meet the requirements for the PTO Parameters PTO Vehicle Speed Limit The park brake switch
that are Dedicated. No other parameter can be and the interlocks for the neutral switch are required
programmed first in order to allow programming of in the circuit for the PTO On/Off Switch if the
other Dedicated PTO Parameters. parameter for the PTO Vehicle Speed Limit is used
in order to avoid the disconnection of the vehicle
PTO Top Engine Limit The PTO Top Engine speed circuit. The requirement is because of the
Limit should be programmed above the fact that the PTO is driven by the transmission in
programmed Low Idle. this instance.
PTO Engine RPM Set Speed The PTO Engine PTO Shutdown Time The timer will become
RPM Set Speed disables the Idle/PTO Bump RPM active when the PTO is switched ON. The timer
for the PTO operation. cannot be overridden if the PTO Shutdown Time
has been programmed properly. The engine will
PTO Engine RPM Set Speed A Input 7 must shut down regardless of the load when the elapsed
be programmed to PTO Engine RPM Set Speed time equals the programmed value .
Input A and a dedicated switch must be installed
in order for the engine to operate at the desired i01488532
speed for this parameter. This feature is available
for JUL99 and newer Personality Modules. PTO Configurations - Test
PTO Engine RPM Set Speed B Input 19 must SMCS Code: 1000-081; 1165-081
be programmed to PTO Engine RPM Set Speed
Input B and a dedicated switch must be installed The tables that follow list the following information:
in order for the engine to operate at the desired Sequence of events, Action that is taken by the
speed for this parameter. This feature is for JUL99 Operator of the PTO, and Position of the controlling
and newer Personality Modules. equipment. The positions produce the resultant
engine RPM within a specific programmed limit. The
PTO to Set Speed The PTO to Set Speed following components are used in order to provide a
requires the PTO Engine RPM Set Speed to be demonstration of the interaction of different systems:
programmed to an engine rpm above low idle. The Cruise Control On/Off switch, PTO On/Off switch,
PTO Configuration must be programmed to Cab Set/Resume switch, Fast Idle On/Off switch, and
Switches or to Remote Switches. Accelerator Pedal. Most systems will require only
some of the components.
73
The Four Programmable Engine

Limits
The parameters that are given in Table 10 must be
programmed in order to perform the following test.
Table 10
Parameter Programming for the Four Programmable Engine Limits
PTO Configuration Cab Switches
PTO Top Engine Limit 2100 rpm
PTO Cab Throttle RPM Limit PTO Top Engine Limit
Low Idle RPM 700 rpm
Idle RPM Limit 900 rpm
Top Engine Limit 2640 rpm
Fast Idle Engine RPM 1000 rpm
g00645720
Illustration 44
Table 11
The Four Programmable Engine Limits
Frame 1
Action that was taken by
Controlling Equipment Result Resultant Engine RPM
the Operator of the PTO
The Cruise Control switch is Park the vehicle with the The engine is at the
OFF. The PTO switch is OFF. engine at idle. programmed low idle rpm.
The Set/Resume switch is
700 rpm
OFF. The Fast Idle switch is
OFF. The Accelerator Pedal
is not depressed.
74
g00645734
Illustration 45
Table 12
Frame 2
Controlling Equipment Action that was taken by Result Resultant Engine RPM
The Cruise Control switch is Fully depress the accelerator The engine is limited by the
OFF. The PTO switch is OFF. pedal. programmed Top Engine
The Set/Resume switch is Limit (TEL). The TEL in this
2640 rpm
OFF. The Fast Idle switch is instance is 2640 rpm.
is fully depressed.
g00645737
Illustration 46
75
Table 13
Frame 3
The Cruise Control switch Place the Cruise Control The engine is limited by the
is ON. The PTO switch is switch to the ON position. programmed TEL which is
OFF. The Set/Resume switch Place the Set/Resume switch 2640 rpm.
is in the Set position. The to the Set position. 2640 rpm
Fast Idle switch is OFF. The
Accelerator Pedal is fully
depressed.
g00645742
Illustration 47
Table 14
Frame 4
The Cruise Control switch is Release the Accelerator The engine is at the
ON. The PTO switch is OFF. Pedal. Release the programmed idle RPM
The Set/Resume switch is Set/Resume switch from Limit which is 900 rpm.
900 rpm
OFF. The Fast Idle switch is the Set position.
is released.
g00645749
Illustration 48
76
Table 15
Frame 5
The Cruise Control switch is Turn the PTO On/Off switch The engine will return to
ON. The PTO switch is ON. to ON. Low Idle RPM because a
The Set/Resume switch is PTO rpm has not been set.
OFF. The Fast Idle switch is The PTO On/Off switch will
OFF. The Accelerator Pedal override the Cruise Control 700 rpm
is released. On/Off switch. The PTO
Vehicle Speed Limit must be
higher than the actual vehicle
speed.
g00645753
Illustration 49
Table 16
Frame 6
The Cruise Control switch Place the Set/Resume switch The engine is at the PTO TEL
is ON. The PTO switch is in the Set position and fully which is 2100 rpm.
ON. The Set/Resume switch depress the accelerator
is in the Set position. The pedal. 2100 rpm
Fast Idle switch is OFF. The
depressed.
77
g00645759
Illustration 50
Table 17
Frame 7
The Cruise Control switch is Release the Set/Resume The engine will remain at the
ON. The PTO switch is ON. switch. Release the PTO TEL which is 2100 rpm.
The Set/Resume switch is accelerator pedal.
2100 rpm
is released.
g00645762
Illustration 51
78
Table 18
Frame 8
The Cruise Control switch is Turn the Cruise Control The engine will return to the
OFF. The PTO switch is OFF. On/Off switch to the OFF low idle rpm which is 700
The Set/Resume switch is position. Turn the PTO rpm.
700 rpm
OFF. The Fast Idle switch is On/Off switch to the OFF
OFF. The Accelerator Pedal position.
is released.
g00645764
Illustration 52
Table 19
Frame 9
The Cruise Control switch is Turn the Fast Idle switch to The engine will accelerate
OFF. The PTO switch is OFF. the ON position and then to the programmed Fast Idle
The Set/Resume switch is release. The switch will RPM which is 1000 rpm.
1000 rpm
OFF. The Fast Idle switch is automatically return to the
ON. The Accelerator Pedal is OFF position when the switch
released. is released.
g00645765
Illustration 53
79
Table 20
Frame 10
The Cruise Control switch is Turn the Cruise Control The engine remains at the
ON. The PTO switch is OFF. On/Off switch to the ON programmed Fast Idle rpm
The Set/Resume switch is position. which is 1000 rpm.
1000 rpm
is released.
g00645767
Illustration 54
Table 21
Frame 11
The Cruise Control switch is Turn the PTO On/Off switch The engine returns to the
ON. The PTO switch is ON. to the ON position. programmed Low Idle rpm
The Set/Resume switch is because a PTO rpm has not
700 rpm
OFF. The Fast Idle switch is been set. The PTO On/Off
OFF. The Accelerator Pedal switch will override the Fast
is released. Idle.
g00645768
Illustration 55
80
Table 22
Frame 12
The Cruise Control switch Turn the PTO On/Off switch The engine will return to the
is ON. The PTO switch is to the OFF position. Turn Idle RPM Limit that was set
OFF. The Set/Resume switch the Set/Resume switch to in Frame 4.
is in the RESUME position. the RESUME position. The 900 rpm
The Fast Idle switch is OFF. switch will release after the
The Accelerator Pedal is RESUME position.
released.
g00645771
Illustration 56
Table 23
Frame 13
The Cruise Control switch is Turn the Fast Idle switch to The engine will accelerate
ON. The PTO switch is OFF. the ON position and then to the programmed Fast Idle
The Set/Resume switch is release. RPM, which is 1000 rpm. The
OFF. The Fast Idle switch is Fast Idle rpm is set higher 1000 rpm
ON. The Accelerator Pedal is than the Idle rpm. The Fast
released. Idle rpm overrides the Cruise
Control.
Fast Idle Operation NOTE: The programmed value for the Fast Idle
Engine RPM 1 can be overridden by using the
Table 24 illustrates the engine speed control by accelerator pedal that is in the cab. Once the
using the Fast Idle Enable Switch. The Fast Idle programmed value is overridden, the new value is
Enable Switch is a dash mounted switch. The used until the ignition key is turned OFF. Press the
switch is standard in GMC and Chevrolet Medium accelerator pedal to the new speed and press the
Duty Trucks. The switch is optional in all other Fast Idle switch. This will override the Fast Idle
chassis. The Fast Idle Engine RPM 1 parameter Engine RPM 1. The programmed value for the
provides one set speed above Low Idle operation. Fast Idle Engine RPM 2 can not be overridden.
The Fast Idle Engine RPM 2 parameter provides
an additional set speed above Low Idle operation. The parameters that are given in Table 24 must be
programmed in order to perform the following test.
81
Table 24
Parameter Programming for Fast Idle Operation
PTO Configuration OFF
Low Idle RPM 700 rpm
Fast Idle Engine RPM 1 1000 rpm
Fast Idle Engine RPM 2 1500 rpm
g00646866
Illustration 57
Table 25
Fast Idle Operation
Frame 1
The Fast Idle Switch is OFF. Start the engine. The engine is at the
The Accelerator Pedal is programmed low idle of 700 rpm
released. 700 rpm.
g00646868
Illustration 58
82
Table 26
Fast Idle Operation
Frame 2
The Fast Idle Switch is ON. Turn the Fast Idle switch to The engine will ramp up
The Accelerator Pedal is the ON position and then to 1000 rpm, which is the
1000 rpm
released. release. programmed Fast Idle
Engine RPM 1.
g00646869
Illustration 59
Table 27
Fast Idle Operation
Frame 3
The Fast Idle Switch is ON. Turn the Fast Idle switch to The engine will then ramp
The Accelerator Pedal is the ON position and then up to 1500 rpm. 1500 rpm is
1500 rpm
released. release. the programmed Fast Idle
Engine RPM 2.
g00646871
Illustration 60
83
Table 28
Fast Idle Operation
Frame 4
The Fast Idle Switch is ON. Turn the Fast Idle switch to The engine will return to the
The Accelerator Pedal is the ON position and then programmed Low Idle of 700 700 rpm
released. release. rpm.
g00646873
Illustration 61
Table 29
Fast Idle Operation
Frame 5
The Fast Idle Switch is ON. In order to override the The engine will go to 1200
The Accelerator Pedal is programmed Fast Idle rpm. The programmed Fast
depressed. Engine RPM, the accelerator Idle Engine RPM 1 has been
pedal must be depressed overridden.
until the desired rpm is NOTE: The programmed
1200 rpm
achieved. Quickly toggle the Fast Idle Engine RPM 2 can
Fast Idle Enable Switch to not be overridden.
the ON position and then
release. In this example,
1200 rpm is used.
g00646874
Illustration 62
84
Table 30
Fast Idle Operation
Frame 6
The Fast Idle Switch is OFF. Release the accelerator The engine is now at the
The Accelerator Pedal is pedal. new Fast Idle Engine RPM,
released. which is 1200 rpm. 1200 rpm 1200 rpm
is the temporary Fast Idle
Engine RPM.
Engine Operation with PTO Engine

RPM Set Speed
The parameter for the PTO Engine RPM Set Speed
is useful only if one or two specific engine rpm
above low idle is required. Program this parameter
to the same value as the PTO Top Engine Limit if
ONLY one specific engine rpm above low idle is
required.
This parameter determines the amount of engine

rpm when the PTO On/Off switch is turned to the
ON position. The parameter for the PTO to Set
Speed must also be programmed to YES. If the
PTO to Set Speed is programmed to NO, then
this speed can be achieved by using the RPM
Increase/RPM Decrease switch.
NOTE: The parameter for the PTO Engine RPM

Set Speed can override the parameter for the
Idle/PTO Bump RPM. If the PTO Engine RPM
Set Speed is programmed above 0 rpm, then
the Set/Resume switch will function as the RPM
Increase/RPM Decrease switch. This occurs when
the PTO On/Off switch is ON.
Example 1 illustrates PTO operation with two

specific engine rpm above low idle. Example 1 also
illustrates the PTO Engine RPM Set Speed. In this
example, the PTO Engine RPM Set Speed is for
applications that require engine operation at low
idle, at an intermediate rpm, and at the PTO Top
Engine Limit.
Example 2 illustrates PTO operation with one

specific engine rpm above low idle.
Example 1
Table 31
Example 1 of the Parameter Programming for the PTO
Engine RPM Set Speed
PTO Engine RPM Set Speed 1500 rpm
85
g00646879
Illustration 63
Table 32
Example 1 of the PTO Engine RPM Set Speed
Frame 1
The PTO On/Off Switch Turn the PTO On/Off Switch The engine will remain at low
is ON. The RPM to the ON position and leave idle, which is 700 rpm.
700 rpm
Increase/Decrease switch is the throttle at the low idle
OFF. position.
g00646884
Illustration 64
86
Table 33
Frame 2
The PTO On/Off Switch Turn the RPM There should be no change
is ON. The RPM Increase/Decrease switch to in engine rpm. The PTO
Increase/Decrease switch is the Increase position. Engine RPM Set Speed is
set to Increase. programmed and the engine 700 rpm
will not respond until the RPM
Increase/Decrease switch is
released.
g00646885
Illustration 65
Table 34
Frame 3
The PTO On/Off Switch Release the RPM The engine will ramp up to
is ON. The RPM Increase/Decrease switch. the PTO Engine RPM Set
Increase/Decrease switch is Speed which is 1500 rpm.
1500 rpm
released. This will happen only after
the RPM Increase/Decrease
switch is released.
g00646886
Illustration 66
87
Table 35
Frame 4
released.
g00646887
Illustration 67
Table 36
Frame 5
is ON. The RPM Increase/Decrease switch. the PTO Top Engine Limit,
Increase/Decrease switch is which is 2100 rpm. This will
2100 rpm
released. happen only after the RPM
released.
g00646888
Illustration 68
88
Table 37
Frame 6
Increase/Decrease switch is the Decrease position. Engine RPM Set Speed is
set to Decrease. programmed and the engine 2100 rpm
released.
g00646889
Illustration 69
Table 38
Frame 7
The PTO On/Off Switch Release the RPM The engine will ramp to
Increase/Decrease switch is Speed, which is 1500 rpm.
1500 rpm
switch is released.
g00646890
Illustration 70
89
Table 39
Frame 8
released.
g00646891
Illustration 71
Table 40
Frame 9
The PTO On/Off switch is ON. Release the RPM The engine will ramp to the
The RPM Increase/Decrease Increase/Decrease switch. programmed low idle rpm,
switch is released. which is 700 rpm. This will
700 rpm
happen only after the RPM
released.
90
Example 2
Table 41
PTO to Set Speed NO
g00646892
Illustration 72
Table 42
Frame 1
is ON. The RPM to the ON position. idle, which is 700 rpm.
700 rpm
OFF.
g00646894
Illustration 73
91
Table 43
Frame 2
released.
g00646896
Illustration 74
Table 44
Frame 3
1500 rpm
switch is released.
g00646898
Illustration 75
92
Table 45
Frame 4
set to Increase. programmed. The engine will 1500 rpm
not respond until the RPM
released.
g00646897
Illustration 76
Table 46
Frame 5
The PTO On/Off Switch Release the RPM There should be no change
is ON. The RPM Increase/Decrease switch. in engine rpm. The PTO Top
Increase/Decrease switch is Engine Limit is programmed
1500 rpm
released. to the same rpm as the PTO
Engine RPM Set Speed,
which is 1500 rpm.
g00646899
Illustration 77
93
Table 47
Frame 6
released.
g00646900
Illustration 78
Table 48
Frame 7
The PTO On/Off Switch Release the RPM The engine will ramp to the
is ON. The RPM Increase/Decrease switch. programmed low idle rpm,
Increase/Decrease switch is which is 700 rpm. This will
700 rpm
released.
PTO to Set Speed Engine

Operation
The engine will accelerate to the PTO Engine RPM
Set Speed when the PTO to Set Speed parameter
is programmed to YES. The PTO On/Off switch must
be ON. This is useful for applications that require
only one specific engine rpm above low idle. Only
one circuit is required.
Table 49
Parameter Programming for PTO to Set Speed Engine Operation
PTO to Set Speed YES
94
g00646902
Illustration 79
Table 50
PTO to Set Speed Engine Operation
Frame 1
The PTO On/Off switch is Start the engine. The engine is at the
OFF. The Set/Resume switch programmed low idle of 700 rpm
is set to OFF. 700 rpm.
g00646904
Illustration 80
95
Table 51
Frame 2
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine will ramp to the
ON. The Set/Resume switch to the ON position. programmed PTO Engine 1500 rpm
is set to OFF. RPM Set Speed.
Multiple Speed PTO Operation by

Using the PTO Engine RPM Set
Speed Input A and PTO Engine
RPM Set Speed Input B
JUL99 and Later Personality Modules
Input 7 and Input 19 are provided for the

connection of the dedicated switches for the
multiple speed PTO operation. Input 7 can be
programmed to PTO Engine RPM Set Speed Input
A. Input 19 can be programmed to PTO Engine
RPM Set Speed Input B. A desired engine rpm
can then be programmed for each input (PTO
Engine RPM Set Speed A and PTO Engine RPM
Set Speed B).
Perform the following functions so that the engine

will proceed to the corresponding rpm that is
programmed for the PTO Engine RPM Set Speed
Input A or PTO Engine RPM Set Speed Input B:
Turn the PTO On/Off Switch to the ON position.

Turn the switch for the PTO Engine RPM Set
Speed Input A or the PTO Engine RPM Set
Speed Input B to the ON position.
If both switches are ON, the engine will proceed

to PTO Engine RPM Set Speed A because the
PTO Engine RPM Set Speed Input A has priority
over Input B. If switch A is then turned OFF,
the engine will proceed to the programmed PTO
Engine RPM Set Speed B. If switch A is then
turned ON, then the engine will proceed back to the
PTO Engine RPM Set Speed A. If both switches
are in the OFF position, then the engine will return
to Low Idle.
Example 1
Table 52
Example 1 of the Parameter Programming for the Multiple Speed
PTO Operation by Using the PTO Engine RPM Set Speed Input
A and PTO Engine RPM Set Speed Input B
PTO Engine RPM Set Speed A 1500 rpm
PTO Engine RPM Set Speed B 1200 rpm
96
g00648607
Illustration 81
Table 53
Example 1 for the Multiple Speed PTO Operation by Using the PTO Engine RPM Set Speed
Input A and PTO Engine RPM Set Speed Input B
Frame 1
The PTO On/Off Switch is Start the engine. The engine is at the
OFF. The PTO Engine RPM programmed low idle of
Set Speed A is OFF. The 700 rpm. 700 rpm
PTO Engine RPM Set Speed
B is OFF.
g00648609
Illustration 82
97
Table 54
Frame 2
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine is at the
ON. The PTO Engine RPM to the ON position. programmed low idle of
B is OFF.
g00648610
Illustration 83
Table 55
Frame 3
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine is now at the
ON. The PTO Engine RPM to the ON position. Turn the programmed PTO Engine
Set Speed A is ON. The PTO Engine RPM Set Speed RPM Set Speed A. 1500 rpm
PTO Engine RPM Set Speed A to the ON position.
B is OFF.
g00648612
Illustration 84
98
Table 56
Frame 4
The PTO On/Off Switch is Turn the PTO Engine RPM The engine will remain at the
ON. The PTO Engine RPM Set Speed B to the ON programmed PTO Engine
Set Speed A is ON. The position. RPM Set Speed A.
1500 rpm
PTO Engine RPM Set Speed NOTE: Set Speed A has
B is ON. priority over Set Speed
B.
g00648614
Illustration 85
Table 57
Frame 5
The PTO On/Off Switch is Turn the PTO Engine RPM The engine will go to the
ON. The PTO Engine RPM Set Speed A to the OFF programmed PTO Engine
Set Speed A is OFF. The position. RPM Set Speed B. 1200 rpm
B is ON.
g00648617
Illustration 86
99
Table 58
Frame 6
The PTO On/Off Switch is Turn the PTO Engine RPM The engine is at programmed
ON. The PTO Engine RPM Set Speed A to the ON PTO Engine RPM Set Speed
Set Speed A is ON. The position. A.
1500 rpm
B.
g00648615
Illustration 87
Table 59
Frame 7
OFF. The PTO Engine RPM to the OFF position. programmed low idle of
Set Speed A is ON. The 700 rpm. 700 rpm
B is ON.
g00648618
Illustration 88
100
Table 60
Frame 8
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine is at programmed
ON. The PTO Engine RPM to the ON position. PTO Engine RPM Set Speed
Set Speed A is ON. The A.
1500 rpm
B.
Example 2
The switches for the PTO Engine RPM Set Speed
A or B can also be used in conjunction with
other features that control engine speed during
PTO operation. Set Speed A and Set Speed B
have priority over all of the other features that are
used to adjust engine rpm. Table 61 describes the
interaction between the parameter for the PTO to
Set Speed and the parameter for the PTO Engine
RPM Set Speed. The parameter for the PTO to Set
Speed is programmed to YES.
Note: The feature for the PTO Engine RPM Set

Speed is not available for the Remote Throttle PTO
Configuration. The PTO Engine RPM Set Speed
A and the PTO Engine RPM Set Speed B are
available for all three PTO configurations.
Table 61
Example 2 for the Parameter Programming for the Multiple Speed
PTO Operation by Using the PTO Engine RPM Set Speed Input
A and PTO Engine RPM Set Speed Input B
PTO to Set Speed Yes
g00648624
Illustration 89
101
Table 62
Frame 1
The PTO On/Off Switch is Start the Engine. The engine is at the
B is OFF.
g00648654
Illustration 90
Table 63
Frame 2
ON. The PTO Engine RPM to the ON position. programmed PTO Engine
Set Speed A is OFF. The RPM Set Speed of 1000 rpm. 1000 rpm
B is OFF.
g00648656
Illustration 91
102
Table 64
Frame 3
The PTO On/Off Switch is Turn the PTO Engine RPM The engine is now at the
ON. The PTO Engine RPM Set Speed A to the ON programmed PTO Engine
1500 rpm
B is OFF. priority over Set Speed
B. Set Speed A also
has priority over the PTO
to Set Speed.
g00648657
Illustration 92
Table 65
Frame 4
1500 rpm
B. Set Speed A also
to Set Speed.
103
g00648658
Illustration 93
Table 66
Frame 5
Set Speed A is OFF. The position. RPM Set Speed B.
1200 rpm
PTO Engine RPM Set Speed NOTE: Set Speed B has
B is ON. priority over the PTO to Set
Speed.
g00648659
Illustration 94
104
Table 67
Frame 6
ON. The PTO Engine RPM Set Speed B to the OFF PTO Engine RPM Set Speed.
Set Speed A is OFF. The position. 1000 rpm
B is OFF.
g00648660
Illustration 95
Table 68
Frame 7
B is OFF.
g00648661
Illustration 96
105
Table 69
Frame 8
ON. The PTO Engine RPM to the ON position. Turn the PTO Engine RPM Set Speed
Set Speed A is OFF. The PTO Engine RPM Set Speed B. 1200 rpm
PTO Engine RPM Set Speed B to the ON position.
B is ON.
Programmable Torque Limit

Programming the parameter for the Torque Limit
provides an engine torque limit for PTO operation
or other special situations. This feature should only
be used for temporary protection of equipment.
The programmable range for this parameter is
136 to 2720 Nm (100 to 2000 lb ft). The range is in
1 Nm (1 lb ft) increments. Programming the Torque
Limit above the rated torque of the engine will not
provide additional torque. The engine will operate
using the normal torque curve whenever the normal
torque is less than the programmed value of the
Torque Limit.
g00621329
The tables demonstrate the Torque Limit for the Illustration 97
PTO. The tables also demonstrate the Torque Limit (1) Engine Speed (RPM)
when the PTO is OFF. The Torque Limit operates (2) Torque
(3) Normal Engine Torque Curve
when the PTO On/Off switch is ON. When the PTO (4) Programmed Torque Limit
On/Off switch is OFF and the Torque Limit Switch is
ON, the Torque Limit will operate. Refer to 3126B
and 3126E Truck Engine Electronic PTO Installation
and Applications Manual, Cab Switches with
Torque Limiting and Ignore Brake/Clutch Switch for
more information if the configuration for the PTO
is programmed to Cab Switches. Refer to 3126B
and 3126E Truck Engine Electronic PTO Installation
and Applications Manual, Remote Switches with
more information if the configuration for the PTO is
programmed to Remote Switches. The Torque Limit
switch should be part of the system that requires
the torque limit. Program the Torque Limit to the
torque that is rated for the device that is protected
by the Torque Limit. Illustration 98
g00621335
(1) Engine Speed (RPM)

NOTE: The programmed torque level is an estimate. (2) Torque
To achieve precise torque limiting, a chassis (4) Programmed Torque Limit
dynamometer may be required.
106
Operation of the Torque Limit With PTO

On/Off Switch
Table 70
Parameter Programming
PTO Configuration Cab Switches, Remote Switches, or
Remote Throttle
Torque Limit The value should be below rated
torque of the engine.
Table 71
Action that was taken by the
Controlling Equipment Result
Operator of the PTO
The PTO On/Off Switch is OFF. Start the engine. The normal engine torque is used.
The PTO On/Off Switch is ON. Turn the PTO On/Off Switch to the ON The Torque Limit that has been
position. programmed is activated. This will
reduce the torque that is available.
Operation of the Torque Limit With A

Torque Limit Switch
Table 72
Remote Throttle
Table 73
Operator of the PTO
The PTO On/Off switch is OFF. The Start the engine. The normal engine torque is used.
Torque Limit switch is OFF. Refer to Illustration 97.
The PTO On/Off switch is OFF. The Turn the Torque Limit Switch to the ON The Torque Limit that has been
Torque Limit switch is ON. position. programmed is activated. This will
reduce the torque that is available.
107
PTO Cab Throttle RPM Limit

The PTO Cab Throttle RPM Limit is active when
the PTO Configuration is programmed to Cab
Switches. The accelerator in the cab is always
limited to low idle when the PTO Configuration is
programmed to Remote Switches. The accelerator
position sensor that is in the cab is limited to the
value of the PTO Cab Throttle RPM Limit only when
the PTO On/Off circuit is in the ON position. This is
useful for applications with equipment that may be
damaged by engine overspeed. This parameter has
three programmable choices. The following items
are the three programmable choices: Low Idle, Top
Engine Limit, and PTO Top Engine Limit.
If the PTO Cab Throttle RPM Limit is

programmed to Low Idle, then the engine will
not exceed the programmed Low Idle when the
accelerator pedal is depressed. The PTO On/Off
circuit must also be in the ON position. The
accelerator pedal is ignored.
If PTO Cab Throttle RPM Limit is programmed

to the Top Engine Limit, then depressing the
accelerator pedal will allow the engine to achieve
the programmed Top Engine Limit.
If PTO Cab Throttle RPM Limit is programmed

to the PTO Top Engine Limit, then depressing
the accelerator pedal will allow the engine to
reach the programmed PTO Top Engine Limit.
The PTO On/Off circuit must also be in the ON
position.
The next three tables describe each of the three

options that are for this parameter.
108
PTO Cab Throttle RPM Limit That is

Programmed to Low Idle
Table 74
Parameter Programming for PTO Cab Throttle RPM Limit
That is Programmed to Low Idle
PTO Cab Throttle Limit Low Idle
g00647857
Illustration 99
Table 75
PTO Cab Throttle RPM Limit That is Programmed to Low Idle
Frame 1
The PTO On/Off Switch is Fully depress the Accelerator The engine will not exceed
OFF. The Accelerator Pedal Pedal. the programmed Top Engine 2640 rpm
is fully depressed. Limit of 2640 rpm.
g00647858
Illustration 100
109
Table 76
PTO Cab Throttle RPM Limit That is Programmed to Low Idle
Frame 2
The PTO On/Off switch is Turn the PTO On/Off Switch The engine will return to the
ON. The Accelerator Pedal is to the ON position. low idle rpm of 700. 700 rpm
fully depressed.
Cab Throttle RPM Limit That is

Programmed to The Top Engine Limit
Table 77
Parameter Programming for Cab Throttle RPM Limit That is
Programmed to The Top Engine Limit
PTO Cab Throttle Limit TEL
g00647862
Illustration 101
Table 78
Cab Throttle RPM Limit That is Programmed to The Top Engine Limit
Frame 1
110
g00647863
Illustration 102
Table 79
Cab Throttle RPM Limit That is Programmed to The Top Engine Limit
Frame 2
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine will remain at the
ON. The Accelerator Pedal is to the ON position. Top Engine Limit of 2640 2640 rpm
fully depressed. rpm.

Programmed to The PTO Top Engine
Limit
Table 80
Parameter Programming for Cab Throttle RPM Limit That is
Programmed to The PTO Top Engine Limit
PTO Cab Throttle Limit PTO TEL
g00647869
Illustration 103
111
Table 81
Cab Throttle RPM Limit That is Programmed to The PTO Top Engine Limit
Frame 1
The PTO On/Off switch is Fully depress the Accelerator The engine will accelerate to
g00647870
Illustration 104
Table 82
Cab Throttle RPM Limit That is Programmed to The PTO Top Engine Limit
Frame 2
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine will decelerate to
ON. The Accelerator Pedal is to the ON position. the PTO Top Engine Limit 2100 rpm
fully depressed. of 2100 rpm.
Idle/PTO RPM Ramp Rate Idle/PTO Bump RPM

The Idle/PTO RPM Ramp Rate determines the rate The Idle/PTO Bump RPM can be programmed to
of acceleration and deceleration of the engine when change the engine rpm when the Set/Resume switch
the engine rpm is changing. This happens because is toggled. This parameter determines the change
of the actuation of the following items: Set/Resume in rpm when the Set/Resume switch is toggled. If
switch, Idle/PTO Bump RPM, PTO to Set Speed, the PTO Engine RPM Set Speed is programmed to
and parameters for the PTO Engine RPM Set one rpm or above, then the parameter is overridden.
Speed. The Idle/PTO RPM Ramp Rate is not
applicable to the acceleration and the deceleration Note: The Idle/PTO Bump RPM can not be used
of the engine due to an accelerator position sensor. with the Fast Idle operation. The Fast Idle RPM
is not set or changed with the Cruise Control
The parameter is programmed in one rpm per Set/Resume switch.
second increments from 5 to 1000 rpm per second.
This parameter should be programmed in order
to match the application. Some applications have
a reduced cycle time that is critical. This will
provide reduced cycle times for those applications.
Programming excessive ramp rates may stress the
driven equipment.
112
Table 83
Parameter Programming for Idle/PTO Bump RPM
PTO to Set Speed NO

Cruise/Idle/PTO Switch Set/Accelerate
Configuration
Idle/PTO Bump RPM 400 rpm
g00647871
Illustration 105
Table 84
Idle/PTO Bump RPM
Frame 1
The PTO On/Off Switch is Start the engine. The engine will remain at the
OFF. The Set/Resume Switch low idle of 700 rpm. 700 rpm
is OFF.
g00647873
Illustration 106
113
Table 85
Idle/PTO Bump RPM
Frame 2
ON. The Set/Resume Switch to the ON position. low idle of 700 rpm because
700 rpm
is OFF. the PTO to Set Speed is
programmed to NO.
g00647874
Illustration 107
Table 86
Idle/PTO Bump RPM
Frame 3
The PTO On/Off switch is Quickly toggle the The engine will accelerate
ON. The Set/Resume Switch Set/Resume Switch to 400 rpm. This is the Idle/PTO
1100 rpm
is in the SET position. the SET position and then Bump RPM value. The
release. engine rpm is now 1100.
g00647875
Illustration 108
114
Table 87
Idle/PTO Bump RPM
Frame 4
1500 rpm
PTO Vehicle Speed Limit Note: The Set Switch serves as the RPM Increase
position and the Resume Switch serves as the RPM
The parameter for the PTO Vehicle Speed Limit Decrease position under the following conditions:
is used to disable a PTO Set Speed when The PTO On/Off Switch is in the ON position. and
the vehicle speed exceeds the programmed The PTO Engine RPM Set Speed is programmed
limit. The PTO On/Off switch operates the PTO to one rpm or more. This is regardless of the
Vehicle Speed Limit. The programmable range is programmed setting for the Cruise/Idle/PTO
2 to 204 km/h (1 to 127 mph) in increments of one. Switch configuration.
By programming the parameter to one, the PTO Set
RPM will be disabled while the vehicle is moving. Engine Monitoring
The following item will cause disengagement of an
active set rpm: exceeding the PTO Vehicle Speed
An engine monitoring function is available for the
Limit. 3126B and 3126E truck engines. The parameter
can be programmed to Off, Warning, Derate or
Note: A PTO that is driven by the transmission
Shutdown. Refer to the engine Operation and
will produce a vehicle speed signal. Program the Maintenance Manual for additional information
parameter for the PTO Vehicle Speed Limit to the
regarding this feature.
maximum value of 204 km/h (127 mph) instead of
disconnecting the vehicle speed circuit during the
operation of the PTO. This will ensure that the PTO
Set Speed will not be disabled due to vehicle
speed. If Engine Monitoring is programmed to Derate
or Shutdown, and one of the monitored condi-
Note: In some instances, a false vehicle signal can tions is exceeded, then the engine will derate or
be produced during the operation of the PTO due shutdown. This should be considered especially if
to the movement of the drive train. If the parameter derating or shutting the engine down during PTO
for the PTO Vehicle Speed Limit is programmed operation. This could present a problem for the ve-
to a very low value, then the operation of the PTO hicle or possible injury to the operator.
will abort when the false vehicle speed exceeds the
programmed limit. It may be necessary to isolate
the source of the false speed signal. The PTO
Vehicle Speed Limit can also be programmed to
a higher value.
Configuration
This parameter will determine the ACCEL and
DECEL function of both the Cruise Control On/Off
switch and the PTO On/Off switch. The switch can
be used for the Set/Resume switch or the switch
can be held in position for a constant acceleration.
The default positions follow: The Set position is the
ACCEL position and the Resume position is the
DECEL position. This can be changed by using the
Caterpillar Electronic Service Tool.
115
Index Section
Index
Numerics PTO Configurations - Test ..................................... 72
Cruise/Idle/PTO Switch Configuration ........... 114
0030-08 Invalid PTO Throttle Signal (29) .............. 44 Engine Monitoring ......................................... 114
0030-13 PTO Throttle Sensor Calibration (29) ...... 44 Engine Operation with PTO Engine RPM Set
0071-14 PTO Shutdown Timer Occurrence (47) ... 44 Speed.............................................................. 84
Fast Idle Operation .......................................... 80
Idle/PTO Bump RPM ..................................... 111
C Idle/PTO RPM Ramp Rate ............................ 111
Multiple Speed PTO Operation by Using the PTO
Component Installation............................................ 8 Engine RPM Set Speed Input A and PTO Engine
Considerations for the Installation........................ 9 RPM Set Speed Input B................................. 95
Installation for Three PTO Configurations .......... 13 Programmable Torque Limit........................... 105
Installation of Fast Idle Configuration................. 12 PTO Cab Throttle RPM Limit ......................... 107
PTO to Set Speed Engine Operation .............. 93
PTO Vehicle Speed Limit............................... 114
D The Four Programmable Engine Limits ............. 73
PTO Parameters - Program ................................... 70
Diagnostic Functional Tests................................... 46 Installation and Programming That Is Based on
The Questionnaire Response .......................... 70
Programming the Parameters ............................ 72
G PTO Shutdown Timer - Test .................................. 46
PTO Switch Circuit - Test....................................... 48
General Information..................................... 4, 29, 38 PTO Switch ON Lamp Circuit - Test ...................... 57
Advantages of a Dedicated PTO........................ 29
Cold Mode Operation......................................... 40
Definition of Power Take-Off (PTO).................... 30 R
Installation Questionnaire .................................. 33
Instructions for the Operator of the PTO ............ 36 Remote PTO Accelerator Position Sensor Circuit -
Programmed Parameter Information Sheet for the Test ...................................................................... 61
Operator of the PTO......................................... 34
PTO.................................................................. 33 S
Starting The Engine ........................................... 39
Truck Installation Diagram for The Switches and Specifications Section ............................................. 4
The Components.............................................. 36 Switches .................................................................. 4
Electrical Specifications for the Remote Accelerator
Pedal Position Sensor ........................................ 5
I Selecting a Switch Type....................................... 5
Specifications for the Harness ............................. 6
Important Safety Information ................................... 2 Switch Electrical Specifications ........................... 4
Systems Operation Section ................................... 29
P
T
Programmable Parameters.................................... 40
Available Ranges, Options, and Default Settings for Table of Contents..................................................... 3
the Programmable Parameters ........................ 41 Testing and Adjusting ............................................ 70
Understanding Programmable Engine RPM Testing and Adjusting Section ............................... 70
Limits................................................................ 40 Troubleshooting Section ........................................ 44
Troubleshooting with a Diagnostic Code ............... 44
2001 Caterpillar
RENR1367-03
May 2001
Troubleshooting
BKD1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents 0030-08 Invalid PTO Throttle Signal (29) .............. 95

0041-03 8 Volt Supply Above Normal (21) ............ 95
0041-04 8 Volt Supply Below Normal (21) ............ 96
Troubleshooting Section 0042-11 Injection Actuation Pr Control Valve Driver
(18) ...................................................................... 96
Electronic Troubleshooting
0043-02 Ignition Key Switch Fault (71) ................. 96
System Overview .................................................... 5
0064-02 Loss of Engine RPM Signal #2 (34) ....... 97
Glossary ............................................................... 14
0064-11 No Pattern on Speed Sensor #2 (34) ..... 97
Component Diagram ............................................. 21
0070-05 Inlet Air Heater Open Circuit (49) ........... 97
Electronic Service Tools ........................................ 22
0070-06 Inlet Air Heater Short Circuit (49) ........... 98
Sensors and Electrical Connectors ....................... 24
0071-00 Idle Shutdown Override (01) ................... 98
Electrical Connectors and Functions .................... 26
0071-01 Idle Shutdown Occurrence (47) .............. 98
Engine Wiring Harness Diagram .......................... 26
Vehicle Wiring Harness Diagram .......................... 28
0084-00 Vehicle Overspeed Warning (41) ............ 99
0084-01 Loss of Vehicle Speed Signal (31) .......... 99
Programming Parameters
0084-02 Invalid Vehicle Speed Signal (36) ......... 100
Programming Parameters ..................................... 29
0084-08 Vehicle Speed Out of Range (36) ......... 100
Customer Passwords ............................................ 31
0084-10 Vehicle Speed Rate of Change (36) ..... 100
Customer Specified Parameters ........................... 31
0091-08 Invalid Throttle Signal (32) .................... 101
Customer Specified Parameters Table ................. 48
0091-13 Throttle Sensor Calibration (28) ........... 101
Customer Specified Parameters Worksheet ......... 51
0100-03 Oil Pressure Sensor Open Circuit (24) .. 101
ECM Date/Time Stamped Information .................. 53
0100-04 Oil Pressure Sensor Short Circuit (24) .. 102
ECM Snapshot ...................................................... 54
0100-11 Very Low Oil Pressure (46) ................... 102
Electronic Technician (ET) .................................... 56
0102-03 Boost Pressure Sensor Open Circuit
Factory Passwords ................................................ 57
(25) .................................................................... 102
Factory Passwords Worksheet ............................. 58
0102-04 Boost Pressure Sensor Short Circuit
Flash Programming .............................................. 58
(25) .................................................................... 103
System Configuration Parameters ........................ 60
0102-07 Excessive Boost Pressure .................... 103
Service Information Report ................................... 60
0105-00 High Inlet Manifold Temp Warning (64) .. 103
0105-03 Inlet Manifold Temp Sensor Open Circuit
Troubleshooting without a Diagnostic Code
(38) .................................................................... 104
Can Not Reach Top Engine RPM ......................... 62
0105-04 Inlet Manifold Temp Sensor Short Circuit
Can Not Reach Vehicle Speed Limit ..................... 63
(38) .................................................................... 104
Check Engine Lamp or Warning Lamp Is
0105-11 Very High Inlet Manifold Temp (64) ....... 104
Malfunctioning ..................................................... 65
0108-03 Atmospheric Pr Sensor Open Circuit
Cruise Control, Idle, or PTO Can Not Be Set ........ 66
(26) .................................................................... 105
Driver Questionnaire ............................................. 68
0108-04 Atmospheric Pr Sensor Short Circuit
Driver Questionnaire Response ............................ 70
(26) .................................................................... 105
ECM Will Not Accept Factory Passwords ............. 71
0110-00 High Coolant Temperature Warning
Electronic Service Tool Will Not Communicate with
(61) .................................................................... 106
ECM .................................................................... 72
0110-03 Coolant Temp Sensor Open Circuit
Engine Cranks but Will Not Start .......................... 73
(27) .................................................................... 106
Engine Misfires, Runs Rough or Is Unstable ........ 76
0110-04 Coolant Temp Sensor Short Circuit
Engine Will Not Crank ........................................... 78
(27) .................................................................... 107
Excessive Black Smoke ........................................ 79
0110-11 Very High Coolant Temperature (61) .... 107
Excessive Fuel Consumption ............................... 80
0111-01 Low Coolant Level Warning (62) ........... 107
Excessive White Smoke ....................................... 80
0111-02 Coolant Level Sensor Fault (12) ........... 108
Intermittent Cruise Control, Idle, or PTO Kickout .. 81
0111-11 Very Low Coolant Level (62) ................. 108
Intermittent Engine Shutdown ............................... 83
0164-00 Injection Actuation Pr Out of Range
Intermittent Low Power or Power Cutout ............... 84
(17) .................................................................... 109
Low Power/Poor or No Response to Throttle ........ 86
0164-02 Injection Actuation Pr Sensor Erratic
Poor Acceleration or Response ............................ 89
(15) .................................................................... 109
0164-03 Injection Actuation Pr Sensor Open Circuit
(15) .................................................................... 109
No Diagnostic Code Detected (55) ....................... 92
0164-04 Injection Actuation Pr Sensor Short Circuit
0001-11 Cylinder 1 Fault (72) ............................... 92
(15) .................................................................... 110
0002-11 Cylinder 2 Fault (72) ............................... 92
0164-11 Injection Actuation Pressure System
0003-11 Cylinder 3 Fault (73) ............................... 93
(39) .................................................................... 110
0004-11 Cylinder 4 Fault (73) ............................... 93
0168-02 Intermittent Battery (51) ........................ 110
0005-11 Cylinder 5 Fault (74) ............................... 94
0190-00 Engine Overspeed Warning (35) .......... 111
0006-11 Cylinder 6 Fault (74) ............................... 94
0190-02 Loss of Engine RPM Signal (34) .......... 111
0022-13 Check Timing Sensor Calibration (42) .... 94
0190-11 No Pattern on Speed Sensor #1 (34) ... 111
4
Table of Contents
0224-11 Theft Deterrent Active (00) ................... 112 Transmission (AT/MT/HT) Relay Circuit - Test .... 348
0224-14 Engine Cranking with Theft Deterrent Active Vehicle Speed and Speedometer Circuit - Test .. 351
(00) .................................................................... 112 Wait To Start Lamp Circuit - Test ........................ 360
0231-11 J1939 Data Link Fault (58) ................... 112 Warning Lamp Circuit - Test ............................... 363
0232-03 5 Volt Supply Above Normal (21) .......... 113
0232-04 5 Volt Supply Below Normal (21) .......... 113 Calibration Procedures
0246-11 Brake Switch #1 .................................... 114 Engine Speed/Timing Sensor - Calibrate ........... 368
0247-11 Brake Switch #2 ................................... 114 Vehicle Speed Circuit - Calibrate ........................ 370
0252-11 Incorrect Engine Software (59) ............. 114
0253-02 Check Customer or System Parameters Index Section
(56) .................................................................... 115
0253-14 Truck Manufacturer Parameter Not Index ................................................................... 373
Programed ........................................................ 115

5 Volt Engine Pressure Sensor Supply Circuit -
Test ................................................................... 116
Air Inlet Heater Circuit - Test ............................... 120
Accelerator Pedal (Throttle) Position Sensor Circuit -
Test ................................................................... 130
ATA (SAE J1587 / J1708) Data Link Circuit -
Test ................................................................... 137
Check Engine Lamp Circuit - Test ....................... 144
Clutch Pedal Position Switch Circuit - Test ......... 149
Coolant Level Sensor Circuit - Test ..................... 160
Cooling Fan Circuit and A/C High Pressure Switch
Circuit - Test ...................................................... 166
Cruise Control Switch Circuit - Test .................... 180
ECM Memory - Test ............................................ 191
Electrical Connectors - Inspect ........................... 195
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 202
Engine Running Output Circuit - Test ................. 210
Engine Speed/Timing Sensor Circuit - Test ........ 212
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 219
Event Codes - Test .............................................. 224
Exhaust Brake Circuit - Test ................................ 228
Fast Idle Lamp Circuit - Test ............................... 233
Idle Shutdown Timer - Test ................................. 236
Ignition Key Switch Circuit and Battery Supply Circuit
- Test ................................................................. 239
Ignore Brake/Clutch Switch Circuit - Test ............ 246
Injection Actuation Pressure - Test ..................... 249
Injection Actuation Pressure Control Valve Circuit -
Test ................................................................... 259
Injection Actuation Pressure Sensor - Test ......... 264
Injector Solenoid Circuit - Test ............................ 267
Input Selection Switch Circuit - Test ................... 274
Neutral Switch Circuit - Test ................................ 280
Powertrain Data Link Circuit - Test ...................... 291
PTO Shutdown Timer - Test ................................ 298
PTO Switch Circuit - Test .................................... 300
PTO Switch ON Lamp Circuit - Test .................... 310
Test ................................................................... 315
Service Brake Pedal Position (Switch 1) Circuit -
Test ................................................................... 322
Test ................................................................... 333
Tachometer Circuit - Test .................................... 343
5
i01315830
System Overview
SMCS Code: 1900
System Operation
The engine uses a Hydraulic Electronic Unit Injector
fuel system. The injection pump, the fuel lines and
the nozzles that are used in mechanical engines
have been replaced with an hydraulic electronic
unit injector in each cylinder. A solenoid on each
injector controls the amount of fuel that is delivered
by the injector. An axial piston pump increases the g00693055
Illustration 1
engine oil pressure in order to activate the injector.
An Engine Control Module (ECM) sends a signal The governor considers the desired conditions
to the injection actuation pressure control valve in and the actual conditions. The governor then takes
order to control injection pressure. Another electrical the action that best accommodates the desired
signal is sent to each injector solenoid in order to conditions. The desired conditions are typically
inject fuel. the accelerator pedal position, the desired vehicle
speed during cruise control, or the desired engine
Electronic Controls speed during PTO control. The actual conditions
are based on current operating conditions such as
The engines electronic system consists of the coolant temperature, load conditions, etc.
Engine Control Module (ECM), the engine sensors,
injection actuation pressure control valve, and the Timing Considerations
vehicle interface. The ECM is the computer. The
personality module is the software for the computer. Once the ECM has determined the amount of fuel
The personality module contains the operating that is required, the ECM must then determine
maps. The operating maps define the following when the injection is needed. Injection timing is
characteristics of the engine: determined by the ECM after considering input
from the coolant temperature sensor, the sensor for
Horsepower the intake air temperature, and the boost pressure
sensor.
Torque curves
RPM
Engine Governor
The electronic controls on the engine serves as
the engine governor. The electronic control system
determines:
the timing of the fuel delivery to the cylinders

the amount of fuel that is delivered to the cylinders
injection pressure
The electronic control system uses the actual
conditions and the desired conditions in order to
make the decisions. The electronic control system
controls the engine during starting and operation.
6
The personality module inside the ECM sets certain

limits on the amount of fuel that can be injected.
The FRC Fuel Limit is a limit that is based on the
boost pressure. The FRC Fuel Limit is used to
control the air/fuel ratio for control of emissions.
When the ECM senses a higher boost pressure,
the ECM increases the FRC Fuel Limit . A higher
boost pressure indicates that there is more air in the
cylinder. When the ECM increases the FRC Fuel
Limit, the ECM allows more fuel into the cylinder.
g00693339
Illustration 2
The ECM knows the cylinder position for timing

because of the signal from the engine speed/timing
sensors. The ECM adjusts timing for best engine
performance, for fuel economy, and for the control
of white smoke. Actual timing and desired timing
cannot be viewed with an electronic service tool.
The ECM determines the location of top center of
the number one cylinder from the signal that is
provided by the engine speed/timing sensors. The
ECM decides when injection should occur relative
to top center. The ECM then provides the signal to
the injector at the desired time.
Fuel Injection
The ECM controls the amount of fuel that is injected
by varying the signals to the injectors. The injectors
will pump fuel only if the injector solenoid is
energized. The ECM sends a high voltage signal
in order to energize the solenoid. The injector
solenoid unseats the poppet valve. The oil path
to the drain passage will close while the inlet oil
passage opens for the high pressure oil. The high
pressure oil enters the injector and pushes on the
intensifier piston. This causes the fuel pressure to
increase. The diesel fuel is then injected into the
combustion chamber. By controlling the timing and
the duration of the high voltage signal, the ECM can
control injection timing and the ECM can control the
amount of fuel that is injected.
The ECM controls the fuel pressure that is injected

into the cylinder by controlling the injection actuation
pressure control valve. The output pressure of the
injection actuation pressure control valve is a dump
valve that is controlling the output pressure of the
high pressure oil pump.
7
g00457847
Illustration 3
HEUI Fuel System
(1) Hydraulic pump. (2) Oil flow to engine. (3) Oil filter. (4) Engine oil pump. (5) Oil cooler. (6) IAP sensor. (7) Injectors. (8) Fuel supply rail.
(9) Fuel pressure regulator. (10) IAP control valve. (11) Fuel filter. (12) Fuel tank. (13) Back of cam gear. (14) Speed/Timing sensors. (15)
ECM. (16) Boost pressure sensor. (17) Accelerator pedal. (18) Accelerator pedal position sensor. (19) Batteries. (20) Coolant temperature
sensor. (21) Data link. (22) Exhaust brake relay. (23) Inlet air temperature sensor. (24) Transmission relay. (25) Vehicle speed sensor. (26)
Inlet air heater relay. (27) Air inlet heater. (28) Fast idle lamp. (29) Check engine lamp. (30) Speedometer and tachometer. (31) Cruise
ON/OFF switch and SET/RESUME switch. (32) PTO ON/OFF switch and SET/RESUME switch. (33) Service brake switches. (34) Neutral and
clutch switches. (35) Fuel transfer pump.
8
The Rated Fuel Limit is a limit that is based on Basic Systems and Full Feature
the power rating of the engine and engine rpm. Systems
The Rated Fuel Limit is similar to the rack stops
and the torque spring on a mechanically governed Some 3126B HEUI Truck Engines ((S/N: 7AS; 8SZ))
engine. The Rated Fuel Limit provides the power use two different Engine Control Modules. Each
curves and the torque curves for a specific engine ECM uses different personality module software.
family and a specific engine rating. All of these These systems are commonly referred to as Basic
limits are determined at the factory. These limits are and Full Feature. Basic systems are typically
in the personality module and these limits cannot found in GM trucks and chassis, while Full Feature
be changed. systems are found in other applications. The
Basic system and the Full Feature system use
Injection Actuation Pressure Control different default values for several of the customer
System parameters that are common to both of the systems.
The personality module for a Basic ECM cannot
The ECM controls fuel injection by controlling oil be used with a Full Feature ECM, and a Full
pressure to the fuel injectors. The pressure of the Feature personality module cannot be used with a
oil in the high pressure oil manifold is controlled by Basic ECM. The Full Feature personality module
the ECM through control of the injection actuation provides some features that are not available
pressure control valve. The injection actuation with the Basic personality module. Refer to
pressure control valve (dump valve) controls the Troubleshooting, Programming Parameters for
high pressure pump outlet pressure by dumping more details.
excess flow back to the oil sump.
Other 3126B Truck Engines ((S/N: 8YL; 8SZ))
The ECM monitors the pressure in the high pressure use one ECM and one set of personality module
manifold through the injection actuation pressure software. A new ECM parameter that is called
sensor. The injection actuation pressure sensor is Truck Manufacturer has been added to the
located in the top of the manifold on the left side Basic personality module and to the Full Feature
of the engine. The injection actuation pressure personality module in order to provide both options
sensors signal is compared by the ECM to the with one ECM. This ECM parameter is configured at
desired injection actuation pressure. The injection the factory to select the correct defaults and options
actuation pressure sensors signal is based on for any given application. If an ECM replacement is
sensor inputs. The sensor inputs are used to adjust required, the Truck Manufacturer parameter must
the position of the injection actuation pressure be programmed for the specific vehicle. The ECM
control valve in order to adjust the oil pressure in will then reconnect with the correct configuration
the high pressure manifold. parameter for that application.
High pressure oil is routed from the pump to the Customer Parameters and Engine Speed
high pressure manifold through a steel tube. From Governing
the manifold, the oil is routed to each injector
through the high pressure oil manifold. All injectors A unique feature with electronic engines is
have a constant supply of oil while the engine Customer Specified parameters. These parameters
is running. Disabling the electrical signal to the allow the vehicle owner to fine tune the ECM for
injector solenoid does not interrupt the oil flow to engine operation. Fine tuning the ECM for engine
the fuel injector. operation allows the vehicle owner to accommodate
the typical usage of the vehicle and the power train
of the vehicle.
Many of the customer parameters provide additional

restrictions on the actions that will be performed
by the ECM in response to the drivers input. For
example, the PTO Top Engine Limit is an engine
rpm limit. The PTO Top Engine Limit is an engine
rpm limit that is used by the ECM as a cutoff for
the fuel. The ECM will not fuel the injectors above
this rpm.
9
Some parameters are intended to notify the DERATE Operation

driver of potential engine damage (Engine
Monitoring Parameters). Some parameters enhance If the system is programmed to DERATE, the
fuel economy (Vehicle Speed, Cruise Control, ECM begins by flashing the Check Engine/Service
Engine/Gear Speed Limit Parameter and Idle Engine Soon lamp. The flashing lamp indicates
Shutdown). Other parameters are used to enhance that a problem has been detected by the engine
the engine installation into the vehicle. Other monitoring system. The diagnostic code is logged.
parameters are also used to provide engine High coolant temperature will signal the ECM to
operating information to the truck engine owner. limit the maximum vehicle speed and the ECM will
reduce the engine power rating. Refer to Illustration
4 and Illustration 5.
Engine Monitoring
Caterpillar provides a factory installed engine
monitoring system. The Caterpillar Engine
Monitoring system monitors coolant temperature,
and coolant level (optional device). The coolant
temperature sensor is standard on all engines.
Caterpillar Engine Monitoring can be programmed

to four different modes. The four modes of
programming are OFF, WARNING, DERATE,
and SHUTDOWN. The coolant temperature sensor
will operate in the engine monitoring mode that is
selected.
g00694414
Caterpillar Engine Monitoring Illustration 4
Coolant temperature bargraph
Off Operation Derate mode is limited. (10% per second)
If Caterpillar Engine Monitoring is programmed

to OFF, the ECM will not flag high coolant
temperature or high inlet manifold air temperature.
No warnings will occur even though conditions
that could cause the ECM to take action (engine
monitoring) are exceeded.
The ECM still uses this sensor for engine operation.

The coolant temperature sensor is still used for cold
mode operation.
WARNING Operation
If Caterpillar Engine Monitoring is programmed

to WARNING, the ECM causes the Check Illustration 5 g00694655
Engine/Service Engine Soon lamp to flash because Coolant temperature bargraph for emergency vehicles
of the active diagnostic code. The flashing lamp
Derate mode is limited. (10% per second)
indicates that a problem has been detected by the
engine monitoring system. The diagnostic code is
logged. No further action by the ECM or action by This derating of engine performance is provided in
the engine occurs if the ECM is programmed to order to get the drivers attention so the driver can
WARNING. take action in order to avoid engine damage.
SHUTDOWN Operation
If the system is programmed to SHUTDOWN, the

ECM takes all the action that is indicated for the
DERATE mode and the ECM will eventually shut
down the engine under some conditions.
The SHUTDOWN mode begins when any of the

following conditions exist:
very low oil pressure

10
very low coolant level Diagnostic codes that identify operating conditions
outside the normal operating range are called
very high coolant temperature events. Event codes are not typically an indication
of an electronic system problem.
Note: very low oil pressure is only available on Full
Feature systems. Some of the diagnostic codes require passwords to
be cleared from memory. Diagnostic codes that do
SHUTDOWN mode begins by flashing the warning not require passwords to be cleared from memory
lamp. This response is similar to the response when are automatically deleted after 50 hours of engine
the system is in DERATE. SHUTDOWN mode will operation.
eventually shut down the engine if the conditions
continue for a long enough time and the conditions
are severe enough. The engine can be restarted as
Engine Snapshot Data
many times as needed after an Engine Monitoring
Whenever most diagnostic codes occur, the ECM
Shutdown. This allows the vehicle to be pulled off
records the time in engine hours of the occurrence.
of the road. Also, the ECM records the operating parameters of
the engine for 9.6 seconds before the diagnostic
Other ECM Functions of code and 3.4 seconds after the diagnostic code.
The operating parameters of the engine that are
Performance recorded are similar to the operating parameters of
the engine that are displayed in the status screens
The ECM also provides enhanced control of the
of the Electronic Technician. Not all of the status
engine for vehicle functions such as exhaust
screens of the Electronic Technician or parameters
brake control. Refer to Troubleshooting, Customer
are recorded. The Engine Snapshot can also be
Specified Parameters for supplemental information
triggered from the cruise control set/resume switch.
about the systems that can be monitored by
In order to trigger the Engine Snapshot from the
the ECM in order to provide enhanced vehicle
cruise control set/resume switch, quickly toggle
performance, fuel economy and convenience for
the switch to the Set position. Then, quickly toggle
the driver.
the switch to the Resume position. You can also
toggle the cruise control set/resume switch from the
Self-Diagnostics Resume position to the Set position. The Engine
Snapshot can also be triggered from the Electronic
The electronic system has the ability to diagnose Technician.
problems. When a problem is detected, a diagnostic
code is generated and the check engine/diagnostic
lamp may be turned on. In most cases, the code is
Effect Of Diagnostic Codes on
also stored in permanent memory or logged in the Engine Performance
ECM.
The discussion on engine monitoring mentions that
When diagnostic codes occur, the diagnostic the check engine lamp flashes when a specific
codes are called active diagnostic codes. Active condition exists. When the ECM detects the engine
diagnostic codes indicate that a problem of some problem, the ECM generates an active diagnostic
kind currently exists. Active diagnostic codes code. Also, the ECM logs the diagnostic code
should always be serviced before any other work is in order to indicate the time of the problems
performed. If a truck is brought in with an active occurrence. The ECM also logs the number of
code, find the code in the table of contents and occurrences of the problem. There are two types of
proceed to diagnose the cause. diagnostic codes. There are fault codes and event
codes.
Diagnostic codes that are stored in memory are
called logged diagnostic codes. Logged diagnostic Diagnostic Fault Codes
codes do not necessarily indicate that something
needs to be repaired. The problem may have been Diagnostic fault codes are provided in order to
temporary, or the problem may have been repaired indicate that an electrical problem or an electronic
since the problem was logged. Logged diagnostic problem has been detected by the ECM. In some
codes are instead meant to be an indication of cases, the engine performance can be affected
probable causes for intermittent problems. when the condition that is causing the code exists.
More frequently, the driver cannot detect any
difference in the engine performance.
11
If the check engine lamp is flashing and the driver The total time is the engines operating hours. The
indicates that a performance problem occurs, the engine hours do not include operating time when
diagnostic code may indicate the cause of the the ECM is powered ON but the engine is not
problem. The problem should be corrected. running.
If the driver does not indicate a problem with Distance data requires a vehicle speed sensor or
the engine performance and a diagnostic code an electronic vehicle speed source to be connected
is logged by the ECM, the situation indicates to the ECM. The same sensor is used for ECM
that the ECM detected an abnormal condition, vehicle speed. Distance can be displayed in miles
but the abnormal condition did not affect engine or kilometers.
performance.
PTO time and PTO fuel are logged when engine rpm
In this situation, the system has no faults except is set by using the cruise switches and the engine
when either of the following conditions exist: is operating under some load. Also, PTO time and
PTO fuel are logged when the PTO on/off switch is
There are several occurrences of the diagnostic in the ON position and vehicle speed is within the
code in a very short period of time. range of the PTO Vehicle Speed Limit parameter.
The ECM is indicating an active code at the Idle time and idle fuel can include operating time
present time. when all of the following conditions are met:
Diagnostic Event Codes When engine speed is set by using the cruise
switches and the vehicle speed is within the
Diagnostic event codes are used to indicate that range of the Idle Vehicle Speed Limit parameter.
some operational problem has been detected in
the engine or in the truck by the ECM. Usually, this The engine is not operating under a load.
does not indicate an electronic malfunction.
Fuel information can be displayed in US gallons
The ECM also provides an ECM date/time clock or liters.
that is used to time stamp the following diagnostic
event codes: Average Load Factor provides relative engine
operating information. Engine load factor compares
84-00 Vehicle Overspeed Warning (41) actual engine operation information to the maximum
engine operation that is available. Average Load
100-11 Very Low Oil Pressure (46) Factor is determined by using Total Maximum
Fuel, Idle Fuel, and Fuel Consumption. Total
110-11 Very High Coolant Temperature (61) Maximum Fuel is the maximum amount of fuel that
is used by the engine during operation. All of these
111-11 Very Low Coolant Level (62) parameters are available by using an electronic
service tool. These parameters are available within
190-00 Engine Overspeed Warning (35) the menu for current tools.
ECM Lifetime Totals Trip Data that is Stored in the ECM

The ECM maintains total data of the engine for the The trip data allows the tracking of engine operation
following parameters: by the vehicle owner over intervals that are defined
by the vehicle owner. Two types of trip data are
Total Time (Engine Hours) stored in the ECM, Driver Trip Data and Fleet Trip
Data (July 1999 and newer personality modules). All
Total Distance of the trip data is stored in memory and the trip data
is maintained through the unswitched battery lines
PTO Time and PTO Fuel when the ignition switch is off. An internal battery
will maintain this information while the unswitched
Idle Time and Idle Fuel battery lines are disconnected.
Average Load Factor (Engine) Driver Trip Data

Total Fuel Driver Trip Data is known as the Driver Trip
Segment. The Driver Trip Segment includes data for
Total Maximum Fuel the following parameters:
Time
12
Driving Time Three histograms are available. One histogram

records the engines operation versus the engine
Distance speed. The second histogram records time versus
vehicle speed. The third histogram records time
Fuel versus engine speed and vehicle speed.
Idle Time The electronic service tool calculates the

percentage of time that is spent in each of the
Idle Fuel engine rpm or vehicle speed ranges. Custom data
is available. Custom data allows the recording of
PTO Time engine parameters that are specified by the vehicle
owner. The ECM records the custom data.
PTO Fuel
A reset of the Fleet Trip Data which includes the
Average Load Factor Fleet Trip Segment, the histograms, and the
custom data can be done in several ways. The
Average Vehicle Speed following tools can be used to reset the Fleet Trip
Data:
Percent Idle Time
An electronic service tool which may require
Percent PTO Time customer passwords
Overall Fuel Economy Caterpillar Fleet Information Software (FIS)

Driving Fuel Economy CAT ID which requires Customer Parameters
Programming to provide access
Average Driving Speed
When the data is reset, the ECM records the current
Maximum Vehicle Speed totals at the time of the reset. These totals are used
as the starting point for the fleet trip. The following
Maximum Engine Speed tools access the recorded starting point:
Start Time An electronic service tool

End Time Caterpillar Fleet Information Software (FIS)
Start Odometer CAT ID
End Odometer The tool then subtracts the recorded starting point
from the current totals in the ECM in order to
A Driver Trip Segment can be reset by using calculate the Fleet Trip Data. Resetting the Fleet Trip
an electronic service tool or a Caterpillar Driver Data requires customer passwords if the passwords
Information Display (CAT ID). are programmed.
When the data is reset, the ECM stores the current Maintenance Indicator Data
totals at the time of the reset. This data is used
as the starting point for the driver trip data. The The ECM records the current totals when a reset
electronic service tool or the CAT ID accesses this occurs for the following three levels of maintenance:
starting point and the current totals from the ECM
in order to calculate the data for the Driver Trip PM1
Segment. Resetting the driver trip segment does
not require passwords. PM2
Fleet Trip Data Cooling system clean/flush
Fleet Trip Data includes a Fleet Trip Segment, The ECM uses the previous point of maintenance in
histograms, and custom data. The Fleet Trip order to calculate the timing of the next scheduled
Segment records the same parameters as the maintenance work.
driver trip segment except that the Fleet Trip
Segment can be reset independently of the driver
trip segment.
13
The Maintenance Indicator Mode is programmable An available feature of the CAT ID is the Theft
to hours or distance. The PM1 maintenance is Deterrent. The Theft Deterrent allows the driver
programmable to the Off, Automatic Distance, to input a password prior to shutdown. The Theft
Automatic Hours, Manual Distance, or Manual Deterrent will prevent the engine from restarting
Hours setting. until the password is successfully entered. The CAT
ID must have the version of software that is capable
If the PM1 is programmed to the Automatic of supporting this feature.
mode, the ECM calculates the next point of
maintenance by considering the history of the Note: The use of a DEC97or later ECM Personality
vehicles operation from the previous maintenance Module is required for the CAT ID to function
interval. If the vehicle has a history of poor fuel properly. The CAT ID must have a EPROM chip
economy the Maintenance Indicator parameter that is capable of supporting communication with
will occur sooner than a vehicle with better fuel HEUI engines. Use version 1.3 software or later
economy. software. The software version is displayed on the
initialization screen when the CAT ID is powered up.
The ECM also uses the engine oil capacity. A larger
engine oil capacity provides a longer maintenance An Auto-Enable option is available as a Theft
interval. The engine oil capacity is programmed Deterrent on personality modules which are
into the ECM in liters or quarts. If the PM1 is datedJUL99 and newer. If this option is selected,
programmed to the Manual mode, the owner the Theft Deterrent feature will automatically be
can program the ECM in the owners specific activated when the engine is shut down. The driver
maintenance interval. The maintenance interval can must input the correct password in order to start the
be programmed to the owners specific interval engine. This requires a CAT ID with a 2.1 or newer
that is based on mileage or time. The interval for EPROM.
the PM2 and the interval for the cooling system
clean/flush are established by the factory. Fleet Information Software (FIS) (JUL99
and Newer Personality Modules)
CAT ID
The Caterpillar Fleet Information Software (FIS) is
The Caterpillar Driver Information Display (CAT ID) another method that can be used to review the trip
is available to provide engine operating information information. The entire Fleet Trip Segment, which
to the driver. The driver trip segment, the Fleet Trip includes the following elements of data can be
Segment, and the Maintenance Indicator data can accessed with the Caterpillar FIS:
be viewed. However, the fleet trip histograms and
the custom data cannot be viewed from the display. histograms
The CAT ID provides the ability to enter an ID custom data
code for a driver in order to divide the Fleet Trip
Segment for two drivers. If the driver enters the information that is tagged by the id code
information regarding the state of travel, the Fleet
Trip Segment can be tagged by the state of travel. information that is tagged by the state of travel
The CAT ID can be used in order to tag portions Maintenance Indicator information can also be
of the Fleet Trip Segment into two ID codes. The accessed by using the Caterpillar FIS.
CAT ID can also be used in order to tag portions of
the Fleet Trip Segment into the state of travel. The When the Caterpillar FIS downloads the information,
ID code and the information regarding the state of the Caterpillar FIS also resets the ECM in order to
travel cannot be viewed from the display. Only the prepare the ECM for the next trip. The information
Caterpillar Fleet Information Software (FIS) can view can be downloaded to a computer with the
this information. The ability to reset any of these Caterpillar FIS program, or the information can be
parameters is dependent on customer parameters downloaded to an Argo Mobile Data Tool (MDT).
in the ECM. The Argo Mobile Data Tool (MDT) is then connected
to a computer in order to download the information.
The CAT ID will also display operating information
such as engine rpm, coolant temperature, boost
pressure, etc.
The CAT ID will also display engine diagnostic

codes with the PID-FMI Diagnostic Codes. The CAT
ID will also display a brief text description of the
diagnostic codes.
14
Programmable Parameters Customer parameters are protected by customer

passwords. The customer passwords are
Certain parameters that affect the operation of the programmed by the customer. Factory passwords
HEUI truck engine may be changed with electronic can be used to change customer passwords if
service tools. The parameters are stored in the ECM, customer passwords are lost.
and the parameters are protected from unauthorized
changes by passwords. These parameters are Refer to Troubleshooting, Customer Passwords
either system configuration parameters or customer and Troubleshooting, Factory Passwords.
parameters.
i01321347
System configuration parameters are set at the
factory. System configuration parameters affect
emissions or power ratings within an engine family.
Glossary
Factory passwords must be obtained and factory SMCS Code: 1000
passwords must be used to change the system
configuration parameters. A/C High Pressure Switch The a/c high pressure
switch senses refrigerant pressure in the air
Customer parameters are variable. Customer conditioning system. The a/c high pressure switch
parameters can be used to affect the following opens the electrical contacts and/or the a/c high
characteristics of the engine within the limits that pressure switch closes the electrical contacts. The
are set by the factory, Caterpillar Engine Monitoring, opening and/or closing of the electrical contacts
and PTO operation: depends on the pressure in the system in order
to turn on the cooling fan. This switch may be
cruise control connected to the ECM or this switch may not be
connected to the ECM.
vehicle speed limits
ATA Data Link (American Trucking Association)
progressive shifting The ATA data link is a two wire electrical connection
for communication with other microprocessor based
rpm ratings devices that are compatible with the American
Trucking Association standards and SAE standards
power ratings (J1587 and J1708) such as trip recorders,
electronic dashboards, power train controls, and
Customer passwords may be required to change maintenance systems. The data link is also the
customer specified parameters. serial communication medium that is used for
programming and troubleshooting with Caterpillar
Some of the parameters may affect engine operation devices.
in an unusual way. A driver might not expect this
type of effect. Without adequate training, these Accelerator Pedal Position The accelerator pedal
parameters may lead to power complaints or position is the interpretation by the ECM of the
performance complaints even though the engines signal from the accelerator pedal position sensor.
performance is to the specification.
Accelerator Pedal Position Sensor The accelerator
Refer to Troubleshooting, Customer Specified pedal position sensor is an electronic sensor
Parameters. that is connected to the accelerator pedal. The
accelerator pedal position sensor sends a pulse
Passwords width modulated signal to the ECM.
System configuration parameters are protected Active Diagnostic Code An Active Diagnostic
by factory passwords. Factory passwords are Code describes a condition that is currently present
calculated on a computer system that is available in order to alert the driver or the service technician
only to Caterpillar dealers. Since factory passwords of an abnormal parameter of engine operation.
contain alphabetic characters, only an electronic Refer to a Diagnostic Fault Code.
service tool may change system configuration
parameters. System configuration parameters affect Aftermarket Device An aftermarket device is a
the power rating family or emissions. device or an accessory that is installed by the
customer after the vehicle is delivered.
15
Air-To-Air Aftercooler An air-to-air aftercooler is CAT Data Link The data link is an electrical
a device that is used on turbocharged engines connection that is used to communicate with other
in order to cool inlet air that has undergone microprocessor based devices. The microprocessor
compression. The inlet air is cooled after the inlet based devices are compatible with the proposed
air passes through the turbocharger. The inlet air American Trucking Association and the SAE
is passed through an aftercooler (heat exchanger) Standard. These devices include trip recorders,
that uses ambient air for cooling. The inlet air that electronic dashboards, and maintenance systems.
has been cooled advances to the inlet manifold. The data link is also the communication medium that
is used for programming with the electronic service
Alternating Current (AC) Alternating current is an tool. The data link is also used for troubleshooting
electric current that reverses direction at a regular with the electronic service tool.
interval that is reoccurring.
Caterpillar Driver Information Display (CAT ID)
American Wire Gauge (AWG) AWG is a measure The Caterpillar Driver Information Display is a
of the diameter of electrical wire. AWG is also digital readout of the performance parameters of
a measure of the current carrying capacity of the vehicle and performance parameters that are
electrical wire. When the AWG number is smaller, monitored by the ECM.
the diameter of the wire is larger. When the AWG
number is larger, the diameter of the wire is smaller. Caterpillar Engine Monitoring Caterpillar Engine
Monitoring is the part of the Caterpillar Electronic
Anti-Lock Brake System (ABS) An ABS is a brake Engine Control that monitors coolant temperature, oil
system that attempts to reduce a skid during brake pressure, inlet manifold air temperature and coolant
operation. A power train electronic control can turn level. The monitoring alerts the operator of detected
off the engine retarder, if necessary. Also, a power problems. Coolant temperature, intake manifold air
train electronic control can signal the engine ECM temperature, and oil pressure sensors are supplied
to deactivate the engine retarder. by Caterpillar and monitored by the ECM. The
coolant level sensor is installed by the vehicle
Atmospheric Pressure Sensor The atmospheric OEM but still monitored by the ECM. Aftermarket
pressure sensor measures barometric pressure. The engine monitoring systems do not interface with the
sensor sends a signal to the ECM. The signal is Caterpillar Electronic Engine Control.
used in engine control and in engine operation.
Check Engine Lamp The check engine lamp is
Auxiliary Retarder Relay The brakes solenoids sometimes referred to as the diagnostic lamp. The
are driven by an OEM installed relay, which is driven check engine lamp is used to alert the operator of
by the ECM. the presence of an active event. The lamp then
flashes a diagnostic code.
Before Top Center (BTC) BTC is the 180 degrees
of crankshaft rotation before the piston reaches Clutch Pedal Position Switch The switch is
the top center position in the normal direction of typically supplied and installed by the OEM. This
rotation. switch is typically a limit switch that is mounted near
the clutch pedal. The switch is usually adjustable.
Boost Pressure Sensor The boost pressure sensor This switch is in the normally closed position when
measures inlet manifold air pressure. The boost the clutch pedal is released. Depressing the clutch
pressure sensor sends a signal to the ECM. pedal will open the circuit.
Bypass Circuit A bypass circuit is a circuit that is Code Refer to the Diagnostic Fault Code and the
used as a substitute circuit for an existing circuit. A Diagnostic Event Code.
bypass circuit is typically used as a test circuit.
Cold Mode Cold Mode is a mode for cold starting
Calibration Calibration is an electronic adjustment and for cold engine operation that includes timing
of a sensor signal. that is retarded and low idle that is raised. This
mode is used for engine protection, reduced smoke
Camshaft Speed/Timing Sensor This sensor emissions and faster warm up time.
provides a variable amplitude and PWM signal to
the ECM. The ECM interprets this signal as the Coolant Level Sensor This OEM installed sensor
crankshaft position and the engine speed. detects the absence or presence of coolant at the
probe. The sensor then sends a signal to the ECM.
16
Coolant Temperature Sensor This sensor detects Diagnostic Flash Code The Diagnostic Flash
the engine coolant temperature for Cold Mode Codes are flashed on the check engine lamp. These
operation and the Caterpillar Engine Monitoring. The flash codes indicate a malfunction in the electronic
Caterpillar Engine Monitoring must be programmed system or an event that is detected by the ECM.
in the ON position for the coolant temperature
sensor to be effective. Diagnostic Lamp A diagnostic lamp is sometimes
called the check engine light. The diagnostic lamp
Cooling Fan Cab Override Switch This switch is used to warn the operator of the presence of an
overrides control of the cooling fan relay so the active diagnostic code.
cooling fan operates continuously. This switch is
supplied and installed by the OEM. Direct Current (DC) Direct current is the type of
Cooling Fan Relay This relay is controlled by
the ECM which uses information from the coolant Dual Coil Vehicle Speed Sensor The dual coil
temperature sensor, the engine retarder and the vehicle speed sensor is a magnetic pickup that
air conditioning high pressure switch. The air senses movement of the teeth on the output shaft
conditioning high pressure switch is not always of the transmission. The sensor contains two coils.
installed. The relay and the air conditioning high One of the coils supplies a signal to the vehicle
pressure switch is supplied and installed by the speedometer, and the other coil is a vehicle speed
OEM. buffer.
Cruise Control Range The cruise control range Duty Cycle Refer to Pulse Width Modulation.
is the speed range that is monitored by the cruise
control. This speed range is typically the anticipated Electronic Control Analyzer Programmer (ECAP)
speed range on the open road. The cruise control The ECAP is an electronic service tool that was
range is programmable by using the low cruise limit replaced by the CAT Electronic Technician.
and the high cruise limit.
Electronic Engine Control The electronic engine
Custom Data Custom data is part of the fleet trip control is a complete electronic system. The
data that is stored in the ECM. This capability allows electronic engine control monitors the engine
the vehicle owner to specify operating parameters operation under all conditions. The electronic
for monitoring purposes while the engine is in engine control also controls the engine operation
service. under all conditions.
Customer Specified Parameter A customer Electronic Technician (CAT ET) The ET is a service
specified parameter is a value that can be set and tool that uses a software program in order to run on
changed by the customer. The parameters can be a personal computer (PC). This program replaced
protected by customer passwords. the ECAP tool.
Data Link Refer to the ATA Data Link. Engine Control Module (ECM) The ECM is the
engines control computer. The ECM provides power
Desired RPM The desired rpm is input to the to the electronics. The ECM monitors data that is
electronic governor within the ECM. The electronic input from the engines sensors. The ECM acts as a
governor uses the signal from the accelerator pedal governor in order to control engine rpm.
position sensor, the engine speed sensor, the cruise
control, and the customer parameters in order to Estimated Dynamic Timing The estimated dynamic
determine desired rpm. timing is the estimate that is provided by the ECM
of the actual injection timing.
Diagnostic Event Code These codes indicate an
event that describes an abnormal engine condition Exhaust Brake Relay The brake solenoids are
such as an idle shutdown occurrence. These codes driven by an OEM installed relay, which is driven
are not necessarily an indication of problems within by the ECM.
the electronic system.
Failure Mode Identifier (FMI) This identifier
Diagnostic Fault Code A Diagnostic Fault Code is indicates the type of failure that has been
sometimes referred to as a fault code. These codes experienced by the component. The FMI has
indicate an electronic system malfunction. been adopted from the SAE practice of J1587
diagnostics. The descriptions for the diagnostic
codes are shown in the following list:
17
0 The data is valid but the data is above the Fuel Ratio Control (FRC) The FRC is a limit that
normal operational range is based on the control of the fuel to air ratio. The
FRC is used for purposes of emission control. When
1 The data is valid but the data is below the the ECM senses a higher boost pressure (more air
normal operational range into the cylinder), the FRC increases the FRC limit
(more fuel into the cylinder).
2 The data is erratic, intermittent, or incorrect.
Fuel Temperature Sensor This sensor detects
3 The voltage is above normal or the voltage is the fuel temperature. The ECM monitors the fuel
shorted high temperature and the ECM adjusts the calculated
fuel rate accordingly.
4 The voltage is below normal or the voltage is
shorted low Full Load Setting (FLS) The FLS is the number
that represents the fuel system adjustment. This
5 The current is below normal or the circuit is adjustment is made at the factory in order to help
open ensure the maximum fuel delivery of the fuel system.
The correct value for this parameter is stamped on
6 The current is above normal or the circuit is the engine information ratings plate. This parameter
grounded must be programmed. If the parameters are not
programmed 253-02 Check Customer Parameters
7 The mechanical system is not responding will be generated or 56 Check System Parameters
properly will be generated.
8 Abnormal frequency, pulse width, or period Full Torque Setting (FTS) The FTS is similar to
the FLS. This parameter must be programmed. If
9 Abnormal update the parameters are not programmed 253-02 Check
Customer Parameters will be generated or 56
10 Abnormal rate of change Check System Parameters will be generated.
11 The failure mode is not identifiable Gear Down Protection This feature consists of the
high gear limits that are programmable. High gear
12 Damaged device or component limits are used in order to promote driving in higher
gears for increased fuel economy.
13 The device or the component is not calibrated
Harness The harness is the bundle of wiring
14 and 15 These locations are reserved for a (loom) that connects all components of the
future assignment electronic system.
Flash Code (FC) The Flash Codes are proprietary Hertz (Hz) Hertz is the measure of electrical
Caterpillar code numbers that are flashed on the frequency in cycles per second.
diagnostic lamp.
High Pressure Oil Manifold The high pressure
Flash Programming Flash programming is the oil manifold is an oil gallery that is added to the
method of programming or updating an ECM with cylinder head in order to supply the unit injectors
an electronic service tool over the data link instead with high pressure oil.
of replacing components.
High Pressure Oil Pump The high pressure oil
Fleet Information Software (FIS) FIS is a software pump is an axial piston pump that is driven by
program that operates on a PC. This program gears. The high pressure oil pump is used to raise
allows the user to review the trip information. the engine oil pressure in order to activate the unit
The program also allows the user to reset the injectors. The amount of oil pressure that is required
trip information which includes the Maintenance to activate the unit injectors is called the actuation
Indicator information. pressure.
Fuel Position This is an internal signal within Histogram The histogram is a bar graph which
the ECM. The signal comes from the electronic may indicate the relative frequency of vehicle
governor and the signal then goes to the fuel operation in specific operating ranges. A histogram
injection control. The information that is gathered is can be used to show many relationships.
based on the desired rpm, the FRC limit, the rated
fuel limit, and the actual engine rpm.
18
Hydraulic Electronic Unit Injector (HEUI) The unit Latch Mode This is a programmable parameter
injector is an injection pump which is a hydraulically for control of the exhaust brake. The exhaust
actuated, electronically controlled unit injector. This brake engages when the service brake pedal is
unit combines the pumping, electronic fuel metering depressed. The exhaust brake remains engaged
and injecting elements in a single unit. until the control detects a change in a control input.
Idle rpm Limit This is a programmable parameter Logged Diagnostic Codes Logged Diagnostic
which indicates the maximum allowable engine rpm Codes are codes which are stored in memory.
that is allowed when the engine rpm is set with the These codes are meant to be an indicator of
cruise set/resume switch. possible causes for intermittent problems. Refer to
the Diagnostic Fault Code for more information.
Idle Shutdown Time This programmable
parameter indicates a designated idle time in Oil Pressure Sensor This sensor measures engine
minutes that is allowed before shutdown. oil pressure and the sensor signals the ECM.
Idle/PTO Bump rpm This programmable parameter Open Circuit An open circuit is a condition that is
indicates the amount of change to the engine rpm caused by an open switch, or an electrical wire or
that will occur when the switch for acceleration is a connection is broken. When this condition exists,
toggled or the switch for deceleration is toggled. the signal or the supply voltage can no longer reach
the intended destination.
Injector Codes The injector codes or injector trim
codes are numeric codes or alphanumeric codes Original Equipment Manufacturer (OEM) The
that are etched or stamped on individual injectors. OEM is the manufacturer of a vehicle that uses a
Caterpillar engine for the power source.
Injection Actuation Pressure Control Valve This is a
dump valve that is controlled by an electrical signal Parameter A parameter is a value or a limit that
that maintains high pressure for the high pressure is programmable. This helps determine specific
oil manifold. The ECM controls the pressure in characteristics or behaviors of the engine and/or
the high pressure oil manifold by inputs from the vehicle.
other sensors. The control valve regulates the high
pressure oil to the hydraulic electronic unit injector Parameter Identifier (PID) The PID is a two digit
through the high pressure oil manifold. Proper fuel code or a three digit code which is assigned to
injection pressure is necessary for desired engine each component in order to identify data via the
operation. data link to the ECM.
Injection Actuation Pressure Sensor An electrical Passive Magnetic Speed Sensor (Vehicle) This
sensor on the high pressure oil manifold converts sensor is a vehicle speed sensor that does not
oil pressure into an electrical signal for the ECM. require a power and a ground connection. The
sensor produces a signal that is based on the
Inlet Manifold Air Temperature Sensor This sensor change in magnetic flux of a ferrous metal gear
detects the air inlet temperature. The ECM monitors near the sensing tip.
the inlet air temperature and other data in order
to adjust injection timing and other performance Password A password is a group of numeric
functions. characters or a group of alphanumeric characters
that is designed to restrict access to parameters.
Integrated Electronic Controls The engine is The electronic system requires correct passwords
designed with the electronic controls as a necessary in order to change customer specified parameters
part of the system. The engine will not operate (customer passwords) or certain engine
without the electronic controls. specifications (factory passwords). Passwords are
also required to clear certain diagnostic codes.
J1939 Data Link This data link is an SAE
diagnostic communications data link that is used to Pedal Mounted Accelerator Pedal Position Sensor
communicate between the electronic engine, the This sensor measures the position of the accelerator
transmission, and/or the power train controls. pedal and the sensor sends a signal to the ECM.
The sensor is mounted on an accelerator pedal
Kickout Switch This term refers to the service assembly.
brake switch and the clutch switch. These switches
are used as an exit or a kickout for the cruise
control set speed, the idle speed setting, or the
PTO/idle set speed.
19
Personality Module or Ratings Personality Module Reference Voltage The reference voltage is a
This module is attached to the inside of the regulated voltage and a steady voltage that is
ECM. The module contains all the instructions supplied by the ECM to a sensor. The reference
(software) for the ECM and the module contains the voltage is used by the sensor to generate a signal
performance maps for a specific horsepower family. voltage.
Power Take-Off (PTO) The PTO operates with Remote Station Operation This is a location that
the cruise control switches and the dedicated is outside of the vehicle cab. The functions such
PTO on/off switch. This mode permits the setting as the engine speed control are typically used for
of constant engine speeds or the mode permits some type of PTO operation that is for pumping
varying the speed with either the accelerator pedal or for some other application that uses the engine
in the cab or a remote accelerator. power. These functions are controlled from the
remote station.
Pro-Link Pro-Link is an electronic service tool that
is hand-held. The tool is manufactured by Micro Sensor The sensor is a device that is used
Processor Systems, Inc. (MPSI). This tool is supplied to detect a change in pressure, temperature, or
with a Caterpillar cartridge in order to service a mechanical movement. The information that is
Caterpillar engine that is electronically controlled. detected is converted into an electrical signal.
Progressive Shifting This is a method of upshifting Service Brake Pedal Position Switch This switch
through the lower gears quickly and not using is typically a pressure switch that is supplied and
excessive engine rpm in each gear. Shifts are made installed by the OEM. This switch is normally closed
above peak torque but below rated rpm. Using when the brake pedal is in the released position.
excessively high engine rpm ranges before shifting Depressing the brake will open the circuit.
to the next gear wastes fuel. Using the excessively
high engine rpm ranges also fails to take advantage Service Engine Soon Lamp This is sometimes
of the torque rise of the engine. The two steps LoGr referred to as the diagnostic lamp. The Service
1 and LoGr 2give the opportunity for progressive Engine Soon Lamp is used to alert the operator
shifting. LoGr 1 is typically setat no lower than peak of the presence of an active event by flashing a
torque plus 200 rpm. LoGr 2 is typically set at a diagnostic code.
point that is midway between the LoGr 1 rpm limit
and the top engine limit. Service Program Module (SPM) The service
program module is a software program that is used
PTO Configuration This is a programmable to adapt the electronic service tool to a specific
parameter that determines the best use of the ECM engine application.
input and the ECM output for PTO applications.
Short Circuit A short circuit is a condition that has
Pulse Width Modulation (PWM) The PWM is a an electrical circuit that is inadvertently connected
signal that consists of pulses that are of variable to an undesirable point. An example of a short
width. These pulses occur at fixed intervals. The circuit is a wire which rubs against a vehicle frame
ratio of time on versus total time off can be and this rubbing eventually wears off the wire
varied. This ratio is also referred to as a duty cycle. insulation. Electrical contact with the frame is made
and a short circuit results.
Signal The signal is a voltage or a waveform that

is used in order to transmit information typically
from a sensor to the ECM.
Speed Burp A speed burp is a sudden, brief,

unwanted change in the engine rpm.
Standard SAE Diagnostic Communications Data

Link Refer to the ATA Data Link.
Subsystem A subsystem that is used in this

application is a part of the electronic system that
relates to a particular function. An example of a
g00284479
Illustration 6 subsystem is the throttle subsystem.
Rated Fuel Limit This term indicates the maximum

allowable fuel position (longest injection pulse). This
position will produce rated power for this engine
configuration.
20
Supply Voltage The supply voltage is a constant Vehicle Speed Calibration The Vehicle Speed
voltage that is supplied to a component in order Calibration is a programmable parameter that is
to provide electrical power that is required for used by the ECM to convert the vehicle speed
the component to operate. The power may be signal into miles per hour or kilometers per hour.
generated by the ECM or the power may be battery
voltage that is supplied by the vehicle wiring. Vehicle Speed Sensor The vehicle speed sensor
is an electromagnetic pickup that measures vehicle
System Configuration Parameters System speed from the rotation of gear teeth in the drive
configuration parameters are parameters that affect train of the vehicle.
the power rating family or emissions.
T-Harness The T-Harness is a test harness that is

designed to connect into the vehicle harness or the
engine harness. This connection allows a normal
circuit operation and the connection simultaneously
provides a breakout T in order to measure the
signals.
Theft Deterrent This feature uses a four digit code

in order to prevent the engine from starting. The
feature requires a password to be entered via the
CAT ID.
Throttle Position The ECM calculates the throttle

position from the signal of the accelerator pedal
position sensor. The throttle position may be used
as part of a power take-off control.
Timing Calibration The timing calibration is the

adjustment of an electrical signal as a means of
correcting the timing error between the crankshaft
and the crankshaft position sensor.
Torque Limit The torque limit is a programmable

parameter which limits the maximum torque that is
based on the programming of the parameter. An
OEM installed torque limit switch is required.
Total Tattletale The Total Tattletale is the total

number of changes to all the customer specified
parameters that are stored in the ECM.
Transducer A transducer is a device that converts

Transmission Style The Transmission Style is

a programmable parameter that designates the
type of transmission in the vehicle and the various
circuits that are connected to the ECM. The relay for
the transmission, cruise control, PTO/idle set speed,
and the operation of the exhaust brake are affected
by this parameter setting.
Trip Recorder The trip recorder is an after

market device that is dedicated to recording the
parameters of the vehicle and the parameters of the
operating engine during the vehicle service. The
trip recorder is used to analyze the driving habits
and the recorder is used in order to produce the
logs of the driver.
21
i01327787
Component Diagram
SMCS Code: 1400-035; 1900-035
g00703531
Illustration 7
22
i01327958 There are several adapter cables, breakout T

cables, probes, and other miscellaneous items
Electronic Service Tools that are used in order to access measurements of
signals. A heavy duty multimeter is suitable in order
SMCS Code: 1900 to make the necessary measurements. A multimeter
that has the ability to measure the Duty Cycle may
The Caterpillar electronic service tools for the also be required. Special Tools that are used to
electronic control system are designed to help the measure pressure and temperature may be needed.
service technician analyze faults or problems within
the system. The Caterpillar electronic service tools
are required to perform some sensor calibrations Service Tools
electronically. The Caterpillar Electronic Service
Table 1
Tools are required to read engine parameters and
the Caterpillar electronic service tools are required Part Number Description
to change engine parameters. The Caterpillar
Caterpillar Electronic Technician
Electronic Technician (ET) requires a personal
computer with ET software that is installed and the JERD2124 Single Use Program License
Caterpillar Electronic Technician (ET) also requires
JERD2125 Data Subscription (Truck Engine)
a Caterpillar Communication Adapter.
or
The ET can be used to display the following JERD2128 Data Subscription (Truck and
information: Commercial Engine)
or
Programmable Parameter Settings
JERD2129 Data Subscription (All Engine and
Active Diagnostic Codes and Logged Diagnostic Machine)
Codes
5P-7277 Voltage Tester (Test Lamp)
Logged Events 9U-5103 Socket (Coolant Temperature Sensor
Removal)
Engine Rating History 6V-2197 Magnetic Transducer (Timing
Calibration Probe)
Driver and Fleet Trip Segments
7X-1171 Transducer Adapter (Timing Probe
Histograms Adapter)
7X-1695 Cable (Timing Probe Cable)
Custom Data
171-4400 Communication Adapter Gp (Support
ECM Date/Time Clock for J1939 Flash)
1U-5804 Crimp Tool
Maintenance Intervals
1U-5805 Wire Removal Tool (14 AWG Wire)
The ET can also be used to perform the following 151-6320 Wire Removal Tool (16 and 18 AWG
functions: Wire)
Diagnostic Tests 167-9225 Harness (Bypass for Service Tool)

140-2266 Harness (Breakout T for ECM)
Sensor Calibrations
Flash Programming 9U-7330 Digital Multimeter
Copy Configuration for ECM Replacement
Data Logging
Real Time Graphing
Snapshot Recorder
23
Service Tools That Are Optional

Table 2
Part Number Description
4C-3406 Connector Repair Kit (1)
7X-6370 Adapter Cable (3 Pin DT Breakout T)
8T-8726 Adapter Cable (3 Pin HD Breakout T)
7X-1710 Multimeter Probe (Spoons)
1U-5718 Vacuum Pump
1U-8757 Tube (Attachment for Vacuum Pump)
1U-5814 Bottle Assembly (Vacuum Pump)
9S-9082 Engine Turning Tool
6V-9130 Temperature Adapter
124-5643 Cable (3 Pin Packard Breakout T)
125-3662 Cable (3 Pin DT Bypass T)
157-4829 Cable Adapter (9 Pin J1939 Dash)
7X-1403 Adapter Cable (9 Pin Navistar Dash)
7X-1686 Cable Adapter (6 Pin Dash)
139-4166 Data Link Cable As (Communication Illustration 9 g00772551
Adapter to Dash Connector)
9U-7330 Digital Multimeter
7X-1412 Adapter Cable (9 Pin Service Tool
Breakout T)
(1) This kit includes a 1U-5804 Crimp Tool.
g00241203
Illustration 8
24
i01329696
Sensors and Electrical

Connectors
SMCS Code: 1900-035
g00754879
Illustration 10
Left side engine view
25
g00754881
Illustration 11
Top engine view
26
i01327887 (Table 3, contd)
Electrical Connectors and J501/P501 Air Inlet Heater Relay (2-Pin

Connector)
Functions J648/P648 Air Inlet Heater Lamp (2-Pin
Connector)
SMCS Code: 1900
Table 3
i01340982
Connector Function
J1/P1 ECM Connector (70-Pin OEM
Engine Wiring Harness
Harness) Diagram
J2/P2 ECM Connector (70-Pin Engine
Harness) SMCS Code: 1408-035
J100/P100 Coolant Temperature Sensor (2-Pin

Connector)
J103/P103 Inlet Manifold Air Temperature
Sensor (2-Pin Connector)
J200/P200 Boost Pressure Sensor (3-Pin
Connector)
J201/P201 Engine Oil Pressure Sensor (3-Pin
Connector)
J203/P203 Atmospheric Pressure Sensor
Connector (3-Pin Connector)
J204/P204 Injection Actuation Pressure Sensor
(3-Pin Connector)
J300/P300 Injector Solenoid Harness (12-Pin
Connector)
J301/P301 Injector Solenoid for Cylinder number
1 (2-Pin Connector)
2 (2-Pin Connector)
3 (2-Pin Connector)
4 (2-Pin Connector)
5 (2-Pin Connector)
6 (2-Pin Connector)
J400/P400 Engine Timing Calibration Probe
(2-Pin Connector)
J401/P401 Top Camshaft Speed/Timing Sensor
(2-Pin Connector)
J402/P402 Bottom Camshaft Speed/Timing
J403/P403 Accelerator Pedal Position Sensor
(3-Pin Connector)
J500/P500 Injection Actuation Pressure Control
Valve (2-Pin Connector)
(continued)
27
g00709250
Illustration 12
3126B Engine Wiring Diagram
28
i01341001
Vehicle Wiring Harness

Diagram
SMCS Code: 1408-035
g00772699
Illustration 13
29
Programming Parameters Replacing The ECM With the Use Of

The ECM Replacement Feature From
Caterpillar Electronic Technician (ET)
i01181843
Programming Parameters 1. Ensure that the ECM is the problem by first

connecting a test ECM. This is a temporary
SMCS Code: 1900 connection. Hang the test ECM on the side of the
engine. Flash Program the identical Personality
Many programmable parameters affect the Engine Module that was used in the suspect ECM
operation. These parameters may be changed by into the test ECM. Use the ECM Replacement
using Electronic Service Tools. The parameters are Feature that is in the ET in order to copy the
stored in the ECM. The parameters are NOT stored parameters from the ECM that is suspect. Copy
in the personality module. Any parameter can be these parameters into the test ECM. Ensure that
read. However, passwords protect parameters from the parameters in the test ECM are equal to the
unauthorized changes. parameters in the suspect ECM.
Two categories contain various parameters, System 2. If the test ECM repairs the problem, reconnect
Configuration Parameters and Customer Specified the suspect ECM. Verify that the problem returns
Parameters. System Configuration Parameters can when the suspect ECM is reconnected.
be altered only with the proper factory passwords
by using the Caterpillar Electronic Technician (ET). 3. Select the ECM Replacement Feature under the
Service/Copy Configuration menu and load the
Customer Specified Parameters can be changed by parameters from the failed ECM.
using an Electronic Service Tool only with the proper
customer passwords. Refer to Troubleshooting, 4. Temporarily connect the new ECM by connecting
Customer Passwords and Troubleshooting, both ECM Connectors. Do not mount the ECM
Factory Passwords for additional information. on the engine yet.
5. Flash program the Personality Module into the

Programming a New ECM new ECM if the personality module is not already
installed. The new ECM is shipped with a blank
The Engine Control Module or the ECM is the Personality Module.
brain of the system. So when a problem occurs,
it is easy to assume that the ECM is responsible. 6. Use the ECM Replacement Feature in the ET to
This is usually the wrong assumption. Most failures program the new ECM.
occur at the wiring and connectors or at a sensor
input or sensor output. Follow the procedures in 7. Enter the parameter for the Rating Number into
the troubleshooting guide, and do not replace the new ECM.
an ECM on an assumption. However, when your
troubleshooting indicates that a failure has in fact 8. Check for Active Codes. Program any required
occurred in the ECM, use the following procedure parameters that have not been programmed.
to replace a faulty ECM.
Note: On initial powerup of a new ECM, the
Note: If a replacement for the ECM is required, the parameter for the Rating Number must be
following information can be transferred from the programmed to avoid a 253-02 Check Customer Or
suspect ECM to the replacement ECM: customer System Parameters (56) Diagnostic Code.
parameters, injector trim codes, and timing
calibration.Timing calibration will NOT be necessary. 9. If a 22-13 Check Timing Sensor Calibration
This feature requires the Caterpillar Electronic Diagnostic Code is not Active, install the new
Technician (ET) and this feature is only possible if ECM on the engine. Otherwise, perform a timing
the suspect ECM can communicate with the ET. calibration first.
30
Replacing The ECM Without the Use Of Note: The following parameters can be programmed
The ECM Replacement Feature From on a new ECM without factory passwords: Full Load
Setting (FLS), Full Torque Setting (FTS), and Engine
Caterpillar Electronic Technician (ET) Serial Number. System Configuration parameters
must be entered before the Customer Specified
1. Ensure that the ECM is the problem by first
Parameters are entered. If Customer Parameters
are entered before the System Configuration
connection. Hang the test ECM on the side of the Parameters, the Total Tattletale will change. It will
then be necessary to obtain another set of Factory
Module that was used in the suspect ECM into
Passwords in order to access System Configuration
the test ECM. Program any parameters that Parameters.
are necessary to use the ECM for the test. For
example, Vehicle Speed Parameters need to be
8. Perform the following operations.
programmed to check the vehicle speed circuit.
Program the parameters in the test ECM to be
a. Use the Troubleshooting, Factory Passwords
equal to the parameters in the suspect ECM.
Worksheet to record the following information
from the Engine Information Plate: Full Load
2. If the test ECM repairs the problem, reconnect
Setting (FLS), Full Torque Setting (FTS), and
the suspect ECM. Verify that the problem returns
Engine Serial Number.
when the suspect ECM is reconnected.
b. Record the mileage from the vehicle odometer.
3. Obtain customer parameters from the failed
Use the ET to access System Configuration
ECM. Parameters. When the Factory Specified
Passwords screen appears, record the
a. Obtain the Customer Passwords and
following information: ECM Serial Number,
record the Customer Passwords. If the Engine Serial Number, ET Serial Number, Total
customer (owner) has lost the passwords
Tattletale, and Reason Code.
or if the customer (owner) has forgotten the
passwords, proceed to Troubleshooting, c. Leave the ET on the Factory Specified
Customer Passwords for more details.
Passwords screen and obtain the Factory
Passwords. Complete the Troubleshooting,
b. Use the ET to access Customer Specified Factory Passwords Worksheet.
Parameters from the ECM that is being
replaced. If the ECM does not communicate
9. Program the new ECM.
with the Electronic Service Tool, obtain the
required Parameter List from the OEM.
Note: On initial powerup of a new ECM, the following
six parameters must be programmed to avoid a
c. Use the Troubleshooting, Customer Specified 253-02 Check Customer Or System Parameters
Parameters Worksheet to record the customer
(56) Diagnostic Code: Full Load Setting (FLS), Full
parameters.
Torque Setting (FTS), Vehicle Speed Calibration
(ppm), Rating Number, Engine Serial Number, and
4. Record ECM lifetime Totals.
Injector Trim Codes.
a. Use the Troubleshooting, Customer Specified a. Use the ET to access System Configuration
Parameters Worksheet (Current Totals
Parameters. Enter the following parameters
Worksheet) to record the old ECM Current
that are recorded on the worksheet: Full Load
Totals.
5. Temporarily connect the new ECM by connecting
both ECM Connectors. Do not mount the ECM to
b. Use the ET to access Customer Specified
the engine until the timing calibration has been
Parameters. Enter the Customer Specified
performed.
Parameters and the original Customer
Passwords that are recorded on the
worksheet.
new ECM if the Personality Module is not already
Personality Module.
7. Obtain the Factory Passwords when the

passwords are required.
31
c. Use the ET to access Current Totals from 5. When the Read Customer Passwords screen
the Read/Change Current Totals main appears, record the customer passwords. The
menu. Record the information by using customer passwords may then be used to
the Troubleshooting, Factory Passwords change customer parameters.
Worksheet to obtain the Factory Passwords.
Enter the Totals from the original ECM that are
i01330393
recorded on the worksheet.
d. Select the following screens in order

Customer Specified
to calibrate the engine timing: Service, Parameters
Calibrations, and Timing Calibration. Calibrate
the timing. Refer to Troubleshooting, Engine SMCS Code: 1901
Speed/Timing Circuit - Test.
Customer Specified Parameters allow the vehicle
10. Install the new ECM on the engine. owner to influence the operating technique of
a driver. Some parameters may affect engine
operation in a way that would not be expected by
i01330282 an inadequately trained driver. These parameters
may lead to power or performance complaints
Customer Passwords even though the engines performance is within the
engines specification.
SMCS Code: 1901
Customer parameters may be changed repeatedly
If Customer passwords have been entered, then
as a customers operation changes or as new
the customer passwords are required to change
drivers are assigned to a truck. Customer passwords
ANY customer parameter. Customer parameters
are required to change these parameters.
are those parameters that affect the vehicle speed
limits, the power rating within an engine family
The following information is a brief description of
and the PTO operation. Refer to Troubleshooting,
the Customer Specified Parameters. The following
Customer Specified Parameters for more detail on
parameter values are included with the descriptions:
parameters that are customer programmable.
An ET or a MPSI Pro-Link with the Caterpillar Minimum

cartridge may change customer parameters. To
obtain customer passwords, contact the owner Maximum
of the vehicle. If the owner has lost the owners
passwords, customer passwords may be read by Default
using an ET.
Note: Parameter values that are shown in bold text
are programmed settings that disable the feature.
Note: Factory passwords are required in order to
read customer passwords.
The tables show values in an approximate range for
metric units that is followed by the metric conversion
Use the following procedure in order to read
to English units. The exact range of the parameter
customer passwords with an ET:
in metric units depends on the service tool that is
being used. Each tool may use slightly different
1. Use the ET to access the Utilities Menu. Then
conversion factors.
access View Passwords under the Utilities Menu.
2. When the Factory Password screen appears, Customer Parameter Lockout

record the information that is listed on the Factory
Passwords Worksheet. Refer to Troubleshooting, The Customer Parameter Lockout is available in
Factory Passwords Worksheet. order to restrict access to changing some of the
available parameters. Locking out a parameter
3. Obtain the factory passwords. The information requires customer passwords (if used). Once a
that is recorded on the Factory Passwords parameter is locked out, factory passwords are
Worksheet must be provided. When the factory required to change the parameter. Also, once a
passwords are obtained, a permanent record of parameter is locked out, factory passwords are
the access is generated at Caterpillar. required to unlock the parameter.
4. From the Factory Password screen, enter the

factory passwords.
32
If a lockable parameter is not locked out, factory Selected Engine Rating

passwords are not required. A locked out parameter
restricts the parameter from being changed directly Rating Number
by the customer. This helps vehicle owners that
are encountering problems with operators that are The Rating Number is the selected Rating within a
obtaining customer passwords and altering some of power rating family. The Personality Module defines
these parameters. the power rating family (224 kW (300 hp)) and the
personality module may contain only one or several
A locked out parameter also provides an audit ratings. The rating number defines the power rating
trail. The audit trail can be used to determine the that is used within the power rating family.
following information:
Time of change ECM Identification Parameters

Operator during change Vehicle ID
The following customer parameters are available Vehicle Identification is the identification of the
for lockout: vehicle that is assigned by the customer. Vehicle
Identification is used only for the customers
A/C Pressure Switch Fan-On Time (Full feature) reference. Vehicle Identification is not required by
the ECM.
High Cruise Control Speed Set Limit
High Speed Range Axle Ratio
Input #6 Truck Manufacturer
Low Speed Range Axle Ratio(MAR98 and June 1999 Truck Personality Modules and newer.
newer personality modules)
This parameter is used to configure the correct
Soft Vehicle Speed Limit set of default parameter options/ranges for the
application. The 3126B truck engine with serial
Top Engine Limit number prefix 7AS is equipped with a Basic ECM
or the 3126B truck engine is equipped with a Full
Transmission Style Feature ECM. The Personality Module software will
depend on the vehicle application. The option for
Vehicle Speed Cal (J1939-Trans) the Truck Manufacturer parameter is set at the
factory to provide the same functionality with one
Vehicle Speed Calibration ECM and one set of Personality Module software.
If an ECM replacement is required, the Truck
Vehicle Speed Limit Manufacturer parameter must be programmed
before programming other customer parameters in
VSL Protection order to configure the proper set of defaults/ranges.
When a Basic ECM is replaced in a General
When an attempt to change a locked out parameter Motors chassis, program the Truck Manufacturer
occurs, the Factory Password screen will come parameter to the GM option. When a Full Feature
up. If changing the parameter is required, follow the ECM is replaced on a engine in any other chassis,
instructions on the service tool display. program the Truck Manufacturer parameters to
Other.
Factory passwords are also required to change a
Table 4
parameter from a locked parameter to an unlocked
parameter. If more than one parameter is locked Alternative Default
out, and each one needs to be unlocked, one
GM, Other Not Programmed
factory password is required.
33
Vehicle Speed Parameters Vehicle Speed Limit (VSL)
Vehicle Speed Calibration The Vehicle Speed Limit (VSL) is the maximum
vehicle speed that is allowed by the ECM. The ECM
This calibration is used when the ECM is configured will shut off fuel above this speed. An inexperienced
to use a vehicle speed sensor that is connected to driver may think that something is wrong with the
the ECM vehicle harness connector J1/P1:32 & 33. engine because the ECM will not fuel the engine
above this vehicle speed limit. Vehicle speed
The Vehicle Speed Calibration is the value that limiting allows the implementation of a gear fast/run
is used by the ECM in order to translate the slow specification for the truck. The gear fast/run
vehicle speed signal into kilometers per hour slow specification for the truck improves fuel
(miles per hour). The Vehicle Speed Input must economy while the parameter for the vehicle speed
be programmed to J1/P1:62. This parameter is limit limits the maximum vehicle speed of the truck.
programmed in pulses per kilometer (PPKM) or
Table 7
pulses per mile (PPM). This parameter must be
programmed. If this parameter is not programmed, Engine Minimum Maximum Default
the diagnostic code 253-02 that is Check Customer GM 48 km/h 121 km/h 121 km/h
or System Parameters (56) will occur. This parameter (30 mph) (75 mph) (75 mph)
affects the cruise control and the ECM speedometer
signal. Also, this parameter can affect the PTO Other 48 km/h 204 km/h 204 km/h
operation, extended idle and trip totals. (30 mph) (127 mph) (127 mph)
Table 5
VSL Protection
Engine Minimum Maximum Default
GM 2485 PPKM 238080 19884 PPKM The VSL Protection is the maximum engine rpm
(4000 PPM) PPKM (32000 PPM) when there is a problem with the vehicle speed
(384000 signal that is detected by the ECM. The ECM limits
PPM) the engine to this engine rpm when the ECM senses
no vehicle speed signal, and a load on the engine.
Other 2485 PPKM 238080 Not
(4000 PPM) PPKM Programmed This is a feature that is used to prevent tampering by
(384000 running without a Vehicle Speed input to the ECM.
PPM)
Note: When this parameter is programmed to the
TEL rpm, the ECM disables the diagnostic code
Vehicle Speed Cal (J1939-Trans) 84-01 that is Loss Of Vehicle Speed Signal (31)
and 84-10 that is Vehicle Speed Rate of Change
The Vehicle Speed Cal (J1939-Trans) is used (36) and the VSL Protection can be exceeded by
when the ECM is configured to use the speed of disconnecting the vehicle speed sensor.
the transmission output shaft in order to calculate
vehicle speed. The Vehicle Speed Input parameter Table 8
must be programmed to Vehicle Speed Cal Engine Minimum Maximum Default
J1939-Trans. This value represents the revolution
of the transmission output shaft as revolutions per GM 1700 rpm 1700 rpm 1700 rpm
kilometer (revolutions per mile). This parameter Other 1700 rpm TEL rpm TEL rpm
must be programmed. If this parameter is not
programmed, the diagnostic code 253-02 that is
Check Customer or System Parameters (56) will Tachometer Calibration
occur. This parameter affects the cruise control and
the ECM speedometer signal. Also, this parameter The Tachometer Calibration is used by the ECM
can affect the PTO operation, extended idle and to translate the engine speed signal into revolutions
trip totals. per minute for a tachometer. The Tachometer
Calibration is programmed in pulses per revolution
Table 6 (PPR). The programmable range is from 12.0 to
Minimum Maximum Default 500.0 in increments of 0.1 PPR.
0 revolutions 43000 Not Programmed Table 9
per km (0 revolutions
revolutions per km (65000 Engine Minimum Maximum Default
per mile) revolutions per GM 12.0 PPR 500.0 PPR 17.5 PPR
mile)
Other 12.0 PPR 500.0 PPR 134.0 PPR
34
Soft Vehicle Speed Limit Table 12

Minimum Maximum Default
The Soft Vehicle Speed Limit operates in
conjunction with the Vehicle Speed Limit. The 0.00 9.99 0.00
Soft Vehicle Speed Limit limits the vehicle speed
within the following range:
The minimum value is 4 km/h (2.5 mph) below the
programmed Vehicle Speed Limit at full load. Low Cruise Control Speed Set Limit
The maximum value is 4 km/h (2.5 mph) above The Low Cruise Control Speed Set Limit sets
the selected Vehicle Speed Limit at no load. the lowest vehicle speed that will allow the cruise
control to be set. Programming this parameter to
Table 10 the maximum value disables cruise control.
Engine Alternative Default
Table 13
All Applications YES NO
Low Speed Range Axle Ratio 48 km/h 121 km/h 48 km/h

GM
(30 mph) (75 mph) (30 mph)
March 1998 Personality Modules and newer.
24 km/h 204 km/h 204 km/h
Other
The Low Speed Range Axle Ratio parameter (15 mph) (127 mph) (127 mph)
must be programmed when a two-speed axle
on/off switch is used by the ECM to adjust the
vehicle speed calibration. When a two-speed axle High Cruise Control Speed Set Limit
is used, the change in gear ratios from the high
speed range to the low speed range alters the The High Cruise Control Speed Set Limit sets
calibration of the vehicle speed signal. Since the the highest vehicle speed that will allow the cruise
vehicle speed signal has been altered, a calibration control to be set. If a driver attempts to set a vehicle
adjustment is required to ensure that the ECM speed higher than this limit, the High Cruise
driven speedometer and the information that is Control Speed Set Limit will be the cruise set
stored in the ECM correctly reflect the actual vehicle speed. If the High Cruise Control Speed Set Limit
speed. This parameter should be programmed to is programmed to a value that is greater than the
the Low Speed Range Axle Ratio. This parameter Vehicle Speed Limit, the cruise control switches
only requires programming when the Two-Speed can be used to exceed the programmed Vehicle
Axle Switch parameter is enabled. Speed Limit.
Table 11 Table 14
0.00 19.99 0.00
High Speed Range Axle Ratio 48 km/h 121 km/h 121 km/h
GM
(30 mph) (75 mph) (75 mph)
The High Speed Range Axle Ratio must be
programmed when a two-speed axle on/off switch 32 km/h 204 km/h 204 km/h
Other
is used by the ECM to adjust the vehicle speed (20 mph) (127 mph) (127 mph)
calibration. When a two-speed axle is used, the
change in gear ratios from the high speed range
to the low speed range alters the calibration of Engine Brake Mode
the vehicle speed signal. Since the vehicle speed
signal has been altered, a calibration adjustment is Engine Brake Mode determines the operation of
required to ensure that the ECM driven speedometer the engine brake while the cruise control on/off
and the information that is stored in the ECM switch is in the ON position but the engine is not
correctly reflect the actual vehicle speed. This in cruise control. This does not determine the
parameter should be programmed to the High operation of the engine brake while the engine is in
Speed Range Axle Ratio. This parameter only cruise control. Also, this does not allow operation
requires programming when the Two-Speed Axle of the engine brake while the engine is in cruise
Switch parameter is enabled. control.
35
The following modes are allowable options: 4 km/h (2.5 mph) above the set vehicle speed
at no load
Coast
Latch
Manual
When the Engine Brake Mode is programmed to
the Coast Mode, the engine brake is enabled only
while the service brakes are being applied. When
the ECM is programmed to the Latch Mode, the
engine brake stays enabled after the service brakes
are released. A direct, immediate pressure on the
brake pedal latches the engine brake in the ON
position and the engine brake will remain in the ON
position until the accelerator pedal is depressed.
When the Engine Brake Mode is programmed

to the Manual Mode, the engine brake operates
independently of the cruise control status.
The engine brake operates with the application and

the release of the service brake in the Coast Mode. Illustration 14 g00670797
SoftCruise control and soft vehicle speed limit

The engine brake turns on with the application of
the service brakes in the Latch Mode. The engine Table 17
brake stays on even when the service brakes are
released. Engine Alternative Default
Table 15
Alternative Default GM YES NO
Coast or Latch Manual

Other NO YES
Cruise/Idle/PTO Switch Configuration

Cruise/Idle/PTO Switch Configuration defines the
Idle Parameters
function of the set/resume switch for ACCEL mode
and DECEL mode. This parameter affects cruise Idle Vehicle Speed Limit
control mode, idle mode and PTO mode.
The Idle Vehicle Speed Limit is the maximum
Table 16 vehicle speed for setting or maintaining a set
engine rpm in the idle mode. In order to enter the
idle mode, the engine rpm must be set by the
GM
Set/Accel-Res/ Set/Decel-Res/ set/resume switch while the cruise control on/off
Decel Accel switch is in the ON position. If the vehicle speed
Set/Decel-Res/ Set/Accel-Res/ signal exceeds this value, the engine will not
Other maintain the set engine rpm.
Accel Decel
Table 18
Soft Cruise Control Minimum Maximum Default
Soft Cruise Control provides a 8 km/h (5 mph) 2 km/h (1 mph) 24 km/h (15 mph) 2 km/h (1 mph)
operating range around the cruise control set speed
in order to provide a smoother cruise control. Soft
Cruise Control controls the cruise speed within the
following range:
4 km/h (2.5 mph) below the set vehicle speed

at full load
36
Idle RPM Limit Idle/PTO Bump RPM

The Idle RPM Limit is the maximum engine rpm in The Idle/PTO Bump RPM determines the
idle mode. The Idle Mode occurs if the engine rpm increment or the decrement in engine rpm when the
is set by using the cruise control on/off switch and Accel switch or the Decel switch is briefly toggled.
the set/resume switch. Refer to Idle Vehicle Speed The Idle/PTO Bump RPM also pertains to the
Limit. The actual high limit of this parameter is dedicated PTO and idle. If a PTO Engine RPM Set
determined by the programmed Top Engine Limit. Speed has been programmed, the Idle/PTO Bump
The lower limit is determined by the programmed RPM pertains only to the control of the engine rpm
Low Idle Engine RPM. that is initiated by utilizing the cruise control on/off
input circuit. If a PTO Engine RPM Set Speed has
Programming this parameter to 600 rpm will prevent been programmed, the Idle/PTO Bump RPM does
the engine from idling at a constant rpm above the not pertain to the control of the engine rpm that is
programmed Low Idle Engine RPM. initiated by utilizing the PTO on/off circuit.
Table 19 Table 21
Minimum Maximum Default Minimum Maximum Default
700 rpm TEL rpm TEL rpm 5 rpm 500 rpm 20 rpm
Idle/PTO RPM Ramp Rate Fast Idle RPM 1

The Idle/PTO RPM Ramp Rate determines the Fast Idle RPM 1 determines the fast idle engine
rate of increase or decrease of engine rpm. This rpm that is controlled by the fast idle enable
parameter determines rates of increase or decrease switch. This rpm can be overridden within the
in engine rpm for the following functions: programmable range by the operator. To override
the Fast Idle RPM 1 setting, depress the
Accel. accelerator pedal until the desired rpm is reached.
Once the desired engine rpm is reached, then
Decel. depress the fast idle enable switch. This rpm setting
will be the fast idle rpm until the ECM is shut down.
Resume Idle
Table 22
PTO engine rpm Minimum Maximum Default
The parameter can be set to a value between 5 rpm 700 rpm TEL rpm 1000 rpm
and 1000 rpm in one rpm increments.
Fast Idle RPM 2
Note: The parameter affects both idle control and
PTO control. The idle mode occurs if the engine
Fast Idle RPM 2 determines the second fast
rpm is set by using the cruise control on/off switch
idle engine rpm that is controlled by the fast idle
and the set/resume switch. The PTO mode occurs
enable switch. The Fast Idle RPM 2 is disabled by
if the engine rpm is set by using the PTO on/off
changing the parameter to 0.
switch and the set/resume switch.
Table 20 Actuating the fast idle enable switch will increase
the engine idle speed to the fast idle engine rpm
Minimum Maximum Default 2 setting. The fast idle engine rpm will increase if
5 rpm/sec 1000 rpm/sec 50 rpm/sec the Fast Idle RPM 2 parameter is set to a number
higher than 0. Actuating the fast idle enable switch
for a third time will cause the engine rpm to return to
low idle. The engine rpm increases to the fast idle
rpm, Fast Idle RPM 2, and low idle rpm at a rate
that is independent of the programmed idle/PTO
ramp rate.
Table 23
700 rpm TEL rpm 0 rpm
37
Dedicated PTO Parameters Table 25

PTO Configuration
700 TEL rpm TEL rpm
The PTO Configuration determines the features
that are available for dedicated PTO applications PTO Engine RPM Set Speed
and the input signals that are used for dedicated
PTO applications. When the PTO Configuration is The PTO Engine RPM Set Speed is the engine
turned off, the application does not use the PTO. rpm that is allowed by the ECM when the PTO on/off
The remaining PTO programmable options require a circuit is on and the set switch is actuated.
PTO on/off circuit that is connected to ECM Input 1
(ECM connector J1/P1:56). A PTO switch on lamp If the PTO to Set Speed parameter is programmed
can also be connected to Output 1 (ECM J1/P1 to YES, the engine will proceed to this speed
terminal 30). whenever the PTO on/off circuit is turned ON.
If the ECM is programmed to the cab switches, Note: PTO Configuration must be programmed to
the ECM will use the signals from the following two cab switches or remote switches for this parameter
switches for PTO control and cruise control: to function.
Cab set switch (J1/P1 terminal 35) This parameter must be programmed higher than
the programmed low idle. If the PTO to Set Speed
Resume switch (J1/P1 terminal 44) is programmed to a higher value than the PTO Top
Engine Limit, the set speed will be limited by the
If the ECM is programmed to Remote Switches, lower PTO Top Engine Limit.
the ECM will monitor programmed signals such as
the remote set switch and remote resume switch. For one rpm set speed operation above low idle, the
Signals from the cab controls will be ignored PTO Top Engine Limit should be programmed to
when the PTO on/off circuit is ON. The following the same rpm as the PTO Engine RPM Set Speed.
components are cab controls:
For two rpm set speeds above low idle, program
Brake switch this parameter to some intermediate value between
the low idle and the PTO Top Engine Limit.
Clutch switch
Place the PTO on/off switch to the ON position.
Accelerator Toggle the set switch once in order to cause the rpm
to advance to the PTO Engine RPM Set Speed.
Cruise control switches Toggle the set switch again in order to increase the
engine rpm to the PTO Top Engine Limit. Toggling
If the ECM is programmed to remote throttle, the resume switch decreases the engine rpm to the
the ECM will monitor Input #8(J1/P1:68) for the previous set speed.
remote accelerator pedal. The ECM will monitor
programmed signals and the ECM will ignore all Table 26
cab controls when the PTO on/off circuit is ON.
Table 24 Low Idle rpm (0) PTO TEL rpm 0 rpm
Alternative Default
Cab Switches, Remote PTO Engine RPM Set Speed Input A
Switches, and Remote OFF
Throttle July 1999 Personality Modules and newer.
If the PTO Engine RPM Set Speed A parameter

PTO Top Engine Limit is programmed to the corresponding switch input
option, the switch is used in order to control
The PTO Top Engine Limit is the top engine limit
engine speed during PTO operation. The PTO
that is available by using a PTO on/off circuit that is
Configuration parameter must be programmed to
connected to Input #1 of ECM Connector (J1/P1:56).
cab switches, remote switches, or remote throttle
and the PTO Engine RPM Set Speed A parameter
Note: The PTO Configuration must be programmed
must be programmed to a valid speed.
to cab switches, remote switches, or remote throttle
before this parameter can be programmed.
38
Table 27 Note: PTO Configuration must be programmed

to cab switches for this parameter to take effect.
If PTO Configuration is programmed to remote
Low Idle rpm (0) PTO TEL rpm 0 rpm switches or remote throttle, the ECM will always
ignore the cab controls when the PTO on/off circuit
is ON.
PTO Engine RPM Set Speed Input B
Table 30
July 1999 Personality Modules and newer.
Alternative Default
If the PTO Engine RPM Set Speed B parameter Low Idle, TEL and
TEL
is programmed to the corresponding switch input PTO TEL
option, the switch is used in order to control
Configuration parameter must be programmed to PTO Vehicle Speed Limit (VSL)
cab switches, remote switches or remote throttle
and the PTO Engine RPM Set Speed Bparameter This is the maximum vehicle speed for setting or
must be programmed to a valid speed. maintaining a set engine rpm in PTO mode. PTO
Mode is entered if the PTO on/off switch is ON.
Table 28 (This uses Input #1.) If the vehicle speed signal
exceeds this value, the engine will not maintain the
set engine rpm.
Low Idle rpm (0) PTO TEL rpm 0 rpm
Table 31
PTO to Set Speed
204 km/h
2 km/h (1 mph) 2 km/h (1 mph)
This parameter causes the ECM to proceed to the (127 mph)
programmed PTO Engine RPM Set Speed when
the PTO on/off switch is ON. PTO Configuration
must be programmed to cab switches or remote Torque Limit
switches before this parameter can be programmed.
Note: This parameter is not available for PTO

Configuration remote throttle.
Table 29
Alternative Default
YES NO
PTO Cab Throttle RPM Limit

This determines the engine rpm limit of the
cab accelerator pedal position sensor and cab
set/resume switch when PTO Configuration is g00628600
Illustration 15
programmed to cab switches and the PTO on/off Operation of Torque limit
circuit is ON. This parameter is intended to prevent
(1) Programmed torque limit
engine overspeed when dedicated PTO is used.
The parameter for the Torque Limit defines the
If the parameter is programmed to low idle, the maximum torque output of the engine during
Cab Controls are ignored.
dedicated PTO operation. This parameter provides
temporary protection of equipment. The Torque
If the parameter is programmed to Top Engine Limit of the engine is active when the circuit for the
Limit (TEL), the engine will operate to the
torque limit switch is ON. The maximum value is the
programmed Top Engine Limit.
rated torque of the engine. The Torque Limit is
programmable to Nm (lb ft) of torque. Programming
If the parameter is programmed to PTO Top a value higher than the rated torque is limited by the
Engine Limit, the engine will operate to the
ECM to rated torque. The torque limit is indicated
programmed PTO Top Engine Limit.
by the dashed line in Illustration 15.
39
Table 32 Table 35
Minimum Maximum Default Minimum Maximum Default
135 Nm 2712 Nm 2712 Nm 1500 rpm TEL rpm TEL rpm
(100 lb ft) (2000 lb ft) (2000 lb ft)
Lower Gears Turn Off Speed

PTO Shutdown Time
The Lower Gears Turn Off Speed parameter is
The PTO Shutdown Time is the time (minutes) of the vehicle speed when the Lower Gears Engine
engine operation with the PTO on/off circuit ON and RPM Limit is shut off. This must be matched with
no vehicle speed before shutting down. The timer the Lower Gears Engine RPM Limit to the specific
will only count with no vehicle speed and the PTO drive train for best performance.
on/off circuit ON. The PTO shutdown timer will not
begin counting if the engine is in Cold Mode. This Table 36
parameter requires the PTO Configuration to be Minimum Maximum Default
programmed to cab switches, remote switches or
remote throttle for the timer to function. 2 km/h (1 mph) 24 km/h (15 mph) 2 km/h (1 mph)
Note: This feature does not shut down the vehicles

power. The ECM and the vehicle remain powered. Intermediate Gears Engine RPM Limit
Table 33 This parameter is similar to the Lower Gears

Engine RPM Limit. The engine will accelerate at
Minimum Maximum Default a slower rate when this limit is exceeded under
3 minutes 1440 minutes 0 minutes normal driving conditions. This parameter is
typically programmed to a slightly higher rpm than
the Lower Gears Engine RPM Limit.
PTO Activates Cooling Fan
Table 37
This parameter requires the use of the ECM cooling Minimum Maximum Default
fan circuit. When this parameter is programmed to
Continuous Mode, the ECM will signal the cooling 1500 rpm TEL rpm TEL rpm
fan to run continuously when the PTO on/off circuit
is ON. The cooling fan runs continuously in order
to reduce changes in the load while the engine is Intermediate Gears Turn Off Speed
being used for dedicated PTO applications. When
this parameter is programmed to the normal mode, This parameter is similar to the Lower Gears Turn
the fan operates the same way with the PTO on/off Off Speed. This parameter is typically programmed
circuit ON or OFF. In this mode, the operation of to a slightly higher vehicle speed than the Lower
the fan is based on coolant temperature, inlet air Gears Turn Off Speed.
temperature or air conditioning high head pressure. Table 38
The PTO Configuration must be programmed to
cab switches, remote switches or remote throttle Minimum Maximum Default
before this parameter can be programmed. The 16 km/h (10 mph) 80 km/h (50 mph) 16 km/h (10 mph)
Fan Control Type must be programmed to the
on/off setting.
Gear Down Protection RPM Limit
Table 34
Engine Alternative Default This parameter is the engine rpm limit when the
vehicle speed is above the Gear Down Protection
GM N/A N/A Turn On Speed. This is a hard limit. The ECM will
Other Continuous Normal not allow fuel to the engine above this limit. This
parameter is used to encourage the driver to shift
into overdrive or top gear.
Engine/Gear Parameters
Lower Gears Engine RPM Limit
The engine will accelerate at a slower rate when this
limit is exceeded under normal driving conditions.
This parameter is used to encourage the driver to
shift to the next highest gear.
40
Table 39 Table 43
Alternative Default
Decrease 1, 2, 3, or 4, Nominal
Increase 1, 2, 3, or 4
1700 rpm TEL rpm TEL rpm
Transmission Style
Gear Down Protection Turn On Speed
(Full Feature Only)
This parameter is the vehicle speed when the Gear
Down Protection RPM Limit is turned on. This must This parameter indicates the type of transmission
be matched to the specific drive train for best configuration that is installed in the vehicle to the
performance. Above this Vehicle Speed Limit, ECM. This parameter is used by the ECM to read
the engine rpm will be limited by the Gear Down the signals from the following devices:
Protection RPM Limit.
Brake switch (No. 2)
Table 40
Clutch switch
Neutral switch
48 km/h 121 km/h 121 km/h
GM
(30 mph) (75 mph) (75 mph)
Output (No. 7)
Note: Output No. 7 sends a electrical signal to
48 km/h 204 km/h 204 km/h
Other
(30 mph) (127 mph) (127 mph)
the ECM from the Allison Transmission Electronic
Control.
Top Engine Limit (TEL) The ECM must be programmed to one of the
following options if an Allison Wt Automatic
This parameter is the maximum engine rpm when Transmission transmission is installed:
the engine is under load. The engine will still
achieve rated rpm under no load conditions. AT/MT/HT option 1
Table 41 AT/MT/HT option 2
AT/MT/HT option 3
2640 rpm 2640 rpm 2640 rpm
AT/MT/HT option 4
Note: Select ratings have a different Top Engine
Limit. If any other automatic transmission is installed, this
parameter should be programmed to one of the
following options:
Low Idle Engine RPM
Automatic Option 1
The Low Idle Engine RPM is the minimum engine
rpm. Automatic Option 2
Table 42
Automatic Option 3
700 rpm 800 rpm 700 rpm Automatic Option 4
Idle Quality Calibration

March 1998 Personality Modules and newer.
This parameter should not be adjusted without first

consulting a Caterpillar representative.
41
Table 44 Allison Wt Automatic Transmission require an

Switch Usage.
input from the ECM to regulate the transmission
Setting For shifting. The ECM monitors the accelerator pedal
Transmission Service Service position, engine speed, vehicle speed, load,
Style Brake Brake cruise control status and neutral switch status in
Clutch Neutral
Parameter Switch Switch order to determine if the transmission should use
1 2 closed throttle or full throttle shift modulation. The
Manual X X AT/MT/HT Part Throttle Shift Speed parameter
provides three different shift modulation settings:
Automatic
X
Option 1 Table 46
Automatic Alternative Default
X X
Option 2
Low (80% Enable/65% High (60% Enable/ 45%
Automatic Disable) Disable)
X X X
Option 3 Medium (70% Enable/
55% Disable)
Automatic
X X
Option 4
AT/MT/HT
The high setting will cause the transmission to
X remain in a lower gear longer before upshifting to
Option 1
the next gear. The medium setting is a compromise
AT/MT/HT between the default setting and the high setting.
X X
Option 2
Table 47
AT/MT/HT
X X X
Option 3 Alternative Default
AT/MT/HT Medium, High Default
X X
Option 4
Universal
Option
X X X X Timer Parameters
Table 45
Idle Shutdown Time
Engine Alternative Default The Idle Shutdown Time is the time (minutes)
Automatic Option 1, of engine idle before shutting down. The engine
Automatic Option 2, will only shut down if the ECM senses low engine
Automatic Option 3, load and no vehicle speed. The Idle Shutdown
Automatic Option 4, Time will not begin counting if the engine is in Cold
GM Universal
AT/MT/HT Option 1, Mode. If this parameter is programmed to zero, this
AT/MT/HT Option 2, feature is disabled and the engine will idle until the
AT/MT/HT Option 3, keyswitch for the ignition is in the OFF position.
AT/MT/HT Option 4
Automatic Option 1, Note: This feature does not shut down the vehicles
Automatic Option 2, power. The ECM and the vehicle remain powered.
Automatic Option 3,
Automatic Option 4, Table 48
Other Manual
AT/MT/HT Option 1, Minimum Maximum Default
AT/MT/HT Option 2,
AT/MT/HT Option 3, 3 minutes 1440 minutes 0 minutes
AT/MT/HT Option 4
Allow Idle Shutdown Override

AT/MT/HT Part Throttle Shift Speed
This parameter determines if the clutch or the
JUL99 and newer Personality Module. service brake can be used to override the idle
shutdown timer during the driver alert. The driver
alert is the last 90 seconds when the check engine
lamp begins flashing. This parameter requires the
Idle Shutdown Time to be programmed to a 3
or more minutes for the parameter to be enabled.
When the Idle Shutdown Time is programmed to
0, the parameter is turned off.
42
Table 49 Engine Monitoring Parameters

Alternative Default
Engine Monitoring Mode
NO YES
This parameter determines the level of action that
A/C Switch Fan-On Time will be taken by the ECM in response to a condition
that has the capability to damage the engine. The
(Full Feature Only) ECM reads the Caterpillar coolant temperature
sensor and the coolant level sensor, if equipped.
The input 11 to the ECM can be used for the If the ECM has been programmed to monitor the
connection of a normally closed high pressure A/C OEM installed coolant level sensor, the ECM will
switch. The ECM has a built-in timer. The timer is read that sensor.
used to prevent excessive cycling of the cooling fan Table 52
clutch due to successive cycling of the A/C switch.
Programming this parameter to 0 disables the Engine Alternative Default
function. Programming depends on the refrigerant, GM OFF, DERATE WARNING
and the design of the air conditioning system as
well as the use of the signal input. Program the OFF,
timer to 1 second for the connection of this input to Other DERATE and WARNING
another system. Programming the timer to 1 second SHUTDOWN
also provides a time delay. This feature requires the
Fan Control Type to be programmed to On/Off.
Engine Monitoring Lamps
Table 50
The Engine Monitoring Lamps parameter is
Engine Minimum Maximum Default only available for the GM Truck Manufacturer
GM N/A N/A N/A configuration. The Warning Lamp option
configures Output #9 to be used for the
600 connection of a warning lamp for use with the
Other 0 second 0 seconds
seconds Caterpillar Engine Monitoring System. The optional
High Coolant Temp Warning Lamp setting
Fan with Engine Brake On configures the ECM to provide an indication when
engine coolant temperature is abnormally high. This
(Full Feature Only) circuit is used to interface the GM Vehicle Shutdown
System. When Output #9 is programmed to High
This parameter determines whether the cooling fan Coolant Temp Warning Lamp, you can not use
will turn on when the engine brake has been active the output for a warning lamp for the Caterpillar
for at least two seconds. This feature requires the Monitoring System.
Fan Control Type parameter to be programmed Table 53
to On/Off. An on/off fan must also be installed in
order for this option to be functional. Engine Alternative Default
High Coolant Temp Warning
Table 51 GM
Warning Lamp Lamp
Engine Alternatives Default
Other N/A N/A
GM N/A N/A
Other YES NO Coolant Level Sensor
This parameter determines if the ECM monitors
the input signal of the coolant level sensor. This
feature requires the Engine Monitoring Mode
to be programmed to Warning, Derate, or
Shutdown. An OEM installed coolant level sensor
must be connected to the ECM in order to use this
parameter.
43
Table 54 PM 1 Interval (Manual Maintenance

Engine Alternative Default Indicator Mode)
GM N/A N/A The PM 1 Interval allows a maintenance interval
Other 4-pin connector NO (PM 1) to be specified by the user. This parameter
(PM 1 Interval) must be programmed only when
the Maintenance Indicator Mode is programmed to
Engine Oil Pressure Sensor a Manual Mode (Distance or Hours).
JUN98 and newer Personality Module. Table 57

Manual Distance
An optional engine oil pressure sensor is sometimes
installed on applications with an instrument cluster Minimum Maximum Default
that requires an engine oil pressure gauge. The 8047 km 56327 km 24140 km
3126B does not require an engine oil pressure (5000 miles) (35000 miles) (15000 miles)
indicator for engine protection. The HEUI fuel
system will not allow the engine to run if no engine
Table 58
oil pressure is present.
Manual Hours
If the engine oil pressure sensor is installed in the Minimum Maximum Default
engine, the Engine Oil Pressure Sensor parameter
must be set to Installed. The engine oil pressure 100 750 250
signal will be communicated over the ATA Data link.
Table 55 PM1 Engine Oil Capacity (Automatic
Alternatives Default Maintenance Indicator Mode)
Installed Not Installed The PM 1 Interval can be determined by the
ECM. The ECM bases the PM 1 Interval on
fuel usage. This parameter (PM 1 Interval) must
Maintenance Parameters be programmed only when the Maintenance
Indicator Mode is programmed to an Automatic
Maintenance Indicator Mode Mode (Distance or Hours). Capacity of the sump
influences the maintenance interval.
The ECM records data that is related to the
vehicles maintenance. If Distance is selected, Table 59
all maintenance indications on the service tool will Engine Minimum Maximum Default
be displayed in distance. Typical maintenance
indications are PM 1, PM 2 and the Coolant GM 19 L (20 qt) 57 L (60 qt) 21 L (22 qt)
Flush/Fill. Other 19 L (20 qt) 57 L (60 qt) 31 L (33 qt)
If Hour is selected, all maintenance indications

on the service tool will be displayed in Hours. Trip Parameters
Typical maintenance indications are PM 1, PM
2 and the Coolant Flush/Fill. The ECM provides
Dash - PM 1 Reset
PM 1 maintenance interval and last maintenance
information.
This parameter determines if the Caterpillar Driver
Table 56
Information Display (Cat ID) can be used to reset
the PM 1 Maintenance Interval. The Maintenance
Alternative Default Indicator Mode cannot be programmed to OFF
Manual Distance for the PM 1 reset parameter to take effect.
Manual Hours
OFF Table 60
Automatic Distance
Automatic Hours Alternative Default
YES NO
44
Dash - Customer Parameters Theft Deterrent Password

Four parameters can be accessed when this The Theft Deterrent Password is the password
parameter is programmed to YES. The Cat ID is that is required by the ECM before the feature of
used to change the Dash - Customer parameters. theft deterrent is enabled. After the theft deterrent
The following four parameters can be accessed: is enabled, the Theft Deterrent Password is the
password that is required to restart the engine. All of
SoftCruise Control the characters must be uppercase. Four characters
are available for the password. If the password
Fast Idle RPM #1 is lost, a service tool and a factory password are
required in order to start the engine.
Fast Idle RPM #2
Table 63
Low Idle Engine RPM Alternative Default
Each parameter that is listed has a YES/NO option Four Characters

with NO as the default. The Cat ID must have the A through Z 0000
0 through 9
EEPROM chip that is capable of communicating
with the 3126B HEUI engine software with version
1.3 or later. Quick Stop Rate
Table 61
This parameter determines the rate of vehicle
Alternative Default speed change that is used by the ECM to record a
YES NO
Quick Stop Event Code and a quick stop snapshot.
Programming this parameter to 0 will disable this
feature and no quick stop events will be logged.
Theft Deterrent System Control Each quick stop snapshot contains 60 frames of
information. Frame 45 is the quick stop event. The
When this parameter is used with a Theft Deterrent quick stop snapshot also contains 44 frames before
Password, this parameter prevents the engine from the quick stop event and 15 frames after the quick
starting unless the password has been entered via stop event. Each frame is separated by 1.0 second.
the dash display of the CAT ID. Before the operator
Table 64
can use the feature of theft deterrent of the CAT
ID, the system must be turned on. In order to turn ECM Snapshot Frame Data
on the theft deterrent, a service tool must be used
Engine rpm Vehicle Speed
to program the parameter for the theft deterrent to
Throttle Position Cruise Status
YES. The operator must first enter the password Clutch Switch Brake Switch
before the engine is shut off. This will enable the
system. Enabling the system prevents the engine
from starting without re-entering the password The most recent quick stop snapshot is stored in
on the next attempted start. If this parameter is the ECM memory. When a quick stop event occurs
programmed to the Auto-Enable option, the the ECM replaces the old quick stop snapshot with
system will automatically be armed when the the new quick stop snapshot. The ECM also logs a
keyswitch is turned off. diagnostic event code for each quick stop event.
The ECM stores a maximum of 255 occurrences.
Note: The Auto-Enable feature requires a July
1999 Personality Module or newer with an Cat ID Table 65
(version number 2.1 or newer). Alternative Default
Table 62 0 kilometers per hour

per second ( 0 miles per
Alternative Default 0 kilometers per hour
hour per second) to 205
second (0 miles per
kilometers per hour per
YES, Auto-Enable NO hour per second)
second (128 miles per
hour per second)
45
Note: Programming the Quick Stop Rate too low The Input #4 to the ECM can be used to connect a
will cause an excessive number of Quick Stop Event torque limit switch in order to limit the engine torque.
Codes. A vehicle without a load or a trailer will be This feature should only be used for temporary
able to stop much more quickly than a vehicle with protection of equipment. This parameter must be
a heavy load. If too many Quick Stop Event Codes programmed to Torque Limit Switch in order to
are being logged, the Quick Stop Rate should be enable this feature.
increased. This will improve the detection of the
exceptions when the exceptions occur. Table 68
Alternative Default
Input Selections Torque Limit Switch NONE
Transmission Neutral Switch

Input #5
This parameter is used to specify the input that
will be used by the ECM to receive the status MAR99 and newer Personality Modules .
information from the Neutral Switch. The default
J1/P1:62 configures the ECM to monitor pin 62 of The Input #5 to the ECM can be used to connect
the vehicle harness connector for a connection for an brake/clutch disable switch. The brake/clutch
the neutral switch circuit. disable switch is used for applications that
require the mobile use of the vehicle with a set
The ECM can also be configured to receive the engine rpm that does not require the brake or the
status of the neutral switch via the J1939 data clutch to disengage the engine rpm set speed.
link. The transmission ECU must be capable of This parameter must be programmed to Ignore
supporting the required protocol of the broadcast Brake/Clutch Switch for this feature to be enabled.
announcement message.
Table 69
Table 66 Alternative Default
Alternative Default Ignore Brake/Clutch Switch NONE
J1939 J1/P1:62
Input #6
Exhaust Brake Switch
MAR99 and newer Personality Modules.
The exhaust brake can be controlled by connecting
an on/off switch into the ECM circuit for the output The Input #6 to the ECM is used to connect the
of the exhaust brake. The Exhaust Brake Switch two-speed axle switch. When a two-speed axle
parameter must be programmed to Not Installed if is used, the change in gear ratios from the main
a switch is installed in the output circuit. A switch drive axle ratio to the two-speed axle ratio alters
that is installed in the output circuit will disable the the calibration of the vehicle speed signal. When
brake by opening the output circuit. the parameter is programmed to Two Speed
Axle Switch and the switch is in the ON position
The exhaust brake can also be controlled by the ECM automatically adjusts the vehicle speed
connecting a switch circuit to the ECM switch input. calibration. This will ensure that the ECM driven
This parameter must be programmed to Installed speedometer and the information that is stored in
if a switch is connected to the ECM at the dedicated the ECM correctly reflect the actual vehicle speed.
input for the exhaust brake.
Table 70
Alternative Default Two Speed Axle Switch NONE
Installed Not Installed
Input #7
Input #4
JUL99 and newer Personality Modules.
MAR98 and newer Personality Modules.
46
A PTO engine rpm set speed A switch or a The ECM can also be configured to receive vehicle
diagnostic enable switch can be connected speed information from an Electronic Transmission
to Input #7. If the parameter is programmed Control Unit via the J1939 data link. The transmission
to Diagnostic Enable, the switch is used to must be capable of supporting the J1939 ETC1
prompt diagnostic flash codes. If the parameter Broadcast Message. The Vehicle Speed Input
is programmed to PTO Engine RPM Set Speed must be programmed to J1939-Trans.
Input A, the switch is used to control engine speed
during PTO operation. The PTO Configuration Table 73
parameter must be programmed to Cab Switches, Alternative Default
Remote Switches or Remote Throttle and the
PTO Engine RPM Speed Input A parameter must J1939-Trans J1/P1:32 & 33
be programmed to a valid speed.
Table 71 Output Selections
Alternatives Default
Output #9
Diagnostic Enable, PTO
Engine RPM Set Speed None OCT98 and newer Personality Modules.
Input A
Output #9 can be used to connect a fast idle lamp
Input #19 or a wait to start lamp.
JUL99 and newer Personality Modules. If Output #9 is programmed to Fast Idle Lamp,
the output will turn on when fast idle operation
The PTO engine rpm set speed B switch can is active. This requires the Fast Idle RPM #1
be connected to Input #19. If the Input #19 parameter to be programmed to a value above
parameter is programmed to PTO Engine RPM low idle and a momentary switch to be installed
Set Speed Input B, the switch is used to control on Input #18.
Configuration parameter must be programmed to If the Output #9 parameter is programmed to Wait
Cab Switches, Remote Switches or Remote to Start Lamp, the output will turn on when the air
Throttle and the PTO Engine RPM Speed Input B inlet heater is on and the engine is not running.
parameter must be programmed to a valid speed.
Table 74
Table 72 Engine Alternative Default
Alternatives Default GM N/A N/A
PTO Engine RPM Set Other Wait to Start Fast Idle Lamp
None
Speed Input B Lamp
Vehicle Speed Input When the Truck Manufacturer parameter is

programmed to GM the Output #9 (Warning
The ECM has an input circuit that can be used to Lamp) is used with the standard Caterpillar
receive vehicle speed information. The ECM input Engine Monitoring system. With SEP00 and
can receive the vehicle speed information in either newer Personality Modules, Output #9 can be
of the following ways: configured to only activate when the ECM detects
high engine coolant temperature. The Engine
A vehicle speed sensor can be connected to the Monitoring Lamps parameter can be programmed
input. to Warning Lamp for normal operation with the
Engine Monitoring system. This is the default
A signal wire from an electronic control can be option. The Engine Monitoring Lamps parameter
connected to the input. can also be programmed to the High Coolant
Temp Warning Lamp option. In this configuration,
The Vehicle Speed Input parameter must be the ECM will only provide an indication of high
programmed to J1/P1:32 & 33 to use this option. coolant temperature. This setting allows the ECM to
interface with the Vehicle Shutdown System. When
this setting is used, the warning lamp will not be
available for normal use with the Caterpillar Engine
Monitoring System.
47
When the ECM is configured for the High Coolant Fan Control Type
Temp Warning Lamp option, the output for the
warning lamp (terminal 29) will be connected to the If the ECM is used to operate the cooling fan, this
vehicle shutdown module. The ECM will provide parameter must be programmed to the On/Off.
a ground path at terminal 29, if a high coolant This parameter should be programmed to NONE
temperature is detected. If a ground path is present if the ECM is not connected to the cooling fan relay
at the ECM output for the warning lamp (terminal or the cooling fan solenoid. Also, this parameter
29), the vehicle shutdown module will disrupt should be programmed to NONE if the ECM is
keyswitch power to the ECM. This will cause the not operating the cooling fan relay or the cooling
engine to shut down. The ECM will only pull terminal fan solenoid. When this parameter is programmed
29 to ground when all of the following conditions to NONE, the service technician can use an
are present: Electronic Service Tool to determine that the ECM is
not connected to the fan circuit.
Truck Manufacturer parameter is programmed
to GM. Table 75
Alternative Default
Engine Monitoring Mode parameter is not
programmed to OFF. On/Off NONE
Engine Monitoring Lamps parameter is

programmed to High Coolant Temp Warning Passwords
Lamp.
Customer Password #1
The engine has been running for a minimum of
30 seconds. Customer Password #1 is a password that is
assigned by the customer. The Customer Password
The coolant temperature sensor circuit has no #1 is eight digits in length. A customer password is
open circuit faults that are active. required to change any of the customer specified
parameters.
The coolant temperature sensor circuit has no
short circuit faults that are active. Customer Password #2
The coolant temperature is at 113 C (235 F) or Customer Password #2 is an additional eight digits

above 113 C (235 F) for four seconds. that will decrease the possibility of breaking the
customer password. This is an optional password.
Note: If the circuit for terminal 29 is shorted to
ground in the wiring harness, the vehicle shutdown Table 76
module will shut down the engine . Alternative Default
After a ground has been detected for two seconds, Eight Alphanumeric
Not Programmed
the vehicle shutdown module will alert the driver Characters Available
of an impending shutdown. A Check Gauges
message and an audible tone will be present for
approximately 25 seconds. A second tone will then Data Link Parameters
sound when the vehicle shutdown module removes
keyswitch power from the ECM input. When the Power Train Data Link
keyswitch power is removed from the ECM input,
the engine will shut down. This parameter (Power Train Data Link) determines
if the ECM will communicate to a power train
Note: When the High Coolant Temp Warning Lamp device by using the J1939 data link. If the vehicle
feature is utilized, the other Caterpillar engine is not using the data link for communication to
monitoring features are not available to shut down the power train systems, this parameter should be
the engine. The vehicle shutdown module may programmed to NONE. The following systems are
provide similar functions. examples of power train systems:
Traction control systems

Anti-lock brake systems
Electronically controlled transmissions
48
Note: A 231-11 (diagnostic code J1939 Data Link

Fault) with a flash code of 58 will occur if the
parameter for the power train data link is set to SAE
J1939 without a SAE J1939 power train ECM on the
vehicle. The SAE J1939 power train ECM is used to
communicate with the engine ECM.
Table 77
GM NONE J1939
Other J1939 NONE
i01341225
Customer Specified
Parameters Table
SMCS Code: 1901
Table 78
Customer Specified Parameter Table
Selected Engine Rating Dependent on engine power
Vehicle ID
Vehicle ID 17 Digits
Available characters are dependent all zeroes
on the service tools.
Truck Manufacturer GM, Other Not Programmed
Vehicle Speed Calibration GM: 2485 to 238080 PPKM
(4000 to 384000 PPM) GM: 19884 PPKM (32000 PPM)
Other: 2485 to 93226 PPKM Other (Not Programmed)
(4000 to 15000 PPM)
Vehicle Speed CAL (J1939-Trans) 0 rev per km (0 rev per mile) to 43000
(Not Programmed)
rev per km (65000 rev per mile)
Vehicle Speed Limit (VSL) GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
VSL Protection GM: 1700 rpm GM: 1700 rpm
Other: 1700 to TEL rpm Other: TEL rpm
Tachometer Calibration GM: 17.5 ppr
12.0 to 500.0 ppr
Other: 134.0 ppr
Soft Vehicle Speed Limit YES or NO NO
Low Cruise Control Speed Set Limit GM: 48 to 121 km/h (30 to 75 mph) GM: 48 km/h (30 mph)
(continued)
49
(Table 78, contd)

High Cruise Control Speed Set Limit GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
Engine Brake Mode Coast, Latch or Manual Manual
Cruise/Idle/PTO Switch Configuration GM: Set/Decel
Set/Decel-Set/Accel
Other: Set/Accel
Soft Cruise Control GM: NO
YES or NO
Other: YES
Idle Parameters
Idle Vehicle Speed Limit 2 to 24 km/h (1 to 15 mph) 2 km/h (1 mph)
Idle RPM Limit 700 rpm to TEL rpm TEL rpm
Idle/PTO RPM Ramp Rate 5 to 1000 rpm/sec 50 rpm/sec
Cab Switches
OFF
Remote Switches
Remote Throttle
PTO Top Engine Limit 700 to TEL rpm TEL rpm
PTO Engine RPM Set Speed Low idle rpm to PTO TEL rpm 0
PTO Engine RPM Set Speed A
Low Idle rpm, PTO TEL rpm 0
PTO Engine RPM Set Speed B
PTO Cab Controls RPM Limit Low idle rpm, TEL rpm, or PTO TEL rpm TEL rpm
Torque Limit 135 Nm (100 lb ft) to Rated Torque 2712 Nm (2000 lb ft)
Lower Gears Engine RPM Limit 1500 to TEL rpm TEL rpm
Intermediate Gears Engine RPM Limit 1500 to TEL rpm TEL rpm
Gear Down Protection RPM Limit 1700 to TEL rpm TEL rpm
Gear Down Protection Turn On Speed GM: 48 to 121 km/h (30 to 75 mph) GM: 121 km/h (75 mph)
Top Engine Limit (TEL) Dependent on the engine and the rating Dependent on the engine rating
Idle Quality Calibration Decrease 1, 2, 3, or 4
Nominal
Increase 1, 2, 3, or 4, Nominal
(continued)
50
(Table 78, contd)

Transmission Style GM: Universal
Manual
Automatic Option 1
Automatic Option 2
Automatic Option 3 GM: Universal
Automatic Option 4 Other: Manual
AT/MT/HT Option 1
AT/MT/HT Option 2
AT/MT/HT Option 3
AT/MT/HT Option 4
AT/MT/HT Part Throttle Shift Speed Low, Medium, High High
Timer Parameters
Idle Shutdown Time 3 to 1440 minutes 0 minutes
Allow Idle Shutdown Override YES
YES
NO
A/C Switch Fan-On Time
0 to 600 seconds 0 seconds
Full Feature Only
Fan with Engine Brake On
YES or NO NO
Full Feature Only
Engine Monitoring Mode GM: OFF,DERATE,WARNING
Other: OFF,DERATE, WARNING
SHUTDOWN,WARNING
Engine Monitoring Lamps (GM only) High Coolant Temp Warning Lamp
Warning Lamp
or Warning Lamp
Coolant Level Sensor NO or 4-pin NO
Oil Pressure Sensor Installed or Not Installed Not Installed
Maintenance Parameters
Maintenance Indicator Mode OFF
Manual Distance
Manual Hours OFF
Automatic Distance
Automatic Hours
PM 1 Interval (Manual Maintenance 8050 to 56325 km (5000 to 35000 miles) 24140 km (15000 miles)
Indicator Mode) 100 to 750 hours 250 hours
Engine Oil Capacity (Automatic GM: 21 L (22 qt)
19 to 57 L (20 to 60 qt)
Maintenance Indicator Mode) Other: 31 L (33 qt)
Trip Parameters
Dash - PM 1 Reset YES or NO NO
Dash - Customer Parameters YES or NO NO
Theft Deterrent System Control YES, NO or AUTO-Enable NO
Theft Deterrent Password Four Characters
A thru Z 0000
0 thru 9
Quick Stop Rate 0 km/h per second ( 0 mph per
second) to 205 km/h per second 0 km/h per second (0 mph per second)
(128 mph per second)
(continued)
51
(Table 78, contd)

Input Selections
Transmission Neutral Switch None,
J1/P1:62 J1/P1:62
J1939
Exhaust Brake Switch Installed or Not Installed Installed
Input #4 None,
None
Torque Limit Switch
Input #5 None,
None
Input #6 None,
None
2-Speed Axle On/Off Switch
Input #7 None,
Diagnostic Enable None,
PTO Engine RPM Set Speed Input A
Input #19 None,
None
PTO Engine RPM Set Speed Input B
Vehicle Speed Input J1/P1:32 & 33
J1/P1:32 & 33
J1939-Trans
Output Selections
Output #9 Wait to Start Lamp GM: Unavailable
Fast Idle Lamp Other: Fast Idle Lamp
Fan Control Type None
None
(Full Feature Only) On/Off
Customer Passwords
Customer Password (1) 8 Digits
Available characters are dependent
Customer Password (2) on the service tools.
Data Link Parameters
Power train Data Link GM: J1939
None, J1939
Other: None
i01343105 Table 81
Customer Specified Truck Manufacturer Parameters
Parameters Worksheet Vehicle ID
SMCS Code: 1901

Table 79
Rating Number
Table 80
Vehicle ID
52
Table 82 Table 85
Vehicle Speed Parameters Dedicated PTO Parameters
Vehicle Speed Calibration PTO Configuration
(PPM)
Vehicle Speed Limit (VSL)
PTO Engine RPM Set
VSL Protection (rpm) Speed
Tachometer Calibration PTO Engine RPM Set
(PPR) Speed Input A
Soft Vehicle Speed Limit PTO Engine RPM Set
Speed Input B
Low Speed Range Axle
Ratio PTO to Set Speed
High Speed Range Axle PTO Cab Throttle RPM
Ratio Limit
Table 83
Torque Limit
PTO Shutdown Time
Set Limit PTO Activates Cooling Fan
High Cruise Control Speed
Set Limit Table 86
Engine Brake Engine/Gear Parameters
Cruise/Idle/PTO Switch Lower Gears Engine RPM

Configuration Limit
Soft Cruise Control Lower Gears Turn Off

Speed
Table 84 Intermediate Gears Engine

RPM Limit
Idle Parameters
Intermediate Gears Turn
Idle Vehicle Speed Limit Off Speed
Idle RPM Limit Gear Down Protection
Idle/PTO RPM Ramp Rate RPM Limit
(rpm/sec) Gear Down Protection Turn
Idle/PTO Bump RPM On Speed
Fast Idle RPM (1) Top Engine Limit (TEL)
Fast Idle RPM (2) Low Idle Engine rpm

Idle Quality Calibration
Transmission Style
AT/MT/HT Part Throttle
Shift Speed
53
Table 87 Table 92
Timer Parameters Output Selections
Idle Shutdown Time Output No. 9
(minutes)
Fan Control Type
Allow Idle Shutdown
Override
Table 93
A/C Switch Fan-On Time Customer Passwords
Fan with Engine Brake On Customer Password (1)
Customer Password (2)
Table 88
Engine Monitoring Parameters Table 94
Engine Monitoring Mode Data Link Parameters
Coolant Level Sensor Power train Data Link
Oil Pressure Sensor
Current Totals Worksheet
Table 89
Table 95
Lifetime Totals
Maintenance Indicator
Mode Total Time
PM 1 Interval Total PTO Time
(Distance/Hrs.)
Total Idle Time
Engine Oil Capacity
(Quarts/Liters) Total Distance
Total Fuel
Table 90
Total PTO Fuel
Dash Display Access Parameters
Total Idle Fuel
Dash - PM 1 Reset
Dash - Customer
Parameters i01486069
Theft Deterrent Control ECM Date/Time Stamped

System
Information
Theft Deterrent Password
SMCS Code: 1901
Table 91
The date/time clock indicates the month, the day,
Input Selections the year and the time of day. This clock is used to
Transmission Neutral time stamp the following diagnostic event codes:
Switch
Exhaust Brake Switch
84-00 Vehicle Overspeed Warning
Input No. 4 110-11 Very High Coolant Temperature
Input No. 5
111-11 Very Low Coolant Level
Input No. 6
Input No. 7
190-00 Engine Overspeed Warning
Input No. 19 The following types of ECM data are also time
stamped information:
Diagnostic snapshots
Snapshots that are triggered by using the
Set/Resume switch
54
Quick Stop snapshots ECM Diagnostic Clock

Adjustment of ECM Date/Time The Diagnostic Clock should not be confused
with the ECM Date/Time clock. The Diagnostic
Clock Clock records the actual hours of the ECM under
power. The information from the diagnostic clock
Before adjusting the ECM Date/Time Clock on is used in order to log occurrences of diagnostic
a vehicle, ask the owner/operator if the time code and occurrences of event code . Logged
stamped information should be recorded. After the diagnostic codes and logged event codes display
time stamped information is recorded, clear this the diagnostic clock hour of the first occurrence
information before adjusting the ECM Date/Time and the last occurrence and the total number
Clock. This is a very important step if the adjustment of occurrences. The Diagnostic Clock does
of the clock is a big adjustment. This will prevent not represent actual engine Hours. The clock
unnecessary confusion if someone else views the increments any time of the ECM under power. This
information at a later date. happens when the engine is running or when the
engine is not running. Actual Engine Running hours
Occurrence of Time Stamped (Total Time) can be obtained from the menu for
Current Totals of Electronic Technician (ET).
Information
When the time stamped information is being viewed, i01330152
remember that the vehicle may be based in a
different time zone. Also remember the following ECM Snapshot
two possibilities:
SMCS Code: 1901
Someone may have incorrectly set the clock. The ECM can record a snapshot of the engine
parameters and vehicle parameters. The snapshot
No one ever set the clock. records the parameters for a period of 13 seconds
Compare the electronic control modules current that surrounds the event. The event is either a
time of day to the time stamped information in the diagnostic code or an external trigger.
ECM in order to determine the amount of time
that has passed since the occurrence of the time Use Of Snapshot
stamped event. DO NOT REPLACE AN ECM
BECAUSE OF AN INCORRECT TIME OF DAY. The Use snapshots ONLY to help determine
following example indicates the proper use of the engine/vehicle operating conditions when an
clock. intermittent problem occurs. If an intermittent
diagnostic code is causing problems, use the
Proper Use of ECM Date/Time snapshot data. Snapshot data can be used to
determine whether the problem seems to occur
Stamped Information under specific circumstances. The following list of
conditions is an example of some of the specific
The Electronic Service Tool indicates that a circumstances:
diagnostic code occurred. The 190-00 Engine
Overspeed Warning occurred on 19 November Engine rpm
1998 at 10:30:46. The Electronic Service Tool also
indicates that the current time of day in the ECM is Ranges of vehicle speed
24 November 1998 at 11:20:58. This indicates that
the problem occurred in the past (approximately Ranges of coolant temperature
one week and 50 minutes).
Use this data to attempt to duplicate these
Do not compare the electronic control modules conditions with the vehicle and get the code to
time of day to the current time of day at your reoccur.
location. If the electronic control modules time of
day differs significantly from the current time of
day (wrong month), ensure that the important time
stamped information is recorded. After recording
the information, clear the code or the snapshot, and
then adjust the clock.
55
Replacement of electronic components should

not be based on the snapshot data alone. When
the snapshot information is triggered externally, the
snapshot information is stored in frames during
every 0.24 seconds. When the snapshot information
is triggered by a diagnostic code , the snapshot
information is stored in frames during every 0.48
seconds. Frequently, the parameters are changing
at a rate that is different from 0.24 seconds. If
too much emphasis is put on this information, the
result could be a misdiagnosed problem. Also
when snapshot information that is triggered by a
diagnostic code is being viewed, the ECM sets a
sensor value with an Active Diagnostic Code to
a default value when the code is active. This is g00627693
the reason that the sensor value suddenly jumps Illustration 16
to a specific value at the trigger point and the (1) OFF position
sensor value remains there for the rest of the (2) SET position
(3) RESUME position
snapshot frames. DO NOT attempt to interpret
the information and DO NOT attempt to analyze
1. Toggle the switch quickly from the OFF position
the reason that the engine is operating from this
(1) to the SET position (2).
historical information. Incorrect diagnoses will occur
by looking at this information under a microscope.
2. Toggle the switch quickly from the SET position
Incorrect diagnoses will occur because some of
(2) to the RESUME position (3).
the parameters will not be set to the values that
are expected. Even though the parameters are not
3. Toggle the switch quickly from the RESUME
related to the problem that is under investigation,
position (3) back to the OFF position (1).
the parameters can lead to incorrect diagnoses.
Note: The switch must be toggled within a one
Snapshot Information that is second time period in order to take a snapshot of
Triggered by a Diagnostic Code the engine parameters. The procedure can also be
performed in the reverse order.
When a diagnostic code occurs the ECM records
many of the status parameters that are available on For the Electronic Technician, the snapshot can be
the Caterpillar ET. The ECM records this information triggered from the Snapshot Recorder Tool. Refer
for approximately 9 seconds before the code to the instructions on the screen or the systems
occurs, and approximately 4 seconds after the documentation for help.
code.
Quick Stop Snapshot
Snapshot Information That Is A snapshot can also be stored for a quick stop
Triggered Externally event if the customer parameter is programmed.
The ECM stores the number of occurrences of the
A snapshot can be triggered externally by using Quick Stop Event and a snapshot of the latest
either the cruise control set/resume switch, or an occurrence.
electronic service tool. Use the following procedure
in order to trigger the snapshot by using the cruise One data record is kept for the most recent quick
control set/resume switch: stop event. The previous record is replaced by the
most recent record.
Each quick stop record contains 60 frames of

information. Frame 45 is the quick stop event. The
record contains 44 frames before the quick stop
event and 15 frames following the quick stop event.
Each frame is separated by 1.0 second. Each frame
of the quick stop record stores the following data:
Engine rpm
Throttle position
Clutch switch
56
Vehicle speed i01441435
Cruise status Electronic Technician (ET)

Brake switch SMCS Code: 1901
Storage of Snapshots in the ECM

The ECM can store a maximum of two snapshots
that are triggered by a diagnostic code, two
snapshots that are triggered externally, and one
quick stop snapshot. The snapshots are stored in
a circular buffer. The newest snapshot will replace
the oldest snapshot.
The ECM stores the snapshots in memory. The

memory is maintained through the unswitched
battery connections. If the unswitched + battery
pins are disconnected, or if the vehicle batteries
are disconnected, the snapshot information is
maintained by the internal battery in the ECM .
Also, the snapshots can be cleared manually by

using an electronic service tool. Snapshots are
automatically cleared by the ECM after 100 hours
of operation. Snapshots are similar to diagnostic
codes in this characteristic.
g00755974
Illustration 17
171-4400 Communication Adapter Gp consists of the following
components:
(1) Personal computer. (2) 160-0141 Data Link Cable. (3)
171-4401 Communication Adapter II. (4) 160-0133 Data Link
Cable. (5) 7X-1403 Adapter Cable As, 7X-1688 Adapter Cable
As, or 157-4829 Cable Adapter.
57
4. Connect the Communication Adapter to the PC

by using the appropriate Data Link Cable as
shown in 17 and 18.
5. Turn the ignition key switch to the ON position

in order to begin testing. The Service Tool will
operate while the engine is running. The Service
Tool will also operate while the engine is OFF and
the ignition key switch is ON. If the Tool does not
communicate with the ECM, disconnect the data
link cable and reconnect the data link cable.
Check the communication. If the problem is still
present, refer to Troubleshooting, Electronic
Service Tool Will Not Communicate With ECM.
Note: The Service Tool may restart during engine

cranking due to a voltage dip on the battery line.
Note: The ET must be configured in order to

communicate with a specific type of Communication
Adapter that is used. Go to the Preferences menu
that is located under Settings in order to select
the appropriate Communication Adapter.
i01180426
Factory Passwords
g00755977
Illustration 18
SMCS Code: 1901
7X-1701 Communication Adapter consists of the following
components:
Factory passwords are required to perform each of
(1) Personal computer. (2) 7X-1425 Data Link Cable As. (3) the following six functions:
7X-1701 Communication Adapter. (4) 139-4166 Data Link Cable
As, 160-0133 Data Link Cable As, or 7X-1412 Adapter Cable
As. (5) 7X-1403 Adapter Cable, 7X-1686 Cable Adapter, or 1. Program a New ECM.
157-4829 Cable Adapter.
When an ECM is replaced, the System
Connecting Electronic Technician Configuration Parameters must be programmed
into the new ECM. A new ECM will allow these
(ET) parameters to be programmed once without
Factory Passwords. After the initial programming,
The vehicle battery supplies the Communication these parameters are protected by factory
Adapter Tool with 12 VDC. This permits the passwords.
operation of ET beside the engine or in the vehicle
cab. The Electronic Technician can be used in the 2. Rerate to Another Engine Family
vehicle cab, which allows the use of ET during
vehicle operation. This requires changing the Personality Module
Code, which is protected by factory passwords.
Use the following procedures to connect the service This includes changing from a non-multitorque
tool to the engine: personality module to a multitorque personality
module.
1. Turn the ignition key switch to the OFF position.
3. Read Customer Passwords
2. The Service Tool should be connected to the
system through the Cab Data Link connector. If the owner loses the owners customer
Select the correct Adapter Harness Assembly for passwords, the owner will not be able to
your vehicle. Connect the appropriate adapter to program customer parameters. By Using factory
the Data Link Cable as shown in 17 and 18. passwords, one can read customer passwords.
Then use those customer passwords to program
3. Connect the opposite end of the cable for the customer parameters.
Service Tool connector to the Communication
Adapter. 4. Clear Certain Diagnostic Codes
58
The Diagnostic Code 190-00 that is Engine i01180795

Overspeed Warning requires the use of factory
passwords in order to clear the code once the Factory Passwords Worksheet
code has been logged. The Diagnostic Code
252-11 that is Incorrect Engine Software (59) SMCS Code: 1901
requires factory passwords. This diagnostic code
should be cleared only when you are certain that Note: A mistake in recording these parameters will
the personality module is for the specific engine. result in incorrect passwords.
Table 96
5. Unlock a Customer Parameter That is Locked.
Dealer Code
If a Customer Parameter has been locked
Customers Name
out, Factory Passwords are required to unlock
the parameter. Also if a Customer Parameter Address
has been locked out, Factory Passwords
are required to change the parameter. Refer
to Troubleshooting, Customer Specified
Parameters for additional information. Telephone Number
6. Enable ECM Wireless Communication Enable Information From Engine Information Plate
Parameter. Engine Serial Number
Enabling this feature requires Factory Passwords. Full Load Setting

This parameter allows the ECM to transfer Full Torque Setting
trip information over the data link via remote
communications systems. This feature can only Information From Vehicle Odometer
be enabled after the truck has been delivered to Engines Miles (km)
the customer.
Information From Factory Password Entry
Screen on ET
NOTICE
Operating the engine with a Personality Module not Electronic Service Tool
designed for that engine will damage the engine. Be Serial Number
sure the Personality Module is correct for your engine. Engine Serial Number
ECM Serial Number
Certain other codes require customer passwords.
The majority of logged codes do not require Total Tattletale
passwords to be cleared. Since the factory Reason Code
passwords contain alphabetic characters, the
Electronic Technician (ET) may perform these From Interlock(1)
functions. In order to obtain the factory passwords, To Interlock(1)
proceed as if you already have the password. At
some point, if the factory passwords are actually Factory Passwords
needed, the Electronic Technician (ET) will request Factory Password (No. 1)
the factory passwords and the Electronic Technician
(ET) will display the information that is required to Factory Password (No. 2)
obtain the passwords. (1) This parameter is required when the engine is being rerated.
This parameter is only displayed when the engine is being
Note: The Customer Parameter Lockout may rerated.
restrict changing some Customer Parameters
unless Factory Passwords are obtained. If changing
i01330008
a Customer Parameter indicates that the Factory
Passwords are required, the Parameter has been
Locked Out. Refer to Troubleshooting, Customer
Flash Programming
Specified Parameters for additional information. SMCS Code: 1901
1. Connect the components. Refer to

Troubleshooting, Electronic Technician
(ET).
2. Start the WinFlash PC Program.

59
3. Ensure that the ignition key switch is ON and i. Solution Stop the transfer of files. Access
ensure that the engine is off. information about the ECM Status under the
menu for the ECM. Ensure that the ECM on the
4. Select the part number of the engine personality engine is for an On-Highway truck application.
module that needs to be programmed into the
ECM. Program the personality module. A new Note: The amount of time that is required to flash a
ECM is shipped with a blank personality module. personality module is significantly longer than earlier
applications. The amount of time that is required
Note: The WinFlash PC Program provides the to flash a personality module with a 7X-1700
part number of the selected file for the ECM, the Communication Adapter is approximately ten
application and the software. Ensure that this file minutes or more. The amount of time that is required
matches the engine before you begin to flash the to flash a personality module with a MPSI Pro-link
file into the ECM. with the Caterpillar cartridge as a communications
adapter is approximately 20 minutes or more.
5. Messages from the personality module and the
meaning of the messages Note: If you access the ECM status under the menu
for the ECM, but you do not program the personality
A new ECM comes with a blank personality module, complete the following procedure. Before
module. A blank personality module has not using the ET, turn the vehicles ignition keyswitch
been programmed. A blank personality module to the OFF position, and then turn the vehicles
will prompt you for all three of the following ignition keyswitch to the ON position. If the ignition
messages. The information that is contained in keyswitch is not cycled after reading the ECM
the ECM Status will be scrambled if the module Status, the ECM will not communicate with your
has not been programmed previously. This is service tool or the ECM will not start. Cycling
normal. the ignition keyswitch is not necessary after the
personality module has been programmed by using
a. Message The engine ID in the flash file does the WinFlash PC Program.
not match the engine ID in the ECM.
6. Start the engine and check for proper operation.
b. Meaning The ECM has a personality module
for a different engine. a. Program any parameters that were not
previously in the old personality module
c. Solution Stop the transfer of files. Access if a 253-02 Check Customer Or System
information about the ECM status under the Parameters (56) diagnostic code is active.
menu for the ECM. Ensure that the file that Read the diagnostic code from the ET Active
was being transferred matches the engine Diagnostic Code screen in order to determine
application. the parameter (parameters) that requires
programming.
d. Message The application ID in the flash file
does not match the application ID in the ECM. b. On initial powerup of a new ECM, six
parameters must be programmed to avoid
e. Meaning The ECM has a personality module a 253-02 Check Customer Or System
for a different application. For example, the Parameters (56) Diagnostic Code: Full Load
ECM has a personality module for a 3126B Setting (FLS), Full Torque Setting (FTS),
HEUI On-Highway truck engine and you are Vehicle Speed Calibration (ppm), Rating
attempting to program a personality module Number, Engine Serial Number, and Injector
for a 3508B Marine engine. Trim Codes. Refer to Troubleshooting,
Programming Parameters.
f. Solution Stop the transfer of files. Access
information about the ECM status under the
menu for the ECM. Ensure that the file that
was being transferred is for a personality
module for an On-Highway truck.
g. Message The ID of the ECM in the flash file

does not match the ID of the ECM in the ECM.
h. Meaning The ECM is not for use with an

On-Highway truck application.
60
i01182873 A 253-02 Check Customer Or System Parameters

(56) Diagnostic Code will also be generated.
System Configuration
Parameters Note: The flash programming of a personality
module replaces the personality module.
SMCS Code: 1901
When the engine is being rerated, programming
System Configuration Parameters affect the this code to 0 will prompt the ECM to read the
emissions of the engine or the power of the engine. stored code and programming this code to 0 will
System Configuration Parameters are programmed prompt the ECM to match the stored code to the
at the factory. System Configuration Parameters Personality Module Code. This code does not need
would never need to be changed through the to be programmed when a personality module is
life of the engine normally. System Configuration replaced under both of the following conditions:
Parameters must be reprogrammed if an ECM is
replaced. Unless the engine rating has changed, The new personality module is from the same
System Configuration Parameters do not need to family.
be reprogrammed when the Personality Module
is replaced. Proper values for these parameters The new personality module is from the same
are stamped on the engine information ratings emission year.
plate. The engine information ratings plate is
located on the valve cover or the air inlet manifold. If the Personality Module is from a different family,
Factory Passwords are required to change the following components may need to be changed:
these parameters. The following information is a pistons, injectors, and other components. The
description of the System Configuration Parameters. engine information ratings plate must also be
changed in order to reflect the new rating.
Full Load Setting Some vehicle systems such as the cooling system
or the transmission may also require changes when
Full Load Setting is a number that represents the the engine is rerated. Please contact the local OEM
adjustment to the fuel system that was made at dealer for further information.
the factory in order to fine tune the fuel system.
The correct value for this parameter is stamped on
the engine information ratings plate. A new ECM Engine Serial Number
requires this parameter to be programmed to avoid
generating a 253-02 Check Customer Or System The Engine Serial Number should be programmed
Parameters (56) Diagnostic Code. to match the engine serial number that is stamped
on the engine information plate. When a new ECM
is delivered, the engine serial number in the ECM
Full Torque Setting is not programmed.
Full Torque Setting is similar to Full Load Setting.
This parameter must be programmed to avoid Personality Module Release Date
generating a 253-02 Check Customer Or System
Parameters (56) Diagnostic Code. This parameter is defined by the Personality
Module and this parameter is not programmable.
The Personality Module Release Date is used to
Personality Module Code provide the version of the software. The Customer
parameters and the software change levels can be
The Personality Module Code is a code that monitored by this date. The date is provided in the
prevents the use of an incorrect personality module month and the year (NOV99). NOV is the month
for this engine. Each horsepower family and each (November). 99 is the year (1999).
emission certification has a different code that
is associated with the horsepower family or the
emission certification. i01183143
When a personality module is replaced this code Service Information Report

must match the code that is stored in the ECM. If
the personality module code does not match the SMCS Code: 1000
code that is stored in the ECM, both of the following
situations will exist: After verifying the correct repair has been performed
on the vehicle it is critical to provide brief, detailed
information. This information helps Caterpillar better
The engine will only run at low idle. serve you and the Customer.
61
Recommendations
Customers Complaint
Provide a copy of the Troubleshooting, Driver
Questionnaire. Include comments in as many
categories as possible. The following information is
of particular importance:
Indicate whether the Check Engine Lamp was

ON continuously or whether the Check Engine
Lamp was ON intermittently.
Indicate the symptoms of vehicle operation that

are present.
Cause of Failure
Comments on the Cause of Failure should include
the number of diagnostic codes that were logged.
Comments should also indicate if the code was an
Active Code. Indicate the source of the problem.
Also indicate the method that was used to discover
the problem. Examples of the methods that were
used to discover the problem could be one of the
following methods:
A specific procedure in the manual was followed.

A visual inspection indicated that wire abrasion
on the engine harness existed.
An engine dynamometer test indicated that the

power was below the specification at 1700 rpm
due to the loss of the no. 4 injector and an engine
dynamometer test indicated that the power was
below the specification at all engine speeds
above 1700 rpm due to the loss of the no. 4
injector.
Be as specific as possible.
Repair Procedure
Comments on the Repair Procedure should include
the following types of information:
The wiring harness was repaired.

The FLS was changed per the factorys
instructions.
62
Troubleshooting without a PTO Top Engine Limit with the PTO On/Off
Switch turned ON.
Diagnostic Code
PTO Vehicle Speed Limit with the PTO On/Off
Switch turned ON.
i01486152
4. Set each parameter to the parameters maximum
Can Not Reach Top Engine value one at a time and determine whether the
RPM problem is corrected.
SMCS Code: 7569 Check Cold Mode Operation.
Probable Causes Note: This is normal operation if the problem occurs

only after start-up in cold weather.
Note: If this problem occurs under load, refer to
Troubleshooting, Low Power/Poor or No Response 1. Connect an Electronic Service Tool.
to Throttle.
2. Monitor the Electronic Service Tool in order to
The probable root causes are listed in order below: verify that the engine has progressed from Cold
Mode.
Customer Specified Parameters (normal An Active Cold Mode is indicated in the upper
operation)
corner of any Status Screen.
Cold Mode Operation
Check the Accelerator Pedal Position
Accelerator Pedal Position Sensor Sensor.
Vehicle Speed Signal 1. Use the Cruise/Idle On/Off Switch to put the
engine in Idle mode.
Fuel Supply
2. Vary the engine rpm with the Set/Resume
Dedicated PTO Switch On or Torque Limit Switch switches.
always on
If both of the following conditions are met, connect
Recommended Actions an Electronic Service Tool and monitor the status of
the Accelerator Pedal Position Sensor.
Perform the following diagnostic procedures in
order: The engine is stable by using idle mode to control
the engine rpm.
Check Customer Specified Parameters
The engine is unstable by using the Accelerator
Pedal Position Sensor.
1. Verify that the complaint is not normal operation
(programmed parameter).
If the status of the Accelerator Pedal Position Sensor
is unstable, refer to Troubleshooting, Accelerator
2. Connect an Electronic Service Tool.
Pedal (Throttle) Position Sensor Circuit - Test.
3. Check the following parameters:
Vehicle Speed Signal
Vehicle Speed Limit
Monitor the vehicle speed signal. Ensure the
Lower Gears Engine RPM Limit accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle speed.
Intermediate Gears Engine RPM Limit
If the vehicle speed is greater than the VSL, the
Gear Down Protection Engine RPM Limit engine rpm is limited to the programmed VSL
Protection. If a problem is discovered, refer to
Top Engine Limit Troubleshooting, Vehicle Speed Circuit - Test.
VSL Protection
63
Fuel Supply Cold Mode Operation

1. Check the fuel supply. Electronic System problem
2. Monitor the exhaust for smoke while the engine Fuel Position
is being cranked.
Accelerator Pedal Position Sensor
If no smoke is present, there may be a problem
with the fuel quality or there may be a problem Vehicle Speed Sensor
with the fuel supply.
Fuel supply
3. Check the fuel quality. Refer to Testing and
Adjusting, Fuel Quality - Test. Also refer to the Air Inlet System or Exhaust System
Truck Performance and Driveability Diagnostic
Guide, LEBT3477.
Recommended Actions
4. Check the fuel pressure. Refer to Testing and
Adjusting, Fuel System Pressure - Test.
order:
5. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting, Fuel System - Customer Specified Parameters
Prime.
6. Check for fuel supply lines that are restricted. (programmed parameter).
7. Check the fuel filters. 2. Connect an Electronic Service Tool.
8. If the temperature is below 0 C (32 F), check 3. Check the following parameters:
for solidified fuel (wax).
Rating #. If the Rating # is 0, the engine is
9. Check for air in the fuel system. Refer to Testing limited to 87.5 kW87.5 kW (118 hp).
and Adjusting, Air in Fuel - Test.
Vehicle Speed Limit
Dedicated PTO Switch On or Torque Limit
Switch always On Soft Vehicle Speed Limit
Gear Down Protection Engine RPM Limit
Check the parameter setting for the Dedicated PTO
parameter. If the Torque Limit is programmed
below 2720 Nm (2000 lb ft) check the status screen
VSL Protection
for Input No. 1 and Input No. 2. Ensure that the
status indicates OFF.
Incorrect programming of the Vehicle Speed
calibration (ppm).
Note: The system is operating correctly if the torque 4. Set each parameter to the parameters maximum
limit is programmed and the status is On. If the value one at a time and determine whether the
PTO switch is connected to the PTO input and problem is corrected.
the PTO switch is not switching on or off refer to
Troubleshooting, PTO Switch Circuit - Test. Note: The Soft Vehicle Speed Limit will not allow
the vehicle to achieve the programmed VSL under
i01345591 all engine load conditions. Programming the Soft
Vehicle Speed Limit to NO may be required to
Can Not Reach Vehicle Speed eliminate the complaint.
Limit
Cold Mode Operation
SMCS Code: 7569
Note: This is normal operation if the problem occurs
Probable Causes
The probable root causes are listed in order below:
Customer Specified Parameters (normal verify that the engine has progressed from Cold
operation) Mode.
64
An Active Cold Mode is indicated in the upper Also, ensure that the duty cycle changes as the
corner of any status screen. pedal position changes.
If a problem with the accelerator pedal position

Electronic System problem sensor is suspected, refer to Troubleshooting,
Accelerator Pedal (Throttle) Position Sensor Circuit
Fuel Position - Test.
Vehicle Speed Sensor
2. Monitor the Fuel Position, the Rated Fuel Limit,
Monitor the vehicle speed signal. Ensure the
and the FRC Limit.
accuracy of the vehicle speed signal by comparing
While the vehicle is operating under full load, the
parameters should meet the following conditions:
If the vehicle speed is greater than the VSL, the
Power is limited. If a problem is discovered, refer to
The Fuel Position is equal to the Rated Fuel Troubleshooting, Vehicle Speed Circuit - Test.
Limit.
The Fuel Position is less than the FRC Limit. Fuel Supply
If the Fuel Position is equal to the Rated Fuel 1. Monitor the exhaust for smoke while the engine
Limit and the Fuel Position is less than the FRC is being cranked.
Limit, the Electronics are operating correctly.
3. If the Fuel Position is not equal to the Rated Fuel with the fuel quality or there may be a problem
Limit and/or the Fuel Position is not less than the with the fuel supply.
FRC Limit, perform the following tests in order:
4. When the engine is OFF, turn the ignition key Adjusting, Fuel Quality - Test. Also refer to the
switch to the ON position. Check the boost Truck Performance and Driveability Diagnostic
pressure on an Electronic Service Tool Status Guide, LEBT3477.
Screen.
When the engine is OFF, the boost pressure Adjusting, Fuel System Pressure - Test.
should be 0 kPa (0 psi).
Accelerator Pedal Position Sensor Refer to Testing and Adjusting, Fuel System -
Prime.
Monitor the status of the accelerator pedal position
sensor. Operate the engine at high idle with the 5. Check for fuel supply lines that are restricted.
vehicle in neutral.
6. Check the fuel filters.
If the engine can not reach the programmed top
engine limit, check the throttle position sensor duty 7. If the temperature is below 0 C (32 F), check
cycle in order to ensure that the throttle position for solidified fuel (wax).
sensor duty cycle is within calibration (75 to 90
percent at high idle). 8. Check for air in the fuel system. Refer to Testing
If the accelerator pedal position is unstable, check
the throttle position sensor duty cycle. check
the throttle position sensor duty cycle by slowly
operating the accelerator pedal in order to verify
that the accelerator pedal position sensor is within
calibration. the accelerator pedal position sensor
is within calibration when both of the following
conditions are met:
10 to 22 percent at low idle

75 to 90 percent at high idle
65
i01346082 If the check engine lamp comes on, check the

power connection and the ground connection
Check Engine Lamp of the ECM. Refer to Troubleshooting, Check
or Warning Lamp Is Engine Lamp Circuit - Test for additional
information.
Malfunctioning
If the lamp does not come on, check the lamp
SMCS Code: 7400; 7569 in order to ensure that the lamp is not burned
out. Also, check the wiring in order to ensure
Probable Causes that there is not an open circuit.
The probable root causes are listed in order below: Warning Lamp
Intermittent diagnostic codes 1. In order to check the warning lamp, start the
engine.
Check engine lamp
The warning lamp should come on for at least 2
Warning Lamp seconds. Then, the warning lamp should turn off.
The warning lamp will remain on or flash if there
Cruise control set/resume switch is a problem with the engine.
Short in vehicle harness a. If the warning lamp does not operate correctly
remove the warning lamp (terminal 29) from
Service engine soon lamp (GM) the ECM connector (seventy terminal).
Recommended Actions b. Connect the warning lamp (terminal 29) to the

ground stud. Turn the ignition key switch to
Note: GM vehicles refer to the Check Engine the ON position.
Lamp as the Service Engine Soon Lamp.
c. Observe the warning lamp.
order: If the warning lamp comes on, check the
power connection and the ground connection
of the ECM. Refer to Troubleshooting,
Intermittent Diagnostic Codes Warning Lamp Circuit - Test for additional
information.
Check for logged diagnostic codes and active
diagnostic codes with an Electronic Service Tool. If the lamp does not come on, check the lamp
Check for any intermittent diagnostic codes. in order to ensure that the lamp is not burned
out. Also, check the wiring in order to ensure
Check Engine Lamp that there is not an open circuit.
1. In order to check the check engine lamp, turn Cruise Control Set/Resume Switch
the ignition key to the ON position while the
engine is OFF. Connect an Electronic Service Tool. Observe the
status screen for the cruise control set/resume
The check engine lamp should turn on. Then, switch.
the check engine lamp should turn off. The
check engine lamp will flash if there is an active If the status screen indicates that the switch is on
diagnostic code. and the switch is not in the ON position, the switch
is shorted out. Refer to Troubleshooting, Cruise
a. If the check engine lamp does not operate Control Switch Circuit - Test.
correctly remove the check engine lamp
(terminal 28) from the ECM connector (seventy
terminal).
b. Connect the check engine lamp (terminal

28) to the ground stud. Turn the ignition key
switch to the ON position.
c. Observe the check engine lamp.

66
Short in Vehicle Harness

Check Engine Lamp
Monitor the check engine lamp while the check
engine lamp (terminal 28) is removed from the ECM
connector (seventy terminal). Also, the technician
could monitor the check engine lamp while the ECM
connector (P1) is disconnected.
If the lamp remains on and the pin has been

removed from the ECM, there is a short circuit to
ground in the vehicle harness.
Warning Lamp
Monitor the warning lamp while the warning lamp
(terminal 29) is removed from the ECM connector
(seventy terminal). Also, the technician could
monitor the warning lamp while the ECM connector
(P1) is disconnected. g00711023
Illustration 19
If the lamp remains on and the pin has been GM ALDL cab connector.
removed from the ECM, there is a short circuit to (4) BAT Negative
ground in the vehicle harness. (5) BAT Negative
(6) Diagnostic Enable
(7) J1587 Data Link Positive
Service Engine Soon Lamp (GM) (15) J1587 Data Link Negative
(16) BAT Positive
Check the ALDL Connector in order to ensure
that there is not a short circuit between electrical i01348057
terminal 4 and electrical terminal 6 or between
electrical terminal 5 and electrical terminal 6. Cruise Control, Idle, or PTO
Can Not Be Set
SMCS Code: 1408; 1901
Probable Causes
Customer Specified Parameters (normal

operation)
On/Off switch for cruise control and idle control

Electronic Service Tool status screen
Recommended Actions
order:
Customer Specified Parameters

When cruise control or idle control is set by
using the cruise control on/off switch, use an
Electronic Service Tool to check customer specified
parameters. Check the following parameters:
67
Low Cruise Control Set Speed Limit If the Electronic Service Tool indicates Switch
Turned Off, go to Step 2.
High Cruise Control Set Speed Limit
If the Electronic Service Tool indicates Brake,
Idle Vehicle Speed Limit Clutch or Neutral go to Step 3.
Idle rpm Limit If the Electronic Service Tool indicates Bad

Vehicle Speed, Vehicle Speed < Limit or
Note: If the vehicle speed exceeds the High Cruise Vehicle Speed >= Limit go to Step 4.
Control Set Speed Limit and the driver attempts to
set a cruise control speed, the cruise set speed will 2. If the Electronic Service Tool indicates Switch
be the High Cruise Control Set Speed Limit. If the Turned Off, the ECM has detected an open
vehicle speed is below the Low Cruise Control Set circuit in the on/off switch circuit. This pertains
Speed Limit, the cruise control can not be set or to the cruise control, the idle control or the PTO.
resumed. If the engine rpm is above the idle rpm Perform the following tests in order:
limit and the driver attempts to set an idle engine
rpm the idle engine rpm will be the idle rpm limit. If a. Ensure that the operator has not actually
the driver attempts to set an idle engine rpm and the turned off the cruise control on/off switch or
vehicle speed exceeds the idle vehicle speed limit, the PTO on/off switch.
the idle will not activate. Refer to Troubleshooting,
Cruise Control Switch Circuit - Test. b. Check the Electronic Service Tool status
screen while the switch is being used. If the
problem is not apparent check the switch and
On/Off switch for Cruise Control the wiring.
and Idle Control
c. If the problem is related to the cruise control
When the PTO is set by using a dedicated PTO or idle control refer to Troubleshooting, Cruise
on/off switch, use an Electronic Service Tool to Control Switch Circuit - Test , Troubleshooting,
check Customer Specified Parameters. Check the Service Brake Pedal Position (Switch 1)
following parameters: Circuit - Test, and Troubleshooting, Clutch
Pedal Position Switch Circuit - Test.
d. If the problem is related to the PTO refer to
PTO Top Engine Limit Troubleshooting, PTO Switch Circuit - Test.
If the vehicle speed exceeds the programmed PTO 3. If the Electronic Service Tool indicates Brake,
VSL, the ECM will not maintain the set speed. Clutch or Neutral, the ECM has detected an
Typically, the operation of the PTO requires an open circuit in the switch circuit for the service
interlock switch such as a parking brake switch. brake, the switch circuit for the clutch or the
Ensure that all interlocks are set to allow PTO transmission neutral switch circuit. Perform the
operation. Refer to Troubleshooting, PTO Switch following tests in order:
Circuit - Test for additional information.
a. Ensure that the operator has not actually
Electronic Service Tool Status depressed the service brake pedal or the
clutch pedal. Also ensure that the operator
Screen has not actually shifted the transmission to
neutral.
1. Connect an Electronic Service Tool. Check the
status screen for the last item that caused the b. Check the Electronic Service Tool status
kickout for the cruise control, the idle control or screen while the service brake or the clutch
the PTO control. is being used. If the problem is not apparent
check the switches. Check the service brake
Note: The Electronic Service Tool will only provide switch for the air system. Ensure that the
access to the last cause of the kickout. If the ECM treadle valve is operating freely. A treadle
is powered down and the ECM is powered up, the valve that is not operating freely can cause
Electronic Service Tool display will be blank. The pressure spikes. Check the clutch switch
ECM is powered down when the ignition key switch adjustment and the return spring.
is turned to the OFF position. It may be necessary
to take the vehicle for a test drive in order to repeat
the problem. Check the Electronic Service Tool
before the ECM is turned off by the keyswitch.
68
c. If the problem is related to the cruise control c. Inspect both ECM connectors for moisture.
or idle control refer to Troubleshooting, Cruise Refer to Troubleshooting, Inspecting
Control Switch Circuit - Test , Troubleshooting, Electrical Connectors.
Service Brake Pedal Position (Switch 1)
Circuit - Test, and Troubleshooting, Clutch Note: Full Feature systems require the transmission
Pedal Position Switch Circuit - Test. style parameter to match the switches that are
installed in the vehicle. The Basic system requires
d. If the problem is related to the PTO refer to the status of the clutch switch and the neutral switch
Troubleshooting, PTO Switch Circuit - Test. to be reviewed.
4. If the electronic service tool indicates Bad

i01183503
Vehicle Speed, the vehicle speed signal is
erratic or intermittent. This relates to cruise
control only.
Driver Questionnaire
SMCS Code: 1000; 7569
If the electronic service tool indicates Vehicle
Speed < Limit, the vehicle speed signal was Ask the driver to answer the following questions
lost at least briefly. This pertains to cruise control before attempting to repair an intermittent problem,
only. or a problem with symptoms but no diagnostic
codes. Use this and the response guideline to these
If the electronic service tool indicates Vehicle questions on the next page.
Speed >= Limit, the vehicle speed signal
exceeded the programmed Idle/PTO vehicle
speed limit or the vehicle speed limit is erratic
or intermittent. This pertains to idle control and
PTO control only.
If the electronic service tool indicates a Set

SW Timeout, then either the set switch was
depressed by the operator longer than 15
seconds, or the circuit has a short. The cruise
control switch must be turned off and then turned
on before the cruise control will work.
If the electronic service tool indicates a Res

depressed by the operator longer than 15
control switch must be turned off and then turned
Perform the following diagnostic procedure in

order:
a. Inspect the Vehicle speed sensor for debris on

the sensor. Inspect the vehicle speed circuit.
b. Check the vehicle speed that is displayed

on the Electronic Service Tool status screen
while the vehicle is parked. Adjust the engine
rpm up and down. Also check the vehicle
speed while the vehicle is being driven in
order to determine that the vehicle speed that
is indicated by the Electronic Service Tool
does not vary significantly from the vehicle
speed that is indicated by the speedometer.
If the problem is not apparent, refer to
Troubleshooting, Vehicle Speed Circuit -
Test.
69
Table 97
Questions Yes Comments
1. Ask the driver if the Check Engine Lamp turned on during the problem
or if the Check Engine Lamp turned on after the problem.
The Check Engine Lamp stays on for the following time period:
2. Ask the driver for the number of occurrences for this problem.
Ask the driver to duplicate the problem if the problem can be duplicated
in less than one hour.
3. Ask the driver if other shops have worked on the same problem.
If the answer is yes, ask the names of the shops. Also ask for the time
period for the work that was performed.
4. Ask the driver if the engine completely shut down. Ask the driver if the
restart required the use of the ignition key switch.
Ask the driver for the waiting period before the driver could restart the
engine after the shutdown.
5. Ask the driver if the engine had a hesitation, a speed burp or a misfire
without a complete shutdown.
6. Ask the driver if the radio, dash gauges or lights momentarily turn off
during an occurrence of the problem.
Ask the driver if there are any other observations about the trucks
components.
7. Ask the driver if the problem occurs only at specific engine loads.
Ask the driver for additional details.
8. Ask the driver if the problem occurs at a specific engine operating
temperature.
If the problem occurs at a specific engine operating temperature, record
the engine temperature.
9. Ask the driver if the problem occurs only at specific outside
temperatures or temperature ranges.
If the problem occurs only at specific outside temperatures or
temperature ranges, record the outside temperature or temperature
range.
10. Ask the driver if the problem occurs during any other specific
conditions.
11. Ask the driver if the problem occurs at a specific vehicle speed.
If the problem occurs at a specific vehicle speed, record the vehicle
speed.
12. Ask the driver if the vehicle kicked out of cruise control mode, idle
mode or PTO mode.
13. Ask the driver if the problem occurs during the use of the accelerator.
During this time, the engine is not in cruise control mode or PTO mode.
14. Ask the driver if the problem occurs at a specific engine rpm.
If the problem occurs at a specific engine rpm record the engine rpm.
70
i01183869
Driver Questionnaire
Response
SMCS Code: 1000; 7569
Table 98
Response
1. If the Check Engine Lamp turned on there will be a logged diagnostic code. Refer to Troubleshooting, Possible
Performance Effect of Active Diagnostic Codes in order to determine if the drivers indicated symptoms agree with
the symptoms that are associated with the diagnostic code. If the drivers symptoms do not match the symptoms of the
diagnostic code, troubleshooting the diagnostic code will not correct the problem. Review the snapshots that are associated
with each diagnostic code in order to determine the operating conditions of the engine during the occurrence of the problem.
Try to duplicate these conditions. If there are not any logged diagnostic codes, check the ECM battery connections. Refer to
Troubleshooting, Ignition Key Switch Circuit and Battery Supply Circuit - Test.
2. If the problem is easily repeatable, take the vehicle for a test drive with an Electronic Service Tool that is connected to
the engine. Note the conditions when the problem occurs. The operator should be prepared to take snapshot data by
using the Electronic Service Tool or the Cruise Control Set/Resume switches. Ensure that you operate the vehicle after
correcting the problem. During vehicle operation, duplicate the operating conditions before releasing the vehicle in order to
verify that the problem has been corrected.
3. If the vehicle has been to other shops for the same problem, call the other shops in order to determine the type of work that
has been done. Avoid replacing the same components again, unless you are absolutely sure that the components are the
problem. If a component has recently been changed, it is unlikely that the component will fail again.
4. Troubleshoot the reason that the engine will not start. Repair the reason that the engine does not start. When you
repair the reason that the engine did not start you should repair the reason that the engine shut down. If the engine shut
down completely, check the ECM battery connections, the ground connections, the fuel system, the fuel, the crankshaft
position sensor and the camshaft position sensor. If the engine will not restart, refer to Troubleshooting, Engine Cranks
but Will Not Start.
5. If the problem is easily repeatable, refer to Troubleshooting, Engine Misfires, Runs Rough or Is Unstable.
If the problem is not easily repeatable, refer to Troubleshooting, Intermittent Low Power or Power Cutout.
6. If other devices on the vehicle are affected, something is wrong with the vehicle wiring. Refer to Troubleshooting, Ignition
Key Switch Circuit and Battery Supply Circuit Test for information on inspecting the ECM battery connections.
7. Operate the engine under similar load conditions. Check the low pressure fuel lines for restrictions. Also check the
fuel/water separator and the fuel tanks for foreign objects that are blocking the fuel supply.
8. Operate the engine at this temperature. Attempt to duplicate the problem.
9. When possible, troubleshoot the problem in this temperature range.
10. If the problem seems to occur during the rain or a washing, thoroughly inspect the connectors for moisture. Refer to
Troubleshooting, Inspecting Electrical Connectors.
11. If the problem occurs at a specific vehicle speed, check the parameters that affect vehicle speed in order to verify that the
parameters are programmed close to the vehicle speed of the occurrence of the problem. Check the following parameters:
Vehicle Speed Limit
VSL Protection
Low Cruise Control Speed Set Limit
Idle Vehicle Speed Limit
Engine/Gear Speed Limit
Set each parameter to the maximum value one at a time and verify that the problem is corrected.
12. If the vehicle kicks out of cruise control mode, idle mode or PTO mode and it can be duplicated, check the Electronic
Service Tool Status Screen. Check the status of the Cruise Kickout, the Idle Kickout or the PTO Kickout. If the problem
can not be duplicated, inspect the vehicle speed circuit, the service brake circuit and the clutch switch circuit and switch
adjustment, the circuit for the neutral switch and the circuits for the cruise/idle/pto switches, as required.
(continued)
71
(Table 98, contd)

13. Check for logged diagnostic codes that are associated with the accelerator pedal position sensor. Refer to
Troubleshooting, Accelerator Pedal (Throttle) Position Sensor Circuit - Test.
14. If the problem occurs at a specific engine rpm, check the VSL Protection, the Idle rpm Limit, the Top Engine Limit, the
PTO Top Engine Limit and the Progressive Shift Parameters. These parameters are programmable. Set each parameter
to the maximum value one at a time and verify that the problem is corrected.
i01348166
ECM Will Not Accept Factory

Passwords
SMCS Code: 7569
Probable Causes
Incorrect password
Incorrect serial number
Reason code
Recommended Actions
order: g00714012
Illustration 20
Incorrect password 3. Verify that the information was obtained from the
ECM that is being programmed. Do not accept
Verify that the Electronic Service Tool is on the the information from the old ECM in order to
factory password screen. Also, verify that the program Factory Passwords on a replacement
Electronic Service Tool expects Factory Passwords ECM. Do not copy the information from the old
rather than Customer Passwords. ECM in order to program Factory Passwords on
a replacement ECM.
Incorrect Serial Number 4. Verify that all characters in the ECM and/or the
Electronic Service Tool serial number have been
1. Verify that the engine serial number that is used supplied.
to calculate the password is from the Electronic
Service Tool screen rather than the engine 5. Verify that the correct passwords were entered
information plate. in upper case only. Also check the characters in
the password for accuracy.
For example, the engine serial number that is
programmed in a new ECM is 0XX00000. If 6. Turn the ignition key switch to the OFF position
the Electronic Service Tool indicates that the and retry.
Engine Serial Number is 0XX00000, this engine
serial number must be used to obtain Factory Note: Refer to Illustration 20. Ensure that the
Passwords. Do not use the information on the recorded information that is used to request the
engine information plate. password is an exact match to the information that
is displayed on the Electronic Service Tool screen.
2. Verify that all of the information on the Electronic
Service Tool screen is the information that was 7. If rechecking the passwords does not correct the
supplied to Caterpillar in order to obtain the problem, change a Customer Parameter from the
password. Refer to Illustration 20. current value to another value and then change
the Customer Parameter back to the original
value. Then revert to the screen and proceed to
obtain Factory Passwords again.
72
Note: The Total Tattletale password will need to 3. Connect another Electronic Service Tool to the
be changed. system and also try another Electronic Service
tool harness. This method is used to determine if
the problem is with the Electronic Service Tool or
Reason Code the Electronic Service tool harness.
1. Verify that the correct reason code from the
Factory Password Screen was entered. Do not Vehicle Harness
assume the reason code. This must be obtained
from the Electronic Service Tool. Reason codes Disconnect ECM Connector P1 from the ECM. Install
are assigned for specific purposes and reason the bypass harness or make a bypass harness,
codes are not interchangeable. as shown. Refer to Illustration 21. Connect the
bypass harness directly to the Electronic Service
2. Turn the ignition key switch to the OFF position Tool and the ECM, as shown. Refer to Illustration21.
and retry. If the ECM communicates with the installed bypass
harness, either the vehicle wiring or another device
Note: Ensure that the information that is entered is in the vehicle is causing the problem with data
an exact match to the information that is displayed link communication. The ECM is OK. Refer to
on the Electronic Service Tool screen. Troubleshooting, ATA (SAE J1587 / J1708) Data
Link Circuit - Test.
i01348331
Electronic Service Tool Will

Not Communicate with ECM
SMCS Code: 7569
Probable Causes
Service tool
Vehicle harness
Override switches
Personality Module
Recommended Actions
order:
Service Tool
1. Start the engine. If the engine starts but the
engine will not communicate with the ECM
go to Step 2. If the engine will not start refer
to Troubleshooting, Engine Cranks but Will
Not Start. If the engine will not crank refer to
Troubleshooting, Engine Will Not Crank.
2. Check the connections and wiring for the

73
g00741090
Illustration 21
Bypass Harness
Override Switches i01348628
1. Ensure that the ignition key switch is in the Engine Cranks but Will Not
ON position. Ensure that there are no override
switches that are creating the problem.
Start
SMCS Code: 7569
2. Ensure that there are no aftermarket devices that
are preventing battery voltage from reaching the
ECM. Probable Causes
3. Start the engine and then connect an Electronic The probable root causes are listed in order below:
Service Tool. Some type of override switch is
interrupting power to the ECM when the following Ignition switch
conditions are met: Communication occurs when
the engine is started but no communication Engine oil pressure
occurs with the ignition key switch in the ON
position. ECM Communications
Engine protection devices
Personality Module
ECM power supply
A new ECM requires a Personality Module.
The engine will not start or the engine will not Personality Module
communicate until the Personality Module has been
flashed. Try to communicate with the ECM by using ECM
the WinFlash program. The location of the WinFlash
program is in the ET. Hydraulic Electronic Unit Injectors
Engine speed/timing signal
Injection actuation pressure control system
74
Engine software 3. Ensure that the ignition key switch is in the ON

position. Attempt to access one of the electronic
Theft deterrent service tool status screens.
Fuel supply If the electronic service tool indicates that the

ECM will not communicate go to the next step. If
Combustion problem the ECM communicates go to Engine Software.
Note: A new ECM has a Personality Module that is

Recommended Actions not programmed. A Personality Module that is not
programmed will cause this symptom. Accessing
the ECM status in the ET WinFlash Program without
order:
programming the Personality Module will cause the
engine not to start or accessing the ECM status
Ignition Switch in the ET WinFlash Program without programming
the Personality Module will cause the engine not to
1. Connect an Electronic Service Tool. communicate. Cycling the ignition key switch from
the OFF to the ON position will correct this problem.
2. Access the status of the ignition switch.
3. Slowly cycle the ignition key switch on and off

Engine Protection Devices
while the status of the ignition key switch is being
1. Check aftermarket engine protection devices.
monitored. The status should indicate the state
These devices usually interrupt power to the
of the switch.
ECM and the ECM will not communicate with the
electronic service tool.
If the ECM will not communicate and the ignition
key switch is in the ON position, refer to the next
2. Check for the correct installation of the
step.
aftermarket engine protection device.
Note: If the Idle Shutdown is used or the PTO
Shutdown Time is used, the status of the ignition 3. Check for the correct operation of the aftermarket
engine protection device.
key switch may indicate that the switch is ON even
though the ignition key switch is turned to the OFF
position. Note: It may be necessary to disable the aftermarket
engine protection device before you continue.
Engine Oil Pressure 4. Verify the voltage supply at the ECM.
1. Check the engine oil level. Engine oil is used to

activate the high pressure hydraulic pump.
ECM Power Supply
1. Verify that the ECM is receiving battery voltage.
2. Ensure that the engine oil meets the
recommendations of the engine manufacturer.
2. Check the electrical power supply to the ECM.
Refer to Operation and Maintenance Manual for
further details.
3. Check the power connection of the ECM and the
ground connection of the ECM.
3. Check for air in the high pressure oil system.
4. Verify that the ECM is receiving battery voltage
Note: Crank the engine for 30 seconds. Allow time
when the ignition key switch is turned on. Refer
for the starter motor to cool. Crank the engine up
to Troubleshooting, Ignition Key Switch Circuit
to five times in order to purge the air from the high
pressure oil system. and Battery Supply Circuit - Test.
5. Connect a bypass circuit for the ECM. Refer to

ECM Communications Illustration 22.
1. Check the communications between the ECM

and the Electronic Service Tool.
2. Connect an electronic service tool.

75
g00741090
Illustration 22
Personality Module 3. Check for logged diagnostic codes that are

related to the cylinder. Go to Troubleshooting,
A new ECM has a Personality Module that is not Injector Solenoid Circuit - Test if diagnostic
programmed. The engine will not start until the codes that are related to the cylinder are present.
Personality Module has been flashed. Also, the
engine will not communicate until the Personality
Module has been flashed.
Engine Speed/Timing Signal
1. Check the Engine Speed/Timing signal.
ECM
2. Observe the engine rpm with an electronic
Before replacing the ECM, try to flash program service tool while the engine is being cranked.
the existing ECM. Refer to Troubleshooting, Flash
Programming. This may require the electronic service tool to
be powered directly by the vehicle batteries or
If the ECM is suspected of being the problem, this may require the electronic service tool to be
temporarily connect a test ECM. This will show powered directly by a separate power source
whether the problem has been resolved or the (12 VDC). Refer to Illustration 22.
problem has not been resolved.
There is a problem in the circuit of the
Speed/Timing Sensor if the electronic service
Hydraulic Electronic Unit Injectors tool display reads 0 rpm during cranking. Refer
to Troubleshooting, Engine Speed/Timing Circuit
1. Check the electrical connections to the Hydraulic
- Test.
Electronic Unit Injectors.
If an engine rpm is present, check the sensor
2. Ensure that the Hydraulic Electronic Unit Injector
Connector (J300/P300) is fully connected and installation. If the sensor is not properly installed,
the sensor may read RPM but the sensor may
ensure that the Hydraulic Electronic Unit Injector
not be able to sense the tooth pattern. The
Connector (J300/P300) is free of corrosion.
ability to sense the tooth pattern is necessary to
determine the cylinder position. Engine rpm is
present when the engine rpm is 50 rpm or more.
76
Injection Actuation Pressure 4. Check the fuel pressure. Refer to Testing and
System
1. Crank the engine and monitor the injection
actuation pressure and the Injection Actuation
Prime.
Control Valve output. The high pressure oil
system is operating properly if the pressure
6. Check for fuel supply lines that are restricted.
output is a minimum of 6 MPa (870 psi).
2. Connect the electronic service tool and check for
Event Code 164-11 Injection Actuation Pressure
8. If the temperature is below 0 C (32 F), check
system fault . If an 164-11 Event Code has
been logged recently, refer to Troubleshooting,
Injection Actuation Pressure System-Test.
Combustion Problem
3. If higher than actual pressure is being indicated,
then disconnect the injection actuation pressure Check for combustion problems.
sensor and try to start the engine. If the engine
starts, refer to Troubleshooting, Injection Examples of combustion problems are shown in the
Actuation Pressure Sensor-Test. following list:
Engine Software Outside temperatures are too cold.
Connect an electronic service tool and check for Mechanical problem

the correct engine software. Ensure that there is not
an active 252-11 diagnostic code (Incorrect Engine i01349619
Software 59) .
Engine Misfires, Runs Rough
If the diagnostic code is present, refer to
Troubleshooting, ECM Memory - Test.
or Is Unstable
SMCS Code: 1000; 7569
Theft Deterrent
Ensure that the theft deterrent (if equipped) is not
Probable Causes
active. Turn the ignition switch to the ON position. The probable root causes are listed in order below:
Observe the display screen on the CAT ID.
Note: If the problem is intermittent and the problem
If the display screen on the CAT ID indicates that can not be duplicated, refer to Troubleshooting,
the theft deterrent is enabled, the Theft Deterrent Intermittent Low Power or Power Cutout.
Passwords must be entered before the engine will
start.
Individual cylinder malfunction
Fuel Supply Fuel Supply
1. Check the fuel supply. Low Injection Actuation Pressure
2. Monitor the exhaust for smoke while the engine Accelerator Pedal Position Sensor
is being cranked.
Power train Data Link
with the fuel quality or there may be a problem Camshaft Position Sensor
Valve Lash
Adjusting, Fuel Quality - Test. Also refer to Recommended Repairs
Guide, LEBT3477.
order:
77
Note: If the problem only occurs under certain 8. Check for air in the fuel system. Refer to Testing
conditions, test the engine under those conditions. and Adjusting, Air in Fuel - Test.
Examples of certain conditions are high rpm,
full load and engine operating temperature.
Troubleshooting the symptoms under other
Low Injection Actuation Pressure
conditions can give misleading results.
Individual Cylinder Malfunction
1. Check for an individual cylinder malfunction. recommendations of the engine manufacturer.
2. Ensure that the Hydraulic Electronic Unit Injector further details.
Connector (J300/P300) is fully connected and
ensure that the Hydraulic Electronic Unit Injector 3. Crank the engine and monitor the Injection
Connector (J300/P300) is free of corrosion. Actuation Pressure and the output of the Injection
Actuation Pressure Control Valve. The High
3. Ensure that the ECM Engine Harness Connector Pressure Oil system is operating properly if the
(J2/P2) is fully connected and ensure that the pressure output is a minimum of 6 MPa (870 psi).
Engine Harness Connector (J2/P2) is free of
corrosion. 4. Connect the electronic service tool and check for
Event Code 164-11 Injection Actuation Pressure
4. Connect an electronic service tool. Use the system fault . If an 164-11 Event Code has
Cylinder Cutout Test. Access the Cylinder Cutout been logged recently, refer to Troubleshooting,
Test by selecting the Diagnostic Menu and Injection Actuation Pressure System-Test.
the Diagnostics Test Menu. Run the Cylinder
Cutout Test in order to disable each cylinder.
Disabling each cylinder allows the technician to
isolate the misfiring cylinders.
1. If the engine is in the Cruise Control Mode
and the problem does not occur, check the
If the misfiring cylinder can be isolated to Accelerator Pedal Position Sensor.
a specific cylinder, refer to Troubleshooting,
Injector Solenoid Circuit - Test.
2. Use the Cruise/Idle On/Off Switch to put the
engine in Idle mode.
Fuel Supply
3. Vary the engine rpm with the Set/Resume
1. Monitor the exhaust for smoke while the engine switches.
is being cranked.
If both of the following conditions are met,
If no smoke is present, there may be a problem connect an Electronic Service Tool and monitor
with the fuel quality or there may be a problem the status of the Accelerator Pedal Position
with the fuel supply. Sensor.
2. Check the fuel quality. Refer to Testing and The engine is stable by using idle mode to
Adjusting, Fuel Quality - Test. Also refer to the control the engine rpm.
Guide, LEBT3477. The engine is unstable by using the
Accelerator Pedal Position Sensor.
Adjusting, Fuel System Pressure - Test. If the status of the Accelerator Pedal Position
Sensor is unstable, refer to Troubleshooting,
4. Ensure that the fuel system has been primed. Accelerator Pedal (Throttle) Position Sensor
Refer to Testing and Adjusting, Fuel System - Circuit - Test.
Prime.

Power train Data Link
1. Check the Power train Data Link. Ensure that
the SAE J1939 Power Train Data Link is not
limiting the power.
2. Connect an electronic service tool.
78
3. Monitor the Power Train Data Linkstatus screen Recommended Actions

while the vehicle is experiencing problems.
If the Power Train Data Link status screen order:
indicates that the Power Train Data Link is
limiting the power or the rpm, verify that this 1. Inspect the batteries.
is not normal operation. If this is not normal
operation, refer to the vehicle OEM for repairs. a. Charge the batteries. Refer to Special
Instruction, SEHS7633, Battery Test
Procedure.
Camshaft Position Sensor
b. Load test the batteries. Refer to Special
If the signal for the Camshaft Position Sensor is
lost during engine start-up, additional time may be Instruction, SEHS9249, Use of 4C-4911
required to start the engine. The engine may also Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries.
misfire during this time until the ECM determines
the proper firing order. Refer to Troubleshooting,
Engine Speed/Timing Circuit - Test. 2. Check the vehicle wiring to the starting motor
solenoid. Refer to the OEM vehicle manual.
Valve Lash 3. Check the engine start switch and the relay for
switch power.
Refer to Systems Operation, Testing and Adjusting
for the correct procedure. 4. Inspect the starting motor cables for damage
or loose connections.
i01351154
5. If the starting motor cables are corroded, remove
Engine Will Not Crank the starting motor cables and clean the starting
motor cables.
SMCS Code: 7569
6. Test starting motor operation.
Probable Causes 7. Inspect flywheel ring gear for damage.
Note: This is NOT an electronic system problem. 8. Ensure free movement of the driveline.
Refer to Testing and Adjusting for additional
information. 9. Remove engine accessories that may lock up
the engine and inspect engine accessories that
The probable root causes are listed in order below: may lock up the engine.
Batteries The following list illustrates examples of engine
accessories that may lock up the engine:
Starting circuit
Air compressor
Starting motor solenoid
Power steering pump
Starting motor
Engine oil pump
Flywheel ring gear
10. Check for fluid in the cylinders (hydraulic
Transmission cylinder lock) by removing the individual
hydraulic electronic unit injectors.
PTO
Note: Drain the fuel from the cylinder head. Fuel will
Engine accessory flow from the cylinder head into the cylinders when
the hydraulic electronic unit injector is removed.
Hydraulic cylinder lock
11. Disassemble the engine. Inspect the internal
Internal engine problem components for the following conditions:
Ring gear Seizure

79
Broken components 3. Connect an Electronic Service Tool. Use the

Cylinder Cutout Test. Access the Cylinder Cutout
Bent components Test by selecting the Diagnostic Menu and
Refer to Disassembly and Assembly. Cutout Test in order to disable each cylinder.
12. Inspect the flywheel ring gear for damage. isolate the misfiring cylinders.
Refer to Disassembly and Assembly for more
information. If the misfiring cylinder can be isolated to
i01352455
Excessive Black Smoke Electronic System

SMCS Code: 1088-035; 7569 1. Connect an Electronic Service Tool.
Probable Causes 2. While the problem is occurring, check for

Diagnostic Codes that are related to the Boost
The probable root causes are listed in order below: Pressure Sensor and the Atmospheric Pressure
Sensor. If a Diagnostic Code is found, refer to
Troubleshooting, Engine Pressure Sensor Open
Air Inlet System or Exhaust System or Short Circuit - Test.
Valve Lash 3. Monitor the Fuel Position, the Rated Fuel Limit
and the FRC Fuel Limit.
Hydraulic Electronic Unit Injector
Electronic System parameters should meet the following conditions:
ECM or Personality Module
The Fuel Position is equal to the Rated Fuel
Limit.
Recommended Actions
The Fuel Position is less than the FRC Fuel
Perform the following diagnostic procedures in Limit.
order:
If the Fuel Position is equal to the Rated Fuel
Air Inlet System or Exhaust System Limit and the Fuel Position is less than the FRC
Fuel Limit, the Electronics are operating correctly.
Check the Air Inlet System for restrictions or Go to Vehicle Speed Signal.
leakage. Check the Exhaust System for restrictions
or leakage. Refer to Testing and Adjusting, Air Inlet 4. If the Fuel Position is not equal to the Rated Fuel
and Exhaust System - Inspect. Limit and/or the Fuel Position is not less than
the FRC Fuel Limit, perform the following tests
in order:
Valve Lash
5. When the engine is OFF, turn the Ignition Key
Check the valve lash. Refer to Testing and Adjusting, Switch to the ON position. Check the boost
Engine Valve Lash - Inspect/Adjust. pressure on an Electronic Service Tool Status
Screen.
Hydraulic Electronic Unit Injector
When the engine is OFF, the boost pressure
1. Ensure that the Hydraulic Electronic Unit Injector should be 0 kPa (0 psi).
Connector (J300/P300) is fully connected and
ensure that the Hydraulic Electronic Unit Injector ECM or Personality Module
Connector (J300/P300) is free of corrosion.
Check the ECM or the Personality Module.
2. Ensure that the ECM Engine Harness Connector
(J2/P2) is fully connected and ensure that the Refer to Troubleshooting, ECM Memory - Test.
corrosion.
80
i01353627 Fuel Supply

Excessive Fuel Consumption Check the fuel quality. Refer to Testing and
Adjusting, Fuel Quality - Test. Also refer to the
SMCS Code: 1250-035; 7569 Truck Performance and Driveability Diagnostic
Guide, LEBT3477.
Probable Causes
Air Inlet System or Exhaust System
Check the Air Inlet System for restrictions or
Vehicle Operation leakage. Check the Exhaust System for restrictions
or leakage. Refer to Testing and Adjusting, Air Inlet
Vehicle Specifications and Exhaust System - Inspect.
Fuel Supply
i01352697
Air Inlet System or Exhaust System
Excessive White Smoke
Recommended Actions SMCS Code: 1088-035; 7569
order: Probable Causes
Vehicle Operation
Normal Operation
1. Inspect the ECM Totals.
Fuel Supply
2. Inspect the ECM Totals for idle time.
Coolant Temperature Circuit
3. Inspect the Fleet Trip Histograms for excessive
idling or poor driving habits. Hydraulic Electronic Unit Injector
4. Check the following items: Combustion Problem
Load factor Intake Air Heater
Average vehicle speed Air Inlet Restriction
Vehicle Speed Limit
Recommended Actions
Look for excessively high values for these items.
5. Consider the following environmental conditions: order:
Wind Normal Operation

Snow 1. Be aware of normal operating conditions.
Vehicle Specifications Cold outside temperatures can affect the

production of white smoke.
Check the specifications on the following items:
Fuel Supply
Gearing or Power train
1. Monitor the exhaust for smoke while the engine
Vehicle Aerodynamics is being cranked.
Heavy Loads If no smoke is present, there may be a problem

with the fuel quality or there may be a problem
81
2. Check the fuel quality. Refer to Testing and Combustion Problem

Truck Performance and Driveability Diagnostic Check for combustion problems.
Guide, LEBT3477.
Examples of combustion problems are shown in the
3. Check the fuel pressure. Refer to Testing and following list:
Outside temperatures are too cold.
Refer to Testing and Adjusting, Fuel System - Mechanical problem
Prime.

Intake Air Heater
1. Inspect the wiring for the Intake Air Heater for
damage or bad connections.
2. Connect the electronic service tool.
3. Check the coolant temperature sensor and
8. Check for air in the fuel system. Refer to Testing
the intake air temperature sensor for proper
operation.
Coolant Temperature Circuit 4. Check the element inside the Intake Air Heater.
1. Connect an electronic service tool. 5. Check the Inlet Air Heater Relay for proper
operation.
2. Check for Diagnostic Codes that are related to
the Coolant Temperature circuit.
Air Inlet Restriction
3. Monitor the status of the Coolant Temperature
Check the Air Inlet System for restrictions. Refer
Sensor on the electronic service tool status
to Testing and Adjusting, Air Inlet and Exhaust
screen. If an Active Open or a Short Circuit
System - Inspect.
Diagnostic Code is detected, refer to
Troubleshooting, Engine Temperature Sensor
Open or Short Circuit - Test. i01350125
Hydraulic Electronic Unit Injector Intermittent Cruise Control,

Idle, or PTO Kickout
1. Ensure that the Hydraulic Electronic Unit Injector
Connector (J300/P300) is fully connected and SMCS Code: 1900; 7569
ensure that the Hydraulic Electronic Unit Injector
Connector (J300/P300) is free of corrosion. Probable Causes
2. Ensure that the ECM Engine Harness Connector The probable root causes are listed in order below:
(J2/P2) is fully connected and ensure that the
corrosion.
Cruise control, idle control and PTO control status
3. Connect an electronic service tool. Use the

A clutch pedal position switch that is incorrectly
adjusted
Test by selecting the Diagnostic Menu and
Malfunctioning on/off switch for cruise control and
idle control
Malfunctioning switch for service brake pedal
position
If the misfiring cylinder can be isolated to
Malfunctioning transmission neutral switch
Vehicle speed circuit problem
Battery power or ground to the ECM
82
Recommended Actions 3. If the Electronic Service Tool indicates Brake,

Clutch or Neutral, the ECM has detected an
Perform the following diagnostic procedures in open circuit in the switch circuit for the service
order: brake, the switch circuit for the clutch or the
transmission neutral switch circuit. Perform the
following tests in order:
Electronic Service Tool Status
Screen a. Ensure that the operator has not actually
depressed the service brake pedal or the
1. Connect an Electronic Service Tool. Check the clutch pedal. Also ensure that the operator
status screen for the last item that caused the has not actually shifted the transmission to
kickout for the cruise control, the idle control or neutral.
the PTO control.
b. Check the Electronic Service Tool status
Note: The Electronic Service Tool will only provide screen while the service brake or the clutch
access to the last cause of the kickout. If the ECM is being used. If the problem is not apparent
is powered down and the ECM is powered up, the check the switches. Check the service brake
Electronic Service Tool display will be blank. The switch for the air system. Ensure that the
ECM is powered down when the ignition key switch treadle valve is operating freely. A treadle
is turned to the OFF position. It may be necessary valve that is not operating freely can cause
to take the vehicle for a test drive in order to repeat pressure spikes. Check the clutch switch
the problem. Check the Electronic Service Tool adjustment and the return spring.
before the ECM is turned off by the keyswitch.
c. If the problem is related to the cruise control
If the Electronic Service Tool indicates Switch or idle control refer to Troubleshooting, Cruise
Turned Off, go to Step 2. Control Circuit, Service Brake Pedal Position
(Switch 1) Circuit, and Clutch Pedal Position
If the Electronic Service Tool indicates Brake, Switch Circuit - Test.
Clutch or Neutral go to Step 3.
If the Electronic Service Tool indicates Bad Troubleshooting, PTO Switch Circuit - Test.
Vehicle Speed, Vehicle Speed < Limit or
Vehicle Speed >= Limit go to Step 4. 4. If the electronic service tool indicates Bad
Vehicle Speed, the vehicle speed signal is
2. If the Electronic Service Tool indicates Switch erratic or intermittent. This relates to cruise
Turned Off, the ECM has detected an open control only.
circuit in the on/off switch circuit. This pertains
to the cruise control, the idle control or the PTO. If the electronic service tool indicates Vehicle
Perform the following tests in order: Speed < Limit, the vehicle speed signal was
lost at least briefly. This pertains to cruise control
a. Ensure that the operator has not actually only.
turned off the cruise control on/off switch or
the PTO on/off switch. If the electronic service tool indicates Vehicle
Speed >= Limit, the vehicle speed signal
b. Check the Electronic Service Tool status exceeded the programmed idle/PTO vehicle
screen while the switch is being used. If the speed limit or the vehicle speed limit is erratic
problem is not apparent check the switch and or intermittent. This pertains to idle control and
the wiring. PTO control only.
c. If the problem is related to the cruise control If the electronic service tool indicates a Set
or idle control refer to Troubleshooting, Cruise SW Timeout, then either the set switch was
Control Circuit, Service Brake Pedal Position depressed by the operator longer than 15
(Switch 1) Circuit, and Clutch Pedal Position seconds, or the circuit has a short. The cruise
Switch Circuit - Test. control switch must be turned off and then turned
Troubleshooting, PTO Switch Circuit - Test.
83
If the electronic service tool indicates a Res Engine speed/timing sensors

depressed by the operator longer than 15 Low injection actuation pressure
control switch must be turned off and then turned ECM or Personality Module
Note: Shut down the engine before attempting to
Perform the following diagnostic procedure in troubleshoot the problem.
order:
a. Inspect the vehicle speed sensor for debris on

Recommended Actions
the sensor. Inspect the vehicle speed circuit.
order:
b. Check the vehicle speed that is displayed
while the vehicle is parked. Adjust the engine Idle Shutdown and Engine
rpm up and down. Also check the vehicle Monitoring
speed while the vehicle is being driven in
order to determine that the vehicle speed that 1. Check the parameters for Engine Monitoring
is indicated by the Electronic Service Tool and Idle Shutdown.
does not vary significantly from the vehicle
speed that is indicated by the speedometer. 2. Connect an electronic service tool. Read the
If the problem is not apparent, refer to following customer parameters:
Test.
Engine Monitoring
c. Inspect both ECM connectors for moisture.
Refer to Troubleshooting, Inspecting
Idle Shutdown Time
Electrical Connectors. 3. If Engine Monitoring is programmed to
shutdown, use an electronic service tool to look
Note: Full Feature systems require the transmission for the following diagnostic codes:
style parameter to match the switches that are
installed in the vehicle. The Basic system requires
the status of the clutch switch and the neutral switch
110-11 Ver High Coolant Temperature (61)
to be reviewed.
111-11 Very Low Coolant Level (62)
ECM Connections 4. If the Idle Shutdown Time or the PTO
Shutdown Time is programmed above 0, use an
A problem with the battery power, the ground to the electronic service tool to look for the following
ECM or the vehicle wiring can cause erratic engine diagnostic codes:
rpm or other more severe problems. If this is a
suspected cause, refer to Troubleshooting, Ignition 71-01 Idle Shutdown Occurrence (47)
Key Switch Circuit and Battery Supply Circuit Test.
71-14 PTO Shutdown Occurrence (47)
i01351635
Battery Power or Ground to the
Intermittent Engine Shutdown ECM
SMCS Code: 7569
1. Ensure that the following connectors have been
installed correctly:
Probable Causes
ECM connectors (J1/P1 and J2/P2) with
The probable root causes are listed in order below: seventy pins
Idle Shutdown and Engine Monitoring Injector connector (J300/P300)

Battery power or ground to the ECM Camshaft position sensor connector
(J401/P401 and J402/P402)
Aftermarket engine protection devices
Fuel supply
84
2. Use a electronic service tool to check for Engine Speed/Timing Sensors

diagnostic code 168-02 (Intermittent Battery
Power to the ECM). Check the power connections Check the Engine Speed/Timing Sensors.
for the ECM and the ground connections for the
ECM. If a problem is suspected, wire a bypass. Refer to Troubleshooting, Engine Speed/Timing
Refer to Troubleshooting, Ignition Key Switch Circuit - Test.
Circuit and Battery Supply Circuit - Test.
3. If the problem occurs only after engine warm-up

Low Injection Actuation Pressure
and the problem disappears after the engine
cooldown, the circuit breakers may be tripping
because of the heat. Check the circuit breakers
on the vehicle in order to determine if the circuit
breakers reset automatically.
Aftermarket Engine Protection further details.
Devices 3. Crank the engine and monitor the injection
1. Check aftermarket engine protection devices. actuation pressure and the output of the injection
These devices usually interrupt power to the actuation pressure control valve. The high
ECM and the ECM will not communicate with the pressure oil system is operating properly if the
Electronic Service Tool. pressure output is a minimum of 6 MPa (870 psi).
2. Check for the correct installation of the 4. Connect the electronic service tool and check for
aftermarket engine protection device. event code 164-11 injection actuation pressure
system fault . If an 164-11 event code has
3. Check for the correct operation of the aftermarket been logged recently, refer to Troubleshooting,
engine protection device. Injection Actuation Pressure System-Test.
4. Verify that the ECM is receiving battery voltage. ECM or Personality Module
Fuel Supply Check the ECM or the Personality Module.
1. Monitor the exhaust for smoke while the engine Refer to Troubleshooting, ECM Memory - Test.
is being cranked.
i01352083
with the fuel quality or there may be a problem Intermittent Low Power or
Power Cutout
SMCS Code: 7569
Adjusting, Fuel Quality - Test. Also refer to
Guide, LEBT3477. Probable Causes
3. Check the fuel pressure. Refer to Testing and The probable root causes are listed in order below:
Electrical connections
Refer to Testing and Adjusting, Fuel System - Engine Monitoring
Prime.
Battery power or ground to the ECM
Electronic system
Accelerator pedal position sensor
for solidified fuel (wax). Vehicle speed signal
Power train data link
85
Fuel supply 2. Monitor the Fuel Position, the Rated Fuel Limit
and the FRC Fuel Limit.
Torque limit switch
Low injection actuation pressure parameters should meet the following conditions:
Recommended Actions The Fuel Position is equal to the Rated Fuel

Limit.
order: The Fuel Position is less than the FRC Fuel
Limit.
Electrical Connectors If the Fuel Position is equal to the Rated Fuel

Limit and the Fuel Position is less than the FRC
Check the vehicle harness and the connectors. Fuel Limit, the electronics are operating correctly.
Refer to Troubleshooting, Inspecting Electrical Proceed to Vehicle Speed Signal.
Connectors.
3. If the Fuel Position is not equal to the Rated Fuel
Engine Monitoring Limit and/or the Fuel Position is not less than
the FRC Fuel Limit, perform the following tests
1. Check the parameters for Engine Monitoring. in order:
2. Connect an electronic service tool. 4. When the engine is off, turn the ignition key
switch to the ON position. Check the boost
3. Check for diagnostic codes that are capable of pressure on an Electronic Service Tool Status
derating the engine when Engine Monitoring is Screen.
programmed to Derate or Shutdown.
When the engine is off, the boost pressure
110-00 High Coolant Temperature Warning (61)
110-11 Very High Coolant Temperature (61) Accelerator Pedal Position Sensor
111-11 Very Low Coolant Level (62) Monitor the status of the accelerator pedal position
sensor. Operate the engine at high idle with the
Battery Power or Ground to the vehicle in neutral.
ECM If the engine can not reach the programmed
Top Engine Limit, check the duty cycle of the
1. Ensure that the following connectors have been accelerator pedal position sensor in order to ensure
installed correctly: that the duty cycle is within calibration (75 to 90
Percent at high idle).
ECM connectors (J1/P1 and J2/P2) with
seventy pins If the accelerator pedal position is unstable,
check the duty cycle of the accelerator pedal
Injector connector (J300/P300) position sensor. Check the duty cycle of the
accelerator pedal position sensor by slowly
Camshaft position sensor connector operating the accelerator pedal in order to verify
(J401/P401 and J402/P402) that the accelerator pedal position sensor is within
calibration. The accelerator pedal position sensor
2. Use an electronic service tool to check for a is within calibration when both of the following
diagnostic code 168-02 (Intermittent Battery conditions are met:
Power to the ECM). Check the power connections
for the ECM and the ground connections for the 10 to 22 percent at low idle
ECM. If a problem is suspected, wire a bypass.
Refer to Troubleshooting, Ignition Key Switch 75 to 90 percent at high idle
Circuit and Battery Supply Circuit - Test(51).
Also, ensure that the duty cycle changes as the
Electronic System pedal position changes.

86
If a problem with the accelerator pedal position 8. Check for air in the fuel system. Refer to Testing
sensor is suspected, refer to Troubleshooting, and Adjusting, Air in Fuel - Test.
- Test.
Torque Limit Switch
Vehicle Speed Signal 1. Connect an Electronic Service Tool.
Monitor the vehicle speed signal. Ensure the 2. Check the setting for the Customer Parameter
accuracy of the vehicle speed signal by comparing for the Torque Limit.
If the Torque Limit is programmed below
If the vehicle speed is greater than the VSL, the 2712 Nm (2000 lb ft), check the status screen
Power is limited. If a problem is discovered, refer to for the torque limit switch. Ensure that the status
Troubleshooting, Vehicle Speed Circuit - Test. screen indicates that the torque limit switch is
off. If the status of the torque limit switch is
on and a Torque Limit is programmed, the
Power Train Data Link system is operating correctly. If the switch that is
connected to this signal input is not switching on
1. Check the Power train Data Link. Ensure that
and switching off, refer to Troubleshooting, PTO
the SAE J1939 Power Train Data Link is not
Switch Circuit - Test.
limiting the power.
2. Connect an Electronic Service Tool. Low Injection Actuation Pressure

3. Monitor the Power train Data Link status screen 1. Check the engine oil level. Engine oil is used to
while the vehicle is experiencing problems. activate the high pressure hydraulic pump.
If the Power Train Data Link status screen 2. Ensure that the engine oil meets the
indicates that the Power Train Data Link is recommendations of the engine manufacturer.
limiting the power or the rpm, verify that this Refer to Operation and Maintenance Manual for
is not normal operation. If this is not normal further details.
operation, refer to the vehicle OEM for repairs.
actuation pressure and the output of the injection
Fuel Supply actuation pressure control valve. The high
pressure oil system is operating properly if the
1. Monitor the exhaust for smoke while the engine
pressure output is a minimum of 6 MPa (870 psi).
is being cranked.
event code 164-11 injection actuation pressure
system fault . If an 164-11 event code has
Truck Performance and Driveability Diagnostic i01531049
Guide, LEBT3477.
Low Power/Poor or No
3. Check the fuel pressure. Refer to Testing and Response to Throttle
SMCS Code: 7569
Prime. Probable Causes
5. Check for fuel supply lines that are restricted. The probable root causes are listed in order below:
6. Check the fuel filters. Customer Specified Parameters (normal

operation)
for solidified fuel (wax). Cold Mode Operation
87
Torque limit switch Torque Limit Switch

Electronic system 1. Connect an Electronic Service Tool.
Vehicle speed signal 2. Check the setting for the Customer Parameter
for the Torque Limit.
Power train data link
Fuel supply 2712 Nm (2000 lb ft), check the status screen
for the torque limit switch. Ensure that the status
Air Inlet and exhaust system screen indicates that the torque limit switch is
off. If the status of the torque limit switch is
Malfunction of an individual cylinder on and a Torque Limit is programmed, the
system is operating correctly. If the switch that is
Low injection actuation pressure connected to this signal input is not switching on
and switching off, refer to Troubleshooting, PTO
Recommended Actions Switch Circuit - Test.
Perform the following tests in order: Electronic System

Customer Specified Parameters 1. Connect an Electronic Service Tool.
1. Check Customer Specified Parameters. 2. Monitor the Fuel Position, the Rated Fuel Limit
and the Fuel Limit for the Fuel Ratio Control
2. Verify that the complaint is not normal operation (FRC).
(programmed parameter).
3. Connect an Electronic Service Tool. parameters should meet the following conditions:
4. Check the following parameters: The Fuel Position is equal to the Rated Fuel
Limit.
Rating Number
The Fuel Position is less than the FRC Limit.
Top Engine Limit If the Fuel Position is equal to the Rated Fuel
Vehicle Speed Limit Limit, the Electronics are operating correctly.
Proceed to Vehicle Speed Signal.
3. If the Fuel Position is not equal to the Rated Fuel
Intermediate Gears Engine RPM Limit Limit and/or the Fuel Position is not less than the
Gear Down Protection Engine RPM Limit
5. Set each parameter to the parameters maximum 4. When the engine is off, turn the ignition key
value one at a time and determine whether the switch to the ON position. Check the boost
problem is corrected. pressure on an Electronic Service Tool status
screen.
Cold Mode Operation When the engine is off, the boost pressure
Accelerator Pedal Position
verify that the engine has progressed from cold 2. Monitor the status of the accelerator pedal
mode. position sensor. Operate the engine at high idle
with the vehicle in neutral.
An active cold mode is indicated in the upper
corner of any status screen.
88
If the engine can not reach the programmed Fuel Supply

Top Engine Limit, check the duty cycle of the
accelerator pedal position sensor in order to 1. Monitor the exhaust for smoke while the engine
ensure that the duty cycle of the accelerator is being cranked.
pedal position sensor is within calibration (75 to
90 Percent at high idle). If no smoke is present, there may be a problem
If the accelerator pedal position is unstable, with the fuel supply.
check the duty cycle of the accelerator pedal
position sensor. Check the duty cycle of the 2. Check the fuel quality. Refer to Testing and
accelerator pedal position sensor by slowly Adjusting, Fuel Quality - Test. Also refer to the
operating the accelerator pedal in order to verify Truck Performance and Driveability Diagnostic
that the accelerator pedal position sensor is Guide, LEBT3477.
within calibration. The accelerator pedal position
sensor is within calibration when both of the 3. Check the fuel pressure. Refer to Testing and
following conditions are met: Adjusting, Fuel System Pressure - Test.
10 to 22 percent at low idle 4. Ensure that the fuel system has been primed.
75 to 90 percent at high idle Prime.
Also, ensure that the duty cycle changes as the 5. Check for fuel supply lines that are restricted.
pedal position changes.
If a problem with the accelerator pedal position
sensor is suspected, refer to Troubleshooting, 7. If the temperature is below 0 C (32 F), check
Accelerator Pedal (Throttle) Position Sensor for solidified fuel (wax).
Circuit - Test.
8. Check for air in the fuel system. Refer to Testing
Vehicle Speed Signal and Adjusting, Air in Fuel - Test.
Monitor the vehicle speed signal. Ensure the Air Inlet and Exhaust System
accuracy of the vehicle speed signal by comparing
the vehicle speed signal to the actual vehicle speed. 1. Check for leakage in the air-to-air aftercooler
core . Refer to Testing and Adjusting, Aftercooler
If the vehicle speed is greater than the VSL, the - Test.
Power is limited. If a problem is discovered, refer to
Troubleshooting, Vehicle Speed Circuit - Test. 2. Check the air inlet system for restrictions
or leakage. Check the exhaust system for
Power Train Data Link restrictions or leakage. Refer to Testing and
Adjusting, Air Inlet and Exhaust System -
1. Check the Power Train Data Link. Ensure that Inspect.
the SAE J1922 or the SAE J1939 Power Train
Data Link is not limiting the power. Individual Cylinder Malfunction
2. Connect an Electronic Service Tool. 1. Ensure that the electronic unit injector connector
(J300/P300) is fully connected and ensure that
3. Monitor the Power Train Data Link status screen the electronic unit injector connector (J300/P300)
while the vehicle is experiencing problems. is free of corrosion.
If the Power Train Data Link status screen 2. Ensure that the ECM engine harness connector
indicates that the Power Train Data Link is (J2/P2) is fully connected and ensure that the
limiting the power or the rpm, verify that this engine harness connector (J2/P2) is free of
is not normal operation. If this is not normal corrosion.
operation, refer to the vehicle OEM for repairs.
89
3. Connect an Electronic Service Tool. Use the Injection actuation pressure

Test by selecting the Diagnostic Menu and Combustion problem
Recommended Actions
order:
If the misfiring cylinder can be isolated to
Injector Solenoid Circuit - Test. Customer Specified Parameters
4. Perform a Performance Analysis Report (PAR). 1. Check Customer Specified Parameters.

Low Injection Actuation Pressure (programmed parameter).
4. Check the following parameters:
Refer to Operation and Maintenance Manual for Rating Number
further details.
Top Engine Limit
actuation pressure and the output of the injection Vehicle Speed Limit
actuation pressure control valve. The high
pressure oil system is operating properly if the Lower Gears Engine RPM Limit
pressure output is a minimum of 6 MPa (870 psi).
event code 164-11 injection actuation pressure Gear Down Protection Engine RPM Limit
system fault . If an 164-11 event code has 5. Set each parameter to the parameters maximum
value one at a time and determine whether the
problem is corrected.
i01531171 Electronic System

Poor Acceleration or Response 1. Connect an Electronic Service Tool.
SMCS Code: 1000; 7569
2. While the problem is occurring, check for
diagnostic codes that are related to the boost
Probable Causes pressure sensor and the atmospheric pressure
sensor. If a diagnostic code is found, refer to
The probable root causes are listed in order below: Troubleshooting, Engine Pressure Sensor Open
or Short Circuit - Test.
Customer Specified Parameters
3. Monitor the Fuel Position, the Rated Fuel Limit
Electronic system and the Fuel Limit for Fuel Ratio Control (FRC).
Cold Mode Operation While the vehicle is operating under full load, the
parameters should meet the following conditions:
Malfunction of an individual cylinder
The Fuel Position is equal to the Rated Fuel
Power Train Data Link Limit.
ECM or Personality Module The Fuel Position is less than the FRC Limit.
Torque limit switch If the Fuel Position is equal to the Rated Fuel
Theft Deterrent Limit, the Electronics are operating correctly.
90
4. If the Fuel Position is not equal to the Rated Fuel 3. Monitor the Power Train Data Link status screen
Limit and/or the Fuel Position is not less than the while the vehicle is experiencing problems.
If the Power Train Data Link status screen
5. When the engine is OFF, turn the ignition key indicates that the Power Train Data Link is
switch to the ON position. Check the boost limiting the power or the rpm, verify that this
pressure on an Electronic Service Tool status is not normal operation. If this is not normal
screen. operation, refer to the vehicle OEM for repairs.
When the engine is OFF, the boost pressure

ECM or Personality Module
Check the ECM or the Personality Module.
Cold Mode Operation
Refer to Troubleshooting, ECM Memory - Test.
Torque Limit Switch
2. Check the setting for the Customer Parameter
verify that the engine has progressed from cold
for the Torque Limit.
mode.
An active cold mode is indicated in the upper
2712 Nm (2000 lb ft), check the status screen
corner of any status screen.
for the torque limit switch. Ensure that the status
screen indicates that the torque limit switch is
Individual Cylinder Malfunction off. If the status of the torque limit switch is
on and a Torque Limit is programmed, the
1. Ensure that the electronic unit injector connector system is operating correctly. If the switch that is
(J300/P300) is fully connected and ensure that connected to this signal input is not switching on
the electronic unit injector connector (J300/P300) and switching off, refer to Troubleshooting, PTO
is free of corrosion. Switch Circuit - Test.
2. Ensure that the ECM engine harness connector

(J2/P2) is fully connected and ensure that the
Theft Deterrent
engine harness connector (J2/P2) is free of
Ensure that the theft deterrent (if equipped) is not
corrosion.
active. Turn the ignition switch to the ON position.
Observe the display screen on the CAT ID.
3. Connect an Electronic Service Tool. Use the
If the display screen on the CAT ID indicates that
Test by selecting the Diagnostic Menu and
the theft deterrent is enabled, the Theft Deterrent
Passwords must be entered before the engine will
start.
If the misfiring cylinder can be isolated to System
Injector Solenoid Circuit - Test. Note: Check the actual injection actuation pressure
against the desired injection actuation pressure.
4. Perform a Performance Analysis Report (PAR).
1. Crank the engine and monitor the Injection
Power Train Data Link actuation pressure and the injection actuation
pressure control valve. The high pressure oil
1. Check the Power Train Data Link. Ensure that system is operating properly if the pressure
the SAE J1939 Power Train Data Link is not output is a minimum of 6 MPa (870 psi).
limiting the power.

91

event code 164-11 injection actuation pressure
system fault. If an 164-11 event code has
Injection Actuation Pressure System - Test.
3. If higher than actual pressure is being indicated,

then disconnect the injection actuation pressure
sensor and try to start the engine. If the engine
starts, refer to Troubleshooting, Injection
Actuation Pressure Sensor - Test.
Combustion Problem
Check for combustion problems.
Examples of combustion problems are shown in the

following list:
Outside temperatures are too cold.

Mechanical problem
92
Troubleshooting with a If the cause of the diagnostic code is a short circuit

or an open circuit in the injector common line, a
Diagnostic Code fault will be active for both cylinders because of the
shared common wiring for the injectors.
i01501859 System Response:

No Diagnostic Code Detected Electronic System Response The ECM will
(55) illuminate the Check Engine Lamp while the fault is
active. The ECM will log the diagnostic code.
SMCS Code: 1000; 1900
Engine Response The injector may not operate
Conditions Which Generate This Code: while the conditions exist. If the problem is in the
common return line, neither injector will operate.
A Flash Code 55 indicates that the system has not
detected any system faults since the last powerup. Troubleshooting:
System Response: Perform the following diagnostic procedure:

Injector Solenoid Circuit - Test
This code will not appear on a service tool. The
check engine lamp is used to display the flash Results:
code. For more information on flash codes, refer
to Troubleshooting, Check Engine Lamp Circuit - OK STOP.
Test.
i01226276
Troubleshooting:
0002-11 Cylinder 2 Fault (72)
There are no problems that require troubleshooting.
SMCS Code: 1290-038
Results:
OK STOP.
The ECM detects one of the following items after
attempting to operate the injector:
i01226267
0001-11 Cylinder 1 Fault (72) An open circuit exists in the wiring for the No. 2
cylinder injector solenoid.
SMCS Code: 1290-038
An internal open circuit exists in the No. 2 cylinder
Conditions Which Generate This Code: injector solenoid.
The ECM detects one of the following items after A short circuit to ground on the injector solenoid
attempting to operate the injector: for the No. 2 cylinder exists. The circuit is
grounded to the engine.
An open circuit exists in the wiring for the No. 1
cylinder injector solenoid. A short circuit in the injector solenoid for the No.
2 cylinder exists.
injector solenoid. A short circuit in the injector solenoid to battery
voltage for the No. 2 cylinder exists.
A short circuit to ground on the injecor solenoid
for the No. 1 cylinder exists. The circuit is If the cause of the diagnostic code is a short circuit
grounded to the engine. or an open circuit in the injector common line, a
fault will be active for both cylinders because of the
A short circuit in the injector solenoid for the No. shared common wiring for the injectors.
1 cylinder exists.
A short circuit in the injector solenoid to battery

voltage for the No. 1 cylinder exists.
93
System Response: Troubleshooting:
Electronic System Response The ECM will Perform the following diagnostic procedure:
illuminate the Check Engine Lamp while the fault is Injector Solenoid Circuit - Test
Results:
while the conditions exist. If the problem is in the OK STOP.
i01226311
Troubleshooting:
Perform the following diagnostic procedure:

Injector Solenoid Circuit - Test SMCS Code: 1290-038
Results: Conditions Which Generate This Code:
OK STOP. The ECM detects one of the following items after
i01226301
An open circuit exists in the wiring for the No. 4
0003-11 Cylinder 3 Fault (73) cylinder injector solenoid.
SMCS Code: 1290-038 An internal open circuit exists in the No. 4 cylinder
injector solenoid.
A short circuit to ground on the injector solenoid
The ECM detects one of the following items after for the No. 4 cylinder exists. The circuit is
attempting to operate the injector: grounded to the engine.
An open circuit exists in the wiring for the No. 3 A short circuit in the injector solenoid for the No.
cylinder injector solenoid. 4 cylinder exists.
An internal open circuit exists in the No. 3 cylinder A short circuit in the injector solenoid to battery
injector solenoid. voltage for the No. 4 cylinder exists.
A short circuit to ground on the injector solenoid If the cause of the diagnostic code is a short circuit
for the No. 3 cylinder exists. The circuit is or an open circuit in the injector common line, a
grounded to the engine. fault will be active for both cylinders because of the
A short circuit in the injector solenoid for the No.
3 cylinder exists. System Response:
A short circuit in the injector solenoid to battery Electronic System Response The ECM will
voltage for the No. 3 cylinder exists. illuminate the Check Engine Lamp while the fault is
If the cause of the diagnostic code is a short circuit
or an open circuit in the injector common line, a Engine Response The injector may not operate
fault will be active for both cylinders because of the while the conditions exist. If the problem is in the
shared common wiring for the injectors. common return line, neither injector will operate.
Electronic System Response The ECM will Perform the following diagnostic procedure:
illuminate the Check Engine Lamp while the fault is Injector Solenoid Circuit - Test
Results:
while the conditions exist. If the problem is in the OK STOP.
94
i01226327 An open circuit exists in the wiring for the No. 6

SMCS Code: 1290-038 injector solenoid.
Conditions Which Generate This Code: A short circuit to ground on the injector solenoid
for the No. 6 cylinder exists. The circuit is
The ECM detects one of the following items after grounded to the engine.
A short circuit in the injector solenoid for the No.
An open circuit exists in the wiring for the No. 5 6 cylinder exists.
A short circuit in the injector solenoid to battery
An internal open circuit exists in the No. 5 cylinder voltage for the No. 6 cylinder exists.
injector solenoid.
If the cause of the diagnostic code is a short circuit
A short circuit to ground on the injector solenoid or an open circuit in the injector common line, a
for the No. 5 cylinder exists. The circuit is fault will be active for both cylinders because of the
grounded to the engine. shared common wiring for the injectors.
A short circuit in the injector solenoid for the No. System Response:
5 cylinder exists.
Electronic System Response The ECM will
A short circuit in the injector solenoid to battery illuminate the Check Engine Lamp while the fault is
voltage for the No. 5 cylinder exists. active. The ECM will log the diagnostic code.
If the cause of the diagnostic code is a short circuit Engine Response The injector may not operate
or an open circuit in the injector common line, a while the conditions exist. If the problem is in the
fault will be active for both cylinders because of the common return line, neither injector will operate.
Troubleshooting:
System Response:
Electronic System Response The ECM will Injector Solenoid Circuit - Test
illuminate the Check Engine Lamp while the fault is
active. The ECM will log the diagnostic code. Results:
Engine Response The injector may not operate OK STOP.
while the conditions exist. If the problem is in the
i01226262
Troubleshooting:
0022-13 Check Timing Sensor
Perform the following diagnostic procedure: Calibration (42)
Injector Solenoid Circuit - Test
SMCS Code: 1912-038
Results:
OK STOP.
The timing has not been calibrated since the ECM
was installed or the calibration is out of specification
i01226335
by an amount that is greater than the amount that
0006-11 Cylinder 6 Fault (74) is allowed by the ECM.
SMCS Code: 1290-038 System Response:
Conditions Which Generate This Code: Electronic System Response The ECM uses
default timing. Timing can be out of specification by
The ECM detects one of the following items after as much as 4 degrees.
95
Engine Response The engine may run rough or the i01368633

engine may emit white smoke in the exhaust. There
may not be any noticeable performance effect. 0030-13 PTO Throttle Sensor
Troubleshooting:
Calibration (29)
SMCS Code: 1913-524
Perform the following diagnostic procedure: Engine
Speed/Timing Sensor - Calibrate Conditions Which Generate This Code:
Results: The PTO Configuration is a Customer Parameter.
OK STOP. Throttle. The duty cycle of the PTO Accelerator
signal is less than 5 percent or more than 95
i01368614
percent.
0030-08 Invalid PTO Throttle System Response:

Signal (29) Electronic System Response The ECM returns the
engine to low idle when the problem is detected.
SMCS Code: 1913-038
Service Tool Display or Lamps The Service Tool
Conditions Which Generate This Code: will indicate 0 percent Throttle Position for the PTO
The PTO Configuration is a Customer Parameter. Diagnostic Code is Active.
Throttle. The ECM is not receiving a correct PTO Engine Response The engine will remain at low
accelerator signal. idle while the Diagnostic Code is Active.
Note: If the PTO Configuration is programmed to Troubleshooting:
signal from the Remote Accelerator Position Sensor Note: The Remote Accelerator Pedal Position
at all times. The remote throttle signal must be Sensor can not be calibrated.
the OFF position. Perform the following diagnostic procedure:
System Response: Test
Electronic System Response The ECM returns the Results:
Service Tool Display or Lamps The Service Tool

OK STOP.
Accelerator Sensor Status parameter while the i01385778
0041-03 8 Volt Supply Above
Normal (21)
SMCS Code: 1408-081; 1900-038; 1901-038
Troubleshooting:
The diagnostic code is probably caused by an
open circuit in the Accelerator Pedal Position Signal The supply voltage for the accelerator pedal
circuit or an open circuit in the 12 volt sensor supply position sensor is too high.
frequency can also cause this code. System Response:
Perform the following diagnostic procedure: Engine Response An active diagnostic code may
Remote PTO Accelerator Position Sensor Circuit - not cause any noticeable effect on engine response
Test unless the voltage is significantly above 8 volts. The
engine may be limited to Low Idle.
Results:
OK STOP.
96
Troubleshooting: System Response:
Perform the following diagnostic procedure: Electronic System Response The ECM will cycle
Accelerator Pedal (Throttle) Position Sensor Circuit the control valve for the injection actuation system
- Test ON and OFF. The ECM will cycle the control valve
several times in a second when the engine is
Results: running. The fault is active.
OK STOP. Engine Response The engine will stop running if

the signal line for the control valve for the injection
actuation system is shorted to ground.
i01385907
0041-04 8 Volt Supply Below If the pressure sensor common for the control valve
is shorted to ground, the following conditions may
Normal (21) exist:
SMCS Code: 1408-081; 1900-038; 1901-038 The engine may continue to run.
Conditions Which Generate This Code: The idle may be unstable.
The supply voltage for the accelerator pedal Troubleshooting:
position sensor is lower than the required voltage.
System Response: Injection Actuation Pressure Control Valve Circuit -
Test
Engine Response An active diagnostic code may
not cause any noticeable effect on engine response Results:
unless the voltage is significantly below 8 volts. The
engine may be limited to Low Idle. OK STOP.
Troubleshooting:
i01207194
0043-02 Ignition Key Switch
- Test Fault (71)
Results: SMCS Code: 1416-038; 1553-038
OK STOP. Conditions Which Generate This Code:
This indicates that the battery circuit to the Ignition

i01388687
Key Switch has an intermittent condition or a low
0042-11 Injection Actuation Pr battery condition while the engine is running.
Control Valve Driver (18) Note: This code can be generated by rapidly
cycling the Ignition Key Switch. Some control
SMCS Code: 1408-081; 5051-038 modules on the vehicle require this action in order
to prompt flash codes. If this occurs, clear the
Conditions Which Generate This Code: logged diagnostic codes in order to prevent future
confusion or an incorrect diagnosis.
The ECM detected one of the following conditions:
Note: This code can also be generated when an
Open circuit attempt is made in order to restart the engine
immediately after a shutdown. The engine may not
Short to ground start if the engine speed did not reach 0 rpm prior
to the restart.
Short to + battery
Short across the solenoid when the engine is
running.
97
System Response: i01387414
Electronic System Response The ECM may stop 0064-11 No Pattern on Speed
the fuel injection process. This response depends
on the amount of time that occurs in the fault mode.
Sensor #2 (34)
SMCS Code: 1907-038
Engine Response The engine may experience
burps in engine rpm, and engine shutdowns that Conditions Which Generate This Code:
are intermittent or complete.
The signal for the camshaft position sensor 2
Service Tool Display or Lamps The Check Engine (bottom) is lost.
Lamp and the Warning Lamps may come on as
if the Ignition Keyswitch was turned on and the System Response:
engine started.
Electronic System Response The check engine
Troubleshooting: lamp will not be illuminated for this code unless the
code has been Active for 10 hours. The code is
Perform the following diagnostic procedure: Ignition logged.
Key Switch Circuit - Test
Engine Response There should not be a noticeable
Results: change in engine response unless the signal for the
camshaft position sensor 1 (top) is lost. This loss
OK STOP. will shut down the engine.
i01387393
Troubleshooting:
0064-02 Loss of Engine RPM Perform the following diagnostic procedure: Engine
Speed/Timing Sensor Circuit - Test
Signal #2 (34)
Results:
SMCS Code: 1408-081; 1907-038

OK STOP.
The signal for the camshaft position sensor 2 i01387436

(bottom) is intermittent or lost.
0070-05 Inlet Air Heater Open
System Response: Circuit (49)
Electronic System Response The check engine SMCS Code: 1408-081; 1907-038
lamp will not be illuminated for this code unless the
code has been Active for 10 hours. The code is Conditions Which Generate This Code:
logged.
The ECM has detected an open circuit after
Engine Response There should not be a noticeable attempting to activate the air inlet heater.
change in engine response unless the signal for the
camshaft position sensor 1 (top) is lost. This loss System Response:
will shut down the engine.
Electronic System Response The ECM is unable
Troubleshooting: to activate the air inlet heater.
Perform the following diagnostic procedure: Engine Engine Response The engine may be difficult to
Speed/Timing Sensor Circuit - Test start in the cold temperature and the exhaust may
emit white smoke.
Results:
Troubleshooting:
OK STOP.
Perform the following diagnostic procedure: Air
Inlet Heater Circuit - Test
Results:
OK STOP.
98

0070-06 Inlet Air Heater Short Electronic System Response The idle shutdown
Circuit (49) timer stops counting. The idle shutdown timer will
not begin counting again for shutdown until the
SMCS Code: 1090-038; 1408-081 vehicle is moved and the accelerator pedal is
depressed. The diagnostic code requires Customer
Conditions Which Generate This Code: Passwords in order to be cleared from memory.
The ECM has detected an open circuit or an short Service Tool Display or Lamps This code does not
circuit after attempting to activate the air inlet heater. illuminate the Check Engine Lamp.
System Response: Engine Response The only effect on engine

response is the fact that the engine will not shut
Electronic System Response The ECM is unable down until the timer has been reset. The timer
to activate the air inlet heater. is reset by moving the vehicle or cycling the
keyswitch. The timer can also be reset by quickly
Engine Response The engine may be difficult to depressing the accelerator pedal and quickly
start in the cold temperature and the exhaust may releasing the accelerator pedal.
emit white smoke.
NOTE: The Timer cannot be overridden by using the
Troubleshooting: service brakes or by using the clutch if the Allow
Idle Shutdown Override parameter is programmed
Perform the following diagnostic procedure: Air to NO.
Inlet Heater Circuit - Test
Troubleshooting:
Results:
OK STOP. Shutdown Timer - Test
Results:
i01225425
0071-00 Idle Shutdown OK STOP.

Override (01) i01225443
SMCS Code: 1900-038; 1901-038 0071-01 Idle Shutdown

Conditions Which Generate This Code: Occurrence (47)
The brake pedal or the clutch pedal is depressed SMCS Code: 1900
during the last 90 seconds of the idle shutdown
mode after the Check Engine Lamp begins to flash. Conditions Which Generate This Code:
The Allow Idle Shutdown Override parameter must
be programmed to one of the following options: The idle timer has expired and the engine has shut
down.
Yes
Outside Temperature Based does not represent an Electronic System fault.
J1587 Outside Temperature Based System Response:
NOTE: This diagnostic code represents an event. Electronic System Response The ECM remains
This diagnostic code does not represent an powered after the engine shutdown.
Electronic System fault.
code.

99
Perform the following diagnostic procedure: Idle Electronic System Response The ECM will stop
Shutdown Timer - Test fueling the injectors while the diagnostic code is
Active. This diagnostic code requires a Customer
Results: Password in order to be cleared.
OK STOP. Engine Response The engine is not fueled until the

vehicle speed is reduced.
i01225477
Troubleshooting:
0071-14 PTO Shutdown Timer This diagnostic code represents an event. This
Occurrence (47) diagnostic code does not represent an electronic
system fault. There are no problems that require
SMCS Code: 1900 troubleshooting.
Conditions Which Generate This Code: Expected Result:
The timer for the PTO has expired and the engine Results:
has shut down.
OK STOP.
does not represent an Electronic System fault.
i01208127
System Response:
0084-01 Loss of Vehicle Speed
Electronic System Response The ECM remains Signal (31)
SMCS Code: 1900
Passwords are required to clear this diagnostic Conditions Which Generate This Code:
code.
The ECM does not detect vehicle speed when
Engine Response The engine is shut down. conditions indicate that vehicle speed should be
present. This diagnostic code will not occur if the
Troubleshooting: VSL Protection parameter is programmed to 2120
rpm.
Shutdown Timer - Test System Response:
Results: Electronic System Response The ECM will limit

engine rpm to the programmed VSL Protection. If
OK STOP. the ECM is providing the speedometer signal, the
speedometer will reflect the loss of speed when the
vehicle is moving and the problem occurs.
i01226601
0084-00 Vehicle Overspeed Engine Response The driver may think that the
engine power is low and that the engine is unable
Warning (41) to reach the expected rpm.
SMCS Code: 1900 Note: A fuel system restriction has been known to
cause this diagnostic code although this occurrence
Conditions Which Generate This Code: is not common. This situation exists because the
injectors are unable to provide sufficient fuel in
The vehicle speed has exceeded the programmed order to achieve the desired rpm under normal load
Vehicle Speed Limit by more than ten mph for conditions. Because the ECM cannot reach the
at least 20 seconds. This diagnostic code will not desired rpm under the normal load conditions, the
occur if the other vehicle speed circuit diagnostic ECM suspects that the vehicle is under load. This
codes are active. should only occur when the vehicle is in motion.
Note: This code represents a critical event. This

code does not represent an Electronic System fault.
100
Troubleshooting: i01208146
Check the fuel pressure in order to ensure that 0084-08 Vehicle Speed Out of
a fuel system restriction is not the cause of the
problem when the vehicle is not moving.
Range (36)
SMCS Code: 1900
Perform the following diagnostic procedure: Vehicle
Speed Circuit - Test Conditions Which Generate This Code:
Results: The VSL Protection parameter is programmed less
than 2120 rpm and the vehicle speed is greater
OK STOP. than 204 km/h (127 mph) for at least two seconds.
This diagnostic code will not occur if the VSL
i01208133
Protection parameter is programmed to 2120 rpm.
0084-02 Invalid Vehicle Speed System Response:

Signal (36) Electronic System Response Vehicle speed is
set to 0 km/h (0 mph) and engine rpm is limited
SMCS Code: 1900 to the programmed VSL Protection. If the ECM is
providing the speedometer signal, the speedometer
Conditions Which Generate This Code: will reflect the loss of speed when the problem
occurs and the vehicle is moving.
The VSL Protection is programmed less than
2120 rpm, and the vehicle speed is constant when Engine Response The driver may think that the
the engine parameters indicate that the vehicle engine power is low and that the engine is unable
speed should be changing. This diagnostic code to reach the expected rpm.
will not occur if the VSL Protection parameter is
programmed to 2120 rpm. Troubleshooting:
Note: This code typically occurs when someone has Perform the following diagnostic procedure: Vehicle
tampered with the Vehicle Speed Signal. Speed Circuit - Test
System Response: Results:
Electronic System Response Engine rpm is limited
to the programmed VSL Protection for one hour. If
OK STOP.
the ECM is providing the speedometer signal, the
speedometer will reflect the loss of speed when the i01208376
problem occurs and the vehicle is moving.
0084-10 Vehicle Speed Rate of
Engine Response The driver may think that the
Change (36)
to reach the expected rpm. The derate will remain SMCS Code: 1900
for one hour after the fault is no longer active.
Troubleshooting:
This condition involves the vehicle speed that is
Perform the following diagnostic procedure: Vehicle changing at an impossible rate. This diagnostic
Speed Circuit - Test code will not occur if the VSL Protection parameter
is programmed to 2120 rpm.
Results:
System Response:
OK STOP.
Electronic System Response Engine rpm is limited
to the programmed VSL Protection.
Engine Response The driver may think that the

to reach the expected rpm.
101
Perform the following diagnostic procedure: Vehicle 0091-13 Throttle Sensor

Speed Circuit - Test Calibration (28)
Results: SMCS Code: 1913-524
i01208080
The duty cycle for the Accelerator Pedal Position
Sensor signal is less than 5 percent or more than
0091-08 Invalid Throttle Signal 95 percent.
(32) System Response:
SMCS Code: 1913-038 Electronic System Response The ECM returns the
Service Tool Display or Lamps The Electronic
The ECM is not receiving a correct accelerator Service Tool will indicate a Throttle Position of 0
pedal position signal. percent while the Diagnostic Code is Active.
System Response: Engine Response The engine will remain at low
engine to low idle when the problem is detected. Troubleshooting:
Service Tool Display or Lamps The Service Tool Perform the following diagnostic procedure:
will indicate a Throttle Position of 0 percent while Accelerator Pedal (Throttle) Position Sensor Circuit
the Diagnostic Code is Active. This will happen - Test
regardless of the position of the Accelerator Pedal
Assembly. Results:
OK STOP.
This diagnostic code is likely to be caused by an 0100-03 Oil Pressure Sensor

open circuit in the signal circuit for the accelerator
pedal position, or a significant change in the signal
Open Circuit (24)
frequency. SMCS Code: 1408-081; 1924-038
Perform the following diagnostic procedure: Conditions Which Generate This Code:
- Test The Oil Pressure signal voltage is above the
acceptable range.
Results:
System Response:
OK STOP.
Electronic System Response Oil Pressure is set
to 600 kPa (87 psi).

Service Tool will indicate 600 kPa (87 psi) while
the Diagnostic Code is Active and DIAG will be
displayed on the Status Screen.
Engine Response The engine may experience low

power when the Diagnostic Code is Active.
102
Perform the following diagnostic procedure: Engine Electronic System Response The ECM response
Pressure Sensor Open or Short Circuit - Test depends on the programming of the Customer
Parameter for Engine Monitoring. The Event Code
Results: will be logged if the Engine Monitoring is not
programmed OFF.
OK STOP.
This diagnostic code requires a Customer Password
in order to be cleared.
i01226382
0100-04 Oil Pressure Sensor If Engine Monitoring is programmed to WARNING,

The Check Engine Lamp will flash and the Warning
Short Circuit (24) Lamp will illuminate continuously.
SMCS Code: 1408-081; 1924-038 If Engine Monitoring is programmed to DERATE

or SHUTDOWN, the Check Engine Lamp and the
Conditions Which Generate This Code: Warning Lamp will flash.
The Oil Pressure signal voltage is below the Engine Response If the Engine Monitoring is
acceptable range. programmed to WARNING, there is no effect on
engine power.
System Response:
If the Engine Monitoring is programmed to
Electronic System Response Oil Pressure is set DERATE or SHUTDOWN, engine speed is limited
to 600 kPa (87 psi). to a maximum of 1350 rpm. The Vehicle speed is
limited to a maximum of 72 km/h (45 mph), and the
Service Tool Display or Lamps The Electronic power is limited. The engine will shut down if the
Service Tool will indicate 600 kPa (87 psi) while conditions exist for a long enough period in the
the Diagnostic Code is Active and DIAG will be SHUTDOWN mode.
Troubleshooting:
power when the Diagnostic Code is Active. This diagnostic code indicates very low oil pressure.
This diagnostic code does not indicate a problem
Troubleshooting: with the ECM or the Oil Pressure Sensor. Refer
to graphs for oil pressure that are shown in
Perform the following diagnostic procedure: Engine Troubleshooting, System Overview.
Pressure Sensor Open or Short Circuit - Test
Perform the following diagnostic procedure: Event
Results: Codes - Test
OK STOP. Results:
i01226645
OK STOP.
0100-11 Very Low Oil Pressure i01226391
(46) 0102-03 Boost Pressure
SMCS Code: 1924-038 Sensor Open Circuit (25)
Conditions Which Generate This Code: SMCS Code: 1408-081; 1917-038
Oil pressure is extremely low. Engine Monitoring Conditions Which Generate This Code:
must be programmed to WARNING, DERATE, or
SHUTDOWN before this diagnostic code can occur. The Boost Pressure signal voltage is above the
acceptable range.
Note: This diagnostic code represents a critical
event. This diagnostic code does not represent an
103
Electronic System Response Boost Pressure is 0102-07 Excessive Boost

set to 0 kPa (0 psi). Pressure
Service Tool Display or Lamps The Electronic SMCS Code: 1917-038
Service Tool will indicate 0 kPa (0 psi) while the
Diagnostic Code is Active and DIAG will be Conditions Which Generate This Code:
The boost pressure is higher than the boost pressure
Engine Response The engine may experience low that is required for normal operating conditions.
Note: The diagnostic code indicates a mechanical
Troubleshooting: problem. The ECM and the electronic control system
is operating correctly.
Pressure Sensor Open or Short Circuit - Test System Response:
Results: Electronic System Response Boost pressure is
set to 0 kPa (0 psi).
OK STOP.
Service Tool Display or Lamps The electronic
i01226397
service tool will indicate 0 kPa (0 psi) while the
diagnostic code is active and DIAG will be
0102-04 Boost Pressure displayed on the status screen.
Sensor Short Circuit (25) Engine Response The engine may experience low
power when the diagnostic code is active.
SMCS Code: 1408-081; 1917-038
Troubleshooting:
The diagnostic code indicates a problem with
The Boost Pressure signal voltage is below the the turbocharger, the wastegate, or a pinched
acceptable range. turbocharger line. The diagnostic code does not
indicate a problem with the ECM or the electronic
System Response: control system.
Electronic System Response Boost Pressure is Results:
set to 0 kPa (0 psi).

OK STOP.
Service Tool will indicate 0 kPa (0 psi) while the
Diagnostic Code is Active and DIAG will be i01486744
0105-00 High Inlet Manifold
Temp Warning (64)
SMCS Code: 1921-038
Troubleshooting:
Pressure Sensor Open or Short Circuit - Test The engine has been running for at least 30
seconds.
Results:
This indicates that the air temperature for the air
OK STOP. inlet manifold is above 90 C (194 F). Engine
Monitoring must be programmed to WARNING,
DERATE, or SHUTDOWN before this diagnostic
code can occur.
Note: This diagnostic code represents an critical

104
Electronic System Response The ECM does not Perform the following diagnostic procedure: Engine
derate the power. Also, the ECM does not limit Temperature Sensor Open or Short Circuit - Test
the engine rpm or the vehicle speed due to this
diagnostic code. Results:
The Check Engine Lamp will flash. OK STOP.

The Warning Lamp will illuminate if the Engine
i01226433
Monitoring is programmed to WARNING, DERATE,
or SHUTDOWN. 0105-04 Inlet Manifold Temp
This diagnostic code requires a Customer Password Sensor Short Circuit (38)
SMCS Code: 1408-081; 1921-038
Engine Response This diagnostic code does not
affect engine power. Conditions Which Generate This Code:
Troubleshooting: The Air Temperature signal voltage for the Inlet Air
Temperature Sensor is below the acceptable range.
This diagnostic code indicates an excessive
temperature in the air inlet manifold. This diagnostic System Response:
code does not indicate a problem with the ECM or
a problem with the temperature sensor for the air Electronic System Response The Inlet Manifold
inlet manifold. Air Temperature is set to 85 C (185 F) while the
Codes - Test Service Tool Display or Lamps The Check Engine
Lamp will NOT illuminate unless this Diagnostic
Results: Code has been Active for 10 hours. DIAG will be
OK STOP.
Engine Response Occasionally, the engine may
emit white smoke on start-up and misfire during
i01226419 cold ambient air temperatures.
0105-03 Inlet Manifold Temp Troubleshooting:
Sensor Open Circuit (38)
SMCS Code: 1408-081; 1921-038 Temperature Sensor Open or Short Circuit - Test
Conditions Which Generate This Code: Results:
The Air Temperature signal voltage for the Inlet Air OK STOP.
Temperature Sensor is above the acceptable range.
i01486733
System Response:
Electronic System Response The Inlet Manifold

0105-11 Very High Inlet
Air Temperature is set to 85 C (185 F) while the Manifold Temp (64)
SMCS Code: 1921-038
Service Tool Display or Lamps The Check Engine
Lamp will NOT illuminate unless this Diagnostic Conditions Which Generate This Code:
Code has been Active for 10 hours. DIAG will be
displayed on the Status Screen. The engine has been running for at least 30
seconds.
Engine Response Occasionally, the engine may
emit white smoke on start-up and misfire during This indicates that the air temperature for the air
cold ambient air temperatures. inlet manifold is above 110 C (230 F).
105
Note: This diagnostic code represents a critical i01226401

Electronic System fault. 0108-03 Atmospheric Pr
System Response:
SMCS Code: 1408-081; 1923-038
Electronic System Response The ECM response
depends on the programming of the Customer Conditions Which Generate This Code:
Parameter for Engine Monitoring. The Event Code
will be logged if the Engine Monitoring is not The Atmospheric Pressure signal voltage is above
programmed OFF. the acceptable range.
The Check Engine Lamp will flash. System Response:
If Engine Monitoring is programmed to WARNING, Electronic System Response Atmospheric
The Check Engine Lamp will flash and the Warning Pressure is set to 100 kPa (15 psi).
Lamp will illuminate continuously.
If Engine Monitoring is programmed to DERATE Service Tool will indicate 100 kPa (15 psi) while
or SHUTDOWN, the Check Engine Lamp and the the Diagnostic Code is Active and DIAG will be
Warning Lamp will flash. displayed on the Status screen.
This diagnostic code requires a Customer Password Engine Response The engine may experience low
in order to be cleared. power when the Diagnostic Code is Active.
Engine Response If the Engine Monitoring is Troubleshooting:
programmed to WARNING, there is no effect on
engine power. Perform the following diagnostic procedure: Engine
If the Engine Monitoring is programmed to
DERATE or SHUTDOWN, engine speed is limited Results:
to a maximum of 1350 rpm. The vehicle speed is
limited to a maximum of 72 km/h (45 mph), and the OK STOP.
power is limited. The engine will shut down if the
conditions exist for a long enough period in the
SHUTDOWN mode. i01226408
Troubleshooting: 0108-04 Atmospheric Pr

Sensor Short Circuit (26)
This diagnostic code indicates an excessive
temperature in the air inlet manifold. This diagnostic SMCS Code: 1408-081; 1923-038
code does not indicate a problem with the ECM or
a problem with the temperature sensor for the air Conditions Which Generate This Code:
inlet manifold.
The Atmospheric Pressure signal voltage is below
Perform the following diagnostic procedure: Event the acceptable range.
Codes - Test
System Response:
Results:
Electronic System Response Atmospheric
OK STOP. Pressure is set to 100 kPa (15 psi).

Service Tool will indicate 100 kPa (15 psi) while
the Diagnostic Code is Active and DIAG will be
displayed on the Status screen.

106
Troubleshooting: Troubleshooting:
Perform the following diagnostic procedure: Engine This diagnostic code indicates an excessive coolant
Pressure Sensor Open or Short Circuit - Test temperature. This diagnostic code does not indicate
a problem with the ECM or a problem with the
Results: coolant temperature sensor.
OK STOP. Perform the following diagnostic procedure: Event

Codes - Test
i01386123
Results:
0110-00 High Coolant
OK STOP.
Temperature Warning (61)
SMCS Code: 1906-038 i01226461

0110-03 Coolant Temp Sensor
Open Circuit (27)
This condition indicates that the coolant temperature
is above 107 C (228 F). Engine Monitoring SMCS Code: 1408-081; 1906-038
must be programmed to WARNING, DERATE, or
SHUTDOWN before this diagnostic code can occur. Conditions Which Generate This Code:
Note: This diagnostic code represents an event. This The Coolant Temperature signal voltage is above
diagnostic code does not represent an electronic the acceptable range.
system fault.
System Response:
System Response:
Electronic System Response Coolant temperature
Electronic System Response For Engine is set to 90 C (194 F) while the Diagnostic Code
Monitoring that is programmed to DERATE or is Active. Cold Mode is disabled. If the ECM is
SHUTDOWN, the ECM begins to derate the power. controlling the Cooling Fan, the Fan will be ON.
The ECM also limits the vehicle speed.
Service Tool Display or Lamps The Check Engine
If Engine Monitoring is programmed to WARNING, Lamp will NOT illuminate unless this Diagnostic
the check engine lamp will flash and the warning Code has been continuously Active for 10 hours.
lamp will turn ON continuously. DIAG will be displayed on the Status Screen.
If Engine Monitoring is programmed to DERATE Engine Response Occasionally, the engine may
or SHUTDOWN, the check engine lamp and the emit white smoke on start-up because Cold Mode
warning lamp will flash. is not Active.
This diagnostic code requires a customer password Troubleshooting:

Engine Response If Engine Monitoring is Temperature Sensor Open or Short Circuit - Test
programmed to WARNING there is no effect on
engine power. Results:
If Engine Monitoring is programmed to DERATE OK STOP.

or SHUTDOWN, the ECM begins limiting vehicle
speed and power.
107
i01226467 If Engine Monitoring is programmed to WARNING,

the check engine lamp will flash and the warning
0110-04 Coolant Temp Sensor lamp will turn ON continuously.
Short Circuit (27) If Engine Monitoring is programmed to DERATE
SMCS Code: 1408-081; 1906-038 or SHUTDOWN, the check engine lamp and the
warning lamp will flash.
This diagnostic code requires a customer password
The Coolant Temperature signal voltage is below in order to be cleared.
the acceptable range.
Engine Response If Engine Monitoring is
System Response: programmed to WARNING, there is no effect on
engine power.
Electronic System Response Coolant temperature
is set to 90 C (194 F) while the Diagnostic Code If the Engine Monitoring is programmed to
is Active. Cold Mode is disabled. If the ECM is DERATE or SHUTDOWN, the vehicle speed is
controlling the Cooling Fan, the Fan will be ON. limited to a maximum of 72 km/h (45 mph) and
the power is limited. The engine will shut down if
Service Tool Display or Lamps The Check Engine conditions exist for a long enough period in the
Lamp will NOT illuminate unless this Diagnostic SHUTDOWN mode.
Code has been continuously Active for 10 hours.
DIAG will be displayed on the Status Screen. Troubleshooting:
Engine Response Occasionally, the engine may This diagnostic code indicates an excessive coolant
emit white smoke on start-up because Cold Mode temperature. This diagnostic code does not indicate
is not Active. a problem with the ECM or a problem with the
coolant temperature sensor.
Troubleshooting:
Perform the following diagnostic procedure: Engine Codes - Test
Temperature Sensor Open or Short Circuit - Test
Results:
Results:
OK STOP.
OK STOP.
i01226822
i01386134
0111-01 Low Coolant Level
0110-11 Very High Coolant Warning (62)
Temperature (61) SMCS Code: 7422-038
SMCS Code: 1906-038
This condition indicates that the coolant level is
This condition indicates that the coolant temperature low. Engine Monitoring must be programmed
is above 112 C (234 F). Engine Monitoring to WARNING, DERATE, or SHUTDOWN, and the
must be programmed to WARNING, DERATE, or Coolant Level Sensor must be programmed to 4
SHUTDOWN before this diagnostic code can occur. Pin before this diagnostic code can occur.
Note: This diagnostic code represents an event. This Note: This diagnostic code represents an event. This
diagnostic code does not represent an electronic diagnostic code does not represent an Electronic
system fault. System fault.
System Response: System Response:
Electronic System Response For Engine Electronic System Response The ECM does not
Monitoring that is programmed to DERATE or derate the power. Also, the ECM does not limit
SHUTDOWN, the ECM begins to derate the power. the engine rpm or the vehicle speed due to this
The ECM also limits the vehicle speed. diagnostic code.
108
The Check Engine Lamp will flash and the Warning Results:
Lamp will illuminate.
OK STOP.
i01226872
Engine Response This diagnostic code does not

affect engine power.
0111-11 Very Low Coolant
Level (62)
Troubleshooting:
SMCS Code: 7422-038
This diagnostic code indicates low coolant level.
This diagnostic code does not indicate a problem Conditions Which Generate This Code:
with the ECM or a problem with the Coolant Level
Sensor. Check cooling system fluid level. This condition indicates that the coolant level is
very low. Engine Monitoring must be programmed
Perform the following diagnostic procedure: Event to WARNING, DERATE, or SHUTDOWN, and the
Codes - Test Coolant Level Sensor must be programmed to YES
before this diagnostic code can occur.
Results:
Note: This diagnostic code represents a critical
OK STOP. event. This diagnostic code does not represent an
0111-02 Coolant Level Sensor Electronic System Response If the Engine
Fault (12) Monitoring is programmed to DERATE or
SHUTDOWN, the ECM will derate the power and
SMCS Code: 7422-038 the ECM will limit the vehicle speed due to this
diagnostic code.
If Engine Monitoring is programmed to WARNING,
This condition occurs when the coolant level sensor the Check Engine Lamp will flash and the Warning
signals indicate a low condition and a normal Lamp will illuminate continuously.
condition at the same time. Engine Monitoring
must be programmed to WARNING, DERATE, or If Engine Monitoring is programmed to DERATE
SHUTDOWN, and the Coolant Level Sensor must or SHUTDOWN, the Check Engine Lamp and the
be programmed to 4-pin before this diagnostic Warning Lamp will flash.
code is available.
System Response: in order to be cleared.
Electronic System Response The ECM sets the Engine Response If Engine Monitoring is
Coolant Level to OK while this diagnostic code is programmed to WARNING this diagnostic code
Active. does not affect engine power.
Service Tool Display or Lamps The Electronic If Engine Monitoring is programmed to DERATE
Service Tool will indicate DIAG on the status or SHUTDOWN, the vehicle speed is limited to a
screen while the diagnostic code is Active. The maximum of 72 km/h (45 mph), and the power is
check engine lamp will not come on unless the limited. The engine will shut down if conditions exist
diagnostic code has been continuously Active for for a long enough period in the SHUTDOWN mode.
10 hours.
Engine Response There is no effect on engine

response due to this diagnostic code.
Troubleshooting:

Coolant Level Sensor Circuit - Test
109
Troubleshooting: Injection actuation pressure with the engine

shutdown
This diagnostic code indicates low coolant level.
This diagnostic code does not indicate a problem The actual pressure and the desired pressure are
with the electronic system or the Coolant Level substantially different.
Sensor. Check cooling system fluid level.
The change in injection actuation pressure was
Perform the following diagnostic procedure: Event not consistent with the change in sensor current.
Codes - Test
System Response:
Results:
Electronic System Response The ECM will indicate
OK STOP. an Active Code and the code will be logged.
Engine Response This code can occur with the

i01387662
engine off.
0164-00 Injection Actuation Pr Troubleshooting:
Out of Range (17)
SMCS Code: 1925-038 Injection Actuation Pressure System - Test
The ECM detected an injection actuation pressure OK STOP.

above 24000 kPa (3500 psi).
Note: The diagnostic code indicates a mechanical i01387688

problem. The ECM and the electronic control system
is operating correctly.
0164-03 Injection Actuation Pr
System Response:
SMCS Code: 1408-081; 1925-038
Electronic System Response The ECM limits
power output to 89.5 kW (120.0 hp) and the vehicle Conditions Which Generate This Code:
speed is limited to 73 km/h (45 mph).
The voltage in the injection actuation pressure
Engine Response The engine may be low on circuit is higher than normal.
power and the speed may be limited.
System Response:
Note: The problem may only exist at operating
temperature. Electronic System Response The ECM will assume
that the injection actuation pressure is 17.5 MPa
Troubleshooting: (2538 psi). The control valve for the Injection
Actuation Pressure System is set to a fixed position.
Perform the following diagnostic procedure: The fuel delivery is limited.
Injection Actuation Pressure System - Test
Engine Response The engine will run rough at idle.
Results: Power output will be below normal and the vehicle
speed will be limited to 72 km/h (45 mph).
OK STOP.
Troubleshooting:
i01387672
0164-02 Injection Actuation Pr Pressure Sensor Open or Short Circuit - Test
Sensor Erratic (15) Results:
SMCS Code: 1925-038 OK STOP.

The ECM detected one of the following conditions:

110

0164-04 Injection Actuation Pr Engine Response The engine may be low on power
Sensor Short Circuit (15) and the idle may be unstable. The engine may be
difficult to start at normal operating temperatures,
SMCS Code: 1408-081; 1925-038 but the engine may start easily when the engine is
cold.
Note: The problem may only exist at operating
The voltage in the injection actuation pressure temperature. Air may be trapped in the injection
circuit is below normal. actuation system if the system has been serviced
recently. Start the engine and run the engine at
System Response: 1500 rpm for a few minutes in order to remove the
trapped air.
Electronic System Response The ECM will assume
that the injection actuation pressure is 17.5 MPa Troubleshooting:
(2538 psi). The control valve for the Injection
Actuation Pressure System is set to a fixed position. Perform the following diagnostic procedure:
The fuel delivery is limited. Injection Actuation Pressure System - Test
Engine Response The engine will run rough at idle. Results:

Power output will be below normal and the vehicle
speed will be limited to 72 km/h (45 mph). OK STOP.
Perform the following diagnostic procedure: Engine 0168-02 Intermittent Battery

(51)
Results:
SMCS Code: 1408-081; 1900-038; 1901-038
i01387690 This condition indicates that the battery circuit to

the ECM has a battery condition that is intermittent
0164-11 Injection Actuation or a battery condition that is low while the engine
Pressure System (39) is running. If battery voltage disappears without
returning, the ECM will not Log this Diagnostic
SMCS Code: 1714-038; 5051-038 Code and the engine will shut down.
Conditions Which Generate This Code: System Response:
The ECM detected one of the following conditions: Electronic System Response The ECM may stop
injecting fuel. This may be dependent on the length
The actual pressure and the desired pressure are of time of the occurrence of the fault.
substantially different.
Engine Response The engine may experience
The Injection Actuation Pressure Control Valve changes in the engine rpm, and intermittent engine
Driver was at the maximum output or the shutdowns or complete engine shutdowns while
minimum output for a longer time then needed. the conditions that cause this diagnostic code are
present.
Note: The diagnostic code indicates a mechanical
problem. The ECM and the electronic control system Service Tool Display or Lamps The Check Engine
are operating correctly. Lamps and the Warning Lamps may come on as if
the Ignition Key Switch was just turned on and the
engine started.
111
Perform the following diagnostic procedure: Ignition Electronic System Response The check engine
Key Switch Circuit and Battery Supply Circuit - Test lamp will not be illuminated for this code unless the
Results: logged.
OK STOP. Engine Response There should not be a noticeable

change in engine response unless the signal for
the camshaft position sensor 2 (bottom) is lost. This
i01486640
loss will shut down the engine.
0190-00 Engine Overspeed Troubleshooting:
Warning (35)
SMCS Code: 1907-038 Speed/Timing Sensor Circuit - Test
This condition indicates that the engine speed has OK STOP.

exceeded 3300 rpm.
Electronic System Response The ECM shuts off

0190-11 No Pattern on Speed
the fuel injection delivery above the programmed Sensor #1 (34)
Top Engine Limit (TEL).
SMCS Code: 1408-081; 1907-038
This diagnostic code requires a Factory Password
in order to be cleared. Conditions Which Generate This Code:
This diagnostic code represents a critical event. The signal for the camshaft position sensor 1 (top)
This diagnostic code does not represent an is lost.
Electronic System Fault.
System Response:
Troubleshooting:
Electronic System Response The check engine
There are no problems that require troubleshooting. lamp will not be illuminated for this code unless the
This diagnostic code indicates an excessive engine logged.
speed. This diagnostic code does not indicate a
problem with the ECM or the Engine Speed/Timing Engine Response There should not be a noticeable
Sensor. change in engine response unless the signal for
the camshaft position sensor 2 (bottom) is lost. This
Results: loss will shut down the engine.
OK STOP. Troubleshooting:

i01388074
Speed/Timing Sensor Circuit - Test
0190-02 Loss of Engine RPM Results:
Signal (34)
OK STOP.
SMCS Code: 1408-081; 1907-038
The signal for the camshaft position sensor 1 (top)

is intermittent or lost.
112
i01288984 i01289014
0224-11 Theft Deterrent Active 0224-14 Engine Cranking with

(00) Theft Deterrent Active (00)
SMCS Code: 1900 SMCS Code: 1900; 1901
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Theft Deterrent feature has been enabled. The diagnostic code indicates that an attempt is
The correct password must be entered in order to being made in order to start the engine. However,
disable the Theft Deterrent. Then, the engine can the Theft Deterrent feature is enabled. This prevents
be started. the engine from being started.
Note: This diagnostic code represents an event. This Note: This diagnostic code represents an event. This
diagnostic code does not represent an Electronic diagnostic code does not represent an electronic
System fault. system fault.
The ECM will operate in the Secure Idle mode if System Response:
the Theft Deterrent password is entered. The engine
must be running in order to operate in the Secure Electronic System Response The diagnostic code
Idle mode. The ECM will be in the Secure Idle is Active only. The diagnostic code will be Active
mode until the Theft Deterrent password is entered when the Theft Deterrent feature is enabled and the
again. engine is cranking for more than 5 seconds.
System Response: Service Tool Display and Lamps The Check

Engine Lamp will be turned to the ON position while
Electronic System Response The diagnostic code the diagnostic code is Active.
is Active only. The diagnostic code will be Active
when the Theft Deterrent feature is enabled. Engine Response The engine will not start until the
correct password is entered.
Service Tool Display and Lamps The Check
Engine Lamp will not be activated for this event. Troubleshooting:
Engine Response The engine will not start until The diagnostic code indicates that an attempt is
the correct password is entered. The engine will being made in order to start the engine. However,
be limited to the Low Idle rpm if the Secure Idle the Theft Deterrent feature is enabled. This
mode is active. diagnostic code does not represent an electronic
system fault.
Troubleshooting:
There are no problems that require troubleshooting.
This diagnostic code indicates that the Theft
Deterrent feature has been enabled. There is no Results:
OK STOP.
No Troubleshooting is required.
i01225728
Results:
0231-11 J1939 Data Link Fault
OK STOP.
(58)
SMCS Code: 1408-038; 1901-038
This condition indicates that the SAE J1939 Data

Link is not communicating correctly.
113
System Response: Engine Oil Pressure of 600 kPa (87 psi)

Electronic System Response The Communications Atmospheric Pressure of 100 kPa (15 psi)
with other control modules that use the SAE J1939
Data Link may be interrupted while the Diagnostic The Electronic Service Tool will indicate DIAG next
Code is Active. to the Status of the sensor in order to indicate that
the sensor is operating at the value that is shown
Note: If the vehicle is not using the J1939 Data Link, due to an Active diagnostic code.
program the Power Train Data Link (Customer
Parameter) to None or J1922. After the Power Engine Response An Active Diagnostic Code may
Train Data Link is programmed correctly the not cause any noticeable effect on engine response.
following Active Diagnostic Code should be However, the active diagnostic code may cause the
repaired: engine to have the following effects:
231-11 J1939 Data Link Fault (58) Run rough.

Troubleshooting: Low power
Contact the OEM dealer in order to determine if the These effects are dependent on the operating
vehicle was built in order to use the J1922 or J1939 conditions that exist at the time when the code
Data Link. If the vehicle is not using the J1922 or occurs.
J1939 Data Link, program the Power Train Data
Link (Customer Parameter) to None. This will Troubleshooting:
repair the problem.
Perform the following diagnostic procedure: 5 Volt
If the vehicle is using the J1922 or J1939 Data Link Engine Pressure Sensor Supply Circuit - Test
for Power Train Control, proceed with the following
procedure: Results:
Perform the following diagnostic procedure: OK STOP.

Powertrain Data Link Circuit - Test
i01226365
Results:
0232-04 5 Volt Supply Below
OK STOP.
Normal (21)
i01226342 SMCS Code: 1408-081; 1900-038; 1901-038
0232-03 5 Volt Supply Above Conditions Which Generate This Code:
Normal (21)
The supply voltage for the pressure sensors of the
SMCS Code: 1408-081; 1900-038; 1901-038 engine is below normal level.
Conditions Which Generate This Code: System Response:
The supply voltage for the pressure sensors of the Electronic System Response All pressure sensors
engine is exceeding a level that is normal. of the engine are set to default values. All diagnostic
codes for the pressure sensors of the engine are
System Response: disabled while this Diagnostic Code is Active.
Electronic System Response All pressure sensors Service Tool Display or Lamps The Electronic
of the engine are set to default values. All diagnostic Service Tool will indicate the default status of the
codes for the pressure sensors of the engine are sensors. This default status is indicated in the
disabled while this Diagnostic Code is Active. following list:
Service Tool Display or Lamps The Electronic Boost pressure of 0 kPa (0 psi)
Service Tool will indicate the default status of the
sensors. This default status is indicated in the Engine Oil Pressure of 600 kPa (87 psi)
following list:
Atmospheric Pressure of 100 kPa (15 psi)
Boost pressure of 0 kPa (0 psi)
114
The Electronic Service Tool will indicate DIAG next Troubleshooting:

to the Status of the sensor in order to indicate that
the sensor is operating at the value that is shown Perform the following diagnostic procedure: Service
due to an Active diagnostic code. Brake Pedal Position (Switch 1) Circuit -Test
Engine Response An Active Diagnostic Code may Results:

not cause any noticeable effect on engine response.
However, the active diagnostic code may cause the OK STOP.
engine to have the following effects:
i01386146
Run rough.
0247-11 Brake Switch #2
Low power
SMCS Code: 1129-ZS
These effects are dependent on the operating
conditions that exist at the time when the code Conditions Which Generate This Code:
occurs.
The engine is running and both of the following
Troubleshooting: conditions exist:
Perform the following diagnostic procedure: 5 Volt
Engine Pressure Sensor Supply Circuit - Test
The status of the service brake pedal position
switch 2 indicates that the brake pedal has been
depressed.
Results:
The service brake pedal position switch 1
OK STOP. indicates that the pedal has been released.
0246-11 Brake Switch #1 Electronic System Response The diagnostic code

is logged into memory only if the engine is running.
SMCS Code: 1129-ZS This diagnostic code will prevent cruise control,
PTO operation, or idle operation. The check engine
Conditions Which Generate This Code: lamp will not illuminate for this diagnostic code.
The engine is running and both of the following Engine Response The engine will disengage or the
conditions exist: engine will not allow setting of the cruise control,
the PTO, or the idle speed.
The status of the service brake pedal position
switch 1 indicates that the brake pedal has been Troubleshooting:
depressed.
Perform the following diagnostic procedure: Service
The service brake pedal position switch 2 Brake Pedal Position (Switch 2) Circuit - Test
indicates that the pedal has been released.
Results:
System Response:
OK STOP.
Electronic System Response The diagnostic code
is logged into memory only if the engine is running.
i01225906
This diagnostic code will prevent cruise control,
PTO operation, or idle operation. The check engine
lamp will not illuminate for this diagnostic code.
0252-11 Incorrect Engine
Software (59)
Engine Response The engine will disengage or
the engine will not allow the setting of the cruise SMCS Code: 1902-535; 7620-535
control, the PTO, or the idle speed.
This condition occurs when the Personality Module

is changed and the new module that is installed
is for a different engine.
115
Electronic System Response The ECM will not Perform the following diagnostic procedure: ECM
allow the engine to start. Memory - Test
Engine Response The engine will not start. Results:
Troubleshooting: OK STOP.
Perform the following diagnostic procedure: ECM
i01387819
Memory - Test
Results:
0253-14 Truck Manufacturer
Parameter Not Programed
OK STOP.
SMCS Code: 1901-535
i01388425 Conditions Which Generate This Code:
0253-02 Check Customer or The Truck Manufacturer Parameter has not been
System Parameters (56) programmed. The parameter must be programmed
for the manufacturer of the chassis in order to
SMCS Code: 1901-535 configure the correct options and ranges for the
engine.
Note: The Truck Manufacturer Parameter must be
This condition indicates a Customer Specified programmed before the Customer Parameters are
Parameter or a system configuration parameter that programmed.
requires programming has not been programmed.
Once this parameter has been programmed, the System Response:
code may still be active. This can happen if there is
yet another parameter that requires programming. Electronic System Response The code is active,
but the code is not logged. The check engine lamp
System Response: will be ON when the code is active.
Electronic System Response The fault is active Engine Response The ECM will select the GM
only and the fault is not logged. If the Personality parameter as the default until the appropriate
Module Code of the new personality module does parameter is programmed.
not match the code of the old personality module,
the engine is limited to low idle. If the Rating Troubleshooting:
Number has not been programmed, the ECM limits
the engine to 89.5 kW (120.0 hp). When a new ECM Perform the following diagnostic procedure: ECM
is initially powered up, the following parameters Memory - Test
must be programmed to avoid this diagnostic code:
Results:
Full Load Setting (FLS)
OK STOP.
Full Torque Setting (FTS)
Vehicle Speed Calibration
Rating Number
Engine Serial Number
Engine Response The ECM will limit the engine
to low idle if the parameter is the FLS or the FTS.
The ECM may also limit the power if the parameter
is a rating number.
116
Diagnostic Functional
Tests
i01371477
5 Volt Engine Pressure Sensor

Supply Circuit - Test
SMCS Code: 1408-081; 1901-081
Use this procedure to troubleshoot the system when

one of the following diagnostic codes is active or
easily repeated:
232-03 5 Volt Supply Above Normal (21)

g00767035
Illustration 23
232-04 5 Volt Supply Below Normal (21)
Also, use this procedure to troubleshoot the system
when you have been directed here by another
troubleshooting procedure.

to this procedure:
The Engine Control Module (ECM) supplies the

following sensors with regulated +5 V DC power
from the same supply:
J200/P200 boost pressure sensor

J203/P203 atmospheric pressure sensor (specific
ratings only)
J201/P201 engine oil pressure sensor (optional)

J204/P204 injection actuation pressure sensor
The supply for the +5 V engine pressure sensor is
routed from the ECM through ECM engine harness
connector J2/P2 terminal 2 to terminal A of each
pressure sensor connector. The supply voltage is
5.0 0.5 V DC.
The +5 V diagnostic code is probably caused by

a short circuit or an open circuit in the harness.
The next probable cause is a sensor and the least
probable cause is the ECM.
117
g00767119
Illustration 24
Schematic of the +5 V supply for the engine pressure sensor

And Wiring.
g00723875
Illustration 25
118
A. Thoroughly inspect ECM engine harness C. Monitor the Active Diagnostic Code screen of
connector J2/P2, boost pressure sensor the Electronic Service Tool. Check and record
J200/P200, engine oil pressure sensor active diagnostic codes.
J201/P201, atmospheric pressure sensor
J203/P203 and Injection actuation pressure Note: Wait at least 15 seconds in order for the
sensor J204/P204. Refer to Troubleshooting, diagnostic codes to become active.
Inspecting Electrical Connectors for details.
Expected Result:
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated Select the condition of the following codes:
with the +5 V Engine Pressure Sensor supply:
+5 V Engine Pressure Sensor terminal 2
(G828-WH) 232-04 5 Volt Supply Below Normal (21)
Engine Pressure Sensor Common terminal 3 Results:
(G829-GN)
Active Proceed to Test Step 3.
Logged ONLY Proceed to Test Step 5.
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 Nm (55 lb in). Not active or logged The +5 V supply is
operating correctly at this time. STOP.
D. Check the harness and wiring for abrasion and
pinch points from the sensors back to the ECM. Test Step 3. Disconnect The ECM Engine
Harness Connector From The ECM.
Expected Result:
All connectors, pins and sockets should be data link connector.
completely coupled and/or inserted and the harness
and wiring should be free of corrosion, abrasion B. Turn the ignition key switch to the OFF position.
or pinch points.
C. Disconnect ECM engine harness connector
Results: J2/P2.
OK Proceed to Test Step 2. D. Turn the ignition key switch to the ON position.
Not OK E. Access the Active Diagnostic Code screen on

the Electronic Service Tool. Check for one of the
Repair: Perform the following repair: following active diagnostic codes:
Repair the connectors or wiring and/or replace 232-03 5 Volt Supply Above Normal (21)
the connectors or wiring. Ensure that all of the
seals are properly in place and ensure that the 232-04 5 Volt Supply Below Normal (21)
Note: When ECM engine harness connector J2/P2
Verify that the repair eliminates the problem. is disconnected and the ignition key switch is in the
ON position, open circuit diagnostic codes will be
STOP. active or logged for all of the engine sensors. This
is normal. The codes for the 5 Volt supply should
Test Step 2. Connect an Electronic not be active.
Service Tool and Check for Active
Diagnostic Codes. Expected Result:
A. Connect an Electronic Service Tool to the cab The +5 V Diagnostic Code is Active when the ECM
data link connector. Engine Harness Connector is disconnected.

119
Results: Note: When the sensors are disconnected and the

ignition key switch is in the ON position, open circuit
Yes Disconnecting the Engine Harness does diagnostic codes will be active or logged when the
not eliminate the Active +5 V Sensor Diagnostic +5 V diagnostic codes are no longer active. This is
Code. normal. Clear these diagnostic codes after this test
step is completed.
procedure: Expected Result:
1. Temporarily connect a test ECM. Only connect The original +5 V diagnostic code remains active.
ECM harness J1/P1.
Results:
2. Recheck for an +5 V diagnostic code when
the engine harness is disconnected. Yes The +5 V diagnostic code is still active. The
harness is the cause of the problem. Leave the
3. If the problem is resolved with the test ECM, sensors disconnected. Proceed to Test Step 5.
No Disconnecting a specific sensor makes the
4. If the problem returns with the suspect ECM, +5 V diagnostic code no longer active.
replace the ECM.
STOP. procedure:
No The +5 V diagnostic code is no longer 1. Reconnect the sensor that is suspected of

active when the harness is disconnected. Either causing the problem.
the harness or a sensor that is attached to the
harness is causing the problem. Reconnect the 2. If the problem returns after the reconnection of
ECM engine harness connector. Proceed to Test the sensor, disconnect the sensor.
Step 4.
3. If the problem disappears after the
Test Step 4. Disconnect The +5 V Sensors disconnection of the sensor, replace the
While Active Diagnostic Codes Are Being sensor.
Monitored.
4. Clear all diagnostic codes.
data link connector. 5. Verify that the repair eliminates the problem.
B. Turn the ignition key switch to the ON position. STOP.
C. Access the Active Diagnostic Code screen on

the Electronic Service Tool. Verify that one of the
following diagnostic codes is active:

D. Disconnect the following sensors one at a time:
Boost pressure sensor J200/P200

Injection actuation pressure sensor J204/P204
Engine oil pressure sensor J201/P201
Atmospheric pressure sensor J203/P203
E. Wait for 30 seconds after each pressure sensor
is disconnected while the Electronic Service Tool
is being monitored in order to verify that the
disconnection of a specific sensor deactivates
the +5 V diagnostic code.
120
Test Step 5. Check the Engine Harness.
g00724122
Illustration 26
Engine harness connector P2
A. Turn the ignition key switch to the OFF position. b. Wiggle the harness during the measurement
in order to reveal any intermittent short
B. Disconnect ECM engine harness connector condition.
J2/P2. Verify that all of the +5 V engine pressure
sensors that are attached to the ECM engine Expected Result:
harness connector are disconnected.
Each resistance measurement is more than 20
Boost pressure sensor J200/P200 Ohms.
Engine oil pressure sensor J201/P201 Results:
Atmospheric pressure sensor J203/P203 OK The +5 V line is not shorted in the engine
harness. Ensure that the engine harness is
Injection actuation pressure sensor J204/P204 connected to the ECM and that all of the sensors
are reconnected. There does not appear to
C. Set a multimeter in order to measure the be a problem at this time. Clear all diagnostic
resistance on the range that is close to 20 Ohms, codes. Continue to troubleshoot until the original
but not less than 20 Ohms. condition is resolved. STOP.
a. Measure the resistance from the ECM engine Not OK The engine harness has a short circuit.
harness connector P2 terminal 2 (+5 V engine
pressure sensor) to each of the following Repair: Perform the following repair:
terminals:
1. Replace the engine harness.
P2 terminal 14 (atmospheric pressure
signal) 2. Clear all logged diagnostic codes.
P2 terminal 24 (oil pressure signal) 3. Verify that the repair eliminates the problem.
P2 terminal 27 (Injection Actuation Pressure STOP.

Signal)
i01375969
P2 terminal 40 (boost pressure signal)
Air Inlet Heater Circuit - Test
P2 terminal 3 (engine pressure sensor
common) SMCS Code: 1090-081
P2 terminal 65 (battery negative) System Operation Description:
Refer to Illustration 26. Use this procedure under the following situation:
121
Use the following information in order to troubleshoot The lamp for the air inlet heater should turn on for
the air inlet heater circuit when there is an active a minimum of 2 seconds when the ECM is first
code: powered up. The lamp should turn on regardless of
the coolant temperature. The ECM will signal the air
70-05 Air Inlet Heater Open Circuit (49) inlet heater to stay on for 30 seconds if the sum of
the coolant temperature and the inlet manifold air
70-06 Air Inlet Heater Short Circuit (49) temperature is less than 25 C (109 F).
This procedure can also be used to troubleshoot The air inlet heater and the lamp for the air inlet
the following components: heater should turn on. The air inlet heater and the
lamp for the air inlet heater should turn off when the
the air inlet heater cycle is complete.
the air inlet heater relay The ECM will control the air inlet heater for the
Cranking Cycle if the operator starts the engine
the lamp for the air inlet heater before the end of the heating cycle.
The following background information is related Cranking Cycle

to the following procedure:
If the sum of the coolant temperature and the inlet
The air inlet heater is used in order to improve the manifold air temperature equals less than 25 C
engines ability to start when the engine is cold. A (109 F) the air inlet heater will turn on when the
reduction of white smoke is also a benefit of the engine is cranking. The heater will remain on while
air inlet heater. the engine is cranking. The air inlet heater will
reactivate for 30 seconds if the engine fails to start.
The ECM controls the operation of the air inlet heater
and the ECM controls the operation of the lamp for Engine Start Cycle
the air inlet heater through the inlet air heater relay.
The operation of the air inlet heater is determined
The operation of the air inlet heater is determined by the coolant temperature and the inlet manifold
by three different cycle times: air temperature after the engine has started. If the
combined temperature is 25 C (109 F) or less the
Power Up/Preheat Cycle Engine Start Cycle begins. The Engine Start Cycle
has two segments:
Cranking
Continuous Mode
Engine Started
On/Off Cycling Mode
The cycle time is determined by the following
parameters: The Continuous Mode lasts for a maximum of seven
minutes. The On/Off Cycling Mode can last for a
engine parameters maximum of thirteen minutes. The air inlet heater is
turned on and the air inlet heater is turned off for ten
vehicle speed seconds during the On/Off Cycling Mode. The air
inlet heater will turn off when the sum of the coolant
service brake temperature and the inlet manifold air temperature
exceeds 35 C (127 F).
Effects of Vehicle Speed on the Operation of the
Air Inlet Heater and on the Operation of the Brake Note: MAY99 and newer Personality Modules
Pedal Position. use the boost pressure reading to determine
atmospheric pressure. This will indicate if the
The air inlet heater is turned off when the brake engine is operating above 1678 m (5505 ft). If the
pedal is depressed and the vehicle speed is equal altitude is above 1678 m (5505 ft), the temperature
to 8 km/h (5 mph) or greater than 8 km/h (5 mph). calculation is adjusted in order to compensate for
the extreme altitude. The temperature calculation is
If a diagnostic code for the vehicle speed sensor is used in order to determine the operation of the air
active, the ECM will assume that the vehicle speed inlet heater. Refer to Illustration 31 for more details.
is above 8 km/h (5 mph). If an active diagnostic
code is triggered for the vehicle speed sensor, the Active Open Circuit/Short Circuit Diagnostic
ECM will disable the heater when the brakes are Code
applied.
The ECM Powerup and Preheat Cycle.

122
The air inlet heater will turn on if the coolant

temperature sensor has an active open circuit
diagnostic code or an active short circuit diagnostic
code and the inlet manifold air temperature is less
than 10 C (50 F).
The air inlet heater will turn on if the air temperature

sensor for the inlet manifold has an active open
circuit diagnostic code or an active short circuit
diagnostic code and the coolant temperature is less
than 40 C (104 F).
Note: The ECM adds the coolant temperature and

the inlet manifold temperature together. The coolant
temperature and the inlet manifold temperature
are measured in degree celsius. The coolant
temperature and the inlet manifold temperature
must be converted to degree fahrenheit in order to
get the correct conversion.
Add both temperature readings together.

g00726347
Illustration 28
Multiply the answer by 1.8. Top engine view
Add 64 to the answer.

This will convert both the coolant temperature
and the inlet manifold temperature into degree
fahrenheit.
g00726687
Illustration 29
Schematic of the air inlet heater
g00726351
Illustration 27
The Diagram for the air inlet heater
123
g00726706
Illustration 30
Connections for the ECM terminals
124
g00726757
Illustration 31
125
Operational chart for the air inlet heater
Test Step 1. Inspect Electrical Connectors E. Start the test and listen for a click from the air
And Wiring. inlet heater relay.
A. Thoroughly inspect the connector J501/P501 for Note: The inlet air heater relay is located on the
the air inlet heater relay and inspect the ECM front left side of the engine.
engine harness connector J2/P2. Inspect the
electrical connector J648/P648 for the lamp Note: Do not leave the Intake Air Heater Enable
of the air inlet heater and inspect the terminal Special Test on. Avoid unnecessary cycling of the
connections on the air inlet heater relay. Refer air inlet heater in order to prevent the battery from
to Troubleshooting, Electrical Connectors - discharging. The Intake Air Heater Enable Special
Inspect for details. Test has a one minute timer in order to disable the
test when the time expires.
wires in the ECM connector that are associated Expected Result:
with the air inlet heater (terminal 8).
Result 1 The lamp and the relay activate.
the proper torque of 6.0 Nm (55 lb in). Result 2 The lamp and the relay activate. The air
inlet heater is still suspect.
for pinch points from the sensors back to the Result 3 The lamp activates but the relay does not
ECM. activate.
Expected Result: Result 4 The lamp does not activate.
All connectors, pins and sockets should be Results:

and wiring should be free of corrosion, abrasion RESULT 1 The lamp and the relay are
or pinch points. functioning normally. STOP.
Results: RESULT 2 Proceed to Test Step 3.

OK Proceed to Test Step 2. RESULT 3 There is a problem with the relay
circuit. Proceed to Test Step 4.
Not OK
RESULT 4 Proceed to Test Step 5.
Repair: Perform the following repair:
Test Step 3. Check the Voltage at the
Repair the connectors or wiring and/or replace Relay Contacts for the Air Inlet Heater
seals are properly in place and ensure that the A. Turn the ignition key switch to the OFF position.
B. Disconnect the wire from the relay terminal of the
Verify that the repair eliminates the problem. air inlet heater to the air inlet heater.
STOP. C. Fabricate two jumper wires with Deutsch sockets

on one end and Deutsch pins on the other end.
Test Step 2. The Powerup Test for the Air Strip a small amount of insulation from the middle
Inlet Heater of one jumper wire.
A. Turn the ignition key switch to the ON position.
B. The lamp for the air inlet heater should illuminate

for two seconds. The lamp for the air inlet heater
should shut off.
C. Connect an Electronic Service Tool to the cab

D. Go to the Intake Air Heater Enable Special Test

on the Electronic Service Tool.
126
Reconnect the wire to the relay terminal.

Electrical Connector P501 for the Air Inlet
Heater Relay.
g00726988
Illustration 32
Connections for the Test Lamp
D. Disconnect J501/P501 and insert the jumper

wires in the electrical connectors.
E. Connect a voltage test lamp from the

disconnected relay terminal to the jumper wire
that is connected to J501 and P501 terminals.
G. Go to the Intake Air Heater Enable Special Test

H. Start the test and watch the voltage test lamp.
Note: Do not leave the Intake Air Heater Enable

Special Test on. Avoid unnecessary cycling of the
air inlet heater in order to prevent the battery from
discharging. The Intake Air Heater Enable Special Illustration 33
g00727002
Test has a one minute timer in order to disable the
test when the time expires. A. Disconnect the connector J501/P501 for the air
inlet heater relay.
Expected Result:
B. Ensure that the connector J648/P648 for the air
The test lamp turned on and the test lamp turned inlet heaters lamp is still connected.
off with the Intake Air Heater Enable Special Test.
C. Connect a voltage test lamp to the two terminals
Results: of the engine harness side P501 connector of
the air inlet heater relay.
Yes
Repair: The air inlet heater relay and the +battery
connection to the inlet air heater relay are OK. E. Go to the Intake Air Heater Enable Special Test
Leave the wire disconnected from the relay on the Electronic Service Tool.
terminal.
F. Start the test and watch the voltage test lamp.
No Special Test on. Avoid unnecessary cycling of the
Repair: The test lamp does not come on or the discharging. The Intake Air Heater Enable Special
test lamp remains on after the test lamp comes Test has a one minute timer in order to disable the
on. test when the time expires.
127
Expected Result: Test Step 6. Check the Wiring for the Air
Inlet Heater.
The test lamp turns on and the test lamp turns off
with the Intake Air Heater Enable Special Test. A. Turn the ignition key switch to the OFF position.
Results: B. Disconnect both wires from the air inlet heater.
Yes C. Use a multimeter to measure the resistance

between the two ends of the wire that connects
Repair: Replace the air inlet heater and rerun the the air inlet heater to the inlet air heater relay.
test. Verify that the original problem has been
resolved. D. Measure the resistance from the engine ground
stud to the other end of the wire for the air inlet
STOP. heater that connects to the ground stud.
No Expected Result:
Repair: The connector P501 for the air inlet heater The measured resistance is less than 20 Ohms.
relay is not receiving the correct voltage.
Results:
Yes
Lamp for the Air Inlet Heater. Repair: Replace the air inlet heater. Verify that the
problem is resolved.
STOP.
B. Locate the lamp in the dash for the air inlet
heater. Remove the lamp from the dash. No
C. Connect a voltage test lamp between the two Repair: Repair the damaged wire. Verify that the
terminals of the lamp socket. problem is resolved.
D. Turn the ignition key switch to the ON position. STOP.
E. Go to the Intake Air Heater Enable Special Test Test Step 7. Check the Relay Contact at
on the Electronic Service Tool. the +Battery Terminal Connection.
F. Start the test and watch the voltage test lamp. A. Turn the ignition key switch to the OFF position.

discharging. The Intake Air Heater Enable Special
Test has a one minute timer in order to disable the
Expected Result:
with the Intake Air Heater Enable Special Test .
Results:
YES
Repair: Replace the lamp for the air inlet heater.
Verify that the problem has been resolved.
STOP.
g00727399
Illustration 34
No Reinstall the lamp for the air inlet heater.
Proceed to Test Step 9. Connections for the Test Lamp
128
B. Connect a voltage test lamp from the terminal No

for the relay contact that connects to the circuit
protection for the air inlet heater (wire K995-OR). Repair: Repair the wiring. Verify that the problem
has been resolved.
C. Connect the other end of the voltage test lamp
to the engine ground stud. STOP.
D. Turn the ignition key switch to the ON position. Test Step 9. Check the Voltage at
Connector J648/P648 for the Lamp.
Expected Result:
The test lamp comes on when the ignition key
switch is turned to the ON position. B. Disconnect the connector J648/P648 for the air
inlet heaters lamp .
Results:
C. Connect a voltage test lamp from the connector
Yes J648 terminal-Afor the air inlet heater to the
engine ground stud.
Repair: Repair the wiring between the lamp for the
air inlet heater and the connector J648 terminal-B. D. Turn the ignition key switch to the ON position.
Verify that the problem has been resolved.
Expected Result:
STOP.
The test lamp comes on and the test lamp stays on.
No
Results:
Repair: Inspect the circuit protection for the air
inlet heater and the inlet air heater wiring. Repair Yes
the wiring. Verify that the problem has been
resolved. Repair: Repair the wiring from the connector J648
terminal-B for the lamp. Verify that the problem
STOP. has been resolved.
Test Step 8. Check the Battery Voltage to STOP.

Connector J648 for the Lamp.
No
Repair: Repair the wiring from connector J648
B. Disconnect the connector J648/P648 for the air terminal-A for the lamp. Verify that the problem
inlet heaters lamp. has been resolved.
C. Connect a voltage test lamp to the terminal J648 STOP.

terminal-A. Refer to Illustration 33.
Test Step 10. Check Battery Voltage
D. Connect a jumper wire to the ground stud. to the Connector P501 for the Air Inlet
Connect the other lead of the test lamp to the Heater Relay.
jumper wire.
B. Ensure that the connector J648/P648 for the air
Expected Result: inlet heaters lamp is connected.
The voltage test lamp came on and the voltage C. Disconnect the connector J501/P501 for the air
test lamp stays on while the voltage test lamp is inlet heater relay.
connected between J648 terminal-A and the ground
stud. D. Connect a voltage test lamp from the connector
P501 terminal-1 for the air inlet heater relay to
Results: the engine ground stud.
Yes Proceed to Test Step 10. E. Turn the ignition key switch to the ON position.
129
Expected Result: Note: Do not leave the Intake Air Heater Enable
The voltage test lamp comes on and the voltage air inlet heater in order to prevent the battery from
test lamp stays on when the ignition key switch is discharging. The Intake Air Heater Enable Special
in the ON position. Test has a one minute timer in order to disable the
Results:
Note: When ECM engine harness connector J2/P2
Yes Proceed to Test Step 11. is disconnected and the ignition key switch is in
the ON position, open circuit diagnostic codes will
No be active or logged for all of the engine sensors.
This is normal.
Repair: Repair the wiring from J648 terminal-A
to P501 terminal-1. Verify that the problem is Expected Result:
resolved.
The test lamp turned on and the test lamp turned
STOP. off with the Intake Air Heater Enable Special Test.
Test Step 11. Check the ECM. Results:
A. Turn the ignition key switch to the OFF position. Yes

B. Disconnect the connector J648/P648 for the air Repair: Repair the wiring from the connector P501
inlet heaters lamp . for the air inlet heater relay to the ECM connector
P2. Verify that the problem has been resolved.
STOP.

Test Step 12. Test the Battery Voltage to
the ECM.
B. Disconnect the ECM vehicle harness connector

J1/P1 and install a 70-terminal breakout T.
C. Connect a voltmeter between terminal 52 of the

breakout harness and terminal 65 of the breakout
harness. Refer to Illustration 35.
D. Turn the ignition key switch to the ON position

and check the voltmeter.
Illustration 35
g00727433 E. Turn the ignition key switch to the OFF position.
Connections for the Breakout T
F. Connect a voltmeter between terminal 53 of the
breakout harness and terminal 67 of the breakout
C. Disconnect the ECM engine harness connector harness. Refer to Illustration 35.
J2/P2 and install a 70-Terminal breakout T to the
ECM connector J2 only. G. Turn the ignition key switch to the ON position
and check the voltmeter.
D. Connect a voltage test lamp from the connector
J648 terminal-A to the terminal-8 of the breakout Expected Result:
T. Refer to Illustration 34.
The voltage is between 11.0 VDC and 13.5 VDC
E. Turn the ignition key switch to the ON position. when the ignition key switch is in the ON position.
F. Go to the Intake Air Heater Enable Special Test Results:
G. Start the test and watch the voltage test lamp.

Yes
130
Repair: Replace the ECM. Verify that the problem The Pedal Mounted Accelerator Pedal Position
is resolved. Sensor will produce a Duty Cycle of 10 to 22
STOP. accelerator pedal is fully depressed. The percent
No accelerator pedal position of 3 to 100 percent.
Repair: Inspect the vehicle wiring. Repair the The Pedal Mounted Accelerator Pedal Position
vehicle wiring or send the vehicle to the OEM Sensor is powered by the ECM supply voltage (+8
dealer for repair. Verify that the problem has been VDC) from connector P1 terminal 4 to terminal A
resolved. of the Accelerator Pedal Position Sensor Connector.
STOP. Sensor can be replaced separately from the Pedal
i01409096
must be replaced.
Accelerator Pedal (Throttle) If the vehicle is using the ECM Dedicated PTO
Position Sensor Circuit - Test functions, the Cab Accelerator Pedal Position
SMCS Code: 1913-081 mode and the PTO Configuration is programmed
to one of the following parameters:
Remote Switches
Remote Throttle
Use this procedure if any of the following Diagnostic
Codes are indicated: Note: In the Cab Switches Configuration, the cab
accelerator pedal can be used in order to control
91-08 Invalid Throttle Signal (32) the engine rpm for the PTO operation. The cab
accelerator pedal can also be ignored in the Cab
91-13 Throttle Sensor Calibration (28) Switches PTO Configuration. Programming of
customer parameters is required in order to ignore
41-03 8 Volt Supply Above Normal (21) the cab accelerator pedal in the Cab switches
Configuration.
The ECM is in PTO mode if the PTO On/Off
Also, use this procedure if the Accelerator Pedal Switch is ON. This can be checked through an
Position Sensor is suspected of improper operation. Electronic Service Tool Status Screen. Refer to
Troubleshooting, PTO Switch Circuit - Test for
Accelerator Pedal Position Sensor testing if the PTO is being used.
The Accelerator Pedal Position Sensor is used

to provide a throttle position signal to the ECM.

131
g00642016
Illustration 36
Schematic for cab accelerator pedal position sensor
g00668027
Illustration 37
Test Step 1. Inspect Electrical Connectors Terminal 4

And Wiring.
Terminal 5
A. Thoroughly inspect ECM Vehicle Harness
Connector J1/P1, the firewall bulkhead connector Terminal 66
and the Accelerator Pedal Position Sensor
Connector. Refer to Troubleshooting, Inspecting C. Check the ECM Connector (Allen Head Screw)
Electrical Connectors for details. for the proper torque of 6.0 Nm (55 lb in).
wires in the ECM Connector that are associated pinch points from the Accelerator Pedal Position
with the Accelerator Pedal Position Sensor: Sensor to the ECM.
Terminal 3
132
Expected Result: Result 2 Diagnostic Code 41-03 or 41-04 is Active.
All connectors, pins and sockets should be Result 3 There are NO Active Diagnostic Codes that
completely coupled and/or inserted and the harness are related to the Accelerator Pedal Position Sensor
and wiring should be free of corrosion, abrasion Circuit at this time, but a problem is suspected with
or pinch points. operation of the Accelerator Pedal Position Sensor
Circuit.
Results:
Results:
OK Proceed to test step 2.
Not OK
Repair the connectors or wiring and/or replace
the connectors or wiring. Ensure that all of the Test Step 3. Check The Duty Cycle Of The
seals are properly in place and ensure that the Accelerator Pedal Position Sensor.
A. Connect an Electronic Service Tool at the Cab
Verify that the repair eliminates the problem. Data Link Connector.
STOP. B. Turn the Ignition Key Switch to the ON position.
Test Step 2. Check for Active Diagnostic C. Monitor the Duty Cycle of the Throttle Sensor on
Codes. the Electronic Service Tool. Access the following
display screen in order:
Data Link Connector. Service
B. Turn the Ignition Key Switch to the ON position. Calibrations
C. Monitor the Active Diagnostic Code Screen of Monitor Throttle Position Sensor
the Electronic Service Tool. Check and record
Active Diagnostic Codes. Expected Result:
Note: When the ECM automatically calibrates new The Duty Cycle is between 10 and 22 percent with
duty cycle values for the low idle throttle position the accelerator pedal assembly in the Low Idle
and the high idle throttle position the ECM assumes position, and the Duty Cycle is between 75 and 90
22 percent duty cycle at low idle and 75 percent percent with the accelerator pedal assembly in the
duty cycle at high idle. As a result, you may notice High Idle position.
that the Throttle Position status reaches 100 percent
well before the accelerator pedal is fully depressed. Results:
This is normal. After some cycling of the accelerator
pedal to the high idle position, the ECM will adjust Yes The Accelerator Pedal Position Sensor is
the calibration automatically. The ECM will adjust operating correctly. Proceed to test step 6.
the calibration automatically provided that the high
idle stop position is within the 75 to 90 percent duty No The Accelerator Pedal Position Sensor
cycle range, and the low idle is in the 10 to 22 Circuit is not operating correctly. Proceed to test
percent duty cycle range. During normal operation, step 4.
you may also notice that more movement of the
accelerator pedal is required for the Throttle Position Test Step 4. Check The Supply Voltage
status to increase above 3 percent. You may also At The Sensor For The Accelerator Pedal
observe that the status reaches the 100 percent Position Sensor.
value prior to the limit of the high idle position. This
is done in order to ensure that the throttle reaches A. Install a Breakout T with 3 terminals at the
these two critical points for engine operation. Accelerator Pedal Position Sensor Connector
J403/P403.
Expected Result:
Result 1 Diagnostic Code 91-08 or 91-13 is Active.
133
C. Measure the voltage at terminal A (+8 V) with The problem returns after the old Accelerator
reference to terminal B (Accelerator/Switch Pedal Position Sensor has been reconnected.
Sensor Common).
STOP.
Expected Result:
Test Step 6. Check The Status Of The PTO
The measured voltage is between 7.5 VDC and 8.5 On/Off Switch And The Status Of The
VDC for the Pedal Mounted Throttle Position Sensor Power Train Data Link With An Electronic
that is used in the Cab. Service Tool.
Results: A. Check the status of the PTO ON/OFF Switch
on the Electronic Service Tool in order to verify
Yes Proceed to test step 8. that the PTO ON/OFF Switch is OFF. The PTO
mode may cause the ECM to ignore the Cab
No The sensor is not receiving the correct Accelerator Pedal Position Sensor if the PTO
voltage. Proceed to test step 5. Configuration is programmed to one of the
following parameters:
Test Step 5. Monitor The Electronic
Service Tool While The Accelerator Pedal Remote Switches
Position Sensor Is Being Disconnected.
Remote Throttle
A. Access the Active Diagnostic Code Screen of
the Electronic Service Tool. Ensure that one of Cab Switches
the following Diagnostic Code is active before
proceeding: Note: If the PTO Configuration is programmed
to Cab Switches and the CAB Controls rpm Limit
41-03 8 Volt Supply Above Normal (21) is programmed to Low Idle, the PTO mode may
cause the ECM to ignore the Cab Accelerator Pedal
41-04 8 Volt Supply Below Normal (21) Position Sensor. This will occur when the PTO
ON/OFF Switch is in the ON position.
B. Monitor the Active Diagnostic Code Screen while
the Accelerator Pedal Position Sensor is being B. Start the engine. While the Throttle Position status
disconnected and reconnected. is being monitored on the Electronic Service Tool,
depress the accelerator pedal and release the
Expected Result: accelerator pedal. The Throttle Position status
and the engine should respond to the change in
One of the following Diagnostic Codes is still active the accelerator pedal position.
after the Accelerator Pedal Position Sensor has
been disconnected: C. Go to the System Troubleshooting Settings
41-03 8 Volt Supply Above Normal (21) OFF the Power Train Data Link.
41-04 8 Volt Supply Below Normal (21) D. While the Throttle Position status is being
monitored on the Electronic Service Tool, depress
Results: the accelerator pedal and release the accelerator
pedal. Also depress the accelerator pedal and
Yes Ensure that the Accelerator Pedal Position release the accelerator pedal while the engine
Sensor has been reconnected before continuing. response is being monitored.
Expected Result:
No
The Throttle Position status and the engine should
Repair: Perform the following diagnostic respond to the change in the accelerator pedal
procedure: position.
Temporarily install another Accelerator Pedal Result 1 The cab accelerator functions properly.
Position Sensor. Use an Electronic Service Tool
and check if the +8 V Diagnostic Code is still Result 2 The Throttle Response is limited by a
Active. Replace the Accelerator Pedal Position power train data link message.
Sensor if both of the following conditions occur:
Result 3 The PTO limits the Throttle Response.
The problem is corrected with the new
Accelerator Pedal Position Sensor.
134
Results: Check the battery voltage from P1 terminal 52

and terminal 53 (UNSWITCHED +BATTERY)
Result 1 The Accelerator Pedal Position Sensor to terminal 65 and terminal 67 (-BATTERY).
is operating correctly. Continue troubleshooting The measured voltage should be in one of the
until the original condition is resolved. STOP. following ranges:
Result 2 If the engine responds with the Power For 12 Volt Systems, the voltage should be
Train Data Link in a disabled condition and between 11.0 VDC and 13.5 VDC.
the engine does not respond with the Power
Train Data Link in an enabled condition, a For 24 Volt Systems, the voltage should be
component of the Power Train Data Link is between 22.0 VDC and 27.0 VDC.
causing the response problem of the Accelerator
Pedal Position Sensor. Send the truck to the If the battery voltage is correct, temporarily
vehicle manufacturer in order to repair the faulty connect a test ECM. Use an Electronic Service
component of the Power Train Data Link. STOP. Tool and verify that the Active Diagnostic Code
is resolved. If the problem is corrected with the
Result 3 The ECM is operating in PTO mode. test ECM, reconnect the suspect ECM. Verify that
the Active Diagnostic Code returns. If the Active
Repair: If the PTO should not be active, refer to the Diagnostic Code returns with the suspect ECM,
following diagnostic procedure:Troubleshooting, replace the ECM.
PTO Switch Circuit - Test
STOP.
STOP.
No
Test Step 7. Disconnect The Power
Supply Connections For The Accelerator Repair: Perform the following repair:
Pedal Position Sensor At The ECM.
There is a problem in the wiring between the ECM
A. Turn the Ignition Key Switch to the OFF position. and the Accelerator Pedal Position Sensor. While
Active Diagnostic Codes are being monitored,
B. Remove terminal 4 (+8 V) and terminal 5 connect the removed wires one at a time in
(Accelerator/Switch Sensor Common) from order to verify that the Active Diagnostic Codes
Vehicle Harness Connector P1. Disconnect ECM reappear. First connect terminal 5 and then
Vehicle Harness Connector J1/P1, if necessary. connect terminal 4. This procedure is used to find
the wire that is causing the problem. Repair the
C. Reconnect ECM Connector J1/P1. wire or replace the wire, as required. Verify that
the repair eliminates the problem.
D. Turn the Ignition Key Switch to the ON position.
STOP.
E. Use an Electronic Service Tool and check if the
Diagnostic Code is still Active. Test Step 8. Check The Duty Cycle Of
The Accelerator Pedal Position Sensor
Expected Result: At The Sensor.
One of the following Diagnostic Codes is still active Note: Performing certain steps within this procedure
after the terminals for sensor power have been requires the use of a multimeter that is capable of
disconnected: measuring a PWM Duty Cycle.
41-03 8 Volt Supply Above Normal (21) A. Turn the Ignition Key Switch to the OFF position.
41-04 8 Volt Supply Below Normal (21) B. Remove the signal wire for the Accelerator Pedal
Position Sensor (terminal C) from P403. This
Results: is the Vehicle Harness side of the Accelerator
Pedal Position Sensor Connector.
Yes
C. Install a Breakout T with 3 terminals at the
Repair: Perform the following repair: Accelerator Pedal Position Sensor Connector
J403/P403.
135
D. Connect the multimeter probes to terminal G. Turn the Ignition Key Switch to the OFF position.
C (ACCELERATOR PEDAL POSITION) and
terminal B (ACCELERATOR/SWITCH SENSOR H. Insert terminal 66 into the ECM Vehicle Connector
COMMON) of the Breakout T. P1/J1 (70 Terminal).
E. While the Duty Cycle is being monitored on the Expected Result:

release the accelerator pedal. The Duty Cycle is between 10 and 22 percent with
The Duty Cycle is between 10 and 22 percent with High Idle position.
position, and the Duty Cycle is between 75 and 90 Results:
High Idle position. Yes A good signal from the Accelerator Pedal
Position Sensor is reaching the ECM. Verify that
Results: the ECM is receiving the proper battery voltage. If
the ECM is receiving the proper battery voltage,
Yes Reinsert the wire (terminal C) into the temporarily connect a test ECM and verify that the
Vehicle Harness Connector. The Accelerator problem is resolved. If the problem disappears
Pedal Position Sensor is working correctly. with the test ECM, reconnect the suspect ECM.
Proceed to test step 9. If the problem returns with the suspect ECM,
replace the ECM. STOP.
No Leave the PWM Probe Connected to the
Breakout T. Insert the wire (terminal C) into No There is a problem with signal wire for the
the Vehicle Harness Connector. The Accelerator Accelerator Pedal Position Sensor in the Vehicle
Pedal Position Sensor or the Accelerator Pedal Wiring Harness. Proceed to test step 11.
Assembly is faulty. Proceed to test step 10.
Test Step 10. Remove The Accelerator
Test Step 9. Check The Duty Cycle Of Pedal Position Sensor From The
The Accelerator Pedal Position Sensor Accelerator Pedal Assembly.
At The ECM.
Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of B. Remove the Accelerator Pedal Position Sensor
measuring a PWM Duty Cycle. from the Accelerator Pedal Assembly. Note
sensor orientation in the Accelerator Pedal
A. Turn the Ignition Key Switch to the OFF position. Assembly, and the sensor pigtail routing prior to
sensor removal. Thoroughly inspect the pigtail
B. Remove the wire for the ACCELERATOR PEDAL for signs of abrasion.
POSITION SENSOR (terminal 66) from the
Vehicle Harness side (P1) of ECM Connector C. Connect the multimeter that is capable of
P1/J1. You may be required to disconnect ECM measuring a PWM Duty Cycle to terminal C
Connector P1 in order to remove the terminal for of the Breakout T.
the signal input of the ACCELERATOR PEDAL
POSITION SENSOR. D. Turn the ignition key switch to the ON position.
C. Connect the multimeter probes between removed E. Display the Duty Cycle output of the Accelerator
wire and terminal 5 (ACCELERATOR/SWITCH Pedal Position Sensor while the sensor slot is
SENSOR COMMON) of P1. released. Use a screwdriver to advance the
D. Reconnect ECM Connector P1 to the ECM. Illustration 38.
E. Turn the Ignition Key Switch to the ON position. When the sensor is removed from the Accelerator
Pedal Assembly, the following Diagnostic Code
F. Use the multimeter in order to display the may be generated:
Duty Cycle output of the Accelerator Pedal
Position Sensor. While the Duty Cycle output 91-13 Throttle Sensor Calibration (28)
of the Accelerator Pedal Position Sensor is
being monitored on the multimeter, move the
to the High Idle position. Record the results.
136
This is normal. The Diagnostic Code should

assembled back into the Accelerator Pedal
Assembly.
g00706977
Illustration 38
Accelerator pedal assembly
Expected Result: Results:
When the sensor is removed from the Accelerator Yes The Accelerator Pedal Position Sensor is
Pedal Assembly and the sensor slot is released, the working correctly. Clear any diagnostic codes that
Duty Cycle is 10 percent or less. When the sensor were caused by performing this test procedure.
slot is moved to the maximum position, the Duty Refer to the OEM dealer for correct replacement
Cycle increases to 90 percent or more. of the Accelerator Pedal Assembly. STOP.
137
No The Accelerator Pedal Position Sensor is i01364899

faulty. Check the Accelerator Pedal Assembly
in order to ensure that the Accelerator Pedal ATA (SAE J1587 / J1708) Data
Assembly is not causing damage to the sensor.
If the Accelerator Pedal Assembly is causing
Link Circuit - Test
damage to the sensor, refer to the OEM dealer SMCS Code: 1408-081; 1901-081
for correct replacement of the Accelerator Pedal
Assembly. If the Accelerator Pedal Assembly System Operation Description:
appears OK, replace the Accelerator Pedal
Position Sensor. STOP. Use this procedure under the following situation:
Test Step 11. Route The Supply Bypass Use this procedure if the Electronic Service Tool will
Wires To The Accelerator Pedal Position not power up or the Electronic Service Tool will not
Sensor. communicate with the ECM through the cab data
link connector.
B. Remove the signal wire for the accelerator pedal to this procedure:
position sensor (terminal 66) from the ECM
Connector P1. The ATA data link (American Trucking Association)
is the standard data link that is used by the
C. Remove terminal C (Accelerator Pedal Position) ECM to communicate with Electronic Service
from the Accelerator Pedal Position Sensor Tools. The SAE specification J1587 defines the
Connector. format of the messages and data that is being
communicated. The SAE specification J1708
D. Route new wiring from the ECM to the Accelerator defines the hardware requirements and the protocol
Pedal Position Sensor. of the serial communications. The Caterpillar
Electronic Technician (ET) is an example of one
E. Turn the ignition key switch to the ON position. of the Electronic Service Tools. Some electronic
dashboards use this data link to receive information.
F. Check the Duty Cycle of the Accelerator Pedal Some automatic transmissions also receive
Position Sensor with an Electronic Service Tool information from this data link.
while the accelerator pedal assembly is being
moved over the full range. The ECM provides the following two ATA data link
connection terminals from the ECM vehicle harness
Expected Result: connector J1:
The Duty Cycle is between 10 and 22 percent with Terminal 9 (J1587 DATA LINK NEGATIVE)
position, and the Duty Cycle is between 75 and 90 Terminal 8 (J1587 DATA LINK POSITIVE)
High Idle position. The vehicle OEM provides twisted pair wiring from
the ECM to the cab data link connector.
Results:
Remember that there are potentially several devices
Yes that are installed in the vehicle and remember that
these devices are connected to the ATA data link
Repair: Perform the following repair: at one time. These devices include dash displays,
trip recorders and transmission controls. These
The wiring from the ECM to the Accelerator Pedal devices may cause problems with the data link.
Position Sensor appears faulty. Permanently These problems can disrupt communications to the
install new wiring. engine ECM and from the engine ECM.
Verify that the repair eliminates the problem. Communication
STOP. When the ignition key switch is in the OFF position,
the ECM may communicate with the Electronic
No Double check the wiring, the ECM Vehicle Service Tool. The communications may be disrupted
Harness Connector J1/P1 and the Sensor and the communications may require frequent
Connector. If a problem still exists, restart the test reconnection. In order to avoid this problem, turn
procedure. STOP. the ignition key switch to the ON position when the
Electronic Service Tool is being used.
138
The Caterpillar Electronic Technician may indicate

the following error message:
The version of the ECM is not recognized and

the integrity of the changed parameters and
displayed data is not guaranteed.
This message will indicate that the latest version of

the Electronic Technician has not been installed or
this message will indicate that the software in the
ECM is newer than the software for the Electronic
Technician.
g00650338
Illustration 39
Schematic for ATA Data Link with 6-pin connector
139

And Wiring.
g00650339
Illustration 40
A. Thoroughly inspect the following electrical Expected Result:

connectors:
ECM vehicle harness connector J1/P1 completely coupled and/or inserted and the harness
cab data link connector or pinch points.
firewall bulkhead connector Results:
Electronic Service Tool connectors OK Proceed to Test Step 2.

ATA data link (terminal 8 and terminal 9) in the Not OK
connectors
Connectors for details. Repair the connectors or wiring and/or replace
B. Perform a 45 N (10 lb) pull test on each of the seals are properly in place and ensure that the
wires in the ECM connector that are associated connectors are completely coupled.
with the ATA data link.
the proper torque of 6.0 Nm (55 lb in). STOP.
D. Check the harness and wiring for abrasion and Test Step 2. Determine The Type Of
pinch points from the connector to the ECM. Problem With The Data Link.
Refer to Illustration 40. A. Connect an Electronic Service Tool to the cab
140
B. Start the engine. Repair: Perform the following diagnostic

procedure:
Expected Result:
Troubleshooting, Engine Will Not Crank
Result 1 The engine starts. The Electronic Service
Tool powers up and the Electronic Service Tool STOP.
communicates without error.
Result 5 The Electronic Service Tool does not
Result 2 The engine starts. The Electronic Service power up or the Communications Adapter does
Tool powers up but an error is displayed. not power up. Ensure that the ECM is receiving
the correct battery power. Proceed to Test Step 3.
Result 3 The engine cranks but the engine will not
start regardless of the condition of the Electronic Test Step 3. Check The Battery Voltage
Service Tool. Supply To The Cab Data Link Connector.
Result 4 The engine will not crank regardless of the
condition of the Electronic Service Tool.
Result 5 The engine starts but the Electronic

Service Tool does not power up.
Note: Check the display screen or check the

Communication Adapter display in order to
determine if the Electronic Service Tool has
powered up. The Electronic Service Tool will display
information that shows if the tool is getting power.
If the Electronic Service Tool or the Communication
Adapter powers up, the cab data link connector
is receiving power.
Results:
Result 1 There is not a problem with the

ATA data link at this time. If an intermittent
condition exists, thoroughly inspect all wiring and
connectors.

procedure:
Troubleshooting, Inspecting Electrical

Connectors
STOP.
Result 2 The Electronic Service Tool displays

an error message. The ECM is receiving battery
power. Proceed to Test Step 5.
Result 3
procedure:
Troubleshooting, Engine Cranks But Will Not

Start Illustration 41
g00764445
STOP. A. Turn the ignition key switch to the ON position.

Result 4
141
B. Use a multimeter in order to measure the voltage b. Repower the Electronic Service Tool after
from the + battery terminal of the cab data link each of the pieces is replaced. Use this
connector to the battery terminal of the cab method to find the faulty piece.
G. If changing cables does not allow the Electronic
Refer to Illustration 41. Service Tool to operate properly, connect another
Expected Result:
H. Turn the ignition key switch to the ON position.
The voltage is between 11.0 and 13.5 VDC for a 12
Volt system or between 22.0 and 27.0 VDC for a Expected Result:
24 Volt system.
Result 1 The original Electronic Service Tool works
Results: on another vehicle.
Yes The cab data link connector is currently Result 2 A different Electronic Service Tool works on
receiving the correct voltage. Proceed to Test the original vehicle while the engine is being tested.
Step 4.
Results:
No The cab data link connector is not receiving
the correct voltage. Result 1 Proceed to Test Step 5.
Repair: Inspect the wiring and fuses to the Result 2
connector. Repair the wiring or batteries and/or
replace the wiring or batteries, as required. Repair: Send the faulty Electronic Service Tool
Send the vehicle to the OEM dealer for repair, if for repairs.
necessary.
STOP.
STOP.
Test Step 4. Change Electronic Service

Tool Components.
A. If another vehicle or another ECM is available
with a Caterpillar Electronic Engine, connect the
Electronic Service Tool to the other vehicle by
using the same cables.

Determine if the Electronic Service Tool operates
correctly on the other vehicle.
C. If another engine is not available in the shop, find

a different set of electronic service tool cables.
Ensure that the set of electronic service tool
cables is a complete set.
D. Connect the Electronic Service Tool to the cab

data link connector by using the new cables.
F. If changing cables allows the Electronic Service

Tool to operate properly, use the following
procedure:
a. Replace the pieces from the old set of cables

into the new set of cables that operates.
Replace one piece at a time.
142
Test Step 5. Check The Battery Voltage

At The ECM.
g00650356
Illustration 42
ECM Breakout T-connector and terminal locations for ECM P1
A. Ensure that the Electronic Service Tool is Results:

connected to the cab data link connector.
Yes The ECM is currently receiving the correct
B. Disconnect vehicle harness connector P1 from voltage. Proceed to Test Step 6.
ECM connector J1 and insert a 70-Terminal
breakout T. No The ECM is not receiving the correct
voltage. Ensure that there is not an aftermarket
C. Turn the ignition key switch to the ON position. engine protection switch that is overriding battery
power to the ECM.
D. Measure the voltage between vehicle harness
connector P1 terminal 52 (unswitched +battery) Repair: Perform the following diagnostic
and terminal 65 ( battery). procedure:
E. Measure the voltage between vehicle harness Troubleshooting, Ignition Key Switch Circuit and
connector P1 terminal 70 (ignition key switch) Battery Supply Circuit - Test
and terminal 65 ( battery).
STOP.
Expected Result:
The voltage is between 11.0 and 13.5 VDC for a 12

Volt system or between 22.0 and 27.0 VDC for a
24 Volt system.
143
Test Step 6. Connect The Electronic

Service Tool Directly To The ECM.
g00741090
Illustration 43
Note: This bypass directly connects the circuit

for the ignition key switch to the ECM. The ECM
will remain powered until the connection to the
Batteries give off flammable fumes which can ex-
unswitched battery line + is disconnected.
plode.
Remove the 20 Amp fuse from the in-line fuse
holder to power down the ECM. Do Not connect the
To avoid injury or death, do not strike a match,
bypass to the battery posts without first removing
cause a spark, or smoke in the vicinity of a battery.
the 20 Amp in-line fuse or do not remove the bypass
from the battery posts without first removing the 20
NOTICE Amp in-line fuse.
Do Not connect the bypass harness to the battery un-
til the 20 Amp in-line fuse has been removed from the Expected Result:
+battery line. If the fuse is not removed before con-
nection to the battery a spark may result. The Electronic Service Tool is operating correctly.
Results:
Yes
B. Disconnect vehicle harness connector J1/P1
from the ECM. Repair: Perform the following repair:
C. Install an Electronic Service Tool power bypass There is a problem in the vehicle wiring, or
cable. Connect a bypass harness to ECM another device in the vehicle is causing problems
connector J1. on the data link. Either determine the device that
is causing the problem or send the vehicle to the
Refer to Illustration 43 for the bypass harness. OEM dealer for repair.
STOP.
144
No Verify that the 20 Amp fuse in the bypass 6. If the problem returns with the suspect ECM,
harness of the Electronic Service Tool is not open. replace the ECM.
A fuse that is open is a blown fuse. Proceed to
Test Step 7. 7. Verify that the repair eliminates the problem.
Test Step 7. Connect An Electronic STOP.

Service Tool And The ECM To Another
Battery.
i01409099
Check Engine Lamp Circuit -

Test
plode. SMCS Code: 7431-081
To avoid injury or death, do not strike a match, System Operation Description:
NOTICE
Do Not connect the Bypass Harness to the battery
if the Check Engine Lamp is operating incorrectly:
until the 20 Amp in-line fuse has been removed from
the +Battery line. If the fuse is not removed before
The Check Engine Lamp is the only standard lamp
connection to the battery a spark may result.
that is used.
A. Connect the Battery wires from the bypass The following background information is related
harness of the Electronic Service Tool to a to the following procedure:
different battery that is not on the vehicle.
Check Engine Lamp
Expected Result:
The Check Engine Lamp is used to provide the
The Electronic Service Tool is operating correctly. following functions:
Results: Indicate the existence of an Active diagnostic

code.
Yes The vehicle battery is causing the problem.
Indicate driver alert status of the Idle Shutdown
Repair: Perform the following diagnostic Timer.
procedure:
Read diagnostic flash codes.
Troubleshooting, Ignition Key Switch Circuit and
Battery Supply Circuit - Test Power Up Lamp Check
STOP. At powerup, the lamp will turn ON for five seconds.

The lamp will continue to flash if there is an Active
No diagnostic code.
Repair: Perform the following repair: Operation with an Active Diagnostic Code
1. Temporarily connect a test ECM. While the engine is operating, the Lamp will turn ON
for a minimum of five seconds when certain fault
2. Remove all jumpers and replace all connectors. conditions exist. If certain fault conditions exist, the
Lamp will operate in the following manner:
codes. The Check Engine Lamp will turn ON for five
seconds.
The Check Engine Lamp will turn OFF for a short
5. If the problem is resolved with the test ECM, time.
145
The Check Engine Lamp will turn ON for another The ECM provides a path to ground in order to turn
five seconds. the lamp ON.
The Check Engine Lamp will continue to operate in

this manner while the fault condition exists.
Indication of the Driver Alert Status of the Idle

Shutdown Timer
During the final 90 seconds of the operation of the

Idle Shutdown Timer, the Check Engine Lamp will
begin to flash. The flashing of the Check Engine
Lamp indicates that an engine shutdown is near.
Flashing Out Diagnostic Flash Codes
The Flash Codes are two-digit representations of

diagnostic codes. The PID-FMI Diagnostic Code
should be used for troubleshooting. The PID is the
Parameter Identifier. The FMI is the Failure Mode
Identifier. A 110-03 is an example of a PID-FMI
Diagnostic Code. Flash Codes provide an indication
of a failure. Flash codes are not as specific as
diagnostic codes. Flash codes only indicate that a
failure has occurred. Flash codes do not indicate
the specific type of failure. For example, the Flash
code (27) is used for a 110-03 Fault code and a
110-04 Fault code. Flash Codes should not be used
for troubleshooting.
Diagnostic flash codes that are active can be

viewed at any time. Turn the Cruise Control On/Off
switch to the OFF position. Hold the Set/Resume
switch in either the SET position or the RESUME
position until the lamp begins to flash. Then release
the Set/Resume switch.
The Flash Code is determined by the blinking of

the Check Engine Lamp. The lamp will blink for the
first digit of the flash code, and the lamp will pause
for five seconds. Then, the lamp will blink for the
second digit.
Some vehicles are equipped with a Diagnostic

Enable Switch. The Diagnostic Enable Switch is
used to flash the diagnostic codes by grounding the
input of the Diagnostic Enable Switch from terminal
46 (Input 7) to terminal 5 (Sensor Common).
Note: The Check Engine Lamp should not

continuously flash the diagnostic flash codes. If the
Set switch, the Resume switch, or the Diagnostic
Enable switch has not been used, then the circuit is
probably shorted to ground.
Electrical Connection of The Check Engine Lamp
One terminal of the Check Engine Lamp must be

connected to battery voltage through the vehicle
wiring. The other terminal is connected to the ECM
at the Vehicle Harness Connector J1/P1 terminal 28
(CHECK ENGINE LAMP).
146
g00676880
Illustration 44
Schematic for Lamp
g00676965
Illustration 45
Test Step 1. Inspect Electrical Connectors Refer to Illustration 45.

And Wiring.
C. Check the ECM Connector (Allen Head Screw)
A. Thoroughly inspect ECM Vehicle Harness for the proper torque of 6.0 Nm (55 lb in).
Connector J1/P1, the firewall bulkhead
connector, and the Check Engine Lamp (Terminal D. Check the harness and wiring for abrasion and
28). Refer to Troubleshooting, Inspecting pinch points from the battery to the ECM.
Electrical Connectors for details.

with the Check Engine Lamp:
147
Expected Result:

or pinch points.
Results:

Not OK
replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure that
the connectors are completely coupled.
STOP.
Test Step 2. Check For Normal Operation

Of The Lamp.
A. Monitor the Check Engine Lamp.
a. Turn the ignition key switch to the ON position.

The lamp should turn ON for five seconds.
Then, the lamp should turn OFF.
b. The lamp will continue flashing if there is an

Active Diagnostic Code. If there is an Active
Diagnostic Code, connect an Electronic
Service Tool in order to read the Active
Diagnostic Code. Troubleshoot the problem.
Expected Result:
The Check Engine Lamp turns ON and the Check

Engine Lamp turns OFF per the above description.
Results:
Yes The check engine lamp appears to

operating correctly at this time. STOP.
No Proceed to test step 3.

148
Test Step 3. Test The Lamp Circuit.
g00676968
Illustration 46
A. Disconnect ECM Vehicle Harness Connector Result 2 The lamp did not turn ON. The
J1/P1. vehicles lamp circuit is not functioning properly.
The lamp is probably burned out or there is a
B. Fabricate a jumper wire 100 mm (4 inch) long. problem in the wiring from the cab to either the
Crimp a Deutsch Pin to both ends of the wire. ECM or the +Battery connection. Repair the lamp
C. Insert the jumper into the terminal 28 (Check repairs. STOP.
Engine Lamp) of connector P1.
Result 3
D. Connect the other side of the jumper wire to P1
terminal 65 (-BATTERY). Repair: Perform the following diagnostic
procedure:
The circuit between the ECM and the lamp is
F. While the lamp is being watched, insert the shorted to chassis ground. Repair the circuit or
jumper wire and remove the jumper wire. send the vehicle to the OEM dealer for repairs.
Refer to Illustration 46. STOP.
Expected Result:
Result 1 The Check Engine Lamp turns ON while

the jumper is connected to both sockets. Also, the
Check Engine Lamp turns OFF when the jumper is
Result 2 The Check Engine Lamp does not turn ON

while the jumper is connected to both sockets.
Result 3 The lamp will stay on while the ECM

Vehicle Harness Connector is disconnected.
Results:
Result 1 The Check Engine Lamp circuit is

functioning properly. Proceed to test step 4.
149

Check Engine Lamp.
g00642525
Illustration 47
A. Disconnect ECM Vehicle Harness Connector Results:

J1/P1.
B. Insert a 70-Terminal Breakout T between ECM problem in the vehicle wiring or the lamp. Repair
Vehicle Harness Connector J1 and ECM Vehicle the vehicle wiring or the lamp, as required. STOP.
No Temporarily connect a test ECM. Check the
C. Connect a voltage test lamp probe to terminal operation of the Check Engine Lamp when the
65 (-BATTERY) and connect the other probe to test ECM is installed. If the problem is resolved
terminal 52 (UNSWITCHED +BATTERY) of the with the test ECM, then reconnect the suspect
Breakout T. ECM. If the problem returns with the suspect
ECM, then replace the ECM. STOP.
D. The test lamp should turn ON. If the test lamp
does not turn on, either the test lamp is faulty or
i01382486
the wiring to the ECM is faulty. Continue with this
step if the lamp turns ON. Clutch Pedal Position Switch
E. Leave the voltage test lamp probe connected to Circuit - Test
terminal 52 (UNSWITCHED +BATTERY).
Terminal 28 (CHECK ENGINE LAMP) of the System Operation Description:
Breakout T.
Use this procedure to determine if the clutch pedal
G. Watch the voltage test lamp. Turn the ignition position switch is preventing normal operation of
key switch to the ON position. cruise control, fast idle, idle set speed, or PTO
operation:
H. The lamp should turn ON for five seconds. Then,
the lamp should turn OFF. The lamp will continue The following switch circuits can also prevent the
flashing if there is an Active Diagnostic Code. If correct operation of the cruise control, idle set
there is an Active Diagnostic Code, connect an speed or PTO operation:
Electronic Service Tool in order to read the Active
Diagnostic Code. Troubleshoot the problem. service brake pedal position (switch 1)
Expected Result: service brake pedal position (switch 2)
The Check Engine Lamp turns ON and the Check neutral switch
Engine Lamp turns OFF per the above description.
cruise control set/resume switch
cruise control on/off switch
150
PTO on/off switch Note: Idle in this procedure is an engine idle rpm
above the programmed low idle rpm. Idle is set
The switches are described in the respective circuit by using the cruise control on/off switch and the
tests in Troubleshooting. set/resume switch. Refer to Troubleshooting, PTO
Switch Circuit - Test for additional information
All of the following Customer Programmable regarding the programmable options for the
Parameters can affect cruise control, fast idle, idle Dedicated PTO.
set speed, and PTO operation:
Note: Fast idle in this procedure is an engine idle
Low Cruise Control Speed Set Limit rpm above the programmed low idle rpm. Fast idle
is set by using a dedicated fast idle switch.
Cruise Control On/Off Switch
This switch must be on before cruise control or
Fast Idle RPM #1 controlled idle can be activated. This switch is
on when the switch is closed. When the switch is
Fast Idle RPM #2 closed the following terminals are connected:
Cruise/Idle/PTO Switch Configuration ECM connector J1/P1 terminal 59 (cruise control

on/off switch)
Idle/PTO Bump rpm
Terminal 5 (AP sensor/switch sensor common)
Idle/PTO rpm Ramp Rate
Note: If the vehicle is programmed to use the
PTO Vehicle Speed Limit Dedicated PTO, the PTO on/off switch overrides
the cruise control on/off switch. The PTO on/off
The vehicle speed calibration can also affect switch overrides the cruise control on/off switch
the cruise control, the idle set speed, and the when the vehicle speed is within the range of the
PTO if the vehicle speed calibration is incorrectly PTO Vehicle Speed Limit that is programmed.
programmed. Refer to Troubleshooting, Customer
Specified Parameters. Set/Resume Switch
Clutch Switch With the cruise control on/off switch in the ON

position and the vehicle speed within the range
The clutch pedal position switch is normally closed of the programmed Low Cruise Control Speed
when the pedal is released. Depressing the clutch Set Limit and the High Cruise Control Speed Set
pedal should open the circuit. This switch is OEM Limit, momentarily pressing the set switch will
supplied. The clutch pedal position switch is activate cruise control, and the ECM will maintain
typically a limit switch that is mounted near the the current speed.
pedal. The clutch pedal position switch is usually
adjustable. After a speed has been set and the speed is then
disengaged by using the brake, the clutch, or the
The following background information is related on/off switch, the ECM will seek the previous set
to this procedure: speed when the resume switch is toggled. This
assumes that the vehicle speed is above the Low
The kickout switch refers to the switch that is used Cruise Control Speed Set Limit for cruise control or
to exit the cruise control, the fast idle, the PTO, or the vehicle speed is below the Idle/PTO Vehicle
the idle set speed. Speed Limit for the idle and the PTO.
The operation of the Caterpillar Electronic Engine After a speed has been set, pressing and holding
cruise control is similar to the operation of the the set/resume switch in position will cause the
cruise controls that are installed in automobiles. The engine to establish a new set speed. The systems
operation of fast idle, idle and PTO are similar to the reaction depends on the programming of the
operation of cruise except that the idle and the PTO Cruise/Idle/PTO Switch Configuration.
govern engine rpm instead of vehicle speed.
When the set/resume switch is momentarily pressed,
the cruise set point will change one mph. The
rate of change is dependent on the programmed
Idle/PTO Bump rpm when the engine is setting
on idle speed.
151
Kickout Switches Automatic Options 1

The brake pedal position switches, the neutral Automatic Option 2
switch and the clutch pedal position switch are
used in the cruise control mode, the PTO mode, the Automatic Option 3
fast idle mode, and the idle mode to discontinue
cruise operation, PTO operation, fast idle operation, Automatic Option 4
or idle operation. The capability to override the idle
shutdown timer is determined by the Allow Idle AT/MT/HT Option 1
Shutdown Override parameter setting. The Allow
Idle Shutdown Override is a Customer Parameter. AT/MT/HT Option 2
Usage of Transmission Style Switches AT/MT/HT Option 3
The Transmission Style parameter determines AT/MT/HT Option 4
the switches that will be used. The following
switches can be used with being dependent on the Universal Option
parameter setting:
A service brake pedal position (switch 1) is required
clutch pedal position for all configurations. The service brake pedal
position (switch 1) connects to the ECM through
neutral connector P1 terminal 45. The service brake pedal
position (switch 2) connects to the ECM through
service brake pedal position (switch 1) connector P1 terminal 64. The clutch pedal position
switch connects to the ECM through connector P1
service brake pedal position (switch 2) terminal 22. The neutral switch connects to the ECM
through connector P1 terminal 62.
Refer to Table 99 for additional information.
Some engines that were built before JULY 1999
Table 99 may have a Basic ECM. The Basic ECM was used
Switch Usage. only on General Motors chassis. Other chassis used
Setting For engines that were built with a Full Feature ECM.
Transmission Service Service Basic ECM software does not have the parameter
Style Brake Brake for Transmission Style. For these systems, a
Clutch Neutral
Parameter Switch Switch jumper wire must be installed between the clutch
1 2
switch input and the sensor common when an
Manual X X automatic transmission is installed. When the jumper
wire is installed, the Clutch Switch status will
Automatic
Option 1
X always indicate OFF. Engines that were built after
JULY 1999 use only one type of ECM that can be
Automatic configured for Basic or Full Feature operation.
X X
Option 2 A new parameter was added in order to provide
Automatic this flexibility. The Truck Manufacturer parameter
X X X was added in order to allow the configuration of the
Option 3
GM Basic operation or the Other Full Feature
Automatic operation. This parameter is programmed at
X X
Option 4 Caterpillar when the engine is built. The parameter
AT/MT/HT for Transmission Style is not available for engines
X that have software that is dated prior to SEP00
Option 1
and the parameter for Truck Manufacturer is
AT/MT/HT programmed to GM. SEP00 and newer engines
X X
Option 2
that are programmed to GM use the Transmission
AT/MT/HT Style parameter. The factory default for the GM
X X X
Option 3 setting is the Universal option. The Universal
option provides identical features as the Basic
AT/MT/HT
Option 4
X X system that is described above. If the Transmission
Style parameter is programmed to the Universal
Universal option, a jumper wire must be installed between the
X X X X
Option clutch switch input and the sensor common when an
automatic transmission is installed. Otherwise, the
If the Transmission Style parameter is programmed Transmission Style parameter can be programmed
to one of the following options, the input for the to match the specific arrangement of the vehicle.
clutch pedal position switch is not used:
152
If the problem is with undetermined

Cruise/Idle/PTO kickouts use the following
procedure:
Operate the vehicle in Cruise/Idle/PTO mode.
After the kickout, review the Electronic Service

Tool Status parameter. The Electronic Service Tool
Kickout Status parameter indicates the cause. This
is turned off. It is important to remember that the
parameter will only indicate the last kickout since the
ECM has been powered by the ignition key switch.
The following kickout status parameters are

available:
Cruise Kickout
Idle Kickout
PTO Kickout
This parameter is blank when the ECM is first
powered up. If this parameter is blank, No
Occurrence is indicated. This parameter remains
blank until the ECM detects the use of the
cruise/idle/PTO mode. Also, this parameter remains
blank until the ECM detects the disengagement of
the cruise/idle/PTO mode. Refer to Tables 100 and
101 in order to interpret the status screen kickout
status parameter.
153
Table 100
Cruise Control Kickout Status Table
Intermittent vehicle speed signal or lost Refer to Troubleshooting, Vehicle Speed
Vehicle Speed < Limit
vehicle speed signal. Circuit - Test.
The cruise/idle on/off switch is turned off Refer to Troubleshooting, Cruise Control
Switch Turned Off or the switch circuit has an open circuit Switch Circuit - Test.
condition.
Brake the service brake switch circuit has an Pedal Position (Switch 1) Circuit - Test.
The clutch pedal is depressed or the Proceed with the test procedure.
clutch pedal switch circuit has an open
Clutch
The transmission is not in gear or the Refer to Troubleshooting, Neutral Switch
Neutral transmission switch circuit has a short Circuit - Test.
circuit condition.
Vehicle speed signal is erratic or Refer to Troubleshooting, Vehicle Speed
Bad Vehicle Speed intermittent. Circuit - Test if a problem with the signal
exists.
The PTO on/off switch is turned on or the Refer to Troubleshooting, PTO Switch
PTO Switch On circuit for the PTO on/off switch has a short Circuit - Test.
circuit condition.
The set/resume switch was held in the SET Cruise control cannot be set until the cruise
position for more than 15 seconds (Basic) control on/off switch is turned to the OFF
Set Switch Timeout or there is a short circuit in the switch position and then turned back to the ON
circuit. position. If the circuit for the set switch is
suspected, proceed with this test procedure.
Resume Switch Timeout or there is a short circuit in the switch position and then turned back to the ON
circuit. position. If the circuit for the resume switch is
Cruise control has not been enabled since Drive the vehicle in cruise in order to create
No Occurrence
the ECM has been powered up. the problem again.
154
Table 101
Idle Kickout Status Table
Intermittent engine speed signal or lost Refer to Troubleshooting, Engine
No Engine Speed
engine speed signal. Speed/Timing Circuit - Test.
The cruise/idle on/off switch is turned off Refer to Troubleshooting, Cruise Control
condition.
Brake the service brake switch circuit has an open Pedal Position (Switch 1) Circuit - Test.
circuit condition.
Clutch
The vehicle speed has exceeded the Idle Refer to Troubleshooting, Vehicle Speed
PTO Switch On circuit for the PTO on/off switch has a short Circuit - Test.
circuit condition.
Idle set speed has not been enabled since Operate the vehicle in the Idle mode in order
No Occurrence
the ECM has been powered up. to create the problem again.
Table 102
Fast Idle Kickout Status Table
No Engine Speed
The fast idle on/off switch is turned off or the Proceed with the test procedure.
Switch Turned Off
circuit condition.
Clutch
Fast idle set speed has not been exited Operate the vehicle in the Idle mode in order
No Occurrence
since the ECM has been powered up. to create the problem again.
155
g00643881
Illustration 48
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
Test Step 1. Determine The Type Of D. Ensure that the vehicle is not experiencing
Problem. a problem due to one of these parameters.
Refer to Troubleshooting, Customer Specified
A. Connect an Electronic Service Tool. Parameters for a description of the parameters,
if necessary.
E. Check the Electronic Service Tool status screen
C. If the vehicle will not allow setting a cruise that indicates the last cause of a kickout for one
speed, an idle speed or a PTO speed, check the of the following modes:
following Customer Parameters:
Cruise Kickout
Idle Kickout
Fast Idle Kickout
PTO Kickout
Idle Parameters
Refer to Tables 100, 101, and 102 for the
Fast Idle RPM #1 meaning of the Electronic Service Tool status
screen parameter.
Fast Idle RPM #2
Expected Result:
The problem is due to a parameter setting or the
Idle RPM Limit problem is due to a normal kickout.
Top Engine Limit (TEL) Results:
PTO Parameters Yes Explain the proper operation of system to

the driver. STOP.
PTO Configuration
No
Repair: Refer to Tables 100, 101, and 102 for
recommended troubleshooting.
156
If a problem is still suspected with the clutch C. Check the ECM connector (allen head screw) for
switch circuit perform the following procedure: the proper torque of 6.0 Nm (55 lb in).
Proceed to Test Step 2. D. Check the harness and wiring for abrasion and
pinch points from the sensor to the ECM.
And Wiring. Expected Result:

or pinch points.
Results:
OK Proceed to Test Step 3.

Not OK
STOP.
Test Step 3. Check Clutch Switch Status

On The Electronic Service Tool.
Table 103
Clutch Pedal Position Status Table
Switch Position or Pedal Status Circuit
Position
The Clutch Pedal is ON Open
DEPRESSED.
The Clutch Pedal is OFF Closed
RELEASED.
g00773080
Illustration 49 A. Access the Electronic Service Tool status screen.
A. Thoroughly inspect ECM vehicle harness B. Turn the ignition key switch to the ON position.
connector J1/P1, the firewall bulkhead connector
and the terminals for the following switches in C. Depress the clutch pedal while the status of the
the connectors: clutch pedal position switch is being observed.
Also, release the clutch pedal while the status
clutch pedal position switch (terminal 22) of the clutch pedal position switch is being
observed.
AP sensor/switch sensor common (terminal 5)
Expected Result:
Connectors for details. The switch status changes per the information in
Table 103.
wires in the ECM connector that are associated Results:
with the switches.
Yes The switch is operating normally. STOP.
157
Intermittent Problem Suspected Proceed to Test RESULT 2 The Electronic Service Tool Kickout
Step 4. Status displays the following result:
No The ECM is not reading the switch status Switch Turned Off
change. Proceed to Test Step 5.
RESULT 3 The Electronic Service Tool Kickout
Test Step 4. Operate The Vehicle And Status displays the following result:
Check The Kickout Status Parameter.
Brake
A. For an intermittent Cruise Control Kickout, talk to
the driver in order to determine the conditions RESULT 4 The Electronic Service Tool Kickout
when the kickout occurs. Topics of examination Status displays the following result:
could be the following examples:
specific speed
Bad Vehicle Speed
road conditions
Vehicle Speed Limit
weather conditions
Take the vehicle for a road test in order to Status displays the following result:
duplicate these conditions and set the cruise
control. Operate the vehicle in cruise control until PTO Switch ON
the problem reoccurs.
B. For an intermittent idle kickout, talk to the driver Status displays the following result:
in order to determine the conditions when the
kickout occurs. A topic of examination could be Neutral
the following example:
specific engine rpm Status displays the following result:
Start the engine. Duplicate these conditions and No Engine Speed

set the idle rpm. Operate the vehicle in idle until
the problem reoccurs. RESULT 8 The Electronic Service Tool Kickout
Status displays the following result:
Note: The Electronic Service Tool status screen will
only indicate the last kickout. The Electronic Service Ser Switch Timeout
Tool status screen will lose this information if the
ignition key switch is turned off. Resume Switch Timeout
C. Connect an Electronic Service Tool and check Results:
the status screen for the last cause of the kickout.
Refer to Tables 100 and 101 for an explanation Result 1 Proceed to Test Step 5.
of the status parameter.
Result 2
D. If the Electronic Service Tool status screen is
blank, then either there was no kickout of the Repair: Perform the following diagnostic
cruise control, or the power to the ECM was procedure:
turned off before the information could be read.
Perform Steps A,B and C again. Troubleshooting, Cruise Control Switch Circuit -
Test
Note: An Electronic Service Tool status screen that
is blank indicates No Occurrence. STOP.
Expected Result: Result 3

RESULT 1 The Electronic Service Tool Kickout Repair: Perform the following diagnostic
Status displays the following result: procedure:
Clutch
158
Troubleshooting, Service Brake Pedal Position Test Step 5. Check The Switch Circuit for
(Switch 1) Circuit - Test the ECM.
STOP. Table 104
Clutch Switch Input Status Table
Result 4
Condition of Switch
Switch Status Circuit
Repair: Perform the following diagnostic Circuit
procedure: Terminal 22 is Open. ON Open
Troubleshooting, Vehicle Speed Circuit - Test Terminal 22 connected

OFF Closed
to terminal 5.
STOP.
Result 5
Repair: Perform the following diagnostic Crimp a Deutsch pin to both ends of the wires.
procedure:
Troubleshooting, PTO Switch Circuit - Test the ECM.
STOP. D. Connect a 70-Termial breakout T to ECM

Result 6
E. Install the jumper into terminal 22 (clutch pedal
Repair: Perform the following diagnostic position switch) of the breakout T. Connect
procedure: the other end of the jumper to terminal 5 AP
sensor/switch sensor common of the ECM
Troubleshooting, Neutral Switch Circuit - Test connector P1 of the breakout T.
STOP. F. Turn the ignition key switch to the ON position.
Result 7 G. Connect an Electronic Service Tool to the cab

procedure: H. Access the Electronic Service Tool status screen.
Troubleshooting, Engine Speed/Timing Circuit - I. While the clutch switch status is being monitored
Test on the Electronic Service Tool status screen
slowly remove the jumper from terminal 5 AP
STOP. sensor/switch sensor common. Now, slowly insert
the jumper into terminal 5 AP sensor/switch
Result 8 sensor common.
Repair: Perform the following diagnostic Refer to Table 104.

procedure:
Expected Result:
Troubleshooting, Cruise Control Switch Circuit -
Test The switch status changes per the information in
Table 104.
STOP.
Results:
Yes The ECM is functioning properly. Proceed

to Test Step 6.
No The ECM is NOT functioning properly.


159
2. Remove all jumpers and replace all connectors. Repair: Perform the following repair:
3. Recheck the system for active diagnostic Replace the faulty switch.
codes.
STOP.
reconnect the suspect ECM. No There is a problem in the harness between
the switch and the ECM. Proceed to Test Step 7.
6. If the problem returns with the suspect ECM,
replace the ECM. Test Step 7. Insert A Jumper At The
Bulkhead Connector.
Table 106
STOP. Clutch Switch Input Status Table
Test Step 6. Insert A Jumper At The Condition of Switch Switch

Circuit
Clutch Switch. Circuit Status
Bulkhead Wires are
Table 105 ON Open
Disconnected.
Clutch Switch Input Status Table Bulkhead Wires are
OFF Closed
Condition of Switch Switch Connected.
Circuit
Circuit Status
Clutch Pedal Position Switch A. Turn the ignition key switch to the OFF position.
ON Open
Wires are Disconnected.
Clutch Pedal Position Switch Crimp a Deutsch pin to both ends of the wires.
OFF Closed
Wires are Connected.
C. Find the terminal for the clutch switch. Also,
A. Turn the ignition key switch to the OFF position. find the terminal for the sensor common for the
AP sensor/switch. Look for the terminals in the
B. Ensure that ECM vehicle harness connector engine side of the bulkhead connector for the
J1/P1 is connected. vehicle harness.
C. Find the clutch switch in the vehicle. D. Insert the jumper wire between the two terminals
in the engine side of the bulkhead connector.
D. Disconnect the wires from the clutch switch
terminals. E. Turn the ignition key switch to the ON position.
E. Turn the ignition key switch to the ON position. F. Connect an Electronic Service Tool to the cab
F. Connect an Electronic Service Tool to the cab
data link connector. G. Access the Electronic Service Tool status screen.
G. Access the Electronic Service Tool status screen. H. While the switch status is being monitored
H. While the switch status is being monitored on alternately remove the jumper wire between the
the Electronic Service Tool status screen slowly two terminals, and alternately insert the jumper
connect the switch wires and slowly disconnect wire between the two terminals.
the switch wires.
Refer to Table 106.
Refer to Table 105.
Expected Result:
Expected Result:
The switch status changes per the information in
The switch status changes per the information in Table 106.
Table 105.
Results:
Results:
Yes The problem is in the vehicle wiring
Yes between the bulkhead connector and the switch.
160
Repair: Perform the following repair: The coolant level sensor is an OEM installed
component for the vehicle. This sensor is the
Inspect the vehicle wiring and repair the vehicle only optional sensor for Engine Monitoring.
wiring, as required. If the problem still exists with Engine Monitoring is a programmable feature
the wiring, send the vehicle to the OEM dealer. of the Caterpillar ECM. The sensor is selectable
through a Customer Programmable Parameter and
STOP. the Customer Programmable Parameter may be
protected by Customer Passwords. Some OEM
No The problem is in the vehicle wiring between installed coolant level sensors are not connected to
the bulkhead connector and the ECM. the Engine Control Module (ECM). Do not confuse
an OEM installed coolant level sensor that is
Repair: Perform the following repair: independent of Engine Monitoring with the coolant
level sensor that is used for Engine Monitoring.
Inspect the vehicle wiring and repair the vehicle
wiring, as required. If the problem still exists with The sensor operates as a coolant level sensor. The
the wiring, send the vehicle to the OEM dealer. sensor indicates the presence or the absence of
coolant at the sensor probe. A four wire sensor
STOP. that requires a +5 VDC connection to a power
supply must be used. The customer programmable
parameter for the coolant level sensor can be
i01468769
programmed to 4-Pin for a four wire sensor
Coolant Level Sensor Circuit - if a sensor is installed. Also, the customer
programmable parameter for the coolant level
Test sensor can be programmed to None (default) if
the option for the coolant level sensor is not being
SMCS Code: 7422-081 used.
System Operation Description: Four Wire Sensor
Use this procedure under the following situation: The sensor is powered from the ECM through the
ECM vehicle harness connector J1/P1 terminal 2
Use this procedure if the following diagnostic code (+5 VDC). The ECM vehicle harness connector has
is active or easily repeatable: 70 terminals. The signal wires for the coolant level
sensor are connected to the ECM vehicle harness
111-02 Coolant Level Sensor Fault (12) connector J1/P1 at terminal 54 (coolant level low)
and terminal 49 (coolant level normal). The sensor
Do not use this procedure for either of the following common wire is connected to the ECM vehicle
diagnostic codes: harness connector J1/P1 through terminal 5 (ap
111-01 Low Coolant Level Warning (62)
If coolant is present at the sensor probe, Coolant
111-11 Very Low Coolant Level (62) Level Low has an output of near 0 VDC. If coolant
is present at the sensor probe, Coolant Level
These diagnostic codes indicate a low coolant level Normal has an output near +5 VDC. If coolant is
but not an electrical system malfunction. Refer to not present at the sensor probe, the Coolant Level
Troubleshooting, Event Codes - Test. Low output would be near +5 VDC. If coolant is
not present at the sensor probe, the Coolant Level
The following background information is related Normal output would be near 0 VDC.
to this procedure:
Note: If Engine Monitoring is programmed to
OFF, or the coolant level sensor is programmed to
None, the coolant level sensor is ignored by the
ECM. Conversely, if both parameters are set, then a
sensor must be installed. The Engine Monitoring
is set when the Engine Monitoring is programmed
to WARNING, DERATE, or SHUTDOWN. The
Coolant Level Sensor is set when the coolant level
sensor is programmed to 4-Pin. If both parameters
are set and a sensor is not installed, the following
diagnostic code will be Logged:
161
111-02 Coolant Level Sensor Fault (12)
g00650999
Illustration 50
Schematic for 4-pin coolant level sensor
Test Step 1. Check The Electronic Service

Tool For An Active Coolant Level Sensor
Fault.
C. Access the active diagnostic screen of the

D. Verify that the following diagnostic code is active:

Expected Result:
The following diagnostic code is active.

Results:
Yes Proceed to Test Step2.

No, 111-01 or 111-11 Code Active A diagnostic
code 111-01 (Low Coolant Level Warning) is
active or a diagnostic code 111-11 (Very Low
Coolant Level) is active.
Repair: Refer to Troubleshooting, Event Codes -

Test for the proper troubleshooting procedure.
STOP.
No active codes If none of the specified

diagnostic codes are present, clear all diagnostic
codes. If a problem is still suspected with the
coolant level sensor, proceed to Test Step 2.
162

And Wiring.
g00651001
Illustration 51
A. Thoroughly inspect ECM vehicle harness D. Check the harness and wiring for abrasion and
connector J1/P1, the connector for the extension pinch points from the sensor to the ECM.
harness for the coolant level and the terminals
for the coolant level sensor in the connectors. Expected Result:
The connector for the extension harness for the
coolant level connects the coolant level sensor to All connectors, pins and sockets should be
the vehicle harness in the engine compartment completely coupled and/or inserted and the harness
of some chassis. Refer to Troubleshooting, and wiring should be free of corrosion, abrasion
Inspecting Electrical Connectors for details. or pinch points.
B. Perform a 45 N (10 lb) pull test on each of the Results:

wires in the ECM connector that are associated
with the following connections: OK Proceed to Test Step 3.
terminal 2 Not OK
terminal 5 Repair: Repair the connectors or wiring and/or
terminal 49 of the seals are properly in place and ensure that
terminal 54
Verify that the repair eliminates the problem. Clear
Refer to Illustration 51. all diagnostic codes.
C. Check the ECM connector (allen head screw) for STOP.

the proper torque of 6.0 Nm (55 lb in).
163
Test Step 3. Disconnect The Coolant E. While the jumper wire is in place, access the
Level Sensor And Check The Supply status screen of the Electronic Service Tool that
Voltage (+5 VDC). indicates the coolant level status.
A. Turn the ignition key switch to the OFF position. F. Wait for 30 seconds. Read the status and record
the status.
B. Disconnect the coolant level sensor from the
harness. G. Turn the ignition key switch to the OFF position.
C. Use a multimeter to measure the voltage at the Expected Result:

harness connector from terminal C (+ 5 VDC) to
terminal B (ap sensor/switch sensor common). The coolant level status indicates LOW with the
jumper in place.
Results:
Expected Result:
Yes Leave the jumper wire in place. If a
The measured voltage is between 4.5 VDC and 5.5 breakout T is installed, leave the breakout T in
VDC. place also. Proceed to Test Step 6.
Results: No Proceed to Test Step 7.

Yes Proceed to Test Step 4. Test Step 5. Disconnect The Sensor
Supply Terminal (+5 VDC) From The ECM
No Proceed to Test Step 5. Connector.
Test Step 4. Disconnect The Coolant
Level Sensor And Check The Coolant
Level Normal Harness.
g00651005
Illustration 52
Jumper wire
g00756042
Illustration 53
B. Disconnect the coolant level sensor from the
harness.
C. Use a jumper wire in order to connect terminal
J1/P1.
D (coolant level normal) to terminal b (ap
sensor/switch sensor common) at the harness
C. Install a 70-Terminal breakout T between ECM
connector.
vehicle harness connector J1 and vehicle
harness connector P1.
E. Measure the voltage at the breakout T from
terminal 2 to terminal 5.
164
Refer to Illustration 53. C. Turn the ignition key switch to the ON position.
Expected Result: D. While the jumper wires are in place, access the
active diagnostic code screen of the Electronic
The measured voltage is between 4.5 VDC and 5.5 Service Tool.
VDC.
E. Check for the following active diagnostic code:
Results:
Yes The problem is located in the harness
wiring. Note: Wait for 30 seconds for the activation of the
diagnostic code.
Repair: Repair the wiring or replace the wiring,
as required. Expected Result:
Verify that the repair eliminates the problem. The following diagnostic code is active while the
jumper wires are in place.
STOP.
No The problem is on the ECM side.
Results:
Repair: Temporarily connect a test ECM. Ensure
that the Engine Monitoring and the Coolant Yes The harness and the ECM are working
Level Sensor are programmed to match the correctly.
old ECM. Check the test ECM by measuring
the voltage at the breakout T from terminal 2 to Repair: Remove the jumpers. Replace the sensor
terminal 5 again. If the problem is resolved with and ensure that the following diagnostic code
the test ECM, reconnect the suspect ECM. If the disappears with the new sensor:
problem returns with the suspect ECM, replace
the ECM. 111-02 Coolant Level Sensor Fault (12)
STOP. Verify that the repair eliminates the problem. Clear
all diagnostic codes.
Test Step 6. Check The Wire Harness for
the Coolant Level Low . STOP.
g00651008
Illustration 54
Jumper wire
B. Use a jumper wire in order to connect terminal

A (coolant level low) and terminal d (coolant
level normal) to terminal b (sensor common) at
the harness connector.

165
Test Step 7. Use The 70-Terminal J. While both jumper wires are in place, access the
Breakout T To Check The ECM. active diagnostic code screen of the Electronic
Service Tool. Check for the following active
diagnostic code:

Wait for 30 seconds for the activation of the
diagnostic code.
Expected Result:
The Coolant Level Sensor Status behaves in the

following manner:
The Coolant Level Sensor Status indicates OK

before the jumper wire is installed between
terminal 49 and terminal 5. Note: A 111-02 fault
code may be active.
The Coolant Level Sensor Status changes to

Illustration 55
g00756043 LOW after the jumper wire is installed between
terminal 49 and terminal 5. Also, the diagnostic
code 111-01 (Low Coolant Level Warning) is
active.
A. Disconnect the ECM vehicle harness connector
J1/P1. The following active diagnostic code exists when
both jumper wires are installed.
B. Connect a 70-Termial breakout T to ECM
C. Fabricate two jumper wires 100 mm (4 inch) long.
Results:
Crimp a Deutsch pin to both ends of each wire.
D. Turn the ignition key switch to the ON position. Yes The ECM is functioning properly.
Repair: Repair the harness or replace the
E. Observe the Coolant Level Sensor Status on the
harness, as required.
Electronic Service Tool (ET). Install the jumper
into the breakout T in order to connect terminal Verify that the repair eliminates the problem. Clear
49 (coolant level normal) to terminal 5 (ap
all diagnostic codes.
STOP.
F. Monitor the Coolant Level Sensor Status while
the jumper is being inserted and removed. Wait
for 30 seconds between the insertion of the No
jumper and the removal of the jumper. Waiting
for 30 seconds allows the ECM to acknowledge
that the Engine Monitoring and the Coolant
the change. While the jumper remains in place, Level Sensor are programmed to match the
the following diagnostic code should be active:
old ECM. Recheck the test ECM by using the
70-terminal Breakout T and the same procedure
111-01 Low Coolant Level Warning (62) that was used previously. If the problem is
resolved with the test ECM, reconnect the suspect
G. Record the result.
ECM. If the problem returns with the suspect
ECM, replace the ECM.
H. Leave the jumper installed in the breakout T.
STOP.
I. While the active diagnostic code screen of
the Electronic Service Tool is being monitored,
connect another jumper from terminal 54 (coolant
level low) to terminal 18 (input sensor common
no. 1) of the breakout T.
166
i01365249 Manual fan override switch

Cooling Fan Circuit and A/C A control unit for the A/C may be connected to
High Pressure Switch Circuit the A/C high pressure switch (input 11) instead of
a switch.
- Test
The output for the cooling fan is intended to connect
SMCS Code: 1359-081-ZS; 1802-081-ZS directly to the circuit for the cooling fan solenoid.
Program the Fan Control Type parameter to
System Operation Description: ON/OFF. The fan will be off when the ECM output
is ON (energized). When the ECM activates the fan,
Use this procedure under the following situation: the fan will remain on for a minimum of 30 seconds
except for the following conditions:
Use this procedure to determine if the cooling fan
(output 5) or the A/C high pressure switch (input Engine start-up
11) is operating correctly.
The A/C Pressure Switch Fan On Time is
Note: Not all vehicle manufacturers, or all trucks programmed to less than 30 seconds.
for a manufacturer use the Caterpillar cooling fan
circuit. Prior to troubleshooting, determine if the During engine start-up, the ECM will keep the fan
vehicle is using the ECM cooling fan circuit. ON for two seconds after the engine has reached
the programmed low idle (700 to 800 rpm). The fan
Check the following items in order to determine if a will be ON continuously if the electrical circuit to the
vehicle is using the ECM cooling fan circuit: cooling fan air solenoid valve has an open circuit or
if the ECM Fan Relay circuit is opened.
The Fan Control Type parameter must be
programmed to On/Off. The Caterpillar factory Cooling Fan ON Conditions
default is None.
The ECM will turn the cooling fan ON under any of
A wire is present in the ECM vehicle harness the following circumstances if engine speed is less
connector J1/P1(terminal 11) which is output 5 than 2750 rpm:
(cooling fan solenoid). This occurs if an On/Off
type of fan is used. The engine is not running.
Perform the Special Test for the On/Off Cooling Engine cranking
Fan. Access each menu in the order that follows:
Diagnostics, Diagnostic Tests, and Special The coolant temperature is greater than 96 C
Test. Activating and then deactivating the circuit
(205 F).
should cause the air solenoid to click if the circuit
is working properly. Active diagnostic code for the coolant temperature
sensor
to this procedure: The inlet manifold air temperature is greater than

87 C (189 F).
Cooling Fan
The inlet manifold

air temperature is greater than
The signal for the cooling fan is provided by the 72 C (162 F) while the boost pressure is greater
ECM in order to control the cooling fan. An input than 70 kPa (10 psi).
from one of the following items may cause the fan
to turn ON: The Fan with Exhaust Brake ON is programmed
to YES and the exhaust brake has been on at
Engine coolant temperature sensor least two seconds.
Air inlet temperature sensor The manual fan override switch is on.
Exhaust Brake The A/C Switch Fan On-Time is programmed
to a value above 0 and the A/C high pressure
PTO on/off switch switch is open.
OEM installed A/C high pressure switch The ECM is counting after the A/C high pressure
switch has closed.
167
The PTO Activates Cooling Fan parameter is The Cooling Fan Control can be Operated
programmed to Continuous and the PTO on/off Independently of the ECM.
switch is on.
Operation of the cooling fan control can be
The last three items in the previous list are controlled independently of the ECM. The OEM
dependent upon the programming of the Customer installed air conditioning high pressure switch may
Parameters. be used for independent cooling fan control. A cab
mounted override switch in the solenoid circuit can
Note: The ECM will turn OFF the cooling fan for 10 also operate the cooling fan.
seconds during engine shutdown.
Troubleshooting
Cooling Fan OFF Conditions
Before troubleshooting the cooling fan circuit,
The cooling fan will be turned OFF by the ECM determine the type of fan drive system that is used.
if engine rpm exceeds 2800 rpm or when all the The fan drive can use the following controls in order
following circumstances are met: to control the fan:
The coolant temperature is less than 92 C normally open with a pneumatic air solenoid

(198 F).
normally closed with a pneumatic air solenoid
The fan has been ON for at least 30 seconds.
normally open with an electrically controlled
The inlet manifold

air temperature is less than solenoid
53 C (127 F).
normally closed with an electrically controlled
The strategy for the exhaust brake is not active solenoid
and the Fan with Exhaust Brake ON parameter
is programmed to YES. The following OEM installed components may
affect the operation of the cooling fan in some
The A/C high pressure switch is not active. applications:
The PTO on/off switch is in the OFF position and OEM installed, normally open relay
the PTO Activates Cooling Fan parameter is
programmed to Continious. The a/c high pressure switch is connected to
the ECM or the a/c high pressure switch is
The manual fan override switch is OFF. independent of the ECM.
A/C High Pressure Switch Input Connected to Cab mounted manual override switch
A/C Control Unit.
A timer that keeps the fan in the ON position
A control unit for the A/C that is supplied by the
OEM may be used. The control unit for the A/C Cooling fan air solenoid valve
determines when the cooling fan should operate.
This is based on the following input information:
A/C high pressure switch

low pressure switch
evaporator thermostat
The output for the fan for the control unit to the
A/C is designed to interface with the ECM. The
output for the fan may be connected to the input
for the A/C high pressure switch. The input for the
A/C high pressure switch is Input 11 of the ECM
connector J1/P1 terminal 41. The fan is in the ON
position when the A/C high pressure switch is in
the OPEN position. This type of control has a time
delay. Typically, the A/C Switch Fan On-Time is
programmed to one second since the control unit
for the A/C provides an additional time delay.
168
g00766507
Illustration 56
This schematic represents the on/off fan with a direct solenoid connection to the ECM and the A/C pressure switch connected to the ECM input.
Table 107
The following conditions will turn the Fan ON for Illustration 56.
Circuit Condition that will turn the Fan ON
Coolant temperature sensor The coolant temperature is greater than 96 C (205 F).
A diagnostic code for the coolant temperature sensor is
active.
Exhaust brake The Fan with Exhaust Brake ON parameter is programmed
to YES.
The exhaust brake is on at least two seconds.
OEM installed A/C high pressure switch The A/C Switch Fan On-Time is programmed to a value
above 0.
The switch circuit is open or on.
The external timer is counting or the ECM timer is counting.
The engine rpm is less than 2750 rpm. The engine is cranking. The engine has been running two
seconds or the ignition key is ON and the engine OFF.
Air inlet temperature sensor The temperature in the air inlet manifold is greater than 87 C
(189 F).
The temperature in the air inlet manifold is greater than 72 C
(162 F) while the boost pressure is greater than 70 kPa
(10 psi).
OEM installed manual fan override switch There is an open circuit in the switch or the switch is ON.
OEM installed cooling fan air solenoid valve Open solenoid circuit
Circuit breaker for the cooling fan Tripped breaker or open circuit
Dedicated PTO on/off switch The PTO Configuration is programmed.
The PTO Activates Cooling Fan is programmed.
There is a short circuit in the switch or the switch is on.
169
g00766679
Illustration 57
This schematic represents an on/off fan with a direct solenoid connection to the ECM and the A/C high pressure switch is not connected to
the ECM input.
Table 108
active.
to YES.
OEM installed A/C high pressure switch The switch circuit is open or ON.
The engine rpm is less than 2750 rpm. The engine is cranking. The engine has been running for
two seconds or the ignition key is in the ON position and the
engine off.
(189 F).
(10 psi).
There is a short circuit in the switch or the switch is ON.
170
g00675587
Illustration 58
This schematic represents the on/off fan with a direct solenoid connection to the ECM and the control unit for the A/C connected to the
ECM input.
Table 109
active.
to YES.
OEM installed A/C control unit The A/C Switch Fan On-Time parameter is programmed
to a value above 0 seconds.
The A/C control unit circuit is open.
The engine rpm is greater than 2750 rpm. The engine is cranking. The engine has been running two
seconds or the ignition key is on the ON position and the
engine off.
(189 F).
(10 psi).
OEM installed manual fan override switch There is an open circuit in the switch or the switch is on.
171
g00766689
Illustration 59
This schematic represents the on/off fan with a normally closed relay and the A/C high pressure switch that is not connected to the ECM input.
Table 110
active.
to YES.
OEM installed A/C high pressure switch The circuit for the switch is closed or the switch is on.
engine off.
(189 F).
(10 psi).
OEM installed cooling fan air solenoid valve The solenoid is energized.
OEM installed cooling fan relay There is an open circuit on the coil side of the relay.
172
g00675623
Illustration 60
This schematic represents the on/off fan with a normally open relay connection and an A/C high pressure switch connected to the ECM input.
Table 111
active.
to YES.
OEM installed A/C high pressure switch The A/C Switch Fan On-Time parameter is programmed
The switch circuit is open or the switch is on.
engine off.
(189 F).
(10 psi).
OEM installed cooling fan relay Open circuit in either coil or contact side of relay
173
g00675640
Illustration 61
This schematic represents the on/off fan with a normally open relay connection and an A/C high pressure switch connected to the ECM input.
Table 112
active.
to YES.
OEM installed A/C high pressure switch The switch circuit is open or the switch is ON.
engine off.
(189 F).
(10 psi).
OEM installed cooling fan relay Open circuit in either coil or contact side of relay
174
g00675642
Illustration 62
This schematic represents the on/off fan with a normally closed relay connection and an A/C high pressure switch connected to the ECM input.
Table 113
active.
to YES.
OEM installed A/C high pressure switch The A/C Switch Fan On-Time parameter is programmed
The switch circuit is open or the switch is on.
engine off.
(189 F).
(10 psi).
OEM installed manual fan override switch There is a short circuit in the switch or the switch is on.
OEM installed cooling fan air solenoid valve The solenoid is energized.
OEM installed Cooling Fan Relay Open circuit in coil side of relay
175
Test Step 1. Check The Electrical

Connectors And The Wiring.
g00675876
Illustration 63
Terminal locations for the ECM
A. Thoroughly inspect the ECM vehicle harness Refer to Illustration 63 for terminal locations for
connector J1/P1, the A/C high pressure switch the ECM.
connector, the connections to the cooling fan
solenoid, and the firewall bulkhead connectors. Expected Result:
Connectors for details. All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and
B. Perform a 45 N (10 lb) pull test on each of the wiring should be free of corrosion, abrasion or pinch
wires in the ECM connector that are associated points.
with the following connections:
Results:
Cooling fan
A/C high pressure switch
Not OK
the proper torque of 6.0 Nm (55 lb in). Repair: Repair the wiring or replace the wiring, if
necessary. Repair the connectors or replace the
D. Check the harness and the wiring for abrasion connectors, if necessary. Ensure that all of the
and pinch points from the battery to the ECM. seals are in the proper place. Ensure that all of
Then, check from the ignition key switch to the the connectors are connected properly.
ECM.
E. Ensure that the ECM is wired to the cooling fan on
the vehicle and/or the A/C high pressure switch. STOP.
Check for wires that are connected to terminal
11 (output 5) and for wires that are connected to ECM not wired to fan or switch If the ECM is not
terminal 41. Input 11 is the A/C high pressure wired to the cooling fan on the vehicle and/or the
switch of vehicle harness connector P1. A/C high pressure switch, then the ECM is not
being used for fan control. STOP.
176
Test Step 2. Check The Programming of Results:

the Fan Control Type Parameter.
Yes The status of the A/C high pressure switch
A. Connect an Electronic Service Tool to the cab is ON or OFF. Proceed to Test Step 4.
No The status of the A/C high pressure switch
B. Check the Fan Control Type parameter. Ensure is Unavailable. The ECM is not programmed
that the parameter is programmed toOn-Off, to use the A/C high pressure switch. Proceed to
if the ECM is used to control the fan. If the Test Step 5.
parameter is programmed to None and the
ECM is connected to the fan, then the fan will Test Step 4. Connect An Electronic
always be ON. Service Tool And Check The Operation of
the A/C Pressure Switch.
Expected Result:
The Fan Control Type parameter is programmed data link connector.
to match the vehicle wiring. This is determined in
the previous step. B. Turn the ignition key switch to the ON position.
Results: C. Access the A/C High Pressure Switch status

screen on the Electronic Service Tool.
Yes Proceed to Test Step 3.
D. Fabricate a jumper wire 100 mm (4 inch) long.
No Program the Fan Control Type to the Crimp a Deutsch pin to both ends of the wire.
correct setting and then recheck the system. If
conditions are not resolved, then proceed to Test E. Disconnect the A/C High Pressure Switch from
Step 3. the vehicle harness at the switch and use the
jumper wire to short the two terminals in the
Test Step 3. Connect An Electronic harness connector together.
Service Tool In Order To Check The A/C
Pressure Switch. F. Remove the jumper wire and then insert the
jumper wire. At the same time, view the A/C
A. Connect an Electronic Service Tool at the cab High Pressure Switch status on the service tool
data link connector. status screen.
B. Turn the ignition key switch to the ON position. Expected Result:
C. View the following Customer Specified The Electronic Service Tool Status Screen
Parameters. indicates that the A/C High Pressure Switch is
turning to the ON position. Then, the A/C High
Fan Control Type Pressure Switch is turning to the OFF position.
A/C Switch Fan On-Time Results:
Ensure that the A/C Switch Fan On-Time is Yes The A/C high pressure switch harness is
programmed to a greater value than 0. If the OK. Proceed to Test Step 6.
A/C Switch Fan On-Time is programmed to
0, then the A/C High Pressure Switch Input No Proceed to Test Step 7.
(Input 11) is not used.
Test Step 5. Use The Electronic Service
Note: If the Fan Control Type parameter indicates Tool In Order To Check Active Codes or
None, then the cooling fan driver is not used. Logged Codes.
View the A/C High Pressure Switch status on A. Connect an Electronic Service Tool to the cab
the Electronic Service Tool. data link connector.
Expected Result: B. Turn the ignition key switch to the ON position.
The status of the A/C high pressure switch indicates C. Access the Logged Diagnostic Codes and
ON or OFF. the Active Diagnostic Codes on the Electronic
Service Tool.
177
D. Check for the following diagnostic codes. Expected Result:
110-00 High Coolant Temperature Warning The resistance measures 10 Ohms or less.
110-11 Very High Coolant Temperature Results:
110-03 Coolant Temp Sensor Open Circuit Yes The ECM, the A/C high pressure switch,
and the wiring are electrically OK.
Repair: Check the A/C pressure or send the
Record any logged diagnostic codes. Record vehicle to the OEM dealer for repairs.
any active diagnostic codes.
STOP.
Expected Result:
No
Result 1 None of the diagnostic codes that are
listed are Logged or Active. Repair: Replace the A/C high pressure switch.
Result 2 Diagnostic Code 110-00, or 110-11 is Verify that the repair eliminates the problem.
Logged or Active.
STOP.
Result 3 Diagnostic Code 110-03 or 110-04 is
Logged or Active.
Results:

Result 2 The cooling fan is ON because of a
high coolant temperature.

procedure: Troubleshooting, Event Codes - Test
STOP.
Result 3 The cooling fan is ON because of a

coolant temperature sensor fault.

procedure: Troubleshooting, Engine Temperature
Sensor Open or Short Circuit - Test
STOP.
Test Step 6. Check The A/C Pressure

Switch By Using A Voltmeter.
B. Turn the ignition key switch to the OFF position.
C. Ensure that the A/C high pressure switch is

disconnected from the vehicle harness at the
switch terminals.
D. Connect a multimeter and measure the

resistance between the two terminals of the A/C
high pressure switch. The switch must be closed
in order to check the resistance.
178
Test Step 7. Connect An Electronic

Service Tool In Order To Check The ECM.
g00676088
Illustration 64
Connector for the Breakout T
A. Connect an Electronic Service Tool to the cab Results:

Yes The ECM is OK.
Repair: If a problem still exists, then the problem
C. Disconnect the ECM vehicle harness connector is in the OEM Wiring. Repair the problem or send
J1/P1. the vehicle to the OEM dealer for repair. Verify
that the repair eliminates the problem.
D. Remove terminal 41 (output 11) from the vehicle
harness connector P1. STOP.
E. Install a 70 Terminal Breakout T between No

connectors J1 and P1.
F. Fabricate a jumper wire 100 mm (4 inch) long. that the A/C Pressure Switch Fan On-Time
Crimp a Deutsch pin to both ends of the wire. parameter is programmed in the same manner
as the suspect ECM. Use an Electronic Service
G. Connect the jumper wire to terminal 5 (ap Tool to check the ECM. If the problem is resolved
sensor/switch common) and to terminal 41 (input with the test ECM, install the suspect ECM. If the
11) of the breakout T. problem returns with the suspect ECM, replace
the ECM.
Refer to illustration 64.
H. Turn the ignition key switch to the ON position.
STOP.
I. Access the A/C High Pressure Switch status
screen on the Electronic Service Tool. Test Step 8. Use The Electronic Service
Tool In Order To Check Inlet Manifold
J. Remove the jumper wire and then insert the Air Temperature And The Coolant
jumper wire. At the same time, watch the A/C Temperature.
High Pressure Switch status on the Electronic
Service Tool. A. Connect an Electronic Service Tool to the cab
Expected Result:
The Electronic Service Tool status screen indicates
that the A/C High Pressure Switch status is OFF
when the jumper wire is in place. The Electronic
Service Tool status screen indicates ON when the
jumper wire is removed.
179
C. Access the Electronic Service Tool status screen.

Locate the Coolant Temperature and the Inlet
Manifold Air Temperature status screen. Monitor
the status screen for a few minutes in order to
verify that the temperatures are changing as the
engine warms up.
Expected Result:
The Coolant Temperature and the Inlet Manifold

Air Temperature appear to have the correct
reading.
Results:

No
Repair: Temporarily connect another sensor. Test
the new sensor by checking Inlet Manifold Air
Temperature and Coolant Temperature again.
If the problem is resolved with the new sensor,
then install the old sensor in order to verify that
the problem returns. If the problem returns, then
replace the old sensor.
STOP.
Test Step 9. Use The Electronic Service

Tool Special Test To Check The Circuit
for the Cooling Fan Solenoid.
g00676097
Illustration 65
Connector for the Breakout T
A. Connect an Electronic Service Tool to the cab Special Test

NOTE: If any override switches are installed, the
B. Turn the ignition key switch to the ON position. switch must be in the OFF position.
C. Access the Cooling Fan Special Test. Access D. Cycle the Special Test to the ON position and
each menu in the order that follows: to the OFF position. Listen for the solenoid to
click. You may need to be near the engine in
Diagnostics order to hear the click of the solenoid.
Diagnostic Tests
180
An audible clicking is heard, and the solenoid Yes The output for the ECM cooling fan relay
appears to be operating properly. is functioning properly.
Results: Repair: If a problem still exists, then the problem

is in the OEM Wiring. Repair the problem or send
Yes The cooling fan circuit from the ECM to the the vehicle to the OEM dealer for repair.
Solenoid is functioning properly at this time.
Repair: If a problem still exists, then the problem
is in the OEM Wiring. Repair the problem or send STOP.
the vehicle to the OEM dealer for repair.
No
Repair: Temporarily connect a test ECM. Use the
STOP. Electronic Service Tool Special Test to Check the
ECM cooling fan circuit. If the problem is resolved
No Proceed to Test Step10. with the test ECM, install the suspect ECM. If the
problem returns with the suspect ECM, replace
Test Step 10. Use The Electronic Service the ECM.
Tool Special Test In Order To Check
The ECM To The Cooling Fan Circuit. Verify that the repair eliminates the problem.
A. Turn the ignition key switch to the OFF position. STOP.

i01381570
J1/P1.
C. Remove terminal 11 (Output 5) from the vehicle

Cruise Control Switch Circuit
harness connector P1. - Test
D. Connect a 70 Terminal Breakout T to the ECM SMCS Code: 1900-081-ZS
connector J1 and vehicle harness connector P1.
E. Connect a Voltage Test Lamp between terminal
11 (Output 5) and terminal 67 (negative battery) Use this procedure under the following situation:
of the breakout T.
Use this procedure to determine if one of the
F. Turn the ignition key switch to the ON position. following switches is preventing normal operation
of cruise control, fast idle, idle set speed, or PTO
G. Access the Cooling Fan Special Test on the operation:
Cycle the Cooling Fan Special Test to the ON
position and to the OFF position. At the same cruise control on/off switch
time, watch the voltage test lamp.
The following switch circuits can also prevent the
NOTE: A multimeter can not be used in place correct operation of the cruise control, idle set
of the voltage test lamp when the ECM output speed, fast idle, or PTO operation:
is tested.
service brake pedal position (switch 1)
Expected Result:
The voltage test lamp turns to the ON position when
the test is Active. The voltage test lamp turns to neutral switch
the OFF when the test is NOT Active.
cruise control on/off switch
181
PTO on/off switch After a speed has been set and the speed is then
The switches are described in the respective circuit on/off switch, the ECM will seek the previous set
tests in Troubleshooting. speed when the resume switch is toggled. This
All of the following Customer Programmable Cruise Control Speed Set Limit for cruise control or
Parameters can affect cruise control, fast idle, idle the vehicle speed is below the Idle/PTO Vehicle
set speed, and PTO operation: Speed Limit for the idle and the PTO.
Low Cruise Control Speed Set Limit After a speed has been set, pressing and holding
the set/resume switch in position will cause the
High Cruise Control Speed Set Limit engine to establish a new set speed. The systems
reaction depends on the programming of the
Idle Vehicle Speed Limit Cruise/Idle/PTO Switch Configuration.
Fast Idle RPM #1 When the set/resume switch is momentarily pressed,

the cruise set point will change one mph. The
Fast Idle RPM #2 rate of change is dependent on the programmed
Idle/PTO Bump RPM when an idle speed is set.
Idle/PTO Bump rpm to this procedure:
Idle/PTO rpm Ramp Rate The kickout switch refers to the switch that is used
to exit the cruise control, the PTO, the fast idle, or
PTO Vehicle Speed Limit the idle set speed.
The vehicle speed calibration can also affect the The operation of the Caterpillar Electronic Engine
cruise control, the fast idle, the idle set speed, cruise control is similar to the operation of the
and the PTO if the vehicle speed calibration is cruise controls that are installed in automobiles.
incorrectly programmed. Refer to Troubleshooting, The operation of idle fast idle, and PTO are similar
Customer Specified Parameters. to the operation of cruise except that the idle, fast
idle, and the PTO govern engine rpm instead of
Cruise Control On/Off Switch vehicle speed.
This switch must be ON before cruise control or Note: Idle in this procedure is an engine idle rpm
controlled idle can be activated. This switch is above the programmed low idle rpm. Idle is set
ON when the switch is closed. When the switch is by using the cruise control on/off switch and the
closed the following terminals are connected: set/resume switch. Refer to Troubleshooting, PTO
ECM connector J1/P1 terminal 59 (cruise control regarding the programmable options for the
on/off switch) dedicated PTO.
Terminal 5 (ap sensor/switch sensor common) Kickout Switches
Note: If the vehicle is programmed to use the The service brake pedal position switches, the
dedicated PTO, the PTO on/off switch overrides the neutral switch and the clutch pedal position switch
cruise control on/off switch. The PTO on/off switch are used in the cruise control mode, the PTO mode,
overrides the cruise control on/off switch when the fast idle mode, and the idle mode in order to
the vehicle speed is within the range of the PTO discontinue cruise operation, PTO operation, fast
Vehicle Speed Limit that is programmed. idle operation, or idle operation. The capability to
override the idle shutdown timer is determined
Set/Resume Switch by the Allow Idle Shutdown Override parameter
setting. The Allow Idle Shutdown Override is a
With the cruise control on/off switch in the ON Customer Parameter.
of the programmed Low Cruise Control Speed Usage of Transmission Style Switches
Set Limit and the High Cruise Control Speed Set
Limit, momentarily pressing the set switch will The Transmission Style parameter determines
activate the cruise or controlled idle, and the ECM the switches that will be used. The following
will maintain the current speed. switches can be used with being dependent on the
parameter setting:
182
clutch pedal position Universal Option

neutral A service brake pedal position (switch 1) is required
for all configurations. The service brake pedal
service brake pedal position (switch 1) position (switch 1) connects to the ECM through
connector P1 terminal 45. The service brake pedal
service brake pedal position (switch 2) position (switch 2) connects to the ECM through
connector P1 terminal 64. The clutch pedal position
Refer to Table 114 for additional information. switch connects to the ECM through connector P1
terminal 22. The neutral switch connects to the ECM
Table 114 through connector P1 terminal 62.
Switch Usage.
Setting For Some engines that were built before JULY 1999
Transmission Service Service may have a Basic ECM. The Basic ECM was used
Style Brake Brake only on General Motors chassis. Other chassis used
Clutch Neutral
Parameter Switch Switch
engines that were built with a Full Feature ECM.
1 2
Basic ECM software does not have the parameter
Manual X X for Transmission Style. For these systems, a
jumper wire must be installed between the clutch
Automatic
Option 1
X switch input and the sensor common when an
automatic transmission is installed. When the jumper
Automatic wire is installed, the Clutch Switch status will
X X
Option 2 always indicate OFF. Engines that were built after
Automatic JULY 1999 use only one type of ECM that can be
X X X configured for Basic or Full Feature operation.
Option 3
A new parameter was added in order to provide
Automatic this flexibility. The Truck Manufacturer parameter
X X
Option 4 was added in order to allow the configuration of the
AT/MT/HT GM Basic operation or the Other Full Feature
X operation. This parameter is programmed at
Option 1
Caterpillar when the engine is built. The parameter
X X
Option 2
that have software that is dated prior to SEP00
AT/MT/HT and the parameter for Truck Manufacturer is
X X X
Option 3 programmed to GM. SEP00 and newer engines
AT/MT/HT
Option 4
X X Style parameter. The factory default for the GM
setting is the Universal option. The Universal
Universal option provides identical features as the Basic
X X X X
Option system that is described above. If the Transmission
If the Transmission Style parameter is programmed option, a jumper wire must be installed between the
to one of the following options, the input for the clutch switch input and the sensor common when an
clutch pedal position switch is not used. automatic transmission is installed. Otherwise, the
Transmission Style parameter can be programmed
Automatic Option 1 to match the specific arrangement of the vehicle.
Automatic Option 2 If the problem is with undetermined

Automatic Option 3 procedure:
Automatic Option 4 Operate the vehicle in Cruise/Idle/PTO mode.
AT/MT/HT Option 1 After the kickout, review the status parameter on

the Electronic Service Tool. The status parameter on
AT/MT/HT Option 2 the Electronic Service Tool indicates the cause. This
AT/MT/HT Option 3 is turned OFF. It is important to remember that the
AT/MT/HT Option 4 the ECM has been powered by the input for the
ignition key switch.
183

Cruise/Idle/PTO Mode. Also, this parameter remains
blank until the ECM detects the disengagement of
the Cruise/Idle/PTO Mode. Refer to Tables 115 and
116 in order to interpret the status screen kickout
status parameter.
Table 115
Table For The Cruise Control Kickout Status Screen On The Electronic Service Tool
The cruise/idle on/off switch is turned off Proceed with the test procedure.
Switch Turned Off or the switch circuit has an open circuit
condition.
The clutch pedal is depressed or the Refer to Troubleshooting, Clutch Pedal
clutch pedal switch circuit has an open Position Circuit - Test.
Clutch
circuit condition.
exists.
PTO Switch ON PTO on/off switch circuit has a short circuit Circuit - Test.
condition.
The Set/Resume switch was held in the Cruise control cannot be set until the cruise
SET position for more than 15 seconds control on/off switch is turned to the OFF
Set Switch Timeout (Basic) or there is a short circuit in the position and then turned to the ON position
switch circuit. again. If the circuit for the set switch is
Resume Switch Timeout or there is a short circuit in the switch position and then turned to the ON position
circuit. again. If the circuit for the set switch is
No Occurrence
184
Table 116
Table For The Idle Kickout Status Screen On The Electronic Service Tool
No Engine Speed
The cruise/idle on/off switch is turned off Proceed with the test procedure.
condition.
circuit condition.
clutch pedal switch circuit has an open Position Circuit - Test.
Clutch
PTO Switch ON PTO on/off switch circuit has a short circuit Circuit - Test.
condition.
Idle has not been enabled since the ECM Operate the vehicle in the Idle mode in order
No Occurrence
has been powered up. to create the problem again.
Table 117
No Engine Speed
The fast idle on/off switch is turned off or the Proceed with the test procedure.
Switch Turned Off
circuit condition.
Clutch
Fast idle set speed has not been exited Operate the vehicle in the Idle mode in order
No Occurrence
185
g00643881
Illustration 66
Schematic for cruise control switch, service brake pedal position switch 1 and clutch pedal position switch
Test Step 1. Determine The Type Of D. Ensure that the vehicle is not experiencing
Problem. a problem due to one of these parameters.
A. Connect an Electronic Service Tool. Parameters for a description of the parameters,
if necessary.
C. If the vehicle will not allow setting a cruise that indicates the last cause of a kickout for one
speed, an idle speed or a PTO speed, check the of the following items:
Cruise Control Kickout
Idle Kickout
Fast Idle Kickout
PTO Kickout
Idle Parameters
Fast Idle RPM #1 meaning of the Electronic Service Tool status
screen parameter.
Fast Idle RPM #2
Expected Result:
Idle rpm Limit problem is due to a normal kickout.
Top Engine Limit (TEL) Results:
PTO Parameters Yes Explain the proper operation of system to

the driver. STOP.
PTO Configuration
No
Repair: Refer to Tables 115, 116, and 117 for
186
If a problem is still suspected with the cruise

control on/off switch or the set/resume switch,
perform the following procedure:

And Wiring.
g00703076
Illustration 67
connector J1/P1, the firewall bulkhead connector pinch points from the sensor to the ECM.
and the terminals for the following switches in
the connectors: Expected Result:
AP sensor/switch sensor common (terminal 5) All connectors, pins and sockets should be
set/resume switch (terminals 35 and 44) and wiring should be free of corrosion, abrasion
or pinch points.
cruise control on/off switch (terminal 59)
Results:
Connectors for details. OK Proceed to Test Step 3.
B. Perform a 45 N (10 lb) pull test on each of the Not OK
with the switches. Repair: Repair the connectors or wiring and/or
Refer to Illustration 2. of the seals are properly in place and ensure that
187
Verify that the repair eliminates the problem. Test Step 4. Operate The Vehicle And
STOP.
A. For an intermittent cruise control kickout, talk to
Test Step 3. Check The Cruise Control the driver in order to determine the conditions
Switch Status On The Electronic Service when the kickout occurs. Topics of examination
Tool. could be the following examples:
Table 118 specific speed
Table for Cruise Control Switch Status
road conditions
Switch Position Switch Status Circuit
The Cruise/Idle On/Off weather conditions
ON Closed
Switch is turned ON.
Take the vehicle for a road test in order to
The Cruise/Idle On/Off duplicate these conditions and set the cruise
OFF Open
Switch is turned OFF. control. Operate the vehicle in cruise control until
The Set/Resume Switch the problem reoccurs.
Set Switch ON Closed
is in the SET position.
B. For an intermittent idle kickout, talk to the driver
The Set/Resume Switch
Resume Switch in order to determine the conditions when the
is in the RESUME Closed
ON kickout occurs. A topic of examination could be
position.
A. Access the Electronic Service Tool status screen. specific engine rpm
B. Turn the ignition key switch to the ON position. Start the engine. Duplicate these conditions and
C. Operate the cruise control on/off switch while the the problem reoccurs.
status of the cruise/idle on/off switch is being
observed. Note: The Electronic Service Tool status screen will
only indicate the last kickout. The Electronic Service
D. Leave the cruise control on. Tool status screen will lose this information if the
ignition key switch is turned OFF.
E. Operate the Set switch while the status of the
set/resume switch is being observed. The status C. Connect an Electronic Service Tool and check
screen should indicate Set Switch ON when the Status screen for the last cause of the
the set switch is held in the SET position. The kickout. Refer to Tables 115 and 116 for an
status screen should indicate Off when the set explanation of the status parameter.
switch is released.
F. Operate the resume switch while the status of blank, then either there was no kickout of the
the resume switch is being observed. The status cruise control, or the power to the ECM was
screen should indicate Resume Switch ON turned OFF before the information could be read.
when the resume switch is held in the RESUME Perform Steps A,B and C again.
position. The status screen should indicate Off
when the resume switch is released. Note: An Electronic Service Tool status screen that
is blank indicates No Occurrence.
Expected Result:
Expected Result:
Table 118. RESULT 1 The Electronic Service Tool Kickout
Results:
Switch Turned Off
Yes The switches are operating normally. STOP.
Intermittent Problem Suspected Proceed to Test Status displays the following results:
Step 4.
No The ECM is not reading the switch status
change. Proceed to Test Step 5. Bad Vehicle Speed
188
Vehicle Speed Limit Troubleshooting, Neutral Switch Circuit - Test.
RESULT 3 The Electronic Service Tool Kickout STOP.

Result 5
PTO Switch ON
RESULT 4 The Electronic Service Tool Kickout procedure:
Troubleshooting, Service Brake Pedal Position
Neutral (Switch 1) Circuit - Test

Result 6
Brake
Troubleshooting, Clutch Pedal Position Switch
Clutch Circuit - Test

Result 7
No Engine Speed
Troubleshooting, Engine Speed/Timing Switch
Ser Switch Timeout Circuit - Test
Resume Switch Timeout STOP.
Results: Result 8
RESULT 1 Proceed to Test Step 5. Repair: Perform the following diagnostic
procedure:
Result 2
Troubleshooting, Cruise Control Switch Circuit -
Repair: Perform the following diagnostic Test
procedure:
STOP.
Troubleshooting, Vehicle Speed Circuit - Test
STOP.
Result 3
procedure:
Troubleshooting, PTO Switch Circuit - Test
STOP.
Result 4
procedures:
189
Test Step 5. Check The Switch Circuit.

Table 119
Table for Status of the Cruise Control Switch Input
Condition of Switch Circuit Switch Status Circuit
Terminal 59 Cruise/Idle On/Off Switch is Open. OFF Open
Terminal 59 Cruise/Idle On/Off Switch is connected to
ON Shorted
terminal 5.
Set Switch Terminal 35 is Open. OFF Open
Set Switch Terminal 35 connected to terminal 5. Set Switch ON Shorted
Resume Switch (Terminal 44) is Open. OFF Open
Resume Switch (Terminal 44) connected to terminal 5. Resume Switch ON Shorted
A. Turn the ignition key switch to the OFF position. 2. Remove all jumpers and replace all connectors.
B. Fabricate a jumper wire 100 mm (4 inch) long. 3. Recheck the system for active diagnostic
Crimp a Deutsch pin to both ends of the wires. codes.
C. Disconnect vehicle harness connector P1 from 4. Repeat the test step.

the ECM.
D. Connect a 70-Termial Breakout T to ECM reconnect the suspect ECM.
E. Install the jumper into the suspect switch socket replace the ECM.
of the breakout T. Connect the other end of the
jumper to ECM connector P1 terminal 5 (ap 7. Verify that the repair eliminates the problem.
sensor/switch sensor common) of the breakout T.
STOP.
G. Connect an Electronic Service Tool to the cab

H. Access the Electronic Service Tool Status Screen.
I. While the switch status is being monitored

on the Electronic Service Tool Status Screen
slowly remove the jumper from terminal 5 and
slowly insert the jumper from terminal 5 (ap
Refer to Table 119.
Expected Result:

Table 119.
Results:
Yes The ECM is functioning properly. Proceed

to Test Step 6.
No The ECM is not functioning properly.


190
Test Step 6. Insert A Jumper At The

Suspect Switch.
Table 120
The wires for the Cruise/Idle On/Off Switch are
OFF Open
disconnected.
ON Shorted
connected.
Set Switch wires are disconnected. OFF Open
Set Switch wires are connected. Set Switch ON Shorted
The Resume Switch wires are disconnected. OFF Open
The Resume Switch wires are connected. Resume Switch ON Shorted
A. Turn the ignition key switch to the OFF position. No There is a problem in the harness between
the switch and the ECM. Proceed to Test Step 7.
B. Ensure that ECM vehicle harness connector
J1/P1 is connected.
C. Find the suspect switch in the vehicle.
D. Disconnect the wires from the suspect switch

terminals.

G. Access the Electronic Service Tool Status Screen.
H. While the switch status is being monitored on

the Electronic Service Tool Status Screen slowly
connect the suspect switch wires and slowly
disconnect the suspect switch wires.
Refer to Table 120.
Expected Result:

Table 120.
Results:
Yes
Replace the faulty switch.
STOP.
191

Bulkhead Connector.
Table 121
OFF Open
disconnected.
ON Shorted
connected.
The Set Switch wires are disconnected. OFF Open
The Set Switch wires are connected. Set Switch ON Shorted
The Resume Switch wires are disconnected. OFF Open
The Resume Switch wires are connected. Resume Switch ON Shorted
A. Turn the ignition key switch to the OFF position. Inspect the vehicle wiring and repair the vehicle
wiring, as required. If the problem still exists with
B. Fabricate a jumper wire 100 mm (4 inch) long. the wiring, send the vehicle to the OEM dealer.
Crimp a Deutsch pin to both ends of the wires.
STOP.
C. Find the suspect switch terminal and the AP
Sensor/Switch Sensor Common terminal in the No The problem is in the vehicle wiring between
engine side of the bulkhead connector for the the bulkhead connector and the ECM.
vehicle harness.
D. Insert the jumper wire between the two terminals
in the engine side of the bulkhead connector. Inspect the vehicle wiring and repair the vehicle
E. Turn the ignition key switch to the ON position. the wiring, send the vehicle to the OEM dealer.
F. Connect an Electronic Service Tool to the cab STOP.

i01367829
H. While the switch status is being monitored

ECM Memory - Test
on the Electronic Service Tool Status Screen SMCS Code: 1901-081
alternately remove the jumper wire between the
two terminals, and alternately insert the jumper System Operation Description:
wire between the two terminals.
Refer to Table 121.
Use this procedure if one of the following diagnostic
Expected Result: codes is present:
252-11 Incorrect Engine Software (59)
Table 121.
Results:
253-02 Check Customer or System Parameters
(56)
Yes The problem is in the vehicle wiring 253-14 Truck Manufacturer Parameter Not
between the bulkhead connector and the switch. Programmed (56)
Repair: Perform the following repair: Also, use this procedure if the integrity of the
Customer Parameters or the System Parameters in
the ECM is questionable. Also, use this procedure
if the data for the Engine Lifetime Totals is
questionable.
192

to this procedure:
The Engine Control Module (ECM) is the computer

which controls the Caterpillar Electronic Truck
Engine. The Personality Module contains the
software that controls the operation of the computer
(ECM).
The Personality Module software is the instructions

that are used by the ECM to control the engine. For
this reason, updating the Personality Module to a
different version may cause some engine functions
to behave in a different manner.
Performance Maps
Performance Maps define characteristics for various

operating conditions. These characteristics are used
to achieve optimum performance while emissions
requirements are being met. Examples of these
characteristics are included in the following list: Illustration 68 g00772334
ECM and harness connectors

fuel rate
Logged Diagnostics
timing
Logged diagnostics are stored by the ECM into
These characteristics are programmed into the memory so a permanent record of the diagnostic
Personality Module at the factory only. code is retained. Logged faults that are not critical
are automatically cleared after 100 hours.
Microprocessor
Input Circuits
The ECM uses a microprocessor to perform the
computing that is required to perform the following Input circuits filter electrical noise for sensor signals.
functions: Also, input circuits protect internal circuits from
potentially damaging voltage levels.
governing
Output Circuits
controlling timing
Output circuits provide the voltage or current
generating diagnostic codes that is required to energize components that are
connected to the ECM.
communicating with service tools
Power Circuits
The microprocessor reads the instructions from the
software in the Personality Module. Power circuits provide clean stable electrical power
to internal circuits and external sensors.
Programmable Parameters are stored in permanent
And Wiring.
memory. This includes both Customer Specified
Parameters and System Configuration Parameters. A. Thoroughly inspect ECM vehicle harness
connector J1/P1 and the battery connections.
Parameters for details on Customer Specified
Parameters and refer to Troubleshooting, System Connectors for details.
Configuration Parameters for details on System
Configuration Parameters. B. Perform a 45 N (10 lb) pull test on each of the
following wires in the ECM connector:
ignition key switch (terminal 70)

193
+battery (terminals 52 and 53) Results:
battery (terminals 65 and 67) Result 1 Proceed to Test Step 3.

ATA data link (terminals 8 and 9) Result 2 Proceed to Test Step 4.
C. Check the ECM connector (allen head screw) for Result 3 Proceed to Test Step 5.
pinch points from the data link connectors back Test Step 3. Use An Electronic Service
to the ECM. Tool To Check The Part Number Of The
ECM Personality Module.
Expected Result:
A. Connect an electronic service tool at the cab
All connectors, pins and sockets should be data link connector.
and wiring should be free of corrosion, abrasion B. Turn the ignition key switch to the ON position.
or pinch points.
C. Read the Customer Specified Parameters. Refer
Results: to Troubleshooting, Programming Parameters.
OK Proceed to Test Step 2. D. Ensure that the Personality Module Part Number
agrees with the original engine arrangement.
Not OK
Expected Result:
replace the connectors or wiring. Ensure that all The correct Personality Module is installed in the
of the seals are properly in place and ensure that ECM for the engine.
Results:
Yes
STOP.
Repair: The diagnostic code 252-11 must be
Test Step 2. Check For Diagnostic Codes. cleared if the correct Personality Module has
been installed. Clearing this diagnostic code
Connect an electronic service tool and check for requires Factory Passwords and resetting the
diagnostic codes. Personality Module Code to zero.
Expected Result: STOP.
Result 1 The following diagnostic code requires No

troubleshooting:
Repair: Reprogram the ECM with the correct
252-11 Incorrect Engine Software (59) Personality Module. Refer to Troubleshooting,
Flash Programming.
Result 2 The following diagnostic code requires
troubleshooting: Verify that the repair eliminates the problem.
253-02 Check Customer or System Parameters STOP.

(56)
Test Step 4. Use An Electronic Service
Result 3 Scrambled parameters or data require Tool To Determine Parameters That
troubleshooting. Require Programming.
Result 4 The following diagnostic code requires A. Connect an electronic service tool at the cab
troubleshooting: data link connector.
253-14 Truck Manufacturer Programmed Not B. Turn the ignition key switch to the ON position.
Programmed (6)
194
C. Check the active diagnostic codes. Note any Repair: Try to reprogram the suspect parameter
parameters that are listed in the following active or parameters. If the ECM does not maintain
diagnostic code: the parameters, temporarily connect a test
ECM. Ensure that the test ECM will allow the
253-02 Check Customer or System Parameters programming of the parameters. If the test
(56) ECM does not allow the programming of the
parameters, the old ECM is OK. Something is
Expected Result: wrong in the vehicle wiring. Check the battery
supply circuit to the ECM and repair, as required.
The ECM allows the parameters that are listed under
the following active diagnostic code in the Active Verify that the repair eliminates the problem.
Diagnostic Code screen to be programmed:
STOP.
(56) No The ECM is OK. STOP.
Results: Test Step 6. Use An Electronic Service
Tool to Determine Programming
Yes Requirements
Repair: Ensure that the cause of all diagnostic A. Connect an Electronic Service Tool to the cab
codes is repaired. data link connector.
STOP. B. Turn the ignition key switch to the ON position.
No C. Check for active diagnostic codes.
Repair: Temporarily connect a test ECM. Ensure Note: If the diagnostic code 253-14 is active,
that the test ECM will allow the programming of the Truck Manufacturer parameter must be
the Parameters. If the test ECM does not allow programmed.
the programming of the Parameters, the old ECM
is OK. Something is wrong in the vehicle wiring. D. Determine the type of chassis. If the engine is
Check the battery supply circuit to the ECM and installed in a General Motors chassis, program
repair, as required. the Truck Manufacturer parameter to GM. For
any other chassis, program the parameter to
Verify that the repair eliminates the problem. Other.
STOP. Note: The Electronic Service Tool will indicate

that the communication to the ECM must be
Test Step 5. Use An Electronic Service reestablished in order for the change in the
Tool To Review Parameters And Data. parameter to take effect.
A. Turn the ignition key switch to the ON position. Expected Result:
B. Check the active diagnostic codes and the There are no active diagnostic codes.
logged diagnostic codes by using an electronic
service tool. Results:
C. Review the Customer and System Parameters. Yes Diagnostic codes are active. Proceed to
the appropriate troubleshooting procedure for the
D. Review the Engine Lifetime Totals. active diagnostic code. STOP.
Expected Result: No The ECM has been properly programmed.

STOP.
The parameters and totals are scrambled.
Results:
Yes
195
i01194405
Electrical Connectors - Inspect

SMCS Code: 1408-040-CY
Use the following steps to help determine if the

connector is the cause of the problem. If a problem
is found in the electrical connector, repair the
connector and verify that the problem has been
corrected.

to this procedure:
Many of the Operational Procedures and the

Diagnostic Code Procedures in this troubleshooting
guide will instruct you to check a specific electrical
connector. These Truck Engines use a variety of
Deutsch and AMP connectors.
Intermittent electrical problems are often caused

by poor connections. Always check for an Active
Diagnostic Code before breaking any connections.
Also, always check for an Active Diagnostic Code
after the connector is reconnected in order to verify
that the problem disappears.
Simply disconnecting the connectors and then

reconnecting the connectors can temporarily solve
a problem at times. If this occurs, likely causes are
loose terminals, bent terminals, improperly crimped
terminals, corrosion, or harness routing that is
improper.
The original source of the problem must then be

identified in order to ensure that the problem does
not reoccur.
Follow this procedure to thoroughly inspect the

connectors in order to determine if the connectors
are the cause of the problem.
196
g00640093
Illustration 69
ECM connector
(1) Vehicle harness connector P1 (2) ECM side (3) Harness side
g00640136
Illustration 70
ECM connector
(1) Engine harness connector P2 (2) ECM side (3) Harness side
197
g00640144
Illustration 71
Connector receptacles (Deutsch) and connector plugs (Deutsch)
(1) Wedge (receptacle) (3) Terminal pin (5) Machined socket terminal
(2) Wedge (plug) (4) Stamped and formed socket terminal (6) Sealing plug
198
g00640158
Illustration 72
Routing of the Harness and insertion of the plug
(1) Correctly routed harness (3) Incorrectly routed harness
(2) Correctly inserted plug (4) Incorrectly inserted plug
Test Step 1. Check The Locking Of The Test Step 2. Check The Allen Head Screw
DT Connector (Deutsch) And Check The On The ECM Connector.
Lock Ring Of The HD Style Connector
(Deutsch). A. Ensure that the Connector Bolt is properly
tightened. Be careful not to overtighten the bolt
A. Ensure that the connector is properly locked. and break the bolt.
Also ensure that the two halves of the connector
can not be pulled apart. B. Do not exceed 6.0 Nm (55 lb in) of torque on
the Connector Bolt of the ECM when the 70-pin
B. Verify that the latch tab of the connector is connector is being installed on the ECM.
properly latched. Also verify that the latch tab
of the connector returns to the Fully Latched Expected Result:
position.
The ECM Connector is secure and the Connector
Expected Result: Bolt of the ECM is properly torqued.
The connector will securely lock. The connector and Results:

the locking mechanism is without cracks or breaks.
Results:
Not OK Secure the ECM connector. Ensure that
OK Proceed to test step 2. the connector bolt is properly torqued. STOP.
Not OK Repair the connector or replace the

connector, as required. STOP.
199
Test Step 3. Perform A Pull Test On Each Run the engine. Listen for speed burps or power
Wire Terminal Connection. cutouts while the wiring or the connectors are
pulled. If the harness is being pulled and the
A. Each terminal and each connector should engine has a speed burp or a power cutout,
withstand 45 N (10 lb) of pull. Each wire should there could be a problem in the wiring or the
remain in the connector body. This test checks connector.
whether the wire was properly crimped in the
terminal and whether the terminal was properly Expected Result:
inserted into the connector.
The problem appears to be external to the
B. The DT connectors use an orange wedge to lock harnesses and connectors. Pulling on the harness
the terminals in place. and the connectors has no effect on the component
status of the Active Diagnostic Code or engine
C. Check in order to ensure that the orange wedge performance.
is not missing and that the orange wedge is
installed properly on the DT connectors. Results:
Note: Terminals should ALWAYS be crimped onto OK Proceed to test step 5.

the wires by using a Crimp Tool. Do not solder
terminals. Use the 1U-5804 Crimp Tool. Not OK Repair the harness and/or the
connectors or replace the harness and/or
Expected Result: connectors that are causing the problem. STOP.
Each terminal and each connector withstands 45 N Test Step 5. Check Wires For Nicks In
(10 lb) of pull. Each wire remains in the connector The Insulation Or Abrasion.
body.
A. Carefully inspect each wire for signs of abrasion,
Results: nicks, or cuts.
OK Proceed to test step 4. The following areas are locations that should
be checked:
Not OK Repair the wiring or replace the
connector or the terminal. STOP. Exposed insulation
Test Step 4. Monitor The Electronic Points of rubbing wire against the engine
Service Tool While The Wiring And The
Connectors Are Being Pulled. Points of rubbing wire against a sharp point
A. If there is an Active Diagnostic Code that B. Check all of the hold down clamps for the
pertains to the circuit, perform the following test: harness in order to verify that the harness is
properly clamped. Also check all of the hold
Monitor the Active Diagnostic Code Screen of down clamps for the harness in order to verify
the Electronic Service Tool while all harnesses that the harness is not compressed by the
and connectors that connect to the component clamp. Pull back the harness sleeves in order
with the Active Diagnostic Code are pulled. to check for a flattened portion of wire. The
If the harness is being pulled and the Active flattened portion of wire is caused by the clamp
Diagnostic Code disappears there is a problem that holds the harness.
in the wiring or the connector.
Expected Result:
B. If there are no Active Diagnostic Codes that
pertain to the circuit, perform the following test: The wires are free of abrasion, nicks, or cuts and
the harness is properly clamped.
Monitor the Status Screen of the Electronic
Service Tool for the component while the Results:
harnesses are being pulled. If the harness is
being pulled and the reading changes erratically, OK Proceed to test step 6.
there is a problem in the wiring or the connector.
Not OK Repair the wires or replace the wires,
C. If there are no Active Diagnostic Codes and as required. STOP.
the driver is complaining about speed burps or
power cutouts, perform the following test:
200
Test Step 6. Check Connectors For

Moisture Or Corrosion.
g00640213
Illustration 73
Connector seals
(1) ECM connectors (2) DT Connector plug (3) Seal
A. Ensure that the connector seals and the white Improperly mated connectors
sealing plugs are in place. If any of the seals or
plugs are missing, replace the seal or plug. If Moisture can also travel from one connector
necessary, replace the connector. through the inside of a wire to the ECM
Connector. If moisture is found in the ECM
B. Check all of the wiring harnesses in order to connector, thoroughly check all connectors and
verify that the harness does not make a sharp wires on the harness that connect to the ECM.
bend out of a connector. This will deform the The ECM is not the source of the moisture. Do
connector seal and this will create a path for the not replace an ECM if moisture is found in either
entrance of moisture. ECM connector.
Thoroughly inspect ECM Connectors J1/P1 and Note: If corrosion is evident on the pins, sockets or
J2/P2 for evidence of moisture entry. the connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush
Note: It is normal to see some minor seal abrasion to remove the corrosion. Do not use any cleaners
on the ECM Connector seals. Minor seal abrasion that contain 1,1,1 trichloro-ethylene because 1,1,1
will not allow the entry of moisture. trichloro-ethylene may damage the connector.
C. If moisture or corrosion is evident in the Expected Result:

connector, the source of the moisture entry
must be found and the source of the moisture All of the connectors should be completely coupled
entry must be repaired. If the source of the and all of the seals should be completely inserted.
moisture entry is not repaired, the problem will The harness and the wiring should be free of
reoccur. Simply drying the connector will not fix corrosion, abrasion or pinch points.
the problem. Likely paths for the entrance of
moisture are illustrated in the following list: Results:
Missing seals OK Proceed to test step 7.

Improperly installed seals Not OK
Nicks in exposed insulation
201

Verify that the repair eliminates the problem

by running the engine for several minutes and
by checking again for moisture. If moisture
reappears, the moisture is wicking into the
connector. Even if the moisture entry path is
repaired, it may be necessary to replace the
wires that have moisture. These wires may have
moisture that is trapped inside the insulation.
STOP.
Test Step 7. Inspect The Connector

Terminals.
A. Verify that the terminals are not damaged. Verify
that the terminals are properly aligned in the
connector and verify that the terminals are
properly located in the connector.
Expected Result:
The terminals are properly aligned and the terminals

appear undamaged.
Results:

Not OK Repair the terminals and wiring and/or
replace the terminals and wiring. STOP.
202
Test Step 8. Check Individual Pin

Retention Into The Socket.
g00640220
Illustration 74
Pin retention of the connector
(1) Contact of the pin (2) Contact of the socket
Note: This is especially important for intermittent i01372256

problems.
Engine Pressure Sensor Open
A. Use a new pin. Insert the pin into each socket or Short Circuit - Test
one at a time in order to check for a good grip
on the pin by the socket. SMCS Code: 1408-081; 1917-081; 1923-081;
1924-081
B. Use a new socket. Insert the socket over each
pin one at a time in order to check for a good System Operation Description:
grip on the pin by the socket. The pins are
located on the mating side of the connector. Use this procedure under the following situation:
C. The contact terminal should stay connected Use this procedure to troubleshoot the system only
when the connector is held in the position shown when there is an active diagnostic code or when
in Illustration 74. The contact terminal is the pin a diagnostic code can easily be activated. This
or the socket. procedure covers open circuit diagnostic codes and
short circuit diagnostic codes that are associated
Expected Result: with the following sensors:
The pins and the sockets appear to be OK. Boost pressure sensor
Results: Oil pressure sensor (optional)
OK STOP. Atmospheric pressure sensor (specific ratings
only)
Not OK Replace the terminal. STOP.
Injection actuation pressure sensor
Use this procedure for the following Diagnostic
Codes:
100-03 Oil Pressure Sensor Open Circuit (27)

203
100-04 Oil Pressure Sensor Short Circuit (27)

102-00 Boost Pressure Reading Stuck High (25)
102-03 Boost Pressure Sensor Open Circuit (25)
102-04 Boost Pressure Sensor Short Circuit (25)
164-03 Injection Actuation Pressure Sensor Open
Circuit (15)
164-04 Injection Actuation Pressure Sensor Short

Circuit (15)
108-03 Atmospheric Pressure Sensor Open

Circuit (26)
108-04 Atmospheric Pressure Sensor Short Circuit

(26)

to this procedure:
The troubleshooting procedures for the diagnostic

codes of each pressure sensor are identical. The
pressure sensors are sensors that have three
terminals. The pressure sensors are active sensors.
Active sensors require supply voltage from the
ECM. ECM connector J2/P2 terminal 2 supplies + 5
volts to terminal A of each sensor. ECM connector
J2/P2 terminal 3 is the common connection for the
pressure sensors. The sensor common connection
is shared between all of the pressure sensors. The
common line is connected to each sensor connector
terminal B. The signal voltage from terminal C of
each sensor is supplied to the appropriate terminal
at ECM connector J2/P2.
g00767035
Illustration 75
204
g00767119
Illustration 76
Test Step 1. Check For Active +5 V Test Step 2. Verify All Active Diagnostic
Sensor Supply Diagnostic Codes. Codes.
A. Connect an electronic service tool to the cab A. Turn the ignition key switch to the ON position.
data link connector. Wait at least 15 seconds for activation of the
diagnostic codes.
Wait at least 15 seconds for activation of the B. Verify if any of the following diagnostic codes
diagnostic codes. are active:
C. Verify if any of the following diagnostic codes 100-03 Oil Pressure Sensor Open Circuit (27)
are active:
100-04 Oil Pressure Sensor Short Circuit (27)
102-00 Boost Pressure Reading Stuck High
232-04 5 Volt Supply Below Normal (21) (25)
Expected Result: 102-03 Boost Pressure Sensor Open Circuit

(25)
One or more of the preceding diagnostic codes
are active. 102-04 Boost Pressure Sensor Short Circuit
(25)
Results:
Yes (26)
Repair: Perform the following diagnostic 108-04 Atmospheric Pr Sensor Short Circuit
procedure: Troubleshooting, 5 Volt Engine (26)
Pressure Sensor Supply Circuit - Test.
164-03 Injection Actuation Pressure Sensor
STOP. Open Circuit (15)
No Proceed to Test Step 2. 164-04 Injection Actuation Pressure Sensor

Short Circuit (15)
Note: The following diagnostic codes should not

be active:
205

Expected Result:

are active.
Results:
Yes Proceed to Test Step4.

No
Repair: If the preceding codes are logged but
not active and the engine is not running properly,
refer to Troubleshooting, Troubleshooting
without a Diagnostic Code. If the engine is
running properly at this time, an intermittent
condition may be causing the logged codes.
Connectors for additional information on
intermittent connections. If the problem is not
evident and there were logged open circuit faults
or short circuit faults, perform the following repair:
1. Replace the pin terminals with 9X-3401

Connector Pin terminals.
Replace the socket terminals with 9X-3402

Connector Socket terminals.
2. Do not replace the Sensor or the ECM.
Note: If the sensor has an integral connector the

pin terminals cannot be removed. Only replace the
socket terminal in the wiring harness connector.
STOP.
206

And Wiring.
g00741955
Illustration 77
A. Thoroughly inspect ECM Engine Harness Results:

Connector J2/P2, Boost Pressure Sensor
J200/P200, Engine Oil Pressure Sensor OK Proceed to Test Step 4.
J201/P201, Injection Actuation Pressure Sensor
J204/P204, and Atmospheric Pressure Sensor Not OK
J203/P203. Refer to Troubleshooting, Inspecting
Electrical Connectors for details. Repair: Repair the connectors or wiring and/or
B. Perform a 45 N (10 lb) pull test on each of the of the seals are properly in place and ensure that
wires in the ECM Connector and the sensor the connectors are completely coupled.
connectors that are associated with the active
diagnostic code. Verify that the repair eliminates the problem.
Refer to Illustration 77. Clear all Logged diagnostic codes.
C. Check the ECM connector (allen head screw) for STOP.

Test Step 4. Verify That the Diagnostic
D. Check the harness and wiring for abrasion and Code Is Still Active.
pinch points from the sensors back to the ECM.
Expected Result: Wait at least 15 seconds for activation of the
diagnostic codes.
completely coupled and/or inserted and the harness B. Monitor the Active Diagnostic Code screen of
and wiring should be free of corrosion, abrasion the Electronic Service Tool. Check and record
or pinch points. active diagnostic codes.
207
C. Determine if the problem is related to an E. Set a multimeter to the VDC setting. Measure
open circuit diagnostic code or a short circuit the voltage from the terminal A (pressure
diagnostic code. sensor supply) to terminal B (sensor common).
Expected Result: Expected Result:
Either a short circuit diagnostic code is active or an The DC voltage from terminal A to terminal B
open circuit diagnostic code is active. measures 4.5 to 5.5 VDC.
Results: Results:
SHORT Circuit A short circuit diagnostic code OK The sensor supply voltage is correct.
is active at this time. Proceed to Test Step 5. Remove the Breakout T. Proceed to Test Step 8.
OPEN Circuit An open circuit diagnostic code Not OK The sensor supply voltage is out of
is active at this time. Proceed to Test Step 6. range. Continue testing the sensor supply circuit.
Test Step 5. Disconnect The Sensor In Repair: Proceed to the following repair:
Order To Create An Open Circuit. Troubleshooting, 5 Volt Engine Pressure Sensor
Supply Circuit - Test
STOP.
B. Disconnect the sensor connector of the sensor
with the short circuit diagnostic code. Test Step 7. Determine If The Short
Circuit Is In The Connector Or In The
C. Turn the ignition key switch to the ON position. Sensor.
Wait at least 15 seconds for activation of the
diagnostic codes. A. Thoroughly inspect the connector for moisture.
D. Access the Active Diagnostic Code screen on B. Inspect the seals and reconnect the sensor.
the Electronic Service Tool. Check for an active
open circuit diagnostic code. C. If the short circuit diagnostic code reappears,
the sensor or the pigtail harness connector is
Expected Result: the problem.
An open circuit diagnostic code for the a. Temporarily connect a new sensor to the
disconnected sensor is now active. harness, but do not install the new sensor in
the engine.
Results:
D. Check for a short circuit diagnostic code while
OK A short circuit diagnostic code was active the new sensor is connected to the harness.
before disconnecting the sensor. An open
circuit diagnostic code became active after Expected Result:
disconnecting the sensor. Proceed to Test Step 7.
The short circuit diagnostic code is not present
Not OK There is a short circuit between the when a new sensor is connected.
sensor harness connector and the ECM. Leave
the sensor disconnected. Proceed to Test Step 9. Results:
Test Step 6. Measure the Sensor Supply OK Verify that the repair eliminates the problem.
Voltage. Clear the logged diagnostic codes. STOP.
A. Turn the ignition key switch to the OFF position. Not OK Repair the engine harness connector.
STOP.
B. Disconnect the sensor from the engine harness.
Test Step 8. Create A Short Circuit
C. Connect a 3-Terminal breakout T to the engine Between The Signal And The Common
harness only. Do Not connect the sensor to the
breakout T.

208
Terminals At The Engine Harness

Connector.
g00664397
Illustration 78
Terminals for the pressure sensor connector
A. Turn the ignition key switch to the ON position. 2. If the diagnostic code remains active, replace
the sensor.
Crimp a Deutsch terminal to both ends of the 3. Ensure that the diagnostic code is no longer
wire. active.
C. Monitor the Active Diagnostic Code screen 4. Verify that the repair eliminates the problem.
before installing the jumper wire and after
installing the jumper wire. STOP.
D. Install the jumper on the engine harness Not OK The open circuit diagnostic code
connector. Install one end of the jumper at the remains active when the jumper is installed. The
sensor signal (terminal C). Install the other most probable location for the open is in the
end of the jumper at the common connection sensor common or the sensor signal wire in the
for the pressure sensor (terminal B). Wait at Engine Harness between the ECM and the sensor.
least 15 seconds for activation of the short circuit Remove the jumper. Proceed to Test Step 9.
diagnostic code.
Expected Result:
A short circuit diagnostic code is active when the

jumper is installed. An open circuit diagnostic code
is active when the jumper is removed.
Results:
OK The engine harness and the ECM are OK.

1. Temporarily connect the suspect sensor.

209
Test Step 9. Check The Operation Of

The ECM By Creating Open And Short
Circuits At The ECM Connector.
g00741957
Illustration 79
Engine harness connector P2
A. Turn the ignition key switch to the OFF position. Refer to Illustration 79 for the engine harness
connector P2.
B. Disconnect ECM engine harness connector
J2/P2. Thoroughly inspect both halves of the Expected Result:
connector J2/P2 for signs of corrosion or
moisture. Open circuit diagnostic codes and short circuit
diagnostic codes were active.
C. Turn the ignition key switch to the ON position.
Monitor the Active Diagnostic Code screen. Results:
code. OK The ECM is operating properly. Proceed to
Test Step 10.
An open circuit diagnostic code should be active
for the suspect sensor. Not OK One of the following conditions exists:
The open circuit diagnostic code is not active
Note: When the engine harness is disconnected, all when the harness is disconnected. The short
of the open circuit diagnostic codes for the pressure circuit diagnostic code is not active when the
sensors will be active. This is normal. Disregard the jumper wire is installed.
diagnostic codes for the other pressure sensors.
Direct your attention to the diagnostic codes for the Repair: Perform the following repair:
suspect sensor only.
D. Turn the ignition key switch to the OFF position.
E. Fabricate a jumper wire 150 mm (6 inch) long.
Crimp a Deutsch Socket to both ends of the wire. 3. Recheck the system for active diagnostic
codes.
F. Install the jumper wire on the ECM connector
J2. Insert the jumper wire between the terminal 4. Repeat the Test Step.
for the suspect sensor signal and the common
connection for the engines pressure sensor 5. If the problem is resolved with the test ECM,
(terminal 3). reconnect the suspect ECM.
A short circuit diagnostic code should be active 6. If the problem returns with the suspect ECM,
when the jumper wire is installed. replace the ECM.
Note: If access to ECM connector J2 is limited, it 7. Verify that the repair eliminates the problem.
may be helpful to connect a 70-Termial Breakout T
to ECM connector J2 so the jumper wire can be STOP.
inserted into the breakout T. Ensure that the jumper
wire is inserted into the breakout T and that the full
wiring harness is attached.
210
Test Step 10. Bypass The Harness Wiring Not OK Restart this procedure and carefully
Between The ECM And The Sensor perform each step. STOP.
Connector.
i01379460

Engine Running Output Circuit
J2/P2, and the sensor connector. - Test
C. Remove the sensor signal wire from ECM SMCS Code: 1900-081
Connector P2 on the engine harness.
D. Remove the signal wire (terminal C) from the
sensor connector on the Engine Harness . Use this procedure under the following situation:
E. Fabricate a jumper wire that is long enough to Use this procedure in order to determine if the
reach from the ECM to the sensor connector or Engine Running Output circuit is operating
use an engine sensor harness bypass with 3 properly.
terminals.
Note: If an engine sensor harness bypass is being to this procedure:
made, crimp a Deutsch socket on one end in order
to connect to the ECM. Crimp either a Deutsch pin Engine Running Output
or a Deutsch socket on the other end, as required.
The Engine Running Output is located on ECM
F. Insert the engine sensor harness bypass into J1/P1:13 (Output 4).
the ECM connector P2 on the engine harness.
Insert the other end of the engine sensor harness The Engine Running Output comes ON when the
bypass into the sensor connector of the engine engine is running. The Engine Running Output
harness . turns OFF when the engine rpm equals 0. This can
be used to prevent the engagement of the starter
G. Reconnect ECM engine harness connector J2/P2 motor while the engine is running. The ECM can
and the sensor connector. be connected to a relay that disables the starter.
The relay is normally closed so cranking can be
H. Turn the ignition key switch to the ON position. achieved immediately at powerup. During cranking,
the ECM energizes the Engine Running Output
I. Monitor the Active Diagnostic Code screen for once engine rpm reaches 50 rpm below low idle.
either the open circuit diagnostic code for the The output is de-energized if the engine speed falls
sensor or the short circuit diagnostic code for below the programmed low idle by 100 rpm. The
the sensor. low idle rpm is programmable. The range for low
idle is between 700 rpm and 800 rpm.
Expected Result:
The diagnostic code disappears when the jumper

or the bypass is installed.
Results:
OK There is a problem in the wiring harness.

1. Repair the faulty wiring harness or replace the

faulty wiring harness.
2. Clear all diagnostic codes.
STOP.
211
g00728509
Illustration 80
Engine Running Output Circuit
g00728510
Illustration 81
Location for the ECM terminal
Test Step 1. Inspect Electrical Connectors Refer to Troubleshooting, Inspecting Electrical

And Wiring. Connectors for details.
A. Thoroughly inspect ECM vehicle harness B. Perform a 45 N (10 lb) pull test on terminal 13
connector J1/P1, and the firewall bulkhead in the ECM connector.
connector.
212
D. Check the harness and wiring for abrasion and C. Disconnect the ECM vehicle harness connector
for pinch points from the sensor to the ECM. J1/P1.
Expected Result: D. Connect a 70-Terminal breakout T between ECM

connectorsJ1 and P1.
completely coupled and/or inserted and the harness E. Connect a voltage test lamp to terminal 13
and wiring should be free of corrosion, abrasion (OUTPUT 4) and terminal 65 (-battery) of the
or pinch points. breakout T.
Results: F. Turn the ignition key switch to the ON position.
OK Proceed to Test Step 2. G. Access the Engine Running Output Special

Test on the Electronic Service Tool.
Not OK
H. Cycle the Engine Running Output Special Test
Repair: Perform the following repair: to the ON position and to the OFF position and
watch the voltage test lamp.
the connectors or wiring. Ensure that all of the I. Stop the special test.
seals are properly in place and ensure that the
connectors are completely coupled. Note: A multimeter can not be used in place of the
voltage test lamp when the ECM outputs are being
Verify that the repair eliminates the problem. tested.
STOP. Expected Result:
Test Step 2. Use An Electronic Service The voltage test lamp turns ON when theEngine
Tool To Check The Relay. Running Output Special Test is active. The voltage
test lamp turns OFF when the Engine Running
A. Turn the ignition key switch to the ON position. Output Special Test is not active.
B. Access the Engine Running Output Special Results:

Test on the Electronic Service Tool. The Engine
Running Output Special Test will enable the YES The ECM is OK. The problem is in the
Engine Running Output when the test is active. vehicle wiring. Inspect the vehicle wiring and then
repair the vehicle wiring. Otherwise, send the
C. Begin the Engine Running Output Special Test vehicle to the OEM dealer for repair. Verify that
and listen for the relay to click. You may need the original condition is resolved. STOP.
to be near the engine in order to hear the click.
NO Temporarily connect a test ECM. Use the
Expected Result: Electronic Service Tool Engine Running Output
Special Test to check the ECM. If the problem is
The relay activates when the special test is enabled. resolved with the test ECM, install the suspect
ECM. If the problem returns with the suspect
Results: ECM, replace the ECM. Verify that the repair
eliminates the problem. STOP.
Yes The ECM and vehicle components are
operating correctly. STOP.
i01368757
No Proceed to Test Step 3. Engine Speed/Timing Sensor

Test Step 3. Use An Electronic Service Circuit - Test
Tool To Check The ECM.
SMCS Code: 1912-081
data link connector. System Operation Description:
B. Turn the ignition key switch to the OFF position. Use this procedure under the following situation:
213
Use this procedure to troubleshoot the system only

under the following conditions:
There is an active diagnostic code or an easily

repeated diagnostic code that is associated with
the Engine Speed/Timing circuit.
You have been referred to this test from

Troubleshooting, Troubleshooting without a
Diagnostic Code.

to this procedure:
The engine uses two engine speed/timing sensors.

Both of the engine speed/timing sensors detect
the reference for engine speed and timing from
a unique pattern on the camshaft gear. The ECM
counts the time between pulses that is created by
the sensor as the gear rotates in order to determine
rpm. The ECM remembers the pattern of the pulses.
The ECM uses the pattern of the pulses in order to Illustration 82 g00722303
determine the position of the crankshaft. Left side engine view
When the timing has been established, the ECM If a replacement of the ECM is required, the
triggers each injector in the correct firing order at ECM parameters and the timing calibration can
the correct time. be transferred from the suspect ECM to the
replacement ECM. Timing calibration will NOT be
The actual timing and duration of each injection is necessary. This feature requires the Caterpillar
based on engine rpm and load. If the engine is Electronic Technician (ET) and this feature is only
running and the signal from one of the camshaft possible if the existing ECM can communicate with
position sensors is lost, no noticeable change in the Caterpillar Electronic Technician (ET). Use the
engine performance will be noticed. Copy Configuration - ECM Replacement that is
an (ET) procedure.
The engine will start and the engine will run when
only one sensor signal is present from either of the The top camshaft position sensor is connected to the
sensors. The loss of the signal from both of the ECM through the engine harness connector J2/P2
sensors during engine operation will result in the terminal 48 (Top Camshaft Speed/Timing Positive)
termination of injection and the shutting down the and terminal 49 (Top Camshaft Speed/Timing
engine by the ECM. The loss of the signal from Negative). The bottom camshaft position sensor
both of the sensors during start-up will prevent the is connected to the ECM through engine harness
engine from starting. connector J2/P2 terminal 58 (Bottom Camshaft
Speed/Timing Positive) and terminal 59 (Bottom
Both sensors are magnetic sensors. The two Camshaft Speed/Timing Negative).
sensors are not interchangeable. Do not switch
the positions of the sensors. The two sensors When the sensors are being installed, complete
must be replaced as a pair. If the sensors are all of the following tasks:
replaced, a timing calibration is not necessary for
the engine. Timing calibration is only necessary
after replacing an ECM that will not communicate. Lubricate the O-ring with oil.
Ensure that the sensor has a connector face seal
inside the connector body. If a seal is damaged
or missing, replace the seal.
Ensure that the sensor is fully seated into the

engine before tightening the bracket bolt.
Ensure that the connector is latched on both

sides.
Ensure that the harness is properly secured,

and ensure that the harness is attached to the
harness clip.
214
g00722914
Illustration 83
Test Step 1. Connect An Electronic Note: If you have been referred here from
Service Tool And Note All Active Troubleshooting, Troubleshooting without a
Diagnostic Codes And Logged Diagnostic Code for the following reason, select
Diagnostic Codes. No Engine rpm:
A. Connect an electronic service tool to the cab The engine rpm was not indicated on an
data link connector. Electronic Service Tool.
B. Turn the ignition key switch to the ON position. Results:
C. Check for one of the following logged diagnostic YES There is an active diagnostic code or a
codes or active diagnostic codes: Logged diagnostic code. Proceed to Test Step 3.
64-02 Loss of Engine RPM Signal on Bottom No If none of the codes that are listed are
Sensor (No. 2) (34) active diagnostic codes or Logged diagnostic
codes and the engine is not running properly,
64-11 No Pattern on Bottom Engine Speed refer to the appropriate symptoms in the service
Sensor (No. 2) (34) manual. STOP.
190-02 Loss of Engine RPM Signal on Top No Engine rpm Engine rpm is not indicated on
Sensor (No. 1)(34) an Electronic Service Tool. Proceed to Test Step 2.
190-11 No Pattern on Top Engine Speed Test Step 2. Check The Installation Of
Sensor (No. 1)(34) The Sensors And The Bracket.
Note: If the diagnostic code is logged but not
active, run the engine until the engine is at normal
operating temperature. The problem may only
occur when the engine is at the normal operating
temperature. If the engine will not start, monitor the
engine rpm from the Electronic Service Tool while
the engine is being cranked. The Electronic Service
Tool may need to be powered from another battery g00767308
Illustration 84
while the engine is being cranked. This is done Flange of the sensor and mounting bracket
in order to ensure that the Electronic Service Tool
does not reset. A. The flange of the sensor should be flush against
the engine in order to ensure proper operation.
Expected Result:
B. Inspect the bracket in order to ensure that the
One or more of the diagnostic codes that are listed installation allows the flange of the sensor to be
above are logged or active. flush against the engine.
Verify that the bracket is not bent.

215
Note: The bracket cannot be replaced separately.
C. Ensure that one O-ring has been installed on

the sensor, and ensure that the O-ring is free of
damage.
Note: If the flange of the sensor is bent or if an

obstruction is preventing the sensor from reading a
good pattern, the engine will not start.
Results:
OK The sensors and the bracket are properly

installed. Proceed to Test Step 3.
Not OK
Repair: Perform the following procedure in order
to properly install the sensors and the bracket:
1. Loosen the bolt that holds the sensor mounting

bracket to the engine.
2. Seat the sensor and tighten the bolt.
If the sensor will not seat, repair the sensor or

replace the sensor, as required.
Note: The sensor must not be removed from the

bracket.
3. Ensure that the sensor is properly oriented

and that the harness is secured in the proper
location.
STOP.
216
Test Step 3. Measure The Sensor

Resistance Through The Engine
Harness.
g00722949
Illustration 85
A. Turn the ignition key switch to the OFF position. F. Repair the harness or repair the connector if a
problem is found.
B. Thoroughly inspect ECM vehicle harness
connector J2/P2. Refer to Troubleshooting, G. Ensure that the wiring harness is correctly routed
Inspecting Electrical Connectors for details. and secured at the proper locations.
C. Perform a 45 N (10 lb) pull test on the following H. Ensure that the harness wiring is not pulled
wires in the ECM engine harness connector P2 too tightly. When the harness wiring is pulled
that are associated with the engine speed/timing too tightly, vibrations or movement can cause
sensors: intermittent connections.
Terminal 48 I. Inspect the harness wiring for nicks and

abrasions.
Terminal 49
J. If the harness and the connector are OK,
Terminal 58 disconnect ECM connector J2/P2.
Terminal 59 K. Use the following procedure to measure the

sensor resistance (Ohms) for the top camshaft
Refer to Illustration 85. position sensor:
D. Ensure that the latch tab on the connector is Refer to Illustration 85.
properly latched and ensure that the latch tab is
fully latched.
E. Check the ECM connector (allen head screw) for

217
a. Use a multimeter to measure the resistance C. Disconnect the suspect sensor from the engine
from terminal 48 (Top Camshaft Speed/Timing harness.
Sensor Positive) of the engine harness
connector P2 to terminal 49 (Top Camshaft D. Thoroughly inspect ECM engine harness
Speed/Timing Sensor Negative) of the engine connectors for the sensors J401/P401 or
harness connector P2. J402/P402. Refer to Troubleshooting, Inspecting
b. Check for an intermittent open circuit or
short circuit by moving the harness while the E. Use the following procedure to measure the
measurement for resistance is being taken. sensor resistance (Ohms) for the camshaft
Pull the wires that are directly behind the position sensor at the sensor connector between
sensors or shake the wires that are directly terminal A and Terminal B:
behind the sensors.
a. Use a multimeter to measure the sensor
Resistance ........................... 75 to 230 Ohms resistance (Ohms) from terminal B
(E964-WH) of the sensor connector J401
L. Use the following procedure to measure the to Terminal A (E963-BK) of the sensor
sensor resistance (Ohms) for the bottom connector J401.
camshaft position sensor:
Terminal B of the sensor connector is Top
Refer to Illustration 85. Camshaft Speed/Timing Positive.
a. Use a multimeter to measure the sensor Terminal A of the sensor connector is Top
resistance (Ohms) from terminal 58 (Bottom Camshaft Speed/Timing Negative.
Camshaft Speed/Timing Positive) of the
engine harness connector P2 to terminal 59 Resistance ............................ 75 to 230 Ohms
(Bottom Camshaft Speed/Timing Negative) of
the engine harness connector P2. F. Use the following procedure to measure the
sensor resistance (Ohms) for the bottom
b. Check for an intermittent open circuit or camshaft position sensor at the sensor connector
short circuit by moving the harness while the between terminal A and terminal B:
measurement for resistance is being taken.
Pull the wires that are directly behind the a. Use a multimeter to measure the sensor
sensors or shake the wires that are directly resistance (Ohms) from terminal B (E966-YL)
behind the sensors. of the sensor connector J402 to terminal A
(E965-BU) of the sensor connector J402.
Resistance ....................... 600 to 1800 Ohms
Terminal B of the sensor connector is Bottom
Expected Result: Camshaft Speed/Timing Positive.
The readings agree with the values that are listed Terminal A of the sensor connector is Bottom
above. Camshaft Speed/Timing Negative.
Results: Resistance ....................... 600 to 1800 Ohms
OK Neither a short circuit nor an open circuit is Note: Timing calibration is not necessary following
indicated. Proceed to Test Step 5. replacement of the Speed/Timing Sensors. Refer
to the information in the System Operation Section
Not OK The sensor resistance is not within the regarding the installation of sensors.
acceptable range when the sensor resistance is
measured through the engine harness. Proceed Expected Result:
to Test Step 4.
The readings agree with the values that are listed
Test Step 4. Measure The Resistance Of above.
The Sensor At The Sensor.
Results:
OK The sensor resistance is correct. Proceed
B. Check the harness and the wiring for abrasion to Test Step 5.
and pinch points from the sensor back to the
ECM. Not OK The sensor resistance is out of range.
218
Repair: Perform the following procedure in order Expected Result:

to check and install the new sensor:
The problem is corrected with the installation of the
1. Before installing the new sensor, measure the bypass harness.
resistance of the new sensor.
Results:
Note: If the new sensor resistance is not in the
correct range, inspect the wiring harness for Yes
damage.
Repair: Permanently install a new section of
If the new sensor resistance is in the correct harness.
range, install the new sensor in the engine,
as follows: STOP.
a. Loosen the bolt that holds the sensor No

mounting bracket to the engine.
Repair: Verify that the correct terminals have been
b. Ensure that one O-ring is installed and free installed in the correct location of the ECM engine
of damage. harness connector P2. If the temporary harness
was installed correctly, install the original wiring.
c. Seat the sensor and tighten the bolt.
If the sensor will not seat, repair the sensor
or replace the sensor, as required. Test Step 6. Check The ECM.
Note: The sensor must not be removed from the A. Turn the ignition key switch to the OFF position.
bracket.
B. Temporarily connect a test ECM.
d. Ensure that the sensor is properly oriented
and that the harness is secured in the C. Start the engine. Run the engine in order to
proper location. repeat the conditions when the problem occurs.
2. Verify that the repair eliminates the problem. D. If the problem is resolved with the test ECM,
STOP.
E. If the problem returns with the suspect ECM,
Test Step 5. Install The Bypass Harness replace the ECM.
For the Engine Speed/Timing Sensors.
Expected Result:
B. Disconnect ECM connector J2/P2.
The problem remains with the suspect ECM.
C. Install the wiring harness to the ECM engine
harness connector P2. Connect the wiring: Results:
Terminal 48 to the white wire Yes

Terminal 49 to the black wire Repair: If the problem is resolved with the test
ECM and the problem returns with the suspect
Terminal 58 to the yellow wire ECM, replace the ECM.
Terminal 59 to the blue wire Verify that the repair eliminates the problem.
Note: Twisted pair wiring is required. Ensure that the STOP.

wires have at least one twist per inch.
No
D. Reconnect the engine harness connector J2/P2.
Repair: Replace the sensor.
E. Start the engine in order to determine if the
bypass harness repairs the problem.
219
STOP.
i01372534
Engine Temperature Sensor

Open or Short Circuit - Test
SMCS Code: 1906-081; 1917-081; 1922-081;
1928-081
Use this procedure to troubleshoot the system only

when there is an active diagnostic code or when
a diagnostic code can easily be activated. This
procedure covers open circuit diagnostic codes and
short circuit diagnostic codes that are associated Illustration 86 g00767354
with the following sensors:
coolant temperature sensor

air inlet temperature sensor
Use this procedure for the following Diagnostic
Codes:
105-03 Inlet Manifold Temperature Sensor Open

Circuit (38)
105-04 Inlet Manifold Temperature Sensor Short

Circuit (38)
110-03 Coolant Temperature Sensor Open Circuit

(27)
110-04 Coolant Temperature Sensor Short Circuit

(27)

to this procedure:
The troubleshooting procedures for the diagnostic

codes of each temperature sensor are identical. The
temperature sensors are passive sensors that have
two terminals. The passive sensors do not require
supply voltage from the ECM. ECM connector
J2/P2 terminal 18 is the common connection for the
engine temperature sensors. The sensor common
connection is shared between all of the temperature
sensors. The common line is connected to each
sensor connector terminal 2. Terminal 1 is the
sensor output. The signal voltage from terminal 1 of
each sensor is supplied to the appropriate terminal
at ECM connector J2/P2.
220
g00724478
Illustration 87
Schematic for engine temperature sensors
Test Step 1. Verify All Active Diagnostic Repair: If the preceding codes are logged but
Codes. not active and the engine is not running properly,
refer to Troubleshooting, Troubleshooting
A. Connect the Electronic Service Tool to the cab without a Diagnostic Code. If the engine is
data link connector. running properly at this time, an intermittent
condition may be causing the logged codes.
B. Turn the ignition key switch to the ON position. Refer to Troubleshooting, Inspecting Electrical
Wait at least 15 seconds for activation of the Connections.
diagnostic codes.
STOP.
C. Verify if any of the following diagnostic codes
are active:
105-03 Inlet Manifold Air Temperature Sensor

Open Circuit (38)
105-04 Inlet Manifold Air Temperature Sensor

Short Circuit (38)
110-03 Coolant Temperature Sensor Open

Circuit (27)
110-04 Coolant Temperature Sensor Short

Circuit (27)
Expected Result:

are active.
Results:

No
221

And Wiring.
g00724517
Illustration 88
A. Thoroughly inspect ECM engine harness Results:

connector J2/P2 and the suspect sensor
connector. Refer to Troubleshooting, Inspecting OK Proceed to Test Step 3.
Not OK
wires in the sensor connector and the ECM Repair: Repair the connectors or wiring and/or
connector that are associated with the active replace the connectors or wiring. Ensure that all
diagnostic code. of the seals are properly in place and ensure that
C. Verify that the latch tab of the connector is
properly latched and that the latch tab of the STOP.
connector has returned to the Fully Latching
position. Test Step 3. Verify That The Diagnostic
Code Is Still Active.
D. Check the ECM connector (allen head screw) for
the proper torque of 6.0 Nm (55 lb in). A. Turn the ignition key switch to the ON position.
E. Check the harness and wiring for abrasion and diagnostic codes.
B. Access the Active Diagnostic Code screen
Expected Result: of the Electronic Service Tool. Check for active
diagnostic codes.
completely coupled and/or inserted and the harness C. Determine if the problem is related to an
and wiring should be free of corrosion, abrasion open circuit diagnostic code or a short circuit
or pinch points. diagnostic code.
222
Expected Result: D. Install the jumper on the engine harness

connector. Install one end of the jumper at the
A short circuit diagnostic code or an open circuit sensor signal (terminal 1). Install the other end
diagnostic code is active. of the jumper at the common connection for the
engine temperature sensor (terminal 2). Wait at
Results: least 15 seconds for activation of the short circuit
diagnostic code.
SHORT Circuit A short circuit diagnostic code
is active at this time. Proceed to Test Step 4. Expected Result:
OPEN Circuit An open circuit diagnostic code A short circuit diagnostic code is active when the
is active at this time. Proceed to Test Step 5. jumper is installed. An open circuit diagnostic code
is active when the jumper is removed.
Test Step 4. Disconnect The Sensor In
Order To Create An Open Circuit. Results:
A. Turn the ignition key switch to the OFF position. OK The engine harness and the ECM are OK.
B. Disconnect the sensor connector of the sensor Repair: Perform the following repair:
with the short circuit diagnostic code.
1. Temporarily connect the suspect sensor.
Wait at least 15 seconds for activation of the 2. If the diagnostic code remains active, replace
diagnostic codes. the sensor.
D. Access the Active Diagnostic Code screen of 3. Verify that the repair eliminates the problem.
the Electronic Service Tool. Check for an active
open circuit diagnostic code. 4. Clear all Logged diagnostic codes.
Expected Result: STOP.
An open circuit diagnostic code for the Not OK The open circuit diagnostic code
disconnected sensor is now active. remains active with the jumper in place. The
most probable location for the open is in the
Results: sensor common or the sensor signal wire in the
engine harness between the ECM and the sensor.
OK A short circuit diagnostic code was active Remove the jumper. Proceed to Test Step 7.
before disconnecting the sensor. An open
circuit diagnostic code became active after Test Step 6. Determine If The Short
disconnecting the sensor. Proceed to test step 6. Circuit Is In The Connector Or In The
Sensor.
Not OK There is a short circuit between the
sensor harness connector and the ECM. Leave A. Thoroughly inspect the connector for moisture.
the sensor disconnected. Proceed to Test Step 7.
B. Inspect the seals and reconnect the sensor.
Test Step 5. Create A Short Circuit
Between The Signal And The Common C. If the short circuit diagnostic code reappears,
Terminals At The Sensor Connector. the sensor is the problem.
A. Turn the ignition key switch to the ON position. a. Temporarily connect a new sensor to the
harness, but do not install the new sensor in
B. Fabricate a jumper wire 150 mm (6 inch) long. the engine.
Crimp a Deutsch terminal to both ends of the
wire. D. Check for a short circuit diagnostic code while
the new sensor is connected to the harness.
C. Monitor the Active Diagnostic Code screen
before installing the jumper wire and after Expected Result:
installing the jumper wire.
The short circuit diagnostic code is not present
when a new sensor is connected.
223
Results:
OK Verify that the repair eliminates the problem.

Clear the logged diagnostic codes. STOP.
Not OK
Repair: Repair the engine harness connector.
STOP.
Test Step 7. Check The Operation Of

The ECM By Creating Open And Short
Circuits At The ECM Connector.
g00767376
Illustration 89
Engine harness connector
A. Turn the ignition key switch to the OFF position. A short circuit diagnostic code should be active
when the jumper wire is installed.
B. Disconnect the Connector for the ECM harness.
Thoroughly inspect both halves of the connector Note: If access to the ECM connector is limited, it
for signs of corrosion or moisture. may be helpful to connect a 70-Termial Breakout T
to the ECM connector. This will allow the jumper
C. Turn the ignition key switch to the ON position. wire to be inserted into the breakout T. Ensure that
Monitor the Active Diagnostic Code screen. the jumper wire is inserted into the breakout T and
Wait at least 15 seconds for activation of the that the full wiring harness is attached.
code.
Refer to Illustration 89 for the engine harness
An open circuit diagnostic code should be active connector p2.
for the suspect sensor.
Expected Result:
Note: When the engine harness is disconnected, all
of the open circuit diagnostic codes for the pressure Open circuit diagnostic codes are active when the
sensors will be active. This is normal. Disregard the jumper is removed. Short circuit diagnostic codes
diagnostic codes for the pressure sensors. are active when the jumper is installed.
D. Turn the ignition key switch to the OFF position. Results:
E. Fabricate a jumper wire 150 mm (6 inch) long. OK The ECM is working properly. Proceed to
Crimp a Deutsch socket to both ends of the wire. Test Step 8.
F. Install the jumper wire on the ECM pin terminal. Not OK One of the following conditions exists:
Insert the jumper wire between the terminal for The open circuit diagnostic code is not active
the suspect sensor signal and the common when the harness is disconnected. The short
connection for the engine temperature sensor circuit diagnostic code is not active when the
(terminal 18). jumper wire is installed.

224
1. Temporarily connect a test ECM. Repair: Perform the following repair:
2. Remove all jumpers and replace all connectors. 1. Repair the faulty wiring harness or replace the
faulty wiring harness.
codes. 2. Clear all diagnostic codes.
4. Repeat the test step. 3. Verify that the repair eliminates the problem.
5. If the problem is resolved with the test ECM, STOP.

Not OK Restart this procedure and carefully
6. If the problem returns with the suspect ECM, perform each step. STOP.
replace the ECM.
i01372155
STOP.
Event Codes - Test
SMCS Code: 1900-081; 1901-081
Test Step 8. Bypass The Harness Wiring
Between The ECM And The Sensor System Operation Description:
Connector.
This procedure covers the following diagnostic
B. Disconnect the connector for the ECM harness, event codes.
and the sensor connector.
84-00 Vehicle Overspeed Warning (41)
C. Remove the sensor signal wire from the ECM
connector. 84-14 Quick Stop Occurrence (00)
D. Remove the signal wire (terminal 1) from the 100-01 Low Oil Pressure Warning (46)
sensor connector on the engine harness.
100-11 Very Low Oil Pressure (46)
E. Fabricate a jumper wire that is long enough to
reach from the ECM to the sensor connector with 105-00 High Inlet Manifold Temp Warning (64)
Deutsch sockets on both ends.
105-11 Very High Inlet Manifold Temp (64)
F. Insert one end of the jumper into the ECM
Connector. Insert the other end of the jumper 110-00 High Coolant Temperature Warning (61)
into the sensor connector of the engine harness.
110-11 Very High Coolant Temperature (61)
G. Reconnect the Connector for the ECM Harness
and the sensor connector. 111-01 Low Coolant Level Warning (62)
H. Turn the ignition key switch to the ON position. 111-11 Very Low Coolant Level (62)
I. Monitor the Active Diagnostic Code screen for 190-00 Engine Overspeed Warning (35)
either the open circuit diagnostic code for the
sensor or the short circuit diagnostic code for 224-11 Theft Deterrent Active (00)
the sensor.
224-14 Engine Cranking with Theft Detterent
Expected Result: Active (00)
The diagnostic code disappears when the jumper The following background information is related
is installed. to this procedure:
Results:
OK There is a problem in the wiring harness.

225
The diagnostic event codes that are listed are b. Check the engine oil level. If the dipstick
used to indicate the existence of an operating indicates that the oil level is at the FULL
condition which could damage the engine if the mark and this is a chronic problem with the
condition is allowed to continue for an extended engine, verify that the dipstick is calibrated
period of time. The diagnostic event codes are correctly.
also used to indicate the existence of an operating
condition which could degrade the performance c. Check for coolant or fuel dilution of the oil.
of the engine.
C. Use the following procedure in order to check
The following diagnostic codes are part of the any of the following diagnostic codes:
Caterpillar Engine Monitoring System:
105-00 High Inlet Manifold Temp Warning (64)
100-01 Low Oil Pressure Warning (46)
105-11 Very High Inlet Manifold Temp (64)
100-11 Very Low Oil Pressure (46)
a. Ensure that a winter front is not obstructing
110-00 High Coolant Temperature Warning (61) the flow of air to the air filter. Also check for
other restrictions that may be preventing an
110-11 Very High Coolant Temperature (61) adequate flow of air to the air filter.
111-01 Low Coolant Level Warning (62) Expected Result:
111-11 Very Low Coolant Level (62) All mechanical systems are OK.
Note: Most of the diagnostic codes are shown in Results:

the Electronic Service Tool under both Diagnostic
Event Codes and Diagnostic Fault Codes. Yes Proceed to Test Step 2.
The diagnostic event codes usually indicate a
mechanical problem or abnormal engine operation. No Correct the problem and clear all diagnostic
The diagnostic event codes seldom indicate an codes. STOP.
electronic problem. The critical events are ECM
date/time stamped information. Test Step 2. Inspect Electrical Connectors
And Wiring.
Test Step 1. Check The System That Is
Being Monitored By The Sensor. A. Thoroughly inspect the following connectors:
A. Use the following procedure in order to check J2/P2 ECM engine harness connector
any of the following diagnostic codes:
J1/P1 ECM vehicle harness connector
110-00 High Coolant Temperature Warning (61)
extension harness for the coolant level
110-11 Very High Coolant Temperature (61) connector
111-01 Low Coolant Level Warning (62) connector terminals for the sensor
111-11 Very Low Coolant Level (62) Refer to Troubleshooting, Inspecting Electrical
Connectors for details.
a. Check the coolant level.
Note: The connector for the extension harness for
Note: For the coolant level sensor, ensure that the the coolant level connects the coolant level sensor
sensor probe is fully immersed in the fluid. to the vehicle harness in the engine compartment
of some chassis.
B. Use the following procedure in order to check
any of the following diagnostic codes: B. Perform a 45 N (10 lb) pull test on each of the
100-01 Low Oil Pressure Warning (46) with the appropriate diagnostic code.
100-11 Very Low Oil Pressure (46) C. Check the ECM connector (allen head screw) for
a. Verify that the engine oil pressure sensor is
installed in the correct engine port. Also verify D. Check the harness and wiring for abrasion and
that the sensor is connected to the correct pinch points from the appropriate sensor back
harness connector. to the ECM.
226
Expected Result: B. Connect an Electronic Service Tool to the cab

completely coupled and/or inserted and the harness C. Turn the ignition key switch to the ON position.
or pinch points. D. Note the temperature for the sensor on the
Electronic Service Tool status screen.
Choose the OK option in order to select the sensor
that requires troubleshooting or select the NOT OK E. Start the engine but remain parked.
option if the wiring is causing the problem.
F. Monitor the temperature for the sensor that is
Results: being checked on the Electronic Service Tool
Status screen as the engine is warming.
Expected Result:
Not OK Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all The temperature before starting the engine should
of the seals are properly in place and ensure that be within reasonable limits, and the temperature
the connectors are completely coupled. Verify increases as the engine warms.
that the repair eliminates the problem. STOP.
Note: The engine may require several hours to cool
Test Step 3. Select a Sensor. down depending on the ambient air temperature
around the vehicle.
To troubleshoot coolant temperature sensors or inlet
manifold temperature sensors, select Group 1. Results:
To troubleshoot the engine oil pressure sensor, Yes The sensor is functioning correctly. If
select Group 2. a problem is still suspected the problem is a
mechanical problem. The problem is not an
To troubleshoot the coolant level sensor, select electronic problem.
Group 3.
Expected Result: procedure:
Results: Refer to Troubleshooting, Troubleshooting without

a Diagnostic Code for a procedure that best
Group 1 Proceed to Test Step 4. describes the conditions.
OK Group 2 Proceed to Test Step 6. STOP.
Group 3 No Proceed to Test Step 5.

Repair: Perform the following diagnostic Test Step 5. Compare The Temperature
procedure: Reading To The Temperature From
Another Gauge.
Troubleshooting, Coolant Level Sensor Circuit -
Test A. Use the following procedure in order to check
the following sensors:
STOP.
coolant temperature sensor
Not OK Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all a. Remove the temperature sensor from the
of the seals are properly in place and ensure that engine.
the connectors are completely coupled. Verify
that the repair eliminates the problem. STOP. b. Connect the sensor to the engine harness.
Insert the sensor and the thermocouple probe
Test Step 4. Check Temperature Sensors from the 6V-9130 Temperature Adapter into
In The Engine. a container of water that is room temperature.
Allow three minutes for the sensor and the
A. Ensure that the temperature of the engine is cool probe to respond to the temperature of the
before starting this procedure. water.
227
c. The Electronic Service Tool status screen NO

will display the temperature reading from
the sensor. Compare the temperature Repair: Perform the following diagnostic
reading to the temperature reading from procedure:
the 6V-9130 Temperature Adapter. The
temperature reading from the sensor can also 1. Temporarily install another sensor.
be compared to the temperature gauge on
the dash of the truck. 2. Repeat this test step.
d. Insert the sensor and the thermocouple probe 3. If the problem is resolved with the new sensor,
from the 6V-9130 Temperature Adapter into replace the sensor.
a container of hot water. Again, compare
the temperature reading from the sensor to 4. Verify that the repair eliminates the problem.
the temperature reading of the 6V-9130
Temperature Adapter. STOP.
B. Use the following procedure in order to check Test Step 6. Check The Engine Oil
the air inlet temperature sensor. Pressure Sensor.
a. Remove the temperature sensor from the A. Connect an Electronic Service Tool to the cab
engine. data link connector.
b. Connect the sensor to the engine harness. B. Turn the ignition key switch to the ON position.
Hold the sensor and the thermocouple probe
from the 6V-9130 Temperature Adapter in the C. The Electronic Service Tool status screen will
air. Allow three minutes for the sensor and the display the pressure reading from the sensor.
probe to respond to the temperature of the air. The pressure reading for the engine oil pressure
sensor should be less than 21 kPa (3 psi).
c. The Electronic Service Tool status screen will
display the temperature reading from the D. Use the 1U-5470 Engine Pressure Group to
sensor. Compare the temperature reading to measure the engine oil pressure on the right
the temperature reading from the 6V-9130 side engine high pressure oil gallery. Select a
Temperature Adapter. port that is located near the engine oil pressure
sensor, but not the sensor port.
d. Hold the sensor and the thermocouple probe
in your hand and check the temperatures E. Start the engine and run at low idle. If the engine
again. Do not expose the sensor to a flame. oil pressure does not exceed 35 kPa (5 psi) after
five seconds, stop the engine.
Expected Result:
F. Depress the accelerator pedal to the high idle
The two measurements are within 15 C (27 F) of position and check for oil leakage. Repair any
each other. leaks.
Note: Do not expect the sensor and the G. Operate the engine at low idle, at 1200 rpm and
thermocouple probe from the 6V-9130 Temperature at high idle in order to compare the engine oil
Adapter to respond to the temperature change at pressure from the Electronic Service Tool status
the same rate. screen to the 1U-5470 Engine Pressure Group
measurement at each rpm.
Results:
Expected Result:
YES The sensor is functioning correctly. If
a problem is still suspected the problem is a The Electronic Service Tool display and the
mechanical problem. The problem is not an measured engine oil pressure from the 1U-5470
electronic problem. Engine Pressure Group are within 35 kPa (5 psi)
of each other.
procedure: Results:
Refer to Troubleshooting, Troubleshooting without YES The sensor is functioning correctly. If

a Diagnostic Code for a procedure that best a problem is still suspected the problem is a
describes the conditions. mechanical problem. The problem is not an
electronic problem.
STOP.
228
Repair: Perform the following diagnostic The switch for the exhaust brake is on.
procedure:
When the cruise control on/off switch is in the ON
Refer to Troubleshooting, Troubleshooting without position, the following conditions exist:
a Diagnostic Code for a procedure that best
describes the conditions. Exhaust Brake Mode Parameter
STOP. When the cruise control on/off switch is on, this

parameter provides two special options that allow
NO the exhaust brake to be operated only after the
driver has depressed the service brake pedal. The
Repair: Perform the following diagnostic two modes of operation that follow are customer
procedure: programmable:
1. Temporarily install another sensor. The Coast mode engages the exhaust brake
when the driver depresses the service brake
2. Repeat this test step. pedal. The exhaust brake disengages when the
driver releases the service brake pedal.
3. If the problem is resolved with the new sensor,
replace the sensor. The Latch mode engages the exhaust brake
when the driver depresses the service brake
4. Verify that the repair eliminates the problem. pedal. The exhaust brake remains engaged until
the control detects a change in the control input.
STOP. The following actions are examples of a change
in a control input:
i01380403
The throttle is depressed.
Exhaust Brake Circuit - Test
The clutch pedal is depressed.
SMCS Code: 1093-081
The engine speed drops below 900 rpm.
The third option for the Exhaust Brake Parameter is
Use this procedure under the following situation: Manual. The Manual mode operates in the same
manner regardless of the position of the cruise
Use this procedure to determine if the circuit for the control on/off switch. The driver is not required to
exhaust brake (output 3) is operating correctly. depress the service brake pedal in order to initiate
the exhaust brake. Depress the service brake pedal
The following background information is related in order to initiate the exhaust brake in the Latch
to this procedure: mode and the Coast mode.
The exhaust brake relay circuit is provided by Note: The Latch mode and the Coast mode are
the ECM. The circuit indicates that conditions customer programmable options. The Latch mode
are acceptable for an exhaust brake to operate. and the Coast mode determine the operation of
Operation of the exhaust brake is inhibited during the exhaust brake only when the cruise control
undesirable engine operating conditions. switch is in the ON position. The Latch mode and
the Coast mode do not determine the operation
When the cruise control on/off switch is in the of the exhaust brake when the engine is active in
OFF position, the following conditions exist: cruise control. Latch mode and Coast mode
require the initiation of the service brake before
All of the following conditions must be met in order acting. The action of the service brake disengages
to ensure the proper operation of the exhaust brake: the cruise control.
Note: The output for the exhaust brake is disabled

Engine speed is above 1000 rpm.
whenever the PTO on/off circuit is on and the
customer parameter PTO Configuration is
The accelerator pedal position is less than seven programmed to Cab Switches, Remote Switches,
percent.
or Remote Throttle.
The clutch pedal is released. Exhaust Brake On/Off Switch
229
An on/off switch can be used to provide operator

control of the exhaust brake in order to inhibit
operation during undesirable conditions. Two
different methods may be used. An in-line switch
can be installed in the output circuit for the exhaust
brake (terminal 12). The switch will turn the brake off
by opening the circuit. This removes power from the
brake relay. Opening the switch does not disable
the output driver. Opening the switch disables the
exhaust brakes.
With NOV99 and newer Personality Modules, an

optional feature was added in order to provide an
input to the ECM. The input is used to connect
an on/off switch for the exhaust brake. The input
uses terminal 16. When the switch is opened, the
ECM will turn off the output circuit for the exhaust
brake. This method allows the ECM to broadcast
the correct status of the exhaust brake over the
data link. With the first method that is described
above, the brake can be disabled but the output
remains active.
Note: If the on/off switch for the exhaust brake is

installed in the output circuit, the Exhaust Brake
Switch parameter must be programmed to NOT
INSTALLED. If the on/off switch is connected to
the ECM switch input (terminal 16), the Exhaust
Brake Switch parameter must be programmed to
INSTALLED.
g00729018
Illustration 90
Schematic for the exhaust brake
230
g00769855
Illustration 91
g00769856
Illustration 92
231

STOP.
Test Step 2. Connect an Electronic

Service Tool and Check the Accelerator
Pedal Position Sensor and the Clutch
Pedal Position Switch.
A. Ensure that the cruise control on/off switch is
OFF.
B. Connect an Electronic Service Tool at the cab

D. Use the following procedure to check the

accelerator pedal position sensor:
g00729019
a. Monitor the duty cycle of the throttle sensor
Illustration 93 on the electronic service tool. Access the
ECM terminal Accelerator Pedal Positiondisplay screen.
Test Step 1. Check Electrical Connectors b. While the duty cycle is being monitored on the
and Wiring. electronic service tool depress the accelerator
pedal and release the accelerator pedal.
A. Thoroughly inspect ECM connectors J1/P1 Repeat this action several times.
and the firewall bulkhead connector. Refer
to Troubleshooting, Inspecting Electrical E. If a manual transmission is installed, use the
Connectors for details. following procedure to check the status of the
Clutch Pedal Position Switch:
wires in the ECM connector that are associated a. Access the status screen on the electronic
with the connections for the circuit for the service tool for the Clutch Pedal Position
exhaust brakes. Switch.
C. Check the ECM connector (allen head screw) for b. While the status screen is being monitored on
the proper torque of 6.0 Nm (55 lb in). the electronic service tool, depress the clutch
pedal and release the clutch pedal. Repeat
D. Check the harness and wiring for abrasion and this action several times.
for pinch points from the sensor to the ECM.
Expected Result:
Expected Result:
The duty cycle of the accelerator pedal position
All connectors, pins, and sockets should be sensor is between 3 percent and 100 percent. The
completely coupled and/or inserted and the harness status of the Clutch Pedal Position Switch on the
and wiring should be free of corrosion, abrasion electronic service tool changes from OFF to ON
or pinch points. when the clutch pedal is depressed. The status of
the Clutch Pedal Position Switch on the electronic
Results: service tool changes from ON to OFF when the
clutch pedal is released.
OK Proceed to the Test Step 2.
Results:
Not OK
232
Not OK Incorrect accelerator pedal position F. Begin the Exhaust Brake Special Test while you
listen for the solenoids to click. You may need to
Repair: Perform the following diagnostic be closer to the engine in order to hear the click
procedure: of the solenoid.
Troubleshooting, Accelerator Pedal (Throttle) Expected Result:

Position Sensor Circuit - Test.
All of the solenoids and all of the relays are
STOP. operating.
Not OK Clutch switch status is incorrect. Results:
Repair: Perform the following diagnostic Yes The ECM is operating correctly. STOP.
procedure:
Circuit - Test. Test Step 4. Use an Electronic Service
Tool to Check the ECM.
STOP.
Service Tool and Check the Solenoids B. Disconnect the ECM engine harness connector
and the Relays. J1/P1.
C. Connect a 70-Terminal breakout T to the ECM

connector J1/P1.
D. Connect a voltage test lamp to terminal 12

(Output 3) and terminal 65 (-battery) of the
70-Terminal breakout T.
F. Access the special test for the Exhaust Brake

Special Test on the electronic service tool.
G. While the voltage test lamp is being observed,

cycle the special test for the exhaust brake to
the ON and OFF positions.
H. Stop the special test.
Expected Result:
g00769913 The voltage test lamp behaves in the following

Illustration 94
manner:
Breakout T
The voltage test lamp turns ON when the test is
A. Connect an Electronic Service Tool at the cab active.
The voltage test lamp turns OFF when the test
B. Turn the ignition key switch to the ON position. is NOT active.
C. Turn the switch ON for the exhaust brake. Results:
D. Access the status screen on the electronic Yes There is a problem in the harness.
service tool for the Exhaust Brake Special Test.
E. Turn the on/off switch for the exhaust brake to
the ON position.
233
Repair the engine harness or replace the engine One terminal of the lamp must be connected to
harness. Verify that the repair eliminates the battery voltage through the vehicle wiring. The other
problem. terminal is connected to the ECM at the vehicle
harness connector J1/P1 at terminal 31.
STOP.
The ECM provides a path to ground that will turn
No Verify that the switch for the exhaust brake on the lamp.
is ON and verify that the electronic service tool
status screen reflects this condition. If the ECM
is reading the switch status change, temporarily
connect a test ECM. Repeat this test step. If the
problem is resolved with the test ECM, reconnect
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.

g00729696
codes. Illustration 95
Schematic for the fast idle enable switch
5. If the problem is resolved with the test ECM, And Wiring.

replace the ECM.
STOP.
i01382648
Fast Idle Lamp Circuit - Test

SMCS Code: 1900-081
Use this procedure to determine if the fast idle lamp

(terminal 31 output #9) is operating properly.
Output 9 can operate as a fast idle lamp or a wait

to start lamp. The Output #9 parameter defaults to
Fast Idle Lamp and the ECM will turn on output 9
when the fast idle is active.
Note: For GM Truck Manufacturer configurations,

the Output #9 parameter is unavailable and output
9 functions as an output only for the fast idle lamp.
Electrical Connections of the Lamp
g00770189
Illustration 96
234
A. Thoroughly inspect ECM vehicle harness If any of the switches do not display the indicated
connector J1/P1, the firewall bulkhead connector, status, fast idle will not activate.
and the terminals for the fast idle lamp.
E. Use the Electronic Service Tool status screen to
Refer to Troubleshooting, Inspecting Electrical monitor the fast idle switch and the fast idle rpm.
F. Depress the fast idle switch while the status of
B. Perform a 45 N (10 lb) pull test on each of the the fast idle enable switch is being observed.
wires in the ECM connector that are associated Also observe the fast idle lamp. Release the
with the fast idle lamp. fast idle switch. The fast idle lamp should turn
on when the fast idle switch is pressed and
C. Check the ECM connector (allen head screw) for released.
G. Depress the service brake pedal. The fast idle
D. Check the harness and wiring for abrasion and lamp should turn off when the service brake is
for pinch points from the sensor to the ECM. applied.
All connectors, pins, and sockets should be The switch status changes per the above
completely coupled and/or inserted and the harness information. The fast idle lamp turns on and the fast
and wiring should be free of corrosion, abrasion idle lamp turns off per the description above.
or pinch points.
Results:
Results:
Yes The fast idle lamp is operating normally.
OK Proceed to Test Step 2. STOP.
Not OK No The ECM is not reading the switch status

replace the connectors or wiring. Ensure that all Test Step 3. Test the Fast Idle Lamp
of the seals are properly in place and ensure that Circuit.
STOP.
Test Step 2. Check for Normal Operation

of the Fast Idle Lamp.
A. Verify that a fast idle enable switch is installed.
B. Connect an Electronic Service Tool.
D. Access the Electronic Service Tool status screen.

Verify that the following switches indicate the
correct status:
The service brake switch 1 is off.

The service brake switch 2 is off. Illustration 97 g00770210
The neutral switch is on. A. Turn the ignition key switch to the OFF position.
The clutch switch is off. B. Fabricate a jumper wire 100 mm (4 inch) long.
235
C. Disconnect vehicle harness connector P1 from Test Step 4. Check ECM Operation Of The
the ECM. Fast Idle Lamp.
D. Insert the jumper into terminal 31 of connector
P1.
E. Connect the other end of the jumper wire to

terminal 65 (battery) of connector P1.
G. While the lamp is being watched, insert the

Expected Result:
Result 1 The fast idle lamp turns on while the

jumper is connected to both sockets. Also, the fast
idle lamp turns off when the jumper is removed from
one of the sockets.
Result 2 The fast idle lamp does not turn on while

g00770221
Illustration 98
Result 3 The fast idle lamp will stay on while the
ECM vehicle harness connector is disconnected.
A. Disconnect ECM vehicle harness connector
J1/P1.
Results:
B. Insert a 70-Terminal breakout T between ECM
Result 1 The fast idle lamp is functioning vehicle harness connector J1 and ECM vehicle
properly. Proceed to Test Step 4.
harness connector P1.
Result 2 The fast idle lamp did not turn on. The C. Connect one probe of the voltage test lamp to
vehicles lamp circuit is not functioning properly.
The lamp is probably burned out or there is a terminal 65 (-battery). Connect the other probe of
the voltage test lamp to terminal 52 (unswitched
+battery) of the breakout T.
ECM or the +battery connection. Repair the lamp
D. The test lamp should turn on. If the test lamp
repairs. STOP.
Result 3 step if the lamp turns on.
procedure:
terminal 52 (unswitched +battery).
shorted to chassis ground. Repair the circuit or
send the vehicle to the OEM dealer for repairs.
STOP.
236
K. Start the engine and connect the other probe of

the test lamp to terminal 31 (output #9, fast idle
enable lamp).
L. Insert a jumper wire into terminal 40 (input #18,

fast idle enable switch) and momentarily touch
the other end of the jumper wire to terminal 65
(-battery) of the breakout T in order to activate
fast idle.
Note: The fast idle enable switch is a momentary

switch. In order to activate this input, the jumper wire
can not remain connected to the -battery terminal.
The jumper wire must only make momentary
contact.
The voltage test lamp should turn on and the

engine rpm should increase to the programmed
fast idle rpm.
M. Remove the jumper wire at terminal 45 (service

Illustration 99 g00770231 brake pedal position switch). The voltage test
lamp should turn off when the jumper is removed.
F. Fabricate four jumper wires 100 mm (4 inch)
long. Crimp a Deutsch pin to both ends of the Expected Result:
wires.
G. Insert one end of a jumper wire into terminal 45 per the above description.
(service brake pedal position switch) and the
other end into terminal 18 (input sensor common Results:
#1) of the breakout T.
H. Insert one end of a jumper wire into terminal problem in the vehicle wiring or the lamp. STOP.
22 (clutch pedal position switch) and the other
end into terminal 5 (AP sensor/switch sensor No
common) of the breakout T.
Repair: Temporarily connect a test ECM. Check
I. Insert one end of a jumper wire into terminal 62 the ECM operation of the fast idle lamp when the
(input #12, neutral switch) and the other end test ECM is installed. If the problem is resolved
into terminal 53 (unswitched +battery) of the with the test ECM, reconnect the suspect ECM.
breakout T. If the problem returns with the suspect ECM,
replace the ECM.
J. Access the Electronic Service Tool status screen.
Verify that the following switches indicate the STOP.
correct status:
i01364544
Idle Shutdown Timer - Test
SMCS Code: 1900-081
The neutral switch is on.
The clutch switch is off.
If any status displays Not Available that option
is not used on the vehicle. If any of the switches Use this procedure to determine if the idle shutdown
do not display the correct status, fast idle will is operating correctly.
not activate.
to this procedure:
237
Idle Shutdown Timer The ECM will shut down the engine but not the
vehicle electrical system when the Idle Shutdown
The Idle Shutdown Timer is intended to improve Timer time expires. The Engine Shutdown Output
fuel economy by limiting idling time. can be used to shut down the vehicle electrical
system after the Idle Shutdown Timer time has
The Idle Shutdown Time is a Customer Specified expired.
Parameter that may be programmed for any period
from 3 to 1440 minutes. The Idle Shutdown Timer Feature can be
temporarily disabled by using an Electronic
The timer is activated when all of the following Service Tool. The Idle Shutdown Timer Feature
conditions are met regardless of the position of the can be temporarily disabled through the System
parking brake: Troubleshooting Settings screen in order to help
troubleshoot other problems. Temporarily disabling
The vehicle speed is 0. this feature avoids engine shutdowns when you
are troubleshooting other systems. Using this
The engine is not in Cold Mode or Dedicaed method eliminates the need to temporarily alter the
PTO Mode. Customer Specified Parameter of Idle Shutdown
Timer.
The engine is not under load.
Note: If the following diagnostic code is active, the
The timer can be reset by moving the vehicle or Idle Shutdown Timer will not operate.
the timer can be reset by quickly depressing the
accelerator pedal and releasing the accelerator 84-08 Vehicle Speed Out Of Range (36)
pedal.
Test Step 1. Verify Activation Of The Idle
The check engine lamp will begin to rapidly flash Shutdown Timer.
90 seconds before the programmed time expires.
During this 90 second time period, the following A. Connect an Electronic Service Tool to the cab
conditions can disable the timer: data link connector.
The driver moves the clutch pedal. B. Access the Customer Parameters on the
The driver moves the service brake pedal.
a. Access the following display screens in order:
The following event code will be logged when the
driver overrides the timer by using the clutch pedal Service
or the brake pedal during the 90 second period:
Configuration
71-00 Idle Shutdown Override (01)
b. Record the programmed time for the Idle
If the parameter for the Allow Idle Shutdown Shutdown Timer. The Idle Shutdown Timer
Override is programmed to NO, the timer can not must be between 3 and 1440 minutes. If the
be overridden by using the clutch pedal or the brake Idle Shutdown Timer is programmed to 0,
pedal during the final 90 second period. YES then the timer is disabled.
is the factory default that is programmed for the
parameter for the Allow Idle Shutdown Override. c. Record the programmed status of the
The allowance of the override is the default. parameter for the Allow Idle Shutdown
Override and the Idle Shutdown Timer
If the timer is activated and the timer is allowed to Maximum RPM.
shut down the engine the following Event Code will
be generated: C. Start the engine. Allow the engine to warm up
71-01 Idle Shutdown Occurrence (47) Allow the engine to operate at the programmed
Code 71-01 records the event and the code does devices.
not indicate an electrical system malfunction or an
electronic system malfunction. Disable the timer by D. Ensure that all unnecessary loads are turned
programming Idle Shutdown Time to 0 (Caterpillar OFF.
Factory Default).
a. Park the vehicle.
238
b. Ensure that the Vehicle Speed on the check engine lamp

Electronic Service Tool Status screen is 0 km/h
(0 mph). Idle Shutdown Status
c. Ensure that the engine speed on the D. If the customer parameter of Allow Idle
Electronic Service Tool Status screen is at Shutdown Override is programmed to YES,
Low Idle. perform either of the following actions in order to
override the shutdown:
d. Ensure that the clutch pedal is not depressed.
Ensure that the brake pedal is not depressed. Press the clutch pedal.
e. Ensure that the status of the PTO on/off switch Press the service brake pedal.
is OFF.
Note: This action must be accomplished while the
f. Observe the Idle Shutdown Status. check engine lamp is flashing. The check engine
lamp flashes during the 90 second period before
Expected Result: the programmed shutdown time.
Result 1 The Idle Shutdown Status indicates E. Reprogram the Idle Shutdown Time to the value
Counting. that was recorded earlier for this test.
Result 2 The Idle Shutdown Status indicates Not Expected Result:

Active.
During the 90 second period before the scheduled
Results: shutdown, the status should change from Counting
to Driver Alert and the check engine lamp should
Result 1 The ECM is reading the proper flash rapidly. If the Allow Idle Shutdown Override
conditions for the activation of the Idle Shutdown is programmed to YES, the Idle Shutdown Status
Timer. Proceed to Test Step 2. should change to Override after the pedals are
depressed.
conditions for activation of the Idle Shutdown Result 1 The Idle Shutdown Timer behaves in the
Timer. Proceed to Test Step 3. manner that is described above.
Test Step 2. Verify The Driver Alert Result 2 The check engine lamp did not flash
Function For Idle Shutdown And The during the alert.
Override Function For Idle Shutdown.
Result 3 The ECM did not sense a change in the
A. Connect an Electronic Service Tool to the cab status of the service brake.
Result 4 The ECM did not sense a change in the
B. Access the Customer Parameters on the status of the clutch.
Results:
a. Access the following display screens in order:
Result 1 The Idle Shutdown Timer is operating
Service properly. STOP.
Configuration Result 2 The check engine lamp did not flash

during the alert.
b. Record the programmed time for the Idle
Shutdown Time. The Idle Shutdown Time Repair: Perform the following diagnostic
must be between 3 and 1440 minutes. If the procedure: Troubleshooting, Check Engine Lamp
Idle Shutdown Time is programmed to 0, Circuit - Test
the timer is disabled.
STOP.
c. Reprogram the Idle Shutdown Time to 3
minutes for this test. Result 3 The ECM did not sense a change in
the status of the service brake.
C. Observe the following items during the 90 second
period before the programmed shutdown time:
239
Repair: Perform the following diagnostic Repair: The engine must not be in Cold Mode
procedure: Troubleshooting, Service Brake Pedal operation while this test procedure is being
Position (Switch 1) Circuit - Test performed. Allow the engine to run until the
coolant temperature exceeds 20 C (68 F).
STOP. Troubleshoot and repair any related conditions.
Result 4 The ECM did not sense a change in STOP.

the status of the clutch.
Result 3 The status of the PTO on/off switch
Repair: Perform the following diagnostic is not OFF.
procedure: Troubleshooting, Clutch Pedal
Position Switch Circuit - Test Repair: Perform the following diagnostic
procedure: Troubleshooting, PTO Switch Circuit -
STOP. Test
Test Step 3. Check The State Of The STOP.

Related Conditions When The Vehicle Is
Parked. Result 4 The engine is not at low idle.
A. Check the state of the following related conditions Repair: Return the engine to Low Idle. Perform
when the vehicle is parked: the test procedure again.
Ensure that the vehicle speed is 0 km/h STOP.

(0 mph) on the Electronic Service Tool or the
Dash Display.
i01410646
Ensure that the engine is not in cold mode.

(The Electronic Service Tool Status Screen
Ignition Key Switch Circuit and
will indicate that the Cold Mode is Active in Battery Supply Circuit - Test
the corner of the display screen.)
SMCS Code: 1408-081; 1553-081
Ensure that the PTO on/off switch is OFF.
Ensure that the engine is at low idle.
Expected Result:
This procedure tests whether proper voltage is
Result 1 Vehicle speed is not indicated as 0 km/h supplied by vehicle wiring. Use this procedure
(0 mph). if any one of the following diagnostic codes are
logged several times:
Result 2 The Electronic Service Tool status screen
indicates that the engine is in Cold Mode. 168-02 Intermittent Battery (51)
Result 3 The status of the PTO on/off switch is not 43-02 Ignition Key Switch Fault (71)
OFF.
Also, use this procedure if you suspect that the
Result 4 The engine is not at low idle. ECM is not receiving the battery supply voltage.
Results: Note: This code can be generated by rapidly

cycling the ignition key switch. Some control
Result 1 Vehicle speed is not indicated as modules on the vehicle require this action in order
0 km/h (0 mph). to prompt flash codes. If this occurs, clear the
logged diagnostic codes in order to prevent future
Repair: Perform the following diagnostic confusion or an incorrect diagnosis.
Circuit - Test The following background information is related
to this procedure:
STOP.
Result 2 The Electronic Service Tool Status

Screen indicates that the engine is in cold mode.
240
The ECM receives electrical power (battery voltage) For intermittent problems such as intermittent
through the wiring that is supplied by the vehicle shutdowns that could be caused by vehicle wiring,
manufacturer. The ECM input at connector P1 temporarily bypassing the vehicle wiring may be
terminal 70 (Ignition Key Switch) receives battery an effective means of determining the root cause.
voltage from the ignition key switch when the If the symptoms disappear with the bypass wiring,
ignition key switch is in the ON position or the the vehicle wiring is the cause of the problem. A
START position. When the ECM detects battery means of bypassing vehicle wiring is explained in
voltage at this input, the ECM will power up. When this test procedure. This is especially important for
battery voltage is removed from this input, the ECM vehicles that do not provide dedicated circuits for
will power down. the unswitched battery and the ignition key switch
connections.
The cause of an intermittent power supply to
the ECM can occur on either the positive side
(Unswitched +Battery) or the negative side
(Battery). Both sides are routed from the ECM
to the battery. The two Unswitched +Battery
connections should be routed through a dedicated
protection circuit.
Some vehicles may be equipped with an engine

protection shutdown system or an idle timer
shutdown system that interrupts electrical power
to the ECM in order to shut down the engine.
Also, some vehicles may be equipped with an
engine protection shutdown system or an idle timer
shutdown system that interrupts electrical power
to the ignition key switch. The engine protection
shutdown system can be an aftermarket device and
the idle timer shutdown system can be external
to the ECM. Some of these systems will not
supply power to the ECM until one of the following
conditions is met:
The engine is cranked.

The engine oil pressure achieves acceptable
limits.
An override button is pressed.

Keep in mind that these devices may be the cause
of intermittent power to the ECM.
Usually, battery power to the cab data link connector

is available and the battery power to the cab data
link connector is independent of the ignition key
switch. Therefore, you will be able to power up an
electronic service tool, but you may not be able
to communicate with the engine ECM. The engine
ECM requires the ignition key switch to be in the ON
position in order to maintain communications. The
ECM may power down a short time after connecting
the electronic service tool if the ignition key switch
is in the OFF position. This is normal. Refer to
Troubleshooting, ATA (SAE J1587 / J1708) Data
Link Circuit - Test.
241
g00742658
Illustration 100
Schematic for ECM battery circuit
g00640974
Illustration 101
242
Test Step 1. Inspect Electrical Connectors C. Monitor the status of the ignition key switch while
And Wiring. the ignition key switch is being cycled slowly
from the ON position to the OFF position.
A. Thoroughly inspect ECM vehicle harness
connector J1/P1, the battery connections and Note: The electronic service tool may indicate that
the connections to the ignition key switch. a new ECM has been detected. This condition is
Refer to Troubleshooting, Inspecting Electrical normal, due to a powerdown of the ECM with the
Connectors for details. ignition key switch in the OFF position.
B. Perform a 45 N (10 lb) pull test on each of the Note: Cycling the ignition key switch several times
wires in the ECM connector that are associated may cause additional 43-02 faults to be logged.
with the following connections: This is normal. Clear any logged faults.
Unswitched +Battery (terminals 52 and 53) Expected Result:
Battery (terminals 65 and 67) The status of the ignition key switch changes from
On with the ignition key switch in the ON position
Ignition Key Switch (terminal 70) to Off with the ignition key switch in the OFF
position.
the proper torque of 6.0 Nm (55 lb in). Results:
D. Check the harness and wiring for abrasion and YES The input for the ignition key switch is
pinch points from the battery to the ECM, and functioning properly at this time.
from the ignition key switch to the ECM.
Repair: If an intermittent connection is suspected,
Expected Result: refer to Troubleshooting, Inspecting Electrical
Connectors. Excessive cycling of the ignition key
All connectors, pins and sockets should be switch can cause this fault to be logged. This is
completely coupled and/or inserted and the harness normal. Clear any logged faults.
or pinch points. STOP.
Results: NO Proceed to Test Step 3.

OK, Troubleshooting a 43-02 Code Proceed to Test Step 3. Check the Battery Voltage at
Test Step 2. the ECM.
OK, Troubleshooting a 168-02 Code Proceed Perform Steps A, B, and C if the following
to Test Step 3. Diagnostic Code is Active or Logged:
Not OK There is a problem with the connectors 168-02 Intermittent Battery (51)
or wiring.
A. Disconnect vehicle harness connector P1 from
Repair: Repair the connectors or wiring and/or ECM connector J1 and insert a 70-Terminal
replace the connectors or wiring. Ensure that all Breakout T.
the connectors are completely coupled. B. Measure the voltage between vehicle harness
connector P1 terminal 52 (Unswitched +Battery)
STOP. and terminal 65 (-Battery).
Test Step 2. Use the Electronic Service

Tool to Check the Ignition Key Switch.
B. Connect an electronic service tool to the Cab

data link connector and access the Status screen
that shows the status of the ignition key switch.
243
g00640981
Illustration 102
C. Measure the voltage from vehicle harness Battery Voltage is out of range Proceed to Test
connector P1 terminal 53 (Unswitched +Battery) Step 4.
and terminal 67 (-Battery).
Intermittent Or No Voltage Proceed to Test Step
Refer to Illustration 102 for the ECM Breakout 5.
T-connector.
Key Switch Voltage Out Of Range
Perform Steps D, E, and F if the following
Diagnostic Code is active or logged: Repair: Trace the wiring for the ignition key switch
from the ECM through the key switch circuit to
43-02 Ignition Key Switch Fault (71) the batteries. Find the problem and repair the
problem. Check the circuit protection for the
D. Disconnect vehicle harness connector P1 from circuit and the wiring. Refer to the vehicle service
ECM connector J1 and insert a 70-Terminal manual for instructions on troubleshooting the
Breakout T. circuit for the ignition key switch.
E. Turn the ignition key switch to the ON position. Verify that the repairs eliminate the problem.
F. Measure the voltage between vehicle harness STOP.

connector P1 terminal 70 (Ignition Key Switch)
and terminal 65 (-Battery). Test Step 4. Check The Batteries.
Refer to Illustration 102 for the ECM Breakout A. Measure no-load battery voltage at the battery
T-connector. posts.
Expected Result: B. Load test the batteries. Use the 4C-4911

Battery Load Tester. Refer to Special Instruction,
For 12 Volt Systems, the measured voltage is a SEHS9249, Use of 4C-4911 Battery Load Tester
constant 11.0 to 13.5 VDC with no suspected for 6, 8 and 12 Volt Lead Acid Batteries and
intermittent problems at this time. Special Instruction, SEHS7633, Battery Test
Procedure.
For 24 Volt Systems, the measured voltage is a
constant 22.0 to 27.0 VDC with no suspected Expected Result:
intermittent problems at this time.
The batteries pass the load test. For 12 Volt
Results: Systems, the measured voltage is at least 11.0. For
24 Volt Systems, the measured voltage is at least
OK The ECM is receiving the correct voltage. 22.0.
Repair: If an intermittent condition is suspected, Results:

refer to Troubleshooting, Inspecting Electrical
Connectors. YES
STOP.
244
Repair: Refer to the vehicle service manual for

instructions on troubleshooting the vehicle wiring
harness. Troubleshoot the vehicle wiring harness
and repair the vehicle wiring harness, as required.
Verify that the repairs eliminate the problem.
STOP.
NO
Repair: Recharge or replace the faulty batteries.
STOP.
Test Step 5. Use the Bypass Harness for

the Electronic Service Tool to Bypass the
Vehicle Wiring.

plode.

NOTICE
Do Not connect the bypass harness to the battery un-
til the 20 Amp in-line fuse has been removed from the
+Battery line. If the fuse is not removed before con-
nection to the battery, a spark may result.
245
g00741090
Illustration 103
Bypass harness
Note: This bypass harness is ONLY for TEST E. Connect an electronic service tool to the data
APPLICATIONS. This bypass harness may be left link connector of the bypass harness and verify
only temporarily on the vehicle. The bypass harness that communication is established.
can be used in order to determine if the cause of
the intermittent problem is interruptions in battery F. Restore all wiring to the original condition after
power to the ECM or the keyswitch circuit. testing.
A. Turn the ignition key switch to the OFF position. Expected Result:
B. Disconnect vehicle harness connector J1/P1 Installing the bypass eliminates the problem.
from the ECM.
Note: The status of the ignition key switch will always
C. Connect a bypass harness to ECM connector J1. indicate On while the bypass harness is installed.
D. Remove the 20 Amp in-line fuse from the Results:

+Battery line of the Bypass Harness and connect
the Unswitched +Battery and BATTERY LINES YES The symptoms disappear when the
directly to the battery posts. bypass harness is installed. Also, the symptoms
return when the bypass harness is removed. The
Note: This bypass directly connects the circuit problem is in the vehicle wiring that supplies
for the ignition key switch to the ECM. The ECM power to the ECM. Check for aftermarket engine
will remain powered until the connection to the protection switches that interrupt power. Send the
Unswitched battery line + is disconnected. vehicle to the OEM dealer to repair. STOP.
Remove the 20 Amp fuse from the in-line fuse
holder to power down the ECM. Do Not connect the NO
bypass to the battery posts without first removing
the 20 Amp in-line fuse or do not remove the bypass Repair: Connect the bypass to another battery
from the battery posts without first removing the 20 and verify if the problem is resolved. If the
Amp in-line fuse. problem is resolved, the problem is with the
vehicle batteries.
246
If the problem still exists, temporarily connect The Input Sensor Common 1 is terminal 18.
a test ECM. Remove all jumpers and replace
all connectors. Recheck the system for Active The Input Sensor Common 2 is terminal 3.
diagnostic codes and repeat the Test Step. If the
problem is resolved with the test ECM, reconnect The AP Sensor/Switch Sensor Common is
the suspect ECM. If the problem returns with the terminal 5.
suspect ECM, replace the ECM.
STOP.
i01471586

Circuit - Test
Use this procedure to determine if the circuit for the

Ignore Brake/Clutch Switch is operating correctly.
Note: This feature is available with Mar98 and newer

software.

to this procedure:
The ECM can use various inputs in a number

of ways. The inputs depend on the parameter
programming. Certain features are available on
several different inputs. The configuration for the
switch must match the actual switch installation in
order for the switch to function properly.
The ignore brake/clutch switch is typically used

with a Cab Switches PTO Configuration which
requires mobile use of the vehicle during PTO
operation. When the ignore brake/clutch switch is
ON, depressing the brake or the clutch will NOT
disengage PTO operation or a set engine speed. If
the Input # 5 parameter is programmed to None
(default), this feature is not used. If the Input # 5
parameter is programmed to Ignore Brake/Clutch,
then the feature is available and the switch circuit
should be connected to terminal 47 of the J1/P1
ECM vehicle harness connector.

within the ECM:
247
g00682286
Illustration 104
Schematic for ignore brake/clutch switch
g00682292
Illustration 105
Terminal Locations for ECM
Test Step 1. Check the Electrical Expected Result:

Connectors and the Wiring
All connectors, pins, and sockets are completely
A. Thoroughly inspect the ECM vehicle harness coupled and/or inserted, and the harness and
connector J1/P1, the connectors, and the firewall wiring should be free of corrosion, abrasion or pinch
bulkhead connectors. Refer to Troubleshooting, points.
Results:
wires in the ECM connector that are associated OK Proceed to Test Step 2.
with the circuit for the Ignore Brake/Clutch
Switch. Not OK Repair the wiring and connectors or
replace the wiring or the connectors. Ensure that
C. Check the ECM connector (allen head screw) for all of the seals are properly connected. Verify that
the proper torque of 6.0 Nm (55 lb in). the repair eliminates the problem. STOP.
D. Check the harness and the wiring for abrasion Test Step 2. Check the Status of the
and pinch points from the ignore brake/clutch Ignore Brake/Clutch Switch on the
switch to the ECM. Electronic Service Tool.
Refer to Illustration 105 for terminal locations A. Connect an electronic service tool at the cab
for the ECM. data link connector.
248
C. Operate the switch in the ON and OFF positions.
D. View the Input # 5 status on the electronic

service tool.
E. If the Input # 5 status indicates None, then the

Input # 5 parameter has not been programmed.
Expected Result:
The status screen should indicate On if the switch

is turned ON. The status screen should indicate
Off if the switch is turned OFF.
Results:
YES The switch is operating normally. Continue

troubleshooting if the original condition is not
resolved. STOP.
NO The ECM is not reading the change in

switch status. Proceed to Test Step 3.
Test Step 3. Check The Switch Circuit at

the ECM.
g00682301
Illustration 106
Connector for breakout T
A. Turn the ignition key switch to the OFF position. F. Turn the ignition key switch to the ON position.
B. Install a 70 terminal breakout T to the ECM G. Alternately remove the jumper wire and insert the
vehicle harness connector J1/P1. jumper wire at terminal 18 while you monitor the
status screen on the Electronic Service Tool.
C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire. Expected Result:
D. Insert the jumper wire into terminal 18 (Input The switch status changes from On with the
Sensor Common #1) of the breakout T. Insert the jumper wire in place to Off when the jumper wire
other end of the jumper wire into terminal 47 is removed.
(Ignore Brake/Clutch Switch) of the breakout T.
Results:
E. Connect an electronic service tool at the cab
data link connector. YES The ECM is functioning properly at this
time. Proceed to Test Step 4.
249
NO The ECM is not functioning properly. Test Step 5. Insert a Jumper Wire at the
Bulkhead Connector.
2. Remove all jumpers and replace all connectors. Crimp a Deutsch pin to both ends of the wire.
3. Recheck the system for active diagnostic C. Insert the jumper wire between the two terminals
codes. for the ignore brake/clutch switch on the engine
side of the ECM bulkhead connector.
reconnect the suspect ECM. E. Alternately connect and then disconnect the
jumper wire. At the same time, monitor the status
6. If the problem returns with the suspect ECM, screen on the electronic service tool.
replace the ECM.
Expected Result:
The switch status changes from On with the jumper
STOP. wire in place to Off when the jumper wire is
removed.
Test Step 4. Insert a Jumper Wire at the
Switch. Results:
A. Turn the ignition key switch to the OFF position. YES The problem is in the vehicle wiring
between the bulkhead connector and the switch.
B. Reconnect the ECM vehicle harness connector
J1/P1. Repair: Inspect the vehicle wiring and then repair
the vehicle wiring. Otherwise, send the vehicle to
C. Fabricate a jumper wire 100 mm (4 inch) long. the OEM dealer for repair.
Verify that the original condition is resolved.
of the ignore brake/clutch switch. STOP.
E. Turn the ignition key switch to the ON position. NO The problem is in the vehicle wiring
between the bulkhead connector and the ECM.
F. Alternately remove the jumper wire and then
insert the jumper wire at the switch terminals. At Repair: Inspect the vehicle wiring and then repair
the same time, watch the status screen on the the vehicle wiring. Otherwise, send the vehicle to
Electronic Service Tool. the OEM dealer for repair.
Expected Result: Verify that the original condition is resolved.
The switch status changes to On with the jumper STOP.

wire in place to Off when the jumper wire is
removed.
i01540427
Results: Injection Actuation Pressure -

YES Test
Repair: Replace the ignore brake/clutch switch. SMCS Code: 1714-081
Verify that the repair eliminates the problem. System Operation Description:
STOP. Use this procedure under the following situation:
NO There is a problem in the wire harness Use the following information in order to troubleshoot
between the Ignore Brake/Clutch Switch and the the system when there is an active code:
ECM. Proceed to Test Step 5.
250
164-00 Injection Actuation Pressure Out of Range Test Step 1. Check the Engine Oil
(17)
A. Verify that the engine has the proper amount of
164-11 Injection Actuation Pressure System (39) engine oil. If necessary, adjust the oil level. Refer
to the specifications for oil capacity from the
Note: Do not perform this test if any of the following vehicle manufacturer.
diagnostic codes have been logged.
B. Consult the Operation and Maintenance Manual
42-11 Injection Actuation Pressure Control Valve in order to verify that the oil change interval for
Driver Fault (18) this engine and this application have not been
exceeded. Extended oil drain intervals may
164-02 Injection Actuation Pressure Erratic (15) cause elevated levels of soot in the engine oil.
Extended oil drain intervals may also deplete the
164-03 Injection Actuation Pressure Open Circuit additive package of the oil. This can affect the
(15) operation of the high pressure oil system.
164-04 Injection Actuation Pressure Sensor Short Expected Result:

Circuit (15)
The engine has the proper amount of oil. The
Note: Repair these diagnostic codes first. recommended oil drain intervals have been
followed.
to the following procedure: Results:
The 164-11 Injection Actuation Pressure System YES Proceed to Test Step 2.
(39) indicates a problem with the high pressure
oil system. A mechanical problem has probably NO
triggered this code.
Repair: The customer should change the engine
oil and the filter. The customer should follow
the recommendations in the Operation and
Maintenance Manual. After the oil change,
operate the engine until normal operating
temperature has been reached. Run the engine
up and down through the operating rpm range for
10 minutes to 15 minutes in order to purge any
trapped air or debris from the injection actuation
pressure control valve. Verify that the problem is
solved.
If the problem is not solved, proceed to Test Step

2.

Diagnostic Codes.
C. Check for the following diagnostic codes:
42-11 Injection Actuation Pressure Control

Valve Driver Fault (18)
g00725749
Illustration 107
Location of the components for the Injection Actuation Pressure 164-02 Injection Actuation Pressure Erratic (15)
System
164-03 Injection Actuation Pressure Open
Circuit (15)
251
164-04 Injection Actuation Pressure Sensor Expected Result:

Short Circuit (15)
The injection actuation pressure sensor indicates
Note: If 42-11 Injection Actuation Pressure 0 kPa (0 psi).
Control Valve Driver Fault (18) is active, refer to
Troubleshooting, Injection Actuation Pressure Results:
Control Valve Circuit - Test.
YES Proceed to Test Step 4.
Note: If the 164-02 Injection Actuation Pressure
Erratic (15) is NOT active or logged, try to start NO
the engine. If the engine will not start refer to
Troubleshooting, Injection Actuation Pressure Repair: Refer to Troubleshooting, Injection
Sensor - Test. Actuation Pressure Sensor - Test.
Note: If 164-03 Injection Actuation Pressure STOP.

Open Circuit (15) or 164-04 Injection Actuation
Pressure Sensor Short Circuit (15) is active, refer to Test Step 4. Attempt to Start the Engine.
Troubleshooting, Engine Pressure Sensor Open or
Short Circuit-Test. A. Try to start the engine.
Diagnostic code 164-00 or diagnostic code 164-11 The engine starts.

is active or logged.
Results:
Results:
NO Proceed to Test Step 6.
NO No codes are active or logged.
Test Step 5. Use the Injection Actuation
Repair: Refer to Troubleshooting, Troubleshooting Pressure Test to Test the System.
Without a Diagnostic Code.
A. Start the engine.
STOP.
B. Run the engine until the coolant temperature
Test Step 3. Check the Injection Actuation reaches at least 70 C (158 F) before performing
Pressure Sensor Status with the Engine this test.
Off.
C. Connect the Electronic Service Tool to the cab
A. Connect the Electronic Service Tool to the cab data link connector.
D. Run the engine at low idle.
E. Go to the Injection Actuation Pressure Test on
C. Check the Injection Actuation Pressure on the the Diagnostic Menu of the Electronic Service
Electronic Service Tool status screen. Tool.
Note: The following codes will cause the injection Note: The Injection Actuation Pressure Test has
actuation pressure sensor to default to 17500 kPa the ability to step up the injection actuation pressure
(2538 psi). or the Injection Actuation Pressure Test has the
ability to step down the injection actuation pressure.
Circuit (15) F. Start the test and monitor the actual injection
actuation pressure reading from the Electronic
164-04 Injection Actuation Pressure Sensor Service Tool. Step up the injection actuation
Short Circuit (15) pressure through the pressure range. Compare
the actual pressure reading to the desired
232-03 5 Volt Supply Above Normal (21) pressure reading at different pressure settings.
232-04 5 Volt Supply Below Normal (21) Note: Use Table 122 for the comparison.
252
Table 122 B. Perform a road test. Operate the engine under

Injection Actual Pressure Actual Pressure
a load until the engine reaches operating
Actuation Range (kPa) Range (psi) temperature.
Pressure
Test (Desired C. Check for the following diagnostic codes:
Pressure)
6000 kPa (870 5300-6700 770-970
42-11 Injection Actuation Pressure Control
Valve Driver Fault (18)
psi)
10000 kPa (1450 9300-10700 1350-1550 164-02 Injection Actuation Pressure Erratic (15)
psi)
15000 kPa (2175 14300-15700 2075-2275 164-03 Injection Actuation Pressure Open
psi) Circuit (15)
23000 kPa (3336 22300-23700 3236-3436 164-04 Injection Actuation Pressure Sensor
psi) Short Circuit (15)
Expected Result: Note: If 42-11 Injection Actuation Pressure

Control Valve Driver Fault (18) is active, refer to
The actual injection actuation pressure follows the Troubleshooting, Injection Actuation Pressure
desired injection actuation pressure. The output for Control Valve - Test.
the injection actuation pressure is under 65%.
Note: If the 164-02 Injection Actuation Pressure
Results: Erratic (15) is active, refer to Troubleshooting,
Injection Actuation Pressure Sensor - Test.
Note: If 164-03 Injection Actuation Pressure
NO Proceed to Test Step 9. Open Circuit (15) or 164-04 Injection Actuation
Pressure Sensor Short Circuit (15) is active, refer to
Test Step 6. Disconnect the Injection Troubleshooting, Engine Pressure Sensor Open or
Actuation Pressure Sensor and Start the Short Circuit-Test.
Engine.
Expected Result:
Multiple diagnostic codes for the injection actuation
B. Disconnect the electrical connector J204/P204 system are active or logged in after the road test.
for the injection actuation pressure sensor from
the engine harness. Results:
C. Try to start the engine. YES Proceed to the appropriate troubleshooting

section for the code.
Expected Result:
NO
The engine starts.
Repair: The system is operating correctly.
Results:
STOP.
YES
Test Step 8. Monitor the Injection
Repair: Refer to Troubleshooting, Injection Actuation Pressure when the Engine is
Actuation Pressure Sensor - Test. being Cranked.
STOP.
NO Proceed to Test Step 8. Batteries give off flammable fumes which can ex-
plode.
Test Step 7. Check for Diagnostic Codes.
A. Clear the logged faults and the logged events.
253
B. Disconnect the ECM engine harness connector

J1/P1.
C. Connect the bypass harness for the service tool.
Note: The bypass harness connects the ignition

key switch directly to the ECM. The ECM will
continue to receive battery power until the battery
is disconnected. Remove the in-line fuse (20 amp)
before disconnecting the power supply from the
ECM.
D. Connect the Electronic Service Tool to the

Bypass Data Link Connector.
E. View the Actual Injection Actuation Pressure

and the Desired Injection Actuation Pressure on
the status screen of the Electronic Service Tool.
F. Crank the engine for several seconds and

compare the actual injection actuation pressure
to the desired injection actuation pressure.
g00741090
Illustration 108
Expected Result: Result 2 The actual injection actuation pressure is

not within 700 kPa (101 psi) of desired injection
Result 1 The actual injection actuation pressure actuation pressure or injection actuation output is
is within 700 kPa (101 psi) of desired injection greater than 75% for at least 5 seconds.
actuation pressure and the injection actuation
output remains below 76% for at least 5 seconds. Results:
RESULT 1
254
Repair: Refer to Troubleshooting, Engine Cranks NO The engine will not start. Proceed to Test
but Will Not Start. Step 20.
STOP. Test Step 10. Connect an Electronic

RESULT 2 Proceed to Test Step 9. Diagnostic Codes.
Test Step 9. Disconnect the Injection A. Clear the logged faults and the logged events.
Actuation Pressure Control Valve and
Test the System with the Injection B. Perform a road test. Operate the engine under
Actuation Pressure Test. a load until the engine reaches operating
temperature.
C. Check for the following diagnostic codes:
B. Disconnect the injection actuation pressure
control valve from the engine harness at 42-11 Injection Actuation Pressure Control
connector J500/P500. Valve Driver Fault (18)
C. Crank the engine for 10 seconds. This will clear 164-02 Injection Actuation Pressure Erratic (15)
the debris from the system which could cause
the valve to stay open. The engine will not start. 164-03 Injection Actuation Pressure Open
Circuit (15)
D. Turn the ignition key switch to the OFF position.
Connect the injection actuation pressure control 164-04 Injection Actuation Pressure Sensor
valve to the engine harness at connector Short Circuit (15)
J500/P500.
Expected Result:
E. Start the engine and run the engine until the
coolant temperature reaches 70 C (158 F). There are active diagnostic codes after the road
test.
F. Access the Injection Actuation Pressure Test in
the Diagnostics Menu of the Electronic Service Results:
Tool and begin the test.
YES Diagnostic code 164-00 or diagnostic
Note: The Injection Actuation Pressure Test has code 164-11 is active. Proceed to Test Step 11.
the ability to step up the injection actuation pressure
or the Injection Actuation Pressure Test has the YES Diagnostic code 42-11 is active.
ability to step down the injection actuation pressure.
Repair: Refer to Troubleshooting, Injection
G. Start the test and monitor the actual injection Actuation Pressure Control Valve Circuit - Test in
actuation pressure reading from the Electronic order to troubleshoot this code.
Service Tool. Compare the actual pressure
reading to the desired pressure reading at STOP.
different pressure settings.
YES Diagnostic code 164-02 is active.
Note: Refer to Table 122 for the comparison.
Repair: Refer to Troubleshooting, Injection
Expected Result: Actuation Pressure Sensor - Test in order to
troubleshoot this code.
The actual injection actuation pressure follows the
desired injection actuation pressure. The output for STOP.
the injection actuation pressure is below 65%.
YES Diagnostic code 164-03 or diagnostic
Results: code 164-04 is active.
YES Proceed to Test Step 10. Repair: Refer to Troubleshooting, Engine

Pressure Sensor Open or Short Circuit-Test in
NO Proceed to Test Step 11 for diagnostic order to troubleshoot this code.
codes 164-00 or 164-11.
STOP.
255
NO The system for the injection actuation

pressure is working properly. STOP.
Test Step 11. Check the High Pressure

Oil System for Leaks.
Always use a board or cardboard when checking

for a leak. Escaping fluid under pressure, even a
pin hole leak, can penetrate body tissue, causing
serious injury and possible death. If fluid is inject-
ed into your skin, it must be treated immediately
by a doctor familiar with this type of injury.
A. Start the engine and run the engine until the

coolant temperature reaches 70 C (158 F).
C. Remove the rocker arm cover.
D. Start the engine and run the engine until the

E. Access the Injection Actuation Pressure Test in

the Diagnostics Menu of the Electronic Service g00726041
Illustration 109
Potential leak points
F. Run the engine at low idle.
Expected Result:
Note: The Injection Actuation Pressure Test has
the ability to step up the injection actuation pressure No leaks are apparent.
or the Injection Actuation Pressure Test has the
ability to step down the injection actuation pressure. Results:
G. Start the test and monitor the actual injection OK

Service Tool. Step up the injection actuation Repair: No leaks are apparent. Check the engine
pressure through the pressure range. Inspect the oil level. If the engine oil level is low, disconnect
engine for internal oil leakage during the test. the fuel return line. Crank the engine and take a
small sample of fuel. Check the fuel for engine
H. Compare the discharge from each injector and oil. If oil is in the fuel the oil may be leaking from
look for an injector with a obvious leak. Compare the high pressure system into the low pressure
the discharge to the other injectors. The injectors fuel system. Replace the fuel injector seals and
will discharge a small amount of oil from the top run the test again.
vent hole.
If the problem is not solved, proceed to Test Step
13.
Not OK
Repair: Repair the damaged component.
Test Step 12. Use the Injection Actuation

Pressure Test to Validate the Repair.
A. Start the engine and run the engine until the
256
B. Connect the Electronic Service Tool to the cab Results:

C. Access the Injection Actuation Pressure Test in
the Diagnostics Menu of the Electronic Service NO
Repair: Replace the faulty injector. Refer to
D. Start the test and monitor the actual injection Troubleshooting, Injector Solenoid Circuit - Test.
Service Tool. Compare the actual pressure STOP.
reading to the desired pressure reading at
different pressure settings. Refer to Table 122. Test Step 14. Check the Harness by using
the Electronic Service Tool Injection
Expected Result: Actuation Pressure Driver Test.
The actual injection actuation pressure follows the A. Connect the Electronic Service Tool to the cab
desired injection actuation pressure. The output for data link connector.
the Injection Actuation Pressure is below 65%.
Results:
C. Access the Injection Act Press Driver Test.
YES STOP.
D. Disconnect the injection actuation pressure
NO control valve from the engine harness.
Repair: Repair the components if the 164-00 or Note: Do not insert any wire that is larger than
164-11 diagnostic codes are logged. Rerun the 18 AWG into the harness connector (P500). Do
test if no codes are logged and the engine failed not insert the probe for the voltage test lamp into
the Injection Actuation Pressure Test. the harness connector (P500). These actions will
spread the sockets of the connector which will
STOP. damage the connector. Damaged connectors could
cause intermittent connections.
Test Step 13. Run the Injector Solenoid
Test. E. Insert a 9X-7200 ECM Pin Terminal into each
of the harness connector sockets P500 for the
A. Turn the ignition key switch to the ON. injection actuation pressure driver.
B. Connect the Electronic Service Tool to the cab F. Connect a voltage test lamp to the ECM pin
data link connector. terminals that are inserted in the P500 connector
and start the Injection Act Press Driver Test
C. Access the Injector Solenoid Test in the with the Electronic Service Tool. Then stop
Diagnostics Menu of the Electronic Service the Injection Act Press Driver Test with the
Tool. Electronic Service Tool.
Note: The Injector Solenoid Test actuates each Note: This test procedure may cause a 42-11
injector solenoid one at a time. An audible click Injection Actuation Pressure Control Valve Driver
can be heard for the solenoid when the solenoid is Fault (18). This is normal.
energized.
Expected Result:
D. Run the test on all six cylinders. This will ensure
that all of the solenoids are working properly. The voltage test lamp should come on when the
test is active.
Note: Each injector solenoid may have a different
sound. This test is used to check the solenoid for
operation.
Expected Result:
All of the solenoids are operating.

257
Note: Personality Modules with a manufactured date Expected Result:

before JUNE 99 require an electrical connector
for the injection actuation pressure sensor to be The high pressure oil pump is capable of generating
disconnected in order for the Injection Actuation pressures between the range of zero and 28000 kPa
Pressure Control Valve Driver Special Test to turn (4060 psi).
off the driver for the injection actuation pressure
control valve. If the connector J204/P204 for Results:
the injection actuation pressure sensor is not
disconnected, the voltage test lamp will remain on YES Proceed to Test Step 16.
when the special test is not active.
NO The pressure is above 28000 kPa
Results: (4060 psi).
YES Proceed to Test Step 15. Repair: The high pressure pump is operating
properly but oil is leaking elsewhere in the
NO system. Repair the leak.
Repair: Refer to Troubleshooting, Injection STOP.

Actuation Pressure Control Valve Circuit - Test for
information on troubleshooting this problem. NO The pump output is 0 psi.
STOP. Repair: Replace the Injection actuation pressure
control valve in the pump and retest the high
Test Step 15. Plug the High Pressure Oil pressure oil pump.
Pump and Check the Pressure.
STOP.
A. Disconnect the high pressure oil line from the
pump to the high pressure oil manifold. Test Step 16. Remove the Injection
Actuation Pressure Control Valve and
B. Install a 8T-0852 Pressure Gauge to the outlet Inspect the O-Rings.
of the high pressure oil pump.
A. Remove the injection actuation pressure control
C. Crank the engine and monitor the injection valve from the engine. Refer to Systems
actuation pressure with the 8T-0852 Pressure Operation, Testing and Adjusting, RENR1271.
Gauge.
B. Inspect the O-Rings.
Expected Result:
The O-Rings are in good condition.
Results:

NO
Repair: Replace the O-Rings.
If the problem still exists, proceed to Test Step 17.
Test Step 17. Plug the High Pressure Oil

Pump in order to Check the New O-Rings.
A. Reinstall the injection actuation pressure control
valve.
g00726050
Illustration 110
B. Disconnect the high pressure oil line from the
Diagram for the high pressure oil pump
pump to the high pressure oil manifold.
C. Install a 8T-0852 Pressure Gauge to the outlet

of the high pressure oil pump. Refer to Illustration
110.
258
D. Crank the engine and monitor the injection B. Check for any physical damage to the drive
actuation pressure with the 8T-0852 Pressure gear. Replace the drive gear, if necessary.
Gauge.
C. Verify that the drive gear and the retaining bolt
Expected Result: are properly tightened. Also verify that the pump
shaft rotates freely.
The high pressure oil pump is capable of generating
pressures above 28000 kPa (4060 psi). Expected Result:
Results: The drive gear and the retaining bolt for the high
pressure oil pump are tight. The pump shaft rotates
YES The high pressure oil pump is working freely.
correctly. STOP.
Results:
NO Proceed to Test Step 18.
YES The drive gear bolt is properly tightened
Test Step 18. Temporarily Replace the and the pump shaft rotates freely.
Injection Actuation Pressure Control
Valve and Plug the High Pressure Oil Repair: Replace the high pressure oil pump. If
Pump. this does not fix the problem, troubleshoot for an
electrical problem.
A. Install a known good injection actuation pressure
control valve. STOP.
B. Disconnect the high pressure oil line from the NO The pump shaft does not rotate freely.
pump to the high pressure oil manifold.
Repair: Replace the high pressure oil pump. If
C. Install a 8T-0852 Pressure Gauge to the outlet this does not fix the problem, troubleshoot for an
of the High Pressure Oil Pump. electrical problem.
D. Crank the engine and monitor the injection STOP.

actuation pressure with the 8T-0852 Pressure
Gauge. NO The pump shaft rotates freely and there
is no obvious mechanical damage that would
Expected Result: indicate a different failure.
The high pressure oil pump is capable of generating Repair: Tighten the drive gear bolt to a torque of
a pressure of 28000 kPa (4060 psi). 110 14 Nm (80 10 lb ft). If this does not fix the
problem, troubleshoot for an electrical problem.
Results:
STOP.
YES The hydraulic system is working correctly.
STOP. Test Step 20. Check the High Pressure
Oil System for Leaks.
NO The hydraulic oil pump is not generating
the correct pressure.
Repair: Reinstall the original injection actuation

pressure control valve. Replace the high pressure Always use a board or cardboard when checking
oil pump. If this does not fix the problem, reinstall for a leak. Escaping fluid under pressure, even a
the original high pressure oil pump. Troubleshoot pin hole leak, can penetrate body tissue, causing
for an electrical problem. serious injury and possible death. If fluid is inject-
ed into your skin, it must be treated immediately
Proceed to Test Step 19. by a doctor familiar with this type of injury.
Test Step 19. Check the Drive Gear for A. Start the engine and run the engine until the
the High Pressure Oil Pump coolant temperature reaches 70 C (158 F).
A. Remove the high pressure oil pump. B. Turn the ignition key switch to the OFF position.
C. Remove the rocker arm cover.

259
D. Start the engine and run the engine until the i01373204
E. Access the Injection Actuation Pressure Test in
the Diagnostics Menu of the Electronic Service
Control Valve Circuit - Test
Tool and begin the test. SMCS Code: 5051-081
F. Run the engine at low idle. System Operation Description:
Note: The Injection Actuation Pressure Test has Use this procedure under the following situation:
the ability to step up the Injection actuation pressure
or the Injection Actuation Pressure Test has the Use the following information in order to troubleshoot
ability to step down the injection actuation pressure. the system when there is an active code:
G. Start the test and monitor the Actual Injection 42-11 Injection Actuation Pressure Control Valve
Actuation Pressure reading from the Electronic Driver Fault (18)
Service Tool. Inspect the engine for leaks during
the test. Note: Do not use this procedure for an active
diagnostic code of 164-11 Injection Actuation
H. Compare the discharge from each injector and Pressure System unless you are directed to this
look for an injector with a obvious leak. The procedure from the Injection Actuation Pressure
injectors will discharge a small amount of oil from System - Test. If the diagnostic code of 164-11
the top vent hole. Injection Actuation Pressure System is active, refer
to Troubleshooting, Injection Actuation Pressure
Expected Result: System - Test.
The injectors are acceptable. The following background information is related
Results:
The injection actuation pressure control valve
YES regulates the high pressure oil to the injectors
through a high pressure rail. The high pressure oil
Repair: Check the engine oil level. If the engine manifold is used to actuate the injectors and the
oil level is low, disconnect the fuel return line. high pressure oil manifold is used to control the fuel
Crank the engine and take a small sample of fuel. injection pressure. The injection actuation pressure
Check the fuel for engine oil. If oil is in the fuel the control valve relieves excess high pressure oil
oil may be leaking from the high pressure system back to the sump. The ECM controls the operation
into the low pressure fuel system. Replace the of the injection actuation pressure control valve
fuel injector seals and run the test again. by monitoring the engine rpm and the injection
actuation pressure sensor.
STOP.
YES
Repair: Refer to Troubleshooting, Engine Cranks
but Will Not Start.
STOP.
NO
Repair: Replace the faulty fuel injector.

260
g00724789
Illustration 111
Location of the injection actuation pressure control valve
g00724834
Illustration 112
Schematic for the injection actuation pressure control valve
261
g00724865
Illustration 113
Locations for the ECM terminals
Test Step 1. Connect an Electronic Test Step 2. Inspect Electrical Connectors

Service Tool and Check for Active And Wiring.
Diagnostic Codes.
A. Thoroughly inspect the connector J500/P500 for
A. Connect an Electronic Service Tool to the cab the Injection actuation pressure control valve
data link connector. and inspect the ECM engine harness connector
B. Start the Engine. Electrical Connectors for details.
C. Monitor the Active Diagnostic Code screen of B. Perform a 45 N (10 lb) pull test on each of the
the Electronic Service Tool. Check and record wires in the ECM connector that are associated
active diagnostic codes. with the injection actuation pressure sensor
(terminals 61 and terminal 62).
Note: Wait at least 15 seconds in order for the
diagnostic codes to become active. C. Check the ECM connector (allen head screw) for
Expected Result:
42-11 Injection Actuation Pressure Valve Driver pinch points from the sensors back to the ECM.
Fault is active.
Expected Result:
Results:
YES Proceed to Test Step 2. completely coupled and/or inserted and the harness
NO or pinch points.
Repair: Refer to Troubleshooting, Troubleshooting Results:

Without a Diagnostic Code.
STOP.
Not OK
262
Repair: Perform the following repair: C. Check the electrical resistance from the ECM
engine harness connector P2 terminal 61 to P2
Repair the connectors or wiring and/or replace terminal 62. The resistance should be within 2
the connectors or wiring. Ensure that all of the ohms of the previous test results.
connectors are completely coupled. D. Check the electrical resistance from the ECM
engine harness connector P2 terminal 62 to the
Verify that the repair eliminates the problem. surrounding terminals for a short circuit:
STOP. Terminal 51
Test Step 3. Measure the Solenoid Terminal 52
Resistance of the Injection Actuation
Pressure Control Valve. Terminal 63
A. Turn the ignition key switch to the OFF position. E. Check the resistance from the ECM engine
harness connector P2 terminal 61 to the
B. Disconnect the connector for the injection surrounding terminals for a short circuit:
actuation pressure control valve J500/P500.
Terminal 50
Note: Ensure that the seal on the connector
P500 remains on P500 when the connector is Terminal 51
disconnected.
Terminal 52
C. Use a multimeter to measure the resistance
between the two terminals of the section of the Terminal 60
harness for the injection actuation pressure
control valve. Record the value that was Note: The resistance should be greater than 10k
measured. ohms.
D. Reverse the leads of the multimeter and measure F. Check the resistance from the ECM engine
the resistance again. harness connector P2 terminal 61 to the engine
ground stud and from P2 terminal 62 to the
Expected Result: engine ground stud. The resistance should be
greater than 10k ohms.
The solenoid resistance of the injection actuation
pressure control valve should be between 4.0 and Expected Result:
16.0 Ohms.
The resistance measurements are within the proper
Results: range.
YES Record the measured resistance. Results:

Reconnect the harness connector for the injection
actuation pressure control valve. Proceed to Test YES Proceed to Test Step 5.
Step 4.
NO
NO
Repair: Replace the harness for the injection
Repair: Replace the injection actuation pressure actuation pressure control valve.
control valve. Start the engine and verify that the
fault is no longer active. STOP.
STOP. Test Step 5. Check the Harness by using

the Electronic Service Tool Injection
Test Step 4. Measure the Solenoid Actuation Pressure Driver Test.
Resistance through the Engine Harness.
A. Connect the Electronic Service Tool to the cab
A. Turn the ignition key switch to the OFF position. data link connector.
B. Disconnect the ECM engine harness connector B. Turn the ignition key switch to the ON position.
J2/P2.
263
C. Access the Injection Act Press Driver Test. C. Connect the injection actuation pressure control
valve to the engine harness at connector
D. Disconnect the injection actuation pressure J500/P500.
control valve from the engine harness.
D. Start the engine and run the Injection Actuation
Note: Do not insert any wire that is larger than Pressure Test. The Injection Actuation Pressure
18 AWG into the harness connector (P500). Do Test is located in the Diagnostics menu of
not insert the probe for the voltage test lamp into the Electronic Service. Step through all of the
the harness connector (P500). These actions will pressure ranges.
spread the sockets of the connector which will
damage the connector. Damaged connectors could Note: This is not the Injection Act Press Driver Test.
cause intermittent connections.
E. After performing the Injection Actuation Pressure
E. Insert a 9X-7200 ECM Pin Terminal into each Test, check for active diagnostic codes or
of the harness connector sockets P500 for the logged diagnostic codes 42-11.
injection actuation pressure driver.
Expected Result:
F. Connect a voltage test lamp to the ECM pin
terminals that are inserted in the P500 connector The engine should start and the engine should run
and start the Injection Act Press Driver Test without triggering any diagnostic codes.
with the Electronic Service Tool. Then stop
the Injection Act Press Driver Test with the Results:
YES The problem has been corrected. STOP.
Note: This test procedure may cause a 42-11
Injection Actuation Pressure Control Valve Driver NO
Fault (18). This is normal.
Repair: Replace the injection actuation pressure
Expected Result: control valve. Verify that the problem is resolved.
The voltage test lamp should come on when the STOP.

test is active.
Test Step 7. Check the ECM by using the
Note: Personality Modules with a manufactured date Electronic Service Tool Injection Act
before JUNE 99 require an electrical connector Press Driver Test.
for the injection actuation pressure sensor to be
disconnected in order for the Injection Actuation A. Disconnect the ECM engine harness connector
Pressure Control Valve Driver Special Test to turn J2/P2.
off the driver for the injection actuation pressure
control valve. If the connector J204/P204 for B. Turn the ignition key switch to the ON position.
disconnected, the voltage test lamp will remain on C. Access the Injection Act Press Driver Test in
when the special test is not active. the Diagnostics menu of the Electronic Service
Tool.
Results:
D. Connect a 70-Terminal breakout T to the ECM
YES Proceed to Test Step 6. engine harness connector J2.
NO Proceed to Test Step 7. E. Connect a voltage test lamp to the engine

harness connector for the injection actuation
Test Step 6. Perform Injection Actuation pressure control valve, terminal 61 and terminal
Pressure Test. 62 of the breakout T.
A. Disconnect the injection actuation pressure F. Start and stop the Injection Act Press Driver
control valve from the engine harness at Test.
connector J500/P500.
Note: This test procedure may cause a 42-11
B. Crank the engine for 30 seconds. Crank the Injection Actuation Pressure Control Valve Driver
engine three times. This will purge the air from Fault (18). This is normal.
the system.
264
Expected Result: The injection actuation pressure sensor measures

the pressure of the oil in the high pressure oil
The voltage test lamp should come on when the manifold. The high pressure oil in the manifold is
test is active. used to actuate the injectors and the high pressure
oil is used to control the fuel injection pressure.
Note: Personality Modules with a manufactured date Fuel injection pressure is based on inputs from
before JUNE 99 require an electrical connector the sensors. The inputs are used by the ECM
for the injection actuation pressure sensor to be for calculating the fuel injection pressure. The
disconnected in order for the Injection Actuation ECM uses the reading from the injection actuation
Pressure Control Valve Driver Special Test to turn pressure sensor in order to control the operation of
off the driver for the injection actuation pressure the injection actuation pressure control valve.
control valve. If the connector J204/P204 for
disconnected, the voltage test lamp will remain on
when the special test is not active.
Results:
YES
Repair: Replace the harness for the injection
STOP.
NO
Repair: Temporarily install a test ECM. Repeat
the test step. If this corrects the problem, then
reinstall the old ECM and verify that the problem
reoccurs. Replace the ECM if the problem
reoccurs with the old ECM.
g00725343
Illustration 114
STOP.
location of the injection actuation pressure control valve
i01373904

Sensor - Test
SMCS Code: 1925-081
Use the following information in order to troubleshoot

the system when there is an active code:
164-02 Injection Actuation Pressure Erratic (15)

Note: This procedure can check the accuracy of
the injection actuation pressure sensor against a
pressure gauge.

265
g00725355
Illustration 115
Schematic for the injection actuation pressure sensor
g00725426
Illustration 116
Locations for the ECM terminals
Test Step 1. Connect an Electronic Results:

Diagnostic Codes. YES The engine will not start. Proceed to Test
Step 2.
data link connector. NO The engine will not start. Proceed to Test
Step 2.
Test Step 2. Disconnect the Injection
Note: If the 164-02 Injection Actuation Pressure Actuation Pressure Sensor and Start the
Erratic (15) is not active or logged, try to start the Engine.
engine.
Note: If 164-03 Injection Actuation Pressure
Open Circuit (15) or 164-04 Injection Actuation B. Disconnect the electrical connector J204/P204
Pressure Sensor Short Circuit (15) is active, refer to for the injection actuation pressure sensor from
Troubleshooting, Engine Pressure Sensor Open or the engine harness.
Short Circuit-Test.
C. Try to start the engine.
Expected Result:
164-02 Injection Actuation Pressure Erratic is active.

266
Expected Result: Test Step 4. Check the Sensor Status

with the Engine OFF.
The engine starts.
A. Connect the Electronic Service Tool to the cab
Results: data link connector.
YES Proceed to Test Step 3. B. Turn the ignition key switch to the ON position.
NO C. Check the injection actuation pressure on the

Electronic Service Tool status screen.
Repair: Reconnect the electrical connector
J204/P204 for the injection actuation pressure Note: The following codes will cause the injection
sensor to the engine harness. actuation pressure sensor to default to 17500 kPa
(2538 psi).
Refer to Engine Cranks but Will Not Start.
Test Step 3. Inspect Electrical Connectors Circuit (15)
And Wiring.
164-04 Injection Actuation Pressure Sensor
A. Thoroughly inspect the connector J204/P204 Short Circuit (15)
for the injection actuation pressure sensor and
inspect the ECM engine harness connector 232-03 5 Volt Supply Above Normal (21)
Electrical Connectors for details. 232-04 5 Volt Supply Below Normal (21)
B. Perform a 45 N (10 lb) pull test on each of the Expected Result:
with the injection actuation pressure sensor The injection actuation pressure sensor indicates
(terminals 61 and terminal 62). 0 kPa (0 psi).
C. Check the ECM connector (allen head screw) for Results:

for pinch points from the sensors back to the NO Proceed to Test Step 5.
ECM.
Test Step 5. Check the Voltage Supply of
Expected Result: the Injection Actuation Pressure Sensor.
All connectors, pins and sockets should be A. Turn the ignition key switch to the OFF position.
and wiring should be free of corrosion, abrasion B. Disconnect the electrical connector J204/P204
or pinch points. for the injection actuation pressure sensor from
the engine harness.
Results:
C. Connect a 3-Terminal breakout T to the electrical
OK Proceed to Test Step 4. connector J204 only.
Not OK D. Turn the ignition key switch to the ON position.
Repair: Perform the following repair: E. Use a digital multimeter that is set on DC voltage.
Measure the voltage supply from terminal A to
Repair the connectors or wiring and/or replace Terminal B at the breakout T.
seals are properly in place and ensure that the Expected Result:
The voltage reading should be between 4.5 to 5.5
Verify that the repair eliminates the problem. VDC.
STOP.
267
Results: Table 123

Service Tool Pressure Pressure Gauge Reading
YES Proceed to Test Step 6. Reading Range
NO 6000 kPa 4000-7800 kPa (580-1130

psi)
Repair: The voltage supply for the injection 10000 kPa 8000-11800 kPa
actuation pressure sensor is not correct. Refer to (1160-1710 psi)
Troubleshooting, 5 Volt Engine Pressure Sensor
Supply Circuit - Test. 15000 kPa 13000-16800 kPa
(1885-2435 psi)
STOP. 23000 kPa 21000-24800 kPa
(3045-3595 psi)
Test Step 6. Compare the Injection
Actuation Pressure Sensor Reading to a Expected Result:
Pressure Gauge Reading.
The Electronic Service Tool and the Pressure Gauge
readings agree.
Escaping fluid under pressure, even a pinhole size Results:

leak, can penetrate body tissue, causing serious
injury, and possible death. If fluid is injected into YES
your skin, it must be treated immediately by a doc-
tor familiar with this type of injury. Repair: The injection actuation pressure sensor
and the ECM are working properly. Refer to
Always use a board or cardboard when checking Troubleshooting, Troubleshooting without a
for a leak. Diagnostic Code.
STOP.
NO
B. Install a 8T-0852 Pressure Gauge to an oil
supply port on the side of the engine. Repair: Temporarily replace the injection actuation
pressure sensor and repeat the test. Replace the
C. Connect the Electronic Service Tool to the cab injection actuation pressure sensor if this corrects
data link connector. the problem. If the new sensor is out of range,
then the pressure gauge is faulty.
D. Start the engine.
STOP.
E. Go to the Injection Actuation Pressure Test on
the Diagnostic Menu of the Electronic Service
Tool. i01371104
F. Start the test and monitor the Injection Actuation Injector Solenoid Circuit - Test
Pressure Sensor reading from the Electronic
Service Tool. Compare the pressure reading SMCS Code: 1290-038
from the Electronic Service Tool to the pressure
reading on the 8T-0852 Pressure Gauge. System Operation Description:
Perform a comparison of the two different
pressure indicators at varying engine rpm. Use this procedure under the following situation:
Note: Use Table 123 for the approximate range for Use this procedure if any of the following diagnostic
the injection actuation pressure sensor. Compare codes are present:
the 8T-0852 Pressure Gauge pressure reading to
the pressure reading from the table. 1-11 Cylinder 1 Fault (72)
268

Also use this procedure if you have been referred
to this test from Troubleshooting, Engine Misfires,
Runs Rough or Is Unstable or Troubleshooting,
Low Power/Poor or No Response to Throttle.
Perform this procedure under conditions that are

identical to the conditions that exist when the
problem occurs. Typically, problems with the injector
solenoid occur when the engine is warmed up
and/or when the engine is under vibration (heavy
loads).

to this procedure:
The 3126B and 3126E Engines use Hydraulic

Electronic Unit Injectors that are hydraulically
actuated and electronically energized. The solenoid
is mounted on top of the fuel injector body.
The injectors can be individually cut out to aid in

troubleshooting misfire problems. Use the Cylinder
Cutout Test to disable individual injectors.
The injector solenoids can also be actuated without

running the engine in order to check the operation
of the solenoids. Use the Injector Solenoid Test to
perform this function.
Note: The Injector Solenoid Test will not help find

leaks in the high pressure oil system.
g00723522
Illustration 117
269
g00723443
Illustration 118

And Wiring.
g00723444
Illustration 119
Pin locations for ECM
270
C. Monitor the Logged Diagnostic Code screen of

Electrical shock hazard. The electronic unit injec-
the Electronic Service Tool.
tor system uses 90-120 volts.
Expected Result:
A strong electrical shock hazard is present if the One or more of the listed codes have been logged:
ignition key is not turned OFF.
B. Thoroughly inspect the ECM engine harness
connector J2/P2 and the solenoid connector for 2-11 Cylinder 2 Fault (72)
the injector J300/P300. Refer to Troubleshooting,
Inspecting Electrical Connectors for details. 3-11 Cylinder 3 Fault (73)
C. Perform a 45 N (10 lb) pull test on each of the 4-11 Cylinder 4 Fault (73)
wires in the ECM connector and the solenoid
connector for the injector J300/P300 that are 5-11 Cylinder 5 Fault (74)
associated with injector solenoids.
Results:
D. Check the ECM connector (allen head screw) for
the proper torque of 6.0 Nm (55 lb in). Yes Proceed to Test Step 4.
E. Check the solenoid connector for the injector No Proceed to Test Step 3.
J300/P300 in order to ensure the proper mating
of the connector. Test Step 3. Check The Variation Of The
Injectors From Cylinder To Cylinder.
F. Check the harness and wiring for abrasion and
pinch points from the injectors to the ECM. A. Connect an Electronic Service Tool to the cab
Expected Result:
B. When possible, put the truck on a dynamometer.
completely coupled and/or inserted and the harness C. Start the engine.
or pinch points. D. Allow the engine to warm up to normal operating
temperature 77 C (171 F).
Results:
E. After the engine is warmed to operating
OK Proceed to Test Step 2. temperature, access the Cylinder Cutout Test
by accessing the following display screens in
Not OK order:
Repair: Perform the following repair: Diagnostics

Repair the connectors or wiring and/or replace Diagnostic Tests
seals are properly in place and ensure that the Cylinder Cutout Test
F. Enable the cooling fan, if the fan is not controlled
Verify that the repair eliminates the problem. by the ECM. If the ECM controls the cooling fan,
the cooling fan will start automatically when the
STOP. test begins.
Test Step 2. Check For Logged Diagnostic G. Shut off all parasitic loads such as the air
Codes Regarding Injector Solenoids. conditioning and the air compressors which
could affect the results of the test.
271
H. Cut out each cylinder and watch the Fuel Diagnostic Tests
Position of all of the other cylinders.
Injector Solenoid Test
I. Verify that cutting out a specific cylinder causes
only a slight change to the Fuel Position of the G. Activate the test.
other cylinders in comparison to the change
to the Fuel Position that occurs when other Note: Do not confuse the Injector Solenoid Test with
cylinders are cut out. If a cylinder is cut out and the Cylinder Cutout Test. The Cylinder Cutout Test
only a slight change occurs to the Fuel Position is used to shut off fuel to a specific cylinder while
of the other cylinders, a mechanical problem the engine is running. The Injector Solenoid Test
with the injector or a mechanical problem with is used in order to actuate the injector solenoids.
the cylinder may exist. This allows the click of the injector solenoids to be
heard when the engine is not running in order to
J. After the test is finished, use the Electronic determine that the circuit is functioning properly.
Service Tool to check for active diagnostic codes
or for logged diagnostic codes that are new. H. As each solenoid is energized by the ECM an
audible click can be heard at the valve cover.
Expected Result: A black square will appear over the cylinder
number when the cylinder is being fired.
An active diagnostic code for a cylinder fault results
from running the Cylinder Cutout Test. I. Perform the Injector Solenoid Test at least two
times.
Results:
Expected Result:
All cylinders indicate OK.
No Perform the following repair:
Results:
Repair: If a cylinder is cut out and only a slight
change occurs to the Fuel Position of the other Yes There is not an electronic problem with the
cylinders, a mechanical problem with the injector injectors at this time. STOP.
or a mechanical problem with the cylinder
may exist. If the engine is misfiring or if the No The Electronic Service Tool displays
engine has low power, refer to Troubleshooting, SHORT for any cylinder. Proceed to Test Step 5.
Engine Misfires, Runs Rough or Is Unstable
and Troubleshooting, Low Power/Poor or No No The Electronic Service Tool displays OPEN
Response to Throttle. for any cylinder. Proceed to Test Step 6.
If a diagnostic code for a cylinder fault results Test Step 5. Check the Injector Harness
from running the Cylinder Cutout test, proceed From P2 To J300 For Short Circuits.
to Test Step 4.
Test Step 4. Use The Injector Solenoid

Test To Test The Injector Solenoids. Electrical shock hazard. The electronic unit injec-
A. Start the engine.
B. Allow the engine to warm up to 77 C (171 F) A. Turn the ignition key switch to the OFF position.
which is the normal operating temperature. A strong electrical shock hazard is present if the
ignition key switch is not turned off.
C. Turn the ignition key switch to the OFF position.
B. Disconnect the 12-pin connector (J300/P300).
D. Connect an Electronic Service Tool at the cab Check for evidence of moisture entry. Refer
data link connector. to Troubleshooting, Electrical Connectors -
Inspect for details.
F. After the engine is warmed to operating
temperature, access the Injector Solenoid Test D. Access the Injector Solenoid Test on the
by accessing the following display screens in Electronic Service Tool and begin the test.
order:
Diagnostics
272
Expected Result: Test Step 7. Check The Injector Harness

For A Short Circuit Between Connector
The status of the circuit for the suspect P300 And The Injector.
injector displays SHORT before J300/P300 is
disconnected. The status of the circuit for the
suspect injector changes to OPEN after J300/P300
is disconnected.
Results: tor system uses 90-120 volts.
Yes Reconnect J300/P300. Proceed to Test A. Turn the ignition key switch to the OFF position.
Step 7. A strong electrical shock hazard is present if the
B. Remove the valve cover.
Test Step 6. Check The Injector Harness
From P2 To J300 For An Open Circuit. C. Disconnect the harness from the problem injector
at the connector that is attached to the injector
solenoid. For example, if the number one injector
is the suspect injector, disconnect P301 from
J301.
A. Turn the ignition key switch to the OFF position. E. Access the Injector Solenoid Test on the
A strong electrical shock hazard is present if the Electronic Service Tool and perform the test
ignition key switch is not turned off. three times.
B. Disconnect the 12-pin connector (J300/P300). Note: Ensure that the seal is installed in the harness
connector before connecting the harness to the
C. Insert one end of a jumper wire into the socket connector. If the seal is missing, use a replacement
of the suspect injector. Insert the other end of seal. Ensure that the seal is not stuck in the injector
the jumper wire into the socket of the injector connector.
common line for the connector (J300/P300).
Expected Result:
The status for the injector that is disconnected
E. Access the Injector Solenoid Test on the changes to OPEN when the harness is
Electronic Service Tool and begin the test. disconnected.
The status of the circuit for the suspect injector Yes Perform the following repair:
displays OPEN before J300/P300 is disconnected.
The status of the circuit for the suspect Repair: Temporarily connect a new injector to
injector changes to SHORT after J300/P300 is the harness. Run the Injector Solenoid Test. If
disconnected. all cylinders indicate OK, turn the keyswitch to
OFF and reconnect the old injector. If the original
Results: injector again reads OPEN, replace the injector.
Restore the wiring to the proper injectors. Use the
Yes Proceed to Test Step 9. Injector Solenoid Test to verify that the repair
eliminates the problem.
Do not install the valve cover until the problem is
resolved. Clear all diagnostic codes.
STOP.

273
Repair: There is a short in the wiring harness. Test Step 9. Check the Injector Harness
Replace the wiring harness between the 12-pin for an Open Circuit Between Connector
connector (P300) and the injector. P300 and the Injector.
STOP.
Test Step 8. Use the Injector Solenoid tor system uses 90-120 volts.
Test to Check for Short Circuits in The
ECM and in the Harness. A. Turn the ignition key switch to the OFF position.
A strong electrical shock hazard is present if the
Electrical shock hazard. The electronic unit injec- B. Remove the valve cover.
C. Disconnect the harness from the problem injector
at the connector that is attached to the injector
A. Turn the ignition key switch to the OFF position. solenoid. For example, if the number one injector
A strong electrical shock hazard is present if the is the suspect injector, disconnect P301 from
ignition key is not turned OFF. J301.
J2/P2 from the ECM and check for evidence
of moisture entry. Refer to Troubleshooting,
Electrical Connectors - Inspect for details.
D. Access the Injector Solenoid Test on the

Electronic Service Tool and begin the test.
Note: When ECM Connector J2/P2 is disconnected,

all of the open circuit diagnostic codes for the
sensors and the open circuit diagnostic code for the
Air Inlet Heater will be active. This is normal. Clear
all diagnostic codes after completing this test step.
Expected Result:
All cylinders indicate OPEN when the Engine

Harness Connector P2 is disconnected from the
ECM. g00723455
Illustration 120
Results: Connector for injector solenoids
Yes Repair the harness between the ECM D. Insert a jumper wire across the terminals of the
Connector P2 and the 12-pin connector (J300). harness connector that was removed from the
If the harness cannot be repaired, replace the injector. For example, if the number one injector
harness. STOP. is the suspect injector, place the jumper wire
across the terminals of P301.
No Temporarily connect a test ECM. Repeat this
test step. If the problem is resolved with the test E. Turn the ignition key switch to the ON position.
ECM, install the old ECM in order to verify that the
problem returns. If the test ECM works and the F. Access the Injector Solenoid Test on the
old ECM does not work, replace the ECM. STOP. Electronic Service Tool and monitor the cylinder.
Expected Result:
The status of the injector with the short in place

indicates an OPEN.
274
Results: Note: When ECM connector J2/P2 is disconnected,

all of the open circuit diagnostic codes for the
Yes There is an open circuit in the harness. sensors and the open circuit diagnostic code for
Repair the harness between the 12-pin connector the Air Inlet Heater will be active. All of the injectors
(J300) and the injector. Replace the harness if the that are not jumpered will indicate an OPEN circuit
harness cannot be repaired. Verify that the repair during the Injector Solenoid Test. This is normal.
eliminates the problem. STOP. Clear all diagnostic codes after completing this test
step.
No
Expected Result:
Repair: Temporarily connect a new injector to
the harness. Run the Injector Solenoid Test. If The Electronic Service Tool displays SHORT for
all cylinders indicate OK, turn the keyswitch to the cylinder with the jumper wire.
OFF and reconnect the old injector. If the original
injector again reads OPEN, replace the injector. Results:
Restore the wiring to the proper injectors. Use the
Injector Solenoid Test to verify that the repair Yes Repair the harness between the 12-pin
eliminates the problem. connector (J300) and the ECM connector P2.
Replace the harness if the harness cannot be
Do not install the valve cover until the problem is repaired. STOP.
resolved. Clear all diagnostic codes.
STOP. test step. If the problem is resolved with the test
ECM, install the old ECM in order to verify that the
Test Step 10. Use the Injector Solenoid problem returns. If the test ECM works and the
Test to Check for Open Circuits in The old ECM does not work, replace the ECM. STOP.
ECM and in the Harness.
i01379811
Input Selection Switch Circuit

Electrical shock hazard. The electronic unit injec- - Test
A strong electrical shock hazard is present if the System Operation Description:
J2/P2 from the ECM and check for evidence Use this procedure to determine if the following
of moisture entry. Refer to Troubleshooting, circuits are operating correctly:
Electrical Connectors - Inspect for details.
torque limit switch
C. Connect a 70-Terminal breakout T into the ECM.
Do not connect the engine harness connector ignore brake/clutch switch
P2 into the breakout T.
two-speed axle switch
D. Use a jumper wire to short between the socket
of the suspect injector and the common socket diagnostic enable switch
of the suspect injector.
PTO Engine RPM Set Speed Input A Switch
PTO Engine RPM Set Speed Input B Switch
F. Access the Injector Solenoid Test on the
Electronic Service Tool and begin the test. The following background information is related
to this procedure:
275
The ECM can use various inputs in a number The diagnostic enable switch is used to prompt
of ways. The inputs depend on the parameter diagnostic flash codes on the check engine lamp.
programming. Certain features are available on For more information, refer toTroubleshooting,
several different inputs. The configuration for the Flash Programming and Troubleshooting, Check
switch must match the actual switch installation in Engine Lamp or Warning Lamp is Malfunctioning.
order for the switch to function properly. If the Diagnostic Enable Switch parameter is
programmed to None (default), then the feature
Input 4 (Torque Limit Switch) is not used. If the Diagnostic Enable Switch
parameter is programmed to J1/P1:46, then the
MAR98 and Newer Personality Modules feature is available and the switch circuit should be
connected to terminal 46 of the J1/P1 ECM vehicle
The torque limit switch provides a means in order harness connector.
to temporarily protect equipment from damage that
is caused by applying too much torque. Torque The PTO Engine RPM Set Speed A switch or
limiting is typically used during PTO operation. the diagnostic enable switch can be connected to
Torque limiting can also be used when the PTO Input #7. If the PTO Engine RPM Set Speed A
on/off switch is in the OFF position. parameter is programmed to the corresponding
switch input option, the switch is used to control
In order to use torque limiting, a Torque Limit must engine speed during PTO operation. The PTO
be programmed. The Torque Limit parameter is Configuration parameter must be programmed to
located under the Dedicated PTO Parameters. Cab Switches, Remote Switches or Remote
The default setting is 2712 Nm (2000 lb ft). The Throttle and the PTO Engine RPM Speed Input A
Torque Limit Switch input selection must also be parameter must be programmed to a valid speed.
programmed. If the torque limit switch parameter
is programmed to None (default), this feature is The PTO Engine RPM Set Speed A parameter
not used. requires an engine rpm to be programmed.
The PTO Engine RPM Set Speed A parameter
Input 5 (Ignore Brake/Clutch Switch) is located in the Dedicated PTO Parameter
Group. The PTO Engine RPM Set Speed Input
MAR98and Newer Personality Modules A parameter is located in the Input Selections
Parameter Group. The engine will ramp up to the
The ignore brake/clutch switch is typically used engine rpm that is programmed under the following
with a Cab Switches PTO Configuration which conditions:
requires mobile use of the vehicle during PTO
operation. When the ignore brake/clutch switch The switch for the PTO Engine RPM Set Speed
is on, depressing the brake or the clutch will not Input A is in the ON position and the PTO on/off
disengage PTO operation or a set engine speed. switch is then turned on.
If the Ignore/Brake Clutch Switch parameter is
programmed to None (default), this feature is not The switch for the PTO Engine RPM Set Speed
used. Input A is turned to the ON position when the
PTO on/off switch is on.
Input 6 (Two-Speed Axle Switch)
The PTO on/off switch or the switch for the PTO
MAR98 and Newer Personality Modules Engine RPM Set Speed Input A must be cycled
from the OFF position to the ON position in order to
When a two speed axle is used, the change in return to the programmed engine rpm if the PTO
gear ratios from the main drive axle ratio alters the operation is disabled.
calibration of the vehicle speed signal. When the
two-speed axle switch is in the ON position, the Input 19 (PTO Engine RPM Set Speed Input B
ECM will automatically adjust the vehicle speed Switch)
calibration. This will ensure that the ECM driven
speedometer and the stored information in the ECM JUL99 and Newer Personality Modules.
correctly reflect the actual vehicle speed. In order
for this feature to function properly, the Low Speed The PTO Engine RPM Set Speed B switch can be
Range Axle Ratio and High Speed Range Axle connected to Input #19. If the PTO Engine RPM
Ratio parameters must be programmed. If the Two Set Speed B parameter is programmed to Input
Speed Axle Switch parameter is programmed to #19, the switch is used to control engine speed
None (default), this feature is not used. during PTO operation. The PTO Configuration
parameter must be programmed to Cab Switches,
Input 7 (Diagnostic Enable Switch) Remote Switches or Remote Throttle and the
PTO Engine RPM Speed B parameter must be
JUL99 and Newer Personality Modules programmed to a valid speed.
276
The PTO Engine RPM Set Speed B parameter

requires an engine rpm to be programmed.
The PTO Engine RPM Set Speed B parameter
is located in the Dedicated PTO Parameter
Group. The PTO Engine RPM Set Speed Input
B parameter is located in the Input Selections
Parameter Group. The function of the switch for the
PTO Engine RPM Set Speed Input B is similar to
the function of the switch for the PTO Engine RPM
Set Speed Input A. The engine will operate at Set
Speed A when both of the switches are on. If the
PTO Engine RPM Set Speed Input B parameter is
programmed to None (default), this feature is not
used.

within the ECM:

terminal 5.
g00728802
Illustration 121
Schematic for Torque Limit Switch
g00682286
Illustration 122
Schematic for ignore brake/clutch switch
g00682705
Illustration 123
Schematic for Two Speed Axle Switch Circuit
277
g00728804
Illustration 124
Schematic for Diagnostic Enable Switch or the PTO Engine RPM Set Speed Input A Switch
g00728803
Illustration 125
Schematic for the PTO Engine RPM Set Speed Input B switch circuit
278
g00728814
Illustration 126
Terminal Locations for ECM
Test Step 1. Check The Electrical Expected Result:

Connectors and The Wiring
All connectors, pins, and sockets are completely
A. Thoroughly inspect the ECM vehicle harness coupled and/or inserted, and the harness and
connector J1/P1, the connectors, and the firewall wiring should be free of corrosion, abrasion or pinch
bulkhead connectors. Refer to Troubleshooting, points.
Results:
wires in the ECM connector that are associated OK Proceed to Test Step2.
with the suspect switch circuit.
Not OK Repair the wiring and connectors or
C. Check the ECM connector (allen head screw) for replace the wiring or the connectors. Ensure that
the proper torque of 6.0 Nm (55 lb in). all of the seals are properly connected. Verify that
the repair eliminates the problem. STOP.
D. Check the harness and the wiring for abrasion
and for pinch points from the battery to the ECM. Test Step 2. Check the Switch Status On
Then, check from the ignition key switch to the The Electronic Service Tool
ECM.
A. Connect an Electronic Service Tool at the cab
Refer to Illustration 126 for terminal locations data link connector.
for the ECM.
279
C. Operate the switch in the ON position and the

OFF position.
D. View the switch status on the Electronic Service

Tool.
E. If the switch status indicates Not Installed, then

the switch parameter has not been programmed.
Expected Result:
The status screen should indicate ON if the switch

is turned ON. The status screen should indicate
OFF if the switch is OFF.
Results:
YES The switch is operating normally. Continue

troubleshooting if the original condition is not
resolved. STOP.
NO The ECM is not reading the Switch Status

Test Step 3. Check The Switch Circuit for

the ECM.
g00682375
Illustration 127
Connector for Breakout T
A. Turn the ignition key switch to the OFF position. G. Alternately remove the jumper wire and then
insert the jumper wire from terminal 5. At the
B. Install a 70 terminal breakout t to the ECM same time, monitor the Status Screen on the
Vehicle Harness Connector J1/P1. Electronic Service Tool.
C. Fabricate a jumper wire 100 mm (4 inch) long. Expected Result:

The Switch Status changes to ON with the
D. Insert the jumper wire into the suspected terminal jumper wire in place. The Switch Status changes
of the breakout T. Connect the other end of to OFF when the jumper wire is removed.
the jumper wire to terminal 5 in the breakout T.
Terminal 5 is AP sensor/switch common. Results:
E. Connect an Electronic Service Tool at the cab Yes The ECM is functioning properly at this
data link connector. time. Proceed to Test Step E.
F. Turn the ignition key switch to the ON position. No The ECM is not functioning properly.
280
1. Temporarily connect a test ECM. Test Step 5. Insert A Jumper Wire At The
Bulkhead Connector.
codes. B. Fabricate a jumper wire 100 mm (4 inch) long.
C. Locate the suspect switch socket in the engine
5. If the problem is resolved with the test ECM, side of the ECM bulkhead connector.
D. Insert the wire jumper pin between the switch
6. If the problem returns with the suspect ECM, socket and the sensor common connection.
replace the ECM. Install the jumper wire on the engine side of the
ECM bulkhead connector.
STOP.
F. Alternately connect and then disconnect the
Test Step 4. Insert a Jumper Wire at the jumper wire. At the same time, monitor the
Switch. Status Screen on the Electronic Service Tool.
B. Reconnect the ECM vehicle harness connector The Switch Status changes from ON with the
J1/P1. jumper wire in place. The Switch Status changes
to OFF when the jumper wire is removed.
C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire. Results:
D. Insert the jumper wire between the two switch YES The problem is in the vehicle wiring
terminals. between the bulkhead connector and the switch.
Inspect the vehicle wiring and then repair the
E. Turn the ignition key switch to the ON position. vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. Verify that the original
F. Alternately remove the jumper wire and then condition is resolved. STOP.
insert the jumper wire at the switch terminals. At
the same time, watch the Status Screen on the NO The problem is in the vehicle wiring
Electronic Service Tool. between the bulkhead connector and the ECM.
Inspect the vehicle wiring and then repair the
Expected Result: vehicle wiring. Otherwise, send the vehicle to
the OEM dealer for repair. Verify that the original
The Switch Status changes to ON with the condition is resolved. STOP.
jumper wire in place. The Switch Status changes
to OFF when the jumper wire is removed.
i01472904
Results: Neutral Switch Circuit - Test

YES SMCS Code: 1900-081-ZS
Repair: Replace the switch. System Operation Description:
Verify that the repair eliminates the problem. Use this procedure under the following situation:
STOP. Use this procedure to determine if the neutral switch
is preventing normal operation of cruise control, fast
NO There is a problem in the wire harness idle, idle set speed, or PTO operation:
between the switch and the ECM. Proceed to Test
Step 5.
281
The following switch circuits can also prevent the The following background information is related
correct operation of the cruise control, fast idle, idle to this procedure:
set speed or PTO operation:
The kickout switch refers to the switch that is used
service brake pedal position (switch 1) to exit the cruise control, the fast idle, the PTO, or
the idle set speed.
The operation of the Caterpillar Electronic Engine
neutral switch cruise control is similar to the operation of the
cruise controls that are installed in automobiles. The
cruise control set/resume switch operation of fast idle, idle, and PTO are similar to
the operation of cruise except that the idle and the
cruise control on/off switch PTO govern engine rpm instead of vehicle speed.
PTO on/off switch Note: Idle in this procedure is an engine idle rpm
The switches are described in the respective circuit by using the cruise control on/off switch and the
tests in Troubleshooting. set/resume switch. Refer to Troubleshooting, PTO
All of the following Customer Programmable regarding the programmable options for the
Parameters can affect cruise control, fast idle, idle Dedicated PTO.
set speed, and PTO operation:
Note: Fast idle in this procedure is an engine idle
Low Cruise Control Speed Set Limit rpm above the programmed low idle rpm. Fast idle
is set by using a dedicated fast idle switch.
This switch must be ON before cruise control or
Fast Idle RPM #1 controlled idle can be activated. This switch is
ON when the switch is closed. When the switch is
Fast Idle RPM #2 closed the following terminals are connected:
Cruise/Idle/PTO Switch Configuration ECM connector J1/P1 terminal 59 (cruise control

on/off switch)
Idle/PTO Bump rpm
Terminal 5 (AP sensor/switch sensor common)
Idle/PTO rpm Ramp Rate
PTO Vehicle Speed Limit Dedicated PTO, the PTO on/off switch overrides
the cruise control on/off switch. The PTO on/off
The vehicle speed calibration can also affect switch overrides the cruise control on/off switch
the Cruise Control, the Idle Set Speed, and the when the vehicle speed is within the range of the
PTO if the vehicle speed calibration is incorrectly PTO Vehicle Speed Limit that is programmed.
Specified Parameters. Set/Resume Switch
Automatic Transmission Neutral Switch With the cruise control on/off switch in the ON
The automatic transmission neutral switch is of the programmed Low Cruise Control Speed
required when the Transmission Style parameter is Set Limit and the High Cruise Control Speed Set
programmed to Automatic Option 3 or Automatic Limit, momentarily pressing the set switch will
Option 4. This switch is used to indicate when the activate cruise control, and the ECM will maintain
automatic transmission is in neutral. the current speed.
The automatic transmission neutral switch is an After a speed has been set and the speed is then
open circuit when the transmission is in gear. disengaged by using the brake, the clutch, or the
Shifting the transmission to the neutral position on/off switch, the ECM will seek the previous set
should close the circuit, which connects the input speed when the resume switch is toggled. This
to the battery voltage. Many other switches in the assumes that the vehicle speed is above the Low
system connect the input to ground when the circuit Cruise Control Speed Set Limit for cruise control or
is closed. the vehicle speed is below the Idle/PTO Vehicle
Speed Limit for the idle and the PTO.
282
After a speed has been set, pressing and holding Table 124
the set/resume switch in position will cause the Switch Usage.
engine to establish a new set speed. The systems Setting For
reaction depends on the programming of the Transmission Service Service
Cruise/Idle/PTO Switch Configuration. Style Brake Brake
Clutch Neutral
When the set/resume switch is momentarily pressed, 1 2
the cruise set point will change one mph. The Manual X X
rate of change is dependent on the programmed
Idle/PTO Bump rpm when the engine is setting Automatic
X
on idle speed. Option 1
Automatic
X X
Kickout Switches Option 2
Automatic
The brake pedal position switches, the neutral Option 3
X X X
switch and the clutch pedal position switch are
used in the cruise control mode, the PTO mode, the Automatic
X X
fast idle mode, and the idle mode to discontinue Option 4
cruise operation, PTO operation, fast idle operation, AT/MT/HT
or idle operation. The capability to override the idle X
Option 1
shutdown timer is determined by the Allow Idle
Shutdown Override parameter setting. The Allow AT/MT/HT
X X
Idle Shutdown Override is a Customer Parameter. Option 2
AT/MT/HT
Usage of Transmission Style Switches X X X
Option 3
The Transmission Style parameter determines AT/MT/HT

X X
the switches that will be used. The following Option 4
switches can be used with being dependent on the Universal
X X X X
parameter setting: Option
clutch pedal position If the Transmission Style parameter is programmed

to one of the following options, the input for the
neutral clutch pedal position switch is not used:
service brake pedal position (switch 1) Automatic Options 1
service brake pedal position (switch 2) Automatic Option 2
Refer to Table 124 for additional information.
Automatic Option 3
Automatic Option 4
AT/MT/HT Option 1
AT/MT/HT Option 2
AT/MT/HT Option 3
AT/MT/HT Option 4
Universal Option
283
A Service Brake Pedal Position (Switch 1) is required Idle Kickout

for all configurations. The Service Brake Pedal
Position (Switch 1) connects to the ECM through PTO Kickout
connector P1 terminal 45. The Service Brake Pedal
Position (Switch 2) connects to the ECM through This parameter is blank when the ECM is first
connector P1 terminal 64. The Clutch Pedal Position powered up. If this parameter is blank, No
Switch connects to the ECM through connector P1 Occurrence is indicated. This parameter remains
terminal 22. The neutral switch connects to the ECM blank until the ECM detects the use of the
through connector P1 terminal 62. Cruise/Idle/PTO Mode. Also, this parameter remains
blank until the ECM detects the disengagement
Some engines that were built before JULY 1999 of the Cruise/Idle/PTO Mode. Refer to Tables 125,
may have a Basic ECM. The Basic ECM was used 126 and 127 in order to interpret the status screen
only on General Motors chassis. Other chassis used kickout status parameter.
for Transmission Style. For these systems, a
automatic transmission is installed. When the jumper
always indicate OFF. Engines that were built after
configured for Basic or Full Feature operation.
this flexibility. The Truck Manufacturer parameter
was added in order to allow the configuration of the
operation. This parameter is programmed at
for Transmission Style is not available for engines
that have software that is dated prior to SEP00
programmed to GM. SEP00 and newer engines
Style parameter. The factory default for the GM
setting is the Universal option. The Universal
system that is described above. If the Transmission
option, a jumper wire must be installed between the
clutch switch input and the sensor common when an
to match the specific arrangement of the vehicle.

procedure:
After the kickout, review the Electronic Service

Tool Status parameter. The Electronic Service Tool
Kickout Status parameter indicates the cause. This
is turned OFF. It is important to remember that the
parameter will only indicate the last kickout since the
ECM has been powered by the ignition key switch.
The following Kickout Status parameters are

available:
Cruise Kickout
284
Table 125
Cruise Control Kickout Status Table
The Cruise/Idle On/Off switch is turned Refer to Troubleshooting, Cruise Control
Switch Turned Off OFF or the switch circuit has an open Switch Circuit - Test.
circuit condition.
Clutch
circuit condition.
exists.
The PTO On/Off switch is turned ON or Refer to Troubleshooting, PTO Switch
PTO Switch On the PTO On/Off switch circuit has a short Circuit - Test.
circuit condition.
Resume Switch Timeout (Basic) or there is a short circuit in the position and then turned to the ON position
switch circuit. again. If the circuit for the resume switch is
Cruise Control has not been enabled since Drive the vehicle in cruise in order to create
No Occurrence
285
Table 126
Idle Kickout Status Table
No Engine Speed
The Cruise/Idle On/Off switch is turned OFF Refer to Troubleshooting, Cruise Control
condition.
circuit condition.
Clutch
The PTO On/Off switch is turned ON or the Refer to Troubleshooting, PTO Switch
PTO Switch On PTO On/Off switch circuit has a short circuit Circuit - Test.
condition.
Idle set speed has not been enabled since Operate the vehicle in the Idle mode in order
No Occurrence
the ECM has been powered up. to create the problem again.
Table 127
No Engine Speed
The Fast Idle On/Off switch is turned OFF Proceed with the test procedure.
condition.
circuit condition.
Clutch
Fast Idle set speed has not been exited Operate the vehicle in the Idle mode in order
No Occurrence
286
g00646460
Illustration 128
Schematic for transmission neutral switch
Test Step 1. Determine The Type Of PTO Kickout

Problem.
Refer to Tables 125, 126 and 127 for the meaning
A. Connect an Electronic Service Tool. of the Electronic Service Tool status screen
parameter.
Expected Result:
C. If the vehicle will not allow setting a Cruise
speed, an Idle speed or a PTO speed, check the The problem is due to a parameter setting or the
following Customer Parameters: problem is due to a normal kickout.
Cruise Control Parameters Results:
Low Cruise Control Speed Set Limit Yes Explain the proper operation of system to
the driver. STOP.
No
Idle Parameters
Repair: Refer to Tables 125, 126 and 127for
Fast Idle RPM #1 recommended troubleshooting.
Fast Idle RPM #2 If a problem is still suspected with the neutral

switch circuit perform the following procedure:
Idle RPM Limit
Top Engine Limit (TEL)
PTO Parameters
PTO Configuration
D. Ensure that the vehicle is not experiencing
a problem due to one of these parameters.
Parameters for a description of the parameters,
if necessary.

that indicates the last cause of a kickout for one
of the following modes:
Cruise Kickout
Idle Kickout
Fast Idle Kickout
287

And Wiring.
g00705233
Illustration 129
A. Thoroughly inspect ECM vehicle harness Results:

and the terminals for the following switches in OK Proceed to Test Step 3.
the connectors:
Not OK
neutral switch (terminal 62)
Refer to Troubleshooting, Inspecting Electrical replace the connectors or wiring. Ensure that all
Connectors for details. of the seals are properly in place and ensure that
wires in the ECM connector that are associated Verify that the repair eliminates the problem.
with the switches.
STOP.


Expected Result:

or pinch points.
288
Test Step 3. Check Neutral Switch Status B. For an intermittent Idle Kickout, talk to the driver
On The Electronic Service Tool. in order to determine the conditions when the
kickout occurs. A topic of examination could be
Table 128 the following example:
Neutral Switch Status Table
Specific engine rpm
Switch Position Switch Status Circuit
The transmission is in Start the engine. Duplicate these conditions and
ON Closed set the idle rpm. Operate the vehicle in idle until
Neutral.
The transmission is in
OFF Open
Gear. Note: The Electronic Service Tool status screen will
only indicate the last kickout. The Electronic Service
A. Access the Electronic Service Tool status screen. Tool status screen will lose this information if the
C. Connect an Electronic Service Tool and check
C. Shift the transmission into the Neutral position the Status screen for the last cause of the
while the status of the neutral switch is being kickout. Refer to Tables 125 and 126 for an
observed. Also, shift out of Neutral while the explanation of the status parameter.
status of the neutral switch is being observed.
Note: If the status indicates Not Installed, check blank, then either there was no kickout of the
the programming of the Transmission Style cruise control, or the power to the ECM was
Parameter. The Transmission Style must be turned OFF before the information could be read.
programmed to Automatic Option 3 or Automatic Perform Steps A, B, and C again.
Option 4.
Expected Result: is blank indicates No Occurrence.
The switch status changes per the information in Expected Result:

Table 128.
Results: Status displays the following result:
Yes The switch is operating normally. STOP. Neutral

Brake
specific speed
Bad Vehicle Speed
road conditions
Vehicle Speed Limit
weather conditions
289
RESULT 6 The Electronic Service Tool Kickout Troubleshooting, Clutch Pedal Position Switch
Status displays the following result: Circuit - Test
Clutch STOP.
RESULT 7 The Electronic Service Tool Kickout Result 7

No Engine Speed procedure:
RESULT 8 The Electronic Service Tool Kickout Troubleshooting, Engine Speed/Timing Circuit -
Status displays the following result: Test
Ser Switch Timeout STOP.
Resume Switch Timeout Result 8

Results: Repair: Perform the following diagnostic
procedure:
Troubleshooting, Cruise Control Switch Circuit
Result 2 - Test.
Repair: Perform the following diagnostic STOP.

procedure:
Test Step 5. Check The Switch Circuit for
Troubleshooting, Cruise Control Switch Circuit - the ECM.
Test
Table 129
STOP. Neutral Switch Input Status Table
Result 3 Condition of Switch

Circuit
Repair: Perform the following diagnostic Terminal 62 is open. OFF Open
procedure:
Terminal 62 connected
ON Closed
Troubleshooting, Service Brake Pedal Position to +battery.
(Switch 1) Circuit - Test
STOP.
Result 4 Crimp a Deutsch pin to both ends of the wires.
Repair: Perform the following diagnostic C. Disconnect vehicle harness connector P1 from
procedure: the ECM.
Troubleshooting, Vehicle Speed Circuit - Test D. Connect a 70-Termial breakout T to ECM

STOP.
E. Install the jumper into terminal 62 (neutral switch)
Result 5 of the breakout T. Connect the other end of the
jumper to terminal 52 unswitched +battery of the
Repair: Perform the following diagnostic breakout T.
procedure:
STOP. data link connector.
Result 6 H. Access the Electronic Service Tool status screen.

procedure:
290
I. While the neutral switch status is being monitored D. Disconnect the wires from the neutral switch
on the Electronic Service Tool Status Screen terminals.
slowly remove the jumper from terminal 52
unswitched +battery. Now, slowly insert the E. Turn the ignition key switch to the ON position.
jumper into terminal 52 unswitched +battery.
Refer to Table 129. data link connector.
Expected Result: G. Access the Electronic Service Tool status screen.
The switch status changes per the information in H. While the switch status is being monitored on
Table 129. the Electronic Service Tool status screen slowly
connect the switch wires and slowly disconnect
Results: the switch wires.
Yes The ECM is functioning properly. Proceed Refer to Table 130.

to test step 6.
Expected Result:
Repair: Perform the following repair: Table 130.
1. Temporarily connect a test ECM. Results:
2. Remove all jumpers and replace all connectors. Yes The switch is not functioning properly.
3. Recheck the system for Active diagnostic Repair: Perform the following repair:
codes.
Replace the faulty switch.
reconnect the suspect ECM. STOP.
6. If the problem returns with the suspect ECM, No There is a problem in the harness between
replace the ECM. the switch and the ECM. Proceed to Test Step 7.
STOP.

Neutral Switch.
Table 130
Neutral Switch Input Status Table
Condition of Switch
Circuit
Neutral switch wires are
OFF in gear Open
disconnected.
Neutral switch wires are
ON in neutral Shorted
connected.
B. Ensure that ECM vehicle harness connector

J1/P1 is connected.
C. Find the neutral switch in the vehicle.

291
Test Step 7. Insert A Jumper At The Inspect the vehicle wiring and repair the vehicle
Bulkhead Connector. wiring, as required. If the problem still exists with
the wiring, send the vehicle to the OEM dealer.
Table 131
Neutral Switch Input Status Table STOP.
Condition of Switch
Circuit i01367484
Bulkhead wires are

OFF in gear Open Powertrain Data Link Circuit -
disconnected.
Test
Bulkhead wires are
ON in neutral Shorted
connected. SMCS Code: 1900-081
A. Turn the ignition key switch to the OFF position. System Operation Description:
B. Fabricate a jumper wire 100 mm (4 inch) long. Use this procedure under the following situation:
Use this procedure if one of the following diagnostic
C. Find the neutral switch terminal and the +battery codes are active:
connection in the engine side of the bulkhead
connector for the vehicle harness. 231-11 J1939 Data Link Fault (58)
D. Insert the jumper wire between the two terminals Also, use this procedure when the Electronic
in the engine side of the bulkhead connector. Service Tool indicates that the sensor and the ECM
are functioning but the engine is not responding to
E. Turn the ignition key switch to the ON position. the accelerator pedal position sensor.
F. Connect an Electronic Service Tool to the cab The following background information is related
data link connector. to this procedure:
G. Access the Electronic Service Tool Status Screen. Powertrain Data Link
H. While the switch status is being monitored The powertrain data link is designed to offer
on the Electronic Service Tool status screen electronically controlled Anti-Lock Brakes (ABS),
alternately remove the jumper wire between the traction control systems, and/or transmission
two terminals, and alternately insert the jumper controls. This is accomplished by a momentary
wire between the two terminals. reduction of engine rpm and/or engine torque, that
is triggered by a signal from an off-engine control
Refer to Table 131. module for the ABS, the traction control, or the
transmission. An off-engine control module is a
Expected Result: control module that is not part of the Caterpillar
engine control system.
Table 131. Any combination of the following systems may be
installed together on a vehicle:
Results:
traction control
Yes The problem is in the vehicle wiring
between the bulkhead connector and the switch. transmission control
Repair: Perform the following repair: ABS
Inspect the vehicle wiring and repair the vehicle The required components are installed at the OEM
wiring, as required. If the problem still exists with when the vehicle is built.
Powertrain data link sensors, off-engine control
STOP. modules, and wiring are installed by the vehicle
OEM. Questions that relate to the hardware
No The problem is in the vehicle wiring between configuration, software, and installation should be
the bulkhead connector and the ECM. referred to the vehicle OEM.
Repair: Perform the following repair: The following powertrain data link is available:
292
SAE J1939 The presence of an active J1939 data link circuit

can be determined by observing the Powertrain
The J1939 refers to the standard for data link Status parameter on the Electronic Service Tool.
communications of the Society of Automotive The Electronic Service Tool status screen will display
Engineers Inc.. The ECM has a customer INSTALLED if the proper Personality Module is
programmable parameter that is called Powertrain installed on the ECM, and there is no action that is
Data Link which can be programmed to any one being requested at that time by any of the control
of the following options: modules on the data link.
J1939 If an action is being requested by one of the

vehicle control modules, the display will indicate the
NONE control that is making the request (traction control
or transmission control) or a combination of the two
Anti-Lock Brake Systems (ABS) (traction control and transmission control). Power
train control is also displayed in the upper right
The Powertrain Data Link may be used by an hand corner of the display status screen.
anti-lock brake system (ABS) in order to disable
the exhaust brake when the anti-lock brake control J1939 Data Link
determines that the exhaust brake should be
disabled. This is usually achieved when the ABS SAE J1939 is standard on the Full Feature ECM.
system is active. The SAE J1939is not available on the Basic ECM.
All 3126B truck engines ((S/N: 8YL)) have the SAE
Traction Control Systems J1939 Data Link.
Loss of traction is determined by sensors on the If the Truck Manufacturer parameter is programmed
vehicle that are mounted near the wheels. These to GM, then the Powertrain Data Link parameter
sensors are also used by the ABS system. Typically, default is configured to J1939. If the truck
a system with traction control includes anti-lock manufacturer is programmed to OTHER, then the
brakes. default is NONE. If the data link is required, then
the Powertrain Data Link must be programmed to
Transmission Control J1939.
The following characteristics are determined by a If the Truck Manufacturer parameter is programmed
vehicle speed sensor in the transmission: to GM then the J1939 Data Link is self-adjusting.
transmission shift points Note: If a powertrain control is not connected to the

data link for 5 hours, the 231-11 Data Link Fault (58)
engine rpm will not illuminate the Service Engine Soon Lamp.
load If the truck manufacturer is programmed to

OTHER and the Powertrain Data Link parameter is
The sensors for power train control provide signals programmed to J1939, a 231-11 J1939 Data Link
to the Vehicle control module of the Powertrain Data Fault (58) will be active.
Link. The vehicle control module of the Powertrain
Data Link then communicates with the engine Note: The wiring for the J1939 data link is a shielded
ECM. The engine ECM receives a request from the twisted pair cable and the wiring is not serviceable.
Powertrain Data Link. The engine ECM responds The wiring must be replaced when the wiring is
by momentarily limiting the following characteristics: damaged.
engine rpm
torque
both engine rpm and torque
293
g00721499
Illustration 130
Schematic for Power train data link
g00768550
Illustration 131
ECM pin locations
294
g00721539
Illustration 132
Test Step 1. Inspect Electrical Connectors Results:

And Wiring.
connector J1/P1, the firewall bulkhead connector, Not OK
the connectors for the power train control
module, and the connector terminals for the Repair: Perform the following repair:
SAE J1939 data link. Refer to Troubleshooting,
Inspecting Electrical Connectors for details. Repair the connectors or wiring and/or replace
B. Perform a 45 N (10 lb) pull test on each of the seals are properly in place and ensure that the
wires in the ECM Connector that are associated connectors are completely coupled.
with the SAE J1939 Data Link.
STOP.
the proper torque of 6.0 Nm (55 lb in). Test Step 2. Connect an Electronic
D. Check the harness and wiring for abrasion and Diagnostic Codes.
pinch points from the data link connectors back
to the ECM. A. Connect an Electronic Service Tool to the cab
Expected Result:
completely coupled and/or inserted and the harness C. Monitor the active diagnostic code screen of the
and wiring should be free of corrosion, abrasion Electronic Service Tool. Check and record active
or pinch points. diagnostic codes.
295
Expected Result:
One of the following diagnostic codes is active:
231-11 J1939 Data Link Fault (58)

Note: The Powertrain Data Link parameter is a
customer parameter that must not be programmed
to J1939, unless the J1939 Data Link is being
used. If J1939 is not connected with the Parameter
that is programmed for J1939 the following Active
Diagnostic Code will occur:
231-11 J1939 Data Link Fault (58)

Results:
Yes 231-11 Active Verify that the vehicle has

a power train control module that requires the
J1939 data link. Send the vehicle to the OEM
dealer for repair. STOP.

296
Test Step 3. Check The Power Train

Status Screen On The Electronic Service
Tool.
g00721856
Illustration 133
Cat ET display screen
Table 132
Powertrain Status Parameter Group Definition Table
Heading On Status Screen Displayed Message Definition of Message
Engine Speed Actual engine rpm of the engine
Percent Torque Current engine torque during operation
that is expressed as a percent of peak
torque
Powertrain Status Not Installed, ABS Control, Traction Communication of the power train
Control, Traction and ABS Control, control module
Trans Control, Trans and ABS
Control, Trans and Traction Control,
Trans and Traction and ABS
(continued)
297
(Table 132, contd)

Powertrain Status Parameter Group Definition Table
Heading On Status Screen Displayed Message Definition of Message
TC Status or Transmission Status No Communication Communication from the vehicle control
is not being received by the ECM. One
of the following conditions exists: The
vehicle does not support this feature.
The vehicle control is not currently
powered, or the wiring is damaged or
disconnected.
Not Active No requests from the Vehicle Power
Train ECU (Electronic Control Unit)
Speed Command Engine rpm is being controlled by a
Vehicle ECU.
Torque Command Engine torque is being controlled by a
Vehicle ECU.
Speed and Torque Limit Engine rpm and torque is being
determined by a Vehicle ECU.
Torque Limit The Torque limit is being determined by
a Vehicle ECU.
Speed Limit The rpm limit is being determined by a
Vehicle ECU.
TC Speed The TC Speed is the desired engine
rpm setpoint or the engine rpm limit
that is being requested by the vehicles
Traction Control ECU.
TC Torque The TC Torque is the desired percent of
torque or the desired percent of torque
limit that is being requested by the
Vehicles Traction Control ECU.
Transmission Output Speed The Transmission Output Speed is the
desired engine rpm setpoint or the
engine rpm limit that is being requested
by the Vehicles Traction Control ECU.
Transmission Torque The Transmission Torque is the desired
percent of torque or the percent of
torque limit that is being requested by
the Vehicles Traction Control ECU.
ABS Status No Communication The ECM is not receiving
communication from the vehicles
ABS/Traction Control System. One of
the following conditions exists: The
vehicle does not support this feature.
The vehicles ABS/Traction Control
System is not currently powered. The
wiring is damaged or disconnected.
Not Active There are no requests from the ABS
Control .
Disable Retarder The control for the ABS system requests
the operation of the engine retarder to
stop.
A. Connect an Electronic Service Tool to the cab B. While the vehicle is being driven by someone
data link connector. else, monitor the Electronic Service Tool. Use the
298
a. Access the Electronic Service Tool status The following background information is related
screen. Select the Powertrain Status screen. to this procedure:
The Powertrain Status screen relates to the
J1939 data link. PTO Shutdown Timer
b. While the vehicle is being operated, monitor A programmable parameter for the PTO Shutdown
the Powertrain Status Screen. Timer is provided. This timer will shut down the
engine when all of the following conditions are met:
Refer to Table 132 for an explanation of
the parameters that are displayed in the The PTO shutdown time that is programmed has
Powertrain Status screen of the Electronic expired.
Service Tool.
Note: Transmission shifts and/or a momentary loss parameters.
of traction should trigger the Electronic Service Tool
display and the appropriate action by the ECM The PTO on/off switch is ON and the ECM is in
when the correct sensors, controls and wiring are the dedicated PTO mode.
installed on the vehicle.
The engine is not in the Cold Mode.
Expected Result:
During the last 90 seconds of the PTO Shutdown
The Electronic Service Tool status screen indicates Timer, the check engine lamp will begin flashing. If
that the ECM is responding to a power train control. the vehicle is equipped with a PTO switch on lamp,
the PTO switch on lamp will begin flashing during
Note: Some power train control modules have test the last 90 seconds.
modes that are available by activating diagnostic
switches. Ensure that the Caterpillar ECM is not If the PTO shutdown timer is activated and the timer
reacting to a test by the power train control module stops the engine, the following event code will be
if the problem is related to power train control generated.
operation and you believe that the system should
not be active. 71-14 PTO Shutdown Timer Occurrence (47)
Results: Note: Fuel rates are not monitored while the PTO
shutdown timer is active. Shutdown will occur
Yes If the response is abnormal, send the regardless of load. Unlike the idle shutdown timer,
vehicle to the OEM dealer for repairs. STOP. the PTO shutdown timer cannot be overridden by
using the clutch pedal or the brake pedal.
No
Test Step 1. Verify Activation Of The PTO
Repair: Perform the following diagnostic Shutdown Timer.
procedure:
Troubleshooting, Troubleshooting without a data link connector.
Diagnostic Code
B. Access the Customer Parameters on the
STOP. Electronic Service Tool. Access the following
i01474068
Service
PTO Shutdown Timer - Test
Configuration
SMCS Code: 1900-038
a. Record the programmed PTO shutdown time.
System Operation Description: The PTO shutdown Time must be between 3
and 1440 minutes. If the PTO shutdown time
Use this procedure under the following situation: is programmed to 0, the timer is disabled.

Shutdown is operating correctly.
299
C. Start the engine. Allow the engine to warm up C. Observe the following items during the 90 second
until the coolant temperature is 38 C (100 F). period before the programmed shutdown time:
Allow the engine to operate at the programmed
low idle and turn off any unnecessary accessory check engine lamp
devices.
status of the PTO shutdown timer
D. Ensure that all unnecessary loads are turned
OFF. PTO switch on lamp
E. Use the following procedure in order to check During the 90 second period before the
the operation of the PTO shutdown: scheduled shutdown, the status should change
a. Park the vehicle. check engine lamp and the PTO switch on lamp
should flash rapidly.
b. Ensure that the PTO configuration is
programmed to Cab Switches, Remote Note: A PTO switch on lamp is an optional feature
Switches or Remote Throttle. and the PTO switch on lamp may not be installed.
c. Ensure that the status of the PTO on/off switch D. Reprogram the PTO shutdown timer to the value
is on. that was recorded earlier for this test.
d. Observe the status of the PTO Shutdown. Expected Result:
Expected Result: Result 1 The driver alert function of the PTO

shutdown operates in the manner that is described
Result 1 The status of the parameter for PTO above.
Shutdown indicates COUNTING.
Result 2 The PTO switch on lamp did not flash.
conditions for activation of the timer. Result 3 The check engine lamp did not flash.
Results: Results:
Result 1 The ECM is reading the proper Result 1 The PTO shutdown timer is operating
conditions for the activation of the PTO shutdown properly. Clear all diagnostic codes. STOP.
timer. Proceed to Test Step 2.
Result 2 The PTO switch on lamp did not flash
Result 2 Proceed to Test Step 3. during the driver alert.
Test Step 2. Verify The Driver Alert Repair: Perform the following diagnostic
Function Of The PTO Shutdown. procedure: Troubleshooting, PTO Switch ON
Lamp Circuit - Test
data link connector. STOP.
B. Use the following procedure in order to activate Result 3 The check engine lamp did not flash
the PTO shutdown timer: during the driver alert.
a. Access the Customer Parameters on the Repair: Perform the following diagnostic
Electronic Service Tool. Access the following procedure:
Service Test
Configuration STOP.
b. Record the programmed PTO shutdown time. Test Step 3. Check The State Of The
The PTO shutdown time must be between 3 Related Conditions When The Vehicle Is
and 1440 minutes. If the PTO shutdown time Parked.
A. Check the state of the following related conditions
c. Reprogram the PTO shutdown time to 3 when the vehicle is parked:
minutes for this test.
300
a. Ensure that the vehicle speed is 0 km/h Use this procedure to determine that the vehicle
(0 mph) on the Electronic Service Tool or the wiring and the ECM are functioning properly for the
dash display. features of Dedicated PTO.
b. Ensure that the engine is not in cold mode. The following background information is related
to this procedure:
indicate if the cold mode is active. INPUT 1
c. Ensure that the PTO on/off switch is ON. The input 1 is used for the circuit for the PTO on/off
switch when the PTO Configuration is programmed
Expected Result: to Cab Switches, Remote Switches, or Remote
Throttle.
Result 1 Vehicle speed is not indicated as 0 km/h
(0 mph). When the PTO on/off circuit is on, the ECM will be
in Dedicated PTO mode.
indicates that the engine is in the cold mode. When the ECM is in the Dedicated PTO mode the
PTO Top Engine Limit (TEL) is activated. The engine
Result 3 The PTO on/off switch is not ON. may proceed directly to the PTO engine rpm set
speed if the parameter is programmed. If a PTO
Results: switch on lamp is connected to the output 1, the
PTO switch on lamp will turn on whenever the PTO
Result 1 Continue by testing the vehicle speed on/off circuit is on.
circuit.
If the problem is with undetermined PTO kickouts,
Repair: Perform the following diagnostic use the following procedure:
Circuit - Test Operate the vehicle in PTO mode.
STOP. After the kickout, review the Electronic Service

Result 2 The engine must not be in cold mode kickout status parameter indicates the cause. This
operation while this test procedure is being must be performed before the ignition key switch
performed. Allow the engine to run until the is turned OFF. It is important to remember that the
coolant temperature exceeds 38 C (100 F). parameter will only indicate the last kickout since
Troubleshoot and repair any related conditions. the ECM has been powered by the Ignition Key
STOP. Switch Input.
Result 3 Continue by testing the circuit for the This parameter is blank when the ECM is first
PTO on/off switch. powered up. If this parameter is blank, No
Repair: Perform the following diagnostic blank until the ECM detects the use of the PTO
procedure: Troubleshooting, PTO Switch Circuit - mode. Also, this parameter remains blank until the
Test ECM detects the disengagement of PTO mode.
Refer to Table 133 in order to interpret the status
STOP. screen kickout status parameter.
The following kickout status parameter is available:

i01474120
PTO Switch Circuit - Test PTO kickout
SMCS Code: 1165-081-ZS PTO interlocks may also be connected in series with
the PTO on/off switch. The Interlocks are intended
System Operation Description: to prevent the PTO on/off circuit from activating
unless certain conditions are met.
INPUT 2
301
The input 2 is used for the PTO set/rpm increase Note: The wiring for your particular application may
switch when the PTO Configuration is programmed be slightly different. The circuits for the sensor
to Remote Switches or Remote Throttle. common are used interchangeably by the OEM
INPUT 3 within the ECM:
The input 3 is used for the PTO resume/rpm The Input Sensor Common 1 is terminal 18.
decrease switch when the PTO Configuration
is programmed to Remote Switches or Remote The Input Sensor Common 2 is terminal 3.
Throttle.
The PTO Configuration Is Set To Cab Switches. terminal 5.

Cab Switches and the PTO on/off switch is on, the
following circuits can be used to interrupt a set rpm:

clutch pedal position switch
neutral switch
Cab Switches and the PTO on/off switch is on,
the cab accelerator pedal position sensor can be
PTO Cab Throttle RPM Limit parameter:
low idle
top engine limit
The PTO Configuration Is Set To Remote

Remote Switches or Remote Throttle and the
PTO on/off switch is on, the following circuits are
ignored:

clutch pedal position switch
neutral switch
cab accelerator pedal position sensor
cab cruise control set/resume switch
A remote accelerator pedal position sensor
is connected to the input 8 when the PTO
302
Table 133
No Engine Speed
Switch Turned Off
circuit condition.
Clutch
No Occurrence
g00644420
Illustration 134
303
g00644427
Illustration 135
g00644448
Illustration 136
Test Step 1. Check The Programming Of Expected Result:

The Dedicated PTO Customer Parameter.
The PTO Configuration is programmed to Cab
A. Connect an Electronic Service Tool. Switches, Remote Switches, or Remote Throttle.
B. Turn the ignition key switch to the ON position. Results:
C. Access the Dedicated PTO Customer Yes Proceed to Test Step 2.

the programming of the PTO Configuration No The Dedicated PTO features are not
Parameter. programmed for this engine. If PTO operation
is desired, the PTO Configuration must be
304

Installation Setup.
B. Check the cab glove box for any information

regarding the installation of the PTO. It is
function of the PTO Interlocks that are used in
the installation.

necessary.
D. Determine the schematic that most closely

matches the installation. Review the schematics
specific PTO Configuration of the truck.
E. Record the PTO Configuration.
Expected Result:
The requirements for the installation and the

application have been reviewed.
Results:

305

And Wiring.
g00713728
Illustration 137
A. Thoroughly inspect ECM connector J1/P1, Refer to Illustration 137.

connectors that are used by the PTO. C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 nm (55 lb in).
Connectors for details. D. Check the harness and wiring for abrasion and
wires in the ECM connector that are associated Expected Result:
connections should be tested if the connections All connectors, pins and sockets should be
are used: completely coupled and/or inserted and the harness
terminal 3 or pinch points.
terminal 5 Results:
terminal 30 OK Proceed to Test Step 4.

terminal 35 Not OK
terminal 44 Repair: Perform the following diagnostic
procedure:
terminal 56
terminal 58 the connectors or wiring. Ensure that all of the
terminal 60 connectors are completely coupled.
terminal 68
306
Verify that the repair eliminates the problem. Test Step 5. Check Status Of The
Set/Resume Input On The Electronic
STOP. Service Tool.
Test Step 4. Check The PTO On/Off Note: The set/resume input increases the engine
Switch Circuit With An Electronic Service rpm and the set/resume input decreases the engine
Tool. rpm.
A. Turn the ignition key switch to the ON position. A. Find the PTO set/resume switch. If the PTO
Configuration is programmed to Cab Switches,
B. For the input 1 (PTO on/off switch), Access the cruise control set/resume switch will be
the Electronic Service Tool status screens that used. If the PTO Configuration is programmed
display the following status parameters: to Remote Switches or Remote Throttle, a
dedicated PTO set/resume switch will be used.
PTO Config
The PTO Configuration is programmed to
PTO ON/OFF Switch Cab Switches.
C. Verify that each of the PTO interlocks are set. Look at the status for the Cruise Control
Then, while the Electronic Service Tool status Set/Resume Switch parameter on the Electronic
screen is being monitored turn on the PTO on/off Service Tool. The parameter is located on the
switch and turn off the PTO on/off switch. same status screen as the cruise/idle switch.
An example of a PTO interlock would be a B. While the Electronic Service Tool status screen
parking brake that is intended to allow PTO for the switch is being monitored, perform the
engine control under specific conditions. following procedure in order:
Expected Result: Put the cruise control set/resume switch in the

Set position.
Result 1 The status of the PTO on/off switch on the
Electronic Service Tool changes from OFF to ON Release the cruise control set/resume switch
when the PTO on/off switch is turned OFF and ON, from the Set position.
but the set/resume switch is not operating correctly.
Result 2 The status of the PTO on/off switch on the Resume position.
Electronic Service Tool changes from OFF to ON
when the PTO on/off switch is turned OFF and ON. Release the cruise control set/resume switch
However, the remote accelerator is not operating from the Resume position.
correctly.
The PTO Configuration is programmed to
Result 3 The status of the PTO on/off switch on the Remote Switches or Remote Throttle.
Electronic Service Tool does not change from OFF
to ON when the PTO on/off switch is turned OFF View the status parameter on the Electronic
and ON. Service Tool for the Remote PTO Set Switch
Results:
C. While the Electronic Service Tool status screen
Result 1 Proceed to Test Step 5. for the switch is being monitored, perform the
following procedure in order:
Result 2
Put the remote PTO set/resume switch in the
Repair: Perform the following diagnostic Set position.
procedure: Troubleshooting, Remote PTO
Accelerator Position Sensor Circuit - Test Release the remote PTO set/resume switch
from the Set position.
STOP.
Put the remote PTO set/resume switch in the
Result 3 Proceed to Test Step 6. Resume position.

from the Resume position.
307
Expected Result: Test Step 6. Check The Status Of The

When the PTO Configuration is programmed to Service Tool.
Cab Switches, the status parameter for the cruise
control set/resume switch on the Electronic Service
Tool behaves in the following manner:

will display OFF when the set switch is released.

switch is moved to the SET position.

changes from set switch ON to resume switch
ON when the resume switch is moved to the
RESUME position.

parameter for the remote PTO set switch behaves
The status screen for the remote PTO set switch Illustration 138 g00768799
displays OFF when the remote PTO set switch
is released.
The status of the remote PTO resume switch
displays OFF when the remote PTO resume
switch is released.
The status of the remote PTO set switch changes C. Disconnect vehicle harness connector P1 from
from OFF to set switch ON when the remote PTO
set switch is moved to the SET position. the ECM.
D. Connect a 70-Termial breakout T to ECM

The status of the remote PTO resume switch connector J1 and connect P1 to the breakout T.
changes from OFF to resume switch ON when
the remote PTO resume switch is moved to the
RESUME position.
Results:
Yes The set circuit and the resume circuit G. Access the PTO On/Off Switch status on the
H. While the switch status is being observed on the
No (programmed to Cab Switches) The PTO breakout T in order to connect terminal 56 (input
1) to terminal 3 (input sensor common #2).
The input 1 is the PTO on/off switch.
No (programmed to Remote Switches or
Remote Throttle) The PTO Configuration is
programmed to Remote Switches or Remote
Throttle. Proceed to Test Step 8.
Expected Result:
The switch status of the PTO On/Off Switch on

manner:
308
The switch status is OFF when the jumper is Test Step 7. Check The Status Of The
removed. Cruise Control Set/Resume Switch On
The switch status changes from OFF to ON when
the jumper is in place.
Results:
Yes The input 1 (PTO on/off switch) of the ECM

is functioning correctly. The problem is in the
switches of the vehicle or the problem is in the
wiring of the vehicle.

following options:

STOP.
No The ECM is not reading the switch status Illustration 139 g00768798
change.

procedure: A. Turn the ignition key switch to the OFF position.

suspect ECM. the ECM.

codes.
F. Turn the ignition key switch to the ON position,
6. If the problem is resolved with the test ECM, while the engine is off.
G. Access the status of the cruise control set/resume
7. If the problem returns with the suspect ECM, switch on the Electronic Service Tool.
replace the ECM.
H. While the switch status is being observed on
8. Verify that the repair eliminates the problem. the Electronic Service Tool install the jumper
into the breakout T in order to connect terminal
STOP.
common). Also, while the switch status is being
observed on the Electronic Service Tool remove
the jumper from the breakout T in order to
disconnect terminal 35 (Set) from terminal 5 (AP
309
I. While the switch status is being observed on the 3. Remove all jumpers and replace all connectors.
Electronic Service Tool, install the jumper into the
breakout T. This connects terminal 44 (resume) 4. Recheck the system for active diagnostic
to terminal 5 (AP sensor/switch sensor common). codes.
Also, while the switch status is being observed
on the Electronic Service Tool, remove the jumper 5. Repeat the test step.
from the breakout T. This will disconnect terminal
44 (resume) from terminal 5 (AP sensor/switch 6. If the problem is resolved with the test ECM,
sensor common). reconnect the suspect ECM.
Refer to Illustration 3. 7. If the problem returns with the suspect ECM,

replace the ECM.
Expected Result:
switch on the Electronic Service Tool behaves in STOP.
Test Step 8. Check The Status of the
The switch status of the cruise control set/resume Remote PTO Set Switch and the Remote
switch is OFF when the jumper is removed. PTO Resume Switch on the Electronic
Service Tool.
switch changes from OFF to set switch ON
when the jumper is connected from terminal
common).

switch changes from OFF to resume switch
ON when the jumper is connected from terminal
44 (switch resume terminal) to terminal 5 (AP
Results:
Yes The set input and the resume input of the


following options:
g00768769
Illustration 140
Repair the wiring or replace the wiring. ECM Breakout T-connector
Send the vehicle to the OEM dealer for repair. A. Turn the ignition key switch to the OFF position.
STOP. Crimp a Deutsch pin to both ends of the wire.

No The ECM is not reading the switch status the ECM.
change.
procedure:
suspect ECM.
310
G. Access the Remote PTO Set Switch and Remote Results:

PTO Resume Switch status on the Electronic
Service Tool. Yes The input 2 (Remote PTO Set Switch) and
the input 3 (Remote PTO Resume Switch) of the
H. While the status of the Remote PTO Set Switch is ECM are functioning correctly. The problem is in
being observed on the Electronic Service Tool, the switches of the vehicle or the problem is in
install the jumper into the breakout T in order to the wiring of the vehicle.
connect terminal 58 (input 2) to terminal 3 (input
sensor common #2). Also, while the switch status Repair: Inspect the wiring. Select one of the
is being observed on the Electronic Service Tool following options:
remove the jumper from the breakout T in order
to disconnect terminal 58 (input 2) from terminal Repair the wiring or replace the wiring.
3 (input sensor common #2).
I. While the status of the Remote PTO Resume
Switch is being observed on the Electronic Verify that the repair eliminates the problem.
Service Tool, install the jumper into the breakout
T in order to connect terminal 60 (input 3) to STOP.
terminal 3 (input sensor common #2). Also,
while the switch status is being observed on the No The ECM is not reading the switch status
Electronic Service Tool remove the jumper from change.
the breakout T in order to disconnect terminal 60
(input 3) from terminal 3 (input sensor common Repair: Perform the following diagnostic
#2). procedure:
The input 2 is the set switch for the PTO and the 1. Temporarily connect a test ECM.
input 3 is the resume switch for the PTO.
Refer to Illustration 140. ECM matches the PTO Configuration of the
suspect ECM.
Expected Result:
the Electronic Service Tool behaves in the following 4. Recheck the system for Active diagnostic
manner: codes.
The switch status of the Remote PTO Set Switch 5. Repeat the test step.
is OFF when the jumper is removed.
The switch status of the Remote PTO Set Switch reconnect the suspect ECM.
jumper is connected from terminal 58 (input 2) to 7. If the problem returns with the suspect ECM,
terminal 3 (input sensor common #2). replace the ECM.
The switch status of the Remote PTO Resume 8. Verify that the repair eliminates the problem.
Switch on the Electronic Service Tool behaves in
the following manner: STOP.
The switch status of the Remote PTO Resume i01474436

Switch is OFF when the jumper is removed.
Switch changes from OFF to resume switch ON - Test
when the jumper is connected from terminal 60
(input 3) to terminal 3 (input sensor common #2). SMCS Code: 7431-081

311

Output 1 can be used as a PTO Switch On Lamp

output. If the PTO Configuration is programmed to
Cab switches, Remote Switches, or Remote Throttle,
the Output will turn the lamp ON whenever the PTO
Switch Circuit is turned ON.

terminal is connected to the ECM at the Vehicle
Harness Connector J1/P1 at terminal 30.

the lamp ON.
g00703413
Illustration 141
312
g00668646
Illustration 142
Test Step 1. Inspect Electrical Connectors Results:

And Wiring.
connector J1/P1, the firewall bulkhead Not OK
connector, or the PTO Switch ON Lamp.
Refer to Troubleshooting, Inspecting Electrical Repair: Repair the connectors or wiring and/or
Connectors for details. replace the connectors or wiring. Ensure that all
B. Perform a 45 N (10 lb) pull test on each of the the connectors are completely coupled.
with the PTO Switch ON Lamp. STOP.
Refer to Illustration 142. Test Step 2. Check For Normal Operation

Of The PTO Switch ON Lamp.
the proper torque of 6.0 Nm (55 lb in). A. Use the following procedure for the Output 1
(PTO Switch ON Lamp).
pinch points from the battery to the ECM. Connect an Electronic Service Tool. Access
the status screen that displays the PTO
Expected Result: Configuration and the PTO ON/OFF Switch. The
PTO Configuration must indicate Cab Switches,
All connectors, pins and sockets should be Remote Switches, or Remote Throttle. The PTO
completely coupled and/or inserted and the harness Configuration is not programmed to turn the
and wiring should be free of corrosion, abrasion PTO Switch ON Lamp to the ON position if the
or pinch points. PTO Configuration indicates OFF.
313
While the PTO Switch ON Lamp and the status

of PTO ON/OFF Switch is being watched on
the Electronic Service Tool, turn the PTO On/Off
The PTO Switch ON Lamp should turn ON when
the PTO Switch ON Lamp should turn Off when
Expected Result:
The lamp turns ON and the lamp turns OFF per the
above description.
Results:

at this time. STOP.

Lamp Circuit.
g00668711
Illustration 143
A. Disconnect ECM vehicle harness connector Expected Result:

J1/P1.
Result 1 The PTO Switch On Lamp turns ON while
B. Fabricate a jumper wire 100 mm (4 inch) long. the jumper is connected to both sockets. Also, the
Crimp a Deutsch pin to both ends of the wire. PTO Switch On Lamp turns OFF when the jumper is
C. Insert the jumper into terminal 30 of connector
P1. Result 2 The suspect lamp does not turn ON while
D. Connect the other end of the jumper wire to
terminal 65 (battery) of connector P1. Result 3 The lamp will stay ON while the ECM
Results:
F. While the lamp is being watched, insert the
jumper wire and remove the jumper wire. Result 1 The PTO Switch ON Lamp circuit is
314
Result 2 The lamp did not turn ON. The

vehicles lamp circuit is not functioning properly.
ECM or the +Battery connection. Repair the lamp
repairs. STOP.
Result 3
procedure:

STOP.

PTO Switch On Lamp.
g00642533
Illustration 144
A. Disconnect ECM vehicle harness connector Refer to Illustration 144.

J1/P1.
B. Insert a 70-Terminal breakout T between ECM following display screens in order:
harness connector P1. Diagnostics
C. Connect one probe of the voltage test lamp to Diagnostic Test
terminal 65 (-battery). Connect the other probe of
the voltage test lamp to terminal 52 (unswitched Special Test
D. The test lamp should turn ON. If the test lamp Lamp. Observe the voltage test lamp. The lamp
does not turn on, either the test lamp is faulty or should turn ON when the test is Active. Also, the
the wiring to the ECM is faulty. Continue with this lamp should turn OFF when the test is inactive.
Expected Result:
terminal 52 (unswitched +battery). The test lamp turns ON and the test lamp turns OFF
terminal 30 (Output 1) of the breakout T.
315
Results: The ECM will not respond to the Remote PTO

Accelerator Position Sensor if there is a 253-02
Yes The ECM is operating correctly. There is a Check Customer or System Parameters (56) Active
problem in the vehicle wiring or the lamp. STOP. Diagnostic Code under some conditions. Refer to
Troubleshooting, ECM Memory - Test if there is a
No 253-02 Check Customer or System Parameters (56)
Active Diagnostic Code.
that the PTO Configuration of the test ECM The Remote Accelerator Pedal Position Sensor is
matches the PTO Configuration of the suspect used to provide a throttle position signal to the ECM.
ECM. Check the ECM operation of the PTO Switch Sensor output is a constant frequency signal with
ON Lamp when the test ECM is installed. If the a pulse width that varies with the pedal position.
problem is resolved with the test ECM, reconnect This output signal is referred to as either a Duty
the suspect ECM. If the problem returns with the Cycle or a Pulse Width Modulated signal (PWM)
suspect ECM, replace the ECM. and this output signal is expressed as a percentage
STOP.
i01334712
Remote PTO Accelerator Position Sensor requires no adjustment.
Position Sensor Circuit - Test The Pedal Mounted Accelerator Pedal Position
SMCS Code: 1913 percent at low idle and 75 to 90 percent when the
System Operation Description: of duty cycle is translated in the ECM into an
Use this procedure if any of the following Diagnostic Sensor can be replaced separately from the Pedal
Codes are indicated: Assembly. An incorrectly calibrated Pedal Assembly
30-08 Invalid PTO Throttle Signal (29) must be replaced.
30-13 PTO Throttle Sensor Calibration (29) If the vehicle is using the ECM Dedicated PTO
Also, use this procedure if the Remote PTO Sensor will be ignored while the engine is in PTO
Accelerator Position Sensor is suspected of mode and the PTO Configuration is programmed
improper operation. to the following setting:
Remote PTO Accelerator Position Sensor Remote Throttle

Position Sensor must be used for the Remote PTO
Accelerator Position Sensor, and the +8 V version
for the Cab Accelerator Pedal Position Sensor.
316
This prevents the engine from experiencing

unexpected acceleration or sudden acceleration
when the PTO ON/OFF circuit is turned ON. The
Idle before the ECM will respond. The ECM must
also see a transition from the OFF position to the ON
position in the PTO ON/OFF Switch in order to allow
the other PTO speed control functions to operate. If
the engine is started with the PTO ON/OFF Switch
in the ON position, the accelerator will respond. The
response will occur only if the accelerator pedal
speed control functions will not respond.
g00642017
Illustration 145
317
g00642018
Illustration 146
Sensor:
D. Check the ECM Connector (Allen Head Screw) Repair the connectors or wiring and/or replace
for the proper torque of 6.0 Nm (55 lb in). the connectors or wiring. Ensure that all of the
318
Verify that the repair eliminates the problem. B. Measure the voltage at terminal A (+12 V) with
reference to terminal B (sensor common) at the
STOP. connector J406. This connector is for the Remote
Test Step 2. Check for Active Diagnostic
Codes. Expected Result:
A. Connect an Electronic Service Tool to the Cab The measured voltage is between 11.0 VDC and
Data Link Connector. 13.5 VDC.
B. Turn the Ignition Key Switch to the ON position. Results:
C. Monitor the Active Diagnostic Code Screen of OK Proceed to test step 4.

the Electronic Service Tool. Check and record
Active Diagnostic Codes. Not OK The vehicle wiring or the battery is
causing the problem. Repair the wiring or the
Note: When the ECM automatically calibrates new battery. Replace the wiring or the battery. Perform
duty cycle values for the low idle throttle position the repair that is necessary. Verify that the repair
and the high idle throttle position the ECM assumes has fixed the problem. STOP.
22 percent duty cycle at low idle and 75 percent
duty cycle at high idle. As a result, you may notice Test Step 4. Check The Duty Cycle Of The
that the PTO Throttle Position Status reaches 100 Accelerator Pedal Position Sensor.
percent well before the remote PTO accelerator
pedal is fully depressed. This is normal. After A. Turn the Ignition Key Switch to the ON position.
some cycling of the accelerator pedal to the high
idle position, the ECM will adjust the calibration B. Monitor the Duty Cycle of the PTO Throttle
automatically. The ECM will adjust the calibration Sensor on the Electronic Service Tool. Access
automatically provided that the high idle stop the following display screen in order:
position is within the 75 to 90 percent duty cycle
range, and the low idle is in the 10 to 22 percent Service
duty cycle range. During normal operation, you
may notice that more movement of the remote PTO Calibrations
accelerator pedal is required for the PTO Throttle
Position status to increase above 3 percent. You Monitor Throttle Position Sensor
may also observe that the status reaches the 100
percent value prior to the limit of the high idle Expected Result:
position. This is done in order to ensure that the
accelerator reaches these two critical points for The Duty Cycle is between 10 and 22 percent with
engine operation. the accelerator pedal assembly in the Low Idle
High Idle position.
Result 1 Diagnostic Code 30-08 or 30-13 is Active.
Results:
Result 2 There are NO Active Diagnostic Codes that
are related to the Accelerator Pedal Position Sensor Yes The Remote PTO Accelerator Pedal
Circuit at this time, but a problem is suspected with Position Sensor is operating correctly. Proceed
operation of the Remote PTO Accelerator Pedal to test step 5.
Position Sensor Circuit.
No The Remote PTO Accelerator Pedal Position
Results: Sensor Circuit is not operating correctly. Proceed
to test step 6.
Test Step 3. Check the Supply Voltage
for the Remote PTO Accelerator Position
Sensor.
319
High Idle position.
At The ECM.

320
Assembly.
Expected Result:

High Idle position.
Results:




of abrasion.

of the Breakout T.

Illustration 147.
321
g00642019
Illustration 147


replacement of the Accelerator Assembly. STOP. B. Remove the signal wire for the remote PTO
322
C. Remove terminal C (Accelerator Pedal Position) Cruise Control Set/Resume Switch

Connector. Cruise Control On/Off Switch
D. Route new wiring from the ECM to the Remote PTO On/Off Switch
The switches are described in the respective circuit
E. Turn the ignition key switch to the ON position. tests in Troubleshooting.
F. Check the Duty Cycle of the Remote PTO All of the following Customer Programmable
Accelerator Position Sensor with an Electronic Parameters can affect cruise control, idle set speed,
Service Tool while the accelerator pedal fast idle, and PTO operation:
Expected Result:
the accelerator pedal assembly in the Low Idle Idle Vehicle Speed Limit
percent with the accelerator pedal assembly in the Fast Idle RPM #1
High Idle position.
Fast Idle RPM #2
Results:
Pedal Position Sensor appears faulty. Permanently Idle/PTO Bump rpm
the problem. STOP. Idle/PTO rpm Ramp Rate
No Double check the wiring, the ECM Vehicle PTO Vehicle Speed Limit
Connector. If a problem still exists, restart the test The vehicle speed calibration can also affect the
procedure. STOP. cruise control, fast idle, the idle set speed, and the
PTO if the vehicle speed calibration is incorrectly
i01474500
Specified Parameters.
Service Brake Pedal Position Service Brake Pedal Position (Switch 1)
The switch for the Service Brake Pedal Position
SMCS Code: 1900-081-ZS (Switch 1) is normally closed when the respective
pedal is released. Depressing the brake pedal
System Operation Description: should open the individual circuit. This switch is
OEM supplied. The Service Brake Pedal Position
Use this procedure under the following situation: (Switch 1) is typically a pressure switch.
Use this procedure to determine if the Service The following background information is related
Brake Pedal Position (Switch 1) is preventing normal to this procedure:
operation of cruise control, fast idle, idle set speed,
or PTO operation: The kickout switch refers to the switch that is used
to exit the Cruise Control, the PTO, fast idle, or the
The following switch circuits can also prevent the Idle Set Speed.
correct operation of the cruise control, fast idle, idle
set speed or PTO operation: The operation of the Caterpillar Electronic Engine
cruise control is similar to the operation of the
Service Brake Pedal Position (Switch 1) cruise controls that are installed in automobiles. The
operation of fast idle, idle, and PTO are similar to
Service Brake Pedal Position (Switch 2) the operation of cruise except that the Idle and the
PTO govern engine rpm instead of vehicle speed.
Neutral switch
323
Note: Idle in this procedure is an engine idle rpm Kickout Switches

by using the Cruise Control On/Off switch and The service brake pedal position switches, the
the Set/Resume switch. Refer to Troubleshooting, neutral switch and the clutch switch are used in the
PTO Switch Circuit - Test for additional information Cruise Control mode, the PTO mode, the Fast Idle
regarding the programmable options for the mode, and the Idle mode in order to discontinue
Dedicated PTO. the Cruise operation, the PTO operation, the Fast
Idle mode, or the Idle operation. The capability to
Note: Fast idle in this procedure is an engine idle override the Idle Shutdown Timer is determined
rpm above the programmed low idle rpm. Fast idle by the Allow Idle Shutdown Override parameter
is set by using a dedicated fast idle switch. setting. The Allow Idle Shutdown Override is a
Customer Parameter.
Usage of Transmission Style Switches
This switch must be ON before cruise control or
controlled idle can be activated. This switch is The Transmission Style parameter determines
ON when the switch is closed. When the switch is the switches that will be used. The following
closed the following terminals are connected: switches can be used with being dependent on the
parameter setting:
ECM Connector J1/P1 terminal 59 (CRUISE
CONTROL ON/OFF SWITCH) Clutch Pedal Position
Terminal 5 (AP SENSOR/SWITCH SENSOR Neutral
COMMON)
Dedicated PTO, the PTO On/Off switch overrides Service Brake Pedal Position (Switch 2)
the Cruise Control On/Off switch. The PTO On/Off
switch overrides the Cruise Control On/Off switch Refer to Table 134 for additional information.
when the vehicle speed is within the range of the
PTO Vehicle Speed Limit that is programmed. Table 134
Switch Usage.
Set/Resume Switch Setting For
Transmission Service Service
With the Cruise Control On/Off Switch in the ON Style Brake Brake
Clutch Neutral
position and the vehicle speed within the range of
1 2
the programmed Low Cruise Control Speed Set
Limit and the High Cruise Control Speed Set Limit, Manual X X
momentarily pressing the Set Switch will activate
Automatic
cruise control and the ECM will maintain the current Option 1
X
speed.
Automatic
X X
After a speed has been set and the speed is then Option 2
disengaged by using the brake, the clutch, or the Automatic
On/Off switch, the ECM will seek the previous set X X X
Option 3
speed when the Resume switch is toggled. This
assumes that the vehicle speed is above the Low Automatic
X X
Cruise Control Set Speed Limit for cruise control Option 4
or the vehicle speed is below the Idle/PTO Vehicle AT/MT/HT
Speed Limit for the Idle and the PTO. X
Option 1
After a speed has been set, pressing and holding AT/MT/HT

X X
Option 2
the Set/Resume switch in position will cause the
engine to establish a new set speed. The systems AT/MT/HT
X X X
reaction depends on the programming of the Option 3
Cruise/Idle/PTO Switch Configuration.
AT/MT/HT
X X
Option 4
When the Set/Resume switch is momentarily
pressed, the cruise set point will change one Universal
X X X X
mph. The rate of change is dependent on the Option
programmed Idle/PTO Bump rpm when an idle
speed is set.
324
If the Transmission Style parameter is programmed Some engines that were built before JULY 1999
to one of the following options, the input for the may have a Basic ECM. The Basic ECM was used
Clutch Pedal Position Switch is not used. only on General Motors chassis. Other chassis used
Automatic Options 1 Basic ECM software does not have the parameter
for Transmission Style. For these systems, a
Automatic Option 2 jumper wire must be installed between the clutch
Automatic Option 3 automatic transmission is installed. When the jumper
Automatic Option 4 always indicate OFF. Engines that were built after
AT/MT/HT Option 1 configured for Basic or Full Feature operation.
AT/MT/HT Option 2 this flexibility. The Truck Manufacturer parameter
was added in order to allow the configuration of the
AT/MT/HT Option 3 GM Basic operation or the Other Full Feature
operation. This parameter is programmed at
AT/MT/HT Option 4 Caterpillar when the engine is built. The parameter
for Transmission Style is not available for engines
Universal Option that have software that is dated prior to SEP00
A Service Brake Pedal Position (Switch 1) is required programmed to GM. SEP00 and newer engines
for all configurations. The Service Brake Pedal that are programmed to GM use the Transmission
Position (Switch 1) connects to the ECM through Style parameter. The factory default for the GM
connector P1 terminal 45. The Service Brake Pedal setting is the Universal option. The Universal
Position (Switch 2) connects to the ECM through option provides identical features as the Basic
Connector P1 terminal 64. The clutch pedal position system that is described above. If the Transmission
switch connects to the ECM through connector P1 Style parameter is programmed to the Universal
terminal 22. The neutral switch connects to the ECM option, a jumper wire must be installed between the
through connector P1 terminal 62. clutch switch input and the sensor common when an
to match the specific arrangement of the vehicle.

procedure:
After the kickout, review the status parameter on

the Electronic Service Tool. The Electronic Service
Tool Kickout status parameter indicates the cause.
This must be performed before the ignition key
switch is turned OFF. It is important to remember
that the parameter will only indicate the last kickout
since the ECM has been powered by the input of
the ignition key switch.

of the Cruise/Idle/PTO Mode. Refer to Tables 135,
136, and 137 in order to interpret the status screen
kickout status parameter.
325

available:
Cruise Kickout
Idle Kickout
PTO Kickout
Table 135
circuit condition.
The service brake pedal is depressed or Proceed with the test procedure.
Brake the service brake switch circuit has an
Clutch
circuit condition.
exists.
circuit condition.
No Occurrence
326
Table 136
No Engine Speed
condition.
The service brake pedal is depressed or Proceed with the test procedure.
Brake the service brake switch circuit has an open
circuit condition.
Clutch
condition.
No Occurrence
327
Table 137
No Engine Speed
condition.
circuit condition.
Clutch
No Occurrence
g00643881
Illustration 148
Schematic for cruise control switch, service brake pedal position (switch 1) and clutch pedal position switch
Test Step 1. Determine The Type Of Low Cruise Control Speed Set Limit
Problem.
A. Connect an Electronic Service Tool.
Idle Parameters
Fast Idle RPM #1
C. If the vehicle will not allow setting a Cruise
speed, an Idle speed or a PTO speed, check the Fast Idle RPM #2
328
Idle RPM Limit

PTO Parameters
PTO Configuration
if necessary.

of the following items:
Cruise Control Kickout

Idle Kickout
Fast Idle Kickout
PTO Kickout
meaning of the Electronic Service Tool status
screen parameter.
Expected Result:

problem is due to a normal kickout.
Results:
Yes Explain the proper operation of system to

the driver. STOP.
No
Repair: Refer to tables 135, 136, and 137 for
If a problem is still suspected with the circuit

for the Service Brake Pedal Position (Switch 1),
perform the following procedure:

329

And Wiring.
g00702676
Illustration 149
A. Thoroughly inspect ECM vehicle harness Results:

and the terminals for the following switches in OK Proceed to Test Step 3.
the connectors:
Not OK
AP Sensor/Switch Sensor Common (terminal 5)
(terminal 45) Repair the connectors or wiring and/or replace
Refer to Troubleshooting, Inspecting Electrical seals are properly in place and ensure that the
Connectors for details. connectors are completely coupled.
B. Perform a 45 N (10 lb) pull test on each of the Verify that the repair eliminates the problem.
with the switches. STOP.


Expected Result:

or pinch points.
330
Test Step 3. Check The Service Brake B. For an intermittent Idle Kickout, talk to the driver
Switch Status On The Electronic Service in order to determine the conditions when the
Tool. kickout occurs. A topic of examination could be
Table 138
Table for Status of the Service Brake Pedal Position Specific engine rpm
Switch Position or Start the engine. Duplicate these conditions and
Status Circuit
Pedal Position set the idle rpm. Operate the vehicle in idle until
The Service Brake Pedal the problem reoccurs.
ON Open
is DEPRESSED.
The Service Brake Pedal only indicate the last kickout. The Electronic Service
OFF Closed
is RELEASED.
A. Access the Electronic Service Tool Status Screen.
C. Connect an Electronic Service Tool and check
B. Turn the ignition key switch to the ON position. the Status screen for the last cause of the
kickout. Refer to Tables 135, 136, and 137 for an
C. Depress the service brake while the status of the explanation of the status parameter.
service brake pedal position (switch 1) is being
observed. Also, release the service brake while D. If the Electronic Service Tool status screen is
the status of the service brake pedal position blank, then either there was no kickout of the
(switch 1) is being observed. cruise control, or the power to the ECM was
turned OFF before the information could be read.
Refer to Table 138 for the status of the switch or Perform Steps A,B and C again.
for the status of the pedal position.
Expected Result: is blank indicates No Occurrence.
The switch status changes per the information in Expected Result:

Table 138.
Results: Status displays the following result:
Yes The switch is operating normally. STOP. Brake

Clutch
specific speed
Bad Vehicle Speed
road conditions
Vehicle Speed Limit
weather conditions
331
RESULT 6 The Electronic Service Tool Kickout Troubleshooting, Neutral Switch Circuit - Test
STOP.
Neutral
Result 7
Status displays the following result: Repair: Perform the following diagnostic
procedure:
No Engine Speed
Troubleshooting, Engine Speed/Timing Circuit -
RESULT 8 The Electronic Service Tool Kickout Test
STOP.
Ser Switch Timeout
Result 8
Resume Switch Timeout
Results: procedure:
Result 1 Proceed to Test Step 5. Troubleshooting, Cruise Control Switch Circuit

- Test.
Result 2
STOP.
procedure: Test Step 5. Check The Switch Circuit.
Troubleshooting, Cruise Control Switch Circuit - Table 139
Test Table for Status of Service Brake Pedal
Position (Switch 1)
STOP.
Condition of Switch
Circuit
Result 3
Terminal 45 is Open. ON Open
procedure: Terminal 45 connected
OFF Shorted
to terminal 5.
Circuit - Test A. Turn the ignition key switch to the OFF position.
STOP. B. Fabricate a jumper wire 100 mm (4 inch) long.

Crimp a Deutsch Pin to both ends of the wires.
Result 4
Repair: Perform the following diagnostic the ECM.
procedures:
D. Connect a 70-Termial Breakout T to ECM
Troubleshooting, Vehicle Speed Circuit - Test Connector J1 and connect P1 to the Breakout T.
STOP. E. Install the jumper into terminal 45 Service Brake

Pedal Position Switch 1 of the Breakout T.
Result 5 Connect the other end of the jumper to ECM
Connector P1 terminal 5 (AP SENSOR/SWITCH
Repair: Perform the following diagnostic SENSOR COMMON) of the Breakout T.
procedure:
STOP. data link connector.
Result 6 H. Access the Electronic Service Tool Status Screen.

procedure:
332
I. While the status of the Service Brake Pedal B. Ensure that ECM vehicle harness connector
Position (Switch 1) is being monitored on J1/P1 is connected.
the Electronic Service Tool Status Screen
slowly remove the jumper from terminal 5 and C. Find the switch for the Service Brake Pedal
slowly insert the jumper from terminal 5 (AP Position (Switch 1) in the vehicle.
SENSOR/SWITCH SENSOR COMMON).
D. Disconnect the wires from the switch terminals.
Refer to Table 139.
Expected Result:
The switch status changes per the information in data link connector.
Table 139.
Results:
H. While the switch status is being monitored on
Yes The ECM is functioning properly. Proceed the Electronic Service Tool Status Screen slowly
to Test Step 6. connect the switch wires and slowly disconnect
the switch wires.
No The ECM is NOT functioning properly.
Refer to Table 140.
Expected Result:
2. Remove all jumpers and replace all connectors. Table 140.
3. Recheck the system for active diagnostic Results:

codes.
Yes
reconnect the suspect ECM. Replace the faulty switch.
6. If the problem returns with the suspect ECM, Verify that the repair eliminates the problem.
replace the ECM.
STOP.
No There is a problem in the harness between
STOP. the switch and the ECM. Proceed to Test Step 7.

Service Brake Pedal Position (Switch 1).
Table 140
Table for Status of the Service Brake Pedal
Position (Switch 1)
Condition of Switch
Circuit
Service Brake Pedal
Position Switch 1 Wires ON Open
are Disconnected.
Service Brake Pedal
Position Switch 1 Wires OFF Shorted
Connected.

333
Test Step 7. Insert A Jumper At The No The problem is in the vehicle wiring between
Bulkhead Connector. the bulkhead connector and the ECM.
Table 141 Repair: Perform the following repair:

Table for Status of the Service Brake Pedal
Position (Switch 1) Inspect the vehicle wiring and repair the vehicle
Switch Position or the wiring, send the vehicle to the OEM dealer.
Pedal Position
Service Brake Pedal STOP.
Position Switch 1 Wire is ON Open
Disconnected.
i01480720
Service Brake Pedal
Position Switch 1 Wire OFF Shorted Service Brake Pedal Position
Connected.
A. Turn the ignition key switch to the OFF position. SMCS Code: 1900-081-ZS
B. Fabricate a jumper wire 100 mm (4 inch) long. System Operation Description:

Crimp a Deutsch Pin to both ends of the wires.
C. Find the switch for the terminal for the Service
Brake Pedal Position (Switch 1). Also find the Use this procedure to determine if the Service
terminal for the sensor common for the AP Brake Pedal Position (Switch 2) is preventing normal
Sensor/Switch in the engine side of the bulkhead operation of cruise control, fast idle, idle set speed,
connector for the vehicle harness. or PTO operation:
D. Insert the jumper wire between the two terminals The following switch circuits can also prevent the
in the engine side of the bulkhead connector. correct operation of the cruise control, fast idle, idle
set speed or PTO operation:
Service brake pedal position (switch 1)
data link connector. Neutral switch
G. Access the Electronic Service Tool Status Screen. Cruise control set/resume switch
H. While the switch status is being monitored Cruise control on/off switch
on the Electronic Service Tool Status Screen
alternately remove the jumper wire between the PTO on/off switch
two terminals, and alternately insert the jumper
wire between the two terminals. The switches are described in the respective circuit
tests in Troubleshooting.
Refer to Table 141.
All of the following Customer Programmable
Expected Result: Parameters can affect cruise control, idle set speed,
fast idle, and PTO operation:
Table 141. Low Cruise Control Speed Set Limit
Results: High Cruise Control Speed Set Limit
Yes The problem is in the vehicle wiring Idle Vehicle Speed Limit
between the bulkhead connector and the switch.
Fast Idle RPM #1
Fast Idle RPM #2
Inspect the vehicle wiring and repair the vehicle
wiring, as required. If the problem still exists with Cruise/Idle/PTO Switch Configuration
Idle/PTO Bump rpm
STOP.
334
Idle/PTO rpm Ramp Rate Note: If the vehicle is programmed to use the
Dedicated PTO, the PTO on/off switch overrides the
PTO Vehicle Speed Limit cruise control on/off switch. The PTO on/off switch
overrides the cruise control on/off switch when
The vehicle speed calibration can also affect the the vehicle speed is within the range of the PTO
cruise control, fast idle, the idle set speed, and the Vehicle Speed Limit that is programmed.
PTO if the vehicle speed calibration is incorrectly
programmed. Refer to Troubleshooting, Customer Set/Resume Switch
Specified Parameters.
With the cruise control on/off switch in the ON
Service Brake Pedal Position (Switch 2) position and the vehicle speed within the range of
the programmed Low Cruise Control Speed Set
The switch for the service brake pedal position Limit and the High Cruise Control Speed Set Limit,
(switch 2) is normally open when the respective momentarily pressing the set switch will activate
pedal is released. Depressing the brake pedal cruise control and the ECM will maintain the current
should close the individual circuit. This switch is speed.
OEM supplied. The service brake pedal position
(switch 2) is typically a pressure switch. After a speed has been set and the speed is then
The following background information is related on/off switch, the ECM will seek the previous set
to this procedure: speed when the resume switch is toggled. This
The kickout switch refers to the switch that is used Cruise Control Set Speed Limit for cruise control or
to exit the cruise control, the PTO, fast idle, or the the vehicle speed is below the Idle/PTO Vehicle
idle set speed. Speed Limit for the idle and the PTO.
The operation of the Caterpillar Electronic Engine After a speed has been set, pressing and holding
cruise control is similar to the operation of the the set/resume switch in position will cause the
cruise controls that are installed in automobiles. The engine to establish a new set speed. The systems
operation of fast idle, idle, and PTO are similar to reaction depends on the programming of the
the operation of cruise except that the Idle and the Cruise/Idle/PTO Switch Configuration.
PTO govern engine rpm instead of vehicle speed.
When the set/resume switch is momentarily pressed,
Note: Idle in this procedure is an engine idle rpm the cruise set point will change one mph. The
above the programmed low idle rpm. Idle is set rate of change is dependent on the programmed
by using the Cruise Control On/Off switch and Idle/PTO Bump rpm when an idle speed is set.
the Set/Resume switch. Refer to Troubleshooting,
PTO Switch Circuit - Test for additional information Kickout Switches
regarding the programmable options for the
Dedicated PTO. The service brake pedal position switches, the
neutral switch and the clutch switch are used in the
Note: Fast idle in this procedure is an engine idle cruise control mode, the PTO mode, the fast idle
rpm above the programmed low idle rpm. Fast idle mode, and the idle mode in order to discontinue
is set by using a dedicated fast idle switch. the cruise operation, the PTO operation, the fast
idle mode, or the idle operation. The capability
Cruise Control On/Off Switch to override the idle shutdown timer is determined
by the Allow Idle Shutdown Override parameter
This switch must be ON before cruise control or setting. The Allow Idle Shutdown Override is a
controlled idle can be activated. This switch is Customer Parameter.
ON when the switch is closed. When the switch is
closed the following terminals are connected: Usage of Transmission Style Switches
ECM connector J1/P1 terminal 59 (cruise control The Transmission Style parameter determines
on/off switch) the switches that will be used. The following
switches can be used with being dependent on the
Terminal 5 (AP sensor/switch sensor common) parameter setting:
Clutch pedal position

Neutral
335
Service brake pedal position (switch 1) A service brake pedal position (switch 1) is required
for all configurations. The service brake pedal
Service brake pedal position (switch 2) position (switch 1) connects to the ECM through
connector P1 terminal 45. The service brake pedal
Refer to Table 142 for additional information. position (switch 2) connects to the ECM through
connector P1 terminal 64. The clutch pedal position
Table 142 switch connects to the ECM through connector P1
Switch Usage. terminal 22. The neutral switch connects to the ECM
Setting For through connector P1 terminal 62.
Transmission Service Service
Style Brake Brake Some engines that were built before JULY 1999
Clutch Neutral
may have a Basic ECM. The Basic ECM was used
1 2
only on General Motors chassis. Other chassis used
Manual X X engines that were built with a Full Feature ECM.
Automatic
Option 1
X for Transmission Style. For these systems, a
Automatic
X X switch input and the sensor common when an
Option 2 automatic transmission is installed. When the jumper
Automatic wire is installed, the Clutch Switch status will
X X X always indicate OFF. Engines that were built after
Option 3
Automatic configured for Basic or Full Feature operation.
X X
Option 4 A new parameter was added in order to provide
AT/MT/HT this flexibility. The Truck Manufacturer parameter
X was added in order to allow the configuration of the
Option 1
AT/MT/HT operation. This parameter is programmed at
X X
Option 2
X X X
Option 3 that have software that is dated prior to SEP00
AT/MT/HT
Option 4
X X programmed to GM. SEP00 and newer engines
Universal
X X X X Style parameter. The factory default for the GM
Option setting is the Universal option. The Universal
If the Transmission Style parameter is programmed system that is described above. If the Transmission
to one of the following options, the input for the Style parameter is programmed to the Universal
Clutch Pedal Position Switch is not used. option, a jumper wire must be installed between the
clutch switch input and the sensor common when an
Automatic Option 1 automatic transmission is installed. Otherwise, the
Automatic Option 2 to match the specific arrangement of the vehicle.
Automatic Option 3 If the problem is with undetermined

Automatic Option 4 procedure:
AT/MT/HT Option 1 Operate the vehicle in Cruise/Idle/PTO mode.
AT/MT/HT Option 2 After the kickout, review the status parameter on

the Electronic Service Tool. The Electronic Service
AT/MT/HT Option 3 Tool Kickout status parameter indicates the cause.
This must be performed before the ignition key
AT/MT/HT Option 4 switch is turned OFF. It is important to remember
that the parameter will only indicate the last kickout
Universal Option since the ECM has been powered by the input of
the ignition key switch.
336

of the Cruise/Idle/PTO Mode. Refer to Tables 143,
144, and 145 in order to interpret the status screen
kickout status parameter.

available:
Cruise Kickout
Idle Kickout
PTO Kickout
Table 143
circuit condition.
The service brake pedal is depressed or Proceed with this test procedure.
Brake the service brake switch circuit 2 has a
short circuit condition.
Clutch
circuit condition.
exists.
circuit condition.
No Occurrence
337
Table 144
No Engine Speed
condition.
The service brake pedal is depressed or the Proceed with the test procedure.
Brake service brake switch 2 circuit has a short
circuit condition.
Clutch
The Vehicle speed has exceeded the Idle Refer to Troubleshooting, Vehicle Speed
condition.
No Occurrence
Table 145
No Engine Speed
condition.
The service brake pedal is depressed or the Refer to Troubleshooting, Service Brake
Brake service brake switch 2 circuit has a short Pedal Position (Switch 2) Circuit - Test.
circuit condition.
Clutch
The Vehicle speed has exceeded the Idle Refer to Troubleshooting, Vehicle Speed
No Occurrence
338
g00770825
Illustration 150
Test Step 1. Determine The Type Of PTO kickout

Problem.
A. Connect an Electronic Service Tool. meaning of the Electronic Service Tool status
screen parameter.
Expected Result:
C. If the vehicle will not allow setting a cruise
speed, an idle speed or a PTO speed, check the The problem is due to a parameter setting or the
following Customer Parameters: problem is due to a normal kickout.
Cruise Control Parameters Results:
Low Cruise Control Speed Set Limit Yes Explain the proper operation of system to
the driver. STOP.
No
Idle Parameters
Repair: Refer to tables 143, 144, and 145 for
Fast Idle RPM #1 recommended troubleshooting.
Fast Idle RPM #2 If a problem is still suspected with the circuit

for the service brake pedal position (switch 2),
Idle Vehicle Speed Limit perform the following procedure:
Idle RPM Limit Proceed to Test Step 2.

PTO Parameters
PTO Configuration
if necessary.

of the following items:
Cruise control kickout

Idle kickout
Fast idle kickout
339
Test Step 2. Inspect Electrical Connectors Expected Result:

And Wiring.
or pinch points.
Results:

Not OK

STOP.
Test Step 3. Check The Service Brake

Pedal Switch 2 Status On The Electronic
Service Tool.
Table 146
Table for Status of the Service Brake Pedal Position
Switch Position or
Status Circuit
Pedal Position
The Service Brake Pedal
OFF Open
is DEPRESSED.
The Service Brake Pedal
g00770850 ON Closed
Illustration 151 is RELEASED.
A. Thoroughly inspect ECM vehicle harness A. Access the Electronic Service Tool Status Screen.
and the terminal 64 (service brake pedal position B. Turn the ignition key switch to the ON position.
(switch 2)).
C. Start the engine. Ensure that the air system
Refer to Troubleshooting, Inspecting Electrical is charged if the vehicle is equipped with air
Connectors for details. brakes. Depress the service brake while the
status of the service brake pedal position (switch
B. Perform a 45 N (10 lb) pull test on each of the 2) is being observed. Also, release the service
wires in the ECM connector that are associated brake while the status of the service brake pedal
with the switches. position (switch 2) is being observed.
Refer to Illustration 151. Refer to Table 146 for the status of the switch or
for the status of the pedal position.
the proper torque of 6.0 Nm (55 lb in). Note: If the status indicates Not Installed, check
the programming of the Transmission Style. This
D. Check the harness and wiring for abrasion and parameter must be programmed to Automatic
pinch points from the sensor to the ECM. Option 2, Automatic Option 3, AT/MT/HT Option
2, or AT/MT/HT Option 3.
340
The switch status changes per the information in RESULT 1 The Electronic Service Tool Kickout
Table 146. Status displays the following result:
Results: Brake
Yes The switch is operating normally. STOP. RESULT 2 The Electronic Service Tool Kickout
Intermittent Problem Suspected Proceed to Test
Step 4. Switch Turned Off
No The ECM is not reading the switch status RESULT 3 The Electronic Service Tool Kickout
change. Proceed to Test Step 5. Status displays the following result:
Test Step 4. Operate The Vehicle And Clutch

A. For an intermittent cruise control kickout, talk to Status displays the following result:
the driver in order to determine the conditions
when the kickout occurs. Topics of examination Vehicle Speed < Limit
Bad Vehicle Speed
specific speed
Vehicle Speed Limit
road conditions
weather conditions Status displays the following result:
Take the vehicle for a road test in order to PTO Switch ON

control. Operate the vehicle in cruise control until RESULT 6 The Electronic Service Tool Kickout
the problem reoccurs. Status displays the following result:
B. For an intermittent idle kickout, talk to the driver Neutral

in order to determine the conditions when the
kickout occurs. A topic of examination could be RESULT 7 The Electronic Service Tool Kickout
the specific engine rpm. Status displays the following result:
Start the engine. Duplicate these conditions and No Engine Speed

the problem reoccurs. RESULT 8 The Electronic Service Tool Kickout
only indicate the last kickout. The Electronic Service Ser Switch Timeout
ignition key switch is turned off. Resume Switch Timeout
C. Connect an Electronic Service Tool and check Results:
the Status screen for the last cause of the
kickout. Refer to Tables 143, 144, and 145 for an Result 1 Proceed to Test Step 5.
explanation of the status parameter.
Result 2
blank, then either there was no kickout of the Repair: Perform the following diagnostic
cruise control, or the power to the ECM was procedure:
turned OFF before the information could be read.
Perform Steps A,B and C again. Troubleshooting, Cruise Control Switch Circuit -
Test
is blank indicates No Occurrence. STOP.
341
Result 3 Test Step 5. Check The Switch Circuit.

Repair: Perform the following diagnostic Table 147
procedure: Table for Status of Service Brake Pedal
Position (Switch 2)
Circuit - Test Condition of Switch Switch
Circuit
Circuit Status
STOP. Terminal 64 is Open. ON Open
Terminal 64 connected
Result 4 to terminal 5.
OFF Closed

procedures: A. Turn the ignition key switch to the OFF position.
Troubleshooting, Vehicle Speed Circuit - Test B. Fabricate a jumper wire 100 mm (4 inch) long.
STOP.
Result 5 the ECM.
Repair: Perform the following diagnostic D. Connect a 70-termial breakout T to ECM

procedure: connector J1 and connect P1 to the breakout T.
Troubleshooting, PTO Switch Circuit - Test E. Install the jumper into terminal 64 (service brake
pedal position switch 2) of the breakout T.
STOP. Connect the other end of the jumper to ECM
connector P1 terminal 52 (unswitched +battery)
Result 6 of the breakout T.
Repair: Perform the following diagnostic F. Turn the ignition key switch to the ON position.
procedure:
Troubleshooting, Neutral Switch Circuit - Test data link connector.
STOP. H. Access the Electronic Service Tool Status Screen.
Result 7 I. While the status of the service brake pedal

position (switch 2) is being monitored on the
Repair: Perform the following diagnostic Electronic Service Tool Status Screen slowly
procedure: remove the jumper from terminal 52 (unswitched
+battery). Now, slowly insert the jumper into the
Troubleshooting, Engine Speed/Timing Circuit - terminal 52 (unswitched +battery).
Test
Refer to Table 147.
STOP.
Expected Result:
Result 8
Repair: Perform the following diagnostic Table 147.
procedure:
Results:
Troubleshooting, Cruise Control Switch Circuit
- Test. Yes The ECM is functioning properly. Proceed
to Test Step 6.
STOP.

342
3. Recheck the system for active diagnostic Results:

codes.
Yes
reconnect the suspect ECM. Replace the faulty switch.
6. If the problem returns with the suspect ECM, Verify that the repair eliminates the problem.
replace the ECM.
STOP.
No There is a problem in the harness between
STOP. the switch and the ECM. Proceed to Test Step 7.
Test Step 6. Insert A Jumper At The Test Step 7. Insert A Jumper At The
Service Brake Pedal Position (Switch 2). Bulkhead Connector.
Table 148 Table 149
Table for Status of the Service Brake Pedal Table for Status of the Service Brake Pedal
Position (Switch 2) Position (Switch 2)
Condition of Switch Switch Switch Position or
Circuit Switch Status Circuit
Circuit Status Pedal Position
Service Brake Pedal Service Brake Pedal
Position Switch 2 Wires OFF Open Position Switch 2 Wire is OFF Open
are Disconnected. Disconnected.
Service Brake Pedal Service Brake Pedal
Position Switch 2 Wires On Shorted Position Switch 2 Wire ON Shorted
Connected. Connected.
A. Turn the ignition key switch to the OFF position. A. Turn the ignition key switch to the OFF position.
B. Ensure that ECM vehicle harness connector B. Fabricate a jumper wire 100 mm (4 inch) long.
J1/P1 is connected. Crimp a Deutsch pin to both ends of the wires.
C. Find the switch for the service brake pedal C. Find the switch for the terminal for the service
position (switch 2) in the vehicle. brake pedal position (switch 2). Also find the
terminal for the sensor common for the +battery
D. Disconnect the wires from the switch terminals. in the engine side of the bulkhead connector for
the vehicle harness.
F. Connect an Electronic Service Tool to the cab in the engine side of the bulkhead connector.
H. While the switch status is being monitored on data link connector.
the Electronic Service Tool Status Screen slowly
connect the switch wires and slowly disconnect G. Access the Electronic Service Tool Status Screen.
the switch wires.
H. While the switch status is being monitored
Refer to Table 148. on the Electronic Service Tool status screen
alternately remove the jumper wire between the
Expected Result: two terminals, and alternately insert the jumper
wire between the two terminals.
Table 148. Refer to Table 149.
343
Expected Result: The tachometer circuit consists of the tachometer

that is connected to the ECM through Connector
The switch status changes per the information in J1/P1 and associated wiring. The ECM engine
Table 149. speed signal is provided by the Crankshaft Position
Sensor. The ECM converts the signal from the
Results: Crankshaft Position Sensor into engine rpm in
pulses per revolution before the ECM sends a signal
Yes The problem is in the vehicle wiring to the tachometer. The selection of the pulses per
between the bulkhead connector and the switch. revolution for the tachometer is done through the
Customer Programmable Parameter Tachometer
Repair: Perform the following repair: Calibration.
Inspect the vehicle wiring and repair the vehicle The ECM tachometer signal is programmable
wiring, as required. If the problem still exists with from 12.0 to 500.0 pulses per revolution in 0.1
the wiring, send the vehicle to the OEM dealer. increments. The tachometer must be calibrated
identically to this value for proper operation.
STOP.
The most likely source of a tachometer circuit
No The problem is in the vehicle wiring between problem is the vehicle wiring. The second most
the bulkhead connector and the ECM. likely source of a tachometer circuit problem is
the tachometer and the least likely source of a
Repair: Perform the following repair: tachometer circuit problem is the ECM.
Inspect the vehicle wiring and repair the vehicle Note: A tachometer may also be driven by the SAE
wiring, as required. If the problem still exists with J1587 Data Link. If the engine ECM communicates
the wiring, send the vehicle to the OEM dealer. with the Electronic Service Tool and the instrument
cluster uses the signal from the SAE J1587 data
STOP. link, the problem is in one of two locations. Either
the problem is in the wiring from the ECM to the
dash, or the problem is in the dash. The vehicle
i01198290
should be referred to the OEM dealer for service.
Tachometer Circuit - Test Note: Do not disturb the Camshaft Position Sensor
SMCS Code: 7462-081 and the Crankshaft Position Sensor in order to
troubleshoot a tachometer circuit problem. If there
System Operation Description: is a problem that is associated with the Sensors,
refer to Troubleshooting, Engine Speed/Timing
Use this procedure under the following situation: Circuit - Test. Any problem that is associated with
the Camshaft Position Sensor and the Crankshaft
Use this procedure when all of the following Position Sensor will be apparent because of engine
conditions exist: operation with a Diagnostic Code that is present.
There are no diagnostic codes that are associated
with the tachometer circuit.
The ECM is connected to the tachometer.
A problem is suspected.
If the vehicle tachometer is driven by the ECM
the vehicle tachometer will be connected to the
ECM through Connector J1/P1 terminal 38 and/or
terminal 39. Some tachometers require only one of
the ECM tachometer signal lines to operate while
other tachometers may require both of the ECM
tachometer signal lines to operate.

to this procedure:
344
g00649121
Illustration 152
Schematic No. 1 for tachometer
g00649123
Illustration 153
Schematic No. 2 for tachometer

And Wiring.
g00649124
Illustration 154
A. Thoroughly inspect ECM Vehicle Harness B. Perform a 45 N (10 lb) pull test on each of the
Connector J1/P1, the firewall bulkhead wires in the ECM Connector that are associated
connector, and the terminals for the Tachometer with the terminals for the Tachometer:
in the connectors. Refer to Troubleshooting,
Inspecting Electrical Connectors for details. Terminal 38
345
Terminal 39 Repair: Send the vehicle to the OEM dealer in

order to repair the tachometer circuit.
STOP.
for the proper torque of 6.0 Nm (55 lb in). Test Step 3. Use An Electronic Service
Tool And Check The ECM Tachometer
D. Check the harness and wiring for abrasion and Signal.
pinch points from the battery to the ECM.
A. Connect an Electronic Service Tool at the Cab
Expected Result: Data Link Connector.
All connectors, pins and sockets should be B. Turn the Ignition Key Switch to the ON position.
and wiring should be free of corrosion, abrasion C. Access the Tachometer Special Test. Access the
or pinch points. following display screens in order:
Results: Diagnostics
OK Proceed to test step 2. Diagnostic Tests
Not OK Special Test
Repair: Perform the following repair: D. While the dash Tachometer is being monitored,
begin the test.
1. Repair the connectors or wiring and/or replace
the connectors or wiring. Ensure that all of the Expected Result:
connectors are completely coupled. The dash Tachometer indicates approximately 1500
150 rpm and the dash Tachometer is stable.
Results:
STOP.
Yes The ECM and the Tachometer are OK.
Test Step 2. Check The ECM Connection STOP.
To The Tachometer.
Engine rpm Not Indicated or Erratic The
A. Inspect ECM Connector J1/P1. Verify that Tachometer does not indicate an engine rpm or
the connections are present to terminal the Tachometer is erratic. Proceed to test step 4.
39 (TACHOMETER) and/or terminal 38
(TACHOMETER+). Engine rpm Not Within 50 of 1500 rpm The
Tachometer rpm is stable but the Tachometer rpm
Note: Some of the tachometers require only one is not within 50 rpm of 1500 rpm. Proceed to test
signal line to be connected. Either of the ECM step 5.
terminals can be used for this type of tachometer.
The other wire should be left disconnected. If both
wires are connected, and one indicates an open
circuit, repair this line.
Expected Result:
Wires are connected to the ECM terminals for the

tachometer, terminal 39 (TACHOMETER) and/or
terminal 38 (TACHOMETER+).
Results:
Yes The ECM is providing the signal for the

tachometer. Proceed to test step 3.
No The ECM is not connected in order to

supply the signal to the tachometer.
346
Test Step 4. Check The ECM Tachometer

Signal.
g00649125
Illustration 155
Note: Performing certain steps within this procedure Expected Result:

measuring a PWM Duty Cycle. The Multimeter indicates a duty cycle from 30
to 70 percent from each of the terminals for the
A. Disconnect ECM Vehicle Harness Connector Tachometer while the engine is running.
J1/P1.
Results:
B. Connect a 70-Terminal Breakout T to ECM
Vehicle Harness Connector P1. Yes The ECM Tachometer Output is OK.
Connect the ECM Vehicle Harness Connector J1
C. Fabricate two jumper wires 100 mm (4 inch) long. to P1. Proceed to test step 6.
Crimp a Deutsch Pin to one end of each wire.
No
D. Insert one of the jumper wires into terminal
39 (TACHOMETER) of the Breakout T and Repair: Perform the following repair:
insert the other jumper wire into terminal 38
(TACHOMETER+) of the Breakout T. 1. Temporarily connect a test ECM.
Refer to Illustration 155. 2. Remove all jumpers and replace all connectors.
E. Access the Tachometer Special Test. Access the 3. Recheck the system for Active diagnostic
following display screens in order: codes.
Diagnostics 4. Repeat the test step.
Diagnostic Tests 5. If the problem is resolved with the test ECM,

Special Test
F. Attach one of the Multimeter leads to the jumper replace the ECM.
wire from terminal 38.
G. Attach the other Multimeter lead to the jumper
wire from terminal 39. STOP.
H. While the Tachometer Special Test is being run,

observe the reading on the Multimeter.
347
Test Step 5. Inspect The Tachometer Refer to Illustration 155.

Calibration.
C. Check for continuity through the wires to the
A. Determine the tachometer engine speed ECM Connector P1 terminal 39 (TACHOMETER)
calibration setting in pulses per revolution. You and terminal 38 (TACHOMETER+).
may be required to contact the OEM dealer or
you may be required to send the vehicle to the Note: Some of the tachometers require only one
OEM dealer for this information. signal line to be connected. Either of the ECM
terminals can be used for this type of tachometer.
B. Connect an Electronic Service Tool at the Cab The other wire should be left disconnected. If both
Data Link Connector. wires are connected, and one indicates an open
circuit, repair this line.
C. Check the Tachometer Calibration Parameter
on the Customer Parameters screen. Expected Result:
Expected Result: The wires from the ECM to the tachometer are
undamaged.
The tachometer calibration matches the ECM
tachometer calibration. Results:
Results: Yes The wiring is OK. Proceed to test step 7.

Yes The tachometer is correctly calibrated. No The wiring is damaged.
Repair: Perform the following repair: Repair: Perform the following repair:
1. If the Tachometer is correctly calibrated but Either repair the wiring or send the vehicle to the
the Tachometer does not work, replace the OEM dealer. Verify that the repair eliminates the
Tachometer or send the Tachometer to the problem.
OEM dealer for repair.
STOP.
Test Step 7. Check the Tachometer
STOP. Battery Supply.
No The tachometer is not correctly calibrated. A. Connect the tachometer lines to the ECM and
the tachometer.
B. Check the +Battery connections and the Battery
1. Calibrate the tachometer in order to match connections to the tachometer. Include the fuses
the ECM. and the circuit protection.
a. If the Tachometer Calibration is known and Expected Result:

the Tachometer Calibration is within 12.0
to 500.0 pulses per revolution, change the The tachometer is receiving the correct supply
Customer Programmable Parameter of the voltage.
ECM Tachometer Calibration in order to
match the Tachometer. Results:
2. Verify that the repair eliminates the problem. Yes

STOP. Repair: Perform the following repair:
Test Step 6. Check The ECM Connection If the Tachometer is receiving the correct battery
To The Tachometer. voltage but the Tachometer does not work,
replace the Tachometer or send the Tachometer
A. Find the Tachometer Signal connections to the to the OEM dealer for repair.
tachometer.
STOP.
B. Disconnect the wires from the ECM to the
tachometer at the ECM connector and at the No
tachometer.
348
1. Repair the wiring for the battery supply. The accelerator pedal position is less than 65
percent of the programmed value. Refer to the
2. Verify that the repair eliminates the problem. note below.
STOP. Note: JUL99 and newer Personality Modules have

a programmable AT/MT/HT Part Throttle Shift
Speed parameter that provides three different
i01380785
shift modulation settings for the transmission. The
Transmission (AT/MT/HT) Low setting will disable the relay below 65 percent
throttle, the Medium setting below 55 percent
Relay Circuit - Test throttle, and the High setting below 45 percent
throttle.
SMCS Code: 1901-081
The AT/MT/HT transmission interface relay will be
System Operation Description: enabled under any the following conditions:
Use this procedure under the following situation: The engine is running.
Use this procedure to determine if the AT/MT/HT The transmission is in gear or the speed of the
transmission interface relay (output #7) is operating vehicle is greater than 24 km/h (15 mph) (NOV99
correctly. and older Personality Modules).
The following background information is related The accelerator pedal position is greater than 80
to this procedure: percent of the programmed value. Refer to the
note below.
Allison AT/MT/HT transmissions require an input
from the ECM to regulate the transmission shifting. Note: JUL99 and newer Personality Modules have
The ECM monitors various operating parameters a programmable AT/MT/HT Part Throttle Shift
in order to determine if the transmission should Speed parameter that provides three different
use closed throttle shift modulation or full throttle shift modulation settings for the transmission. The
shift modulation. Programming the Transmission Low setting will enable the relay above 80 percent
Style parameter to AT/MT/HT Option1, AT/MT/HT throttle, the Medium setting above 70 percent
Option2, AT/MT/HT Option3, or AT/MT/HT throttle, and the High setting above 60 percent
Option4 activates ECM Output #7 in order to throttle.
control a shift interface relay that is connected to
the Allison transmission. Cruise Control or Vehicle Speed Limiting is
active.
Transmission Style
For engines that have a Full Feature ECM, the disabled when all of the following conditions occur:
Transmission Style must be programmed to one
of the AT/MT/HT options in order for Output #7 The speed of the vehicle is greater than 2 km/h
to control the AT/MT/HT transmission relay. For (1 mph) of the cruise set speed or the vehicle
the Basic (GM) System, Output #7 is always speed limit.
available.
The load factor is less than 75 percent.
Note: The ECM does not communicate with the
Allison AT/MT/HT Transmission through a data link. The engine speed is greater than 2000 rpm.
Cruise Control or Vehicle Speed Limiting is NOT The transmission interface relay will be enabled
active. when the load factor is greater than 98 percent.

disabled if any of the following conditions occur:
The engine is not running.

The transmission is in neutral and the speed of
the vehicle is less than 24 km/h (15 mph) (NOV99
and older Personality Modules).
349
g00729187
Illustration 156
Schematic for the AT/MT/HT Transmission Relay
Test Step 1. Check Electrical Connectors

and Wiring.
A. Thoroughly inspect ECM connectors J1/P1
and the firewall bulkhead connector. Refer
to Troubleshooting, Inspecting Electrical

wires that go to P1:20 or P1:12.
C. Check the ECM connector (Allen Head Screw)


Expected Result:

or pinch points.
Results:

Not OK

Illustration 157
g00729188 seals are properly in place and ensure that the
ECM terminal
350
Verify that the repair eliminates the problem. C. Access the status screen on the Electronic
Service Tool for the AT/MT/HT XMission Interface
STOP. Test.
Test Step 2. Connect An Electronic Note: The Transmission Style must be

Service Tool And Check The Accelerator programmed on Full Feature Systems for the
Pedal Position Sensor . AT/MT/HT XMission Interface Test to be available.
This will allow output 7 to control the AT/MT/HT
A. Ensure that the cruise control switch is off. transmission relay.
B. Connect an Electronic Service Tool at the cab D. Begin the special test for the AT/MT/HT XMission
data link connector. Interface Test while you listen for the solenoids
to click. You may need to be closer to the
C. Turn the ignition key switch to the ON position. transmission in order to hear the click of the relay.
D. Use the following procedure to check the Expected Result:

accelerator pedal position sensor:
The relay activates when the test is enabled.
a. Monitor the duty cycle of the throttle sensor
on the Electronic Service Tool. Access the Results:
display screens in the following order:
Yes The ECM is functioning properly at this
Service time. STOP.
Calibrations No Proceed to Test Step 4.

Throttle Position Test Step 4. Use An Electronic Service
Tool To Check The ECM.
b. While the duty cycle is being monitored
on the Electronic Service Tool, depress the
accelerator pedal and release the accelerator
pedal. Repeat this action several times.
Expected Result:
The duty cycle of the accelerator pedal position

sensor is between 3 percent and 100 percent.
Results:

Not OK
procedure:
Troubleshooting, Accelerator Pedal (Throttle)

g00770060
Illustration 158
STOP.
Breakout T
Test Step 3. Connect an Electronic A. Turn the ignition key switch to the OFF position.
Service Tool and Check the Solenoids
and the Relays. B. Disconnect the ECM engine harness connector
J1/P1.
A. Connect an Electronic Service Tool at the cab
C. Connect a 70-Termial breakout T to the ECM
connector J1/P1.
351
D. Connect a voltage test lamp to terminal 20 5. If the problem is resolved with the test ECM,
(Output 7) and terminal 65 (-Battery) of the reconnect the suspect ECM.
70-Termial Breakout T.
E. Turn the ignition key switch to the ON position. replace the ECM.
F. Access the special test for the AT/MT/HT 7. Verify that the repair eliminates the problem.
XMission Interface Test on the Electronic Service
Tool. STOP.
G. While the voltage test lamp is being observed,

i01474799
cycle the special test to the ON and OFF
positions. Vehicle Speed and
H. Stop the special test. Speedometer Circuit - Test
Note: The Transmission Style must be SMCS Code: 7463-081; 7493-081
programmed on Full Feature Systems for the
AT/MT/HT XMission Interface Test to be available. System Operation Description:
This will allow output 7 to control the AT/MT/HT
transmission relay. Use this procedure under the following situation:
Expected Result: Use this procedure to troubleshoot the system only

under the following conditions:
The voltage test lamp behaves in the following
manner: There is an active diagnostic code.
The voltage test lamp turns on when the test is There is an easily repeated diagnostic code that
active. is associated with the vehicle speed circuit.
The voltage test lamp turns off when the test is Refer to Troubleshooting, Vehicle Speed Circuit -
not active. Calibrate if the vehicle speed is being calibrated
in ppm (pulses per mile) or PPKM (pulses per
Results: kilometer).
Yes The ECM is OK. There is a problem in the The following background information is related
harness. to this procedure:
Repair: Perform the following repair: The vehicle speed circuit consists of the vehicle
speed source and associated wiring. The
Repair the engine harness or replace the engine vehicle speed source is installed by the vehicle
harness. Verify that the repair eliminates the OEM. Usually, a sensor reads movement of the
problem. Transmission output shaft from the teeth on a
chopper wheel. The ECM converts the signal from
STOP. the vehicle speed source into vehicle speed for the
following functions:
test step. If the problem is resolved with the test Cruise Control
ECM, reconnect the suspect ECM. If the problem
returns with the suspect ECM, replace the ECM. Fast Idle
Repair: Perform the following repair: Idle Speed Control
1. Temporarily connect a test ECM. Progressive Shift
2. Remove all jumpers and replace all connectors. Speedometer
3. Recheck the system for Active Diagnostic PTO Operation
Codes.
Vehicle Speed Limiting
Idle Shutdown
352
Operation of the Air Inlet Heater The vehicle speed signal is routed directly into
the ECM at ECM vehicle harness connector J1/P1
Secure Idle Theft Deterrent terminal 32 (vehicle speed in positive) and terminal
33 (vehicle speed in negative).
Trip Data
Speedometer Connection
Maintenance Data
If the vehicle speedometer is driven by the ECM
To begin troubleshooting a vehicle speed problem, output, the vehicle speedometer will be connected
the following information must be determined: to the ECM vehicle harness connector J1/P1
terminal 36 and/or terminal 37. Some speedometers
The problem is electrical or the problem is a require only one of the ECM signal lines to operate.
calibration problem. Other speedometers may require both of the ECM
signal lines to operate.
Electrical problems would be an erratic speed
signal or no speed signal. A calibration problem Speedometer Special Test
would be a stable ECM speed, but an inaccurate
ECM speed. Another calibration problem would be If the vehicle speedometer is driven by ECM
a stable Speedometer speed, but an inaccurate output, the speedometer circuit can be checked
Speedometer speed. by using an Electronic Service Tool. The 55 mph
VSP/Speedometer Test will drive the speedometer
If the problem is related to vehicle speed calibration, to approximately 55 mph under the following
refer to Troubleshooting, Vehicle Speed Circuit - conditions:
Calibration for calibrating the vehicle speed in
PPKM (pulses per kilometer) or ppm (pulses per The 55 mph VSP/Speedometer Test is activated.
mile). The ECM Speedometer output signal is set to
18,600 PPKM (30,000 ppm) for most configurations. The circuit is operating properly.
For GM Truck Manufacturer configurations
with SEP00 or newer software, the output of the The speedometer is operating properly.
speedometer is set to 2,485 PPKM (4,000 ppm).
The ECM speedometer output signal cannot be Note: While the test is active, the odometer will
changed. All speedometers that are driven by the increment mileage.
ECM output (J1/P1 terminal 36 and terminal 37)
must match the fixed output of the ECM for proper Magnetic Sensors
operation.
A magnetic pickup will have only two wires if the
The type of vehicle speed sensor that is installed on magnetic pickup is a single coil magnetic sensor.
the vehicle must be determined. Also, a magnetic pickup will have four wires if the
magnetic pickup is a dual coil magnetic sensor. The
Both single coil magnetic sensors and dual coil magnetic pickup sensor does not require a power
magnetic sensors are commonly used. Caterpillar connection or a ground connection.
recommends single coil magnetic sensors. Some of
the vehicles may provide the vehicle speed through Vehicles with Electronic Vehicle Speed Sources
the Transmission ECM.
For these vehicles, the vehicle speed signal is
You must determine if the vehicle speedometer is provided by an electronic source. The signal is
driven from the ECM. received over a single wire that is connected to
ECM vehicle harness connector J1/P1 terminal 32
The ECM can drive the speedometer through (vehicle speed in positive). No other connection
the connection to ECM connector J1 terminal should be made to this line. A speedometer is an
36 (speedometer positive) and/or terminal 37 example of a connection that should not be made
(speedometer negative). to this line. For this type of signal, the ECM vehicle
harness connector J1/P1 terminal 33 (vehicle speed
Note: The ECM may also drive the speedometer in negative) should not be connected to the ECM
by a connection to the J1587 ATA data link, if the in order to prevent introducing electrical noise into
instrument cluster is capable of interpreting the the circuit.
signal.
Vehicle Speed Circuit Wiring

353
For vehicle speed problems on trucks that are

equipped with either of these vehicle speed
sources, first inspect the wiring from the electronic
source to the engine ECM for open circuits or short
circuits.
With SEP00 and newer software, the ECM can be

configured to receive vehicle speed information
from an Electronic Transmission Control Unit via the
J1939 data link. The transmission must be capable
of supporting the J1939 ETC1 Broadcast Message
(PGN 61,442 Bytes 2 & 3). This message provides
the speed of the transmission output shaft. This
feature requires the hardware for the J1939 data
link to be installed in the chassis of the vehicle. This
also requires a transmission that is electronically
controlled and capable of supporting the necessary
J1939 protocol.
When the engine is configured for the J1939

option, the circuit for the ECM vehicle speed input
(terminals 32 and 33) will be ignored. The ECM uses
the Vehicle Speed Cal (J1939-Trans) parameter
value in order to calculate vehicle speed. The ECM
uses the parameter value and the speed of the
output shaft that is received over the J1939 data
link to calculate the vehicle speed. The Vehicle
Speed Cal (J1939-Trans) parameter is based on
the revolutions per mile of the output shaft. There
are several methods that can be used to arrive
at this calibration value. Refer to Troubleshooting,
Vehicle Speed Circuit - Calibrate for details.
Regardless of the source that is used to determine

vehicle speed, the ECM uses the calculated value
for the vehicle speed in the same manner to control
several features and functions. The diagnostics for
vehicle speed function very similarly when either a
hard-wired signal is provided to the ECM from a
speed sensor, or a message is sent to the ECM via
the J1939 data link. If the ECM detects a loss of
vehicle speed or a value that is invalid, a fault code
will be logged in order to alert the operator or the
technician of the presence of a problem.
g00643046
Illustration 159
Schematic for a single coil speed sensor and an ECM driven speedometer
354
g00643048
Illustration 160
Schematic for a single coil speed sensor and a second single coil sensor for a speedometer
g00643050
Illustration 161
Schematic for a single coil speed sensor and a Data Link driven speedometer
g00643051
Illustration 162
Schematic for an Electronic vehicle speed source and an ECM driven speedometer
355
g00643052
Illustration 163
Schematic for an Electronic vehicle speed source and a speedometer
g00643054
Illustration 164
Test Step 1. Inspect Electrical Connectors C. Check the ECM connector (allen head screw) for
And Wiring. the proper torque of 6.0 Nm (55 lb in).
connector J1/P1, the firewall bulkhead pinch points from the sensor to the ECM.
connector and the terminals for vehicle speed
(terminals 32 and 33) in the connectors. Refer Expected Result:
to Troubleshooting, Inspecting Electrical
Connectors for details. All connectors, pins and sockets should be
B. Perform a 45 N (10 lb) pull test on each of the and wiring should be free of corrosion, abrasion
wires in the ECM connector that are associated or pinch points.
with the vehicle speed sensor.

356
Results: Result 3 The Electronic Service Tool status screen

agrees with the actual speed, but the ECM driven
OK Proceed to Test Step 2. speedometer is incorrect or inoperable.
Not OK Result 4 The speed that is displayed on the

Electronic Service Tool status screen is not present,
Repair: Perform the following repair: unstable, or erratic.
Repair the connectors or wiring and/or replace Results:

seals are properly in place and ensure that the Result 1 There is not a vehicle speed problem
connectors are completely coupled. at this time. If a problem still exists, continue
troubleshooting until the condition is resolved.
Verify that the repair eliminates the problem. STOP.
STOP. Result 2 Proceed with vehicle speed calibration

and adjustment.
Test Step 2. Determine The Type Of
Vehicle Speed Problem. Repair: Perform the following diagnostic
procedure:
A. Perform a Dynamometer test on the vehicle or
perform a road test on the vehicle. Compare Troubleshooting, Vehicle Speed Circuit -
the vehicle speed on the Electronic Service Tool Calibrate
status screen against the speedometer. Also,
compare the vehicle speed on the Electronic STOP.
Service Tool status screen against the actual
vehicle speed. The actual vehicle speed can Result 3 Proceed to Test Step 3.
be measured on a dynamometer or the actual
vehicle speed can be measured by a stopwatch. Result 4 Proceed to Test Step 4.
B. Monitor the vehicle speed status on an Electronic
Service Tool while the vehicle is parked and the
engine is running.
C. Operate various electrical devices in the vehicle

while the vehicle speed is being monitored. In
order to operate the various electrical devices,
cycle the electrical devices to the ON position
and the OFF position.
D. Increase the engine rpm a few times and

decrease the engine rpm a few times.
Note: If the operation of a specific electrical

device is producing a vehicle speed problem, the
electrical device may be the source of an electrical
noise problem. An electrical noise problem is
also a possibility if increasing the engine rpm on
a stationary vehicle produces a vehicle speed
problem.
Expected Result:
Result 1 The speed that is displayed on the

Electronic Service Tool status screen and the speed
of the ECM driven speedometer are stable and both
speeds agree with the actual speed.

and speed is stable, but incorrect.
357
Test Step 3. Use The Special Test Of The

Electronic Service Tool To Check The
Speedometer.
g00723985
Illustration 165
A. Inspect vehicle harness connector P1. Observe Repair: Perform the following repair:
whether connections are present to terminal
36 (speedometer positive) and/or terminal 37 If the ECM is not connected to the OEM
(speedometer negative). speedometer, send the vehicle to the OEM dealer
for repair of the speedometer.
If there is a connection to either of the
speedometer terminals continue with the STOP.
procedure.
No speed indicated If OEM truck wiring
B. Connect an Electronic Service Tool to the cab diagrams are available, trace the wiring to the
data link connector. speedometer and repair the speedometer, as
required. STOP.
C. Access the 55 mph VSP/Speedometer Test by
Accessing the following display screens in order: Speed present, but not in range
Diagnostics Repair: Perform the following diagnostic
procedure:
Diagnostic Tests
Special Test menu Calibrate
D. Activate the test and observe the speedometer. STOP.
Note: Some types of speedometers only require Test Step 4. Determine The Type Of
one ECM signal line to be connected to the Vehicle Speed Circuit.
speedometer. Either of the ECM terminals can be
used for these speedometers. A. Inspect the vehicle wiring for the type of vehicle
speed circuit that is being used.
Compare the vehicle speed circuit with the
Expected Result: detailed circuit schematics:
The speedometer indicates 80 to 96 km/h (50 to Schematic 1 Refer to Illustration 159.

60 mph).
Schematic 2 Refer to Illustration 160.
Results:
Schematic 3 Refer to Illustration 161.
Yes The ECM is providing the signal for the
speedometer and the wiring and the speed are Schematic 4 Refer to Illustration 162.
OK. Send the vehicle to the OEM dealer for repair
of the speedometer. STOP. Schematic 5 Refer to Illustration 163.
ECM not connected to speedometer

358
Select the schematic that is similar to the circuit If the sensor is damaged, replace the damaged
that is being repaired. sensor or send the vehicle to the OEM dealer for
repairs.
Expected Result:
Verify that any repair eliminates the problem.
RESULT 1 The vehicle speed circuit is similar to
Schematic 1, 2, or 3. STOP.
RESULT 2 The vehicle speed circuit is similar to Test Step 6. Inspect The Passive Magnetic
Schematic 4 or 5. Speed Sensor For Vehicle Speed.
RESULT 3 The ECM is configured for the J1939 A. Remove the vehicle speed sensor from the
Trans option. transmission and inspect the vehicle speed
sensor for steel shavings, debris, or damage.
Results:
Note: Shavings and debris on the sensor may
Result 1 Proceed to Test Step 5. occur unless the transmission fluid is drained and
replaced according to the maintenance schedule.
Result 2 The vehicle speed circuit is similar to
Schematic 4 or 5. Proceed to Test Step 7. B. Wipe off the sensor until the sensor is clean.
Test the sensor according to the manufacturers
Result 3 Proceed to Test Step 9. instructions. The sensor is OEM supplied.
Test Step 5. Measure Vehicle Speed Note: If the gap between the vehicle speed sensor
Sensor Resistance At The Sensor. and the chopper wheel is too small, the sensor
may be damaged. Also if the gap between the
A. Disconnect the vehicle speed sensor from the vehicle speed sensor and the chopper wheel is too
vehicle harness. small, the sensor may create a signal due to the
vibration of the chopper wheel. This will cause a
B. Thoroughly inspect the connector. Ensure that vehicle speed signal when the vehicle is parked. If
the connector terminals are free of corrosion the vehicle is parked and a vehicle speed signal is
and ensure that the connector terminals are fully produced, back out the sensor from the wheel until
seated into the housing of the connector. Repair the signal disappears. Use caution. backing out
the connector terminals or replace the connector the sensor too far may cause a loss of the vehicle
terminals, as required. speed signal. Back out the sensor no more than
one turn to one and one quarter turns.
C. Measure the resistance between the two
terminals of the sensor connector. The sensor Expected Result:
resistance measurement should be 100 to 4500
Ohms. The vehicle speed sensor is correctly installed and
undamaged.
D. Reverse the meter leads and measure the
resistance. Switching the probes should not Results:
change the resistance measurement by more
than 10 Ohms. OK Proceed to Test Step 7.
Expected Result: Not OK
The sensor resistance that is measured is between Repair: Perform the following repair:
100 and 4500 Ohms and the sensor resistance
that is measured is within 10 Ohms with the meter If the sensor is damaged, replace the damaged
probes in either position. sensor or send the vehicle to the OEM dealer for
repairs.
Results:
OK Reconnect the sensor to the vehicle
harness. Proceed to Test Step 6. STOP.
Not OK
359
Test Step 7. Test ECM Vehicle Speed

Inputs By Using The Speedometer
Special Test.
g00643436
Illustration 166
Jumper wire locations for breakout T
B. Fabricate two jumper wires 100 mm (4 inch) long. The Electronic Service Tool indicates a constant
Crimp a Deutsch pin to both ends of the wires. vehicle speed between 80 to 96 km/h (50 to 60 mph)
when the jumper wires from the Speedometer circuit
C. Disconnect vehicle harness connector P1 from are connected.
the ECM.
Results:
D. Connect a 70-Terminal breakout T to ECM
connector J1 and connect P1 to the breakout T. OK The ECM is operating correctly. The source
of the problem is either the wiring or the source
E. Install one jumper into the breakout T in order to of the problem is the vehicle speed sensor.
connect terminal 36 (speedometer positive) to
terminal 32 (vehicle speed in positive). Install Repair: Perform the following repair:
the other jumper into the breakout T in order to
connect terminal 37 (speedometer negative) to If the sensor is damaged, replace the damaged
terminal 33 (vehicle speed in negative). sensor or send the vehicle to the OEM dealer for
repairs.
STOP.
data link connector. Not OK Recheck the connections of the jumper
wires. Leave the jumper wires installed in the
H. Access the 55 mph VSP/Speedometer Test by breakout T. Disconnect the breakout T. Proceed
Accessing the following display screens in order: to Test Step 8.
Diagnostics Test Step 8. Test The ECM Vehicle Speed

Inputs When The Test ECM Is Installed.
Diagnostic Tests
A. Connect a test ECM and reconnect the breakout
Special Test menu T.
I. Activate the test and observe the vehicle speed B. Install one jumper into the breakout T in order to
on the vehicle speed status screen. connect terminal 36 (speedometer positive) to
terminal 32 (vehicle speed in positive). Install
the other jumper into the Breakout T in order to
connect terminal 37 (speedometer negative) to
terminal 33 (vehicle speed in negative).

360
C. Turn the ignition key switch to the ON position. E. Verify that the J1939 data link is connected to
the ECM and that the data link is functioning
D. Connect an Electronic Service Tool to the cab properly. Refer to Troubleshooting, Powertrain
data link connector. Datalink Circuit - Test.
E. Access the 55 mph VSP/Speedometer Test by F. Compare the Vehicle speed reading on the
Accessing the following display screens in order: Electronic Service Tool status screen to the
vehicle speedometer and the actual vehicle
Diagnostics speed.
Diagnostic Tests Expected Result:
Special Test menu The Vehicle Speed on the Electronic Service

Tool status screen is within 8 km/h (5 mph) of
F. Activate the test and observe the vehicle speed the speedometer and the actual vehicle speed
on the vehicle speed status screen. readings.
The Electronic Service Tool indicates a constant Yes The ECM is receiving J1939 data from the
vehicle speed between 80 to 96 km/h (50 to 60 mph) Transmission ECM. Send the vehicle to the OEM
when the jumper wires from the Speedometer circuit dealer for repair of the wiring for the speedometer
are connected. or for the repair of the transmission vehicle speed
sensor. STOP.
Results:
OK
Repair: Connect a test ECM. Program all of the
Repair: Perform the following repair: parameters that are related to vehicle speed to
the same setting as the original ECM. Repeat
Reconnect the suspect ECM. If the problem the previous test step. If the test ECM functions
returns with the suspect ECM, replace the ECM. properly and the original ECM does not function
properly, replace the ECM. If the test ECM does
STOP. not correct the problem, send the vehicle to the
OEM dealer for repair of one of the following
Not OK Recheck the connectors. Continue components:
troubleshooting until original condition is resolved.
STOP. speedometer
Test Step 9. Verify Correct Programming wiring
for the J1939 Vehicle Speed Calibration
Parameter Transmission ECU
A. Connect an Electronic Service Tool to the cab transmission speed sensor
wiring for the J1939 data link
B. Access the list of Configuration Parameters
on the service tool and verify that the Vehicle STOP.
Speed Input parameter is programmed to the
J1939 Trans option.
i01479760
C. Verify that the Powertrain Datalink parameter is

programmed to J1939.
Wait To Start Lamp Circuit -
Test
D. Verify that the correct value is used for the
Vehicle Speed Cal (J1939-Trans) parameter. SMCS Code: 7431-081
Refer to Troubleshooting, Vehicle Speed Circuit
- Calibrate for details. System Operation Description:

361

if the Wait to Start Lamp is operating incorrectly.
The output 9 (terminal 31) can be used as a fast idle

lamp or a Wait to Start Lamp output. The Output
#9 parameter defaults to Fast Idle Lamp, but the
parameter can be programmed to operate as a wait
to start lamp.
Note: When the Truck Manufacturer is programmed

to GM configurations the Output #9 parameter is
unavailable. The Output #9 parameter functions
as fast idle lamp output.
If the Output #9 parameter is programmed to

Wait To Start Lamp, the ECM will turn on output 9
when the air inlet heater is operating and the engine
is not running. The wait to start lamp functions
similarly to the lamp for the air inlet heater that can
be installed in parallel with the relay for the air inlet
heater circuit. The wait to start lamp illuminates only
when the engine is not running. The lamp for the
air inlet heater illuminates when the relay for the air
inlet heater is energized.

terminal is connected to the ECM at the vehicle
harness connector J1/P1 at terminal 31.
The ECM provides a path to ground in order to turn Illustration 168 g00770189
on the lamp.
And Wiring.
connector J1/P1, the firewall bulkhead connector,
or the wait to start lamp. Refer to Troubleshooting,

with the wait to start lamp.
g00770585 C. Check the ECM connector (allen head screw) for

Illustration 167

pinch points from the battery to the ECM.
Expected Result:

or pinch points.
362
Results: Test Step 3. Test The Wait to Start Lamp

Circuit.
Not OK
STOP.

Of The Wait to Start Lamp.
A. Connect an Electronic Service Tool. Access the
configuration screen and ensure that the Output
#9 parameter is programmed to Wait To Start
Lamp.
B. Turn the ignition key switch to the OFF position

for ten seconds. Turn the ignition key switch to
the ON position. Illustration 169
g00770210

C. The wait to start lamp should illuminate for
approximately two seconds when the key switch
is turned on. If conditions require the air inlet
J1/P1.
heater to turn on, the wait to start lamp should
remain illuminated until the air inlet heater turns
off or the engine is started.
Expected Result:
C. Insert the jumper into terminal 31 of connector
P1.
The wait to start lamp turns on and the wait to start
lamp turns off per the above description.
D. Connect the other end of the jumper wire to
terminal 65 (battery) of connector P1.
Results:
Yes The wait to start lamp appears to operating
correctly at this time. STOP.
Expected Result:
Result 1 The wait to start lamp turns on while the

jumper is connected to both sockets. Also, the wait
to start lamp turns off when the jumper is removed
from one of the sockets.
Result 2 The lamp does not turn on while the

jumper is connected to both sockets.
Result 3 The lamp will stay on while the ECM

vehicle harness connector is disconnected.
363
Results: D. The test lamp should turn on. If the test lamp
Result 1 The wait to start lamp is functioning the wiring to the ECM is faulty. Continue with this
properly. Proceed to Test Step 4. step if the lamp turns on.
Result 2 The lamp did not turn on. The vehicles E. Leave the probe of the test lamp connected to
lamp circuit is not functioning properly. The lamp terminal 52 (unswitched +battery).
is probably burned out or there is a problem in
the wiring from the cab to either the ECM or the F. Connect the other probe of the test lamp to
+Battery connection. Repair the lamp circuit or terminal 31 (output 9) of the breakout T.
STOP. Refer to Illustration 170.
Result 3 G. Turn the ignition key switch to the OFF position.
Repair: Perform the following diagnostic H. Connect an Electronic Service Tool. Access the
procedure: configuration screen and ensure that the Output
#9 parameter is programmed to Wait To Start
The circuit between the ECM and the lamp is Lamp.
send the vehicle to the OEM dealer for repairs. I. Turn the ignition key switch to the OFF position
for ten seconds. Turn the ignition key switch to
STOP. the ON position.
Test Step 4. Check ECM Operation Of J. The wait to start lamp should illuminate for
Wait to Start Lamp. approximately two seconds when the key switch
is turned on. If conditions require the air inlet
heater to turn on, the wait to start lamp should
remain illuminated until the air inlet heater turns
off or the engine is started.
Expected Result:
Results:

problem in the vehicle wiring or the lamp. STOP.
No
that the Output #9 parameter is programmed to
Wait To Start Lamp. Check the ECM operation
of the PTO Switch ON Lamp when the test ECM
g00770221 is installed. If the problem is resolved with the test
Illustration 170
ECM, reconnect the suspect ECM. If the problem
ECM breakout T-connector returns with the suspect ECM, replace the ECM.
A. disconnect ECM vehicle harness connector STOP.
j1/p1.
B. Insert a 70-Terminal breakout T between ECM i01476290

harness connector P1. Warning Lamp Circuit - Test
C. Connect one probe of the voltage test lamp to SMCS Code: 7431-081
terminal 65 (-battery). Connect the other probe of
the voltage test lamp to terminal 52 (unswitched System Operation Description:
364
Use the following information in order to determine If the Customer Parameter for Engine Monitoring
if the warning lamp is operating incorrectly: is programmed to DERATE or SHUTDOWN,
the lamp flashes whenever Engine Monitoring is
The following background information is related derating engine speed, vehicle speed, and power.
If the Customer Parameter for Engine Monitoring is
Warning Lamp Operation programmed to SHUTDOWN, the warning lamp
will continue flashing after the derate mode until
A warning lamp is required if the Engine Monitoring the engine is shut down. Refer to Troubleshooting,
feature is used. The warning lamp indicates an System Overview.
active problem with one of the monitored conditions
such as high coolant temperature. A flashing Electrical Connection of Lamps
warning lamp indicates that the engine is derating
power. The warning lamp will turn on for a minimum One terminal of the lamp must be connected to
of two seconds after the engine has started. battery voltage through the vehicle wiring. The
other terminal is connected to the ECM at the ECM
With SEP00 software and newer software, an vehicle harness connector J1/P1 at terminal 29
option is available for the GM Truck Manufacturer (warning lamp).
configuration that allows the warning lamp output
to be configured for use as an output for thehigh The ECM provides a path to ground in order to turn
coolant temperature warning lamp. The Engine the lamp ON.
Monitoring Lamps parameter must be programmed
to the Warning Lamp option for standard operation
of engine monitoring. If the Engine Monitoring
Lamps parameter is programmed to the HIgh
Coolant Temp Warning Lamp option, the output is
used as an interface to the GM shutdown system.
Refer to Troubleshooting, High Coolant Temp
Warning Lamp Output Circuit - Test for details.
Operation Of Engine Monitoring
When the ECM has detected an engine condition

that exceeds the acceptable limits, the warning
lamp will turn on. The activation of the lamp depends
on the existing conditions and the programming of
g00769338
the parameter for Engine Monitoring. The lamp will Illustration 171
activate in one of the following modes:
The lamp not only turns on, but the lamp stays on.
The lamp will flash on and off.
If the lamp turns on continuously, the engine is in
warning mode. If the lamp begins to flash, the ECM
has begun to derate engine speed, vehicle speed,
or power.
If the parameter for Engine Monitoring is

programmed to WARNING, the lamp will not
flash. The lamp only flashes when the engine is
programmed to DERATE or SHUTDOWN.
If the Customer Parameter for Engine Monitoring

is programmed to WARNING, DERATE, or
SHUTDOWN the lamp will turn on when a warning
condition exists. The lamp will be turned on
continuously while a warning condition exists.
365
Results:

Not OK
STOP.

Of The Warning Lamp.
A. Monitor the Check Engine Lamp. Turn the ignition
key switch to the ON position, while the engine is
OFF. The lamp should turn on for five seconds.
Then, the lamp should turn off.
The lamp will continue flashing if there is an

active diagnostic code. If there is an active
diagnostic code, connect an Electronic Service
Tool in order to read the active diagnostic code.
Troubleshoot the problem.
Note: The warning lamp will not turn on until the

engine is cranked.
B. Connect an Electronic Service Tool in order

to verify that the Engine Monitoring has
been programmed to WARNING, DERATE,
or SHUTDOWN. If Engine Monitoring is
Illustration 172 g00769348 programmed to OFF, the warning lamp is not
used and the ECM will not turn on the lamp.
And Wiring. While the warning lamp is being observed, start
the engine. The warning lamp should turn on
A. Thoroughly inspect ECM vehicle harness for a minimum of two seconds after the engine
connector J1/P1, the firewall bulkhead connector, starts. Then, the warning lamp should turn off.
and terminal 29. Refer to Illustration 172. If the lamp remains off, immediately shut down
Refer to Troubleshooting, Inspecting Electrical the engine.
Expected Result:
wires in the ECM connector that is associated The warning lamp turns on and the warning lamp
with the suspect terminal for the lamp. turns off per the above description.
Refer to Illustration 172. Results:
C. Check the ECM connector (allen head screw) for OK The lamp appears to operating correctly
the proper torque of 6.0 Nm (55 lb in). at this time. STOP.
D. Check the harness and wiring for abrasion and Not OK The lamp does not turn on. Proceed
pinch points from the battery to the ECM. to Test Step 3.
Expected Result: Not OK The lamp stays on.
All connectors, pins and sockets should be Repair: Perform the following diagnostic
completely coupled and/or inserted and the harness procedure:
or pinch points.
366
Use an Electronic Service Tool in order to Result 2 The lamp does not turn on while the
determine if an Engine Monitoring condition jumper is connected to both sockets.
is causing the lamp to turn on. If an Engine
Monitoring condition is not present, perform the Result 3 The lamp will stay on while the ECM
following diagnostic procedure. vehicle harness connector is disconnected.
Proceed to Test Step 3. Results:
Test Step 3. Test The Lamp Circuit. Result 1 The warning lamp circuit is functioning
properly. Proceed to Test Step 4.
Result 2 The lamp did not turn on. The vehicles

lamp circuit is not functioning properly. The lamp
is probably burned out or there is a problem in
the wiring from the cab to either the ECM or the
+battery connection. Repair the lamp circuit or
STOP.
Result 3
procedure:

STOP.
Illustration 173
g00769361 Test Step 4. Check ECM Operation Of The
Warning Lamp.

J1/P1.

C. Insert the jumper into terminal 29 (warning lamp)

of connector P1. The jumper can be inserted
into the following terminals in order to test the
appropriate lamp circuit:

terminal 65 (-battery).


g00769368
Illustration 174
Expected Result: ECM breakout T-connector
Result 1 The warning lamp turns on while the A. Disconnect ECM vehicle harness connector
jumper is connected to both sockets. Also, the J1/P1.
warning lamp turns off when the jumper is removed
from one of the sockets.
367
B. Insert a 70-Terminal breakout T between the

ECM vehicle harness connectors J1 and P1.
C. Connect a test light probe to terminal 65

(-battery) and connect the other probe to terminal
52 (unswitched +battery) of the breakout T.
D. The test lamp should turn on. If the test lamp

step if the lamp turns on.
E. Leave the test light probe connected to terminal

52 (unswitched +battery).
F. Connect the other test light probe to terminal 29

on the breakout T.
G. Watch the voltage test lamp. Start the engine.

The lamp should turn on for a minimum of two
seconds after the engine starts. Then, the lamp
should turn off. Immediately turn the engine off
if the lamp continues to stay on. Connect an
Electronic Service Tool in order to determine the
cause of the problem.
Expected Result:
The warning lamp turns on and the warning lamp

turns off per the above description.
Results:

problem in the vehicle wiring or the lamp. Repair
the vehicle wiring or the lamp, as required. STOP.
No Temporarily connect a test ECM. Ensure

that the Engine Monitoring parameter of the test
ECM matches the Engine Monitoring parameter
of the suspect ECM. Check the ECM operation of
the lamp when the test ECM is installed. If the
problem is resolved with the test ECM, reconnect
the suspect ECM. If the problem returns with the
368
Calibration Procedures Table 150

Required Special Tools
i01370493 Part Number Description
Engine Speed/Timing Sensor - 6V-2197 Magnetic Transducer
Calibrate 7X-1695 Cable

7X-1111 Grommet
SMCS Code: 1912-524
System Operation Description: 170-3519 Harness

Test Step 1. Install The 7X-1171
Use this procedure if any of the following conditions Transducer Adapter.
exist:
22-13 Check Timing Sensor Calibration (42)
B. Remove the Timing Calibration Plug from the left
The ECM has been replaced. or right front face of the flywheel housing.
Work has been done to the engine drive train C. Install the 7X-1171 Transducer Adapter into the
(front). hole for the plug.
A timing calibration must be performed under the Results:

following conditions:
The ECM requires replacement and the ECM
will not communicate with the Electronic Service Test Step 2. Install The 6V-2197 Magnetic
Tool in order to allow the timing calibration to be Transducer On The Engine.
copied when the ET Copy Configuration-ECM
Replacement Feature is used. A. Put a 2D-6392 O-Ring Seal on the end of the
Magnetic Transducer.
Work has been performed on the engine drive
train (front). Note: A small amount of clean engine oil will allow
the seal to slide onto the transducer more easily.
Note: The Timing Calibration will not increase the
available engine power or the Timing Calibration B. Push the magnetic transducer through the
will not decrease the available engine power. adapter until the magnetic transducer comes in
Do not expect an increase in power due to the contact with the outermost portion of the flywheel
performance of the timing calibration. timing calibration ring. Move the O-Ring Seal
downward against the adapter.
Replacement ECM
C. Withdraw the magnetic transducer 1.0 mm
If a replacement ECM is required, the ECM (0.04 inch) and hand tighten the nut on the
parameters and the timing calibration can adapter sleeve in order to secure the magnetic
be transferred from the suspect ECM to the transducer in place.
replacement ECM. Timing calibration will NOT be
necessary. This feature requires the Caterpillar D. Check that the probe is properly installed and
Electronic Technician (ET) and this feature is only snug. The probe should not move when the
possible if the existing ECM can communicate with engine is started.
the Caterpillar Electronic Technician (ET).
E. Connect the 6V-2197 Magnetic Transducer to
the 7X-1695 Cable.
F. Remove the access cover from the J400 Engine

Timing Calibration Connector.
Note: Some engines do not have a J400 Engine

Timing Calibration Connector in the engine harness.
A 170-3519 Harness is required.
369
Results: Note: To perform a timing calibration, the engine rpm

must remain as steady as possible at approximately
OK Proceed to test step 3. 1100 rpm. This can be performed by using the Idle
engine governor or a steady foot on the accelerator
Test Step 3. Start The Engine And pedal. Any changes to engine rpm that are more
Allow The Coolant To Reach Operating than 100 rpm will slow down the procedure. These
Temperature. changes will also reduce the accuracy of the
procedure.
A. Start the engine and run at low idle until the
engine has warmed up enough to exit Cold C. Connect the 7X-1695 Cable for the 6V-2197
Mode operation. An Electronic Service Tool Magnetic Transducer to the J400 Speed/Timing
status screen will display COLD MODE in the Calibration Connector.
upper corner when Cold Mode operation exists.
The engine will adjust idle rpm from Cold Mode D. Ensure that all of the connections are made
idle to the programmed Low Idle rpm when Cold correctly.
Mode operation is complete.
Results:
B. Check for ACTIVE diagnostic codes. Use the
procedures in this manual to troubleshoot and OK Proceed to test step 5.
repair any ACTIVE diagnostic codes before
attempting a calibration check. The engine must Test Step 5. Calibrate the Speed/Timing
not have any diagnostic fault conditions that are Sensor.
present during the timing calibration except the
following condition: A. To calibrate the timing to the correct setting,
select space on the Electronic Service Tool.
22-13 Check Timing Sensor Calibration (42) Wait until the Electronic Service Tool indicates
that the timing is CALIBRATED.
C. After the engine has warmed up, set the engine
speed to 1100 rpm by using the Cruise Control Note: If the Electronic Service Tool display reads
Switches or by using the accelerator pedal. CALIBRATION UNSUCCESSFUL, the electronic
injection timing has not been set. Recheck the
Note: The engine rpm must be steady within the tool installation and tool operation and try again to
1000 to 1200 rpm range in order to perform a timing calibrate electronic injection timing. If the crankshaft
calibration. and camshaft gears have been reassembled
incorrectly, the engine will not calibrate.
Results:
If the timing calibration has been successfully
OK Proceed to test step 4. completed, do not exit the Timing Calibration
Screen on the Electronic Service Tool until you
Test Step 4. Connect An Electronic have disconnected the 7X-1695 Cable for the
Service Tool. 6V-2197 Magnetic Transducer from the P400
Speed/Timing Calibration Connector.
Data Link Connector. Expected Result:
B. After the engine has exited Cold Mode operation, The Timing Calibration Procedure was completed
access the Timing Calibration Screen on the successfully.
display screens in order: Results:
Service OK The Timing Calibration Procedure was

completed successfully. Proceed to test step 6.
Calibrations
Not OK
Timing Calibration
Repair: Perform the following procedure:
370
1. Verify that the engine rpm was stable during i01476388

the testing ( 50 rpm). If the engine rpm
was unstable or the engine rpm could not Vehicle Speed Circuit -
be controlled within 50 rpm because of
mechanical factors or electrical factors, refer
Calibrate
to Troubleshooting, Engine Misfires, Runs SMCS Code: 7493-524
Rough or Is Unstable.
2. If all of the problems have been corrected but
the timing can not be calibrated, check the The ECM uses vehicle speed information for the
cable of the 6V-2197 Magnetic Transducer following features:
and check the 6V-2197 Magnetic Transducer
in order to verify that the Magnetic Transducer Cruise Control
is not bent. If the 6V-2197 Magnetic
Transducer is not bent, restart this procedure. Fast Idle Control
STOP. Idle Speed Control
Test Step 6. Disconnect The 6V-2197 PTO Operation
Magnetic Transducer Before Exiting The
Monitor/Calibrate Timing Screen On Vehicle Speed Limiting
Speedometer
A. Disconnect the Timing Probe from the J400
Engine Timing Calibration Connector. Progressive Shift
B. Install the cover for the J400 connector. Idle Shutdown
C. Exit the Timing Calibration Screen on the Operation of the Air Inlet Heater
Secure Idle Theft Deterrent
Note: Exiting the Timing Calibration Screen on the
Electronic Service Tool will drop the engine rpm Trip Data
to the programmed Low Idle if the Cruise Control
Switches were used to maintain engine rpm during Maintenance Data
calibration. This is normal.
With SEP00 and newer software, there are two
Expected Result: different methods that can be used to obtain the
information for the ECM to use for calculating
The magnetic transducer was disconnected before vehicle speed. The ECM can calculate vehicle
exiting the Timing Calibration Screen on the speed by either of the following means:
The ECM monitors the signal from a vehicle
Results: speed sensor in pulses per kilometer (mile). The
vehicle speed sensor is connected to the ECM
OK STOP. vehicle speed input circuit (terminals 32 and 33).
This is the Vehicle Speed Calibration option.
Not OK If the magnetic transducer is still
installed after exiting the Timing Calibration The ECM receives a J1939 Datalink Broadcast
Screen on the Electronic Service Tool, Vehicle Message from the Transmission ECU that
Speed Diagnostic Codes may be generated. indicates revolutions per kilometer (mile) of the
transmission output shaft. This option is only
Repair: If Vehicle Speed Diagnostic Codes are available with SEP00 and newer software. This is
generated, the Vehicle Speed Diagnostic Codes the Vehicle Speed Cal (J1939-Trans) option.
should be cleared.
STOP.
371
Each of these methods require a specific calibration Option or from the Vehicle Speed Cal
number to be programmed into the ECM to calculate (J1939-Trans) Option.
vehicle speed. For the Vehicle Speed Calibration
option that uses the vehicle speed sensor, the A. Connect an Electronic Service Tool to the cab
ECM must know the number of pulses that are data link connector. If the software for the ECM
produced by the vehicle speed sensor during each is older than SEP00, proceed to Test Step 3.
kilometer (mile) of travel by the vehicle. In order
to find the number of pulses that are produced B. If SEP00 or newer software is used in the ECM,
by the sensor, multiply the tire size by the axle access the Configuration Parameter List. View
ratio. Multiply the number that was obtained in the the Vehicle Speed Input parameter. Determine
previous calculation by the number of teeth on the if the vehicle is configured to use the Vehicle
output shaft that is used by the sensor to obtain the Speed Calibration option, J1/P1:32&33 or the
pulses. For the Vehicle Speed Cal (J1939-Trans) Vehicle Speed Cal (J1939-Trans) option.
option, the ECM must know the number of times
that the output shaft revolves per kilometer (mile) of Expected Result:
travel by the vehicle. This can be calculated by one
of the following methods: The ECM is using software that is dated prior to
SEP00 or the ECM is configured to use the Vehicle
Divide the pulses per kilometer (mile) of the Speed Calibration option.
sensor on the transmission output shaft by the
number of teeth on the transmission output shaft. Results:
Multiply the axle ratio by the number of revolutions Yes Proceed to Test Step 3.
per kilometer (mile) of the tire.
No The ECM is configured to use the Vehicle
The ECM calculates vehicle speed by converting the Speed Cal (J1939-Trans) option. Proceed to Test
vehicle speed signal to kilometers per hour (km/h) Step 2.
or miles per hour (mph). The conversion factor is
customer programmable and the conversion factor Test Step 2. Calculate the Revolutions
is stored in pulses per km (PPKM) or pulses per Per Kilometer (Mile) of the Transmission
mile (PPM). Output Shaft
The tire revolution variable could be affected by A. The correct revolutions per kilometer (mile) of
changing from bias ply tires to radial tires, and the transmission output shaft must be entered
vice versa. Also, changing to low profile radial for the Vehicle Speed Cal J1939-Trans setting.
tires could affect the tire revolution variable. This If this value is unknown, either of the following
result may change the actual vehicle speed which calculations can be used to obtain the correct
could result in performance complaints or fuel setting:
consumption complaints. If the tire configuration has
been changed, determine the new tire revolution Divide the pulses per kilometer (mile) of the
variable. Enter the new value in pulses per km sensor on the transmission output shaft by the
(PPKM) or pulses per mile (PPM). The preferred number of teeth on the transmission output
method is obtaining the data from the individual shaft.
tire manufacturers for the specific tire that is being
used. Multiply the axle ratio by the number of
revolutions per kilometer (mile) of the tire.
Note: The ECM speedometer signal is set to 18,600
pulses per km (PPKM) or 30,000 pulses per mile B. Program the calculated value into the ECM.
(PPM). For GM Truck Manufacturer configurations
with SEP00 or newer software, the output of the Expected Result:
speedometer is set to 2,485 PPKM (4,000 ppm).
This setting cannot be changed. All speedometers The value is within the valid range of the ECM.
that are driven by the ECM output (J1/P1 terminal
36 and terminal 37) must match the fixed output of Results:
the ECM for proper operation.
Yes Once the value is entered, verify that the
Test Step 1. Determine if the ECM ECM is accurately measuring vehicle speed.
Receives the Vehicle Speed Input Proceed to Test Step 4.
from the Vehicle Speed Calibration
No Recalculate the value and re-enter the
correct value into the ECM. STOP.
372
Test Step 3. Calculating Pulses Per For Other Truck Manufacturer configurations,
Kilometer (Mile) When All The Variables the value is 18,600 pulses per kilometer (30,000
Are Known. pulses per mile).
A. Calculate pulses per kilometer (PPKM) or pulses For GM Truck Manufacturer configurations that
per mile (PPM). have SEP00 or newer software, the value is 2,485
pulses per kilometers (4,000 pulses per mile).
PPKM = K Ra N.
The ECM can only provide the signal that is listed
PPM = M Ra N. above.
K This symbol represents the tire revolutions Results:

per kilometer. This is a constant that is divided
by the tire static loaded radius. OK The speedometer is correctly calibrated.
STOP.
M This symbol represents the tire revolutions
per mile. This is a constant that is divided by the Not OK
tire static loaded radius.
Ra This symbol represents the rear axle ratio. procedure:
The rear axle ratio can typically be found on the
housing of the rear axle, or the rear axle ratio Send the vehicle to the OEM dealer or reprogram
can typically be found on the specification sheet the OEM speedometer to the correct setting for
for the vehicle. the pulses per kilometer (mile).
N This symbol represents the number of STOP.

chopper teeth on the transmission drive shaft.
The magnetic pickup sensor is mounted here.
The number of chopper teeth is usually 16. Some
transmissions have 11 tooth chopper wheels.
B. Enter pulses per km (PPKM) or pulses per mile

(PPM) into the ECM by using an Electronic
Service Tool.
Expected Result:
This value is within the valid range of the ECM.
Results:
OK Once the value is entered, verify that the

ECM is accurately measuring vehicle speed.
Not OK Recalculate the value and re-enter the

correct value into the ECM. STOP.
Test Step 4. Inspect The Speedometer

Calibration.
Determine the speedometers vehicle speed
calibration setting. You may be required to contact
the OEM dealer or you may be required to send the
vehicle to the OEM dealer for this information.
Expected Result:
The speedometer must be calibrated to one of the

following values:
373
Index Section
Index
Numerics 0164-02 Injection Actuation Pr Sensor Erratic
(15) .................................................................... 109
0001-11 Cylinder 1 Fault (72) ................................ 92 0164-03 Injection Actuation Pr Sensor Open Circuit
0002-11 Cylinder 2 Fault (72) ................................ 92 (15) .................................................................... 109
0003-11 Cylinder 3 Fault (73) ................................ 93 0164-04 Injection Actuation Pr Sensor Short Circuit
0004-11 Cylinder 4 Fault (73) ................................ 93 (15) .................................................................... 110
0005-11 Cylinder 5 Fault (74) ................................ 94 0164-11 Injection Actuation Pressure System
0006-11 Cylinder 6 Fault (74) ................................ 94 (39) .................................................................... 110
0022-13 Check Timing Sensor Calibration (42) .... 94 0168-02 Intermittent Battery (51) ........................ 110
0030-08 Invalid PTO Throttle Signal (29) .............. 95 0190-00 Engine Overspeed Warning (35)........... 111
0030-13 PTO Throttle Sensor Calibration (29) ...... 95 0190-02 Loss of Engine RPM Signal (34) ........... 111
0041-03 8 Volt Supply Above Normal (21) ............ 95 0190-11 No Pattern on Speed Sensor #1 (34) .... 111
0041-04 8 Volt Supply Below Normal (21)............. 96 0224-11 Theft Deterrent Active (00) .................... 112
0042-11 Injection Actuation Pr Control Valve Driver 0224-14 Engine Cranking with Theft Deterrent Active
(18) ...................................................................... 96 (00) .................................................................... 112
0043-02 Ignition Key Switch Fault (71) .................. 96 0231-11 J1939 Data Link Fault (58) .................... 112
0064-02 Loss of Engine RPM Signal #2 (34) ........ 97 0232-03 5 Volt Supply Above Normal (21) .......... 113
0064-11 No Pattern on Speed Sensor #2 (34) ...... 97 0232-04 5 Volt Supply Below Normal (21)........... 113
0070-05 Inlet Air Heater Open Circuit (49) ............ 97 0246-11 Brake Switch #1 .................................... 114
0070-06 Inlet Air Heater Short Circuit (49) ............ 98 0247-11 Brake Switch #2 .................................... 114
0071-00 Idle Shutdown Override (01) ................... 98 0252-11 Incorrect Engine Software (59).............. 114
0071-01 Idle Shutdown Occurrence (47)............... 98 0253-02 Check Customer or System Parameters
0071-14 PTO Shutdown Timer Occurrence (47) ... 99 (56) .................................................................... 115
0084-00 Vehicle Overspeed Warning (41)............. 99 0253-14 Truck Manufacturer Parameter Not
0084-01 Loss of Vehicle Speed Signal (31) .......... 99 Programed ......................................................... 115
0084-02 Invalid Vehicle Speed Signal (36).......... 100 5 Volt Engine Pressure Sensor Supply Circuit -
0084-08 Vehicle Speed Out of Range (36).......... 100 Test .................................................................... 116
0084-10 Vehicle Speed Rate of Change (36) ...... 100
0091-13 Throttle Sensor Calibration (28) ............ 101 A
0100-03 Oil Pressure Sensor Open Circuit (24).. 101
0100-04 Oil Pressure Sensor Short Circuit (24).. 102 Accelerator Pedal (Throttle) Position Sensor Circuit -
0100-11 Very Low Oil Pressure (46) ................... 102 Test .................................................................... 130
0102-03 Boost Pressure Sensor Open Circuit Air Inlet Heater Circuit - Test................................ 120
(25) .................................................................... 102 ATA (SAE J1587 / J1708) Data Link Circuit -
0102-04 Boost Pressure Sensor Short Circuit Test .................................................................... 137
(25) .................................................................... 103
0102-07 Excessive Boost Pressure..................... 103
0105-00 High Inlet Manifold Temp Warning (64).. 103 C
(38) .................................................................... 104 Calibration Procedures ........................................ 368
0105-04 Inlet Manifold Temp Sensor Short Circuit Can Not Reach Top Engine RPM .......................... 62
(38) .................................................................... 104 Probable Causes ............................................... 62
0105-11 Very High Inlet Manifold Temp (64) ....... 104 Recommended Actions...................................... 62
0108-03 Atmospheric Pr Sensor Open Circuit Can Not Reach Vehicle Speed Limit ..................... 63
(26) .................................................................... 105 Cold Mode Operation......................................... 63
0108-04 Atmospheric Pr Sensor Short Circuit Customer Specified Parameters ........................ 63
(26) .................................................................... 105 Electronic System problem ................................ 64
0110-00 High Coolant Temperature Warning Fuel Supply ........................................................ 64
(61) .................................................................... 106 Probable Causes ............................................... 63
0110-03 Coolant Temp Sensor Open Circuit Recommended Actions...................................... 63
(27) .................................................................... 106 Check Engine Lamp Circuit - Test ....................... 144
(27) .................................................................... 107
0110-11 Very High Coolant Temperature (61)..... 107
0111-02 Coolant Level Sensor Fault (12) ............ 108
0164-00 Injection Actuation Pr Out of Range
(17) .................................................................... 109
374
Index Section
Check Engine Lamp or Warning Lamp Is E

Malfunctioning...................................................... 65
Check Engine Lamp........................................... 65 ECM Date/Time Stamped Information................... 53
Cruise Control Set/Resume Switch ................... 65 Adjustment of ECM Date/Time Clock ................ 54
Intermittent Diagnostic Codes............................ 65 ECM Diagnostic Clock ....................................... 54
Probable Causes ............................................... 65 Occurrence of Time Stamped Information ......... 54
Recommended Actions...................................... 65 Proper Use of ECM Date/Time Stamped
Service Engine Soon Lamp (GM) ...................... 66 Information ....................................................... 54
Short in Vehicle Harness ................................... 66 ECM Memory - Test............................................. 191
Warning Lamp.................................................... 65 ECM Snapshot ...................................................... 54
Clutch Pedal Position Switch Circuit - Test .......... 149 Quick Stop Snapshot ......................................... 55
Component Diagram ............................................. 21 Snapshot Information that is Triggered by a
Coolant Level Sensor Circuit - Test ..................... 160 Diagnostic Code............................................... 55
Cooling Fan Circuit and A/C High Pressure Switch Snapshot Information That Is Triggered
Circuit - Test....................................................... 166 Externally ......................................................... 55
Cruise Control Switch Circuit - Test ..................... 180 Storage of Snapshots in the ECM ..................... 56
Cruise Control, Idle, or PTO Can Not Be Set ........ 66 Use Of Snapshot................................................ 54
Customer Specified Parameters ........................ 66 ECM Will Not Accept Factory Passwords.............. 71
Electronic Service Tool Status Screen............... 67 Incorrect password............................................. 71
On/Off switch for Cruise Control and Idle Incorrect Serial Number..................................... 71
Control.............................................................. 67 Probable Causes ............................................... 71
Probable Causes ............................................... 66 Reason Code ..................................................... 72
Recommended Actions...................................... 66 Recommended Actions...................................... 71
Customer Passwords............................................. 31 Electrical Connectors - Inspect............................ 195
Customer Specified Parameters............................ 31 Electrical Connectors and Functions..................... 26
Cruise Control Parameters ................................ 34 Electronic Service Tool Will Not Communicate with
Customer Parameter Lockout ............................ 31 ECM..................................................................... 72
Data Link Parameters ........................................ 47 Override Switches.............................................. 73
Dedicated PTO Parameters ............................... 37 Personality Module ............................................ 73
ECM Identification Parameters .......................... 32 Probable Causes ............................................... 72
Engine Monitoring Parameters .......................... 42 Recommended Actions...................................... 72
Engine/Gear Parameters ................................... 39 Service Tool ....................................................... 72
Idle Parameters.................................................. 35 Vehicle Harness ................................................. 72
Input Selections ................................................. 45 Electronic Service Tools ........................................ 22
Maintenance Parameters ................................... 43 Service Tools ..................................................... 22
Output Selections............................................... 46 Service Tools That Are Optional ........................ 23
Passwords.......................................................... 47 Electronic Technician (ET)..................................... 56
Selected Engine Rating ..................................... 32 Connecting Electronic Technician (ET) .............. 57
Timer Parameters .............................................. 41 Electronic Troubleshooting ...................................... 5
Trip Parameters.................................................. 43 Engine Cranks but Will Not Start ........................... 73
Truck Manufacturer Parameters ......................... 32 Combustion Problem ......................................... 76
Vehicle Speed Parameters................................. 33 ECM ................................................................... 75
Customer Specified Parameters Table .................. 48 ECM Communications ....................................... 74
Customer Specified Parameters Worksheet.......... 51 ECM Power Supply ............................................ 74
Current Totals Worksheet .................................. 53 Engine Oil Pressure ........................................... 74
Engine Protection Devices ................................. 74
Engine Software................................................. 76
D Engine Speed/Timing Signal.............................. 75
Fuel Supply ........................................................ 76
Diagnostic Functional Tests................................. 116 Hydraulic Electronic Unit Injectors ..................... 75
Driver Questionnaire.............................................. 68 Ignition Switch.................................................... 74
Driver Questionnaire Response ............................ 70 Injection Actuation Pressure System ................. 76
Personality Module ............................................ 75
Probable Causes ............................................... 73
Recommended Actions...................................... 74
Theft Deterrent................................................... 76
375
Index Section
Engine Misfires, Runs Rough or Is Unstable ......... 76 I

Accelerator Pedal Position Sensor..................... 77
Camshaft Position Sensor ................................. 78 Idle Shutdown Timer - Test .................................. 236
Fuel Supply ........................................................ 77 Ignition Key Switch Circuit and Battery Supply Circuit
Individual Cylinder Malfunction .......................... 77 - Test .................................................................. 239
Low Injection Actuation Pressure....................... 77 Ignore Brake/Clutch Switch Circuit - Test ............ 246
Power train Data Link ...................................... 77 Important Safety Information ................................... 2
Probable Causes ............................................... 76 Injection Actuation Pressure - Test ...................... 249
Recommended Repairs ..................................... 76 Injection Actuation Pressure Control Valve Circuit -
Valve Lash ......................................................... 78 Test .................................................................... 259
Engine Pressure Sensor Open or Short Circuit - Injection Actuation Pressure Sensor - Test.......... 264
Test .................................................................... 202 Injector Solenoid Circuit - Test............................. 267
Engine Running Output Circuit - Test .................. 210 Input Selection Switch Circuit - Test .................... 274
Engine Speed/Timing Sensor - Calibrate ............ 368 Intermittent Cruise Control, Idle, or PTO Kickout... 81
Engine Speed/Timing Sensor Circuit - Test......... 212 ECM Connections .............................................. 83
Engine Temperature Sensor Open or Short Circuit - Electronic Service Tool Status Screen............... 82
Test .................................................................... 219 Probable Causes ............................................... 81
Engine Will Not Crank ........................................... 78 Recommended Actions...................................... 82
Probable Causes ............................................... 78 Intermittent Engine Shutdown ............................... 83
Recommended Actions...................................... 78 Aftermarket Engine Protection Devices ............. 84
Engine Wiring Harness Diagram ........................... 26 Battery Power or Ground to the ECM ................ 83
Event Codes - Test .............................................. 224 ECM or Personality Module ............................... 84
Excessive Black Smoke......................................... 79 Engine Speed/Timing Sensors .......................... 84
Air Inlet System or Exhaust System................... 79 Fuel Supply ........................................................ 84
ECM or Personality Module ............................... 79 Idle Shutdown and Engine Monitoring ............... 83
Electronic System .............................................. 79 Low Injection Actuation Pressure....................... 84
Hydraulic Electronic Unit Injector ....................... 79 Probable Causes ............................................... 83
Probable Causes ............................................... 79 Recommended Actions...................................... 83
Recommended Actions...................................... 79 Intermittent Low Power or Power Cutout ............... 84
Valve Lash ......................................................... 79 Accelerator Pedal Position Sensor..................... 85
Excessive Fuel Consumption ................................ 80 Battery Power or Ground to the ECM ................ 85
Air Inlet System or Exhaust System................... 80 Electrical Connectors......................................... 85
Fuel Supply ........................................................ 80 Electronic System .............................................. 85
Probable Causes ............................................... 80 Engine Monitoring .............................................. 85
Recommended Actions...................................... 80 Fuel Supply ........................................................ 86
Vehicle Operation............................................... 80 Low Injection Actuation Pressure....................... 86
Vehicle Specifications ........................................ 80 Power Train Data Link ........................................ 86
Excessive White Smoke ........................................ 80 Probable Causes ............................................... 84
Air Inlet Restriction............................................. 81 Recommended Actions...................................... 85
Combustion Problem ......................................... 81 Torque Limit Switch............................................ 86
Coolant Temperature Circuit .............................. 81 Vehicle Speed Signal ......................................... 86
Fuel Supply ........................................................ 80
Hydraulic Electronic Unit Injector ....................... 81
Intake Air Heater ................................................ 81 L
Normal Operation .............................................. 80
Probable Causes ............................................... 80 Low Power/Poor or No Response to Throttle ........ 86
Recommended Actions...................................... 80 Accelerator Pedal Position ................................. 87
Exhaust Brake Circuit - Test ................................ 228 Air Inlet and Exhaust System............................. 88
Cold Mode Operation......................................... 87
Customer Specified Parameters ........................ 87
F Electronic System .............................................. 87
Fuel Supply ........................................................ 88
Factory Passwords ................................................ 57 Individual Cylinder Malfunction .......................... 88
Factory Passwords Worksheet .............................. 58 Low Injection Actuation Pressure....................... 89
Fast Idle Lamp Circuit - Test ................................ 233 Power Train Data Link ........................................ 88
Flash Programming ............................................... 58 Probable Causes ............................................... 86
Recommended Actions...................................... 87
Torque Limit Switch............................................ 87
G Vehicle Speed Signal ......................................... 88
Glossary ................................................................ 14
N System Overview..................................................... 5
ECM Lifetime Totals ........................................... 11
Neutral Switch Circuit - Test ................................ 280 Effect Of Diagnostic Codes on Engine
No Diagnostic Code Detected (55)........................ 92 Performance..................................................... 10
Engine Monitoring ................................................ 9
Engine Snapshot Data ....................................... 10
P Other ECM Functions of Performance ............... 10
Passwords.......................................................... 14
Poor Acceleration or Response ............................. 89 Programmable Parameters ................................ 14
Cold Mode Operation......................................... 90 Self-Diagnostics ................................................. 10
Combustion Problem ......................................... 91 System Operation ................................................ 5
Customer Specified Parameters ........................ 89 Trip Data that is Stored in the ECM.................... 11
ECM or Personality Module ............................... 90
Electronic System .............................................. 89
Individual Cylinder Malfunction .......................... 90 T
Injection Actuation Pressure System ................. 90
Power Train Data Link ........................................ 90 Table of Contents..................................................... 3
Probable Causes ............................................... 89 Tachometer Circuit - Test..................................... 343
Recommended Actions...................................... 89 Transmission (AT/MT/HT) Relay Circuit - Test ..... 348
Theft Deterrent................................................... 90 Troubleshooting Section .......................................... 5
Torque Limit Switch............................................ 90 Troubleshooting with a Diagnostic Code ............... 92
Powertrain Data Link Circuit - Test ...................... 291 Troubleshooting without a Diagnostic Code .......... 62
Programming Parameters...................................... 29
Programming a New ECM ................................. 29
PTO Shutdown Timer - Test ................................ 298 V
PTO Switch Circuit - Test..................................... 300
PTO Switch ON Lamp Circuit - Test .................... 310 Vehicle Speed and Speedometer Circuit - Test ... 351
Vehicle Speed Circuit - Calibrate ......................... 370
Vehicle Wiring Harness Diagram........................... 28
R
Remote PTO Accelerator Position Sensor Circuit - W

Test .................................................................... 315
Wait To Start Lamp Circuit - Test ......................... 360
Warning Lamp Circuit - Test ................................ 363
S

Test .................................................................... 322
Test .................................................................... 333
Recommendations ............................................. 61
System Configuration Parameters......................... 60
Engine Serial Number ..................................... 60
Full Load Setting.............................................. 60
Full Torque Setting........................................... 60
Personality Module Code ................................... 60
Personality Module Release Date ................... 60
2001 Caterpillar
RENR1322-04
November 1999
Specifications
C-10 and C-12 Truck Engines
8YS1-Up (Engine)
9NS1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Engine to Transmission Adapter ..........................

Belt Tension Chart ...............................................
40
40
Belt Tensioner ....................................................... 41
Belt Tensioner ....................................................... 41
Specifications Section Belt Tightener ...................................................... 42
Auxiliary Drive Pulley ........................................... 42
Engine Design ....................................................... 4
Engine Design ....................................................... 4
Engine Support (Front) ......................................... 43
Fuel Transfer Pump ................................................ 5
Fuel Lines ............................................................... 5
Fuel Filter and Water Separator .............................. 6
Electronic Unit Injector ............................................ 6
Electronic Unit Injector Mechanism ....................... 6
Electronic Unit Injector Rocker Arm ........................ 7
Electronic Unit Injector Wiring ................................. 7
Fuel Temperature Sensor ..................................... 47
Lifter Group ............................................................. 7
Engine Oil Pressure Sensor ................................. 48
Rocker Shaft .......................................................... 8
Valve Mechanism ................................................... 8
Atmospheric Pressure Sensor .............................. 48
Valve Mechanism ................................................... 9
Inlet Air Temperature Sensor ................................ 49
Valve Rocker Arm .................................................. 9
Valve Mechanism Cover ...................................... 10
Cylinder Head Valves ............................................ 10
Cylinder Head ...................................................... 12 Index Section
Compression Brake .............................................. 13
Compression Brake .............................................. 14 Index ..................................................................... 50
Turbocharger ........................................................ 16
Turbocharger ........................................................ 16
Turbocharger ........................................................ 17
Camshaft ............................................................. 18
Camshaft ............................................................. 19
Camshaft ............................................................. 20
Engine Oil Pump .................................................. 23
Engine Oil Pressure ............................................. 23
Engine Oil Pan ..................................................... 23
Engine Oil Pan ..................................................... 24
Engine Oil Pan ..................................................... 24
Coolant Conditioner Base .................................... 24
Water Temperature Regulator Housing ................ 25
Cylinder Block ...................................................... 25
Cylinder Liner ....................................................... 28
Cylinder Liner ....................................................... 28
Cylinder Liner Projection ...................................... 29
Crankshaft ........................................................... 29
Vibration Damper and Pulley ............................... 30
Connecting Rod ................................................... 31
Connecting Rod ................................................... 32
Piston and Rings .................................................. 33
Piston and Rings .................................................. 34
Housing (Front) ..................................................... 35
Gear Group (Front) ............................................... 37
Rear Power Take-Off (RPTO) ............................... 38
Flywheel ............................................................... 39
Flywheel ............................................................... 40
4
Engine Design
i01012763
SMCS Code: 1201
Engine Design S/N: 9NS1-Up
SMCS Code: 1201
S/N: 8YS1-Up
g00386924
Illustration 2
(A) Exhaust valves and (B) Inlet valves
g00386924
Illustration 1
Cylinder And Valve Location Bore ....................................... 130.0 mm (5.12 inch)
Stroke ..................................... 150.0 mm (5.91 inch)
Bore ....................................... 125.0 mm (4.92 inch)
Displacement ...................................... 12 L (732 in3)
Stroke ..................................... 140.0 mm (5.51 inch)
Cylinder arrangement ..................................... In-line
Displacement ................................... 10.3 L (629 in3)
In order to check the engine valve lash setting,
Valves per cylinder ................................................. 4 the engine must be cold and the engine must be
the engine must be cold and the engine must be Inlet .................................... 0.38 mm (.015 inch)
stopped. Engine valve lash settings Exhaust .............................. 0.64 mm (.025 inch)
Engine compression brake .................. 1.02 mm
Inlet .................................... 0.38 mm (.015 inch) (.040 inch)
Exhaust .............................. 0.64 mm (.025 inch)
Engine compression brake .................. 0.64 mm Type of combustion .......................... Direct Injection
(.025 inch)
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4 flywheel end of the engine. Crankshaft
rotation .......................................... Counterclockwise
flywheel end of the engine. Crankshaft Note: The front end of the engine is opposite of
rotation .......................................... Counterclockwise the flywheel end of the engine. The left side of the
Note: The front end of the engine is opposite of from the flywheel end of the engine. The No. 1
the flywheel end of the engine. The left side of the cylinder is the front cylinder.
from the flywheel end of the engine. The No. 1
cylinder is the front cylinder.
5
i01023243 When the pump is viewed from the drive end the
rotation of the pump is counterclockwise.
Fuel Transfer Pump
SMCS Code: 1256 i00956129
Fuel Lines
SMCS Code: 1274
g00280095
Illustration 3
g00281513
Illustration 5
Typical example
(1) Plug
(2) Fuel manifold
(3) Supply hose assembly from the electronic

control module (ECM)
(4) 104-1729 Spring
Illustration 4
g00280096 Assembled length ............... 18.4 mm (.72 inch)
Operating length (minimum) ................ 15.4 mm
(1) Outlet port (.61 inch)
Free length after test .................. 30.2 0.7 mm
(2) Drain hole (1.19 .03 inch)
Outside diameter ................. 11.3 mm (.44 inch)
(3) Inlet port
(5) Stud
(4) Pressure regulating valve
Apply 9S-3263 Thread Lock Compound on
the taperlock end of the stud to the following
When the fuel transfer pump is using diesel fuel, the
length. .................................... 7.6 mm (.30 inch)
fuel transfer pump has the following specifications.
Tighten the stud to the following
torque. .................... 70 15 Nm (50 11 lb ft)
Run the pump at 846 rpm. The flow at 482 kPa
(70 psi) must be 3.07 L/min (0.811 US gpm).
Run the pump at 3384 rpm. The flow at 654.6 kPa

Run the pump at 147 rpm with a blocked inlet. After

30 seconds the pump must have a suction level of
60.84 kPa/min (18 in-hg/min).
At rated speed, the full bypass pressure should be

the following value. ........................... 680 to 750 kPa
(100 to 110 psi)
6
i00814239 (2) Lubricate the seals and the bore with a 50

percent mix of 8T-2998 Lubricant and engine
Fuel Filter and Water Separator oil.
SMCS Code: 1261; 1263
i01175866
Electronic Unit Injector

Mechanism
SMCS Code: 1290
g00388412
Illustration 6
(1) Filter element
(2) Fuel filter base
(3) Bowl
(4) Plug
(5) Drain
Note: To open the self-ventilated drain, turn the plug g00280175

Illustration 8
counterclockwise.
(1) Electronic unit injector
i01175861
The adjusting instructions for the electronic unit
Electronic Unit Injector injector are listed below.
SMCS Code: 1290 1. Loosen locknut (2).
2. Turn the electronic unit injector rocker arm

adjusting screw clockwise. Stop turning the
adjusting screw when contact is made with the
electronic unit injector.
3. Turn the adjusting screw in the clockwise

direction.
Turn .......................... 180 degrees (1/2 of a turn)
4. Hold the adjusting screw in this position. Tighten

locknut (2).
g00403738 Tighten the locknut to the following

Illustration 7
torque. ........................ 55 10 Nm (40 7 lb ft)
(3) Rocker arm
torque. ........................ 30 7 Nm (22 5 lb ft)
(4) Rocker arm shaft
7
Diameter of new rocker arm i01237756

shaft ...... 34.000 0.010 mm (1.3386 .0004 inch)
Electronic Unit Injector Wiring
(5) Lifter group shaft
SMCS Code: 1290
Diameter of new lifter group
shaft ........ 20.000 0.010 mm (.7874 .0004 inch)
The bore diameter in the body of the electronic unit

injector lifter assembly for the lifter group shaft is
the following value. ................... 20.050 0.015 mm
(0.7894 0.0006 inch)
(6) Electronic unit injector lifter
i01175875
Electronic Unit Injector Rocker

Arm
SMCS Code: 1123
g00280453
Illustration 10
(1) Tighten the nuts that are on the cap assembly

to the following torque. .............. 2.5 0.25 Nm
(22 2 lb in)
(2) Cap assembly
Angle A ................................................... 52 degrees
g00280315 Position connectors so that the wires are not

Illustration 9
contacting any other surfaces.
(1) Bore in rocker arm bearing for
shaft .................................... 34.050 0.015 mm i01175911
(1.3405 0.0006 inch)
Lifter Group
The rocker arm bearing must not extend beyond
either face of the rocker arm. SMCS Code: 1209
(2) Bearing joint
Oil passage angle (A) ............................ 15 degrees
Oil passage angle (B) ............................ 20 degrees
Assemble the bearing. The oil hole openings that

are in the bearing must be centered over the oil
passages that are in the rocker arm. Centers must
be within the following value. ...... 2.3 mm (.09 inch)
(3) Bore in the rocker arm for the

bearing ............................... 37.000 0.020 mm
(1.4567 0.0008 inch) g00280305
Illustration 11
8
(3) The plug is installed into the end of the shaft.
(4) Install the plug to the following

depth. ..... 1.25 0.25 mm (0.049 0.010 inch)
i00924288
Valve Mechanism
SMCS Code: 1102
S/N: 8YS1-Up
g00288322
Illustration 12
View A-A
(2) Valve lifter
(3) Oil supply lifter bracket assembly
(4) Lifter bracket assembly
(5) The dowels extend below the surface of the lifter

bracket assembly. Distance ......... 4.0 1.0 mm
(0.16 0.04 inch)

torque. ........................ 30 3 Nm (22 2 lb ft)
i00887793 g00280461
Illustration 14
Rocker Shaft (1) Valve rocker arm

SMCS Code: 1102 (2) Valve lash (engine stopped)
Inlet valves .. 0.38 0.08 mm (.015 .003 inch)
Exhaust valves ......................... 0.64 0.08 mm
(.025 .003 inch)
Valve lash for the engine compression
brake .......... .64 .08 mm (0.025 0.003 inch)
Note: After setting the valve lash, tighten the

adjusting screw locknut. Recheck the valve lash.
Torque for the adjusting screw locknut .. 25 7 Nm

(18 5 lb ft)
Illustration 13 g00280329 (3) Rocker arm shaft

Diameter of new rocker arm
(1) Pin
shaft .................................... 34.000 0.010 mm
(1.3386 .0004 inch)
(2) Distance from the top surface of the pin to the
opposite side of the shaft .......... 40.0 1.0 mm
(4) Valve bridge
(1.57 0.04 inch)
9
(5) Lifter group shaft Diameter of new rocker arm

shaft .................................... 34.000 0.010 mm
Diameter of new lifter group (1.3386 .0004 inch)
shaft .. 20.000 0.010 mm (.7874 .0004 inch)
(4) Valve bridge
Bore diameter in the body of the valve
lifter ... 20.050 0.015 mm (.7894 .0006 inch)
(5) Lifter group shaft
(6) Valve lifter Diameter of new lifter group
shaft .. 20.000 0.010 mm (.7874 .0004 inch)
i00956795
Valve Mechanism lifter ... 20.050 0.015 mm (.7894 .0006 inch)
SMCS Code: 1102 (6) Valve lifter
S/N: 9NS1-Up
i01013543
Valve Rocker Arm

SMCS Code: 1123
g00280477
Illustration 16
g00280461 (1) Hold the adjusting screw in position for the

Illustration 15
inlet valve. Tighten the locknut to the following
torque. ........................ 25 7 Nm (18 5 lb ft)
(1) Valve rocker arm
Inlet valve lash (engine stopped) .............. 0.38 mm
(2) Valve lash (engine stopped)
(.015 inch)
(2) Hold the adjusting screw in position for the
Exhaust valves ......................... 0.64 0.08 mm exhaust valve. Tighten the locknut to the
(.025 .003 inch) following torque. ......... 25 7 Nm (18 5 lb ft)
Valve lash for the engine compression Exhaust valve lash (engine stopped) ........ 0.64 mm
brake .......... 1.02 0.08 mm (.040 .003 inch) (.025 inch)
Note: After setting the valve lash, tighten the (3) Support assembly
(4) The dowel extends below the surface of the
Torque for the adjusting screw locknut .. 25 7 Nm support assembly. Distance ........ 5.0 0.5 mm
(18 5 lb ft) (.20 .02 inch)
10
i00573207 (5) Cylinder head

Valve Mechanism Cover
i00953496
SMCS Code: 1107
Cylinder Head Valves
SMCS Code: 1105
g00280491
Illustration 17
(1) Seal
Cut the seal to length for each of the three valve

mechanism covers. Coat the joint surface with
3S-6252 Sealant.
(2) Cover
g00448911
Illustration 19
Note: Coat the inlet valve stems and the exhaust

valve stems with 8T-2998 Lubricant prior to
installation into the cylinder head.
(1) Inlet valve
(2) Exhaust valve
(3) Height to the step that is in the valve

guide ........ 22.00 0.50 mm (.866 .020 inch)
(4) 7W-7082 Spring

g00280493
Illustration 18 Assembled Length ........ 51.69 mm (2.035 inch)
Load at assembled length ............... 240 24 N
(3) Tighten bolts 1 through 6 in a numerical (54 5 lb)
sequence to the following torque. ... 12 3 Nm Operating length (minimum) .............. 37.72 mm
(9 2 lb ft) (1.485 inch)
Again tighten bolts 1 through 6 in a numerical (146 7 lb)
sequence to the following torque. ......... 12 3 Nm Free length after test ..... 59.89 mm (2.358 inch)
(9 2 lb ft) Outside diameter ........... 34.00 mm (1.339 inch)
(4) Breather assembly (5) 7W-7083 Spring
The conditions that follow will allow the crankcase Assembled Length ........ 49.19 mm (1.937 inch)
pressure to be less than 0.4 kPa (0.06 psi). Load at assembled length ............... 136 14 N
(31 3 lb)
Inside diameter of fumes disposal Operating length (minimum) .............. 35.22 mm
tube ................................... 31.8 mm (1.25 inch) (1.387 inch)
Blowby per hour .................. 19.82 cubic meters
11
Load at minimum operating length .. 292 15 N Diameter of valve seat insert (inlet
(66 3 lb) valve) .................................. 46.025 0.013 mm
Free length after test ..... 61.39 mm (2.417 inch) (1.8120 .0005 inch)
Outside diameter ............. 23.24 mm (.915 inch) Bore in cylinder head for valve seat insert (inlet
valve) .................................. 45.961 0.013 mm
(6) New valve stem diameter .... 9.441 0.008 mm (1.8095 .0005 inch)
(.3717 .0003 inch) Diameter of valve seat insert (exhaust
valve) .................................. 43.390 0.015 mm
The valves can be reused if the minimum (1.7083 .0006 inch)
dimensions for the valve stems are met. Bore in cylinder head for valve seat insert
(exhaust valve) ................... 43.320 0.025 mm
Inlet ................................ 9.408 mm (.3704 inch) (1.7055 .0010 inch)
Exhaust .......................... 9.408 mm (.3704 inch)
(11) Angle of valve face
Specifications for the valve guides
Angle of the face of the inlet
After installation into the cylinder head, valve ................................. 29 1/4 1/4 degrees
the valve guide bore is the following Angle of the face of the exhaust
value. .. 9.484 0.026 mm (.3734 .0010 inch) valve ................................. 44 1/4 1/4 degrees
The valve guide can be reused. The valve
guide bore must not be larger than the following (12) Minimum thickness of the valve lip
value. ............................. 9.538 mm (.3755 inch)
Inlet valve .......................... 2.51 mm (.099 inch)
(7) Diameter of valve head Exhaust valve .................... 2.03 mm (.080 inch)
Inlet valve ............................... 45.00 0.13 mm
(1.772 .005 inch)
Exhaust valve ......................... 42.00 0.13 mm
(1.654 .005 inch)
(8) Angle of face of valve seat insert

Inlet valve ......................... 29 3/4 1/4 degrees
Exhaust valve ................... 44 3/4 1/4 degrees
g00472047
Illustration 21
(13) Maximum variation of the valve stem length

Inlet valve to inlet valve ..... 0.66 mm (.026 inch)
Exhaust valve to exhaust valve ............ 0.66 mm
(.026 inch)
g00282169
Illustration 20
(9) Depth of the bore in the cylinder head for the

valve seat insert
Inlet ........... 15.00 0.05 mm (.591 .004 inch)
Exhaust ..... 14.10 0.05 mm (.555 .004 inch)
Note: Shrink the valve seat inserts by reducing the

temperature. Shrinking the valve seat inserts allows
placement into the counterbore.
(10) Valve seat insert

12
i01234015
Cylinder Head
SMCS Code: 1100
g00280510
Illustration 22
Note: Lubricate the bolt threads, the underside of Tighten the bolts to the following
the bolt heads, and the washers with 6V-4876 torque. .................. 160 15 Nm (120 11 lb ft)
Lubricant prior to assembly.
6. Tighten bolt (1) through bolt (26) again in a
Use the following procedure in order to tighten the numerical sequence.
cylinder head bolts:
Tighten the bolts again to the following
1. Tighten bolt (1) through bolt (26) in a numerical torque. .................. 160 15 Nm (120 11 lb ft)
sequence.
7. Place a mark on bolt (1) through bolt (26).
Tighten the bolts to the following Rotate bolt (1) through bolt (26) in a numerical
torque. .................. 160 15 Nm (120 11 lb ft) sequence.
2. Tighten bolt (1) through bolt (26) again in a Rotate the bolts in the clockwise
numerical sequence. direction. ............................ 90 degrees (1/4 turn)
Tighten the bolts again to the following 8. Tighten bolt (27) through bolt (33) in a numerical
torque. .................. 160 15 Nm (120 11 lb ft) sequence.
3. Place a mark on bolt (1) through bolt (26). Tighten the bolts to the following
Rotate bolt (1) through bolt (26) in a numerical torque. .......................... 28 7 Nm (20 5 lb ft)
sequence.
Rotate the bolts in the clockwise

direction. ............................ 90 degrees (1/4 turn)
4. Loosen bolt (1) through bolt (26) until the

washers are loose under the bolt heads.
5. Tighten bolt (1) through bolt (26) in a numerical

sequence.
13
i00957649
Compression Brake
SMCS Code: 1119; 1129
S/N: 8YS1-Up
g00284618
Illustration 23
View A-A
(34) The cup plugs are measured from the head

face to the top edge of the plug. Depth of
installation ................................. 1.25 0.25 mm
(0.049 0.010 inch)
Height of new cylinder head ...... 105.00 0.15 mm

(4.134 0.006 inch)
Minimum permissible thickness of cylinder

head ................................... 104.35 mm (4.108 inch)
g00405320
Illustration 24
Note: The flatness of the cylinder head should be
within 0.15 mm (0.006 inch). The flatness should
also be a maximum of 0.05 mm (0.002 inch) for any
150.00 mm (5.906 inch) span.
g00405321
Illustration 25
(1) Compression brake

14
(2) Locknut Refer to the Specifications, Cylinder Head topic

for the tightening procedure.
Tighten the locknut to the following
torque. ........................ 35 8 Nm (26 6 lb ft) (16) Locknut
(3) Slave piston adjustment screw Tighten the locknut on the rocker arm
for the exhaust valve to the following
(4) Hold-down nut torque. ........................ 25 7 Nm (18 5 lb ft)
Tighten the locknut on the rocker arm for the
Tighten the hold-down nuts to the following inlet valve to the following torque. ... 25 7 Nm
torque. .................... 80 15 Nm (60 11 lb ft) (18 5 lb ft)
(5) Stud (17) Inlet valve bridge
Tighten the studs to the following
torque. .................. 100 20 Nm (75 15 lb ft) (18) Exhaust valve bridge
Note: Prior to installation of the compression i00957908

brake, install stud (5) and tighten stud (5) to the
recommended torque. Compression Brake
(6) Slave piston SMCS Code: 1119; 1129
(7) C-10 slave piston lash setting .. 0.64 0.08 mm S/N: 9NS1-Up
(.025 .003 inch)
Adjust the slave piston lash while the engine is not

running. To be adjusted, the exhaust valves must
be closed.
Refer to the Testing and Adjusting, Compression

Brake topic for the adjustment procedure.
(8) Exhaust valve bridge
(9) Actuating pin
Apply 4C-9507 Retaining Compound on the

thread and tighten the locknut to the following
torque. .............................. 25 7 Nm (18 5 lb ft)
(10) Exhaust valve seat insert
(11) Exhaust valve
(12) Bolt g00405320

Illustration 26
Tighten the bolt to the following

torque. ...................... 55 10 Nm (41 7 lb ft)
(13) Spacer
Tighten the spacer to the following
torque. .................. 100 20 Nm (75 15 lb ft)
(14) Bolt
torque. .................. 100 20 Nm (75 15 lb ft)
(15) Head bolt stud

15
Refer to the Testing and Adjusting, Compression

(9) Actuating pin
Apply 4C-9507 Retaining Compound on the

thread and tighten the locknut to the following
torque. .............................. 25 7 Nm (18 5 lb ft)
(10) Exhaust valve seat insert
(11) Exhaust valve
(12) Bolt
torque. ...................... 55 10 Nm (41 7 lb ft)
(13) Spacer
torque. .................. 100 20 Nm (75 15 lb ft)
(14) Bolt
g00405321 torque. .................. 100 20 Nm (75 15 lb ft)
Illustration 27
(15) Head bolt stud
Refer to the Specifications, Cylinder Head topic
(2) Locknut for the tightening procedure.
torque. ........................ 35 8 Nm (26 6 lb ft) (16) Locknut
Tighten the locknut on the rocker arm
(3) Slave piston adjustment screw for the exhaust valve to the following
torque. ........................ 25 7 Nm (18 5 lb ft)
(4) Hold-down nut Tighten the locknut on the rocker arm for the
Tighten the hold-down nuts to the following inlet valve to the following torque. ... 25 7 Nm
torque. .................... 80 15 Nm (60 11 lb ft) (18 5 lb ft)
(5) Stud (17) Inlet valve bridge
Tighten the studs to the following (18) Exhaust valve bridge

torque. .................. 100 20 Nm (75 15 lb ft)
Note: Prior to installation of the compression

recommended torque.
(6) Slave piston
(7) C-12 slave piston lash setting .. 1.02 0.08 mm

(.040 .003 inch)
Adjust the slave piston lash while the engine is not

running. To be adjusted, the exhaust valves must
be closed.
16
i00924243 i00956849
Turbocharger Turbocharger
S/N: 8YS1-Up Part No.: 137-8932
S/N: 9NS1-Up
g00403599
Illustration 28
g00403601
Typical example Illustration 29
Typical example of a turbocharger with a waste gate
(1) Clamp
(1) Clamp
To tighten the clamp (1) on the turbocharger, use
the procedure that follows. To tighten the clamp (1) on the turbocharger, use
the procedure that follows.
1. Tighten the clamp bolts.
1. Tighten the clamp.
Tighten the clamp bolts to the following
torque. .......................... 14 1 Nm (10 1 lb ft) Tighten the clamp to the following
torque. .................................... 18 Nm (13.0 lb ft)
2. Gently tap the clamps with a soft faced hammer.
2. Loosen the clamp.
3. Again tighten the clamp bolts.
Loosen the clamp to the following torque. .. 6 Nm
Tighten the clamp bolts to the following (4.0 lb ft)
torque. .......................... 14 1 Nm (10 1 lb ft)
Tighten the clamp to the following

torque. .......................... 14 1 Nm (10 1 lb ft)
(2) Clamp
torque. ........................ 14 1 Nm (10 1 lb ft)
(3) Waste gate

Opening pressure of the waste
gate ........................... 165 3 kPa (24 .5 psi)
17
i00924255 i00816699
Turbocharger Exhaust Manifold

S/N: 9NS1-Up Part No.: 117-2755, 138-2675
S/N: 8YS1-Up
S/N: 9NS1-Up
g00403599
Illustration 30
Typical example of a turbocharger with a two bolt and a two stud
mounting flange. g00389694
Illustration 31
(1) Clamp Engine exhaust flange that utilizes four studs
To tighten the clamp (1) on the turbocharger, use (1) Apply 5P-3931 Anti-Seize Compound to the
the procedure that follows. stud threads. Tighten the studs to the following
torque. ........................ 35 5 Nm (26 4 lb ft)
Tighten the clamp to the following torque. ...................... 55 10 Nm (41 7 lb ft)
torque. .................................... 18 Nm (13.0 lb ft)
(3) Apply 5P-3931 Anti-Seize Compound to the
2. Loosen the clamp. stud threads. Tighten the studs to the following
torque. ........................ 35 5 Nm (26 4 lb ft)
Loosen the clamp to the following torque. .. 6 Nm
(4.0 lb ft)

torque. .................................... 18 Nm (13.0 lb ft)
18
i00816833 i00816918
Exhaust Manifold Camshaft

Part No.: 148-1993 Part No.: 138-2010
S/N: 9NS1-Up S/N: 8YS1-Up
g00389992 g00466006
Engine exhaust flange that utilizes two bolts and two studs
(1) Torque for thrust pin ... 28 7 Nm (20 5 lb ft)
stud threads. Tighten the studs to the following (2) Diameter of new camshaft
torque. ........................ 35 5 Nm (26 4 lb ft) journals ............................... 74.850 0.025 mm
(2.9468 .0010 inch)
torque. ...................... 55 10 Nm (41 7 lb ft) (3) Key
(3) Apply 5P-3931 Anti-Seize Compound to the (4) Part number

stud threads. Tighten the studs to the following
torque. ........................ 35 5 Nm (26 4 lb ft) (5) Gear
(4) Cylinder head
g00466107
Illustration 34
(6) Camshaft lobe lift

Inlet lobe ...................... 11.371 mm (.4477 inch)
Injector lobe ................ 11.023 mm (.4340 inch)
(7) Camshaft lobe height

19
(8) Base circle
Specified base circle (8)

Exhaust lobe ... 55.0 0.4 mm (2.17 .02 inch)
Inlet lobe ......... 51.0 0.4 mm (2.01 .02 inch)
Injector lobe ..... 51.0 .4 mm (2.01 .02 inch)

g00466107
from the lobe height that is found in Step 1. The Illustration 36
lobe lift and the specified lobe lift of a new Specified camshaft lobe lift (6)
camshaft ............................... 0.13 mm (.005 inch)
i00816964 Injector lobe ................ 11.275 mm (.4439 inch)
Camshaft (7) Camshaft lobe height
SMCS Code: 1210 (8) Base circle
Part No.: 138-2012
S/N: 9NS1-Up Specified base circle (8)

g00466006 Maximum permissible difference between actual

Illustration 35
lobe lift and the specified lobe lift of a new
camshaft ............................... 0.13 mm (.005 inch)
(2) Diameter of new camshaft

journals ............................... 74.850 0.025 mm
(2.9468 .0010 inch)
(3) Key
(4) Part number
(5) Gear
20
i00912894 (8) Base circle

Camshaft Specified base circle (8)
SMCS Code: 1210 Exhaust lobe ... 55.0 0.4 mm (2.17 .02 inch)
Part No.: 129-2887 Injector lobe .. 52.2 .4 mm (2.0551 .02 inch)
S/N: 9NS1-Up


camshaft ............................... 0.13 mm (.005 inch)
g00466006
Illustration 37

journals ............................... 74.850 0.025 mm
(2.9468 .0010 inch)
(3) Key
(4) Part number
(5) Gear
g00466107
Illustration 38


21
i00915801
Engine Oil Filter Base

SMCS Code: 1306
g00280833
Illustration 39
Oil filter base
(1) Oil cooler bypass valve
Opening pressure ..... 155 17 kPa (22.5 2.5 psi)
(2) Oil filter base
Tighten the stud that holds the oil filter (3) to the oil
filter base to the following torque. ......... 68 7 Nm
(50 5 lb ft)
(3) Oil filter
(4) Bolts
Apply 9S-3263 Thread Lock to each of the six g00280834

bolts. Illustration 40
Section A-A
Bypass opening pressure differential ......... 170 kPa

(25 psi)
(5) Seal
(6) 8M-3182 Spring

Load at assembled length ........ 36.5 N (8.21 lb)
Free length after test ......... 91.7 mm (3.61 inch)
Outside diameter ............... 20.6 mm (0.81 inch)
(7) Seal
22
(8) Plunger Assembled length ............. 21.4 mm (0.84 inch)

Load at assembled length ......... 198.0 13.4 N
(9) Seal (44.50 3.00 lb)
Outside diameter ............... 19.6 mm (0.77 inch)
(16) Seal
g00280835
Illustration 41
Section B-B
(10) 2N-6005 Spring g00280977

Illustration 43
Assembled length ............. 96.5 mm (3.80 inch) Oil cooler bypass valve
Load at assembled length ...... 92.5 N (20.80 lb)
Minimum operating length ................... 45.7 mm (17) Minimum stroke ................. 8.4 mm (0.33 inch)
(1.80 inch)
Load at minimum operating length ....... 257.6 N (18) Length of fully compressed
(57.91 lb) valve ................ 44.2 1 mm (1.74 0.04 inch)
Free length after test ....... 124.7 mm (4.91 inch)
Outside diameter ............... 21.8 mm (0.86 inch) (19) Length of fully extended valve .... 52.6 1 mm
(2.07 0.04 inch)
(11) Valve
(B) Position B (Closed)
(12) Seal
Start to close temperature ............ 100 to 103C
(13) Seal (212 to 217F)
Position B will activate at a specific temperature.
Temperature ................................. 111C (232F)
Bypass opening pressure
differential ........... 155 17 kPa (22.5 2.5 psi)
Higher than normal activation
temperature .................................. 127C (261F)
Note: At higher than normal activation temperature,

the oil cooler bypass valve will stroke to position B.
At higher than normal activation temperature, the oil
cooler bypass valve will remain at position B.
g00280836
Illustration 42
Section C-C
Relief pressure ............................. 696 kPa (101 psi)
(14) Spacer
(15) 1A-2170 Spring

23
i01039752 Length of new gears .......... 50.000 0.025 mm

(1.9685 .0010 inch)
Engine Oil Pump
Depth of bores in pump body for the
SMCS Code: 1304 gears ...... 50.13 0.02 mm (1.974 .001 inch)
(5) Seal
(6) Distance between front face of gear and

housing ... 29.40 0.50 mm (1.158 .020 inch)
i00817005
Engine Oil Pressure

SMCS Code: 1924
Operate the engine in order to achieve the normal

operating temperature. When the engine has
Illustration 44 g00280778 achieved the normal operating temperature, the
engine oil temperature should be no greater than
110C (230F). The engine oil temperature should
NOTICE be measured after the engine oil has passed
Before operating the engine, the oil pump must be through the engine oil cooler.
lubricated with clean engine oil. The oil pump must
turn freely by hand. Damage to the drive gear and Check the engine oil pressure in the oil gallery that
internal pump damage can occur if the oil pump is not is located on the right side of the cylinder block.
lubricated with clean engine oil.
Engine oil pressure under full load conditions (1400
Engine oil pump rpm to 1800 rpm) ...... 275 to 414 kPa (40 to 60 psi)
Oil type ................................................... SAE 30 Minimum engine oil pressure at low idle (600 rpm to
Oil temperature .............................. 50C (122F) 800 rpm) .......................................... 68 kPa (10 psi)
Pump speed ........................................ 3000 rpm
Oil pressure ............................. 359 kPa (52 psi)
Minimum oil flow ........... 185 L/min (49 US gpm) i00887123
(1) Diameter of two shafts ....... 18.000 0.005 mm

Engine Oil Pan
(.7087 .0002 inch) SMCS Code: 1302
Bores in pump body for two
shafts ...... 18.050 0.010 mm (.7106 .0004 inch)
(2) Seal groove
Prior to installation, lubricate the bore in the engine

front cover. This will allow the seal groove and the
seal to slide.
(3) Drive gear

In order to install the drive gear, heat the drive
gear to the following temperature. .......... 316 C
(600 F)
g00280790
Illustration 45
(4) Pump gears
Center Sump
In order to install the pump gears, heat the pump
gears to the following temperature. ........ 316 C (1) Oil pan
(600 F)
(2) Tighten the plugs to the following
torque. .................... 70 15 Nm (50 11 lb ft)
24
(3) Apply 9S-3263 Thread Lock Compound to (2) Tighten the plugs to the following
plug threads. Tighten the plug to the following torque. .................... 70 15 Nm (50 11 lb ft)
torque. ...................... 80 11 Nm (60 8 lb ft)
plug threads. Tighten the plugs to the following
i00817425
torque. ...................... 80 11 Nm (60 8 lb ft)
Engine Oil Pan
i00818610
SMCS Code: 1302
Coolant Conditioner Base
SMCS Code: 1352
g00390433
Illustration 46
Rear Sump
(1) Engine oil pan

torque. ...................... 80 11 Nm (60 8 lb ft)
(3) Tighten the plugs to the following Illustration 48

g00391440
torque. .................... 70 15 Nm (50 11 lb ft)
(1) Apply 9S-3263 Thread Lock Compound on
i00817470 the tapered end of the stud to the following
distance. ................................ 7.6 mm (.30 inch)
Engine Oil Pan
(2) Tighten the stud to the following
SMCS Code: 1302 torque. ........................ 60 7 Nm (44 5 lb ft)
g00390460
Illustration 47
Front Sump
(1) Engine oil pan

25
i00817761 (1) Install the lip type seal into the water temperature
regulator housing. Lubricate the sealing lip
Water Temperature Regulator on the lip type seal with a small amount of
Housing antifreeze.
SMCS Code: 1393 (2) Minimum stroke of the water temperature

(0.41 inch)
(3) Fully open temperature of the water temperature

regulator ......................................... 98C (208F)
i00818649
Cylinder Block
SMCS Code: 1201
g00390813
Illustration 49
(1) Manifold
(2) Tighten the plug to the following

torque. ..................................... 25 Nm (18 lb ft)
(3) Water temperature regulator housing
(4) Apply 5P-3413 Pipe Sealant to the plug

threads.
g00283070
Illustration 51
i00817649
(1) The dowels extend past the end of the cylinder
Water Temperature Regulator block. Distance .. 8.0 0.5 mm (.32 .02 inch)
SMCS Code: 1355 (2) The dowels extend past the end of the cylinder
block. Distance .......................... 10.0 0.5 mm
(.39 .02 inch)

block. Distance .......................... 10.0 0.5 mm
(.39 .02 inch)
(4) Cylinder liner
g00390592
Illustration 50
26

bore to the top surface of the cylinder
block .......................... 387.00 mm (15.236 inch)
The flatness of the top contact surface of the

cylinder block must be within 0.05 mm (.002 inch)
for any 150 mm (5.9 inch) section of the surface.
(8) Width of the main bearing

cap ................................... 175.000 0.020 mm
(6.8898 .0008 inch)
Width in cylinder block for the main bearing

cap ...... 175.000 0.018 mm (6.8898 .0007 inch)
g00455305
Illustration 52 (9) Distance from the centerline of the crankshaft
Section A-A to the bottom surface of the cylinder
block ................................ 120.0 mm (4.72 inch)
Bore diameters in the cylinder block for the cylinder
block liners: (10) Main bearing cap bolts
Position (A) ........................... 151.50 0.03 mm Use the following procedure in order to install the
(5.965 .001 inch) main bearing cap bolts:
Position (B) ............................... 149.8 0.3 mm
(5.898 0.012 inch) 1. Orient the main bearing cap correctly. The part
Position (C) ........................... 148.00 0.03 mm number on the main bearing cap must face to
(5.827 .001 inch) the right and to the front face of the block. Also,
Position (D) ........................... 141.90 0.15 mm the tab slots that are in the block and the main
(5.587 .006 inch) bearing caps must be adjacent.
Note: The main bearing caps are marked with

identification numbers 1 through 7. Install the main
bearing caps into the correct positions.
2. Lubricate the main bearing cap bolts. Use SAE

30W oil or molybdenum grease to lubricate the
threads and the washer face.
3. Tighten the main bearing cap bolts.
Tighten bolts to the following torque. .. 95 5 Nm

(70 4 lb ft)
4. Put an alignment mark on each cap and bolt.

direction. ..................................... 90 5 degrees
(11) Bore in the cylinder block for the seven main

bearings ........................... 116.000 0.013 mm
g00283159 (4.5669 .0005 inch)
Illustration 53
(5) Diameter of the camshaft Bore in the bearings for the crankshaft
bores .................................. 81.000 0.015 mm journals ................................... 108.102 0.031 mm
(3.1890 .0006 inch) (4.2560 .0012 inch)
(6) Tighten the bolt that holds the piston cooling jet Note: All of the measurements for the main bearing
to the following torque. .................... 25 7 Nm bore must be made before the main bearing cap is
(18 5 lb ft) disassembled.
27
g00283161 g00391637
View B-B View D-D
The camshaft bearings are installed into the cylinder Note: Illustration 56 represents camshaft bearings 2
block at the values that follow. through 6.
Position (A) .................... 35.20 mm (1.386 inch) (13) Bearing joint
Position (B) .................. 191.20 mm (7.528 inch)
Position (C) ................ 347.20 mm (13.669 inch) (14) Oil hole
Position (D) ................ 503.20 mm (19.811 inch)
Position (E) ................ 659.20 mm (29.953 inch)
Position (F) ................ 815.20 mm (32.094 inch)
Position (G) ................ 954.10 mm (37.563 inch)
NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
g00391638
Illustration 57
View E-E
Note: Illustration 57 represents camshaft bearing 1.
(15) Bearing joint
(16) Oil hole

g00283162
Illustration 55
Note: The width of the number 1 through number 6
View C-C
camshaft bearing is 33.4 0.5 mm (1.32 .02 inch).
The width of the number 7 camshaft bearing is
Note: Illustration 55 represents camshaft bearing 7. 28.0 0.5 mm (1.10 .02 inch). The number
1 camshaft bearing has a 5.0 0.5 mm
(12) Bearing joint (.20 .02 inch) wide single groove on the inside
diameter of the camshaft bearing. The width of
(A) Bearing oil hole at a 45 degree angle the single groove on the outside diameter of
camshaft bearings 2 through 6 is 8.0 0.5 mm
(.32 .02 inch). A single groove is on the outside
diameter of the number 7 camshaft bearing.
28
i00959617 i00959700
Cylinder Liner Cylinder Liner

S/N: 8YS1-Up S/N: 9NS1-Up
g00284834 g00284834
Outside diameters of the cylinder liner Outside diameters of the cylinder liner
Position (A) ........................... 151.25 0.05 mm Position (A) ........................... 151.25 0.05 mm
(5.955 .002 inch) (5.955 0.002 inch)
Position (B) ........................... 147.90 0.03 mm Position (B) ........................... 147.90 0.03 mm
(5.823 .001 inch) (5.823 0.001 inch)
Position (C) ........................... 141.38 0.08 mm Position (C) ........................... 141.38 0.08 mm
(5.566 .003 inch) (5.566 0.003 inch)
Bore diameter for the cylinder Bore diameter for the cylinder
liner ..... 125.037 0.037 mm (4.9227 .0015 inch) liner ... 130.037 0.037 mm (5.1196 0.0015 inch)
Note: Apply 5P-3975 Rubber Lubricant to the Note: Apply 5P-3975 Rubber Lubricantto the
cylinder liner seals prior to assembly. cylinder liner seals prior to assembly.
29
i00819393 Maximum diameter of gear after

assembly ........................... 136.36 mm (5.368 inch)
Cylinder Liner Projection
Note: After the crankshaft is assembled into
SMCS Code: 1216 the block, the crankshaft end play should be a
maximum of 0.50 mm (0.020 inch) and a minimum
Table 1
of 0.10 mm (0.004 inch).
Specifications
Liner Projection 0.040 to 0.200 mm i00959950
(.0016 to .0079 inch)
Maximum Variation in Each
Crankshaft Seals
0.050 mm (.0020 inch)
Liner
SMCS Code: 1160; 1161
Maximum Average
Variation Between 0.050 mm (.0020 inch)
Adjacent Liners
Maximum Variation
0.100 mm (.0040 inch)
Between All Liners
For more information on the cylinder liner projection,

refer to Testing and Adjusting, Basic Block.
i00887024
Crankshaft
SMCS Code: 1201
g00281016
Illustration 61
(A) Rear
(B) Front
g00281828
Illustration 60
(1) Main bearing journals

g00489560
Illustration 62
The thrust plate is used on the center main bearing Rear seal group
only.
Note: Install the front crankshaft seals and the rear
(2) In order to install the gear, heat the gear to the crankshaft seals dry.
following temperature. ............. 210C (410.0 F)
(1) Flywheel housing
Note: Heat the gear for no longer than one hour.
(2) Seal group cover
(3) Connecting rod bearing journals
(3) Seal group
(4) Average diameter of gear after
assembly .............................. 136.20 0.11 mm (4) Crankshaft
(5.362 0.004 inch)
(5) Rear face of cylinder block
30
(6) Bolt i01003510
Apply 7M-7456 Compound to the bolt threads. Connecting Rod Bearing

Journal
torque. ................................ 12 3 Nm (9 2 lb ft) SMCS Code: 1202; 1219; 1225
(7) O-ring seal S/N: 8YS1-Up
Lightly lubricate the O-ring seal. Use the lubricant Table 2

that is being sealed. Connecting Rod Bearing Journal
Original size journal 82.000 0.020 mm
i00826094 (3.2283 .0008 inch)
Vibration Damper and Pulley Undersize journal

0.508 mm (.0200 inch)
81.492 0.020 mm
(3.2083 .0008 inch)
SMCS Code: 1205 Undersize journal 81.238 0.020 mm
0.762 mm (.0300 inch) (3.1983 .0008 inch)
The clearance between a new bearing and a new

journal is the following value. ..... 0.046 to 0.116 mm
(.0018 to .0046 inch)
i01003512

Journal
SMCS Code: 1202; 1219; 1225
S/N: 9NS1-Up
Table 3
Connecting Rod Bearing Journal
(3.5039 .0008 inch)
g00398558
Illustration 63 Undersize journal 88.492 0.020 mm
Typical Example 0.508 mm (.0200 inch) (3.4839 .0008 inch)
Undersize journal 87.238 0.020 mm
(1) Damper assembly 0.762 mm (.0300 inch) (3.4346 .0008 inch)
(2) Pulley
(3) Crankshaft journal is the following value. ..... 0.062 to 0.132 mm
(.0024 to .0052 inch)
torque. ................ 240 40 Nm (175 30 lb ft)

torque. ...................... 55 10 Nm (41 7 lb ft)
31
i00819737 i00962517
Main Bearing Journal Connecting Rod

SMCS Code: 1202; 1203 SMCS Code: 1218
Table 4 S/N: 8YS1-Up
(4.2520 .0008 inch)
0.508 mm (.0200 inch) (4.2320 .0008 inch)
0.762 mm (.0300 inch) (4.2220 .0008 inch)

(.0032 to .0071 inch)
Table 5
Main Bearing Bore
Main bearing bore (original 116.000 0.013 mm
size) (4.5669 .0005 inch)
Oversize bore in block 116.508 0.013 mm
0.508 mm (.0200 inch) (4.5869 .0005 inch)
g00490254
Illustration 64
(1) Bore in the connecting rod for the piston pin

bearing ............................... 55.435 0.013 mm
(2.1825 .0005 inch)
Note: The connecting rod must be heated for the

a torch.
(2) The connecting rod may be heated from

175C to 260C (347F to 500F) for the
installation of the piston pin bearing.
Maximum distance for heating the connecting
rod ..................................... 85.0 mm (3.35 inch)
(3) Bore in the bearing for the piston

pin ... 50.830 0.008 mm (2.0012 .0003 inch)
32
Diameter of the piston pin ........ 50.795 0.005 mm i00962529

(2.0000 .0002 inch)
Connecting Rod
Thoroughly lubricate the piston pin with clean
engine oil prior to assembly of the piston and SMCS Code: 1218
connecting rod.
S/N: 9NS1-Up
(4) The bearing joint must be within 10 degrees
of either location.

bearings ...................... 247.00 mm (9.724 inch)
(6) Etch the cylinder number on the connecting rod

and the cap in this location. Mark the connecting
rod and the cap with a number 1 through 6.
Mark the numbers on the same side of the
connecting rod as the bearing retainer notch.
Note: Install the connecting rod in the engine with

the part number to the rear of the engine.
(7) Tighten the connecting rod bolts. Use the

instructions that follow.
1. Before installing the connecting rod bolts,

lubricate the bolt threads and the seating faces
of the caps with 4C-5593 Anti-Seize Compound.
2. Tighten the connecting rod bolts.
Tighten the connecting rod bolts to the following

torque. ........................ 130 7 Nm (95 5 lb ft)
3. Tighten each connecting rod bolt for an

additional amount.
Rotate each connecting rod bolt in the clockwise

direction. .............. 60 5 degrees (1/6 of a turn)
(8) Bore in the connecting rod for the crankshaft

bearing ............................... 86.800 0.013 mm g00490254
Illustration 65
(3.4173 .0005 inch)
bearing ............................... 57.810 0.013 mm
(2.2760 .0005 inch)

a torch.

rod ..................................... 85.0 mm (3.35 inch)

pin ... 53.205 0.008 mm (2.0947 .0003 inch)
33

(2.0933 .0002 inch)
Piston and Rings
engine oil prior to assembly of the piston and SMCS Code: 1214; 1215
connecting rod.
S/N: 8YS1-Up
of either location.

bearings ...................... 242.50 mm (9.547 inch)


g00283705
Illustration 66
NOTICE
1. Before installing the connecting rod bolts, The piston pin plug prevents the piston pin from scuff-
lubricate the bolt threads and the seating faces ing the cylinder wall. The piston pin plug does not re-
of the caps with 4C-5593 Anti-Seize Compound. tain the piston pin into the assembly. Once the piston
assembly is removed from the cylinder liner, the pis-
2. Tighten the connecting rod bolts. ton pin is free to fall out of the piston assembly at any
time.
torque. ........................ 130 7 Nm (95 5 lb ft) (1) The piston is symmetrical with a center crater.
3. Tighten each connecting rod bolt for an Lubricate the entire piston in zone (A) prior to
additional amount. assembly into the cylinder block. Use clean engine
oil.
direction. .............. 60 5 degrees (1/6 of a turn) (2) Top piston ring
(8) Bore in the connecting rod for the crankshaft Install the piston ring with the side marked
bearing ............................... 93.800 0.013 mm UP-1 toward the top of the piston. The red
(3.6929 .0005 inch) stripe faces to the right of the piston ring end
gap.
The ends of the piston ring have a clearance
when the piston ring is installed in a cylinder
liner with a bore of 125.000 mm (4.9213 inch).
Clearance ............................. 0.625 0.185 mm
(.0250 .0073 inch)
The piston ring has an increase in clearance
for each 0.03 mm (.001 inch) increase in the
cylinder liner bore. Increase ................ 0.09 mm
(.004 inch)
Minimum depth of the groove in new piston for
the top ring ........................ 5.43 mm (.214 inch)
(3) Intermediate piston ring

34
Install the piston ring with the side marked Piston pin bore diameter that is in the bearing of the
UP-2 toward the top of the piston. The blue crown assembly ....................... 50.830 0.008 mm
stripe faces to the right of the piston ring end (2.0012 .0003 inch)
gap.
Width of groove in new piston for intermediate Thoroughly lubricate the piston pin with clean
piston ring ............................ 3.061 0.013 mm engine oil prior to assembly.
(.1205 .0005 inch)
Minimum depth of groove in new piston for (7) Piston skirt
intermediate piston ring .... 5.43 mm (.214 inch)
Thickness of new intermediate piston i00959202
ring ..... 2.988 0.013 mm (.1176 .0005 inch)
Clearance between groove and intermediate Piston and Rings
piston ring ............................ 0.047 to 0.099 mm
(.0019 to .0039 inch) SMCS Code: 1214; 1215
when the piston ring is installed in a cylinder S/N: 9NS1-Up
Clearance ............................. 0.625 0.125 mm
(.0246 .0049 inch)
clearance for each 0.03 mm (.001 inch) increase
in the cylinder liner bore. Increase ...... 0.09 mm
(.004 inch)
(4) Oil control piston ring

The ends of the oil control piston ring should
be a distance of 180 degrees from the ring
end gap when the oil control piston ring is
assembled. The orange colored portion of the
piston ring must be visible at the ring end gap.
g00283705
Illustration 67
Width of groove in new piston for oil control
piston ring ............................ 4.033 0.013 mm
(.1588 .0005 inch) NOTICE
Minimum depth of groove in new piston for oil The piston pin plug prevents the piston pin from scuff-
control piston ring ......... 3.727 mm (.1467 inch) ing the cylinder wall. The piston pin plug does not re-
Thickness of new oil control piston tain the piston pin into the assembly. Once the piston
ring ..... 3.987 0.013 mm (.1570 .0005 inch) assembly is removed from the cylinder, the piston pin
Clearance between groove and oil control piston is free to fall out of the piston assembly at any time.
ring .... 0.020 to 0.072 mm (.0008 to .0028 inch)
The ends of the piston ring have a clearance (1) The piston is symmetrical with a center crater.
liner with a bore of 125.000 mm (4.9213 inch). Lubricate the entire piston in zone (A) prior to
Clearance ... 0.44 0.15 mm (.017 .006 inch) assembly into the cylinder block. Use clean engine
The piston ring has an increase in clearance oil.
for each 0.03 mm (0.001 inch) increase in the
cylinder liner bore. Increase ................ 0.09 mm (2) Top piston ring
(.004 inch)
Install the piston ring with the side marked
After the piston rings have been installed, rotate the UP-1 toward the top of the piston. The green
piston rings so that the end gaps are 120 degrees stripe faces to the right of the piston ring end
from each other. gap.
(5) Crown assembly
(6) Piston pin bore diameter that is in the piston
Clearance ............................. 0.520 0.125 mm
skirt .. 50.815 0.005 mm (2.0006 .0002 inch)
(.0205 .0049 inch)
35
The piston ring has an increase in clearance (5) Crown assembly

cylinder liner bore. Increase ................ 0.09 mm (6) Piston pin bore diameter that is in the piston
(.004 inch) skirt .. 53.190 0.005 mm (2.0941 .0002 inch)
the top ring ........................ 5.43 mm (.214 inch) Piston pin bore diameter that is in the bearing of the
crown assembly ....................... 53.205 0.010 mm
(3) Intermediate piston ring (2.0947 .0004 inch)
Install the piston ring with the side marked Thoroughly lubricate the piston pin with clean
UP-2 toward the top of the piston. The red engine oil prior to assembly.
stripe faces to the right of the piston ring end
gap. (7) Piston skirt
Width of groove in new piston for intermediate
piston ring ............................ 3.052 0.013 mm
i00959246
(.1202 .0005 inch)
Minimum depth of groove in new piston for
Housing (Front)
Thickness of new intermediate piston SMCS Code: 1151
ring ..... 2.950 0.013 mm (.1161 .0005 inch)
Clearance between groove and intermediate
piston ring ............................ 0.076 to 0.128 mm
(.0030 to .0050 inch)
Clearance ............................. 0.625 0.125 mm
(.0246 .0049 inch)
(.004 inch)

assembled. The white colored portion of the
Width of groove in new piston for oil control g00281150
Illustration 68
piston ring ............................ 4.042 0.012 mm
(.1591 .0005 inch)
(1) Bolt
Minimum depth of groove in new piston for oil
control piston ring ......... 3.727 mm (.1467 inch) Tighten the bolts to the following
Thickness of new oil control piston torque. ........................ 28 7 Nm (20 5 lb ft)
ring ..... 3.987 0.013 mm (.1570 .0005 inch)
Clearance between groove and oil control piston (2) Bolt
ring .... 0.030 to 0.080 mm (.0012 to .0031 inch)
The ends of the piston ring have a clearance Tighten the 13 bolts to the following
when the piston ring is installed in a cylinder torque. ........................ 35 8 Nm (26 6 lb ft)
Clearance ... 0.44 0.15 mm (.017 .006 inch) (3) O-ring seal and crankshaft front seal
for each 0.03 mm (.001 inch) increase in the The O-ring seal and the crankshaft front seal are
cylinder liner bore. Increase ................ 0.09 mm part of the front housing. Lubricate the O-ring seal
(.004 inch) lightly. Use the lubricant that is being sealed.
After the piston rings have been installed, rotate the (4) Accessory drive assembly
piston rings so that the end gaps are 120 degrees
from each other.
36
g00281151
Illustration 69
View A-A
(5) The dowel extends past the surface

of the housing by the following
distance. ............. 5.0 0.5 mm (.20 .02 inch)
g00281152
Illustration 70
View B-B

distance. ........... 10.0 0.5 mm (.39 .02 inch)
Note: Apply 8T-9022 Silicone Gasket in order to

fill the space at the connecting joint of the front
housing, engine oil pan, and cylinder block.
37
i00820827
Gear Group (Front)

SMCS Code: 1206
g00281161
Illustration 71
(1) Diameter of gear bore for (8) Front face of the block
bearing ............................... 60.163 0.015 mm
(2.3686 .0006 inch) (9) Camshaft idler gear
Diameter of shaft for idler gear .. 55.047 0.020 mm Diameter of gear bore for
(2.1672 .0008 inch) bearing .. 74.452 0.015 mm (2.9312 .0006 inch)
(2) Idler gear Diameter of shaft for idler gear .. 69.141 0.008 mm
(2.7221 .0003 inch)
(3) Front face of the block
(10) Crankshaft gear
(4) Camshaft gear
(11) Crankshaft
(5) Front timing gear housing
(6) Tighten the bolts to the following torque. .................. 100 20 Nm (75 15 lb ft)
torque. ................ 240 40 Nm (175 30 lb ft)
(13) Align the timing marks that are on the idler
(7) Camshaft gear with the timing marks that are on the
crankshaft gear and the camshaft gear.
38
i00926641
Rear Power Take-Off (RPTO)

SMCS Code: 1165-RE
g00281162
Illustration 72
Typical example of the gear assembly for the idler gears
(14) Inside diameter of bearing that is installed in

idler gear (2) ...................... 55.163 0.041 mm
(2.1718 .0016 inch)
Inside diameter of bearing that is installed in

camshaft idler gear (9) ............. 69.205 0.013 mm
(2.7246 .0005 inch)
(15) Bearing Illustration 73 g00403944
(16) Install the bearing in the idler gear (2) to the

following depth. ........................ 1.00 0.25 mm
(.039 .010 inch)
Install the bearing in the camshaft idler gear (9) to

the following depth. ........................ 1.00 0.25 mm
(.039 .010 inch)
g00403946
Illustration 74
g00403945
Illustration 75
39
(1) Diameter of the output shaft (PTO) i01012861

(A) ... 60.245 0.025 mm (2.3720 .0010 inch)
Flywheel
The end play of the output shaft (1) .. 0.97 0.43 mm
(.038 .017 inch) SMCS Code: 1156
Part No.: 123-0816
(2) The bearing in the carrier assembly
should be installed to the following depth
(B). ...................... 1.6 0.5 mm (.06 .02 inch)
(3) When the engine is viewed from the rear, the

split in the bearings should be located at the
seven oclock position .
(4) Inside diameter of the drive gear for the power

take-off ................................ 60.320 0.025 mm
(2.3750 .0010 inch)
The clearance between the output shaft

(1) and the drive gear (4) for the power
take-off ......... .025 to .125 mm (.0010 to .0050 inch)
(5) When the engine is viewed from the rear, the

split in the bearings should be located at the
seven oclock position.
(6) Thickness of the thrust

washer .................................. 4.690 0.025 mm
(.1850 .0010 inch)
(7) Thickness of the thrust

washer .................................. 4.690 0.025 mm
(.1850 .0010 inch)
(8) Thickness of the thrust plate ................ 6.75 mm Illustration 76

g00394357
(.266 inch)
Refer to the Testing And Adjusting, Basic Block
(9) The bearing must not extend beyond either face topic for the proper procedure to check flywheel
of the idler gear assembly. Relief (12) in the runout.
bearing must line up with the reliefs in the gear
within 2 degrees. (1) Flywheel ring gear
(10) Depth of the seal ........................ 2.5 0.5 mm The flywheel ring gear must be assembled
(.01 .02 inch) against the shoulder (A) of the flywheel. The
maximum temperature of the ring gear for
installation .................................. 300 C (572 F)
(2) Flywheel
(3) Bolt
Apply 7M-7456 Compound to the bolt threads.
torque. ................ 300 40 Nm (220 30 lb ft)
40
i01012848 i00826037
Flywheel Engine to Transmission

SMCS Code: 1156
Adapter
Part No.: 117-2774, 123-0815 SMCS Code: 1001
S/N: 8YS1-Up
S/N: 9NS1-Up
g00398205
Illustration 78
Typical Example
g00393838
Illustration 77 (1) Flywheel
Typical Example
(2) Adapter
topic for the proper procedure to check flywheel (3) Apply 9S-3263 Thread Lock Compound to
runout. the bolts. Tighten the bolts to the following
torque. ................ 300 40 Nm (220 30 lb ft)
(1) Flywheel ring gear
The flywheel ring gear must be assembled torque. .................... 70 15 Nm (51 11 lb ft)
against the shoulder (A) of the flywheel. The
installation .................................. 315 C (599 F) i01211708
(2) Flywheel Belt Tension Chart

(3) Bolt SMCS Code: 1357
Apply 7M-7456 Compound to the bolt threads. Note: Do not use the belt tension chart for belts with
torque. ................ 300 40 Nm (220 30 lb ft)
41
Table 6
Belt Tension Chart
Borroughs Gauge
Gauge Reading
Numbers
Belt
of the Old the New
Initial(1) Used(2)
Gauge Gauge
i00817864 i00817913
Belt Tensioner Belt Tensioner

g00390952 g00390992
Use the following procedure in order to adjust the (1) Plate

belt tensioner:
Note: Install plate (1) with SIDE A toward the front
1. Remove the belt so that there is no tension on of the engine.
the belt tensioner.
2. Align the thick black line on 134-1018 Film (1) torque. ........................ 85 5 Nm (65 4 lb ft)
with shoulder (2) of the tensioners arm (3).
(3) Damper
3. Install the belt. Shoulder (2) should be in the
green zone of 134-1018 Film (1).
42
i01176753 (1) Damper assembly

Belt Tightener (2) Pulley
SMCS Code: 1358 (3) Adapter
(4) Crankshaft

torque. ................ 300 40 Nm (220 30 lb ft)

torque. .................... 70 15 Nm (50 11 lb ft)
i00828135
Auxiliary Drive Pulley

SMCS Code: 1205
Part No.: 129-2907
g00391337
Illustration 81

torque. ........................ 85 5 Nm (65 4 lb ft)
i00826186
Auxiliary Drive Pulley

SMCS Code: 1205
g00400098
Illustration 83
(1) Damper assembly
(2) Pulley
(3) Adapter
(4) Crankshaft

torque. ................ 300 40 Nm (220 30 lb ft)
g00398438
Illustration 82
Typical Example
43
i00820881
Engine Support (Front)

SMCS Code: 1153; 1154
g00289618
Illustration 86

Battery Load Tester in order to get the maximum
alternator output.
g00393398
Illustration 84
Typical Example Polarity ........................................... Negative Ground
(1) Tighten the bolts to the following Rotation ..................................................... Clockwise

torque. .................. 120 20 Nm (90 15 lb ft)
Minimum full load current at 5000 rpm ..... 107 Amp
(2) Front housing group
Minimum full load current at 1500 rpm ....... 45 Amp
i00826442 Output voltage ...................................... 14.0 0.5 V
Alternator and Regulator (1) Shaft nut torque ........ 102 7 Nm (75 5 lb ft)
SMCS Code: 1405; 1410
(2) Positive terminal torque .............. 11.3 2.3 Nm
(100 20 lb in)
(3) Negative terminal torque .............. 6.2 0.6 Nm

(55 5 lb in)
(4) Regulator
Voltage setting .................................. No Adjustment
Permissible voltage range ................. 13.5 to 14.5 V
g00289617
Illustration 85
44
i00969807 (3) Ground terminal

Electric Starting Motor Tighten the nut on the ground terminal to the
SMCS Code: 1453 (20 2 lb in)
Part No.: 8C-3592 (4) Switch terminal
Tighten the nut on the switch terminal to the
(20 2 lb in)
(5) Motor terminal

Tighten the nut on the motor terminal to the
(6) Motor frame terminal

Tighten the nut on the motor frame terminal to
Illustration 87
g00282744 Clearance between the pinion and the
housing ........................................ 9.1 mm (.36 inch)
Typical Example
Solenoid
Current draw at 10 V and 25 C (77 F)
Pull-in windings ......................... 92.5 7.5 Amp
Hold-in windings ................... 23 Amp maximum
i00970021

SMCS Code: 1453
Illustration 88 g00493900 Part No.: 6V-5540

S/N: 8YS1-Up
When the electric starting motor is viewed from S/N: 9NS1-Up
No load conditions at 25 C (77 F)

Speed ..................................... 6900 1800 rpm
Current draw ......................... 127.5 27.5 amp
Voltage ......................................................... 11 V
(1) Battery terminal

A maximum of three cable or wire terminals
should be between the nuts.
Tighten the nut on the battery terminal to the
g00400230
Illustration 89
(2) Ground terminal
Tighten the nut on the ground terminal to the
45

the following torque. ................... 30.5 3.5 Nm
(22 3 lb ft)
Clearance between the pinion and the

housing .................... 8.3 to 9.9 mm (.33 to .39 inch)
Solenoid
Pull-in windings ..................................... 51 Amp
Hold-in windings ..................... 7 Amp maximum
g00494106
Illustration 90
i00970077
When the electric starting motor is viewed from
the pinion end, the motor rotates in the following Electric Starting Motor
SMCS Code: 1453

No load conditions at 25 C (77 F) Part No.: 6V-5582
Speed .................................. 5500 rpm minimum
Current draw ....................... 140 amp maximum
Voltage ......................................................... 24 V

(2) Ground terminal

following torque. ... 30.5 3.5 Nm (22 3 lb ft) g00282453
Illustration 91
(3) Ground terminal

(20 2 lb in)
(4) Switch terminal

The wire terminal that is on the switch terminal
must be insulated with heat shrink tubing. Do
not use molded terminals.
(20 2 lb in)
g00494167
Illustration 92
(5) Motor terminal
Tighten the nut on the motor terminal to the When the electric starting motor is viewed from
following torque. ... 30.5 3.5 Nm (22 3 lb ft) the drive end, the motor rotates in the following
Minimum speed with no load .............. 3300 rpm
46
Maximum current with no load .............. 80 amp i00970013

Voltage ...................................................... 23.5 V
SMCS Code: 1453
should be between the nuts. Part No.: 106-8554
(2) Ground terminal

following torque. .... 1.5 0.5 Nm (13 4 lb in)
(3) Ground terminal

(4) Switch terminal

g00282688
The wire terminal that is on the switch terminal Illustration 93
(20 2 lb in)
(5) Motor terminal


g00493900
(13 2 lb ft) Illustration 94

Solenoid the drive end, the motor rotates in the following
Pull-in windings ................................... 103 Amp No load conditions at 25 C (77 F)
Hold-in windings ................... 19 Amp maximum Speed ..................................... 7643 1683 rpm
Current draw ............................. 67.5 7.5 amp
Voltage ......................................................... 23 V

(2) Ground terminal

47
(3) Ground terminal (2) The plug has pin A, pin B, and pin C.
Tighten the nut on the ground terminal to the Table 7
Table for Wiring
(20 2 lb in)
Pin or Socket Wire Color Circuit
(4) Switch terminal
A OR Vs
The wire terminal that is on the switch terminal B YL GND
not use molded terminals. C GN SIG
i00831264
(20 2 lb in)
(5) Motor terminal

Fuel Temperature Sensor
Tighten the nut on the motor terminal to the SMCS Code: 1922


housing ........................................ 9.1 mm (.36 inch)
Solenoid
Pull-in windings ......................... 56.5 4.5 Amp Illustration 96 g00280388
Hold-in windings ................ 14.6 Amp maximum

(1) Sensor assembly
i00830066 Tighten the sensor assembly to the following

torque. .............................. 20 3 Nm (15 3 lb ft)
Coolant Temperature Sensor
(2) The plug has pin A, pin B, and pin C.
SMCS Code: 1906
Table 8
Table for Wiring
A OR Vs
B YL GND
C GN SIG
g00280388
Illustration 95
(1) Sensor assembly

torque. .............................. 20 3 Nm (15 3 lb ft)
48
i00831226 i00829968
Engine Oil Pressure Sensor Boost Pressure Sensor

g00118253 g00281665
Typical Example
(1) Sensor assembly
(1) Sensor assembly
(2) Plug with socket A, socket B, and socket C torque. ........................... 10 2 Nm (88 18 lb in)
(3) Port fitting (2) The plug has socket A, socket B, and socket C.
Tighten port fitting to the following Table 10

torque. ........................... 10 2 Nm (88 18 lb in) Table for Wiring
Table 9 Pin or Socket Wire Color Circuit
Table for Wiring A OR Vs
Pin or Socket Wire Color Circuit B YL GND
A OR Vs C GN SIG
B YL GND
C GN SIG i00974651

SMCS Code: 1923
g00281665
Illustration 99
(1) Sensor assembly

49
Tighten the sensor assembly to the following i00831594

torque. ..................... 10 2 Nm (88 18 lb in)
Speed and Timing Sensor
(2) The plug has socket A, socket B, and socket C.
SMCS Code: 1907; 1912
i00831317
Inlet Air Temperature Sensor

SMCS Code: 1921
g00285127
Illustration 101
(1) Plug with socket A, socket B, and socket C.
(2) Sensor assembly

g00281563
Illustration 100
Put clean engine oil on the O-ring seal. Put
4C-5598 High Temperature Anti-Seize on the
(1) Sensor assembly
threads. Tighten the control assembly to the
following torque. ............... 40 5 Nm (30 4 lb ft)
torque. .............................. 15 3 Nm (11 2 lb ft) Table 12
(2) The plug has socket A, socket B, and socket C. Table for Wiring
Table 11
A OR Vs
Table for Wiring
B BL GND
C WH SIG
A OR Vs
B BL GND
C WH SIG
50
Index Section
Index
A G
Alternator and Regulator ....................................... 43 Gear Group (Front)................................................ 37

Atmospheric Pressure Sensor............................... 48
Auxiliary Drive Pulley ............................................. 42
H
B Housing (Front)...................................................... 35
Belt Tension Chart ................................................. 40

Belt Tensioner........................................................ 41 I
Belt Tightener ........................................................ 42
Boost Pressure Sensor.......................................... 48 Important Safety Information ................................... 2
Inlet Air Temperature Sensor................................. 49
C
L
Camshaft ......................................................... 1820
Compression Brake ......................................... 1314 Lifter Group.............................................................. 7
Connecting Rod............................................... 3132
Coolant Conditioner Base...................................... 24 M
Coolant Temperature Sensor................................. 47
Crankshaft ............................................................ 29 Main Bearing Journal ............................................ 31
Crankshaft Seals ................................................... 29
Cylinder Block........................................................ 25
Cylinder Head........................................................ 12 P
Cylinder Liner ........................................................ 28 Piston and Rings ............................................. 3334
Cylinder Liner Projection ....................................... 29
R
E
Rear Power Take-Off (RPTO) ................................ 38
Electric Starting Motor ..................................... 4446 Rocker Shaft............................................................ 8
Solenoid ....................................................... 4447
Electronic Unit Injector............................................. 6
Electronic Unit Injector Mechanism ......................... 6 S
Electronic Unit Injector Rocker Arm......................... 7
Electronic Unit Injector Wiring ................................. 7 Specifications Section ............................................. 4
Engine Design ......................................................... 4 Speed and Timing Sensor ..................................... 49
Engine Oil Filter Base............................................ 21
Engine Oil Pan................................................. 2324
Engine Oil Pressure............................................... 23 T
Engine Oil Pressure Sensor .................................. 48
Engine Oil Pump.................................................... 23 Table of Contents..................................................... 3
Engine Support (Front) .......................................... 43 Turbocharger ................................................... 1617
Engine to Transmission Adapter............................ 40
Exhaust Manifold ............................................. 1718
V
F Valve Mechanism ................................................ 89

Flywheel .......................................................... 3940 Valve Rocker Arm .................................................... 9
Fuel Filter and Water Separator .............................. 6 Vibration Damper and Pulley................................. 30
Fuel Lines ................................................................ 5
Fuel Temperature Sensor ...................................... 47
Fuel Transfer Pump ................................................. 5
51
Index Section
Water Temperature Regulator ............................... 25

Water Temperature Regulator Housing ................. 25
1999 Caterpillar
RENR1323-01
July 1998
Systems Operation
8YS1-Up (Engine)
9NS1-Up (Engine)
i00056692

WARNING as shown below.

this publication.
3
Table of Contents
Table of Contents
Engine Design ....................................................... 4
Engine Design ....................................................... 4
Glossary of Electronic Control Terms ..................... 6
Fuel System ......................................................... 14
Cooling System .................................................... 27
Basic Block ........................................................... 31
Electrical System ................................................. 36

Electronic Control System .................................... 40
Fuel System .......................................................... 41
Air Inlet And Exhaust System ............................... 45
Lubrication System ............................................... 51
Cooling System ..................................................... 53
Belt Tension Chart ................................................ 59
Basic Block ........................................................... 60
Basic Block ........................................................... 65
Electrical System .................................................. 72
Index Section
Index ..................................................................... 78
4
Systems Operation Section i00841047
Engine Design
i00840968
SMCS Code: 1000
Engine Design S/N: 9NS1-Up
SMCS Code: 1000
S/N: 8YS1-Up
g00412347
Illustration 2
Cylinder and Valve Location
g00412347
Illustration 1 Bore ....................................... 130.0 mm (5.12 inch)
Stroke ..................................... 150.0 mm (5.91 inch)
Bore ....................................... 125.0 mm (4.92 inch)
Displacement .................................. 12 L (729 cu in)
Stroke ..................................... 140.0 mm (5.51 inch)
Displacement ............................... 10.3 L (629 cu in)
Valves per cylinder ................................................. 4 the engine must be cold and the engine must be
the engine must be cold and the engine must be Inlet .................................... 0.38 mm (.015 inch)
stopped. Engine valve lash settings Exhaust .............................. 0.64 mm (.025 inch)
Engine Compression Brake ... 1.016 0.08 mm
Inlet .................................... 0.38 mm (.015 inch) (.040 .003 inch)
Exhaust .............................. 0.64 mm (.025 inch)
Engine Compression Brake ..... 0.64 0.08 mm Type of combustion .......................... Direct Injection
(.025 .003 inch)
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4 flywheel end of the engine. Crankshaft
rotation .......................................... counterclockwise
flywheel end of the engine. Crankshaft Note: The front end of the engine is opposite of
rotation .......................................... counterclockwise the flywheel end of the engine. The left side of the
Note: The front end of the engine is opposite of from the flywheel end of the engine. The No. 1
the flywheel end of the engine. The left side of the cylinder is the front cylinder.
from the flywheel end of the engine. The No. 1
5
i00841107 Cold Mode Operation

General Information The ECM will set the cold start strategy under the
following conditions:
SMCS Code: 1000
the coolant temperature is below 17C (63F).
The C-10 engines and the C-12 engines are in-line
six cylinder arrangements. The C-10 engines have Under these conditions, low idle rpm will be
a bore of 125.0 mm (4.92 inch) and a stroke of increased to 800 rpm. The engines power will also
140.0 mm (5.51 inch). The displacement is 10.3 L be limited.
(629 cu in). The C-12 engines have a bore of
130.0 mm (5.12 inch) and a stroke of 150.0 mm Cold mode operation will be deactivated after any
(5.91 inch). The displacement is 12 L (729 cu in). one of the following conditions:
The engines have a firing order sequence:1, 5, 3, 6,
2, and 4. The engines rotation is counterclockwise the coolant temperature is above 28C (82F).
when the engine is viewed from the flywheel end of
the engine. The engine utilizes a turbocharger and twelve minutes of running
an air-to-air aftercooler.
Cold mode operation varies the fuel injection amount
The electronic unit injector system (EUI) eliminates for white smoke cleanup. Cold mode operation
many of the mechanical components that are also varies the timing for white smoke cleanup. The
traditionally used in the fuel injector assembly. The engine operating temperature is usually reached
EUI also provides increased control of the timing before the walk-around inspection is completed.
and increased control of the fuel air mixture. The The engine will idle at the programmed low idle rpm
timing advance is achieved by precise control of in order to be put in gear.
the injector timing. Engine rpm is controlled by
adjusting the injection duration. A special pulse
wheel provides information to the Electronic Control NOTICE
Module (ECM) for detection of cylinder position and Do not move the vehicle with the engine in the cold
engine rpm. mode condition. Engine power could be noticeably re-
duced. At a vehicle speed above 8 km/h (5 mph), low
The engine has built-in diagnostics in order to idle rpm will be reduced to the customer programmed
ensure that all of the components are operating low idle and the power will still be reduced.
properly. In the event of a system component
failure, the operator will be alerted to the condition After the cold mode is completed, the engine
by a check engine light. The check engine light is should be operated at low rpm until normal
located on the dashboard. An electronic service operating temperature is reached. The engine will
tool can be used to read the numerical code of reach normal operating temperature faster when
the faulty component or condition. Also, the cruise the engine is operated at low rpm and low power
control switches can be used to flash the code on demand. Typically, the engine should be up to
the check engine light. Intermittent faults are logged operating temperature by just driving the vehicle
and stored in memory. through the yard toward the open road.
Starting The Engine Customer Specified Parameters

The engines ECM will automatically provide the The engine is capable of being programmed for
correct amount of fuel in order to start the engine. several customer specified parameters. For a brief
Do not hold the throttle down while the engine is explanation of each of the customer specified
cranking. If the engine fails to start in 30 seconds, parameters, see the Operation and Maintenance
release the starting switch. Allow the starting motor Manual.
to cool for two minutes before using the starting
motor again.
NOTICE
Excessive ether (starting fluid) can cause piston and
ring damage. Use ether for cold weather starting pur-
poses only.
6
i00842068 Calibration Calibration is an electronic adjustment

of a sensor signal.
Glossary of Electronic Control
Terms CAT Data Link The data link is an electrical
connection that is used to communicate with
SMCS Code: 1900 other devices that utilize microprocessors. The
microprocessor based devices are compatible
ATA Data Link The ATA Data Link is an electrical with the proposed American Trucking Association
connection that is used for communication between and the SAE standard. These devices include trip
microprocessor based devices. The devices recorders, electronic dashboards, and maintenance
must be compatible with the American Trucking systems. The data link is also the communication
Association and SAE Standards (J1587 and J1708) medium that is used for programming with the
such as trip recorders, electronic dashboards, electronic service tool. The data link is also used for
and maintenance systems. The ATA Data Link troubleshooting with the electronic service tool.
is the communication medium that is used for
the programming and the troubleshooting with Caterpillar Engine Monitoring The part of the
Caterpillar electronic service tools. Caterpillar Electronic Engine Control that monitors
coolant temperature, oil pressure, inlet manifold
After Market Device An after market device is air temperature, and coolant level. Caterpillar
a device or an accessory that is installed by the engine monitoring then informs the operator of
customer after the vehicle is delivered. any problems that are detected. The Coolant
Temperature, Inlet Manifold Air Temperature, and Oil
Air-To-Air Aftercooler An air-to-air aftercooler is pressure Sensors are supplied by Caterpillar and
a device that is used on turbocharged engines Monitored by the ECM. The coolant level sensor
in order to cool inlet air that has undergone is installed by the OEM factory but still monitored
compression. The inlet air is cooled after the inlet by the ECM. This is opposed to an aftermarket
air passes through the turbocharger. The inlet air Engine Monitoring System. An aftermarket Engine
is passed through an aftercooler (heat exchanger) Monitoring System does not interface with the
that uses ambient air for cooling. The inlet air that Caterpillar Electronic Engine Control.
has been cooled advances to the inlet manifold.
Clutch Switch The clutch switch is supplied by
Alternating Current (AC) The direction of the the OEM factory. The clutch switch is a limit switch.
current flow changes. The current flow alternates The usually adjustable switch is mounted near the
constantly. pedal. When the pedal is released, the switch is
closed. Depressing the clutch will open the circuit.
American Wire Gauge (AWG) AWG is a measure
of the diameter of electrical wire. AWG is also Code See the Diagnostic Code.
a measure of the current carrying capacity of
electrical wire. When the AWG number is smaller, Coolant Fan Relay The relay is supplied by the
the diameter of the wire is larger. When the AWG OEM manufacturer. The installed relay is controlled
number is larger, the diameter of the wire is smaller. by the ECM. The ECM controls the cooling fan relay.
The ECM uses the following information to control
Atmospheric Pressure Sensor The atmospheric the cooling fan relay: coolant temperature and the
pressure sensor measures barometric pressure. high pressure switch on the air conditioner.
The sensor sends a signal to the electronic control
module (ECM). The signal is used in engine control Coolant Level Sensor The sensor is installed by
and in engine operation. the OEM factory. The sensor detects the absence
of coolant at the probe. The sensor also detects the
Before Top Center (BTC) BTC is the 180 degrees presence of coolant at the probe. The sensor then
of crankshaft rotation before the piston reaches sends the appropriate signal to the ECM.
rotation. Coolant Temperature Sensor The coolant
temperature sensor measures the engine coolant
Boost Pressure Sensor The boost pressure sensor temperature. The sensor sends a signal to the
measures inlet manifold air pressure. The boost electronic control module (ECM). The engines
pressure sensor sends a signal to the Electronic coolant temperature is used in Cold Mode
Control Module (ECM). operation. Coolant temperature is also used in order
to optimize engine performance.
Bypass Circuit A bypass circuit is a circuit that is
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit.
7
Cruise Control Range The cruise control range Dual Coil Speed Sensor The movement of the
establishes the vehicle speed range for the teeth on the output shaft of the transmission is
operation of cruise control. The range is usually detected by the dual coil speed sensor. The sensor
limited to the speed range that is anticipated on contains two coils. One coil is used to supply a
the open road. signal to the speedometer. The second coil is used
to supply a signal to the speed buffer.
Custom Data The custom data is for monitoring
purposes. The ECM stored trip data holds the Duty Cycle See Pulse Width Modulation.
custom data. The custom data allows the owner
to specify operating parameters of the engine Electronic Control Analyzer Programmer (ECAP)
application. The ECAP is a Caterpillar electronic service
tool. The ECAP is used for programming and for
Customer Specified Parameters A customer diagnosing various types of electronic controls.
specified parameter is a parameter that can be
changed. A customer specified parameters value Electronic Control Module (ECM) The ECM is
is set by the customer. These parameters are the engines control computer. The ECM provides
protected by customer passwords. power to the electronics. The ECM monitors data
that is input from the engines sensors. The ECM
Dash Check Engine Lamp The dash check engine acts as a governor in order to control engine rpm.
lamp is sometimes called the diagnostic lamp.
The dash check engine lamp is used to warn the ECM Fan Control The ECM controls the cooling
operator of the presence of an active diagnostic fan relay. The ECM uses the following information
code. to control the cooling fan relay: coolant temperature
and the high pressure switch on the air conditioner.
Desired RPM The desired rpm is input to the
electronic governor within the ECM. The electronic Electronic Engine Control The electronic engine
governor uses the signal from the Accelerator Pedal control is a complete electronic system. The
Position Sensor, the Engine Speed Sensor, the electronic engine control monitors the engine
Cruise Control, and the Customer Parameters in operation under all conditions. The electronic
order to determine desired rpm. engine control also controls the engine operation
under all conditions.
Diagnostic Code A diagnostic code is sometimes
called a fault code. A diagnostic code is an Electronic Technician (ET) The ET is a Caterpillar
indication of a problem or event in the electrical electronic service tool that is used for diagnosing
engine systems. and programming a variety of electronic controls.
Diagnostic Event Code These codes indicate an Engine Retarder Solenoids The engine retarder
event. Diagnostic event codes are not necessarily solenoids are installed by Caterpillar. The solenoids
an indication of problem within the electronic are driven directly from the ECM unlike the auxiliary
system. brake. The auxiliary brake utilizes a relay that is
installed by the OEM factory.
Diagnostic Fault Code Diagnostic fault codes
indicate an electronic system malfunction that Engine Speed/Timing Sensor The engine
indicates a problem with the electronic system. speed/timing sensor provides a pulse width
modulated signal to the ECM. The ECM interprets
Diagnostic Flash Code Diagnostic flash codes are the signal as the crankshaft position and the engine
used to indicate a malfunction within the electronic speed.
system. Diagnostic flash codes are also used to
indicate an event that is detected by the electronic Failure Mode Identifier (FMI) The FMI describes
system. The codes are flashed on the dash check the type of failure that was experienced by the
engine lamp. component. The codes for the FMI were adopted
from the standard practices of SAE (J1587
Diagnostic Lamp A diagnostic lamp is sometimes diagnostics).
called the check engine light. The diagnostic lamp
is used to warn the operator of the presence of an Flash Code TheCaterpillar code numbers that are
active diagnostic code. displayed on the diagnostic lamp.
Direct Current (DC) Direct current is the type of

8
Fuel Ratio Control (FRC) The FRC is a limit that Open Circuit An open circuit is a broken electrical
is based on the control of the fuel to air ratio. The wire connection. The signal or the supply voltage
FRC is used for emission control. When the ECM cannot reach the intended destination.
senses a higher turbocharger outlet pressure, the
ECM increases the limit for the FRC in order to allow Original Equipment Manufacturer (OEM) An OEM
more fuel into the cylinders. is the manufacturer of a vehicle that utilizes a
Caterpillar engine.
Fuel Position The fuel position is a signal within
the ECM. The signal is from the electronic governor. Parameter A parameter is a programmable value
The signal goes to the fuel injection control. The which affects the characteristics or the behavior of
signal is based on the desired engine speed, the the engine and/or vehicle.
FRC, the rated position, and the actual engine
speed. Parameter Identifier (PID) A PID is a numerical
code that contains two digits or three digits. A
Fuel Temperature Sensor This sensor detects numerical code is assigned to each component.
the fuel temperature. The ECM monitors the fuel The numerical code identifies data via the data link
temperature. The ECM then calculates the needed to the ECM.
fuel rate.
Password A password is a group of numeric
Full Load Setting (FLS) The full load setting is characters or alphanumeric characters. A password
used to fine tune the fuel system at the factory. is designed to restrict the changing of information
The correct value for the parameter is printed on in the ECM. The electrical engine systems require
the 115-5852 Plates and Films. The parameter correct customer passwords in order to change
must be programmed. The diagnostic code 253-02 customer specified parameters. The electrical
Customer or System Parameters will be displayed. engine systems require correct factory passwords
in order to clear certain logged events. Factory
Full Torque Setting (FTS) Full torque setting is passwords are also required in order to change
similar to Full Load Setting. The parameter must certain engine specifications.
be programmed. The diagnostic code 253-02
Customer or System Parameters will be displayed. Pedal Mounted Throttle Position Sensor The
pedal mounted throttle position sensor measures
Gear Down Protection High gear limits are used the pedal position and the pedal mounted throttle
to promote driving in higher gears for increased fuel position sensor sends a signal to the ECM. The
economy. The limits are programmable to different sensor is mounted on a throttle pedal assembly.
settings.
Personality Module The personality module is
Harness The harness is the bundle of wiring the module in the ECM which contains all the
that connects all the components of the electrical instructions (software) for the ECM and performance
engine system. maps for a specific horsepower family. Updates and
rerates are accomplished by electronically flashing
Hertz (Hz) Hz is the measure of frequency in in new data. The updates and rerates are flashed in
cycles per second. using an electronic service tool.
Histogram A histogram is a bar graph that Power Take-Off (PTO) The power take-off is
indicates the relative frequency of the engine operated with the cruise control switches or with the
operation in specific operating ranges. dedicated PTO switches. This mode of operation
permits setting constant engine rpm when the
Integrated Electronic Controls The engine is vehicle is not moving or when the vehicle is moving
designed with the electronic controls as a necessary at slow speeds.
part of the system. The engine will not operate
without the electronic controls. Pro-Link The Pro-Link is an electronic service
tool that is manufactured by Micro Processor
Inlet Manifold Temperature Sensor The inlet air Systems, Inc. (MPSI). The Pro-Link is available with
temperature sensor is a sensor that measures the a Caterpillar cartridge to service the Caterpillar
inlet air temperature. The sensor also sends a signal electronic engines.
to the electronic control module (ECM).
Oil Pressure Sensor The oil pressure sensor

measures engine oil pressure and the oil pressure
sensor sends a signal to the ECM as part of
Caterpillar Engine Monitoring.
9
Pulse Width Modulation (PWM) A PWM is a digital Speed Burp A speed burp is a sudden brief
type of electronic signal that corresponds to a change in engine rpm.
measured variable. The length of the pulse (signal)
is controlled by the measured variable. The variable Speed Circuit The speed circuit includes the
is quantified by a certain ratio. This ratio is the speed sensor, the harness and the ECM.
percent of on-time that is divided by the percent
of off-time. A PWM signal is generated by the Speed Sensor The speed sensor is an
Throttle Position Sensor. electromagnetic pickup that measures speed from
the rotation of gear teeth in the drive train.
Rated Fuel Position (Rated Fuel Pos on ECAP)
The rated fuel position indicates the maximum Standard SAE Diagnostic Communications Data
allowable fuel position (longest injection pulse). The Link For more information, refer to ATA Data Link.
rated fuel position will produce rated power for this
engine configuration. Subsystem A subsystem is a part of the engine
system that relates to a particular function.
Reference Voltage The reference voltage is a
regulated voltage that is used by the sensor in order Supply Voltage Supply voltage is a constant
to generate a signal voltage. voltage that is supplied to a component in order
Remote Mounted Throttle Position Sensor The voltage may be generated by the ECM. Supply
remote mounted throttle position sensor measures voltage may also be the battery voltage of the
the pedal position and the remote mounted throttle vehicle that is supplied by the vehicle wiring.
position sensor sends a signal to the ECM. The
sensor is mounted to the throttle pedal assembly T Harness This harness is a test harness that
and near the fire wall in the engine compartment. is designed to permit normal circuit operation and
The throttle pedal is connected through an the measurement of the voltage simultaneously.
adjustable linkage to the pedal. Typically, the harness is inserted between the two
Remote Station Operation Remote station
operation is the ability to control the engine speed Throttle Position The throttle position is interpreted
at a location that is outside of the truck cab. by the ECM. The accelerator pedal position sensor
sends the ECM signals. The throttle position may be
Sensor A sensor is used to detect a change in used as part of a power take-off control.
the pressure, in the temperature, or in mechanical
movement. When any of these changes are Throttle Position Sensor The throttle position
detected, a sensor converts the change into an sensor is an electronic sensor that is connected to
electrical signal. the throttle pedal. The throttle position sensor sends
a pulse width modulated signal to the ECM.
Service Brake Switch The service brake switch
is installed by the OEM factory. The service brake Total Tattletale The total tattletale is the total
switch is normally a pressure switch. The switch number of changes to all system parameters.
is normally closed when the pedal is released.
Depressing the brake will open the circuit. Transducer A transducer is a device that converts
Service Program Module (SPM) The SPM is a
software program on a computer chip that was Trip Recorder The trip recorder records the
programmed at the factory. The computer chip operating parameters of the truck and of the engine.
is designed to adapt an ECAP for a particular The trip recorder is used to analyze the operating
application. habits of the operator. The trip recorder is used to
produce the operators logs.
Short Circuit A short circuit is an electrical circuit
that is mistakenly connected to an undesirable Vehicle Speed Circuit The vehicle speed circuit
point. For example, an electrical contact is made includes the vehicle speed sensor, the harness,
with the frame whenever an exposed wire rubs and the ECM.
against a vehicles frame.
Vehicle Speed Sensor A vehicle speed sensor is
Signal A signal is a voltage or a wave that is an electromagnetic pickup that measures vehicle
used to transmit information that is typically from a speed from the rotation of gear teeth in the drive
sensor to the ECM. train of the vehicle.
10
Warning Lamp The warning lamp is used to warn

the operator of the presence of a Caterpillar engine
monitoring detected problem.
i00845004

Components
SMCS Code: 1900
g00416682
Illustration 3
Top View
(1) Speed sensor or timing sensor (3) Inlet air temperature sensor (5) Fuel temperature sensor
(2) Coolant temperature sensor (4) Boost sensor (6) Atmospheric pressure sensor
11
g00416684
Illustration 4
Front View
(1) Speed sensor or timing sensor
(5) Fuel temperature sensor
g00416687
Illustration 5
Right Side View
(7) Oil pressure sensor
12
g00416689
Illustration 6
Left Side View
(5) Fuel temperature sensor (8) Engine wiring harness
(6) Atmospheric pressure sensor (9) Electronic Control Module (ECM)
The electronic control system has the following The electronic control system is integrally designed
major components: into the engines fuel system and the engines air
inlet and exhaust system in order to electronically
(1) Speed sensor or timing sensor control the fuel delivery and the injection timing. The
electronic control system provides increased timing
(2) Coolant temperature sensor control and fuel air ratio control in comparison to
conventional mechanical engines. Injection timing is
(3) Inlet air temperature sensor achieved by precise control of injector firing time,
and engine rpm is controlled by adjusting the firing
(4) Boost sensor duration. The ECM energizes the solenoid in the unit
injector in order to start the injection of fuel. Also,
(5) Fuel temperature sensor the ECM de-energizes the unit injector solenoids
in order to stop injection of fuel. Refer to Systems
(6) Atmospheric pressure sensor Operation/Testing And Adjusting, Unit Injector for
a complete explanation of the fuel injection process.
(7) Oil pressure sensor
The engine uses the following three types of
(8) Engine wiring harness electronic components:
(9) Electronic Control Module (ECM) input

A remote mounted throttle position sensor control
output
An input component is one that sends an electrical
signal to the electronic control module of the
system. The signal that is sent varies in either
voltage or frequency. The variation of the signal is
in response to a change in some specific system
of the vehicle. The electronic control module sees
the input sensor signal as information about the
condition, environment, or operation of the vehicle.
13
A control component receives the input signals. Table 1

Electronic circuits inside the control evaluate the Electrical Connectors and Functions
signals from the input components. These electronic
circuits also supply electrical energy to the output J/P No. Function
components of the system. The electrical energy
J1/P1 ECM Connector (40 pin,
that is supplied to the output components is based OEM Harness Connector
on predetermined combinations of input signal
values. J2/P2 ECM Connector (40 pin,
OEM Harness Connector
An output component is one that is operated by J3/P3 Boost Pressure Sensor
a control module. The output component receives Connector (3 pin)
electrical energy from the control group. The output
component uses that electrical energy in one of J5/P5 Fuel Injector Connector
two ways. The output component can use that (12 pin)
electrical energy in order to perform work. The J9/P9 Speed Sensor or Timing
output component can use that electrical energy in Sensor Connector (3 pin)
J10/P10 Coolant Temperature
As an example, a moving solenoid plunger will
perform work. By performing work, the component J11/P11 Throttle Position Sensor
has functioned in order to regulate the vehicle. Connector (3 pin)
J16 Reserved Connector
As an example, a dash panel light or an alarm will (3 pin)
provide information to the operator of the vehicle.
J17/P17 Oil Pressure Sensor
These electronic components provide the ability Connector (3 pin)
to electronically control the engine operation. J21/P21 Inlet Manifold Temperature
Engines with electronic controls offer the following Sensor Connector (3 pin)
advantages:
J22/P22 Atmospheric Pressure
improvement in performance
J23/P23 Fuel Temperature Sensor
improvement in fuel consumption Connector (3 pin)
reduction in emissions levels

14
i00845487
Fuel System
SMCS Code: 1250
g00418398
Illustration 7
Fuel System Schematic
(1) Fuel filter base (7) Fuel priming pump (13) Fuel transfer pump
(2) Siphon break (8) Fuel return manifold (14) Pressure regulating valve
(3) Vent plug (9) Secondary fuel filter (15) Check valve
(4) Unit injectors (10) Fuel regulator valve (16) Fuel tank
(5) Fuel supply manifold (11) Fuel return port
(6) Drain plug (12) Electronic control module (ECM)
The fuel supply circuit is a conventional design for After the fuel transfer pump, the fuel flows through
unit injector diesel engines. The fuel transfer pump the cored passages in the electronic control module
(13) is a gear type pump. The clearance in the fuel housing in order to cool the module. The fuel then
transfer pump is constant. The fuel transfer pump flows through the five micron fuel filter (9). A fuel
delivers fuel from the tank to the unit injectors (4). priming pump (7) is located on the fuel filter base.
Fuel is pulled from the fuel tank by the fuel transfer The fuel priming pump is used to fill the system after
pump. The fuel transfer pump incorporates a check draining the fuel supply and return manifolds. The
valve (15) that allows fuel flow around the gears fuel filter base (1) also incorporates a siphon break
for hand priming and a pressure regulating valve (2) that prevents fuel from exiting the cylinder head
(14) to protect the system from extreme pressure. during long periods of storage. The fuel priming
The fuel transfer pump creates excess fuel flow that pump (7) minimizes the fuel that returns to the tank
cools the unit injectors. The excess fuel flow also by utilizing two check valves.
purges the air from the unit injectors.
15
The fuel flows continuously from the fuel supply Fuel System Electronic Control
manifold through the unit injectors and excess fuel
is returned to the tank by the fuel return manifold (8).
Circuit
The plunger displaces some fuel that is not injected
into the cylinder. This fuel is also returned to the
tank by the fuel return manifold. Refer to Systems
Operation/Testing and Adjusting, Unit Injectorfor a
complete explanation of the injection process.
A flow control orifice is located in the fuel return

manifold. The flow control orifice maintains sufficient
system back pressure in order to fill the unit
injectors. Superb fuel flow is provided to the unit
injectors without excessive heating of the fuel tank.
The fuel transfer pump (13) is located at the left

front lower corner of the engine. The fuel transfer
pump is driven by the lower accessory drive gear. Illustration 8 g00418418
C-10 and C-12 Logic for Engine Speed Control

The fuel supply and return manifolds are drilled
(A) Coolant temperature sensor
passages in a common manifold which is mounted (B) Cold mode operation
to the cylinder head. Fuel from the fuel supply (C) Logic for engine control (Desired RPM)
manifold (5) flows through drilled passages in the (D) Customer parameters
cylinder head, and into the unit injectors (4). (E) Control for CRUISE/PTO
(F) Logic for CRUISE/PTO
(G) Throttle position sensor
The fuel return port (11) is located at the end of the (1) Retarder enable signal (to the OEM supplied retarder controls)
fuel return manifold (8). The fuel return port is a part (2) Cruise set in mph or PTO set in rpm
of fuel filter base (1). The pressure regulating orifice (3) Transmission clutch/brake pedal
maintains the needed back pressure in order to fill (4) Cruise ON or Off
(5) Set or resume the cruise
the unit injectors. The pressure regulating orifice (6) Vehicle speed in mph
also provides a constant fuel flow through the unit (7) Engine speed in rpm
injectors.
16
The ECM is the computer. The personality module

is the software for the computer. The personality
module contains the operating maps. The operating
maps define the following characteristics of the
engine:
horsepower
torque curves
rpm
other characteristics
g00418438
The ECM, the personality module, the sensors, and
Illustration 9 the unit injectors work together in order to control
C-10 and C-12 Electronic Governor the engine. Neither of the four can control the
(A) Coolant temperature sensor engine alone.
(B) Engine speed sensor
(C) Boost pressure sensor The ECM determines a desired rpm that is based
(D) Fuel injection control
(E) Engine speed signal interpreter on the following criteria:
(F) FRC maps
(G) Torque maps throttle signal
(H) Electronic governor
(1) Signals to unit injectors
(2) Fuel position certain diagnostic codes
(3) Desired RPM
(4) Engine RPM PTO switch
(5) Coolant temperature
(6) FRC fuel position
(7) Rated fuel position
vehicle speed signal
(8) Boost pressure
(9) Top center for No. 1 cylinder The vehicle must be in a CRUISE/PTO mode in
order to use the last two criteria.
The following traditional Caterpillar fuel system
components have been replaced with an The ECM maintains the desired engine rpm by
electronically controlled, mechanically actuated unit sensing the actual engine rpm. The ECM calculates
injector in each cylinder. the fuel amount that needs to be injected in order to
achieve the desired rpm.
fuel injection pump
Fuel Injection
fuel injection lines
The ECM controls the injected fuel amount by
fuel injection nozzles varying the signals to the unit injectors. The unit
injectors will inject fuel ONLY if the unit injector
A solenoid on each unit injector controls the amount solenoid is energized. The ECM sends a 90 volt
of fuel that is delivered by the unit injector. The signal to the solenoid for energizing the solenoid.
Electronic Control Module (ECM) sends a signal By controlling the timing of the 90 volt signal, the
to each unit injector solenoid in order to provide ECM can control injection timing. By controlling the
complete control of the engine. duration of the 90 volt signal, the ECM can control
the injected fuel amount.
Electronic Controls
The electronic control system for the C-10 and the
C-12 truck engine consists of two main components:
Electronic Control Module (ECM)

Personality Module
17
The ECM sets certain limits on the amount of fuel The unit injector mechanism provides the downward
that can be injected. FRC Fuel POS is a limit that force that is required to pressurize the fuel in the
is based on boost pressure in order to control the unit injector. At the precise time, the unit injector (3)
fuel air mixture for the emission control. When the allows the fuel to be injected into the combustion
ECM senses an increase in the boost pressure, chamber. The camshaft gear is driven by an idler
the ECM increases the FRC Fuel POS. Rated Fuel gear which is piloted in the cylinder block and
POS is a limit that is based on the horsepower bolted through the timing gear housing to the block.
rating of the engine. Rated Fuel POS is similar The idler gear is driven by the crankshaft gear.
to the rack stops and the torque spring on a The timing marks on the crankshaft gear, on the
mechanically governed engine. Rated Fuel POS idler gear and on the camshaft gear are aligned in
provides the horsepower and the torque curves for order to provide the correct relationship between
a specific engine family. Rated Fuel POS provides the piston and the valve movement. The camshaft
the horsepower and the torque curves for a specific has three camshaft lobes for each cylinder. Two
horsepower rating. The limits are programmed by lobes operate the inlet and exhaust valves, and
the factory into the Personality Module. The limits one operates the unit injector mechanism. Force
are not programmable in the field. is transferred from the unit injector lobe on the
camshaft (7) through the lifter (6) to the pushrod
The injection timing relies on the engine rpm, on the (4). From the pushrod, force is transferred through
engine load and on other engine data. The ECM rocker arm assembly (2) and to the top of the
senses the top center position of cylinder number unit injector. The adjusting nut (1) allows setting
1 from the signal that is provided by the engine of the unit injector adjustment. Refer to Systems
speed sensor. The ECM decides when the injection Operation/Testing and Adjusting, Unit Injector
should occur relative to the top center position. The Adjustment for the proper setting of the unit injector
ECM provides the signal to the unit injector at the adjustment.
desired time.
Unit Injector Mechanism
g00418440
Illustration 10
(1) Adjusting nut
(2) Rocker arm assembly
(3) Unit injector
(4) Pushrod
(5) Cylinder head
(6) Lifter
(7) Camshaft
18
Unit Injector
g00418441
Illustration 11
Unit Injector
(1) Solenoid connection (to the multiplex (5) Plunger (10) Spacer
enable circuit) (6) Barrel (11) Body
(2) Solenoid valve assembly (7) Seal (12) Check valve
(3) Spring (8) Seal
(4) Valve (in the closed position) (9) Spring
Fuel at low pressure from the fuel supply manifold

enters the unit injector at the fill port through drilled
passages in the cylinder head.
19
As the unit injector mechanism transfers the i00839358

force to the top of the unit injector, the spring
(3) is compressed and the plunger (5) is driven Air Inlet and Exhaust System
downward. This action displaces fuel through the
valve (4) and into the return manifold to the tank. SMCS Code: 1050
The passage into the barrel (6) is closed by the
outside diameter of the plunger. The passages
within body (11) and along check valve (12) to the
injector tip are filled with fuel as the plunger moves
down. After the passage in the plunger barrel is
closed, fuel can be injected at any time. The start
of injection relies on the software in the electronic
control module.
When the solenoid valve assembly (2) is energized

from a signal across the solenoid connection (1),
the valve (4) closes and pressure is elevated
in the injector tip. Injection starts at 37931 kPa
(5500 psi) as the force of spring (9) above spacer
(10) is overcome. The check valve starts moving
off the valve seat. The pressure continues to rise
as the plunger cycles through the plungers full
stroke. After the correct amount of fuel has been
discharged into the cylinder, the electronic control
module signals across the solenoid connection.
the solenoid valve assembly is de-energized and
valve (4) is opened. The high pressure fuel is then
dumped through the spill port and into the fuel
return manifold. The fuel then goes to the fuel tank.
The check valve in the injector tip seats. Injection
has ended as the fuel pressure decreases to at
least 25517 kPa (3700 psi).
The length of injection meters the fuel that is

consumed during the fuel injection process.
Injection length is controlled by the governor logic
that is programmed into the electronic control
module.
After reaching the maximum lift point, the force to

the top of the unit injector is removed as spring
(3) expands. The plunger returns to the plungers
original position. This uncovers the fuel supply
passage into the plunger barrel in order to refill the
injector pump body. The fuel at low pressure then
circulates through the injector body. After circulating g00411724
through the injector body, the fuel goes out of the Illustration 12
spill port. This happens until the solenoid valve Air Inlet and Exhaust System Components
assembly (2) is again energized. (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
20
From the aftercooler, air is forced into inlet manifold

(8). Air flow from the inlet chambers into the
cylinders is controlled by inlet valves (4). There are
two inlet valves and two exhaust valves (5) in the
cylinder head for each cylinder. Inlet valves open
when the piston moves down on the intake stroke.
When the inlet valves open, cooled compressed air
from the inlet chamber within the inlet manifold is
pulled into the cylinder. The inlet valves close and
the piston 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 injected into the cylinder. The fuel
mixes with the air and combustion starts. During
the power stroke, the combustion force pushes the
piston downward. The exhaust valves open and the
exhaust gases are pushed through the exhaust port
into exhaust manifold (9).
After the piston makes the exhaust stroke, the

exhaust valves close and the cycle starts again.
Illustration 13 g00411725 The complete cycle consists of four stages:
Air inlet and exhaust system components
(2) Air inlet
inlet stroke
(7) Exhaust outlet
(8) Inlet manifold compression stroke
(10) Valve mechanism cover power stroke
(11) Turbocharger
(12) Oil inlet line
(13) Oil drain line exhaust stroke
The components of the air inlet and exhaust system Exhaust gases from the exhaust manifold enter the
control the quality of the air that is available for turbine side of the turbocharger in order to turn the
combustion. These components also control the turbocharger turbine wheel (6). The turbine wheel is
amount of the air that is available for combustion. connected to the shaft that drives the compressor
The system includes all the components in the wheel. Exhaust gases from the turbocharger pass
illustrations plus an air cleaner. through exhaust outlet (7), a muffler and an exhaust
stack.
Inlet air is pulled through the air cleaner into air inlet
(2) by turbocharger compressor wheel (3). The air
is compressed, heated, and pushed through the
aftercooler (1). The temperature of the air is lowered
while the air flows through the aftercooler. Cooling
of the inlet air increases combustion efficiency.
Increased combustion efficiency helps to lower fuel
consumption. Also, increased combustion efficiency Turbocharger
helps to increase the horsepower output.
The turbocharger is mounted to the exhaust
manifold of the engine. All the exhaust gases go
from the exhaust manifold through the turbocharger.
21
The exhaust gases go into the turbocharger. Valve Mechanism

The exhaust gases then push the blades of the
turbocharger turbine wheel. This causes the
turbocharger turbine wheel to spin. Because the
turbocharger turbine wheel is connected by a
shaft to the turbocharger compressor wheel, the
compressor wheel can turn at very high speeds.
Clean air from the air cleaner is pulled through
the compressor housing air inlet by rotation of the
compressor wheel. The action of the compressor
wheel blades causes a compression of the inlet air.
This compression gives the engine more power by
allowing the engine to burn more air and fuel during
combustion.
When the load on the engine increases, or a greater

engine speed is desired, more fuel is injected into
the cylinders. This makes more exhaust gases that
cause the turbine and compressor wheels of the
turbocharger to turn faster. As the compressor
wheel turns faster, more air is forced into the engine.
The increased flow of air gives the engine more
power by allowing the engine to burn the additional Illustration 14
g00411726
fuel with greater efficiency.
Valve System Components
Maximum rpm of the turbocharger is controlled (1) Inlet bridge

(2) Rotocoil
by the electronic control module. The electronic (3) Rocker arm for inlet valve
control module controls the available fuel amount. (4) Pushrod
The programming in the electronic control module (5) Valve springs
is preset at the factory for a specific engine (6) Inlet valves
(7) Valve guide
application. (8) Camshaft
(9) Lifter
Bearings in the turbocharger use engine oil under
pressure for lubrication. The oil comes in through the The valve system components control the flow of
oil inlet port. The oil then goes through passages in inlet air into the cylinders during engine operation.
the center section in order to lubricate the bearings. The valve system components also control the flow
Oil from the turbocharger goes out through the oil of exhaust gases out of the cylinders during engine
outlet port and oil drain line. The oil then goes back operation. The inlet and exhaust valves are opened
to the engine lubrication system. and closed by the valve mechanism as rotation of
the crankshaft causes rotation of camshaft (8). The
Some turbochargers use a waste gate. The waste camshaft gear is driven by an idler gear which is
gate is controlled by boost pressure. At high boost piloted in the cylinder block and bolted through the
pressures, the waste gate opens. To increase boost timing gear housing to the block. The idler gear
pressure at low boost pressures, the waste gate is driven by the crankshaft gear. The camshaft
closes. With this arrangement, the turbocharger can must be timed to the crankshaft in order to get the
be designed to be more effective at lower engine correct relation between the piston movement and
speeds. the valve movement.
The opening pressure of the waste gate is The camshaft has three camshaft lobes for
165 3 kPa (24 .5 psi). 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 the
rocker arm for the inlet valve transfers a downward
force on inlet bridge (1). This force opens two inlet
valves (6). The inlet bridge moves up and down on
a dowel. The dowel is mounted in the cylinder head.
22
Each cylinder has two inlet and two exhaust valves.

Two valve springs (5) for each valve hold the valves
in the closed position when the lifter moves down.
g00411800
Illustration 15
Valves
The following rocker arms are removed from the number two
cylinder: inlet, exhaust, and unit injector.
(1) Inlet bridge
(2) Rotocoil
(3) Rocker arm for inlet valves
(6) Inlet valves
(10) Exhaust rocker arm
(11) Exhaust bridge
(12) Exhaust valves
Rotocoils (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.
23
i00850464
Lubrication System
SMCS Code: 1300
g00421798
Illustration 16
Lubrication System Schematic
(1) Piston cooling jets (9) Engine oil filter
(2) Main oil gallery in cylinder block (10) Engine oil pump
(3) Engine oil pressure sensor (11) Oil filter bypass
(4) Oil flow to valve mechanism (12) Engine oil cooler bypass
(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
24
g00421818
Illustration 17
Right Side of Engine
(9) Engine oil filter
(10) Engine oil pump
(11) Oil filter bypass valve
(13) Engine oil cooler
(17) Engine oil filler
(18) Oil supply line to turbocharger
(19) Oil drain line from turbocharger
The lubrication system supplies 110C (230F)

filtered oil at approximately 275 kPa (40 psi) at
rated engine operating conditions. The oil pump
bypass valve (16) is controlled by the engine oil
manifold pressure. The oil pump bypass valve (16)
is not controlled by the oil pump pressure. The
engine oil manifold pressure is independent of the
pressure drop that is caused by the engine oil filter.
The engine oil manifold pressure is independent
of the pressure drop that is caused by the engine
oil cooler.
The engine oil cooler bypass (12) is thermostatically

controlled in order to maintain an engine oil to
bearing temperature of 110C (230F). The high
pressure relief valve (15) is located in the filter
base. The high pressure relief valve protects the
filters and other components during cold starts. The
opening pressure of the high pressure relief valve is
695 kPa (100 psi). The oil filter bypass element is a
five micron filter that returns five percent of the oil
flow to the oil pan sump (14). The opening pressure
of the oil filter bypass valve is 170 kPa (25 psi). The
engine oil pressure sensor is part of the engine
protection system. The symmetrical oil pan can be
installed as a front sump or a rear sump.
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.
25
Oil Flow Through The Lubrication

System
g00421838
Illustration 18
Engine Oil Filter Group
(1) Oil flow to the piston, to the cooling jets, (5) Oil from engine oil cooler (12) Oil filter bypass valve
to the valve mechanism, to the camshaft (6) High pressure relief valve (13) Passage to main engine oil filter
journals, to the crankshaft main bearings (7) Oil from engine oil pump (14) Oil cooler bypass valve
and to the turbocharger (8) Oil to engine oil cooler (15) Oil pump bypass valve
(2) Main oil gallery in cylinder block (9) Passage to main engine oil filter (16) Oil pump bypass drain
(3) Oil drains to sump (10) Filtered oil (17) Passages to bypass filter
(4) Cylinder block (11) Bypassed oil
The engine oil pump is mounted to the back of the

front gear train on the lower right hand side of the
engine. The engine oil pump is driven by an idler
gear from the crankshaft gear. Oil is pulled from
the sump through the oil pump bypass valve (15)
on the oils way to the engine oil cooler. The bypass
valve controls the oil pressure from the engine oil
pump. The engine oil pump can supply excess oil
for the lubricating system. When this situation is
present, the oil pressure increases and the bypass
valve opens. The open bypass valve allows the
excess oil to return to the sump.
26
The high pressure relief valve (6) regulates high

pressure in the system. The high pressure relief
valve will allow the oil to return to the sump when the
oil pressure reaches 695 kPa (100 psi). The oil then
flows through the engine oil cooler. The engine oil
cooler uses engine coolant in order to cool the oil.
The oil cooler bypass valve (14) is thermostatically
controlled. The oil cooler bypass valve directs the
oil flow through the engine oil cooler when the oil
temperature reaches 100 to 103C (212 to 217F).
A failsafe activation temperature is incorporated
into the oil cooler bypass valve. The failsafe
activation temperature will close the valveand the
failsafe activation temperature will direct the oil
into the engine oil cooler. The failsafe activation g00421839
temperature is 127C (260F). The valve will remain Illustration 19
open if the valve failed. Also, the oil cooler bypass Interior Of Cylinder Block
valve is activated by pressure. If the oil pressure (18) Piston cooling jet
differential across the engine oil cooler reaches (19) Piston
155 17 kPa (22 3 psi), the valve will open. This (20) Connecting rod
will allow the oil to bypass the engine oil cooler.
Filtered oil flows through the main oil gallery in
Approximately five percent of the oil flow is directed the cylinder block. The oil then lubricates the
through an orificed passage. The passage leads piston cooling jets (18). The valve mechanism, the
to the bypass filter (17). The oil then flows through camshaft bearings, the crankshaft main bearings
the bypass filter. The oil then flows to the sump. and the turbocharger cartridge are lubricated.
The main oil flow now reaches the main engine
oil filter. When the oil pressure differential across An oil cooling chamber is formed by the following
the oil filter bypass valve (12) reaches 170 kPa pieces: the lip forge at the top of the skirt of the
(25 psi), the valve allows the oil flow to go around piston (19) and the cavity behind the ring grooves in
the main engine oil filter. The oil then lubricates the the crown. The oil that flows into the piston cooling
engine parts. When the oil is cold, an oil pressure jet enters the cooling chamber through a drilled
difference in the bypass valve also causes the valve passage in the skirt. The oil then returns to the sump
to open. This bypass valve then provides immediate through the clearance gap between the crown and
lubrication to all the engine components when cold the skirt. Four holes are drilled from the piston oil
oil with high viscosity causes a restriction to the oil ring groove to the interior of the piston. The holes
flow through the engine oil filter. The bypass valve are used to drain excess oil from the oil ring.
will also open when there is a restriction in the
engine oil filter. This allows the oil to lubricate the
engine even with a restrictive engine oil filter.
Note: Refer to Specifications, Engine Oil Filter

Group for a cross section of the valves in the
engine oil filter group.
g00421840
Illustration 20
Front Left Side of the Engine
(21) Breather
(22) Hose
(23) Cylinder head
27
The breather (21) allows gases that pass by the The water pump is driven by a gear. The water
piston rings to escape from the crankcase. These pump is located on the right hand side of the
gases discharge into the atmosphere through the engine. The water pump supplies the coolant for
hose (22). This prevents the pressure from building the engine cooling system. The coolant is supplied
up that could cause seals or gaskets to leak. to the following components:
i00851425
engine oil cooler (5)
Cooling System cylinder head (8)
SMCS Code: 1350 cylinder liner (9)

air compressor (not shown)
Coolant Flow
coolant conditioner element (not shown)
Note: In air-to-air aftercooled systems, a coolant
g00423399
Illustration 22
Typical right side of engine
(1) Temperature regulator housing
(4) Water pump
g00423398
Illustration 21
Cooling System Schematic
(2) Radiator
(3) Bypass tube
(4) Water pump
(6) Return manifold
(7) Supply manifold in the block
(8) Cylinder head g00423400
Illustration 23
(9) Cylinder liner
Typical rear of engine
(6) Return manifold
28
The antifreeze coolant solution is pumped through

the engine oil cooler (5). The antifreeze coolant
solution then goes into the supply manifold (7). The
supply manifold is located in the cylinder block. The
supply manifold distributes the antifreeze coolant
solution at each cylinder. The antifreeze coolant
solution then flows around the upper portion of
the cylinder liner. The antifreeze coolant solution
cools the upper portion of the cylinder liner. At each
cylinder, the antifreeze coolant solution flows from
the cylinder liner to the cylinder head. The cylinder
head is divided into single cylinder cooling sections.
In the cylinder head, the antifreeze coolant solution
flows across the center of the cylinder and across
g00423401
the injector seat boss. At the center of the cylinder,
Illustration 24 the antifreeze coolant solution flows around the
Right side engine injector sleeve over the exhaust port. The antifreeze
(8) Coolant from engine oil cooler to supply manifold coolant solution then exits into the return manifold
(6). The return manifold collects the antifreeze
The water pump (4) pulls the antifreeze coolant coolant solution from each cylinder and the return
solution from the bottom of the radiator (2) by using manifold directs the flow to the temperature
the impellers rotation. The water pump is located on regulator housing (1). When the temperature
the right hand side of the front timing gear housing. regulator is in the closed position, the antifreeze
coolant solution flows through the regulator. This
The water pump impeller is rotated at 1.17 times allows the antifreeze coolant solution to flow directly
the engine speed by an idler gear. The idler gear back to the water pump by bypassing the radiator.
is turned by the crankshaft gear. The water pump The water pump then recirculates the antifreeze
shaft is supported by two ball bearings. One ball coolant solution. With the temperature regulator in
bearing is located in the water pump housing. The the open position, the antifreeze coolant solution is
other ball bearing is located in the front timing gear directed through the radiator and back to the water
housing. The water pump impeller face is open. The pump inlet.
impeller vane is radial. The impeller is made out of
cast iron. The rear cover is made out of aluminum. Supply Manifold
The rear cover is a die casting. The water pump
seal is a cartridge seal. The water pump seal is Cooling is provided for only the portion of the
located on the inlet side of the pump in order to cylinder liner above the seal in the block. The
provide good water flow around the seal for cooling. antifreeze coolant solution enters the block at each
cylinder through the slits in the supply manifold. The
supply manifold is an integral casting in the 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 liner so that 60 percent flows
around the liner and the remainder bypasses the
liner and flows directly to the cylinder head.
29
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, the regulator is in the closed position (4). This
allows the coolant to flow through the regulator from
the 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 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 regulator moves to the open position.
This allows all the coolant flow to be directed to the
g00423402
radiator. The coolant then goes to the water pump.
Illustration 25 This route provides the maximum heat release
Front right side of engine from the coolant. A vent line is recommended from
(1) Temperature regulator housing the manifold to the radiator overflow tank in order
(2) Coolant temperature sensor to provide venting for the cooling system. The
recommended vent line is a #4 Aeroquip.
g00423403
Illustration 26
Temperature Regulator Housing
(3) Return manifold
(4) Closed position
30
g00423404
Illustration 27
Coolant Conditioner
(1) Engine oil cooler (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
Pitting has been caused by some operating The coolant conditioner element (7) is a spin-on
conditions. The pitting has been observed on the element that is similar to the fuel filter and to the
following areas: engine oil filter elements. The coolant conditioner
element attaches to the coolant conditioner base
the outer surface of the cylinder liners (8) that is mounted on the engine. Coolant flows
from the engine oil cooler (5) through the inlet
the surface of the cylinder block next to the liners hose (3) and into the coolant conditioner base. The
coolant that is conditioned then flows through the
The pitting has been caused by the following outlet hose (2) into the engine oil cooler (1). There
reasons: is a constant flow through the coolant conditioner
element.
corrosion
cavitation erosion
The addition of a corrosion inhibitor (a chemical that
gives a reduction of pitting) can prevent this type of
damage to a minimum.
31
The element has a specific amount of inhibitor i00853126

for acceptable cooling system protection. As the
coolant flows through the element, the corrosion Basic Block
inhibitor, which is a dry material, disperses into the
coolant. The coolant and the inhibitor are mixed SMCS Code: 1200
to the correct concentration. Two basic types of
elements are used for the cooling system, the Cylinder Block and Head
precharge and the maintenance elements. Each
type of element has a specific use. Each type The cylinder block is an unique design with a deep
of element must be used correctly to get the counterbore that supports the cylinder liner and
necessary concentration for the cooling system forming the coolant jacket. Two oil manifolds are
protection. The elements also contain a filter. Even provided in the cylinder block for engine lubrication.
after the conditioner material is dispersed, the The manifold on the lower right side of the block
elements should be left in the system so the coolant has several purposes:
flows through the filter.
Providing the oil for the piston cooling jets
The precharge element has more than the normal
amount of inhibitor. The precharge element is used Providing the oil for the crankshaft bearings
when a system is first filled with new coolant. This
element must add enough inhibitor in order to bring Providing a direct passage to the oil filter base
the complete cooling system up to the correct
concentration. The upper left side manifold on the upper left side
of the block has two purposes:
The maintenance elements have a normal amount of
inhibitor and the maintenance elements are installed Providing the oil for the camshaft bearings
at the first change interval. The maintenance
elements provide enough inhibitor in order to keep Providing the oil for the valve mechanism
the corrosion protection at an acceptable level.
After the first change interval, only the maintenance The manifold on the right supplies oil to the manifold
elements are installed at the specified intervals in on the left. The oil travels through the cut above the
order to give the protection to the cooling system. number one main bearing and the cut above the
number four main bearing.
Coolant for Air Compressor
The cylinder liner is supported in the middle. The
cylinder liner is seated on a shelf in the block
between the crankcase and the coolant jacket. The
shelf is counterbored. The cylinder liner is piloted
above the face of the shelf. The seals of the coolant
jacket are located at the upper regions and middle
regions of the liner. The lower barrier is above the
seating surface of the liner. The lower barrier uses a
seal that is located in the diameter of the cylinder
liner flange. The seal is a D-ring seal. The upper
barrier is above the coolant jacket. The upper
barrier uses the head gasket as the upper sealing
barrier.
g00423405
Illustration 28
Coolant Flow for Air Compressor
(1) Inlet hose
(2) Outlet hose
(3) Air compressor
The coolant that is used for the air compressor (3)

comes from the cylinder head through the inlet hose
(1). The coolant exits the air compressor through
outlet hose (2) and flows back to the cylinder head.
32
Pistons, Rings, and Connecting The crankshaft drives a group of gears (front gear
train) on the front of the engine. The front gear train
Rods provides power for the following components:
The piston is a two-piece articulated piston. The
piston has a forged steel crown and a forged camshaft
aluminum skirt. Both parts are retained by the piston
pin to the small end of the connecting rod. An oil water pump
cooling chamber is formed by the lip forge at the
top of the skirt of the piston. An oil cooling chamber engine oil pump
is also formed by the cavity behind the ring grooves
in the crown. Oil from the piston cooling jet enters air compressor
the cooling chamber through a drilled passage in
the skirt. The oil returns to the sump through the fuel transfer pump
clearance gap between the crown and the skirt.
hydraulic pump (if equipped)
The pistons have three rings:
The crankcase has seven main bearings in order to
support the crankshaft. Two bolts hold each bearing
a compression ring cap to the block. The oil holes and the oil grooves
in the shell of the upper bearing are located at the
an intermediate ring following main bearing journals: 2, 3, 5, and 6.
an oil ring The oil holes and oil grooves supply oil to the
connecting rod bearings. The crankshaft has eight
The rings are located in grooves in the steel crown.
counterweights that are located at the following
The rings seal the crankcase from the combustion
cheeks: 1, 2, 5, 6, 7, 8, 11, and 12
gases. The oil control piston ring controls the
amount of oil that lubricates the cylinder liner. The
design of the compression ring is a barrel face
crankshaft to control oil leakage. The hydrodynamic
with a plasma face coating. The intermediate ring
grooves in the seal lip move lubrication oil back into
has a tapered shape and the intermediate ring
the crankcase as the crankshaft turns. The front
has a chrome finish. The oil ring has the following
seal is located in the front housing. The rear seal is
characteristics:
installed in the flywheel housing.
double railed
Camshaft
ground profile
The camshaft has three lobes at each cylinder
chrome finish in order to operate the unit injector, the exhaust
valves, and the inlet valves. Seven bearings support
The oil ring has a coil spring expander. Four holes the camshaft. The camshaft is driven by an idler
are drilled in the piston oil ring groove. The holes gear that is turned by the crankshaft in the front
lead to the interior of the piston in order to drain gear train. Each bearing journal is lubricated from
excess oil from the oil ring. the oil manifold in the cylinder block. A thrust pin
that is located at the rear of the block positions
The connecting rod is a conventional design. The the camshaft through a circumferential groove. The
cap is fastened to the shank by two bolts that are groove is machined at the rear of the camshaft.
threaded into the shank. Each side of the small end Timing of the camshaft is accomplished by aligning
of the connecting rod is machined at an angle of marks on the crankshaft gear, idler gear, and
12 degrees in order to fit within the piston cavity. camshaft gear with each other.
This allows the maximum utilization of the available
space for the gas load.
Crankshaft
The crankshaft converts the combustion forces in
the cylinders into rotating torque which powers the
equipment. On this engine, a vibration damper
is used at the front of the crankshaft to reduce
torsional vibrations (twist on the crankshaft) that can
cause damage to the engine.
33
i00858361

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

part of the flywheel housing. When the engine is
viewed from the rear, the rear power take-off is
positioned at the 1 oclock position. The rear power
take-off provides continuous live power through the
following three direct drive gears:
the crankshaft gear

g00427819
the idler gear Illustration 29
Installed Compression Brake
the output shaft gear (1) Control valve
(2) Lead wire
These gears are driven off the rear of the crankshaft. (3) Bolt assembly (head bolt stud, spacer, and bolt)
(4) Slave piston
(5) Solenoid valve
i00856742 (6) Master piston
(7) Stud and nut
Compression Brake
SMCS Code: 1119; 1129
The compression brake is powered from the

Electronic Control Module (ECM). The compression
brake helps the operator to slow the machine
on grades, in curves, or for a necessary speed
reduction. The service brakes should not be
used continuously on long descending grades.
The compression brake gives the vehicle some
braking power without using the service brakes.
The engine crankshaft is turned by the rear wheels
during downhill operation or during any slow down
condition. The engine crankshaft is turned through g00427858
the differential, through the drive shaft, through the Illustration 30
transmission, and through the clutch. An application Exhaust Bridge Assembly
of a braking force can be made to the engine piston (8) Plunger assembly
in order to reduce the speed of the vehicle. (9) Valve bridge assembly
When the compression brake is activated, braking The compression brake consists of three identical
power is accomplished by opening the engines housing assemblies. A housing assembly is installed
exhaust valves. The exhaust valves are opened in each of the valve mechanism compartments
near the top of the compression stroke in order above the rocker arms and above the rocker arm
to release the highly compressed air into the shaft. Each housing assembly is positioned over
exhaust system. The compression brake can only two cylinders. The housing assembly is mounted to
be activated when the engine is in the no-fuel the supports for the rocker arm shaft with studs and
position. Thus, combustion does not occur and nuts (7). The housing assemblies are supported
no positive force is produced on the piston. The on the cylinder head with bolt assembly (3). The
compressed air pressure that is released to the exhaust bridge assembly is used to transfer force
atmosphere prevents the energy from returning to from slave piston (4) to the exhaust valve. The brake
the engine piston on the power stroke. The result is logic signal for the compression brake is carried to
a loss of energy since the work that is done by the solenoid valve (5) by a lead wire. This is done in
compression of the cylinder charge is not returned order to activate the compression brake on the two
by the expansion process. This loss of energy is cylinders of the engine.
taken from the rear wheels. The rear wheels provide
the braking action for the vehicle.
34
Note: Only the exhaust valve mechanism and the Performance of the Compression
exhaust valves are used for the operation of the
compression brake.
Brake
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).
Each compression brake housing assembly and

mounting hardware consists of the following
components:
two control valves (1)

one wire harness (2)
one head bolt stud, spacer, and bolt (3)
slave pistons (4)
one solenoid valve (5)
g00427859
two master pistons (6) Illustration 31
Performance of the Compression Brake
two exhaust bridge assemblies
The performance of the compression brake, which
two studs and nuts (7) is shown in the graph, represents an engine with
the three housing assemblies that are activated in
Plunger assembly (8) in the bridge is nonadjustable. order to stop the vehicle. The compression brake
Refer to Systems Operation/Testing and Adjusting, should not be activated when the engine rpm is
Compression Brake Adjustment for a complete above 2300. 2100 rpm is the maximum engine
description of the adjustment of the exhaust bridge power rating. At this level, the amount of braking
assembly. that is produced by the compression brake is
approximately 315 to 325 horsepower.
Note: Only one of the two exhaust valves for each
cylinder on this engine is used in the operation of
the compression brake.
The control circuit for the compression brake

permits the operation of either one, two, or all three
of the compression brake housing assemblies. This
provides progressive braking capabilities with the
retarding effect of two cylinders, of four cylinders,
or of all six cylinders in the engine.
35
Operation of the Compression

Brake
g00427860
Illustration 32
Schematic for the Master-Slave Circuit
(1) Lead wire (13) High pressure oil passage (20) Exhaust valve
(2) Solenoid valve (14) Slave piston adjustment screw (21) Engine oil pan
(3) Master piston (15) Rocker arm shaft oil passage (22) Oil drain passage
(4) Slave piston (16) Engine oil pump (23) Low pressure oil passage
(5) Control valve (17) Spring (24) Ball check valve
(6) Exhaust bridge assembly (18) Injector rocker arm (25) Exhaust valve rocker arm
(12) Spring (19) Injector pushrod
The compression brake operates by using engine

oil that is distributed around the studs. This oil is
supplied through the supports for the rocker arm
shaft. The solenoid valve (2) controls the oil flow in
the compression brakes housing assembly.
36
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 passage (22) is opened. This allows oil to drain from
(22) to engine oil pan (21) to be closed. At the same underneath control valve (5). This also allows spring
time, low pressure oil passage (23) to control valve (12) to push the control valve to the bottom of the
(5) is opened. As low pressure oil passage (23) is chamber. This position allows oil from high pressure
filled with engine oil, the control valve is pushed oil passage (13) to drain into the chamber above
upward in the chamber against the force of spring the control valves piston. This chamber vents to the
(12). At this position, a groove in control valve atmosphere that is outside the compression brakes
(5) is in alignment with high pressure oil passage housing. Spring (17) now moves master piston (3)
(13). Slave piston (4) and master piston (3) are to the retracted position away from injector arm
supplied by the high pressure oil passage. Engine (18). The time that is necessary for the system to
oil pressure will now lift ball check valve (24). High stop operation is approximately 1/10 of a second.
pressure oil passage (13) and the chambers behind The compression brake will not be able to operate
the slave pistons and behind the master pistons until solenoid (2) is activated again.
will be filled with engine oil pressure. This pressure
moves the master piston downward until contact is
i00854556
made with injector rocker arm (18). When upward
motion is initiated on the master piston, the pressure
increases above the current level of the engine
Electrical System
supply pressure. This causes ball check valve (24) SMCS Code: 1400; 1550; 1900
to seat. The system is now operating in conjunction
with the exhaust valve and with the injector rocker Reference: Refer to Electrical System Schematic for
mechanism. When the solenoid is activated, the the complete C-10 and C-12 electrical schematic.
compression brake could be operable within 1/5
of a second.
Grounding Practices
Injector pushrod (19) will begin to move upward on
the pumping stroke of the electronically controlled Proper grounding for the vehicle electrical system
unit injector. When this occurs, injector rocker arm and engine electrical systems is necessary for
(18) makes contact with extending master piston (3). proper vehicle performance and reliability. Improper
As the master piston begins to move upward, the grounding will result in uncontrolled electrical circuit
oil pressure increases in high pressure oil passage paths and unreliable electrical circuit paths.
(13). This happens because ball check valve (24)
will not allow oil to exit. The upward movement of Uncontrolled engine electrical circuit paths can
the injector rocker arm creates a constant increase result in damage to main bearings, crankshaft
in pressure. This forces the slave piston downward bearing journal surfaces, and aluminum
against the pin and screw assembly in exhaust components.
bridge assembly (6) of compression brake. The
slave piston moves downward with enough force to Uncontrolled electrical circuit paths can cause
open exhaust valve (20). electrical noise which may degrade the vehicle and
radio performance.
This master-slave circuit is designed so that master
piston (3) is moved only when the engine cylinder To ensure proper functioning of the vehicle and
is on the compression stroke. The master-slave engine electrical systems, an engine-to-frame
circuit is designed so that slave piston (4) opens ground strap with a direct path to the negative
one exhaust valve of the same cylinder only on the battery post must be used. This may be provided by
compression stroke. This occurs slightly before the way of a starting motor ground, a frame to starting
piston reaches the top center position. The braking motor ground, or a direct frame to engine ground.
force is constant. The operation of the compression
brake of a cylinder is caused by the motion of the An engine-to-frame ground strap must be used in
valve mechanism of that cylinder. This causes the order to connect the grounding stud of the engine
firing sequence of the valves to be identical to the to the frame of the vehicle and to the negative
firing order of the engine. battery post.
The engine must have a wire ground to the battery.
Ground wires or ground straps should be combined

at ground studs that are only for ground use. All of
the grounds should be tight and free of corrosion.
37
All of the ground paths must be capable of carrying the ammeter

any likely current faults. An AWG #0 or larger wire
is recommended for the grounding strap to the The charging circuit is in operation when the engine
cylinder head. is running. An alternator makes electricity for the
The engine alternator should be battery ground with controls the electrical output in order to keep the
a wire size that is capable of managing the full battery at full charge.
charging current of the alternator.
The starting circuit is in operation only when the
NOTICE start switch is activated.
tems Operation, Engine Starting should be followed The low amperage circuit is connected through the
in order to properly start the engine. ammeter. The charging circuit is connected through
the ammeter. The starting circuit is not connected
This engine may be equipped with a 12 volt starting through the ammeter.
for boost starting should be used. The use of a higher Charging System Components
Alternator
connected at the J1/P1 and J2/P2 locations before The alternator is driven by a belt from the crankshaft
welding on the vehicle. pulley. This alternator is a three-phase, self-rectifying
charging unit, and the regulator is part of the
The engine has several input components which are alternator.
electronic. These components require an operating
voltage. This alternator design has no need for slip rings or
brushes, and the only part that has movement is
Unlike many electronic systems of the past, this the rotor assembly. All conductors that carry current
engine is tolerant to common external sources of are stationary. The following conductors are in the
electrical noise. Buzzers that use electrical energy circuit:
can cause disruptions in the power supply. If the
buzzers are used anywhere on the vehicle, the the field winding
engine electronics should be powered directly from
the battery system through a dedicated relay. The the stator windings
engine electronics should not be powered through a
common power bus with other key switch activated the six rectifying diodes
devices.
the regulator circuit components
Engine Electrical System The rotor assembly has many magnetic poles
that look like fingers with air space between each
The electrical system can have three separate opposite pole. The poles have residual magnetism.
circuits: The residual magnetism produces a small magnetic
field between the poles. As the rotor assembly
the charging circuit begins to turn between the field winding and the
stator windings, a small amount of alternating
the starting circuit current (AC) is produced. The alternating current
(AC) is produced in the stator windings from
the low amperage circuit the small magnetic field. The alternating current
(AC) is changed to direct current (DC) when the
Some of the electrical system components are used alternating (AC) passes through the diodes of the
in more than one circuit. The following components rectifier bridge. The current is used for the following
are common in more than one circuit: applications:
the battery or batteries Charging the battery

the circuit breaker Supplying the low amperage circuit
the cables Strengthening the magnetic field
the wires from the battery
38
The first two applications use the majority of the Starting System Components
current. As the direct current (DC) increases through
the field windings, the strength of the magnetic Starting Solenoid
field is increased. As the magnetic field becomes
stronger, more alternating current (AC) is produced
in the stator windings. The increased speed of
the rotor assembly also increases the current and
voltage output of the alternator.

switch. The voltage regulator senses the voltage in
the system. The voltage regulator switches ON and
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
voltage output.
NOTICE
g00317613
Never operate the alternator without the battery in the Illustration 34
circuit. Making or breaking an alternator connection Typical solenoid
with heavy load on the circuit can cause damage to
the regulator. A solenoid is an electromagnetic switch that does
the following two basic operations:
The solenoid closes the high current starting

motor circuit with a low current start switch circuit.
The solenoid engages the starter motor pinion

with the ring gear.
The solenoid 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 is made. The magnetic field pulls
the plunger forward in the cylinder. This moves the
Illustration 33
g00425518 shift lever in order to engage the pinion drive gear
with the ring gear. The front end of the plunger
Typical alternator components
then makes contact across the battery and motor
(1) Regulator terminals of the solenoid. Next, the starting motor
(2) Roller bearing
(3) Stator winding begins to turn the flywheel of the engine.
(4) Ball bearing
(5) Rectifier bridge When the start switch is opened, current no longer
(6) Field winding flows through the windings. The spring now pushes
(7) Rotor assembly
(8) Fan
the plunger back to the original position. At the
same time, the spring moves the pinion gear away
from the flywheel.
39

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. 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.
The solenoid is fully activated when the connection
across the battery and the motor terminal is
complete. When the solenoid is fully activated, the
current is shut off through the pull-in windings. At g00425521
this point, only the smaller hold-in windings are in Illustration 35
operation. The hold-in windings operate for the Typical starting
duration of time that is required in order to start the (1) Field
engine. The solenoid will now draw less current (2) Solenoid
from the battery, and the heat that is generated by (3) Clutch
(4) Pinion
the solenoid will be kept at an acceptable level. (5) Commutator
(6) Brush assembly
Starting Motor (7) Armature
The starting motor is used to turn the engine

flywheel at a rate that will allow the engine to start
running.
The starting motor has a solenoid. When the ignition

switch is turned to the START position, the starting
motor solenoid will be activated electrically. The
solenoid plunger will now move a mechanical
linkage. The mechanical linkage will push the starter
motor pinion in order to engage with the flywheel
ring gear. The starter motor pinion will engage
with the ring gear before the electric contacts in
the solenoid close the circuit between the battery
and the starting motor. When the circuit between
the battery and the starting motor is complete, the
pinion will turn the engine flywheel. A clutch gives
protection for the starting motor so that the engine
cannot turn the starting motor too fast.
40
Testing and Adjusting Logged Diagnostic Codes and Events

Section When the ECM generates a diagnostic code, the
ECM usually logs the code in permanent memory
within the ECM. The ECM has an internal diagnostic
clock. The ECM records the hour when a code is
Testing and Adjusting logged. Knowing the time and the frequency of the
code can be a valuable tool to a technician that is
troubleshooting intermittent problems. The logged
i00858526 codes can be retrieved with an electronic service
tool. The logged codes can be erased with an
Electronic Control System electronic service tool. The logged codes can be a
SMCS Code: 1900 valuable tool when a technician is troubleshooting
intermittent problems.
Diagnostic Codes Note: Diagnostic Codes that are logged repeatedly

may indicate a problem that needs special
Refer to Electronic Troubleshooting for an investigation. Some codes that are only logged only
explanation of each diagnostic code. a few times. If the drivers do not complain about
the codes, the codes may not need attention until a
Active Diagnostic Codes scheduled maintenance interval.
The C-10 and the C-12 diagnostic codes are used Refer to Electronic Troubleshooting, Troubleshooting
by the electronic control system in order to warn Diagnostic Codes in order to troubleshoot a
the vehicle operator of a problem. The diagnostic logged diagnostic code. If symptoms continue,
codes also indicate the nature of the problem to refer to Electronic Troubleshooting, Troubleshooting
the service technician. Some codes are only used Without a Diagnostic Code.
to record an event and the codes do not indicate
problems that need repair. Note: The most likely cause of an intermittent
problem is a faulty connection or damaged wiring.
An active diagnostic code represents a problem. The next likely cause is a component failure (sensor
The problem should be investigated and the or switch for example). The least likely cause is the
problem should be corrected as soon as possible. ECM.
Repairing the cause of an active code will cause
the code to be cleared. Electronic Service Tools
When an active code is generated, the diagnostic The Caterpillar service tools for the C-10 and C-12
lamp will turn on. The diagnostic lamp will remain electronic control systems are designed to help the
on. The diagnostic lamp will flash after 5 seconds. service technician do the following tasks:
If the condition that generates the fault only occurs
for a brief moment, the diagnostic lamp will go off The technician can diagnose the faults and the
after five seconds. The code will also be logged. system problems.
Some codes only record an event. These events The technician can calibrate the sensors.
are not a performance problem. In these cases,
troubleshooting is not required. The technician can program the parameters.
Some of the C-10 and C-12 diagnostic codes The technician can read the trip data.
generate major changes in the engine operation or
limits. The major changes occur as a result of the The technician can read status of the sensors
code that was generated. and the switches.
The C-10 and the C-12 truck engines require an

Electronic Control Analyzer Programmer (ECAP).
The engines can also accept theCAT Electronic
Technician (ET) in order to communicate with the
C-10 and C-12 Electronic Control Module.
41
Accelerator Pedal Position Sensor Incorrect fuel injection timing

Cold engine operation
Low octane fuel
g00305968
Illustration 36
The accelerator pedal position sensor is mounted g00430179

to the back of the pedal. The pedal is supplied by Illustration 37
the OEM. The accelerator pedal position sensor Fuel System Components
requires no adjustments. The accelerator pedal (1) Fuel filter base
position sensor is automatically calibrated by the (2) Fuel line from ECM
ECM. The correct calibration can be displayed (3) Fuel priming pump
(4) Fuel filter
with the electronic service tool. The percent throttle (5) ECM
reading should be according to the following
situations:
When the throttle is completely released, the

reading should be 3 percent of governor control
movement.
When the throttle is completely depressed, the

reading should be 100 percent of governor
control movement.
i00859047
Fuel System
g00430180
SMCS Code: 1250 Illustration 38
Fuel System Components
Either too much fuel or not enough fuel for (6) Fuel supply and return manifold
combustion can be the cause of a problem in the (7) Fuel transfer pump
fuel system. Work is often done on the fuel system (8) Fuel line (fuel transfer pump to ECM)
when the problem is really with some other part of
the engine. The source of the problem is difficult Fuel System Inspection
to find, especially when smoke comes from the
exhaust. When noticeable smoke rises from the A problem with the components that send fuel to
exhaust, this problem can be caused by a defective the engine can cause low fuel pressure. This can
unit injector. This unusual smoke can also be decrease engine performance.
caused by one or more of the reasons that follow:
1. Check the fuel level in the fuel tank. Make sure
Not enough air for good combustion that the vent in the cap is not filled with dirt.
An overload at high altitude 2. Check all fuel lines for fuel leakage. The fuel
lines must be free from restrictions and defective
Oil leakage into combustion chamber bends. Verify that the fuel return line is not
collapsed.
Not enough compression
42
3. Install a new fuel filter. The 1U-5470 Engine Pressure Group can be used
in order to check the fuel pressure.
4. Remove any air that may be in the fuel
system. Refer to Systems Operation/Testing and This tool group has a indicator to read fuel pressure
Adjusting, Procedure for Fuel Priming for more to the fuel supply manifold. Refer to Special
information. Instruction, SEHS8907 for the information that is
needed to use the tool.
Fuel Transfer Pump
When the engine is operating at the rated rpm and
load condition, the fuel transfer pump moves the
fuel through the following components:
the ECM
the fuel filter base
the fuel supply and return manifolds
An orificed valve in the return fuel manifold restricts
fuel flow. A pressure regulator valve is in the transfer
pump. The normal fuel pressure is 630 kPa (91 psi) Illustration 39 g00293196
at rated rpm.
If the fuel pressure is low 517 kPa (75 psi) or less,

stop the engine. Replace the fuel filter. Check the Procedure for Fuel Priming
fuel lines in order to ensure that the fuel lines are
not plugged. Make sure that the fuel lines are not
damaged.
Start the engine and again check the fuel pressure.

If the fuel pressure is still low, check the fuel
regulator valve in the fuel transfer pump.
Stop the engine if the fuel pressure is at 690 kPa

(100 psi) or above 690 kPa (100 psi). Remove
the orificed valve from the connector. The valve
is directly behind the return line fitting. Check for
debris that is plugging the orifice holes near the tip.
If the orifice holes are plugged, flush any remaining
debris from the return passage. Then check the
g00430181
source of debris. If the orifice holes are not plugged, Illustration 40
check for a plugged return fuel line. If the return Plug
fuel line is not plugged, check the regulator valve in (1) Plug
the fuel transfer pump for debris or for rust. (2) Base assembly
Fuel Pressure Note: If the fuel system runs out of fuel or if air
is introduced into the fuel system the following
Table 2 procedure may be followed. The fuel system does
not need to be primed after changing only the fuel
Tools Needed
filter. The engine will remain running after starting
Part Number Part Name Quantity with a dry filter.
Engine Pressure 1. After fuel is added to the fuel tank, remove the
1U5470 1
Group
plug (1) in fuel filter base.
To check the fuel transfer pump pressure, remove 2. Use the hand priming pump to purge the air from
the fuel pressure sensor from the fuel filter base. the fuel system. Use the hand priming pump to
Install a pressure indicator, and start the engine. pump the fuel into the system. Stop pumping
when fuel appears at the port.
43
3. Install the plug (1). Continue pumping until a 5. To make an adjustment to the unit injectors on
strong pressure is felt on the pump, and you hear cylinders 1, 2, and 4, remove the timing bolt.
a click from the fuel filter base. This pressurizes Turn the flywheel by 360 degrees in the direction
the system with approximately 345 kPa (50). This of the engines rotation. The engine rotates
greatly reduces the cranking time that is needed a counterclockwise manner. This will put the
to start the engine. When the system is primed, number 1 piston at the top center position on
lock the pump in the bottom position in order to the exhaust stroke.
avoid possible damage to the pump.
6. Repeat 2 through 4.
4. Crank the engine as soon as possible after
pressurizing the system. The engine should start 7. Remove the timing bolt from the flywheel after all
within 15 seconds. If the engine does not start the unit injector adjustments have been made.
after 30 seconds, stop the cranking. Two minutes Reinstall the timing cover.
are needed for the starting motor to cool down
before cranking the engine again. Repeat 3 in
order to repressurize the system. Repeat 4 in
Checking Engine Cylinders
order to start the engine. Separately
Table 3
Unit Injector Adjustment
Tools Needed
Laser Infrared
123-6700 1
Thermometer
When the engine runs at low idle, the temperature

of an exhaust manifold port can be an indication
of the condition of a unit injector. Low temperature
at an exhaust manifold port is an indication of no
fuel to the cylinder. This could be caused by an
inoperative unit injector. Extra high temperature at
an exhaust manifold port can be an indication of
too much fuel to the cylinder. This is caused by a
malfunctioning unit injector.
g00430183
Illustration 41
Injector Mechanism Use the 123-6700 Laser Infrared Thermometer to
(1) Rocker arm check exhaust temperature. The Operators Manual,
(2) Adjusting screw Laser Infrared Thermometer II with laser Sighting
(3) Locknut for the 123-6700 Laser Infrared Thermometer
gives the complete operating and maintenance
To make an adjustment to the unit injectors on instructions for the tool.
cylinders 3, 5, and 6 use the following procedure:
1. Put the number 1 piston at the top center position

on the compression stroke. Refer to Systems
Operation/Testing and Adjusting, Finding Top
Center Position For No. 1 Piston.
2. Turn the unit injector adjusting screw (2)

clockwise until contact is made with the unit
injector.
3. Turn the unit injector adjusting screw through

180 degrees in a clockwise direction.
4. Hold the adjusting screw in this position and

tighten the locknut (3) to a torque of 55 10 Nm
(41.0 7.0 lb ft).
44
Timing of the Timing Reference Finding the Top Center Position for
Ring and the Front Gear Group No. 1 Piston
Table 4
Tools Needed
Engine Turning
9S9082 1
Tool
g00430184
Illustration 42
g00430185
Illustration 43
Front Gear Group
Top Center Position
(1) Camshaft gear and timing reference ring
(2) Timing marks (1) Bolts
(3) Idler gear (2) Cover
(4) Crankshaft gear (3) Flywheel housing
The basis for correct fuel injection timing and valve 1. Remove the two bolts (1) and remove the cover
mechanism operation is determined by the timing (2) from the flywheel housing (3) in order to open
reference ring and the alignment of the front gear the turning hole.
group. The timing reference ring is located on the
end of the camshaft group. The timing reference 2. Put one of the 6V-5219 Bolts (1) in the timing
ring is used to measure crankshaft rotation. During hole. The timing hole located approximately
installation of the front gear group, the timing marks 127 to 152 mm (5.0 to 6.0 inch) above the
(2) on the idler gear (3) must be in alignment with turning hole in the flywheel housing. Use the
the timing marks on the crankshaft gear (4) and the 9S-9082 Engine Turning Tool and a 1U-7115
timing marks on the camshaft gear (1). Refer to Reverse Ratchet to turn the engine flywheel.
Disassembly and Assembly, Front Gear Group Turn the engine flywheel in the counterclockwise
for a complete removal and installation procedures direction. View the engine from the flywheel end.
of the front gear group. Turn the flywheel until the timing bolt engages
with the threaded hole in the flywheel.
Note: The timing reference ring (1) can be installed
backward. If this occurs, the engine will not start. Note: If the flywheel is turned beyond the point of
engagement, the flywheel must be turned in the
Check for proper alignment of the camshaft gear direction that is reverse of normal engine rotation.
and timing reference ring (1) on the camshaft Turn the flywheel by approximately 30 degrees.
assembly. Inspect the key between the timing Then turn the flywheel in the direction of normal
reference ring and the camshaft gear. Check the rotation until the timing bolt engages with the
teeth on the timing ring. The teeth should not be threaded hole. This procedure removes the play
defaced. The teeth should have sharp clean edges from the gears when the No. 1 piston is at the top
and the teeth should be free of contaminants. center position.
Note: The electronic injection timing must be 3. Remove the front valve cover from the engine.
45
4. The inlet and exhaust valves for the No. 1 Measurement of Pressure In Inlet
cylinder are fully closed if No. 1 piston is on the
compression stroke and the rocker arms can be
Manifold
moved by hand. If the rocker arms cannot be Table 5
moved and the valves are slightly open, the No.
1 piston is on the exhaust stroke. Tools Needed
Note: When the actual stroke position is identified,
and the other stroke position is needed, remove the 1U-5470 Engine Pressure 1
timing bolt from the flywheel. Then turn the flywheel Group
by 360 degrees in the direction of normal engine
rotation and reinstall the timing bolt. The efficiency of an engine can be checked by
making a comparison of the pressure in the inlet
Checking and Calibrating the Electronic manifold with the information given in the TMI
Injection Timing With the Electronic (Technical Marketing Information). The information
is also given on the Fuel Setting And Related
Service Tool Information Microfiche. This test is used when there
is a decrease of horsepower from the engine, yet
Refer to Troubleshooting, Electronic Injection there is no real sign of a problem with the engine.
Timing for the proper procedure to calibrate the
electronic injection timing. The correct pressure for the inlet manifold is given
in the TMI (Technical Marketing Information). The
i00862665
correct pressure is also on the Fuel Setting And
Related Information Microfiche. Development of this
Air Inlet And Exhaust System information is done with these following conditions:
SMCS Code: 1050 99 kPa (29.7 Inches Hg) dry barometric pressure
Restriction Of Air Inlet And Exhaust 29C (85F) outside air temperature
There will be a reduction in the performance of the 35 API rated fuel

engine if there is a restriction in the air inlet system
On a turbocharged, aftercooled engine, a change
or the exhaust system. in the fuel rating will change the horsepower. A
change in the fuel rating will change the pressure in
The air flow through a used air cleaner may have
the inlet manifold. If the fuel is rated above 35 API,
a restriction. The air flow through a plugged air the pressure in the inlet manifold can be less than
cleaner will be restricted to some magnitude. In
the pressure given in the TMI (Technical Marketing
either case, the restriction must not be more than
Information). The pressure will be less than the
the following amount: pressure listed on the Fuel Setting And Related
Information Microfiche. If the fuel is rated below
6.2 kPa (25 inches of H2O) 35 API, the pressure in the inlet manifold can be
more than the pressure listed in the TMI (Technical
The air flow through a new air cleaner element must
Marketing Information). The pressure can be more
not have a restriction of more than the following
than the pressure that is listed on Fuel Setting And
amount: Related Information Microfiche.
3.7 kPa (15 inches of H2O) Note: Be sure that the air inlet or the exhaust does
not have a restriction when you are making a check
of the pressure in the inlet manifold.
between the exhaust at the outlet elbow and the
atmospheric air. Back pressure from the exhaust .
must not be more than the following amount:
10.0 kPa (40 inches of H2O)

46
Air-To-Air Aftercooled Systems

Table 7
Tools Needed
FT-1984 Aftercooler 1
Testing Group
FT-1438 Dynamometer 1
Testing
Aftercooler
Visual Inspection
g00434159
Illustration 44
Pressure Test Location On Inlet Manifold
(1) Plug all the air lines
To measure the inlet manifold pressure, remove the all the hoses
plug (1) from the inlet manifold. Use the 1U-5470
Engine Pressure Group to check the pressure in all the gasket joints
the inlet manifold.
Make sure that the constant torque hose clamps
are tightened to the correct torque. Check the truck
manufacturers specifications for the correct torque.
Check the welded joints for cracks. Make sure that
Make sure that the brackets are in good condition.
Use compressed air to clean any debris or any dust
from the aftercooler core assembly. Inspect the
cooler core fins for the following conditions:
damage
debris
Illustration 45 g00293196 salt corrosion

1U-5470 Engine Pressure Group Use a stainless steel brush to remove any corrosion.
Make sure that you use soap and water.
This tool group has a indicator to read pressure
in the inlet manifold. The Special Instruction,
SEHS8907 contains the instructions for the tool
group.
Pressurized air can cause personal injury. When
pressurized air is used for cleaning, wear a protec-
Exhaust Temperature tive face shield, protective clothing, and protective
Table 6
shoes.
Tools Needed
Part Number Part Name Quantity system are repaired, a leak test is recommended.
123-6700 Laser Infrared 1 When parts of the air-to-air aftercooler system are
Thermometer replaced, a leak test is recommended.
Use the 123-6700 Laser Infrared Thermometer to

check exhaust temperature. The Operators Manual,
NEHS0630 contains the complete operating and
maintenance instructions for the 123-6700 Laser
Infrared Thermometer.
47
The use of winter fronts or shutters is discouraged

with air-to-air aftercooled systems. Winter fronts can NOTICE
only be used on certain truck models. On these Do not use caustic cleaners to clean the air-to-air af-
trucks, tests have shown that the engine jacket tercooler core.
water will overheat before the inlet manifold air
temperature is excessive. These trucks use sensors Caustic cleaners will attack the internal metals of the
and indicators that are installed in order to indicate core and cause leakage.
engine operating conditions before excessive inlet
the truck manufacturer about the use of both winter Inlet Manifold Pressure
Normal inlet manifold pressure with high exhaust
Air System Restriction temperature can be caused by cooler core fin
blockage. Clean the fins of the aftercooler core.
Pressure measurements should be taken at the Refer to Testing and Adjusting, Visual Inspection
turbocharger outlet and at the inlet manifold. The for the cleaning procedure.
air lines and the cooler core must be inspected
for internal restriction when both of the following Low inlet manifold pressure and high exhaust
conditions are met: manifold temperature can be caused by any of the
conditions that follow:
the air flow is at a maximum level.
Plugged air cleaner Clean the air cleaner, as
total air pressure drop of the charged system required. Replace the air cleaner, as required.
exceeds 13.5 kPa (4 inches Hg).
Blockage in the air lines Blockage in the air lines
If a restriction is discovered, proceed with the between the air cleaner and the turbocharger must
following tasks, as required: be removed.
clean Aftercooler core leakage An aftercooler core

leakage should be pressure tested. Refer to
repair Aftercooler Core Leakage for the correct
procedure to clean parts. Use the same manual
replacement for information on repairing parts and on replacing
parts.
Turbocharger Failure Leakage of the induction system Any leakage from
the pressure side of the induction system should
be repaired.
Personal injury can result from air pressure. Inlet manifold leak An inlet manifold leak can be
caused by both loose fittings and loose plugs.
Personal injury can result without following prop- Missing fittings, missing plugs, damaged fittings,
er procedure. When using pressure air, wear a pro- and damaged plugs can also cause these leaks.
tective face shield and protective clothing. Finally, problems with the manifold to cylinder head
gaskets can cause this same problem. Check all
Maximum air pressure at the nozzle must be less of these items.

aftercooler core. Internally flush the air-to-air
aftercooler core with a solvent that removes oil
and other foreign substances. Shake the air-to-air
aftercooler core in order to eliminate any trapped
debris. Wash the aftercooler with hot, soapy water.
Thoroughly rinse the aftercooler with clean water
and blow dry the aftercooler with compressed air.
Blow dry the assembly in the reverse direction of
normal air flow. To make sure that the whole system
is clean, carefully inspect the system.
48
Aftercooler Core Leakage A large leak of the aftercooler core can often be


2. Install the couplers (5) on each side of aftercooler

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

on the hump hoses is recommended in order to
prevent the hoses from bulging while the aftercooler
core is being pressurized.
NOTICE
or damage to the aftercooler core can be the result.
g00295702
Illustration 46
FT-1984 Aftercooler Testing Group 3. Install the regulator and valve assembly (1) on
(2) Nipple Also, attach the air supply.
(3) Relief valve
(4) Tee 4. Open the air valve and pressurize the aftercooler
(5) Coupler to 205 kPa (30 psi). Shut off the air supply.
(6) Aftercooler
(7) Dust plug
(8) Dust plug 5. Inspect all connection points for air leakage.
(9) Chain
A low power problem in the engine can be the result drop more than 35 kPa (5.0 psi) in 15 seconds.
of aftercooler leakage. Aftercooler system leakage
can result in the following problems: 7. If the pressure drop is more than the specified
low power check all areas for leakage. Look for air bubbles
low boost pressure aftercooler core, or repair the aftercooler core,
as needed.
black smoke
high exhaust temperature
To help prevent personal injury when the tooling is
NOTICE removed, relieve all pressure in the system slowly
Remove all air leaks from the system to prevent engine by using an air regulator and a valve assembly.
pull a manifold vacuum for short periods of time. A
8. After the testing, remove the FT-1984 Aftercooler
leak in the aftercooler or air lines can let dirt and other
Testing Group. Reconnect the air pipes on both
foreign material into the engine and cause rapid wear
sides of the aftercooler core assembly.
49
Dynamometer Test The 8T-2700 Blowby/Air Flow Indicator is used

to check the amount of blowby. The Special
In hot ambient temperatures, chassis dynamometer Instruction, SEHS8712 contains the test procedure
tests for models with an air-to-air aftercooler can for checking the blowby.
add a greater heat load to the jacket water cooling
system. Therefore, the jacket water cooling systems
temperature must be monitored. Also, monitor the
Compression
inlet air temperature, which may need a power
An engine that runs roughly can have a leak at
correction factor. These other measurements may
the valves. An engine that runs roughly can also
also need a power correction factor:
have valves that need an adjustment. Remove
the head and inspect the valves and valve seats.
fuel API rating This is necessary to find those small defects that
do not normally cause a problem. Repairs of
fuel temperature these problems are normally done when you are
reconditioning the engine.
barometric pressure
With dynamometer tests for engines, use the Cylinder Head
FT-1438 Dynamometer Testing Aftercooler. This
tool provides a water cooled aftercooler in order to The cylinder head assembly consists of the
control the inlet air temperature to 43C (110F). following three main components:
Crankcase Pressure (Crankshaft valve seat inserts

Compartment) valve guides
Table 8 dowels for the valve bridge
Tools Needed
When any of these components are worn or
Part Number Part Name Quantity when these components are damaged, these
8T-2700 Blowby/Air Flow 1 components can be replaced. Replacement of
Indicator these components can be made with the tools that
follow. Most of the tools are part of the 1U-9654
Valve Guide and Seat Tool Group.
Pistons or rings that have damage can be the
cause of too much pressure in the crankcase. This Note: Refer to Disassembly and Assembly for the
condition will cause the engine to run rough. There correct procedure to replace these components.
will be more than the normal amount of fumes
(blowby) rising from the crankcase breather. The
breather can then become restricted in a very short Valves
time, causing oil leakage at gaskets and seals that
would not normally have leakage. Blowby can also For the removal and the installation of the valves,
be caused by worn valve guides or by a failed use the following tools:
turbocharger seal.
5S-1330 Valve Spring Compressor
4C-6726 Valve Spring Compressor Group
5S-1322 Valve Keeper Installer
Note: A 1U-7798 Slide Hammer and a 1U-7794
Shaft are used in order to remove the valve seat
insert and the valve guide. These tools are also
used to install the valve seat insert and the valve
guide.
Valve Seat Inserts

The following tools are needed in order to remove
g00286269
Illustration 47 the valve seat insert:
1U-9166 Valve Seat Extractor
50
1U-9170 Valve Seat Driver Note: An adjustment is NOT NECESSARY if the

1U-9706 Plate range. The range is given in Table 9. If the
measurement is not within this range, an adjustment
These tools are also used to install the valve seat is necessary. Refer to Table 10 for the nominal
insert. value for the settings of the inlet valve lash and the
exhaust valve lash.
Valve Guides
Table 10
The following tools needed in order to remove the Valve Lash Setting
valve guide: Engine Stopped
Inlet .38 mm (0.015 inch)
1U-9168 Valve Guide Collar
Exhaust .64 mm (0.025 inch)
1U-9169 Valve Guide Driver
These tools are also used to install the valve guide.
Checking Valve Guide Bores

Use the 5P-3536 Valve Guide Gauge Group to
check the bore of the valve guides. The Special
Instruction, GMG02562 contains the instructions for
the 5P-3536 Valve Guide Gauge Group.
Valve Lash Setting
g00412347
Illustration 48
To prevent possible injury, do not use the starter Cylinder and Valve Location
to turn the flywheel.
To make an adjustment to the valve lash, turn the
Hot engine components can cause burns. Allow adjustment screw in the rocker arm. Valve lash
additional time for the engine to cool before mea- adjustments can be made by using the procedure
suring valve clearance. that follows:
1. Put the No. 1 piston at the top center position

on the compression stroke. Refer to Testing and
Adjusting, Finding the Top Center Position For
This engine uses high voltage to the unit fuel in- No. 1 Piston for more information on finding the
jectors. top center position.
Disconnect injector enable circuit connector to

prevent personal injury.
Do not come in contact with the injector terminals

while the engine is running.
Note: Valve lash is measured between the rocker

arm and the valve bridge.
Table 9
Valve Lash Check
Engine Stopped
Inlet .30 to .46 mm g00434160
(0.012 to 0.018 inch) Illustration 49
Adjustment of the Inlet Valve
Exhaust .56 to .72 mm
(0.022 to 0.028 inch) (1) Rocker arm of the inlet valve
(2) Adjustment locknut
51
low oil pressure

high oil pressure
too much bearing wear
increased oil temperature
Too Much Oil Consumption

Oil Leakage On Outside Of Engine
Check for leakage at the seals at each end of the
crankshaft. Look for leakage at the oil pan gasket
g00434162
Illustration 50 and all lubrication system connections. Look for any
Adjustment of the Exhaust Valve oil that may be leaking from the crankcase breather.
(3) Rocker arm of the exhaust valve This can be caused by combustion gas leakage
(4) Adjustment locknut around the pistons. A dirty crankcase breather
2. Make an adjustment to the valve lash on the crankcase breather will cause the gaskets and the
inlet valves for cylinders 1, 2, and 4. Make an seals to leak.
adjustment to the valve lash on the exhaust
valves for cylinders 1, 3, and 5. Oil Leakage Into Combustion Area Of
Cylinders
3. After each adjustment, tighten the nut for valve
adjustment screw to a torque of 25 7 Nm Oil leakage into the combustion area of the cylinders
(18.0 5.0 lb ft), and check the adjustment can be the cause of blue smoke. There are four
again. possible ways for oil leakage into the combustion
area of the cylinders:
4. Remove the timing bolt and turn the flywheel by
360 degrees in the direction of engine rotation.
This will put the No. 6 piston at the top center
oil leakage between worn valve guides and valve
stems
position on the compression stroke. Install the
timing bolt in the flywheel.
worn components or damaged components
5. Make an adjustment to the valve lash on the
inlet valves for cylinders 3, 5, and 6. Make an
adjustment to the valve lash on the exhaust
incorrect installation of the compression ring
valves for cylinders 2, 4, and 6.
6. After each adjustment, tighten the nut for valve

oil leakage past the seal rings in the impeller end
of the turbocharger shaft
adjustment screw to a torque of 25 7 Nm
(18.0 5.0 lb ft), and check the adjustment Too much oil consumption can also be the result if
again. oil with the wrong viscosity is used. Oil with a thin
viscosity can be caused by fuel leakage into the
7. Remove the timing bolt from the flywheel after all crankcase or by increased engine temperature.
adjustments to the valve lash have been made.
Reinstall the timing cover.
i00867499 First, check the oil pressure electronically by using
the electronic technician. The engine oil pressure
Lubrication System and a restriction in the oil filter can be measured
with the electronic service tool.
SMCS Code: 1300
One of the problems in the list that follows will

generally be an indication of a problem in the
lubrication system for the engine.
too much oil consumption

52
Table 11 Oil pressure to the camshaft and main bearings

Tools Needed
should be checked on each side of the cylinder
block at oil gallery plug (1). Install the 1U-5470
Part Number Part Name Quantity Engine Pressure Group into this opening. Run
1U-5470 1
the engine with SAE 15W40 oil. With the engine
Engine Pressure Group
at operating temperature, the minimum oil
pressure at full load rpm should be approximately
An oil pressure gauge that has a defect can indicate 275 to 414 kPa (40 to 59 psi). Minimum oil pressure
low oil pressure or high oil pressure. at low idle rpm (600 to 800 rpm) should be
Oil Pressure Is Low

Crankcase Oil Level
Check the level of the oil in the crankcase. Add oil
if oil is needed. The oil level can possibly be too far
below the oil pump supply tube. This will cause the
oil pump not to have the ability to supply enough
lubrication to the engine components.
The Oil Pump Does Not Work Correctly

g00296486
Illustration 51 The inlet screen of the supply tube for the oil pump
1U-5470 Engine Pressure Group can have a restriction. This restriction will cause
cavitation and a loss of oil pressure. Air leakage
The 1U-5470 Engine Pressure Group measures the in the supply side of the oil pump will also cause
oil pressure in the system. This tool group has a cavitation and loss of oil pressure. If the bypass
gauge that is used to read the oil pressure inside valve for the oil pump is held in the open position,
the oil manifold. the lubrication system can not reach the maximum
pressure. Oil pump gears that have too much wear
Note: Refer to Special Instruction, SEHS8907 for will cause a reduction in oil pressure.
more information on using the 1U-5470 Engine
Pressure Group. Oil Filter Bypass Valve
If the bypass valve for one or more of the oil filters
is held in the open position due to a restriction,
a reduction in the oil pressure can be the result.
Remove each bypass valve and clean each bypass
valve in order to correct this problem. You must
also clean each bypass valve bore. Install new
Caterpillar oil filters. New filters will prevent more
debris from causing this problem.
Too Much Clearance At Engine Bearings

Or Open Lubrication System
Components that are worn and components that
g00437624 have too much bearing clearance can cause low oil
Illustration 52
Oil Gallery Plug pressure. Low oil pressure can also be caused by
an oil line or an oil passage that is open, broken, or
(1) Plug
disconnected.
Work carefully around an engine that is running.

Engine parts that are hot, or parts that are moving,
can cause personal injury.
53
Piston Cooling Jets An oil pressure indicator that has a defect or a

sender that has a defect can give an indication of a
When the engine is operating, cooling jets direct oil low oil pressure or a high oil pressure.
toward the bottom of the piston in order to cool the
piston. This also provides lubrication for the piston The 1U-5470 Engine Pressure Group can be used
pin. A seizure of the piston will occur quickly if a jet in order to make a comparison with the indicators
experiences any of the following problems: on the instrument panel and the oil pressure that is
displayed on the electronic service tool.
breakage
restriction oil pressure in the system. This tool group has a
gauge that is used to read the oil pressure inside
incorrect installation the oil manifold.
Note: Refer to Special Instruction, SEHS8907 for

Oil Pressure High more information on using the 1U-5470 Engine
Pressure Group.
Oil pressure will be high if the bypass valve for the
oil pump can not move from the closed position.
i00868302
Too Much Bearing Wear Cooling System
When some components of the engine show
SMCS Code: 1350
restriction in an oil passage. This engine has a pressure type cooling system. A
pressure type cooling system has two advantages.
An indicator for the oil pressure may show that there
The cooling system can be operated in a safe
is enough oil pressure, but a component is worn manner at a temperature higher than the normal
boiling point (steam) of water.
the passage for the oil supply to the component. A
restriction in an oil supply passage will not allow
This type of system prevents cavitation in the water
enough lubrication to reach a component. This will
result in early wear.
bubbles in liquids that are caused by mechanical
forces. With this type of cooling system, an air
Increased Oil Temperature pocket or a steam pocket becomes more difficult to
create in the cooling system.
When the engine is at operating temperature and
you are using SAE 15W40 oil, the maximum oil
temperature is 110C (230F). This temperature is
Visual Inspection Of The Cooling
the temperature of the oil after the oil cooler. System
Look for a restriction in the oil passages of the oil Cooling systems that are not regularly inspected are
cooler. The oil temperature may be higher than the cause for increased engine temperatures. Make
the normal oil temperature when the engine is a visual inspection of the cooling system before a
operating. In such a case, the oil cooler may have test is made with test equipment.
a restriction. The oil pressure of the engine will not
get low just because the oil cooler has a restriction.
Determine if the oil cooler bypass valve is held in

Personal injury can result from escaping fluid un-
the open position. This condition will allow the oil
der pressure.
through the valve instead of the oil cooler. The oil
temperature will increase.
push the release valve in order to relieve pressure
Indicators For Oil Pressure before removing any hose from the radiator.
Table 12
Tools Needed Read the two indicators for the coolant level in
Part Number Part Name Quantity the top of the radiator.
1U-5470 Engine Pressure Group 1 2. Look for leaks in the system.
54
Note: A small amount of coolant leakage across

the surface of the water pump seals is normal.
This leakage is required in order to provide
lubrication for this type of seal. A hole is provided
and alkali.
in the water pump housing in order to allow this
coolant/seal lubricant to drain from the pump
housing. Intermittent leakage of small amounts of
coolant from this hole is not an indication of water
pump seal failure. Only replace the water pump
seals if a large amount of leakage is draining from
the water pump housing. Only replace the water
pump seals if a constant flow of coolant is draining
from the water pump housing. Refer to Disassembly
enough to touch with your bare hand.
and Assembly, Water Pump for the replacement
procedure of the water pump seals.
3. Make sure that air flow through the radiator does
not have a restriction. Look for bent core fins
between the folded cores of the radiator. Also, The coolant level must be to the correct level in
look for trash between the folded cores of the order to check the coolant system. The engine must
radiator. be cold and the engine must not be running.
4. Inspect the drive belts for the fan. After the engine is cool, loosen the pressure cap
in order to relieve the pressure out of the cooling
5. Check for damage to the fan blades. system. Then remove the pressure cap.
6. Look for air or combustion gas in the cooling The level of the coolant should not be more than
system. 13 mm (.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass,
7. Inspect the filler cap, and check the surface that the level of the coolant should be to the proper level
seals the filler cap. This surface must be clean. on the sight glass.
Testing The Cooling System Test Tools For Cooling System

Table 13
Part Tools Needed Quantity
Number
4C-6500 Digital Thermometer 1
8T-2700 Blowby/Air Flow Indicator 1
9U-7400 Multitach 1

g00286266 burns from hot parts and can cause injury from
Illustration 53
Boiling Point Of Water rotating parts.
Remember that temperature and pressure work When working on an engine that is running, avoid
together. When a diagnosis is made of a cooling contact with hot parts and rotating parts.
system problem, temperature and pressure must
effect on the cooling system temperature. For an
example, refer to the Illustration 53. This will show
the effect of pressure on the boiling point (steam)
of water. This will also show the effect of height
above sea level.
55
g00286267 g00286276
4C-6500 Digital Thermometer 9U-7400 Multitach
The 4C-6500 Digital Thermometer is used in The 9U-7400 Multitach is used to check the fan
the diagnosis of overheating problems or in the speed. Refer to the testing procedure in Operator
diagnosis of overcooling problems. This group can Manual, NEHS0605.
be used to check temperatures in several different
parts of the cooling system. Refer to the testing
procedure in Operating Manual, NEHS0554.
g00286369
Illustration 57
g00286269
Illustration 55 The 9S-8140 Pressurizing Pump is used to test the
8T-2700 Blowby/Air Flow Indicator filler caps. This pressurizing pump is also used to
check the air flow through the radiator core. Refer
to the testing procedure in Special Instruction,
SEHS8712.
g00439083
Illustration 58
1U-7297 Coolant/Battery Tester or 1U-7298 Coolant/Battery
Tester
56
Check the coolant solution frequently in cold

weather for glycol concentration with the 1U-7297
Coolant/Battery Tester or 1U-7298 Coolant/Battery
Tester. This ensures adequate freeze protection.
Both testers are used for checking the coolants
freezing point. The testers are identical except for
the temperature scale. The testers give immediate,
accurate readings. The testers can be used
for antifreeze/coolants that contain ethylene or
propylene glycol.
Making the Correct Antifreeze Mixtures

Adding pure antifreeze as a makeup solution for the
cooling system top-off is an unacceptable practice. Illustration 59 g00296067
Adding pure antifreeze increases the concentration
Typical Schematic of Filler Cap
of antifreeze in the cooling system. This increases
the concentration of the dissolved solids and the (1) Sealing surface of both filler cap and radiator
undissolved chemical inhibitors in the cooling
system. Add the antifreeze and water mixture to
the same freeze protection as your cooling system.
The following chart assists in determining the Personal injury can result from hot coolant, steam
concentration of antifreeze to use. and alkali.
Table 14
Antifreeze Concentrations and under pressure. The radiator and all lines
Protection Temperature Concentration
30% antifreeze and
Protection to 15C (5.0F)
70% water Remove filler cap slowly to relieve pressure only

Protection to 23 C 40% antifreeze and when engine is stopped and radiator cap is cool
(10.0F) 60% water enough to touch with your bare hand.
Protection to 37C 50% antifreeze and Cooling System Conditioner contains alkali. Avoid
(34.0F) 50% water contact with skin and eyes.
Protection to 51C 60% antifreeze and
(60.0F) 40% water To check for the amount of pressure that opens the
Checking the Filler Cap 1. After the engine cools, carefully loosen the filler
Table 15
cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap.
Number Carefully inspect the filler cap. Look for any
9S-8140 Pressurizing Pump 1 damage to the seals and to the sealing surface.
Inspect the following components for any foreign
substances:
One cause for a pressure loss in the cooling system
can be a defective seal on the radiator filler cap. filler cap
seal
surface for seal
items, and remove any material that is found on
these items.
2. Put the filler cap on the 9S-8140 Pressurizing

Pump.
57
3. Look at the gauge for the exact pressure that You do NOT observe any outside leakage.
opens the filler cap.
The reading remains steady after five minutes.
4. Compare the gauges reading with the correct
pressure that should open the filler cap: The inside of the cooling system has leakage only if
the following conditions exist:
5. If the filler cap is defective, replace the filler cap.
System For Leaks You do NOT observe any outside leakage.
Table 16
Number Test For The Water Temperature Gauge
9S-8140 Pressurizing Pump 1 Table 17
Tools Needed Quantity
Use the following procedure to check the cooling 4C-6500 Digital Thermometer 1
system for leaks: or or
2F-7112 Thermometer

and alkali.
der pressure.
Cooling System Conditioner contains alkali. Avoid burns from hot parts and can cause injury from
contact with skin and eyes. rotating parts.
1. After the engine is cool, loosen the filler cap When working on an engine that is running, avoid
slowly and allow pressure out of the cooling contact with hot parts and rotating parts.
system. Then remove the filler cap from the
radiator. Check the accuracy of the water temperature
indicator or water temperature sensor if you find
2. Make sure that the coolant level is above the top either of the following conditions:
of the radiator core.
3. Put the 9S-8140 Pressurizing Pump onto the

The engine runs at a temperature that is too hot,
but a normal temperature is indicated. A loss of
radiator. coolant is found.
4. Take the pressure reading on the gauge to
20 kPa (3 psi) more than the pressure on the
hot temperature is indicated. No loss of coolant
filler cap. is found.
5. Check the radiator for leakage on the outside. Coolant temperature can also be read on the display
screens of the Electronic Service Tool (ECAP or ET).
6. Check all connection points for leakage, and

58
4. Keep the water at the correct temperature for

ten minutes.
5. After ten minutes, remove the water temperature

regulator. Immediately check the distance that
the water temperature regulator has opened.
6. If the distance is less than 10.4 mm (.41 inch),

make a replacement of the water temperature
regulator.
Refer to the Specifications, Water Temperature

Regulator for more information about the
minimum distance for openings on the water
g00438983
temperature regulator.
Illustration 60
Test Location
(1) Plug
Water Pump Pressure Check
Table 18
Remove the plugs (1). Install one of the following
thermometers: Tools Needed Quantity
The 4C-6500 Digital Thermometer
A temperature indicator of known accuracy can
also be used to make this check.

cover over part of the radiator in order to cause a
restriction of the coolant flow. The reading on the
water temperature indicator should agree with the
test thermometer within the tolerance range of the
water temperature indicator.
Water Temperature Regulator Test

g00439003
der pressure. Illustration 61
Water Pump Group
If a pressure indication is shown on the indicator, (1) Plug
push the release valve in order to relieve pressure (2) Coolant temperature sensor
before removing any hose from the radiator. (3) Water manifold assembly
(4) Water outlet
1. Remove the regulator from the engine. (6) Bypass line
(7) Water pump
2. Heat water in a pan until the temperature is 98C
(8) Plug
(208F). Stir the water in the pan. This allows the
temperature to radiate throughout the pan.
3. Hang the water temperature regulator in the pan

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.
59

rotating parts.

Water pump outlet pressure can be checked on

water manifold assembly (3) next to the coolant
temperature sensor (2). This check will determine if
the water pump is operating correctly.
Remove plug (1) from water manifold assembly (3).

Install the 6V-7775 Air Pressure Gauge in the port
and measure the pump pressure. The water pump
pressure should be 100 to 125 kPa (15 to 18 psi).
A change in pressure can be measured between

plug (1) on the water manifold assembly (4) and
plug (8) on the inlet side of water pump (7).
i00869991
Belt Tension Chart

SMCS Code: 1357
Table 19
Belt Tension Chart
Borroughs Gauge
Gauge Reading
Numbers
Belt
Belt Width Old New
Gauge Gauge
Initial(1) Used(2)
Number Number
8K 27.92 mm (1.099 Inch) 800 22 N (180 5 lb) 489 44 N (110 10 lb) ------ BT-33-109
(2) Belt Tension Used is for a belt with over 30 minutes of operation at the rated speed.
60
i00870157 Connecting Rod and Main Bearings

Basic Block Connecting Rod Bearings
SMCS Code: 1200
Connecting rod bearings are available with
S/N: 8YS1-Up 0.508 mm (.0200 inch) and 0.762 mm (.0300 inch)
smaller inside diameter than the original size
bearings. These bearings are for crankshafts that
Piston Rings have been ground.
The pistons of the engine have a keystone design
ring groove. The piston rings are a keystone Main Bearings
ring. The 1U-6431 Piston Ring Groove Gauge is
available to check the top ring groove in the piston. Main bearings are available with 0.508 mm
Use the 8T-3149 Plug Gauge that is part of this (.0200 inch) and a 0.762 mm (.0300 inch) smaller
Gauge Group to check the top ring groove on the inside diameter than the original size bearings.
piston. Refer to the instruction card for correct use These bearings are for crankshafts that have been
of the 1U-6431 Piston Ring Groove Gauge. ground.
Main bearings are also available with a larger

Connecting Rods and Pistons outside diameter than the original size bearings.
These bearings are used for the cylinder blocks
The C-10 engine uses a 1U-9593 Cylinder Pack with the main bearing bore that is made larger than
Puller with a 1U-9897 Bridge, and a 1U-6319 the bores original size. The size that is available
Socket to remove a cylinder pack (connecting rod has a 0.508 mm (.0200 inch) outside diameter that
and piston) from the block. Use either the 1U-9788 is larger than the original size bearings.
Nylon Brush for reconditioning the cylinder liners.
Use the 1U-9787 Flexible Hone for reconditioning The Special Instruction, SMHS7606 gives the
the cylinder liners. instructions for the use of 1P-4000 Line Boring Tool
Group. The 1P-4000 Line Boring Tool Group is used
Use the 4C-3601 Piston Ring Expander in order to in order to check the alignment of the main bearing
remove the piston rings. Use the 4C-3601 Piston bores. The 1P-3537 Dial Bore Gauge Group can
Ring Expander in order to install the piston rings. be used to check the size of the bore. The Special
Instruction, GMGO0981 gives the instructions for
Use the 1U-6684 Piston Ring Compressor in order the use of 1P-3537 Dial Bore Gauge Group.
to install the pistons into the cylinder block.
Tighten the connecting rod nuts in the step Cylinder Block

sequence that follows:
Table 20
1. Put 4C-5593 Anti-Seize CompoundThread Tools Needed

Lubricant on bolt threads and contact surfaces Part Number Part Name Quantity
of nut and cap.
Dial Bore Gauge
1P-3537 1
2. Install the connecting rod nuts according to the Group
Tighten the connecting rod nuts to the following

torque: ........................ 130 7 Nm (95 5 lb ft)
3. Put a mark on each nut and end of bolt.
4. Tighten each nut by the following method:
Tighten the nut: ........................... 60 5 degrees

in the rod. If the bearing joints are worn, check
g00285686
Illustration 62
1P-3537 Dial Bore Gauge Group
61
If the main bearing caps are installed without 3. The components should be assembled in the
bearings, the bore in the block for the main bearings order that is shown in 63. The 7K-1977 Washer
can be checked. Tighten the nuts that hold the caps (4) is made of a cotton fabric that is impregnated
to the torque that is shown in the Specifications, with resin. The washer will not damage the
Cylinder Block. Alignment error in the bores must sealing surface of the cylinder block.
not be more than 0.08 mm (.003 inch).
Note: Inspect the washer before measuring the liner
The 1P-3537 Dial Bore Gauge Group can be projection. Replace the washer if the washer is
used to check the size of the bores. The Special worn or damaged.
Instruction, GMGO0981 is with the group.
4. Tighten bolts (1) evenly according to the
Cylinder Liner Projection
Table 21 First tighten each bolt to the following
torque. ....................................... 27 Nm (20 lb ft)
Tools Needed
Part Number Part Name Quantity Then tighten each bolt to the following
torque. ....................................... 54 Nm (40 lb ft)
Liner Projection
8T-0455 1
Tool Group Then tighten each bolt to the following
torque. ....................................... 68 Nm (50 lb ft)
1. Clean the cylinder liner flange and the cylinder
block surface. Remove any nicks on the top of Again tighten each bolt to the following
the cylinder block. torque. ....................................... 68 Nm (50 lb ft)
Table 22
Needed Components
Item Part Description Quantity Quantity
Number for One for Six
Cylinder Cylinders
1 8T-4193 Bolt 6 36
2 2S-5658 Washer 6 36
3 8F-1484 Washer 6 36
4 7K-1997 Washer 6 36
g00441537
Illustration 64
(5) Bolt
(6) Dial indicator
(7) Gauge body
(8) Gauge
5. Loosen bolt (5) until dial indicator (6) can be

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

the point contacts the gauge (8). Slide the dial
indicator until the needle of the gauge makes
Illustration 63
g00441535 a quarter of a revolution clockwise. The needle
should be in a vertical position. Tighten bolt (5)
Location of the Components
and zero indicator.
(1) Bolt
(2) Washer
(3) Washer
7. Put the gauge body (7) on the plate for the
(4) Washer cylinder block. The indicator point should be on
the liner flange. Read the dial indicator in order
2. The illustration and the chart identify the to find the amount of liner projection. Check the
components that are required. An 8T-0455 Liner projection at four locations (every 90 degrees)
Projection Tool Group is also required. around each cylinder liner.
62
Table 23 If you use any other method except the method that
Specifications
Liner Projection 0.040 to .200 mm correct measurements.
(.0016 to .0079 inch)
Maximum Variation in 0.050 mm (.0020 inch) 1. Fasten a dial indicator to the flywheel so the anvil
Each Liner of the dial indicator will contact the face of the
flywheel housing.
Maximum Average 0.050 mm (.0020 inch)
Variation Between 2. Put a force on the crankshaft toward the rear
Adjacent Liners before the dial indicator is read at each point.
Maximum Variation 0.100 mm (.0040 inch)
Between Liners
8. If a liner does not meet the recommended

cylinder liner projection specification, check the
following parts:
The depth of the cylinder block bore should be

100.00 0.03 mm (3.937 .001 inch).
The liner flange should be 100.12 0.03 mm

(3.942 0.001 inch).
If the depth of the cylinder block bore is out of

specification, replace the cylinder block. Then Illustration 66
g00285932
repeat the liner projection measurements. If
Checking Face Runout Of The Flywheel Housing
the liner flange is out of specification, replace
the liner. Then repeat the liner projection
measurements. 3. Turn the flywheel while the dial indicator is set at
0.0 mm (.00 inch) at location (A). Read the dial
indicator at locations (B), (C) and (D).
Flywheel and Flywheel Housing
Table 24 and the higher measurements that are performed
Tools Needed at all four points must not be more than 0.38 mm
(.015 inch), which is the maximum permissible
Dial Indicator housing.
8T-5096 1
Group
Bore Runout (Radial Eccentricity) of the
Face Runout (Axial Eccentricity) of the Flywheel Housing
Flywheel Housing
g00285934
Illustration 67
g00285931 8T-5096 Dial Indicator
Illustration 65
8T-5096 Dial Indicator Group
63
1. Fasten a dial indicator to the flywheel so the anvil 6. Turn the flywheel counterclockwise in order to put
of the dial indicator will contact the bore of the the dial indicator at (C). Write the measurement
flywheel housing. in the chart.
7. Turn the flywheel counterclockwise in order to put

the dial indicator at (D). Write the measurement
in the chart.

g00285932
Illustration 68
Checking Bore Runout Of The Flywheel Housing
g00285936
Illustration 69
g00286046
Illustration 70
2. While the dial indicator is in the position at
location (C) adjust the dial indicator to 0.0 mm Graph For Total Eccentricity
(.00 inch). Push the crankshaft upward against (1) Total vertical eccentricity
the top of the bearing. Refer to Illustration 69. (2) Total horizontal eccentricity
Write the measurement for bearing clearance on (4) Unacceptable value
10. On the graph for total eccentricity, find the point
Note: Write the measurements for the dial indicator of intersection of the lines for vertical eccentricity
with the correct notations. This notation is necessary and horizontal eccentricity.
for making the calculations in the chart correctly.
11. If the point of the intersection is in the
3. Divide the measurement from Step 2 by two. Acceptable range, the bore is in alignment. If
Write this number on line 1 in columns (B) and the point of intersection is in the Not acceptable
(D). range, the flywheel housing must be changed.
at (A). Adjust the dial indicator to 0.0 mm
(.00 inch).

the dial indicator at (B). Write the measurements
in the chart.
64
Face Runout (axial eccentricity) of the Bore Runout (radial eccentricity) of the
Flywheel Flywheel
g00286049 g00286054
Checking Face Runout Of The Flywheel Checking Bore Runout Of The Flywheel
1. Refer to Illustration 71 and install the dial (2) 7H-1645 Holding Rod
indicator. Always put a force on the crankshaft (3) 7H-1942 Dial Indicator
in the same direction before the dial indicator (4) 7H-1940 Universal Attachment
is read. This will remove any crankshaft end
clearance. 1. Install the 7H-1942 Dial Indicator (3). Make an
adjustment of the 7H-1940 Universal Attachment
2. Set the dial indicator to read 0.0 mm (.00 inch). (4) so that the dial indicator makes contact on
the flywheel.
read the dial indicator. 2. Set the dial indicator to read 0.0 mm (.00 inch).
4. Take the measurements at all four points. The 3. Turn the flywheel at intervals of 90 degrees and
difference between the lower measurements and read the dial indicator.
all four points must not be more than 0.15 mm 4. Take the measurements at all four points. The
(.006 inch), which is the maximum permissible difference between the lower measurements and
face runout (axial eccentricity) of the flywheel. the higher measurements that are performed at
65
Replace the damper if any of the following

conditions exist:
leaking
bent
damaged
worn bolt holes with loose fit for bolts
crankshaft failure due to torsional forces
NOTICE
Illustration 73 g00286058 Inspect the viscous vibration damper for signs of leak-
Flywheel Clutch Pilot Bearing Bore
Note: Bolts (4) must be tightened to a torque of
6. The runout (eccentricity) of the bore for the pilot 240 40 Nm (175 30 lb ft).
(.005 inch). Note: Bolts (5) must be tightened to a torque of
55 10 Nm (41 7 lb ft).
Vibration Damper
i00874350
Basic Block
SMCS Code: 1200
S/N: 9NS1-Up
Piston Rings
The pistons of the engine have a keystone design
ring groove. The piston rings are a keystone
available to check the top ring groove in the piston.
Use the 8T-3149 Plug Gauge that is part of this
Gauge Group to check the top ring groove on the
piston. Refer to the instruction card for correct use
of the 1U-6431 Piston Ring Groove Gauge.
Connecting Rods and Pistons

g00398558 The C-12 engine uses a 129-6675 Cylinder Pack
Illustration 74
Vibration Damper and Pulley Puller with a 1U-9897 Bridge, and a 1U-6319
(1) Damper assembly
Socket to remove a cylinder pack (connecting rod
(2) Pulley and piston) from the block. Use either the 1U-9788
(3) Crankshaft Nylon Brush for reconditioning the cylinder liners.
(4) Bolt Use the 1U-9787 Flexible Hone for reconditioning
(5) Bolt the cylinder liners.
The vibration damper is installed on the front of Use the 4C-3601 Piston Ring Expander in order to
crankshaft (3). The vibration damper (1) has a remove the piston rings. Use the 4C-3601 Piston
weight in a case. The space between the weight Ring Expander in order to install the piston rings.
and the case is filled with viscous fluid. The weight
moves in the case in order to limit the torsional Use the 1U-6684 Piston Ring Compressor in order
vibration. to install the pistons into the cylinder block.
66
Tighten the connecting rod nuts in the step Cylinder Block

sequence that follows:
Table 25
1. Put 4C-5593 Anti-Seize CompoundThread Tools Needed
Lubricant on bolt threads and contact surfaces
of nut and cap. Part Number Part Name Quantity
Dial Bore Gauge
2. Install the connecting rod nuts according to the 1P-3537 1
Group
Tighten the connecting rod nuts to the following

torque: ........................ 110 7 Nm (80 5 lb ft)
3. Put a mark on each nut and end of bolt.
4. Tighten each nut by the following method:
Tighten the nut: ........................... 60 5 degrees

in the rod. If the bearing joints are worn, check
g00285686
Illustration 75
Connecting Rod and Main Bearings 1P-3537 Dial Bore Gauge Group
Connecting Rod Bearings If the main bearing caps are installed without
bearings, the bore in the block for the main bearings
Connecting rod bearings are available with can be checked. Tighten the nuts that hold the caps
0.508 mm (.0200 inch) and 0.762 mm (.0300 inch) to the torque that is shown in the Specifications,
smaller inside diameter than the original size Cylinder Block. Alignment error in the bores must
bearings. These bearings are for crankshafts that not be more than 0.08 mm (.003 inch).
have been ground.
The 1P-3537 Dial Bore Gauge Group can be
Main Bearings used to check the size of the bores. The Special
Instruction, GMGO0981 is with the group.
Main bearings are available with 0.508 mm
(.0200 inch) and a 0.762 mm (.0300 inch) smaller Cylinder Liner Projection
These bearings are for crankshafts that have been Table 26
ground. Tools Needed
Main bearings are also available with a larger Part Number Part Name Quantity
outside diameter than the original size bearings. Liner Projection
These bearings are used for the cylinder blocks 8T-0455 1
Tool Group
the bores original size. The size that is available
has a 0.508 mm (.0200 inch) outside diameter that 1. Clean the cylinder liner flange and the cylinder
is larger than the original size bearings. block surface. Remove any nicks on the top of
the cylinder block.
The Special Instruction, SMHS7606 gives the
instructions for the use of 1P-4000 Line Boring Tool
Group. The 1P-4000 Line Boring Tool Group is used
in order to check the alignment of the main bearing
bores. The 1P-3537 Dial Bore Gauge Group can
be used to check the size of the bore. The Special
Instruction, GMGO0981 gives the instructions for
the use of 1P-3537 Dial Bore Gauge Group.
67
Table 27
Needed Components
Item Part Description Quantity Quantity
Number for One for Six
Cylinder Cylinders
1 8T-4193 Bolt 6 36
2 2S-5658 Washer 6 36
3 8F-1484 Washer 6 36
4 7K-1997 Washer 6 36
g00441537
Illustration 77
(5) Bolt
(6) Dial indicator
(7) Gauge body
(8) Gauge

6. Slide the dial indicator (6) into the position when

the point contacts the gauge (8). Slide the dial
g00441535
indicator until the needle of the gauge makes
Illustration 76 a quarter of a revolution clockwise. The needle
Location of the Components should be in a vertical position. Tighten bolt (5)
(1) Bolt and zero indicator.
(2) Washer
(3) Washer 7. Put the gauge body (7) on the plate for the
(4) Washer
cylinder block. The indicator point should be on
2. The illustration and the chart identify the
to find the amount of liner projection. Check the
components that are required. An 8T-0455 Liner
projection at four locations (every 90 degrees)
Projection Tool Group is also required.
around each cylinder liner.
3. The components should be assembled in the Table 28
order that is shown in 76. The 7K-1977 Washer
(4) is made of a cotton fabric that is impregnated Specifications
with resin. The washer will not damage the Liner Projection 0.040 to .200 mm
sealing surface of the cylinder block. (.0016 to .0079 inch)
Note: Inspect the washer before measuring the liner Maximum Variation in 0.050 mm (.0020 inch)
Each Liner
projection. Replace the washer if the washer is
worn or damaged. Maximum Average 0.050 mm (.0020 inch)
Variation Between
4. Tighten bolts (1) evenly according to the Adjacent Liners
following procedure: Maximum Variation 0.100 mm (.0040 inch)
Between Liners
First tighten each bolt to the following
torque. ....................................... 27 Nm (20 lb ft)
8. If a liner does not meet the recommended
Then tighten each bolt to the following cylinder liner projection specification, check the
torque. ....................................... 54 Nm (40 lb ft) following parts:
Then tighten each bolt to the following The depth of the cylinder block bore should be
torque. ....................................... 68 Nm (50 lb ft) 100.00 0.03 mm (3.937 .001 inch).
Again tighten each bolt to the following The liner flange should be 100.12 0.03 mm
torque. ....................................... 68 Nm (50 lb ft) (3.942 0.001 inch).
68
If the depth of the cylinder block bore is out of

specification, replace the cylinder block. Then
the liner flange is out of specification, replace
the liner. Then repeat the liner projection
measurements.
Flywheel and Flywheel Housing

Table 29
Tools Needed
Dial Indicator
8T-5096 1 g00285932
Group Illustration 79
Checking Face Runout Of The Flywheel Housing
Face Runout (Axial Eccentricity) of the 3. Turn the flywheel while the dial indicator is set at
Flywheel Housing 0.0 mm (.00 inch) at location (A). Read the dial

and the higher measurements that are performed
at all four points must not be more than 0.38 mm
housing.
Bore Runout (Radial Eccentricity) of the

Flywheel Housing
g00285931
Illustration 78
8T-5096 Dial Indicator Group
If you use any other method except the method that


flywheel housing.
g00285934
Illustration 80
2. Put a force on the crankshaft toward the rear
before the dial indicator is read at each point. 8T-5096 Dial Indicator

of the dial indicator will contact the bore of the
flywheel housing.
69

the dial indicator at (D). Write the measurement
in the chart.

g00285932
Illustration 81
Checking Bore Runout Of The Flywheel Housing
g00285936
Illustration 83
2. While the dial indicator is in the position at Graph For Total Eccentricity
location (C) adjust the dial indicator to 0.0 mm (1) Total vertical eccentricity
(.00 inch). Push the crankshaft upward against (2) Total horizontal eccentricity
the top of the bearing. Refer to Illustration 82. (3) Acceptable value
(4) Unacceptable value
Write the measurement for bearing clearance on
10. On the graph for total eccentricity, find the point
of intersection of the lines for vertical eccentricity
Note: Write the measurements for the dial indicator
and horizontal eccentricity.
11. If the point of the intersection is in the
Acceptable range, the bore is in alignment. If
3. Divide the measurement from Step 2 by two.
the point of intersection is in the Not acceptable
Write this number on line 1 in columns (B) and
range, the flywheel housing must be changed.
(D).

at (A). Adjust the dial indicator to 0.0 mm
(.00 inch).

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

the dial indicator at (C). Write the measurement
in the chart.
70
Face Runout (axial eccentricity) of the Bore Runout (radial eccentricity) of the
Flywheel Flywheel
g00286049 g00286054
Checking Face Runout Of The Flywheel Checking Bore Runout Of The Flywheel
1. Refer to Illustration 84 and install the dial (2) 7H-1645 Holding Rod
indicator. Always put a force on the crankshaft (3) 7H-1942 Dial Indicator
in the same direction before the dial indicator (4) 7H-1940 Universal Attachment
clearance. 1. Install the 7H-1942 Dial Indicator (3). Make an
adjustment of the 7H-1940 Universal Attachment
2. Set the dial indicator to read 0.0 mm (.00 inch). (4) so that the dial indicator makes contact on
the flywheel.
read the dial indicator. 2. Set the dial indicator to read 0.0 mm (.00 inch).
4. Take the measurements at all four points. The 3. Turn the flywheel at intervals of 90 degrees and
difference between the lower measurements and read the dial indicator.
all four points must not be more than 0.15 mm 4. Take the measurements at all four points. The
(.006 inch), which is the maximum permissible difference between the lower measurements and
face runout (axial eccentricity) of the flywheel. the higher measurements that are performed at
71

conditions exist:
leaking
bent
damaged
worn bolt holes with loose fit for bolts
crankshaft failure due to torsional forces
NOTICE
Illustration 86 g00286058 Inspect the viscous vibration damper for signs of leak-
Flywheel Clutch Pilot Bearing Bore
Note: Bolts (4) must be tightened to a torque of
6. The runout (eccentricity) of the bore for the pilot 240 40 Nm (175 30 lb ft).
(.005 inch). Note: Bolts (5) must be tightened to a torque of
55 10 Nm (41 7 lb ft).
Vibration Damper
i00873461
Compression Brake
SMCS Code: 1119; 1129
Adjustment of the Compression

Brake


g00398558
Illustration 87
This engine uses high voltage to the unit fuel in-
Vibration Damper and Pulley
jectors.
(1) Damper assembly
(2) Pulley
(3) Crankshaft
Disconnect injector enable circuit connector to
(4) Bolt prevent personal injury.
(5) Bolt
Do not come in contact with the injector terminals
The vibration damper is installed on the front of while the engine is running.
crankshaft (3). The vibration damper (1) has a
weight in a case. The space between the weight
Note: Refer to Electronic Troubleshooting for more
and the case is filled with viscous fluid. The weight
information on the testing of the integrated engine
moves in the case in order to limit the torsional
retarder.
vibration.
72
Note: Slave piston lash is measured between the 3. Turn the slave piston adjusting screw (1)
slave piston and the actuating pin in the bridge clockwise until the 0.64 mm (.025 inch) feeler
adjusting screw. gauge for the C-10 is set. Turn the slave piston
adjusting screw (1) clockwise until the 1.02 mm
Table 30 (.040 inch) feeler gauge for the C-12 is set.
Slave Piston Lash Setting
4. After each adjustment, tighten the nut for
Engine Brake Model Setting valve adjustment screw to a torque of 35 Nm
No. (25.0 lb ft) and check the adjustment again.
C-10 310A 0.64 .08 mm
(0.025 5. Remove the timing bolt and turn the flywheel by
0.003 inch) 360 degrees in the direction of engine rotation.
This will put No. 6 piston at the top center
C-12 312A 1.02 .08 mm
(0.040 position on the compression stroke. Install the
0.003 inch) timing bolt in the flywheel.
To make an adjustment to the slave piston lash

Make the slave piston adjustments with the engine on cylinders 2, 4, and 6, follow steps 2 through 4.
stopped. The exhaust valves must be closed on the
cylinder in order to be adjusted. 6. Remove the timing bolt from the flywheel after
all adjustments have been made. Reinstall the
To make an adjustment to the slave piston lash on timing cover.
cylinders 1, 3, and 5 use the following procedure.
1. Put No. 1 piston at the top center position on i00872068

the compression stroke. Refer toTesting and
Adjusting, Finding the Top Center Position For Electrical System
No. 1 Piston for more information on finding the
top center position. SMCS Code: 1400
Test Tools For The Electrical

System
Table 31
Tools Needed
4C-4911 Battery Load Tester 1
8T-0900 Ammeter 1
6V-7070 Digital Multimeter 1
g00434165 Most of the tests of the electrical system can be

Illustration 88
Compression Brake in good condition. The wire and cable connections
(1) Adjusting screw and locknut must be clean, and both components must be tight.
(2) Slave piston The battery must be fully charged. If the on-engine
(3) Actuating pin within the bridge adjusting screw assembly
test shows a defect in a component, remove the
component for more testing.
2. Insert a 0.64 mm (.025 inch) feeler gauge for
the C-10 between the slave piston (2) and the Refer to the service manual Testing And Adjusting
actuating pin (3) in the bridge adjusting screw Electrical Components, REG00636 for further
assembly. Insert a 1.02 mm (.040 inch) feeler information. This manual contains the following
gauge for the C-12 between the slave piston (2) information:
and the actuating pin (3) in the bridge adjusting
screw assembly.
complete specifications for the components of
the starting circuits
procedures for the components of the starting

circuits
73
complete specifications for the components of

the charging circuit
procedures for the components of the charging

circuit
g00296441
Illustration 90
8T-0900 Ammeter
The 8T-0900 Ammeter is completely portable.

This ammeter is a self-contained instrument that
measures electrical currents without breaking the
circuit and without disturbing the conductors
insulation.
The ammeter contains a digital display that is used

to monitor current directly within a range between 1
Illustration 89 g00283565 ampere and 1200 amperes. If an optional 6V-6014
Cable is connected between this ammeter and a
4C-4911 Battery Load Tester
directly from the display of the multimeter. This can
The 4C-4911 Battery Load Tester is a portable unit be accomplished under only one condition:
in a metal case. The 4C-4911 Battery Load Tester
can be used under field conditions and under high
temperatures. The tester can be used to load test
all 6, 8, and 12 Volt batteries. This tester has two A lever opens the ammeters jaws over a conductor.
heavy-duty load cables that can easily be fastened The conductors diameter can not be larger than
to the battery terminals. A load adjustment knob is 19 mm (0.75 inch).
located on the top of the tester. The load adjustment
knob permits the current that is being drawn from The spring loaded jaws close around the conductor
the battery to be adjusted to a maximum of 1000 for measuring the current. A trigger switch controls
amperes. The tester is cooled by an internal fan that the ammeter. The trigger switch can be locked into
is automatically activated when a load is applied. the ON position or into the OFF position.
The tester has a built-in LCD. The LCD is a digital After the trigger has been working and the trigger is
voltmeter. The LCD is a digital meter that will turned to the OFF position, the reading appears in
also display the amperage. The digital voltmeter the digital display for five seconds. This accurately
accurately measures the battery voltage at the measures currents in areas with a limited access.
battery through wires for tracing. These wires are For example, these areas include areas that are
buried inside the load cables. The digital meter, beyond the operators sight. For DC operation, an
that displays the amperage, accurately displays the ammeter contains a zero control, and batteries
current that is being drawn from the battery which inside the handle supply the power.
is being tested.
Note: Refer to Operating Manual , SEHS9249 for more information about using the 8T-0900
for more complete information for the use of the Ammeter.
4C-4911 Battery Load Tester.
74
Use the 4C-4911 Battery Load Tester in order to

test a battery that does not maintain a charge when
the battery is active. Refer to Operating Manual,
SEHS9249 for detailed instruction on the use of
the 4C-4911 Battery Load Tester. See Special
Instruction, SEHS7633 for the correct procedure
and for the specifications to use when you test the
batteries.
Charging System
regular inspection will show if the charging system
operates correctly. An adjustment is necessary
Illustration 91 g00283566 when the battery is constantly in a low condition
A large amount of water would be more than one
The 6V-7070 Digital Multimeter is a completely ounce of water per cell per week or per every 100
portable, hand-held instrument with a digital display. service hours.
This multimeter is built with extra protection against
damage in field applications. The multimeter is When it is possible, make a test of the charging unit
equipped with 7 functions and 29 ranges. The and voltage regulator on the engine, and use wiring
6V-7070 Digital Multimeter has an instant ohms and components that are a permanent part of the
indicator. This indicator permits checking continuity system. Off-engine testing or bench testing will give
for a fast inspection of the circuits. The multimeter a test of the charging unit and voltage regulator
can also be used for troubleshooting capacitors operation. This testing will give an indication of
that have small values. needed repair. After repairs are made, perform
Note: Refer to Special Instruction, SEHS7734 for repaired to the original condition of operation.
complete information for the use of the 6V-7070
Digital Multimeter. To check for correct output of the alternator, see
the Specifications module.
Battery Before the start of on-engine testing, the charging

system and the battery must be checked according
to the following steps.
1. The battery must be at least 75 percent (1.225

Never disconnect any charging unit circuit or bat-
Sp Gr) of the full charge. The battery must be
tery circuit cable from the battery when the charg- held tightly in place. The battery holder must not
ing unit is operated. A spark can cause an explo-
put too much stress on the battery.
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec- 2. Cables between the battery, the starter, and the
trolyte through the battery outlets. Injury to per-
engine ground must be the correct size. Wires
sonnel can be the result.
and cables must be free of corrosion. Wires
and cables must have cable support clamps in
The battery circuit is an electrical load on the order to prevent stress on battery connections
charging unit. The load is variable because of the (terminals).
condition of the charge in the battery.
3. Leads, junctions, switches, and panel instruments
that have direct relation to the charging circuit
NOTICE
must give correct circuit control.
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
4. Inspect the drive components for the charging
while in operation. Damage occurs because the load
unit in order to be sure that the components are
from the battery is lost and because there is an in-
free of grease and oil. Be sure that the drive
crease in charging voltage. High voltage will damage
components have the ability to operate the
the charging unit, the regulator, and other electrical
charging unit.
components.
75
checked when an alternator is charging the battery
too much. The charging rate of the alternator
should be checked when an alternator is not
charging the battery enough. Make reference to the
Specifications module in order to find all testing
specifications for the alternators and regulators.

Tightening The Alternator Pulley Nut
g00283568
Illustration 93
Tools For Tightening The Alternator Pulley Nut
(1) 8T-9293 Torque Wrench
(2) 8S-1588 Adapter (1/2 inch female to 3/8 inch male)
(3) 2P-8267 Socket Assembly
(4) 8H-8517 Combination Wrench (1-1/8 inch)
(5) 8T-5314 Socket
Tighten the nut that holds the pulley to the following

torque. ...................... 102 7 Nm (75.0 5.0 lb ft)
Electric Starting System

Use the multimeter in the DCV range to find starting
system components which do not function.
g00286495 Move the start control switch in order to activate the

Illustration 92
starting solenoids. The starting solenoids operation
Alternator can be heard as the pinions of the starting motors
(1) Ground terminal are engaged with the ring gear on the engine
(2) Pulley nut flywheel.
If a solenoid for a starting motor will not operate,

it is possible that the current from the battery
did not reach the solenoid. Fasten one lead of
the multimeter to the connection (terminal) for the
battery cable on the solenoid. Put the other lead to
a good ground. A zero reading indicates that there
is a broken circuit from the battery. More testing is
necessary when there is a voltage reading on the
multimeter.
76
The solenoid operation also closes the electric

circuit to the motor. Connect one lead of the
multimeter to the solenoid connection (terminal)
that is fastened to the motor. Put the other lead to
a good ground. Activate the starting solenoid and
look at the multimeter. A reading of the battery
voltage shows that the problem is in the motor. The
motor must be removed for further testing. A zero
reading on the multimeter shows that the solenoid
contacts do not close. This is an indication of the
need for repair to the solenoid or an adjustment to
be made to the starting motor pinion clearance.
Perform a test. Fasten one multimeter lead to the

connection (terminal) for the small wire at the g00442963
solenoid and fasten the other lead to the ground. Illustration 94
Look at the multimeter and activate the starting Typical Connection for Checking Pinion Clearance
solenoid. A voltage reading shows that the problem (1) Connector for motor terminal on solenoid to starter motor
is in the solenoid. A zero reading indicates that the (2) SW terminal
problem is in the start switch or the wires for the (3) Ground terminal
start switch.
1. Install the solenoid without connector (1) from the
Fasten one multimeter lead to the start switch at the MOTOR connections (terminal) on the solenoid
connection (terminal) for the wire from the battery. to the motor.
Fasten the other lead to a good ground. A zero
reading indicates a broken circuit from the battery. 2. Connect a battery, that has the same voltage as
Make a check of the circuit breaker and wiring. If the solenoid, to the SW terminal (2).
there is a voltage reading, the problem is in the start
switch or in the wires for the start switch. 3. Connect the other side of the battery to
connector (3).
Starting motors that operate too slowly can have an
overload because of too much friction in the engine 4. For a moment, connect a wire from the solenoid
that is being started. Slow operation of the starting connection (terminal), which is marked MOTOR,
motors can also be caused by a short circuit, loose to the ground connection (terminal). The pinion
connections and/or dirt in the motors. will shift to the crank position and the pinion will
To check for correct output of the starting motors
and the starter solenoid, see the Specifications
module.
Pinion Clearance Adjustment

When the solenoid is installed, make an adjustment
of the pinion clearance. The adjustment can be
made with the starting motor removed.
g00283574
Illustration 95
Pinion Clearance Adjustment
(4) Shaft nut
(5) Pinion
(6) Pinion Clearance
5. Push the pinion toward the end with the

commutator in order to remove free movement.
6. Pinion clearance (6) must be 8.3 to 9.9 mm

(0.33 to 0.39 inch).
77


plug over the adjustment nut (4). Install the
connector (1) between the motor terminal on the
solenoid and the starting motor.
78
Index Section
Index
A E
Air Inlet and Exhaust System ................................ 19 Electrical System............................................. 36, 72

Turbocharger...................................................... 20 Battery ............................................................... 74
Valve Mechanism............................................... 21 Charging System ............................................... 74
Air Inlet And Exhaust System ................................ 45 Charging System Components .......................... 37
Air-To-Air Aftercooled Systems .......................... 46 Electric Starting System..................................... 75
Compression...................................................... 49 Engine Electrical System ................................... 37
Crankcase Pressure (Crankshaft Grounding Practices .......................................... 36
Compartment) .................................................. 49 Starting System Components ............................ 38
Cylinder Head .................................................... 49 Test Tools For The Electrical System................. 72
Exhaust Temperature......................................... 46 Electronic Control System ..................................... 40
Measurement of Pressure In Inlet Manifold ....... 45 Accelerator Pedal Position Sensor..................... 41
Restriction Of Air Inlet And Exhaust .................. 45 Diagnostic Codes............................................... 40
Valve Lash Setting ............................................. 50 Electronic Service Tools..................................... 40
Electronic Control System Components................ 10
Engine Design ......................................................... 4
B
Basic Block ................................................ 31, 60, 65 F

Camshaft............................................................ 32
Connecting Rod and Main Bearings ............ 60, 66 Fuel System..................................................... 14, 41
Connecting Rods and Pistons...................... 60, 65 Checking Engine Cylinders Separately.............. 43
Crankshaft.......................................................... 32 Finding the Top Center Position for No. 1
Cylinder Block .............................................. 60, 66 Piston ............................................................... 44
Cylinder Block and Head ................................... 31 Fuel Pressure..................................................... 42
Cylinder Liner Projection.............................. 61, 66 Fuel System Electronic Control Circuit .............. 15
Flywheel and Flywheel Housing .................. 62, 68 Fuel System Inspection...................................... 41
Piston Rings................................................. 60, 65 Fuel Transfer Pump............................................ 42
Pistons, Rings, and Connecting Rods ............... 32 Procedure for Fuel Priming ................................ 42
Vibration Damper ......................................... 65, 71 Timing of the Timing Reference Ring and the Front
Belt Tension Chart ................................................. 59 Gear Group ...................................................... 44
Unit Injector........................................................ 18
Unit Injector Adjustment..................................... 43
C Unit Injector Mechanism .................................... 17
Compression Brake ......................................... 33, 71

Adjustment of the Compression Brake .............. 71 G
Operation of the Compression Brake................. 35
Performance of the Compression Brake ............ 34 General Information................................................. 5
Cooling System ......................................... 27, 29, 53 Cold Mode Operation........................................... 5
Checking the Filler Cap...................................... 56 Customer Specified Parameters .......................... 5
Coolant Conditioner (If Equipped)...................... 30 Starting The Engine ............................................. 5
Coolant Flow ...................................................... 27 Glossary of Electronic Control Terms ...................... 6
Coolant for Air Compressor ............................... 31
Supply Manifold ................................................. 28
Testing The Cooling System .............................. 54 I
Visual Inspection Of The Cooling System.......... 53
Water Pump Pressure Check............................. 58 Important Safety Information ................................... 2
79
Index Section

Increased Oil Temperature................................. 53
Indicators For Oil Pressure ................................ 53
Measuring Engine Oil Pressure ......................... 51
Oil Flow Through The Lubrication System......... 25
Oil Pressure High............................................... 53
Oil Pressure Is Low............................................ 52
Too Much Bearing Wear .................................... 53
Too Much Oil Consumption................................ 51
Testing and Adjusting ............................................ 40
1998 Caterpillar
RENR1318-02
January 2000
Disassembly and
Assembly
8YS1-Up (Engine)
9NS1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Gear Group (Front) - Remove ............................... 52

Disassembly and Assembly Section Accessory Drive - Remove ................................... 56
Accessory Drive - Disassemble ........................... 56
Fuel Priming Pump - Remove and Install .............. 4
Accessory Drive - Assemble ................................ 57
Accessory Drive - Install ....................................... 58
Fuel Manifold - Remove .......................................... 7
Install ................................................................... 59
Fuel Manifold - Install .............................................. 8
Compression Brake - Remove .............................. 60
Electronic Unit Injector - Remove ........................... 8
Compression Brake - Disassemble ....................... 61
Electronic Unit Injector - Install ............................... 9
Compression Brake - Assemble ........................... 64
Electronic Unit Injector Sleeve - Remove .............. 11
Compression Brake - Install .................................. 68
Electronic Unit Injector Sleeve - Install ................. 12
Air Inlet Manifold - Remove ................................... 15
Air Inlet Manifold - Install ....................................... 15
Camshaft - Remove .............................................. 76
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 16
Camshaft Bearings - Remove ............................... 79
Camshaft Bearings - Install ................................... 80
Install ................................................................... 19
Cylinder Liner - Remove ....................................... 83
Install ................................................................... 20
Cylinder Liner - Install ........................................... 84
Engine Centrifugal Oil Filter - Remove and
Install ................................................................... 21
Connecting Rod Bearings - Remove .................... 89
Connecting Rod Bearings - Install ........................ 90
Camshaft Position Sensor - Remove and Install ... 99
............................................................................. 35
Install ................................................................. 100
Water Outlet Manifold - Remove ........................... 38
Crankshaft Position Sensor - Remove and
Water Outlet Manifold - Install ............................... 39
Install ................................................................. 101
Flywheel - Remove ............................................... 39
........................................................................... 101
Electronic Control Module - Remove and Install .. 103
Install ................................................................... 41
Air Conditioner Support Bracket - Remove and
Rear Power Take-Off (RPTO) - Remove ............... 44
Install ................................................................. 106
Rear Power Take-Off (RPTO) - Install ................... 46
............................................................................. 49
Front Cover - Remove ........................................... 51 Index Section
Index ................................................................... 110
4
Disassembly and Assembly Installation Procedure

Section NOTICE
i00999653
Fuel Priming Pump - Remove component life.
and Install
SMCS Code: 1258-010
Removal Procedure
NOTICE

component life.
NOTICE
Illustration 2
during performance of inspection, maintenance, test- Typical example
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before 1. Inspect the condition of the gasket. Replace the
opening any compartment or disassembling any gasket, if necessary.
component containing fluids.
2. Ensure that both valve assemblies are in the
Refer to Special Publication, NENG2500, Caterpillar correct position at the bottom of the fuel priming
Tools and Shop Products Guide, for tools and sup- pump.
plies suitable to collect and contain fluids in Caterpillar
machines. 3. Install the gasket and fuel priming pump (2) on
the fuel filter base.
mandates. 4. Install the washers and bolts (1).
5. Check the operation of the fuel priming pump.
i01015037
Fuel Filter Base - Remove and

Install
SMCS Code: 1262-010
Removal Procedure
Table 1
Illustration 1 g00511626 Required Tools

Typical example Part
Number
1. Remove two bolts (1) and the washers. A 2P-8250 Strap Wrench Assembly 1
2. Remove fuel priming pump (2) and the gasket
from the fuel filter base.
5
3. Disconnect the sensor connector from fuel

NOTICE temperature sensor (2).
4. Remove fuel temperature sensor (2).
component life. 5. Disconnect hose assembly (3). Plug all openings
immediately.
NOTICE 6. Remove two bolts (4) and the washers.

during performance of inspection, maintenance, test- 7. Remove fuel filter base (5) and the two O-ring
ing, adjusting and repair of the machine. Be prepared seals.
to collect the fluid with suitable containers before
opening any compartment or disassembling any 8. Remove the fuel filter mounting stud from the fuel
component containing fluids. filter base, if necessary.
Refer to Special Publication, NENG2500, Caterpillar Installation Procedure

Tools and Shop Products Guide, for tools and sup-
plies suitable to collect and contain fluids in Caterpillar Table 2
machines.
Required Tools
Dispose of all fluids according to local regulations and Part
mandates. Tool Part Description Qty
Number
NOTICE

component life.

threads of the fuel filter mounting stud. Apply
the compound to the tapered end of the stud no
more than 7.6 mm (.30 inch) from the end.
Illustration 3
g00519561 2. Install the stud and tighten to a torque of
70 15 Nm (50 11 lb ft).
1. Remove plug (1) and drain fuel into a suitable
container for storage or disposal. 3. Inspect the condition of the two O-ring seals.
Replace the seals, if necessary.
g00520760
Illustration 5
Typical example
Typical example
2. Use Tool (A) to remove fuel filter (6).
6
4. Install the two O-rings on fuel filter base (5).

NOTICE
5. Install fuel filter base (5) on the fuel manifold with Care must be taken to ensure that fluids are contained
two bolts (4) and the washers. during performance of inspection, maintenance, test-
6. Connect hose assembly (3). to collect the fluid with suitable containers before
opening any compartment or disassembling any
7. Install fuel temperature sensor (2). Connect the component containing fluids.
sensor connector to fuel temperature sensor (2).
8. Use Tool (A) in order to install new fuel filter (6). Tools and Shop Products Guide, for tools and sup-
Follow the instructions on the fuel filter. plies suitable to collect and contain fluids in Caterpillar
machines.

mandates.
g00519561
Illustration 6
9. Install plug (1).
g00511822
Fuel Transfer Pump - Remove 1. Disconnect tube assembly (3). Cover all
openings immediately.
SMCS Code: 1256-011
2. Remove two bolts (2) and the seal washers.
Removal Procedure
3. Remove fuel transfer pump (1) and the gasket.
NOTICE
Keep all parts clean from contaminants. i00999918
Contaminants may cause rapid wear and shortened Fuel Transfer Pump - Install
component life.
SMCS Code: 1256-012
NOTICE

component life.
7
NOTICE

machines.

Illustration 8
mandates.
2. Position the fuel transfer pump (1) and the gasket

on the front housing cover.
Note: Do not reuse the seal washers. Use new seal

washers during installation.
3. Install bolts (2) and the new seal washers.

Tighten the bolts to a torque of 55 10 Nm
(41 7 lb ft).
4. Connect tube assembly (3).

g00519376
Illustration 9
i01012833 Typical example
Fuel Manifold - Remove 1. Remove bolt (2) and move the wiring harness
out of the way.
SMCS Code: 1702-011
2. Remove bolts (3) and the washers.
Removal Procedure
3. Remove fuel manifold (1).
Start By:
a. Remove the fuel filter base.
NOTICE

component life.
g00519417
Illustration 10
4. Remove six O-ring seals (4).
5. Remove plugs (5) and the O-ring seals, if

necessary.
8
i01012956 End By:

Fuel Manifold - Install a. Install the fuel filter base.
SMCS Code: 1702-012
i00999968
Installation Procedure Electronic Unit Injector -

NOTICE
Remove
SMCS Code: 1290-011
component life. Removal Procedure
Table 3
Required Tools
Part
Number
A 5F-4764 Pry Bar 1
Start By:
a. Remove the rocker arm assemblies and the push

rods.
NOTICE

g00519417
component life.
Illustration 11
2. Install plugs (5) and the O-ring seals. NOTICE

3. Install six O-ring seals (4) on fuel manifold (1). during performance of inspection, maintenance, test-

machines.

mandates.
g00519376
Illustration 12
4. Install fuel manifold (1) on the cylinder head with

bolts (3) and the washers.
5. Install the wiring harness with bolt (2). Tighten

all of the bolts to a torque of 28 7 Nm
(21 5 lb ft).
9
g00511865 g00511870
1. Remove plug (1) from the fuel manifold. 6. Position Tool (A) under hold down (8), and
carefully pry unit injector (7) out of the cylinder
2. Drain the fuel from the cylinder head assembly head assembly. Remove the unit injector.
into a suitable container for storage or disposal.
i01233178
Electronic Unit Injector - Install

SMCS Code: 1290-012
Table 4
Required Tools
Number
9U-6682 Tapered Brush 1
g00511868 A
Illustration 14
9U-7237 Brush Extension 1
3. Mark bridge assemblies (4) for reference during 9U-6863 Small Bore Brush 1
installation. B
4. Loosen two nuts (3) and remove cap assembly
(2). NOTICE
5. Remove bolt (5) and spacer assembly (6) that
holds the unit injector in place. Contaminants may cause rapid wear and shortened
component life.
10
g00511929
Illustration 18
3. Lubricate the bore lightly with a 50/50 mix of

clean engine oil and 8T-2998 Lubricant.
4. Position the unit injector (3) in the cylinder head

assembly. Place the hold down clamp (10) at
the base of the unit injector. Push down on the
return spring of the unit injector in order to seat
the unit injector.
5. Install spacer assembly (9) and bolt (8) that

holds the unit injector in place.
g00511917
Illustration 16
(1) Injector seating 6. Pull the unit injector completely into the bore.
(2) Tip bore Tighten the bolt to a torque of 30 Nm (22 lb ft).
1. Use Tool (A) to clean injector seating (1). 7. Install cap assembly (5). Tighten nuts (6) to a
torque of 2.5 0.25 Nm (22 2 lb in).
2. Use Tool (B) to clean tip bore (2).
g00511936
Illustration 19
g00511927
Illustration 17
8. Install plug (11) in the fuel manifold.
Note: Do not reuse seals (4). Use new seals for
installation.
11
i01000108
Electronic Unit Injector Sleeve

- Remove
SMCS Code: 1713-011
Removal Procedure
Table 5
Required Tools
Part
Number
9U-7259 Puller Stud 1
128-7889 Bridge Puller 1
A(1) 9U-6877 Thrust Bearing 1
5P-8247 Hard Washer 1
Illustration 20 g00529729 4K-0367 Nut 1

(1) The tools that are listed in the chart are part of the 9U-6891
(12) Electronic injector code
Injector Tool Group.
NOTICE Start By:

When a fuel injector group is serviced, the new fuel
injector groups electronic injector code must be pro- a. Remove the electronic unit injectors.
grammed into the engines personality module soft-
ware by using the calibration menu on the Electronic
Service Tool. If the new fuel injector groups electronic NOTICE
code is not entered, the previous fuel injector groups Keep all parts clean from contaminants.
characteristics are assumed.
If it is not possible to immediately reprogram the elec- component life.
tronic injector code of the injector into the personal-
ity module software, the engine will not be severely
harmed. The new electronic injector code should be
reprogrammed as quickly as possible in order to opti-
mize engine performance.
9. If a new unit injector or a different unit injector is

installed, program the electronic injector code.
End By:
a. Install rocker arm assemblies and push rods.
b. Adjust the unit injectors. Refer to the Testing and

Adjusting, Fuel System topic for the proper Illustration 21 g00512128
procedure.
Typical example
1. Install the puller stud from Tool (A) into the unit
injector sleeve.
12
g00512002
Illustration 22
2. Install the following parts from Tool (A) over the

stud: bridge puller, thrust bearing, hard washer,
and nut. See Step 1.
3. Tighten the nut until the unit injector sleeve is

pulled free of the cylinder head assembly.
4. Remove Tool (A) from the unit injector sleeve.

remaining unit injector sleeves.
g00512115
Illustration 23
i01000204
1. Use Tool (A) to clean the unit injector bore.
2. Use Tool (B) to clean the unit injector seat.
- Install
Note: Check the fuel passage in the cylinder head
SMCS Code: 1713-012 assembly. Remove any debris left from the use of
Tool (A) and Tool (B).
3. Apply 4C-9507 Retaining Compound to upper
Table 6 land (1) and lower land (2) on the unit injector
sleeve.
Required Tools
Part
Number
A 4C-5552 Large Bore Brush 1
B
9U-7244 End Brush 1
C 9U-7258 Driver Cap 1
NOTICE

component life. g00512116
Illustration 24
4. Position the unit injector sleeve in the cylinder

head assembly. Use Tool (C) and a hammer to
seat the sleeve.
13
5. Repeat Step 1 through Step 4 in order to install

the remaining unit injector sleeves.
End By:
a. Install the electronic unit injectors.
i01017438
SMCS Code: 1052-011

Illustration 26
NOTICE Typical example
during performance of inspection, maintenance, test- 1. Remove two bolts (3) and the washers.
to collect the fluid with suitable containers before 2. Remove bolt (8) with the nut and the washer.
opening any compartment or disassembling any Remove saddle clamp (7).
3. Remove two bolts (9) and the washers.
Tools and Shop Products Guide, for tools and sup- 4. Remove oil supply tube (2) and the gasket.
machines. 5. Remove two bolts (5) and the washers.
Dispose of all fluids according to local regulations and 6. Remove oil drain tube (6). Remove the O-ring
mandates. seal and the gasket from oil drain tube (6).
7. Remove four nuts (11).
8. Remove turbocharger (1) and gasket (10) from

the exhaust manifold.
i01017473
Turbocharger - Install
SMCS Code: 1052-012
g00521929 1. Inspect the condition of the gasket between the
Illustration 25
turbocharger and the exhaust manifold and the
Typical example O-ring seals. Replace the O-ring seals and the
gaskets, if necessary.
14
8. Install oil supply tube (2) and the gasket on

turbocharger (1). Install two bolts (3) and the
washers.
9. Install bolt (8) and saddle clamp (7).
i01000630
Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010
Illustration 27 g00521930 Removal Procedure

Typical example
Start By:
a. Remove the turbocharger.
g00521929
Illustration 28
Typical example
g00512515
Illustration 29
Note: Refer to the Specifications Manual for the
Typical example
tightening procedure of the clamps on specific
turbochargers.
1. Remove locknuts (1) with the washers and
spacers.
2. Place clean engine oil in the oil supply port of
the turbocharger prior to installation. The oil will
2. Remove exhaust manifold (2) and the gaskets.
provide lubrication during starting and protection
during storage.
3. Remove the studs that hold the exhaust manifold
to the cylinder head assembly.
turbocharger mounting studs on the exhaust
4. Remove studs (3) from the exhaust manifold, if
manifold.
necessary.
4. Install turbocharger (1) and gasket (10) on the
exhaust manifold. Install four nuts (11). Tighten Installation Procedure
the nuts to a torque of 70 Nm (52 lb ft).
5. Place the gasket and the O-ring seal on oil drain gasket, if necessary.
tube (6).
6. Install oil drain tube (6) with two bolts (5) and threads of the studs that hold the exhaust
the washers. manifold to the cylinder head assembly.
7. Install two bolts (9) and the washers. 3. Install the studs for the cylinder head assembly.
Tighten the studs to a torque of 35 5 Nm
(26 4 lb ft).
15
g00512515 g00515794
Typical example
1. Disconnect sensor connector (3).
4. Position the gaskets with the tabs in the upward
position. Install exhaust manifold (2). 2. Remove bolt (1) and clip (4).
5. Apply 5P-3931 Anti-Seize Compound to 3. Disconnect sensor connector (2).

locknuts (1). Install locknuts (1) with the washers
and spacers. Tighten the locknuts to a torque of 4. Remove hose assembly (5).
55 10 Nm (41 7 lb ft).
5. Remove bolts (7) and the washers. Remove air
6. Apply 5P-3931 Anti-Seize Compound to the inlet manifold (6) and the three gaskets.
threads of studs (3).
i01005445
7. Install studs (3) in exhaust manifold (2). Tighten
the studs to a torque of 35 5 Nm (26 4 lb ft). Air Inlet Manifold - Install
End By: SMCS Code: 1058-012
a. Install the turbocharger.
i01005444 NOTICE
Air Inlet Manifold - Remove
SMCS Code: 1058-011
component life.
Removal Procedure
NOTICE

component life.
g00515794
Illustration 32
1. Inspect the condition of the gaskets. Replace the

16
2. Position air inlet manifold (6) and the three

gaskets on the cylinder head.
3. Install bolts (7) and the washers. Tighten bolts

4. Install hose assembly (5).
5. Connect sensor connector (2).
6. Install clip (4) and bolt (1). Tighten bolt (1) to a


g00526801
Illustration 33
i01253730
2. Place the bottom portion of Tool (A) on the
Inlet and Exhaust Valve cylinder head. Install the hold down bolt (1) .
Springs - Remove and Install
SMCS Code: 1108-010
Removal Procedure
Table 7
Required Tools
Part
Number
A 4C-6726 Valve Spring Compressor 1
Start By: g00526802

Illustration 34
a. Remove the valve mechanism cover, the
electronic unit injector, the rocker shaft and the 3. Install the remainder of Tool (A).
push rods.
NOTICE

component life.
Note: The following procedure is for the removal

of the inlet valve springs and the exhaust valve
springs without removing the cylinder head. This
procedure can be performed on only one cylinder
at a time. This will prevent the inlet valves and the
exhaust valves from falling into the cylinder. g00526803
Illustration 35
1. Rotate the crankshaft in order to bring the piston

4. Tighten the nut on Tool (A) in order to compress
to the top center position in the cylinder.
the inlet valve springs and the exhaust valve
springs (2).
5. Remove retainer locks (3).
6. Remove Tool (A).

17
Note: Ensure that the piston is at the top center

position in order to install the inlet valve springs and
the exhaust valve springs.
g00526804
Illustration 36
7. Remove valve rotators (4).

g00526805
Illustration 38
8. Remove the inlet valve springs and the exhaust
valve springs (5) from each valve. 1. Install bases (6) for the inlet valve springs and
g00526805
Illustration 37
g00526804
Illustration 39
9. Remove bases (6) from the cylinder head.
2. Install the inlet valve springs and the exhaust
10. Install the inlet valve springs and the exhaust valve springs (5).
valve springs before you rotate the crankshaft.
3. Install valve rotators (4).
Table 8
Required Tools
Part
Number
NOTICE

component life.
g00526803
Illustration 40
4. Install Tool (A).

18
5. Tighten the nut on Tool (A) in order to compress 2. Use Tool (A) to compress valve springs (3).
the inlet valve springs and the exhaust valve Remove retainer locks (1).
springs (2).
3. Remove Tool (A). Remove valve rotator (2) and
6. Install retainer locks (3). valve springs (3).
7. Remove Tool (A). 4. Repeat Steps 2 and 3 in order to remove valve

springs (5) and bridge supports (6).
End By:
5. Remove valves (4) from the cylinder head.
a. Install the push rods, the rocker shaft, the
electronic unit injector, and the valve mechanism 6. Repeat Steps 2 through 5 in order to remove the
cover. remaining inlet valves and exhaust valves.

Inlet and Exhaust Valves - Table 10
Remove and Install Required Tools

Part
SMCS Code: 1105-010 Tool Part Description Qty
Number
Removal Procedure
Table 9
Required Tools
Part
Number
Start By:
a. Remove the cylinder head assembly.
NOTICE

component life.
g00513277
Illustration 42
1. Lubricate the inlet valve (7) and the exhaust

valve (8) with clean engine oil. Install the inlet
valves and exhaust valves in the cylinder head
g00513273
assembly.
Illustration 41
1. Place the cylinder head assembly in an upright

position. See Illustration 41.
19

when the valve spring compressor is released. En-
sure that the valve keepers are properly installed
on the valve stem. To help prevent personal injury,

2. Place the following items on the valve stem:

bridge support (6), valve springs (3), and valve g00513516
Illustration 43
rotators (2).
Typical example
3. Use Tool (A) to compress valve springs (3).
Install retainer locks (1). 1. Use Tool (A) to remove the valve guides from the
remaining inlet valves and exhaust valves. Installation Procedure
End By: Table 12
Required Tools
a. Install the cylinder head assembly.
Part
Number
i01001885
Valve Guide and Seat Tool
A 1U-9654 1
Inlet and Exhaust Valve Guides Group
NOTICE
SMCS Code: 1104-010 Keep all parts clean from contaminants.
Removal Procedure Contaminants may cause rapid wear and shortened

component life.
Table 11
Required Tools
Part
Number
A 1U-9654 1
Group
Start By:
a. Remove the inlet valves and exhaust valves.
NOTICE

component life.
20
Start By:
NOTICE

component life.
g00513641
Illustration 45
Typical example
g00513519
Illustration 44
1. Position the valve guide and tap on the top of

the valve guide. This is done in order to start the
valve guide into the cylinder head assembly.
2. Use Tool (A) to install the valve guides. Install the

valve guides until the protrusion is 22.0 0.5 mm
(.87 .02 inch) above the cylinder head
assembly.
End By:
a. Install the inlet valves and exhaust valves. g00513644

Illustration 46
i01002099 1. Use Tool (A) to remove valve seat inserts (1).

Table 14
SMCS Code: 1103-010
Required Tools
Removal Procedure Part

Number
Table 13 Valve Guide and Seat Tool
A 1U-9654 1
Required Tools Group
Part
Number
A 1U-9654 1
Group
21
i01234011
NOTICE
Keep all parts clean from contaminants. Engine Centrifugal Oil Filter -
Remove and Install
Removal Procedure
Table 15
Required Tools
Part
Number
NOTICE

g00513645
Typical example
NOTICE

products.

Illustration 48 g00513644 mandates.
1. Lower the temperature of new valve seat insert

(1).
2. Use Tool (A) to install the new valve seat insert

in the cylinder head assembly.
End By:
g00512749
Illustration 49
1. Remove filter cover assembly (3) and filter rotor

assembly (1) from the body of the filter assembly.
22
2. Remove two bolts (2) and the washers. Remove

the body of the filter assembly.
g00512845
Illustration 53
Illustration 50
g00512750 6. Remove seal (10) from the body of the filter
assembly (1).
3. Remove filter rotor assembly (4) from filter cover
assembly (3).
g00512756
Illustration 54
Illustration 51
g00512752 7. Remove filter adapter assembly (11) from the
oil filter base.
4. Use Tool (A) to remove retaining ring (5) from
filter cover assembly (3).
g00512755
Illustration 55
Illustration 52 g00512754 8. Remove O-ring seal (12) from filter adapter

assembly (11).
5. Remove the following items from filter cover (7):
filter cover bolt (9), O-ring seal (8), and seal (6).
23
Table 16
Required Tools
Part
Number
NOTICE

component life.
g00512754
Illustration 58
1. Inspect the condition of the O-ring seals. Replace 4. Install O-ring seal (8) on filter cover bolt (9).
g00512752
Illustration 59
g00512755
Illustration 56
5. Install filter cover bolt (9) in filter cover (6) with
2. Install O-ring seal (12) onto filter adapter retaining ring (5).
assembly (11).
6. Install seal (7) on filter cover (6).
g00512756
Illustration 57
g00512750
Illustration 60
3. Place the filter adapter assembly (11) on the oil
filter base. Tighten the adapter to a torque of 7. Place filter rotor assembly (4) on filter cover
47 7 Nm (35 5 lb ft). assembly (3).
24
NOTICE

machines.

Illustration 61
mandates.
8. Install filter cover assembly (4) in the body of
filter assembly (1). Tighten the filter body bolt to
9. Install the O-ring seal on the body of filter

assembly (1).
10. Install the body of filter assembly (1) with two

bolts (2) and the washers. Tighten the bolts to a
i01001046

g00512858
Remove Illustration 62
SMCS Code: 1306-011 1. Remove oil filter assembly (1) with Tool (A).
Removal Procedure
Table 17
Required Tools
Part
Number
NOTICE
Contaminants may cause rapid wear and shortened Illustration 63

g00512861
component life.
Note: Two bolts (6) that hold the oil filter base
assembly to the cylinder block are marked. This is
done for installation purposes.
4. Remove six bolts (2) and the washers.

25
5. Remove oil filter base assembly (4) and the

O-ring seals.
i01001146

Disassemble
SMCS Code: 1306-015
Start By:
g00513037
Illustration 65
a. Remove the engine oil filter base.
Typical example
NOTICE 2. Remove relief valve assembly (2):

a. Loosen bolt (6) slowly in order to release the
Contaminants may cause rapid wear and shortened compression on the spring (4).
component life.
b. Remove the following items from the oil filter
base: bolt (6), seat of the relief valve spring
NOTICE (5), spring (4), and retainer (3).
during performance of inspection, maintenance, test- c. Remove spacer (7) from bolt (6).

machines.

mandates.
g00513077
Illustration 66
Typical example
3. Remove the two bolts and the washers that hold

valve (12).
4. Remove valve (12) and O-ring seal (10) from oil

filter base (8).

cover (13).
g00513002
Illustration 64 6. Remove the following items from oil filter base
(8): cover (13), O-ring seal (14), spring (11), and
1. Remove three O-ring seals (1) from the oil filter oil pump bypass valve (9).
base.
26
g00513080 g00513080
7. Remove the following items from oil filter base 3. Install relief valve plunger (15) and spring (16)
(8): plug (18), O-ring seal (17), spring (16), and into oil filter base (8).
relief valve plunger (15).
4. Place the O-ring seal on plug (18) and install the
8. Remove the stud that holds the oil filter to the oil plug in oil filter base (8).
filter base, if necessary.
i01001219

Assemble
SMCS Code: 1306-016
Assembly Procedure
NOTICE
g00513077
Illustration 69
component life. 5. Install the following items in oil filter base (8): oil
pump bypass valve (9), spring (11), and O-ring
seal (14).
6. Install cover (13) and the two bolts with washers
that hold the cover in place.
2. Install the stud that holds the oil filter to the
oil filter base. Tighten the stud to a torque of
7. Install O-ring seal (10) and valve (12) in oil filter
68 7 Nm (50 5 lb ft).
base (8).
8. Install the two bolts with washers that hold valve

(12) in place.
27
i01001095
Engine Oil Filter Base - Install

SMCS Code: 1306-012
Table 18
Required Tools
Part
Number
g00513037
Illustration 70
Typical example NOTICE
9. Install the following items in oil filter base (8):
retainer (3), retainer spring (4), seat of the relief Contaminants may cause rapid wear and shortened
valve spring (5), and spacer (7). component life.
10. Install bolt (6).

Note: Place all O-ring seals and install all bolts

finger tight before tightening to the standard torque.
g00513002
Illustration 71
11. Install three O-ring seals (1) in the oil filter base
assembly.
g00512861
End By: Illustration 72
a. Install the engine oil filter base. 2. Install the O-ring seals in oil filter base assembly
(4). Position the oil filter base assembly on the
cylinder block. Apply 9S-3263 Thread Lock
Compound to bolts (6) that are marked.
3. Install four bolts (2) and the washers.
5. Install two bolts (5) and the washers.

28
NOTICE

machines.

Illustration 73
mandates.
6. Install oil filter assembly (1) with Tool (A). Follow
the instructions with the oil filter assembly for the 1. Drain the coolant from the cooling system into a
correct installation. suitable container for storage or disposal.
i01002228
Engine Oil Cooler - Remove

SMCS Code: 1378-011
Removal Procedure

and alkali.
g00513708
Illustration 74
and under pressure. The radiator and all lines Typical example
steam. Any contact can cause severe burns. 2. Remove three bolts (2) and the washers.
Remove cooling system pressure cap slowly to 3. Remove elbow (1) of the engine oil cooler and
relieve pressure only when engine is stopped and the O-ring seals.
touch with your bare hand. 4. Remove two bolts (3) from the core of engine
oil cooler (4).
burns.

NOTICE

component life.
29
9. Clean the cooler tube bundles in engine oil

cooler core (4) with a rod that has a suitable
diameter. Thoroughly clean the tube bundles.
Check the oil cooler for cracks or leaks.
i01002243

SMCS Code: 1378-012
g00513711 NOTICE
Illustration 75
Typical example
5. Remove three bolts (5) and the washers. component life.
7. Remove engine oil cooler (4) and the two O-ring the seals, if necessary.
seals from the oil filter base.
g00513712
Illustration 78
g00513712
Illustration 76 Typical example
Typical example
2. Install O-ring seal (9). Position engine oil cooler
8. Loosen hose clamp (7) on hose (8). Remove bonnet (10) in hose (8).
engine oil cooler bonnet (10) and O-ring seal (9).
g00513711
Illustration 79
g00513713
Typical example
30
NOTICE

machines.

Illustration 80
mandates.
Typical example
3. Install the two O-ring seals on the oil filter base.

Position the oil cooler (4) on the oil filter base.
4. Install two bolts (6) with washers and two bolts

(3) with washers.
5. Install three bolts (5) with washers. Tighten hose

clamp (7).
6. Install the O-ring seals on elbow (1) of the engine

oil cooler.
7. Lubricate the bore lightly with glycerin. Position

the elbow of the engine oil cooler on engine oil g00512289
Illustration 81
cooler core (4).
1. Remove bolts (1) and the washers that hold the
8. Install three bolts (2) and the washers.
tube to the elbow of the oil pump.
level. Refer to Operation and Maintenance
elbow of oil pump (3) to the cylinder block.
i01000454

SMCS Code: 1304-011
Removal Procedure
NOTICE

component life. Illustration 82 g00512297

engine oil pump to the front housing. Remove
the engine oil pump and the elbow as a unit.
31
4. Remove the two O-ring seals. One O-ring seal is

on the connection of the tube to the elbow. The
second O-ring seal is on the engine oil pump.
i01253199
Engine Oil Pump - Disassemble

SMCS Code: 1304-015
Table 19
Illustration 83
Part
Number 1. Remove elbow (1) from the engine oil pump.
5F-7344 Block-Puller 1
2. Remove the two O-ring seals from the elbow of
A 7S-7786 Puller Leg 1 the engine oil pump.
5F-7345 Screw 1
Start By: 4. Remove cover (3) from the pump housing.
a. Remove the engine oil pump.
NOTICE

component life.
NOTICE
g00512369
ing any compartment or disassembling any compo- Illustration 84
5. Remove O-ring seal (4) and idler gear (5) from
Refer to Special Publication, NENG2500, Caterpillar the cover.
suitable to collect and contain fluids on Caterpillar 6. Use Tool (A) to remove gear (6) from drive shaft
products. (7).
Dispose of all fluids according to local regulations and NOTICE

mandates. Before removing the drive shaft from the pump hous-
7. Remove drive shaft (7) from the pump housing.

32
i01000588

SMCS Code: 1304-016
Assembly Procedure
NOTICE

component life.
g00512488
Illustration 86
1. Inspect the condition of the O-rings. Replace
O-rings, if necessary. 7. Install the two O-ring seals on elbow (7) of the
oil pump.
pump with clean engine oil. 8. Install the elbow on the engine oil pump.
NOTICE
The pump must rotate freely by hand after assembly.
End By:
a. Install the engine oil pump.
i01000464

SMCS Code: 1304-012
g00512489
Illustration 85
2. Install drive shaft (1) in the pump housing.
Note: Heat gear (4) to a maximum temperature of NOTICE

316 C (600 F). Keep all parts clean from contaminants.
3. Install gear (4) on the end of drive shaft (1). Contaminants may cause rapid wear and shortened
Position the gear so the distance between component life.
the outside face of the gear and the step
face on the pump body is 29.40 0.50 mm
(1.158 .020 inch).
4. Install idler gear (5) in the pump housing.
5. Install O-ring seal (6) in cover (3).
6. Install cover (3) and four bolts (2) with the

washers.
g00512304
Illustration 87
33
1. Inspect the condition of the O-ring seals. There

is one O-ring seal on the connection of the tube
to the elbow. The second O-ring seal is on the
engine oil pump. Replace the seals, if necessary.
and alkali.
2. Install the O-ring seals. Place the engine oil
pump in the correct position in the front housing.
Note: Lubricate the bore in the front housing with
clean engine oil.
3. Install bolts (1) and the washers that hold the
engine oil pump to the front housing.

burns.

NOTICE

g00512305 component life.
Illustration 88
4. Install two bolts (3) that hold the elbow of oil NOTICE
pump (4) to the cylinder block. Care must be taken to ensure that fluids are contained
5. Install two bolts (2) and the washers that hold the ing, adjusting and repair of the machine. Be prepared
tube to the elbow of the oil pump. to collect the fluid with suitable containers before
i01002270
Water Pump - Remove Refer to Special Publication, NENG2500, Caterpillar

SMCS Code: 1361-011 plies suitable to collect and contain fluids in Caterpillar
machines.
Removal Procedure Dispose of all fluids according to local regulations and
mandates.
Start By:
a. Remove the alternator. 1. Drain the coolant from the system into a suitable
container for storage or disposal.
b. Remove the drive belt and the belt tightener.
c. Remove the engine oil cooler.

34
i01002307

SMCS Code: 1361-012
NOTICE

component life.
g00513750
Illustration 89 1. Inspect the condition of the O-ring seals and the
flange gasket. Replace the seals and the gasket,
2. Remove two bolts (4) and the washers from tube if necessary.
assembly (5).
3. Cut tie wrap (3) that holds the wiring from tube
assembly (5).
4. Loosen hose clamp (2) and remove hose (1).
5. Remove bolt (8) and the washer.
6. Remove dipstick tube (6) with the O-ring seal.
7. Remove two bolts (9) and the washers from the

alternator bracket.
g00513750
Illustration 91
2. Install the O-ring seal on water pump (7).

Lubricate the bore lightly with clean engine oil.
3. Lubricate the O-ring seals with coolant and install

the O-ring seals on tube assembly (5). Install
tube assembly (5) on water pump (7).
g00513753
Illustration 90
9. Remove the water pump and the tube assembly.

Remove the flange gasket and the O-ring seal.
10. Remove the tube assembly and O-ring seals

from the water pump, if necessary.
g00513753
Illustration 92
35
4. Position water pump (7) and tube assembly (5) i01002312

in the front housing. Install two bolts (10) and
the washers. Tighten the bolts to a torque of Water Temperature Regulator -
28 7 Nm (21 5 lb ft). Remove and Install
5. Position the flange gasket between tube SMCS Code: 1355-010
assembly (5) and the water temperature regulator
housing. Install two bolts (4) and the washers.
Tighten the bolts to a torque of 28 7 Nm Removal Procedure
(21 5 lb ft).
6. Install hose (1) and tighten hose clamp (2).

7. Put new tie wrap (3) on tube assembly (5) in and alkali.
order to hold the wiring.
8. Install dipstick tube (6) with bolt (8) and the and under pressure. The radiator and all lines
washer. to heaters or the engine contain hot coolant or
level. Refer to the Operation and Maintenance Remove cooling system pressure cap slowly to
Manual for the correct filling procedure. relieve pressure only when engine is stopped and
End By: touch with your bare hand.
a. Install the engine oil cooler. Do not attempt to tighten hose connections when
b. Install the drive belt and the belt tightener. burns.
c. Install the alternator. Cooling System Coolant Additive contains alkali.

NOTICE

component life.
NOTICE

machines.

mandates.
1. Drain the coolant from the system into a suitable

36
g00513801
Illustration 93
Typical example
2. Remove four nuts (1) and the washers from

3. Remove regulator housing (2). Remove four

studs (3), if necessary.
4. Remove pipe plug (4), if necessary.
g00513806
Illustration 96
6. Remove water temperature regulator (6). Remove

pipe plug (7), if necessary.
7. Remove lip seal (8) from regulator housing (2).
Table 20
Required Tools
g00513802
Illustration 94 Part
Typical example Number
5. Remove gasket (5).
NOTICE

component life.
g00513803
Illustration 95
37
g00513801
Illustration 97
Typical example
g00513806
Illustration 99
2. Position the seal with the lip toward the inside of

the housing. Lubricate the lip of the seal with
g00513802
Illustration 98 glycerin. Install lip seal (8) in regulator housing
Typical example (2) with Tool (A). Install the seal until contact with
the counterbore in the housing.
1. Install studs (3) in the water outlet manifold.
Position gasket (5) on studs (3).
g00513803
Illustration 100
3. Install pipe plug (4) and (7) with 5P-3413 Pipe

Sealant.
4. Position water temperature regulator (6) in

5. Install regulator housing (2) with two nuts (1) and

the washers.
38
6. Fill the cooling system with coolant to the correct 1. Drain the level of the coolant below the water
level. Refer to the Operation and Maintenance outlet manifold. Drain the coolant into a suitable
Manual for the correct filling procedure. container for storage or disposal.
i01005442
Water Outlet Manifold -

Remove
SMCS Code: 1362-011
Removal Procedure

and alkali. g00515792
Illustration 101
At operating temperature, engine coolant is hot 2. Remove two bolts (6) and the washers that hold
and under pressure. The radiator and all lines tube (5) to water outlet manifold (3).
steam. Any contact can cause severe burns. 3. Disconnect sensor connector (2) and lay wiring
harness (1) aside.

burns.

NOTICE
g00515793
Illustration 102
Contaminants may cause rapid wear and shortened The air inlet manifold has been removed for photo purposes.
component life.
NOTICE
Care must be taken to ensure that fluids are contained 5. Remove water outlet manifold (3) and water
during performance of inspection, maintenance, test- temperature regulator housing (4) as a unit from
ing, adjusting and repair of the machine. Be prepared the cylinder head. Remove the gaskets.
opening any compartment or disassembling any 6. Remove plugs (7), if necessary.

machines.

mandates.
39
i01005443 6. Connect sensor connector (2).

Water Outlet Manifold - Install 7. Fill the cooling system with coolant to the correct
SMCS Code: 1362-012 Manual for the correct filling procedure.
NOTICE Flywheel - Remove

SMCS Code: 1156-011
component life. Removal Procedure
Table 21
Required Tools
Part
Number

lifting device.
g00515793
Illustration 103
The air inlet manifold has been removed for photo purposes.

2. Install the gaskets and position water outlet

manifold (3) on the cylinder head.
3. Install bolts (8) and the washers.

g00513879
Illustration 105
4. Apply 5P-3413 Pipe Sealant to the threads of
plugs (7). Install plugs (7). 2. Install Tool (A) on the flywheel. Fasten a suitable

the flywheel. The weight of the flywheel is 57 kg
(125 lb).

remove the ring gear.
g00515792
Illustration 104

40
i01183069 6. Check the flywheel runout. Refer to Testing

and Adjusting, Basic Engine for the correct
Flywheel - Install procedure.
SMCS Code: 1156-012
i01002751
Installation Procedure Crankshaft Rear Seal - Remove

Table 22
SMCS Code: 1161-011
Required Tools
Tool
Part
Removal Procedure
Number
Start By:
NOTICE
Always wear protective gloves when handling Care must be taken to ensure that fluids are contained
parts that have been heated. during performance of inspection, maintenance, test-
1. Heat the ring gear to a maximum temperature
of 315 C (599 F). Install the ring gear on the
flywheel. Position the ring gear with the part
number toward the crankshaft. Allow the ring
gear to cool. Use a soft hammer in order to seat
the ring gear against the shoulder of the flywheel.
machines.

mandates.
g00513879
Illustration 106

g00514081
3. Place the flywheel in the original position on the Illustration 107
crankshaft. Align the arrows on the flywheel and
the crankshaft.
4. Apply 7M-7456 Compound to the threads of

eight bolts (1).
5. Install eight bolts (1) and the washers. Tighten

the bolts evenly to a torque of 300 40 Nm
(221 30 lb ft).
41
g00514082 g00514081
1. Remove six nuts (1) and three bolts (2). 2. Clean the seal surface of the crankshaft.
Lubricate O-ring seal (4) with clean engine oil.
2. Use a screwdriver to remove crankshaft rear seal Position O-ring seal (4) on the back of crankshaft
(3). rear seal (3).
3. Remove O-ring seal (4). The O-ring seal is 3. Position the crankshaft rear seal (3) on the
located behind the crankshaft rear seal (3). crankshaft and the studs. Push crankshaft rear
seal (3) in place. This will dislodge the shipping
sleeve.
i01002758
Crankshaft Rear Seal - Install 4. Install the six nuts (1) and the washers.
SMCS Code: 1161-012 5. Apply 7M-7456 Compound to the threads of

three bolts (2). Install three bolts (2) at the bottom
of crankshaft rear seal (3). Tighten the bolts to a
Installation Procedure torque of 12 3 Nm (9 2 lb ft).
Note: Leave the shipping sleeve in place in order to End By:
install the crankshaft rear seal. The crankshaft rear
seal must be installed dry. a. Install the flywheel.
the seal, if necessary. i01017542

Remove and Install
Removal Procedure
Table 23
Required Tools
Part
Number
A 5F-4764 Pry Bar 1
g00514082
Illustration 109
Start By:
a. Remove the flywheel housing.

42
1. Place a new gasket over dowels (3).
g00521945
Illustration 111
g00521970
Illustration 114
1. Remove four bolts (1) and the washers that hold
crankshaft rear seal carrier (2) to the cylinder
block.
g00521945
Illustration 115
g00521947
2. Place crankshaft rear seal carrier (2) on the
Illustration 112 crankshaft.
2. Use Tool (A) to carefully pry crankshaft rear seal 3. Install four bolts (1) and the washers.
carrier (2) from the crankshaft.
End By:
3. Remove the gasket between the cylinder block
and crankshaft rear seal carrier (2). a. Install the flywheel housing.

and Install
SMCS Code: 1157-010
Removal Procedure
Start By:
b. Remove the rear crankshaft seal.

g00521969
Illustration 113
43
5. Remove O-ring seal (4) from rear seal carrier (5).

NOTICE

machines.

mandates.
1. Support the engine with blocks or a suitable g00514040

Illustration 118
lifting device.
1. Apply 1U-6396 O-Ring Assembly Compound to
O-ring seal (4). Install O-ring (4).
2. Apply 1U-8846 Sealant to the face of the

cylinder block.
g00514036
Illustration 116
2. Remove twelve bolts (1) and the washers.
3. Attach a suitable lifting device to flywheel

housing (2). g00514036
Illustration 119
4. Lift flywheel housing (2) away from dowel pins
(3). The weight of flywheel housing (2) is 23 kg 3. Position flywheel housing (2) on the rear of the
(50 lb). cylinder block. Install twelve bolts (1) and the
washers.
End By:
a. Install the rear crankshaft seal.
b. Install the flywheel.
g00514037
Illustration 117
44
i01191085

Remove
Removal Procedure
Table 24
Required Tools
Part
g00520762
A 8T-0514 Guide Bolt 2 Illustration 121
B 1P-0520 Driver Group 1 4. Remove crankshaft gear (5) from the crankshaft.
Remove the O-ring seal from crankshaft gear (5).
Start By:
5. Remove Tool (A).
6. Remove bolts (6) that fasten shaft (7) to the
flywheel housing.
NOTICE

component life.
g00520763
Illustration 122
7. Use a pry bar in order to remove shaft (7) and

gear assembly (8).
g00520761
Illustration 120
1. Install Tool (A) in the crankshaft.
2. Remove bolts (1) and crankshaft seal (2).
3. Remove bolts (3), cover (4), and the gasket.

Inspect the condition of the gasket. Replace the
g00520764
Illustration 123
45
8. Inspect the condition of the bearing in gear

assembly (8). If necessary, remove bearing (9)
from the gear with Tool (B).
g00520769
Illustration 126
g00520766
Illustration 124
9. Remove bolts (10) that fasten carrier assembly

(11) to the flywheel housing. Install two bolts
(10) opposite each other at location (12). Use
these bolts as forcing screws in order to remove
carrier assembly (11).
g00520770
Illustration 127
12. Remove bolts (16), cover assembly (17), and

thrust washer (18). Replace the O-ring seal.
13. Inspect the condition of thrust washer (18).

Replace thrust washer (18), if necessary.
Note: The minimum allowable thickness for thrust

Illustration 125
g00520767 washer (18) is 4.665 mm (.1837 inch).
10. Remove O-ring seal (15) and lip type seal (13) 14. Inspect the condition of the dowels for thrust
from carrier assembly (11). washer (18) in cover assembly (17). Remove the
dowels if replacement is necessary.
11. Inspect the condition of bearing (14). If
necessary, use Tool (B) to remove bearing (14)
from carrier assembly (13).
g00520771
Illustration 128
46
15. Remove bolts (19) and thrust plate (20) from the 19. Inspect the condition of thrust washer (24).
output shaft. Replace thrust washer (24), if necessary.

washer (24) is 4.665 mm (0.1837 inch).
20. Inspect the condition of the dowels for thrust

washer (24) in the flywheel housing. Remove the

necessary, remove bearing (25) from the flywheel
housing with Tool (B).
i01191099
Illustration 129
g00520772 Rear Power Take-Off (RPTO) -
Install
Table 25
Required Tools
Part
A 8T-0514 Guide Bolt 2
g00520773
Illustration 130
NOTICE
16. Remove hex socket head bolts (21) that fasten Keep all parts clean from contaminants.
gear (23) to output shaft (22).
17. Remove output shaft (22) from gear (23). component life.
Remove gear (23) from the flywheel housing.
g00520774
Illustration 131
18. Remove thrust washer (24) from the flywheel

housing.
47
g00520772
Illustration 135
4. Hold gear (23) in the flywheel housing and install

output shaft (22) in gear (23).
5. Fasten gear (23) to output shaft (22) with hex

g00520775 socket head bolts (21).
Illustration 133
1. Install bearing (25) in the flywheel housing with

Tool (B).
Note: The split in the bearing should be located

at angle (XX), which is 23 10 degrees from
the horizontal centerline. The bearing should be
installed to depth (YY), which is 1.5 0.5 mm
(0.06 0.02 inch).
2. Install the dowels for thrust washer (24) in the

flywheel housing.
Note: The dowels should extend beyond the

surface of the flywheel housing by a distance of Illustration 136
g00520771
3.0 0.2 mm (0.12 0.01 inch).
6. Fasten thrust plate (20) to the output shaft with
3. Install thrust washer (24) on the dowels in the bolts (19).
flywheel housing.
g00520770
Illustration 134
48

at angle (X), which is 112 10 degrees from the
centerline in the upper bolt hole in carrier assembly
(11). The bearing should be installed to depth (Y),
which is 1.6 0.5 mm (0.06 0.02 inch).
10. Install O-ring seal (15) and lip type seal (13) in
carrier assembly (11). Lubricate lip type seal
(13) lightly with the lubricant that is being sealed.
Note: Lip type seal (13) should be installed to a

depth of 2.5 0.5 mm (0.1 0.02 inch).
11. Install carrier assembly (11) in the flywheel

g00520769
housing. Install bolts (10).
Illustration 138
7. Install the dowels for thrust washer (18) in cover

assembly (17).

surface of cover assembly (17) by a distance of
3.0 0.2 mm (0.12 0.01 inch).
8. Install thrust washer (18) on the dowels in cover

assembly (17). Fasten cover assembly (17) to
the flywheel housing with bolts (16).
g00520764
Illustration 141
g00520767
Illustration 139
g00520765
Illustration 142
12. Install bearing (9) in gear (8) with Tool (B).

relief groove in gear (8) within two degrees. Bearing
(9) must not extend beyond either face of gear (8).
g00520768
Illustration 140
9. Install bearing (14) in carrier assembly (11) with

Tool (B).
49
i01003008

Remove and Install
SMCS Code: 1205-010
Removal Procedure
Start By:
a. Relieve the tension on the belt tightener and

remove the drive belt.
g00520762
Illustration 143
13. Install shaft (7) and gear assembly (8) in the

flywheel housing. Fasten shaft (7) to the flywheel
housing with bolts (6).
14. Install Tool (A) in the crankshaft. Install a new

O-ring seal on crankshaft gear (5).
15. Install crankshaft gear (5).
g00514208
Illustration 145
2. Remove the following items from the end of the

crankshaft: vibration damper (2), pulley (3), and
adapter (4).
3. Remove eight bolts (5).
g00520761
Illustration 144
Note: Some flywheel housings have locating dowels

for cover (4). If the flywheel housing does not have
these locating dowels, care must be taken in order
to ensure that the cover is properly aligned. Ensure
that the gap between the dust lip and the crankshaft
gear is uniform in order to avoid damage to the
crankshaft seal.
16. Hold cover (4) and the gasket in position on the

flywheel housing and install bolts (3).
g00514209
17. Install crankshaft seal (2) and bolts (1). Illustration 146
18. Remove Tool (A) from the crankshaft. 4. Separate pulley (3) and adapter (4) from vibration
damper (2).
End By:
a. Install the flywheel.

50

Remove
SMCS Code: 1160-011
Removal Procedure
Start By:
NOTICE
g00514210 Keep all parts clean from contaminants.
Illustration 147
component life.
g00514250
Illustration 149
1. Remove nuts (2) and the washers.

g00514211
Illustration 148
2. Remove crankshaft front seal (1).
1. Place adapter (4) and pulley (3) on vibration
damper (2). Install eight bolts (5). Tighten the i01003017
Crankshaft Front Seal - Install
2. Install bolts (1) and the washers. Tighten all
bolts evenly to a torque of 240 40 Nm SMCS Code: 1160-012
(175 30 lb ft).
End By:
NOTICE
a. Install the drive belt and apply the correct
tension.
component life.
Note: Leave the shipping sleeve in place in order to

install the crankshaft front seal. The crankshaft front
seal must be installed dry.
51
1. Clean the seal surface on the crankshaft and

the front cover. NOTICE

machines.

mandates.
g00514250
Illustration 150
2. Place crankshaft front seal (1) on the crankshaft.

Push the crankshaft front seal in place. This will
dislodge the shipping sleeve.
3. Install nuts (2) and the washers.
End By:
i01003668
Front Cover - Remove Illustration 151

g00514870
Typical example
SMCS Code: 1166-011
1. Remove studs (1) with the nuts and the seal
Removal Procedure washers.
Start By: 2. Remove bolts (2) and the washers.
a. Remove the alternator. 3. Remove bolt (5).
b. Remove the drive belt and the belt tightener. 4. Remove cover (3).
c. Remove the crankshaft front seal.
d. Remove the fuel transfer pump.
NOTICE

component life.
g00514872
Illustration 152
Typical example
52
5. Remove housing cover gasket (4). Note: Bolt (5) is a through bolt. Apply 9S-3263
Thread Lock Compound to threads prior to
installation.
i01003675
Front Cover - Install 3. Install the following items on the front housing:
front cover (3), bolts (2), bolt (5), and the
SMCS Code: 1166-012 washers.

Installation Procedure washers for installation.
NOTICE 4. Install studs (1) with new seal washers and the
Keep all parts clean from contaminants. nuts.
Contaminants may cause rapid wear and shortened End By:

component life.
a. Install the fuel transfer pump.
Note: The rear face of the cover and the front face b. Install the crankshaft front seal.
of the housing must be clean.
c. Install the drive belt and the belt tightener.
1. Inspect the condition of the housing cover
gasket. Replace the gasket, if necessary. d. Install the alternator.
i01182648
Gear Group (Front) - Remove

SMCS Code: 1206-011
Removal Procedure
Table 26
Required Tools
Part
g00514872
Illustration 153
A 6V-8214 Bolt 4
Typical example
2. Install housing cover gasket (4). Start By:
a. Remove the water pump.
b. Remove the engine oil pump.
c. Remove the air compressor.
d. Remove the alternator.
e. Remove the camshaft position sensor.
f. Remove the crankshaft position sensor.
g. Remove the camshaft.
g00514870
Illustration 154
Typical example
53
NOTICE

component life.
NOTICE
Illustration 156
Tools and Shop Products Guide for tools and supplies 2. Remove the following items from the front
suitable to collect and contain fluids on Caterpillar housing: bolt (1), shaft (2), gear (3), and the
products. bearing.
Dispose of all fluids according to local regulations and 3. Next, remove the following items from the front
mandates. housing: bolt (4), shaft (5), gear (6), and the
bearing.
Note: During installation, it is possible to install the

accessory drive incorrectly. Before removal, mark
accessory drive (8) for correct orientation.
4. Remove bolts (7) and accessory drive (8).
i01182670
Gear Group (Front) - Install

SMCS Code: 1206-012
g00522893 Installation Procedure

Illustration 155
Note: The sensor plate must be removed from the NOTICE

crankshaft gear for Engines (S/N: 3CS1-11999) Keep all parts clean from contaminants.
and (S/N: 2KS1-39999) in order to remove the front
gear group. The sensor plate can have either two Contaminants may cause rapid wear and shortened
threaded holes to aid in the removal of the sensor component life.
plate or the sensor plate can have four threaded
holes.
1. Install Tool (A) in bolt holes (X). Turn the bolts

evenly in order to separate the sensor plate from
the crankshaft gear.
Note: Align the timing marks on the idler gear with

the marks on the crankshaft gear and the camshaft
gear before removal.
g00522192
Illustration 157
54
1. Hold accessory drive (8) in position and install Note: Steps 4 through 7 are for Engines (S/N:
two bolts (7). Tighten the bolts to a torque of 3CS1-11999) and (S/N: 2KS1-39999) that have the
100 20 Nm (75 15 lb ft). sensor plate.
2. Install the following items in the front housing: End By:

gear (6), the bearing and shaft (5), and bolt (4).
Tighten bolt (4) to a torque of 240 40 Nm a. Install the camshaft.
(175 30 lb ft).
b. Install the camshaft position sensor.
3. Install the following items in the front housing:
gear (3), the bearing and shaft (2), and bolt (1). c. Install the crankshaft position sensor.
Tighten bolt (1) to a torque of 240 40 Nm
(175 30 lb ft). d. Install the alternator.
Note: Ensure that the timing marks on the gears are e. Install the air compressor.
in alignment.
f. Install the engine oil pump.
g. Install the water pump.

Always wear protective gloves when handling
parts that have been heated. i01003046

4. Heat the sensor plate to a temperature of 210 C
(410 F) for no more than 20 minutes. SMCS Code: 1151-011
Removal Procedure
Start By:
a. Remove the front gear group.
NOTICE
g00523036
Illustration 158
5. Position the hot sensor plate so that the tab on Tools and Shop Products Guide, for tools and sup-
the sensor plate aligns with groove (X) on the plies suitable to collect and contain fluids in Caterpillar
crankshaft gear. machines.
6. Push the sensor plate onto the crankshaft gear Dispose of all fluids according to local regulations and
until the back of the sensor plate contacts the mandates.
front of the crankshaft gear. Hold the sensor
plate on the crankshaft gear in this position until
the sensor plate cools and the sensor plate is
properly seated.
7. Use a feeler gauge in order to measure the

clearance between the back of the sensor
plate and the front of the crankshaft gear. The
measurement should be taken in three places
and the clearance should not exceed 0.25 mm
(0.010 inch).
55
g00514280 g00514307
Typical example
1. Remove thirteen bolts (1) and the washers.
2. Install gasket (3). Apply a bead of 8T-9022
2. Remove front housing (2) and the gasket. Silicone Gasket to lower edges (4) of gasket (3).
i01003049

SMCS Code: 1151-012
Note: The face of the housing and the face of the
block must be clean prior to installation.
g00514280
Illustration 162
3. Install front housing (2) and thirteen bolts (1)

with the washers. Tighten the bolts to a torque of
35 8 Nm (26 6 lb ft).
g00514286
Illustration 160
Typical example
1. Apply a bead of 8T-9022 Silicone Gasket to the

lower edges (5) of the cylinder block.
g00514308
Illustration 163
56
4. Remove the excess 8T-9022 Silicone Gasket i01017622

from the face seal joints at the following locations:
cylinder block, front housing, and oil pan. Use a Accessory Drive - Disassemble
suitable sized flat tool such as a putty knife in
order to remove the excess sealant. SMCS Code: 1207-015
NOTICE Disassembly Procedure

Do not use fingers or towels in order to remove the
excess 8T-9022 Silicone Gasket. The use of fingers Table 27
or towels will not leave a flat sealing surface. A leak Required Tools
may develop.
Part
Number
End By:
3H-0468 Puller Plate 4
a. Install the front gear group. 9S-9155 Spacer 1
8B-7550 Push Puller Leg 2
i01003735
A
5F-7344 Block Puller 1
Accessory Drive - Remove 8H-0663 Bearing Puller 1
SMCS Code: 1207-011 5F-7345 Screw 1

Removal Procedure
Start By:
Start By:
a. Remove the accessory drive.
a. Remove the drive belt and the belt tightener.
b. Remove the front cover.
g00521981
Illustration 165
g00515001 1. Remove gear and shaft (1) with two bearings (2)
Illustration 164
from accessory drive housing (3).
Typical example
Note: One end of the gear shaft is longer than the
1. Remove two bolts (1) and the washers. opposite end. Prior to assembly, ensure that the
gear shaft is in the correct position.
2. Remove accessory drive (2).
57
g00521983 g00522020
2. Use Tool (A) to remove two bearings (2) from 1. Cool gear and shaft (1).
gear and shaft (1).

parts that have been heated.
2. Heat two bearings (2) in an oven to a temperature

of 100 C (212 F).
3. Place bearings (2) in the original location on

gear and shaft (1).
g00521986
Illustration 167
3. Use Tool (B) to remove snap ring (4) from

accessory drive housing (3).
i01017666
Accessory Drive - Assemble

SMCS Code: 1207-016
g00522021
Illustration 169
Assembly Procedure
4. Use Tool (A) to install snap ring (4) into accessory
Table 28
drive housing (3).
Required Tools
Part
Number
58
i01004798
Valve Mechanism Cover -

Remove and Install
SMCS Code: 1107-010
Removal Procedure
NOTICE

g00522024
component life.
Illustration 170
5. Install gear and shaft (1) with bearings (2) into NOTICE
accessory drive housing (3). Care must be taken to ensure that fluids are contained
End By: ing, adjusting and repair of the machine. Be prepared
a. Install the accessory drive. opening any compartment or disassembling any
i01003912
Accessory Drive - Install Tools and Shop Products Guide, for tools and sup-
SMCS Code: 1207-012 machines.

Installation Procedure mandates.
g00515001
Illustration 172
Typical example
Typical example
1. Install accessory drive (2).
1. Remove the bolt and the washer that holds clip
2. Install two bolts (1) and the washers. Tighten the (3) to the valve cover base.
2. Move clip (3) and the wiring harness out of the
End By: way.
a. Install the front cover. 3. Remove bolts (1) and the washers.
b. Install the belt tightener and the drive belt. Note: Spacer (5) is used on engines that are
equipped with a compression brake.
59
4. Remove the following items from the cylinder

head: valve cover (2), spacer (5), and seals (4). NOTICE
component life.
NOTICE
NOTICE
Contaminants may cause rapid wear and shortened Care must be taken to ensure that fluids are contained
component life. during performance of inspection, maintenance, test-
1. Cut seals (4) to the correct length for the valve collect the fluid with suitable containers before open-
cover and spacer. Apply 3S-6252 Sealant to ing any compartment or disassembling any compo-
each joint surface after installation. nent containing fluids.
2. Place the following items on the valve cover Refer to Special Publication, NENG2500, Caterpillar
base: seals (4), spacer (5), and valve cover (2). Tools and Shop Products Guide for tools and supplies
3. Place clip (3) on the valve cover. products.

mandates.
g00280493
Illustration 173
4. Install bolts (1) and the washers. Use the

g00668535
following procedure in order to tighten the bolts: Illustration 174
a. Tighten bolts in a numerical sequence to a 1. Disconnect wiring harness (2) and the clips.
torque of 12 3 Nm (9 2 lb ft). Loosen clamp (1) and disconnect the hose from
the side of the valve cover base. Disconnect
b. Tighten bolts again in a numerical sequence sensor (3) from the valve cover base.
to a torque of 12 3 Nm (9 2 lb ft).
i01254195

Remove and Install
SMCS Code: 1120-010
Removal Procedure
Start By:
a. Remove the valve mechanism covers. g00515303

Illustration 175
60
2. Remove bolts (4) and washers (6). End By:
3. Remove isolators (7) and isolator sleeves (8). a. Install the valve mechanism covers.
4. Remove valve cover base (5) and base gasket

i01016425
(9).
Compression Brake - Remove
SMCS Code: 1119-011
NOTICE
Keep all parts clean from contaminants. Removal Procedure
Contaminants may cause rapid wear and shortened Start By:
component life.
a. Remove the valve mechanism covers.
NOTICE

component life.
NOTICE
g00515303 component containing fluids.
Illustration 176
1. Install base gasket (9) and valve cover base (5) Refer to Special Publication, NENG2500, Caterpillar
on the cylinder head. Tools and Shop Products Guide, for tools and sup-
2. Install isolator sleeves (8) and isolators (7). machines.
3. Install washers (6) and bolts (4). Dispose of all fluids according to local regulations and
mandates.
g00668535
Illustration 177
g00521562
Illustration 178
4. Install sensor (3).
1. Disconnect wires (2) from the solenoid valve.
5. Connect wiring harness (2) and the clips.
2. Remove two nuts (1) and bolt (3).
6. Connect the hose to the side of the valve cover
base and tighten clamp (1). 3. Remove compression brake housing (4).
61
i01020348
Compression Brake -
Disassemble
SMCS Code: 1119-015
Table 29
Required Tools
Part
g00523471
A 1P-1858 Retaining Ring Pliers 1 Illustration 179

C 134-2837 Piston Compressor 1
Start By:
a. Remove the compression brake.
NOTICE

component life.
g00523472
Illustration 180
NOTICE
ing, adjusting and repair of the machine. Be prepared Remove accumulator covers carefully. The accu-
to collect the fluid with suitable containers before mulator covers are under load from the accumu-
opening any compartment or disassembling any lator springs. Remove with care to avoid personal
component containing fluids. injury.
Tools and Shop Products Guide, for tools and sup- 1. Apply downward pressure to accumulator cover
plies suitable to collect and contain fluids in Caterpillar (2) with a punch of suitable size. Remove
machines. retaining ring (1) with Tool (A).
Dispose of all fluids according to local regulations and 2. Slowly release the pressure from accumulator
mandates. cover (2) until the spring pressure ceases.
Remove accumulator cover (2) and spring (3).
3. Use a magnet or needle nose pliers to remove

accumulator piston (4) from the bore in
compression brake housing (5).
62
g00523476 g00524781
6. Use a magnet or needle nose pliers in order to

reach into the bore and remove control valve (9)
from compression brake housing (5).
Note: Repeat Steps 1 through 6 for the remaining

control valve.
g00524780
Illustration 182
Remove control valve covers carefully. Control

valve spring covers are under load from the
control valve springs. Remove with care to avoid g00523481
Illustration 184
personal injury.
NOTICE
4. Apply downward pressure to control valve Do not disassemble or tamper with the solenoid valve.
cover (6) with a punch of suitable size. Remove Engine damage could result.
retaining ring (7) with Tool (B).
5. Slowly release the pressure from control valve 7. Unscrew solenoid valve (10) from the
cover (6) until the spring pressure ceases. compression brake housing.
Remove control valve cover (6) and two control
valve springs (8).
63
g00523482 g00523484
Typical example
10. Loosen slave piston adjustment screw (13) until
8. Remove three O-ring seals (11) from solenoid the slave piston is fully retracted.
valve (10). Discard the O-ring seals.
Note: The lower O-ring may stay in the bore in the

compression brake housing. If this is the case,
use a seal pick to remove the O-ring from the
compression brake housing.
g00524785
Illustration 188
g00523483
Illustration 186
NOTICE
Do not diassemble or tamper with slave piston adjust-
ing screw. Engine damage could result.
9. Remove slave piston adjustment screw locknut

(12).
g00523486
Illustration 189
64
g00524782 g00524784
Remove slave pistons carefully. The slave pistons Remove master pistons carefully. The master pis-
are under spring pressure. Remove with care to ton is under spring pressure. Remove with care to
avoid personal injury. avoid personal injury.
11. Place Tool (C) over slave piston adjustment 14. Apply downward pressure to retaining washer
screw (13). Turn the handle on Tool (C) until (19) with a punch of suitable size. Remove
spring retainer (14) is depressed approximately retaining ring (18) with Tool (B).
1.0 mm (.04 inch) in order to relieve the pressure
from retaining ring (15). 15. Slowly release the pressure from retaining
washer (19) until the spring pressure ceases.
12. Remove retaining ring (15) with Tool (A). Slowly Remove retaining washer (19), two springs (20),
back out the handle on Tool (C) until the spring and master piston (21).
pressure ceases. Remove Tool (C).
Note: Repeat Steps 14 and 15 for the remaining
13. Remove spring retainer (14), springs (16), and master piston.
slave piston (17).
i01020662
slave piston. Compression Brake -
Assemble
SMCS Code: 1119-016
Assembly Procedure
Table 30
Required Tools
Part
g00524783
Illustration 191
65
NOTICE

component life.
g00524783
Illustration 195
2. Inspect the condition of master piston (20). The

master piston must be free of wear and score
marks. Replace master piston (21), if necessary.
3. Install master piston (21) in the bore. Install

the small end of spring (20) in the bore. Install
retaining washer (19), and retaining ring (18)
over master piston (21) and compress until
retaining washer (19) is below the retaining ring
groove. Install retaining ring (18) with Tool (B).
Ensure that retaining ring (18) is fully seated in
the groove.

master piston.
g00523650
Illustration 193
1. Inspect the condition of the bores in the

compression brake housing. The bores must be
free of wear and score marks.
g00524782
Illustration 196
g00524784
Illustration 194
66
g00523486 g00523484
4. Inspect the condition of slave piston (17). The 8. Screw in slave piston adjustment screw (13) until
slave piston must be free of wear and score contact is made with the slave piston.
marks. Replace slave piston (17), if necessary.
5. Install slave piston (17), springs (16), spring

retainer (14), and retaining ring (15) in the bore.
g00523483
Illustration 200
9. Install slave piston adjustment screw locknut

(12).
g00524785
Illustration 198
Note: Repeat Steps 8 and 9 for the remaining slave
6. Place Tool (C) over slave piston adjustment piston adjustment screw.
screw (13) and spring retainer (14). Turn the
handle on Tool (C) until spring retainer (14)
is approximately 1.0 mm (.04 inch) below the
retaining ring groove. Install retaining ring (15)
with Tool (A).
7. Remove Tool (C) slowly in order to ensure that

retaining ring (15) is properly seated in the
groove.

slave piston.
g00523482
Illustration 201
Typical example
67
10. Coat three new O-ring seals (11) with clean

engine oil. Install the upper O-ring seal and the
center O-ring seal on solenoid valve (10). Install
the small O-ring seal in the bottom of the bore in
the compression brake housing.
Note: Ensure that O-ring seals (11) are seated

properly on solenoid valve (10). Do not twist the
seals or unseat the seals during installation of the
solenoid valve.
g00524780
Illustration 204
12. Inspect the condition of control valve (9). Insert a

wire into the hole in the base of control valve (9)
until the wire contacts the check ball. The check
ball should rise with light pressure on the wire. If
the check ball is stuck, replace control valve (9).
Apply clean engine oil to control valve (9).
13. Install control valve (9), two control valve springs

g00523481 (8), and control valve cover (6) in compression
Illustration 202
brake housing (5).
11. Carefully install solenoid valve (10) in the
compression brake housing. 14. Apply downward pressure to control valve cover
(6) with a punch of suitable size. Install retaining
There are two different designs of solenoid ring (7) with Tool (B). Slowly release the pressure
valves. The difference can be determined by the from control valve cover (6) in order to ensure
number of points on the head of the solenoid that retaining ring (7) is fully seated in the groove.
valve. Use the correct torque value for your
solenoid valve. Note: Repeat Steps 12 through 14 for the remaining
control valve.
Tighten the solenoid valve with a twelve point
head to the following torque. ......... 12.5 Nm
(9 lb ft)
Tighten the solenoid valve with a six point
head to the following torque. ............ 20 Nm
(15 lb ft)
g00523472
Illustration 205
g00524781
Illustration 203
68
g00523471 g00521562
15. Inspect the condition of accumulator piston 1. Position compression brake housing (4) on the
(4). The accumulator piston should be free of two studs.
wear and score marks. Apply clean engine oil to
accumulator piston (4). 2. Install two nuts (1) and tighten to a torque of
80 15 Nm (60 11 lb ft).
16. Install accumulator piston (4), spring (3), and
accumulator cover (2) in the bore in compression 3. Install bolt (3) and tighten to a torque of
brake housing (5). 55 10 Nm (41 7 lb ft).
17. Apply downward pressure to accumulator cover 4. Connect wires (2) to the solenoid valve on the
(2) with a punch of suitable size. Install retaining compression brake.
ring (1) with Tool (A). Slowly release the pressure
from accumulator cover (2) in order to ensure Note: The valve lash must be adjusted before
that retaining ring (1) is fully seated in the groove. adjusting the slave piston lash.
End By: End By:
a. Install the compression brake. a. Adjust the valve lash. Refer to the Testing and
Adjusting, Air Inlet and Exhaust System topic
for the correct procedure.
i01018713
Compression Brake - Install b. Adjust the slave piston lash. Refer to the Testing
and Adjusting, Compression Brake topic for
SMCS Code: 1119-012 the correct procedure.
c. Install the valve mechanism covers.

i01253784
NOTICE
Keep all parts clean from contaminants. Rocker Shaft and Pushrod -
Contaminants may cause rapid wear and shortened Remove
component life.
SMCS Code: 1102-011; 1208-011
Removal Procedure
Start By:
a. Remove the valve mechanism cover.

69
NOTICE

component life.
NOTICE
Illustration 209
Tools and Shop Products Guide for tools and supplies 4. Remove valve bridge assemblies (4).
products. i01253796
Dispose of all fluids according to local regulations and Rocker Shaft and Pushrod -
mandates.
Install
SMCS Code: 1102-012; 1208-012
NOTICE

component life.
1. Inspect the condition of the following items:

rocker arm assemblies, valve bridge assemblies,
Illustration 208
g00524203 and push rods. Replace the parts, if necessary.
Typical example
1. Put identification marks on each rocker arm in

for installation.
2. Remove bolt (1) and stud (3).
3. Remove rocker arm assembly (2) and the push

rods. Keep each push rod with the respective
rocker arm.
g00524205
Illustration 210
2. Install valve bridge assemblies (4). Apply clean

engine oil to the top surface of the valve bridge
assemblies.
70
NOTICE

machines.

Illustration 211
mandates.
3. Install the push rods in the original location in
the engine.
4. Position rocker arm assembly (2) in the original

location on the engine. Install stud (3) and bolt
(1). Tighten stud (3) and bolt (1) to a torque of
100 20 Nm (75 15 lb ft).
End By:
a. Install the valve mechanism cover.
b. Adjust the unit injectors. Refer to the Testing and

Adjusting, Fuel System topic for the proper
procedure. g00517348
Illustration 212
i01008621 1. Remove bolt (1) and the washer. Remove clip (2).
Cylinder Head - Remove 2. Disconnect sensors from engine wiring harness
(3).
SMCS Code: 1100-011
3. Remove the sensors.
Removal Procedure
Table 31
Required Tools
Part
Number
Start By:
a. Remove the valve cover base.
b. Remove the rocker arms and the push rods.

g00517351
Illustration 213
NOTICE
Keep all parts clean from contaminants. 4. Remove two bolts (5) and the washers.
Disconnect tube assembly (4) and remove the
O-ring seal.
component life.
71

Disconnect tube assembly (6) and the O-ring
seals.
g00517356
Illustration 216
Typical example
g00517354
Illustration 214 9. Remove bolts (15) and the washers.
Typical example
10. Remove water outlet manifold (16).
6. Use Tool (A) in order to remove fuel filter
(8). Disconnect hose (9). Plug all openings
immediately.
7. Loosen bolt (11). Disconnect wiring harness (10).
g00517359
Illustration 217
11. Remove head bolts (17).
12. Remove four water outlet manifold gaskets (18)

g00517355 from cylinder head (19).
Illustration 215
Typical example
8. Disconnect sensor connector (13) and two clips

(12). Remove clip (14) and the bolt with the
washer.
g00517361
Illustration 218
72
13. Attach a suitable lifting device to cylinder

head (19). Remove cylinder head (19) from the
cylinder block. The weight of cylinder head (19)
is 135 kg (300 lb).
14. Remove cylinder head gasket (20) and O-ring

seals (21) from the cylinder block.
i01273458

SMCS Code: 1100-012
g00525534
Table 32 4. Install four gaskets (24) on cylinder head (25).

Required Tools
5. Inspect the condition of cylinder head bolts (23)
Part and the head bolt studs for pitting and corrosion.
Tool Number Part Description Qty Replace the cylinder head bolts and the head
A 2P-8250 Strap Wrench Assembly 1 bolt studs, if necessary.
6. Lubricate the following components with

NOTICE 6V-4876 Lubricant: the bolt threads, the
Keep all parts clean from contaminants. underside of the bolt heads, and the washers.
Install cylinder head bolts and the head bolt
Contaminants may cause rapid wear and shortened studs. Follow Step 7 for the correct tightening
component life. procedure.

cylinder head and the cylinder block.
g00525775
Illustration 219
2. Install a new cylinder head gasket (26) and new

O-ring seals (27) on the cylinder block. Inspect
the condition of the remaining gaskets. Replace
the gaskets, if necessary.

cylinder head.
3. Use a suitable lifting device to install the cylinder

head on the cylinder block.
73
g00517501
Illustration 221
Note: Engines that are equipped with a compression h. Tighten bolt (27) through bolt (33) in a
brake will have three head bolt studs. Install the numerical sequence to a torque of 28 7 Nm
head bolt studs in positions (2), (8), and (10). (20 5 lb ft).
Tighten the head bolt studs in sequence with the
head bolts.


(120 11 lb ft).

160 15 Nm (120 11 lb ft).
c. Place an index mark on each bolt head.

g00525468
Turn bolt (1) through bolt (26) in a numerical Illustration 222
sequence for an additional 90 degrees (1/4
turn). 8. Install spacers (22) on the three head bolt studs.
Tighten spacers (22) to a torque of 100 20 Nm
d. Loosen bolt (1) through bolt (26) until the (75 15 lb ft).
9. Install water outlet manifold (21) and bolts (20).
e. Tighten bolt (1) through bolt (26) in a numerical
(120 11 lb ft).
f. Tighten bolt (1) through bolt (26) again

160 15 Nm (120 11 lb ft).
g. Place an index mark on each bolt head.

Turn bolt (1) through bolt (26) in a numerical
turn).
74
14. Install fuel filter (10) with Tool (A). Follow the
instructions on the fuel filter.
15. Connect hose (9).
16. Install hose (8).
17. Install the bolts, the washers, and two nuts (7).
g00676926
Illustration 223
10. Hold line (19) in position and connect fittings

(17). Install bolts (18).
g00525386
Illustration 226
18. Install tube assembly (5) with the O-ring seals,

two bolts (6), and the washers.
19. Install tube assembly (3) with the O-ring seal,

g00676967
Illustration 224
11. Connect wiring harness (14). Tighten bolt (16) to

a torque of 6 1 Nm (53 9 lb in).
g00524436
Illustration 227
20. Route wiring harness (1) accordingly and

connect sensor connector (2).

g00676971 End By:

Illustration 225
a. Install the rocker arms and the push rods.
13. Connect sensor connector (12). Install the clip,
the washer, and bolt (11). Secure the wiring b. Install the valve mechanism cover base.
harness with tie straps (13).
75
i01005203

Install
SMCS Code: 1209-010
Removal Procedure
Start By:
a. Remove the cylinder head.
NOTICE g00515668
Illustration 229
Contaminants may cause rapid wear and shortened 2. Remove the following items from the right end of
lifter shaft (5): bracket assembly (6), valve lifters
component life.
(8), and unit injector lifter (9).
NOTICE 3. Remove the following items from the middle of

Care must be taken to ensure that fluids are contained lifter shaft (5): valve lifters (8) and unit injector
during performance of inspection, maintenance, test- lifter (9).
to collect the fluid with suitable containers before 4. Remove the following items from the left end of
opening any compartment or disassembling any lifter shaft (5): bracket assembly (7), valve lifters
component containing fluids. (8), and unit injector lifter (9).
Refer to Special Publication, NENG2500, Caterpillar 5. Remove dowel (4) and cap plug (3) from lifter
Tools and Shop Products Guide, for tools and sup- shaft (5).
machines. 6. Remove the spring pin from bracket (7), if
necessary.
mandates.
g00515670
Illustration 230
Typical example
g00515645
Illustration 228
7. Remove dowel (10) from bracket (6), if necessary.
1. Remove bolts (1) and lifter assembly (2). The
lifter assembly can be removed in two sections.
76
NOTICE

component life.
g00515645
Illustration 233
Note: Immerse the entire lifter assembly in clean

engine oil prior to installation on the engine.
6. Place the lifter assembly (2) on the engine and

install bolts (1). Tighten the bolts to a torque of
30 3 Nm (22 2 lb ft).
g00515670
Illustration 231
Typical example End By:
1. Install the spring pin and dowel (10) in bracket a. Install the cylinder head.
(7).
i01191135
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 33
Required Tools
Part
A 131-1525 Camshaft Pilot 1
g00515668
Illustration 232
Start By:
2. Install dowel (4) and cap plug (3) in lifter shaft
(5). Lubricate the lifter shaft with clean engine oil
prior to assembly.
b. Remove the front cover.
3. Install the following items on the left end of lifter
shaft (5): bracket (7), valve lifters (8), and unit
c. Remove the camshaft position sensor.
injector lifter (9).
4. Install the following items on the middle of lifter NOTICE

shaft (5): valve lifters (8) and unit injector lifter (9). Keep all parts clean from contaminants.
5. Install the following items on the right end of Contaminants may cause rapid wear and shortened
lifter shaft (5): bracket (6), valve lifters (8), and component life.
unit injector lifter (9).
77
NOTICE

products.

Illustration 235
mandates.
4. Remove thrust pin (1).
installation.

gears are aligned: the camshaft drive gear, the
g00516005
Illustration 236
5. Install Tool (A) into camshaft (2).
Note: Lubricate Tool (A) for easier removal of the

camshaft. Lubrication also prevents damaging the
camshaft lobes and the camshaft bearings.
g00529917
Illustration 234 6. Carefully remove camshaft (2) from the engine.
Note: It is not necessary to remove the cylinder

head for removal of the camshaft. i01191124

Camshaft - Install
See Illustration 234.
SMCS Code: 1210-012
Table 34
Required Tools
Part
78

g00516006
Illustration 237
Typical example
1. Install Tool (A). g00516004

Illustration 239
Note: Ensure that camshaft (2) and Tool (A) are 4. Install thrust pin (1). Tighten thrust pin (1) to a
clean. Apply clean engine oil to the lobes and torque of 28 7 Nm (20 5 lb ft). Remove the
journals of camshaft (2) and Tool (A). wires that were used to hold the valve lifters.
Note: During installation of camshaft (2), rotate the End By:

camshaft in both directions in order to prevent
binding in the camshaft bearing bores. a. Install the camshaft position sensor.
2. Carefully install camshaft (2) in the engine. b. Install the front cover.
NOTICE c. Install the rocker arms and the push rods.

ber one cylinder is at top center of the compression i01017738
camshaft timing is very important. The timing mark Camshaft Gear - Remove and
on the camshaft drive gear must line up with the tim-
Install
Removal Procedure
Start By:
a. Remove the camshaft.

order to prevent damage to the camshaft.
g00516008
Illustration 238
79
i01253672
Camshaft Bearings - Remove

SMCS Code: 1211-011
Removal Procedure
Table 35
Required Tools
Part
Number
129-6671 Reaction Sleeve 1
g00522082
Illustration 240 129-6672 Puller Plate 1
129-6673 Bearing Pilot 1
NOTICE A
Do not allow the camshaft to fall to the floor when 129-6674 Backup Plate 1
pressing it from the drive gear. Also make sure that
6F-7032 Bolt 1
1P-5542 Taper Lock Stud 1
2. Place camshaft (3) and drive gear (1) in a
suitable press. Press camshaft (3) from drive Start By:
gear (1).
a. Remove the lifter assembly.
3. Remove woodruff key (2) from camshaft (3).
b. Remove the camshaft.
Installation Procedure Note: All of the tools that are listed above are used
with the 8S-2241 Camshaft Bearing Tool Group.
NOTICE

component life.
NOTICE
g00522082 ing any compartment or disassembling any compo-
Illustration 241
1. Install woodruff key (2) in camshaft (3).
2. Heat drive gear (1) to a temperature of 300 C Tools and Shop Products Guide for tools and supplies
(572 F) for 30 minutes. suitable to collect and contain fluids on Caterpillar
products.
3. Install drive gear (1) on the end of camshaft (3).
4. Ensure that woodruff key (2) is aligned. Also mandates.
ensure that drive gear (1) makes contact with the
shoulder on the end of camshaft (3).
End By:
a. Install the camshaft.

80
Note: All of the tools that are listed above are used
NOTICE

component life.
g00516210
Illustration 242
g00516213
Illustration 244
1. Position new bearing (2) in Tool (A) and install the

bearing from the rear to the front of the engine.
NOTICE
Illustration 243 g00516211 Location of the camshaft bearing lubrication holes is
critical. Position the clinch butt joint up for all seven
1. Install Tool (A). Apply Anti-Seize Compound on camshaft bearings. The No. 1 camshaft bearing oil
the threads. hole is located 115 degrees counter clockwise from
top center to align with the oil supply passage in the
2. Remove camshaft bearings (1). block. Camshaft bearings No. 2 through No. 7 are in-
stalled with the oil hole 45 degrees clockwise from
top center. All are viewed from the front of the en-
i01253668 gine. Camshaft bearings 1,2,3,4,5, and 6 are the same
width. Camshaft bearing No. 7 has a smaller width.
Camshaft Bearings - Install Refer to the Specifications Manual for more informa-
tion.
SMCS Code: 1211-012
End By:
a. Install the camshaft.
Table 36
Required Tools b. Install the lifter assembly.
Part
Number
129-6672 Puller Plate 1
A
129-6674 Backup Plate 1
6F-7032 Bolt 1
81
i01183159 2. Remove six bolts (2) and the washers. Remove

sound suppression cover (1), if equipped.
Install
SMCS Code: 1302-010
Removal Procedure

jury.

g00516292
Illustration 246
NOTICE Typical example
Contaminants may cause rapid wear and shortened block: fourteen bolts (5), the washers, the
component life. isolators, and the isolator sleeves.
4. Remove engine oil pan (6) and the gasket.

NOTICE
Care must be taken to ensure that fluids are contained 5. Remove pipe plug (3) and drain plug (4) with the
during performance of inspection, maintenance, test- O-ring seal, if necessary.
ing any compartment or disassembling any compo- Installation Procedure
NOTICE
Refer to Special Publication, NENG2500, Caterpillar Keep all parts clean from contaminants.
suitable to collect and contain fluids on Caterpillar Contaminants may cause rapid wear and shortened
products. component life.

mandates. 1. Inspect the condition of the gasket. Replace the
1. Drain the engine oil into a suitable container for 2. Clean the mating surface of the engine oil pan
storage or disposal. and the cylinder block.
Note: Apply 8T-9022 Silicone Gasket to the right

and the left edges of the cylinder block prior to
installation.
g00516290
Illustration 245
Typical example
82
b. Clean the oil pan bolt and dry the oil pan bolt.
c. Apply 4C-4030 Thread Lock Compound or

9S-3263 Thread Lock Compound to the
threads of the bolt.
d. Install the oil pan bolt and tighten the bolt to a

5. Wipe off excess 8T-9022 Silicone Gasket from

all gasket joints. Use a flat, straight tool in order
to remove the sealant.
6. Apply 9S-3263 Thread Lock Compound to pipe

g00516292
plug (3). Install pipe plug (3). Tighten the plug to
Illustration 247 a torque of 80 11 Nm (60 8 lb ft).
Typical example
7. Install drain plug (4) and the O-ring seal. Tighten
3. Place the gasket and engine oil pan (6) on the the plug to a torque of 70 15 Nm (50 11 lb ft).
cylinder block.
4. Install the following items: isolator sleeves,

isolators, bolts (5), and the washers.
Note: Perform the following procedure in order to

eliminate the possibility of an oil leak from the bolt
for the engine oil pan:
Note: The path of the oil leak is through the threads

of the bolt for the engine oil pan. The third bolt from
the front of the engine block on the right side of the
engine is the suspect bolt.
g00516290
Illustration 249
Typical example
8. Position the sound suppression cover (1) on the

engine oil pan and install six bolts (2) with the
washers.
9. Fill the engine with oil to the correct level. See

the Operation and Maintenance Manual for the
g00633606
Illustration 248
Typical example
(1) Front face of the engine block
(2) Bolt threads
a. Clean the bolt hole and dry the bolt hole.

83
i01006154
Cylinder Liner - Remove

SMCS Code: 1216-011
Removal Procedure
Table 37
Required Tools
1U-9593 Cylinder Pack Puller 1
A 1U-9897 Bridge Group 1 g00474523
Illustration 250
1U-6319 Socket 1
1. Remove two connecting rod cap bolts (2) from
Start By: each connecting rod. Remove connecting rod
caps (4).
2. Tap connecting rod (3) away from the crankshaft
b. Remove the piston cooling jets. with a soft hammer. Remove the top half of
connecting rod bearing (1).
NOTICE

component life.
NOTICE
g00516411
Illustration 251
plies suitable to collect and contain fluids in Caterpillar NOTICE
machines. When removing the cylinder liner, watch the rod, and
prevent it from catching on the bore in the cylinder
Dispose of all fluids according to local regulations and block as it comes out.
mandates.
3. Install Tool (A) and remove cylinder liner (5).
4. Remove Tool (A) from the cylinder liner.

84
1. Apply 5P-3975 Rubber Lubricant to the new

seal. Install new seal (6) in the machined groove
on the cylinder liner.
Note: The word FRONT may be stamped on the

crown of the pistons in some engines. Ensure that
the word FRONT is toward the front of the engine
when the piston is installed. The etched number on
the connecting rod must be on the right side of the
engine in the corresponding cylinder.
2. Lubricate the lower portion of the cylinder

liner with clean engine oil. Ensure that the
corresponding crankshaft throw is at bottom
g00516413
center. Position the cylinder liner and guide the
Illustration 252 connecting rod in place. Use Tool (B) to press
the cylinder liner in place.
5. Remove the connecting rod and the piston from
the cylinder liner. Remove seal (6) from the Note: Refer to the Testing and Adjusting, Cylinder
cylinder liner. Liner Projection topic in order to check the cylinder
liner projection.
i01006456
Cylinder Liner - Install

SMCS Code: 1216-012
Table 38
Required Tools
Part
Tool Part Description 1
Number
Cylinder Liner
A 2P-8260 1
Installation Group Illustration 254
g00474523
NOTICE 3. Install the upper half of connecting rod bearing

Keep all parts clean from contaminants. (1) in connecting rod (3). Ensure that the bearing
tab engages with the slot in the connecting rod.
Contaminants may cause rapid wear and shortened Lubricate the bearing surface with clean engine
component life. oil. Tap the piston with a soft hammer until the
connecting rod bearing makes contact with the
crankshaft.
4. Install connecting rod cap (4). Lubricate

connecting rod cap bolts (2) with 4C-5593
Anti-Seize Compound. Install connecting rod
cap bolts (2).
5. Tighten the bolts to a torque of 130 7 Nm

(95 5 lb ft).
6. Place an index mark on each bolt head. Tighten

each bolt for an additional 60 5 degrees (1/6
turn).
g00516413
End By:
Illustration 253
a. Install the piston cooling jets.
85
b. Install the cylinder head. Installation Procedure
i01007082
NOTICE
and Install component life.
SMCS Code: 1331-010
Removal Procedure
Start By:
a. Remove the engine oil pan.
NOTICE

component life.
g00516600
Illustration 256
NOTICE
Care must be taken to ensure that fluids are contained 1. Position piston cooling jet (2) and install bolt (1)
during performance of inspection, maintenance, test- in each cylinder. Tighten the bolt to a torque of
ing, adjusting and repair of the machine. Be prepared 35 3 Nm (26 2 lb ft).
opening any compartment or disassembling any End By:
a. Install the engine oil pan.
i01007085
machines. Pistons and Connecting Rods
Dispose of all fluids according to local regulations and - Remove
mandates.
SMCS Code: 1225-011
Removal Procedure
Start By:
b. Remove the engine oil pan.
NOTICE

Illustration 255
g00516600 component life.
1. Remove bolt (1) and piston cooling jet (2) from

each cylinder.
86
i01007430

- Disassemble
SMCS Code: 1225-015
Table 39
Required Tools
Part
Number
g00516602
Illustration 257 A 4C-3601 Piston Ring Expander 1
1. Remove the bolts that hold piston cooling jets (1) 5P-8639 Hydraulic Press 1
in position. Remove piston cooling jets (1). 8F-0024 Hose Assembly 1
2. Inspect the connecting rod and connecting 1P-2375 Connecting Coupler 1

rod cap (3) for the proper identification mark. 1P-2376 Connecting Coupler 1
The connecting rod and connecting rod cap B
(3) should have an etched number on the side 5P-9725 Hydraulic Cylinder 1
that is toward the right side of the engine. The 5P-8651 Spacer 1
number should match the cylinder number. The
bearing retainer notch should also be on the right 5P-8649 Adapter 1
side. Mark the connecting rod and connecting 5P-8650 Adapter 1
rod cap (3), if necessary.
3. Remove connecting rod cap bolts (2) and Start By:

connecting rod cap (3). Remove the lower half of
the bearing from connecting rod cap (3). a. Remove the pistons and the connecting rods.
NOTICE

component life.
g00516604
Illustration 258
Typical example
4. Push the piston and connecting rod (4) away

from the crankshaft. Remove the upper half of
g00516756
Illustration 259
5. Remove the piston and connecting rod (4) from
the cylinder block. 1. Use Tool (A) in order to remove piston rings (1)
from piston crown (2).
pistons and connecting rods.
87
i01007505

- Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 40
Required Tools
Part
Number
g00516777
Illustration 260 A 4C-3601 Piston Ring Expander 1
2. Remove plug (3) and the piston pin.

NOTICE
3. Separate piston crown (2) from piston skirt (4) Keep all parts clean from contaminants.
and connecting rod (5).
component life.
NOTICE
NOTICE
Do not use a hard surfaced tool to install plug. Do not
strike or impact plug during installation. If the plug is
Illustration 261
g00516784 dropped, replace the plug with another new plug.
NOTICE Note: The word FRONT may be stamped on the

The connecting rod must be heated for the installation crown of the pistons in some engines. Ensure that
of the piston pin bearing. Do not use a torch. the word FRONT is toward the front of the engine
when the piston is installed. The etched number
on the connecting rod must be on the right side of
4. Heat connecting rod (5) in the indicated area the engine in the corresponding cylinder. Ensure
(7). The maximum distance of area (7) is 85 mm that the piston crown and the etched number are
(3.35 inch). The temperature should be between correctly positioned.
175 C (347 F) and 260 C (500 F).
5. Use Tool (B) in order to remove old bearing (6)

and install new bearing (6) at the same time.
6. The bearing joint must be within 10 degrees of

one of the locations that are indicated by the
arrows.
88
6. After installation, all three of the piston rings

should be placed 120 degrees away from each
other.
End By:
i01007265

- Install
g00516825
SMCS Code: 1225-012
Illustration 262
1. Place piston crown (2) in piston skirt (4). Place Installation Procedure
the piston assembly on connecting rod (5). Put
Table 41
clean engine oil on piston pin (7) and install the
pin. Install new plug (3). Required Tools
Part
2. Check the clearance between the ends of the Tool Part Description Qty
Number
piston rings. See the Specifications Manual,
Pistons and Rings topic. A 1U-6684 Piston Ring Compressor 1
Note: The oil ring must be installed over the spring

NOTICE
with the end gap 180 degrees from the oil ring
spring joint.
3. Install the oil control piston ring. The ends of the
component life.
spring should be rotated 180 degrees from the
ring end gap. The white colored portion of the
spring must be visible at the ring end gap. 1. Place clean engine oil on the following items: the
pistons, the piston rings, and the cylinder bore.
g00516756
Illustration 263
g00516632
Illustration 264
marked UP-2 toward the top of the piston. Use 2. Install Tool (A) in order to compress the piston
Tool (A) in order to install the ring. rings.
5. Install the top piston ring with the side marked 3. With the number one crankshaft throw at the
UP-1 toward the top of the piston. Use Tool (A) bottom center, install the piston and connecting
in order to install the ring. rod in the engine. Ensure that the proper piston
89
Note: The word FRONT may be stamped on the 8. Place clean engine oil on the surface of the
crown of the pistons in some engines. Ensure that lower half of connecting rod bearing (5).
the word FRONT is toward the front of the engine Install connecting rod bearing cap (3) on the
when the piston is installed. The etched number on connecting rod. Ensure that the number on
the connecting rod must be on the right side of the connecting rod bearing cap (3) matches the
engine in the corresponding cylinder. number on the connecting rod. Ensure that the
numbers are on the same side.
9. Lubricate connecting rod cap bolts (2) with

10. Install connecting rod cap bolts (2). Tighten the


turn).

g00516604
Illustration 265 13. Install piston cooling jets (1) and the bolts.
4. Line up the piston and connecting rod (4) with (26 2 lb ft).
piston into the cylinder bore until Tool (A) comes End By:
off of the piston.
5. Before the connecting rod comes in contact
with the crankshaft, install the upper half b. Install the cylinder head.
of connecting rod bearing (5). Ensure that
the bearing tab engages with the slot in the
connecting rod. i01018963
6. Place clean engine oil on the surface of the

upper half of connecting rod bearing (5). Use a Remove
soft hammer in order to tap the piston into the
cylinder bore while you guide the connecting rod SMCS Code: 1219-011
onto the crankshaft.
Removal Procedure
Start By:
a. Remove the engine oil pan.
NOTICE

component life.
g00516602
Illustration 266
7. Place the lower half of connecting rod bearing

(5) in corresponding connecting rod cap (3).
Ensure that the bearing tab engages with the
groove in connecting rod cap (3).
90
i01019145

Install
SMCS Code: 1219-012
NOTICE

g00522734
component life.
Illustration 267
1. Inspect the connecting rod and connecting

The connecting rod and connecting rod cap
bearing retainer notch should also be on the right
side. Mark the connecting rod and connecting
rod cap (2), if necessary.
2. Remove connecting rod cap bolts (1) and

connecting rod cap (2).
3. Remove the lower half of the connecting rod g00522735

Illustration 269
bearing from connecting rod cap (2).
1. Install the upper half of connecting rod bearing
(4) into connecting rod (3). Ensure that the
bearing tab engages with the slot in the
connecting rod.

upper half of connecting rod bearing (4).
3. Position connecting rod (3) and connecting rod

bearing (4) on the crankshaft.
g00522735
Illustration 268
4. Push connecting rod (3) away from the

crankshaft. Remove the upper half of connecting
rod bearing (4).

remaining connecting rod bearings.
g00522734
Illustration 270
91
4. Install the lower half of the connecting rod

bearing in corresponding connecting rod cap
5. Place clean engine oil on the surface of the lower

half of the connecting rod bearing.
6. Install connecting rod cap (2) on the

corresponding connecting rod. Ensure that the

g00516918
8. Install connecting rod cap bolts (1). Tighten the Illustration 271
1. Remove bolts (1) that hold crankshaft main
9. Place an index mark on each bolt head. Tighten bearing cap (2). Remove crankshaft main
each bolt for an additional 60 5 degrees (1/6 bearing cap (2).
turn).
10. Repeat Steps 1 through 9 in order to install the bearing from crankshaft main bearing cap (2).
End By:
i01007616

Remove
SMCS Code: 1203-011
Removal Procedure Illustration 272

g00516920
Typical example
Table 42
Required Tools
NOTICE
Tool
Part
If the crankshaft is turned in the wrong direction, the
Number tab of the crankshaft main bearing will be pushed be-
A 2P-5518 Bearing Tool 1 tween the crankshaft and the cylinder block. this can
cause damage to either or both the crankshaft and the
cylinder block.
Start By:
a. Remove the oil pan.
NOTICE

component life.
92
i01007718

Install
SMCS Code: 1203-012
Table 43
Required Tools
Part
Number
NOTICE
g00516919
Illustration 273
3. Use the following steps in order to remove the component life.
upper half of crankshaft main bearings (3):
a. Turn the crankshaft until Tool (A) can be bearings prior to assembly. Ensure that the tabs on
installed in the crankshaft journal. Install Tool the back side of the crankshaft main bearings fit in
(A). the grooves of the crankshaft main bearing caps
order to get the tab out first, the crankshaft NOTICE
must be turned in the correct direction. Ensure that the crankshaft main bearings are installed
in the correct locations. Two different part numbers are
c. Check the condition of the crankshaft main used in quantities of three and four. The part number
bearings. Refer to the Guideline For Reusable having the quantity of four is to be installed on crank-
Parts, SEBF8009, Main and Connecting shaft main bearings 2, 3, 5, and 6. The part number
Rod Bearings or refer to the Guideline having the quantity of three is to be installed on crank-
For Reusable Parts, SEBF0531, Main and shaft bearing 1, 4, and 7. The thrust plate is to be in-
Connecting Rod Bearings. stalled on the center crankshaft main bearing only.
4. Remove thrust plate (4).
g00516920
Illustration 274
93

the washer face. Install bolts (1).

(70 4 lb ft). Place an index mark on each bolt
head. Tighten each bolt for an additional 90 5
degrees (1/4 turn).
g00516919
Illustration 275
1. Use Tool (A) and install the new upper halves g00517003
of crankshaft main bearings (3) in the cylinder Illustration 277
block. This half of the bearing has an oil hole. Do
not put oil on the back of the crankshaft main 5. Check the end play of the crankshaft with Tool
bearing. (B). The end play must be 0.10 mm (.004 inch)
to 0.50 mm (.020 inch).
Note: The crankshaft end play is controlled by

crankshaft thrust bearings (4). Thrust bearings (4)
are located at the center of the crankshaft.
End By:
a. Install the oil pan.
i01008243
Crankshaft - Remove
SMCS Code: 1202-011
g00516918
Illustration 276
2. Install the new lower halves of the crankshaft Removal Procedure

main bearings in crankshaft main bearing caps
(2). Do not put oil on the back of the crankshaft Start By:
main bearing.
a. Remove the engine oil pump.
NOTICE b. Remove the front housing.

Crankshaft main bearing caps should be installed with
the part number toward the right side of the engine. c. Remove the flywheel housing.
Crankshaft main bearing caps are to be identified by
stamped numbers 1 through 7 located on the bottom d. Remove the pistons and connecting rods.
94
i01008537
NOTICE
Keep all parts clean from contaminants. Crankshaft - Install
SMCS Code: 1202-012
component life.
Table 44
Required Tools
Part
Number
NOTICE

component life.
g00517115
Illustration 278
NOTICE
1. Remove bolts (1). Ensure that the crankshaft main bearing tabs engage
2. Remove crankshaft main bearing caps (2). bearing cap.
3. Remove crankshaft thrust bearings (3).
1. Place the upper halves of the crankshaft main
Note: Crankshaft main bearing caps (2) are marked bearings in the cylinder block. Place the lower
with the numbers 1 through 7. Crankshaft main halves of the crankshaft main bearings in
bearing caps (2) that are not marked should be crankshaft main bearing caps.
marked with the corresponding cylinder number on
the side that is toward the right side of the engine.
g00517116
Illustration 280
g00517116
Illustration 279 2. Fasten suitable lifting device (4) to the crankshaft
and place the crankshaft in the cylinder block.
4. Install a suitable bolt into each end of the
crankshaft. Fasten suitable lifting device (4) to the
bolts in the crankshaft. Remove the crankshaft.
The weight of the crankshaft is 129 kg (285 lb).
5. Remove the upper halves of the crankshaft main

bearings.
95
g00517179 g00517182
3. Install crankshaft thrust bearings (3). 6. Check the end play of the crankshaft with Tool
(A). The end play must be 0.10 mm (.004 inch)
to 0.50 mm (.020 inch).
End By:
a. Install the pistons and connecting rods.
b. Install the flywheel housing.
c. Install the front housing.
d. Install the engine oil pump.
i01017825
g00517115
Illustration 282
4. Install crankshaft main bearing caps (2) with Install
the part numbers toward the right hand side of
the cylinder block. Ensure that crankshaft main SMCS Code: 1204-010-GE
bearing caps (2) have numbers 1 through 7. The
numbers should start at the front of the engine. Removal Procedure
threads and the washers. Install bolts (1). Tighten Table 45
the bolts to a torque of 95 5 Nm (70 4 lb ft).
Required Tools
5. Place an index mark on each bolt head. Turn the Part
bolts for an additional 90 5 degrees (1/4 turn). Tool Part Description Qty
Number
9U-6232 Wheel Grinder 1
A
1U-6801 Cutoff Wheel 1
1F-1161 Cold Chisel 1
B
1U-7237 Hammer 1
C 5F-4764 Pry Bar 2
5P-0598 Clamp 1
D 1U-9579 Paper Towels 1
- Shim Stock 1
E - Plastic Sheeting 1
96
Start By:
a. Remove the front gear group.
g00522197
Illustration 286
g00522193
Illustration 284
1. Place the following items from Tool (D) around the

finished end of the crankshaft in order to prevent
damage: paper towels, shim stock, and clamp.
2. Use paper towels in order to plug all openings

in the cylinder block and prevent debris from
entering the cylinder block.
g00522195
Illustration 287
NOTICE
Do not cut all the way through crankshaft gear. Keep at
least 1.5 mm (.06 inch) from the end of the crankshaft.
Stay away from the hose clamp and the shim stock.
NOTICE
Do not nick or gouge the front face of the cylinder
block with the cutoff wheel while grinding through the
Illustration 285 g00522199 crankshaft gear.
3. Use Tool (E) for added protection on the front 4. Use Tool (A) to make a cut through the root
of the engine. diameter of crankshaft gear (1). Keep at least
1.5 mm (.06 inch) from the finished end of
crankshaft.
Wear eye protection in order to prevent possible

personal injury while performing the following
steps.
97
g00522200 g00522202
5. Use Tool (B) to make a crack in crankshaft gear 1. Rotate the crankshaft in order to get drive pin
(1). (2) at top center.
6. Remove Tool (D) from the crankshaft.
g00522204
Illustration 291
g00522201
Illustration 289
7. Use Tool (C) to pry crankshaft gear (1) loose Always wear protective gloves when handling
from the end of the crankshaft. parts that have been heated.
8. Remove crankshaft gear (1).
2. Heat crankshaft gear to a temperature of 210 C
Note: Remove paper towels and Tool (E) from the (410 F) for no longer than one hour.
cylinder block.
Note: Heating the gear for more than one hour may
change the hardness of the gear.
Table 46 3. Install crankshaft gear (1) on the end of the
crankshaft. Ensure that slot (3) in crankshaft gear
Required Tools (1) is aligned with drive pin (2).
Part
Number
A 6V-2098 Press Sleeve 1
B 8H-8581 Gauge 1
98
NOTICE

component life.

small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
Caterpillar engine bearing is quality checked for
specific wall thickness.
g00522205
Illustration 292
Note: The measurements should be within
4. Use Tool (A) to seat crankshaft gear (1) against specifications and the correct bearings should
the shoulder of the crankshaft. be used. If the crankshaft journals and the bores
for the block and the rods were measured during
However, if the technician still wants to measure
the bearing clearances, Tool (A) is an acceptable
method. Tool (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
(0.004 inch).
NOTICE
The technician must be very careful to use Tool (A)

g00522206 correctly. The following points must be remembered:
Illustration 293
5. Use Tool (B) to ensure that crankshaft gear (1) is

seated against the shoulder on the crankshaft.
Note: Check the crankshaft gear in three places

seated in the tab grooves.
with Tool (B).
End By:
points of Tool (A).
a. Install the front gear group. 1. Put a piece of Tool (A) on the crown of the
i01190340
Note: Do not allow Tool (A) to extend over the edge
Bearing Clearance - Check of the bearing.
SMCS Code: 1203-535; 1219-535 2. Use the correct torque-turn specifications in

order to install the bearing cap. Do not use an
Table 47
Note: Do not turn the crankshaft when Tool (A) is
Part
A - Plastigage -
99
g00473227 g00521613
Typical example
1. Disconnect sensor connector (4) from camshaft
3. Carefully remove the cap, but do not remove position sensor (3).
Tool (A). Measure the width of Tool (A) while Tool
(A) is in the bearing cap or on the crankshaft 2. Remove bolt (1) and the washer.
journal. Refer to Illustration 294.
3. Remove camshaft position sensor (3) and
4. Remove all of Tool (A) before you install the bracket (2) as a unit from the front housing.
bearing cap.
4. Inspect the condition of the O-ring seal on
Note: When Tool (A) is used, the readings can camshaft position sensor (3). Replace the O-ring
sometimes be unclear. For example, all parts of seal, if necessary.
Tool (A) are not the same width. Measure the major
width in order to ensure that the parts are within Installation Procedure
the specification range. Refer to the Specifications
Manual, Connecting Rod Bearing Journal and
NOTICE
Specifications Manual, Main Bearing Journal for
the correct clearances.
i01016545 component life.
Camshaft Position Sensor -

Remove and Install
SMCS Code: 1912-010
Removal Procedure
NOTICE

component life.
g00521613
Illustration 296
1. Install camshaft position sensor (3) and bracket

(2) as a unit into the front housing.
2. Install bolt (1) and the washer.
3. Connect sensor connector (4) to camshaft

position sensor (3).
100
4. Calibrate the engine speed-timing. Refer to

Electronic Troubleshooting for more information.
i01014165

Remove and Install
SMCS Code: 1906-010
Removal Procedure
g00520237
Illustration 297
and alkali. 1. Drain the level of the coolant below the coolant
temperature sensor. Drain the coolant into a
At operating temperature, engine coolant is hot suitable container for storage or disposal.
to heaters or the engine contain hot coolant or 2. Disconnect sensor connector (1) from coolant
steam. Any contact can cause severe burns. temperature sensor (2).
Remove cooling system pressure cap slowly to 3. Remove coolant temperature sensor (2).
cooling system pressure cap is cool enough to Installation Procedure
Do not attempt to tighten hose connections when NOTICE

the coolant is hot, the hose can come off causing Keep all parts clean from contaminants.
burns.
Cooling System Coolant Additive contains alkali. component life.
NOTICE

component life.
NOTICE
opening any compartment or disassembling any Illustration 298
g00520237
1. Install coolant temperature sensor (2). Tighten
Refer to Special Publication, NENG2500, Caterpillar coolant temperature sensor (2) to a torque of
Tools and Shop Products Guide, for tools and sup- 20 5 Nm (15 4 lb ft).
machines. 2. Connect sensor connector (1) to coolant
temperature sensor (2).
mandates. 3. Fill the cooling system with coolant to the correct
Manual for the correct procedure.
101
i01018581 4. Inspect the condition of the O-ring seal on

crankshaft position sensor (2). Replace the
Crankshaft Position Sensor - O-ring seal, if necessary.
Remove and Install
SMCS Code: 1912-010
NOTICE
Removal Procedure Keep all parts clean from contaminants.
NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

component life.
NOTICE

plies suitable to collect and contain fluids in Caterpillar Illustration 300
g00522655
machines. The vibration damper and the front engine support have been
removed for photo purposes.
mandates. 1. Install crankshaft position sensor (2) and bracket
3. Connect sensor connector (4) to crankshaft


i01275540

g00522655
Remove and Install
Illustration 299
The vibration damper and the front engine support have been SMCS Code: 1924-010
1. Disconnect sensor connector (4) from crankshaft

Removal Procedure
NOTICE
2. Remove bolt (1) and the washer. Keep all parts clean from contaminants.
3. Remove crankshaft position sensor (2) and Contaminants may cause rapid wear and shortened
bracket (3) as a unit from the front housing. component life.
102
NOTICE

products.

Illustration 302
mandates.
Typical example

10 2 Nm (88 18 lb in).
2. Connect sensor connector (1). Secure the sensor

wiring to the engine with wire ties.
i01190887

Install
g00512032 SMCS Code: 1358-010
Illustration 301
Typical example
Removal Procedure
1. Disconnect sensor connector (1). Cut the wire
ties that secure the sensor wiring to the engine.
2. Remove engine oil pressure sensor (2).
NOTICE

component life.
g00519255
Illustration 303

tightener (1). Remove the drive belt.
103
g00519256 g00519259
2. Remove bolt (4) and the washer. 5. If the alternator is equipped with an adjustable
support strap, adjust the position of the alternator
3. Remove belt tightener (1). until the indicator edge (5) is aligned with the
green area of the indicator decal.
4. Remove three bolts (2) and the washers.
i01017988
5. Remove support (3).
Electronic Control Module -
Installation Procedure Remove and Install
1. Inspect the condition of the belt tightener and
SMCS Code: 1901-010
the drive belt. Replace the tightener and the belt,
if necessary.
Removal Procedure
NOTICE

component life.
NOTICE
g00519256
Illustration 305 component containing fluids.
2. Install support (3) on the front housing with three Refer to Special Publication, NENG2500, Caterpillar
bolts (2) and the washers. Tighten the bolts to a Tools and Shop Products Guide, for tools and sup-
torque of 55 10 Nm (41 7 lb ft). plies suitable to collect and contain fluids in Caterpillar
machines.
3. Install belt tightener (1) with bolt (4) and
the washer. Tighten the bolt to a torque of Dispose of all fluids according to local regulations and
55 10 Nm (41 7 lb ft). mandates.
4. Install the drive belt. Use a breaker bar to place

the original amount of tension on the belt.
104
NOTICE

component life.
g00522333
Illustration 307
1. Disconnect hose (2) and hose (4) from the

electronic control module.
2. Plug all openings immediately.
3. Loosen allen head screw (3) until engine wiring

g00522336
harness (1) can be disconnected. Illustration 309
4. Disconnect engine wiring harness (1). 1. Position electronic control module (10) on the
cylinder block.
5. Loosen allen head screw (5) until machine wiring
harness (6) can be disconnected. 2. Install the following items: four spacers, eight
rubber mounts (11), four washers (9), strap (7),
6. Disconnect machine wiring harness (6). and four bolts (8).
g00522336 g00522333
7. Remove the following items: four bolts (8), four 3. Connect engine wiring harness (1) and tighten
washers (9), eight rubber mounts (11), strap (7), allen head screw (3).
and four spacers.
4. Connect machine wiring harness (6) and tighten
8. Remove electronic control module (10). allen head screw (5).
5. Connect hose (2) and hose (4) to electronic

control module (10).
Note: Refer to the Electronic Troubleshooting

Manual, SENR5572 for more information about the
disassembly and assembly of the electronic control
module.
105
i01012735 1. Place the alternator on mounting bracket (4).

Install bolt (3) with the washer and nut (2). Hand
Alternator - Remove and Install tighten nut (2).
SMCS Code: 1405-010 2. Install bolt (1) and the washer. Do not tighten.
Removal Procedure 3. Install the drive belt on the drive pulley of the
alternator.
1. Remove the drive belt from the drive pulley on
the alternator. 4. Adjust the tension on the drive belt. Refer to
2. Place an index mark on all of the electrical wires correct adjusting procedure.
the electrical wires from the alternator. 5. Tighten bolt (1).
6. Tighten nut (2).
7. Connect all wires to the alternator. Use the index

marks to correctly connect the wires.
i01012803

Remove and Install
SMCS Code: 1453-010
Illustration 311 g00519357 Removal Procedure

Typical example 1. Place an index mark on all of the electrical wires
3. Remove bolt (1) and the washer. Disconnect the electrical wires from the electric
starting motor.
4. Remove nut (2) with the washer and bolt (3) from
mounting bracket (4).
5. Remove the alternator.
g00519372
Illustration 313
Typical example

starting motor.
g00519357
Illustration 312 3. Remove three bolts (1).
Typical example
the electric starting motor is 29 kg (65 lb).
106
Installation Procedure 1. Remove two bolts (1) with the nuts and the
washers.
gasket, if necessary. 2. Remove two bolts (2) and the washers.
2. Install the gasket on the electric starting motor. 3. Remove air conditioner compressor support
bracket (3).
NOTICE
The air conditioner support bracket provides addition-
al support for the mounting pad on the engine front
housing. However, due to the increased stiffness of
this bracket, extra care is needed when installing the
air conditioner compressor support bracket on the en-
gine. Following the correct installation procedure will
avoid applying assembly stresses to the engine front
housing mounting pad which may lead to a crack.
g00519372
Illustration 314
Typical example

starting motor.


i01024767
g00526793
Air Conditioner Support Illustration 316
Typical example
Bracket - Remove and Install
1. Install air conditioner support bracket (3) with
SMCS Code: 1802-010 the following procedure.
Removal Procedure a. Install two bolts (1) with the nuts and the
washers. Finger tighten the bolts.
b. Install two bolts (2) and the washers. Finger

tighten the bolts.
NOTICE
Ensure that there is no gap between the air condition-
er compressor support bracket and the engine front
housing. Ensure that there is no gap between the air
conditioner support bracket and the cylinder head.
Reposition the air conditioner compressor support
bracket in order to eliminate the gap.
c. Lightly tighten bolts (1) and bolts (2).

g00526793
Illustration 315
Typical example d. Ensure that air conditioner support bracket (3)
remains tight against the engine front housing
107
e. Tighten the bolts to a torque of 47 9 Nm

(35 7 lb ft).
i00999511

Install
SMCS Code: 1803-010
Removal Procedure
Table 48
Illustration 317
Number 2. Remove bolt (6). Disconnect fittings (3) and
remove tube (5).
3. Disconnect hose (1) from the air compressor.
4. Loosen clamps on hose (2) and remove hose (2).

Do not disconnect the air lines until the air pres-
ed under pressure it can cause personal injury.
NOTICE

component life.
NOTICE
during performance of inspection, maintenance, test- g00511528
Illustration 318
opening any compartment or disassembling any 5. Install Tool (A) and a proper lifting device to the
component containing fluids. air compressor. The weight of the air compressor
Tools and Shop Products Guide, for tools and sup- 6. Disconnect hose (9) from the air compressor.
machines. 7. Remove three bolts (7) and the washers.
Dispose of all fluids according to local regulations and 8. Apply tension to the lifting device and remove
mandates. two bolts (8) and the washers. Remove air
compressor (4) and the gasket from the engine.
1. Remove the air pressure from the air tank and
drain the coolant from the cooling system. Installation Procedure
Table 49
Required Tools
Number
108
7. Install tube (5) and connect fittings (3).

NOTICE
Keep all parts clean from contaminants. 8. Install bolt (6).
Contaminants may cause rapid wear and shortened 9. Connect hose (2) and tighten the clamps.
component life.
10. Connect hose (1) to the air compressor.
1. Inspect the condition of the gasket. Replace the 11. Fill the cooling system with coolant to the correct
gasket, if necessary. level. Refer to the Operation and Maintenance
i01067130

Remove
Removal Procedure
Table 50
Required Tools
g00511528
Illustration 319
Part
air compressor. The weight of the air compressor Holding Fixture (Air
A 132-5451 1
is approximately 27 kg (60 lb). Compressor Drive Gear)
3. Position air compressor (4) in the front housing. Start By:

with the gear in the front housing. a. Remove the air compressor.
threads of three bolts (7). Install three bolts (7) NOTICE
and the washers. Tighten bolts (7) to a torque of Keep all parts clean from contaminants.
100 20 Nm (75 15 lb ft).
5. Install two bolts (8) and the washers. Tighten component life.
bolts (8) to a torque of 55 10 Nm (41 7 lb ft).
Remove the lifting device and Tool (A).
g00524786
Illustration 321
Typical example
g00511527
Illustration 320
109
2. Install Tool (A) on air compressor (1), as shown. 6. Remove Tool (A).
3. Remove nut (2). End By:
4. Remove Tool (A) and air compressor drive gear a. Install the air compressor.
(3).
i01068094

Install
Table 51
Required Tools
Part
Holding Fixture (Air
A 132-5451 1
Compressor Drive Gear)
NOTICE

component life.
g00524786
Illustration 322
Typical example
2. Install air compressor drive gear (3) on the air

3. Install nut (2).
4. Install Tool (A) on air compressor (1), as shown.

(340 44 lb ft).
110
Index Section
Index
A Compression Brake - Disassemble ....................... 61
Accessory Drive - Assemble.................................. 57 Compression Brake - Install .................................. 68
Accessory Drive - Disassemble............................. 56 Compression Brake - Remove............................... 60
Disassembly Procedure ..................................... 56 Removal Procedure ........................................... 60
Accessory Drive - Install........................................ 58 Connecting Rod Bearings - Install ......................... 90
Accessory Drive - Remove .................................... 56 Connecting Rod Bearings - Remove ..................... 89
Air Compressor - Remove and Install.................. 107 Coolant Temperature Sensor - Remove and
Installation Procedure ...................................... 107 Install ................................................................. 100
Removal Procedure ......................................... 107 Installation Procedure ...................................... 100
Air Compressor Drive Gear - Install..................... 109 Removal Procedure ......................................... 100
Installation Procedure ...................................... 109 Crankshaft - Install................................................. 94
Air Compressor Drive Gear - Remove................. 108 Installation Procedure ........................................ 94
Removal Procedure ......................................... 108 Crankshaft - Remove............................................. 93
Air Conditioner Support Bracket - Remove and Removal Procedure ........................................... 93
Install ................................................................. 106 Crankshaft Front Seal - Install ............................... 50
Removal Procedure ......................................... 106 Crankshaft Front Seal - Remove ........................... 50
Air Inlet Manifold - Install ....................................... 15 Removal Procedure ........................................... 50
Installation Procedure ........................................ 15 Crankshaft Gear - Remove and Install .................. 95
Air Inlet Manifold - Remove ................................... 15 Installation Procedure ........................................ 97
Alternator - Remove and Install ........................... 105 Crankshaft Main Bearings - Install......................... 92
Removal Procedure ......................................... 105 Crankshaft Main Bearings - Remove..................... 91
B Install ................................................................. 101
Bearing Clearance - Check ................................... 98 Removal Procedure ......................................... 101
Measurement Procedure ................................... 98 Crankshaft Rear Seal - Install................................ 41
Belt Tensioner - Remove and Install .................... 102 Installation Procedure ........................................ 41
Installation Procedure ...................................... 103 Crankshaft Rear Seal - Remove............................ 40
Install ................................................................... 41
C Installation Procedure ........................................ 42
Camshaft - Install................................................... 77 Cylinder Head - Install ........................................... 72
Camshaft - Remove............................................... 76 Cylinder Head - Remove ....................................... 70
Camshaft Bearings - Install ................................... 80 Cylinder Liner - Install............................................ 84
Camshaft Bearings - Remove ............................... 79 Cylinder Liner - Remove ........................................ 83
Camshaft Gear - Remove and Install .................... 78
Removal Procedure ........................................... 78 D
Camshaft Position Sensor - Remove and Install ... 99
Installation Procedure ........................................ 99 Disassembly and Assembly Section........................ 4
Compression Brake - Assemble ............................ 64
111
Index Section
E Front Cover - Install ............................................... 52

Electric Starting Motor - Remove and Install ....... 105 Front Cover - Remove ........................................... 51
Removal Procedure ......................................... 105 Fuel Filter Base - Remove and Install ..................... 4
Electronic Control Module - Remove and Install.. 103 Installation Procedure .......................................... 5
Installation Procedure ...................................... 104 Removal Procedure ............................................. 4
Removal Procedure ......................................... 103 Fuel Manifold - Install .............................................. 8
Electronic Unit Injector - Install ................................ 9 Installation Procedure .......................................... 8
Installation Procedure .......................................... 9 Fuel Manifold - Remove........................................... 7
Electronic Unit Injector - Remove ............................ 8 Removal Procedure ............................................. 7
Removal Procedure ............................................. 8 Fuel Priming Pump - Remove and Install ................ 4
Electronic Unit Injector Sleeve - Install .................. 12 Installation Procedure .......................................... 4
Installation Procedure ........................................ 12 Removal Procedure ............................................. 4
Electronic Unit Injector Sleeve - Remove .............. 11 Fuel Transfer Pump - Install..................................... 6
Removal Procedure ........................................... 11 Installation Procedure .......................................... 6
Engine Centrifugal Oil Filter - Remove and Install.. 21 Fuel Transfer Pump - Remove ................................. 6
Installation Procedure ........................................ 23 Removal Procedure ............................................. 6
Engine Oil Cooler - Install...................................... 29
Installation Procedure ........................................ 29 G
Engine Oil Cooler - Remove .................................. 28
Removal Procedure ........................................... 28 Gear Group (Front) - Install ................................... 53
Engine Oil Filter Base - Assemble......................... 26 Installation Procedure ........................................ 53
Assembly Procedure.......................................... 26 Gear Group (Front) - Remove ............................... 52
Engine Oil Filter Base - Disassemble .................... 25 Removal Procedure ........................................... 52
Engine Oil Filter Base - Install ............................... 27
Installation Procedure ........................................ 27 H
Removal Procedure ........................................... 24 Housing (Front) - Install ......................................... 55
Engine Oil Pan - Remove and Install ..................... 81 Installation Procedure ........................................ 55
Installation Procedure ........................................ 81 Housing (Front) - Remove ..................................... 54
Engine Oil Pressure Sensor - Remove and
Install ................................................................. 101
Installation Procedure ...................................... 102 I
Removal Procedure ......................................... 101
Engine Oil Pump - Assemble................................. 32 Important Safety Information ................................... 2
Assembly Procedure.......................................... 32 Inlet and Exhaust Valve Guides - Remove and
Engine Oil Pump - Disassemble............................ 31 Install ................................................................... 19
Disassembly Procedure ..................................... 31 Installation Procedure ........................................ 19
Engine Oil Pump - Remove ................................... 30 Install ................................................................... 20
Exhaust Manifold - Remove and Install ................. 14 Removal Procedure ........................................... 20
Installation Procedure ........................................ 14 Inlet and Exhaust Valve Springs - Remove and
F Inlet and Exhaust Valves - Remove and Install ..... 18
Flywheel - Remove................................................ 39
Removal Procedure ........................................... 39 L
Flywheel Housing - Remove and Install ................ 42
Installation Procedure ........................................ 43 Lifter Group - Remove and Install.......................... 75
P Water Temperature Regulator - Remove and
Install ................................................................... 35
Piston Cooling Jets - Remove and Install .............. 85 Installation Procedure ........................................ 36
Pistons and Connecting Rods - Install................... 88
Pistons and Connecting Rods - Remove............... 85

Rear Power Take-Off (RPTO) - Remove................ 44
Rocker Shaft and Pushrod - Install ........................ 69
Rocker Shaft and Pushrod - Remove .................... 68

Install ................................................................... 59
Vibration Damper and Pulley - Remove and
Install ................................................................... 49

Water Outlet Manifold - Remove............................ 38
Water Pump - Install .............................................. 34
Water Pump - Remove .......................................... 33
2000 Caterpillar
RENR2234-03
April 2001
Specifications
CPD1-Up (Engine)
2KS1-Up (Engine)
3CS1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Accessory Drive (Air Compressor) .......................

Housing (Front) .....................................................
38
38
Gear Group (Front) ............................................... 40
Specifications Section Flywheel ............................................................... 42
Flywheel ............................................................... 43
Engine Design ....................................................... 4
Flywheel Housing ................................................ 43
Engine Design ....................................................... 4
Flywheel Housing (Rear Power Take-Off
Fuel Transfer Pump ................................................ 5
(RPTO)) ............................................................... 44
Fuel Lines ............................................................... 5
Engine to Transmission Adapter .......................... 44
Fuel Filter (Primary) ................................................ 6
Belt Tension Chart ............................................... 45
Fuel Filter and Water Separator .............................. 6
Belt Tensioner ....................................................... 46
Fuel Priming Pump and Primary Fuel Filter ........... 6
Belt Tensioner ....................................................... 46
Electronic Unit Injector ............................................ 6
Belt Tensioner ....................................................... 46
Electronic Unit Injector Mechanism ....................... 7
Belt Tensioner ....................................................... 47
Electronic Unit Injector Rocker Arm ........................ 7
Belt Tightener ...................................................... 47
Electronic Unit Injector Wiring ................................. 8
Lifter Group ............................................................. 8
Engine Support (Front) ......................................... 48
Rocker Shaft .......................................................... 8
Valve Mechanism ................................................... 9
Valve Mechanism ................................................... 9
Valve Rocker Arm ................................................ 10
Valve Mechanism Cover ...................................... 10
Electrical Ground Stud .......................................... 52
Cylinder Head ...................................................... 13
Fuel Temperature Sensor ..................................... 52
Turbocharger ........................................................ 15
Fuel Pressure Sensor .......................................... 53
Turbocharger ........................................................ 16
Engine Oil Pressure Sensor ................................. 53
Turbocharger ........................................................ 16
Turbocharger ........................................................ 17
Atmospheric Pressure Sensor .............................. 53
Inlet Manifold ....................................................... 17
Inlet Air Temperature Sensor ................................ 54
Camshaft ............................................................. 18
Accelerator Pedal Position Sensor ........................ 55
Camshaft ............................................................. 18
Engine Control Module ......................................... 55
Air Compressor .................................................... 55
Engine Oil Filter ................................................... 21
Engine Centrifugal Oil Filter .................................. 22
Engine Oil Cooler ................................................. 22 Index Section
Engine Oil Pump .................................................. 23
Engine Oil Pressure ............................................. 24 Index ..................................................................... 56
Engine Oil Pan ..................................................... 24
Engine Oil Pan ..................................................... 24
Engine Oil Pan ..................................................... 25
Engine Oil Pan ..................................................... 25
Crankcase Breather ............................................. 25
Coolant Conditioner Base .................................... 26
Water Pump ......................................................... 26
Cylinder Block ...................................................... 27
Cylinder Liner ....................................................... 29
Cylinder Liner ....................................................... 30
Cylinder Liner Projection ...................................... 30
Crankshaft ........................................................... 30
Vibration Damper and Pulley ............................... 32
Connecting Rod ................................................... 33
Connecting Rod ................................................... 34
Piston and Rings .................................................. 35
Piston and Rings .................................................. 36
4
Engine Design
i01012763
SMCS Code: 1201
Engine Design S/N: CPD1-Up
SMCS Code: 1201 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 and (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 ................................... 10.3 L (629 in3)
In order to check the engine valve lash setting, the engine must be cold and the engine must be
the engine must be cold and the engine must be stopped. Engine valve lash settings
stopped. 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
Engine compression brake .................. 0.64 mm (.040 inch)
(.025 inch)
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4
The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft
flywheel end of the engine. Crankshaft rotation .......................................... Counterclockwise
Note: The front end of the engine is opposite of
Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the
the flywheel end of the engine. The left side of the engine and the right side of the engine are viewed
engine and the right side of the engine are viewed from the flywheel end of the engine. The No. 1
from the flywheel end of the engine. The No. 1 cylinder is the front cylinder.
5
i01391676 When the pump is viewed from the drive end the
rotation of the pump is counterclockwise.
Fuel Transfer Pump
SMCS Code: 1256 i00956129
Fuel Lines
SMCS Code: 1274
g00280095
Illustration 3
g00281513
Illustration 5
Typical example
(1) Plug
(2) Fuel manifold
(3) Supply hose assembly from the electronic

control module (ECM)
(4) 104-1729 Spring
Illustration 4
g00280096 Assembled length ............... 18.4 mm (.72 inch)
Operating length (minimum) ................ 15.4 mm
(1) Outlet port (.61 inch)
Free length after test .................. 30.2 0.7 mm
(2) Drain hole (1.19 .03 inch)
(3) Inlet port
(5) Stud
(4) Pressure regulating valve
Apply 9S-3263 Thread Lock Compound on
the taperlock end of the stud to the following
When the fuel transfer pump is using diesel fuel, the
length. .................................... 7.6 mm (.30 inch)
fuel transfer pump has the following specifications.
Tighten the stud to the following
torque. .................... 70 15 Nm (50 11 lb ft)
Run the pump at 2538 rpm. The full bypass pressure
should be the following value. ......... 682 to 751 kPa
(99 to 109 psi)
Run the pump at 846 rpm. The flow at 482 kPa

Run the pump at 3384 rpm. The flow at

585.8 to 654.6 kPa (85 to 90 psi) must be 7.09 L/min
(1.87 US gpm).
Run the pump at 147 rpm with a blocked inlet. After

30 seconds the pump must have a suction level of
60.84 kPa (18 inches of inches hg ) min.
6
i00916443 (5) Drain

Fuel Filter (Primary) Note: To open the self-ventilated drain, turn the plug
counterclockwise.
SMCS Code: 1260
i01197996
Fuel Priming Pump and

Primary Fuel Filter
SMCS Code: 1258; 1261
g00111701
Illustration 6
Typical example
(1) Torque for nut ........... 25 5 Nm (18 4 lb ft)
(2) 7S-9323 Spring

Length under test force ... 27.9 mm (1.10 inch) Illustration 8
g00640576
Test force .................. 125 to 145 N (28 to 33 lb)
Free length after the test .. 42.7 mm (1.68 inch) (1) Fuel priming pump
Outside diameter ................ 17.3 mm (.68 inch)
(2) Primary fuel filter base
i00814239
Fuel Filter and Water Separator torque: ........................ 28 7 Nm (21 5 lb ft)
SMCS Code: 1261; 1263 (4) Primary filter element
i01175861
Electronic Unit Injector

SMCS Code: 1290
g00388412
Illustration 7
(1) Filter element
(2) Fuel filter base
(3) Bowl Illustration 9

g00403738
(4) Plug
7
(1) Tighten the bolt to the following Diameter of new rocker arm
torque. ........................ 30 7 Nm (22 5 lb ft) shaft ...... 34.000 0.010 mm (1.3386 .0004 inch)
(2) Lubricate the seals and the bore with a 50 (5) Lifter group shaft
percent mix of 8T-2998 Lubricant and engine
oil. Diameter of new lifter group
shaft ........ 20.000 0.010 mm (.7874 .0004 inch)
i01175866
The bore diameter in the body of the electronic unit
Electronic Unit Injector injector lifter assembly for the lifter group shaft is
the following value. ................... 20.050 0.015 mm
Mechanism (0.7894 0.0006 inch)
SMCS Code: 1290 (6) Electronic unit injector lifter
i01175875
Electronic Unit Injector Rocker

Arm
SMCS Code: 1123
g00280175
Illustration 10
g00280315
Illustration 11
(1) Electronic unit injector
(1) Bore in rocker arm bearing for
The adjusting instructions for the electronic unit shaft .................................... 34.050 0.015 mm
injector are listed below. (1.3405 0.0006 inch)
1. Loosen locknut (2). The rocker arm bearing must not extend beyond
either face of the rocker arm.
2. Turn the electronic unit injector rocker arm
adjusting screw clockwise. Stop turning the (2) Bearing joint
adjusting screw when contact is made with the
electronic unit injector. Oil passage angle (A) ............................ 15 degrees
3. Turn the adjusting screw in the clockwise Oil passage angle (B) ............................ 20 degrees
direction.
Assemble the bearing. The oil hole openings that
Turn .......................... 180 degrees (1/2 of a turn) are in the bearing must be centered over the oil
passages that are in the rocker arm. Centers must
4. Hold the adjusting screw in this position. Tighten be within the following value. ...... 2.3 mm (.09 inch)
locknut (2).
(3) Bore in the rocker arm for the
Tighten the locknut to the following bearing ............................... 37.000 0.020 mm
torque. ........................ 55 10 Nm (40 7 lb ft) (1.4567 0.0008 inch)
(3) Rocker arm

8
i01237756
Electronic Unit Injector Wiring

SMCS Code: 1290
g00288322
Illustration 14
View A-A
(2) Valve lifter
(3) Oil supply lifter bracket assembly
(4) Lifter bracket assembly
Illustration 12 g00280453 (5) The dowels extend below the surface of the lifter
bracket assembly. Distance ......... 4.0 1.0 mm
(1) Tighten the nuts that are on the cap assembly (0.16 0.04 inch)
to the following torque. .............. 2.5 0.25 Nm
(22 2 lb in) (6) Tighten the bolts to the following
torque. ........................ 30 3 Nm (22 2 lb ft)
(2) Cap assembly
i00887793
Angle A ................................................... 52 degrees
Rocker Shaft
Position connectors so that the wires are not
contacting any other surfaces. SMCS Code: 1102
i01175911
Lifter Group
SMCS Code: 1209
g00280329
Illustration 15
(1) Pin
(2) Distance from the top surface of the pin to the

opposite side of the shaft .......... 40.0 1.0 mm
Illustration 13
g00280305 (1.57 0.04 inch)
9
(3) The plug is installed into the end of the shaft. Diameter of new lifter group
shaft .. 20.000 0.010 mm (.7874 .0004 inch)
(4) Install the plug to the following
depth. ..... 1.25 0.25 mm (0.049 0.010 inch) Bore diameter in the body of the valve
lifter ... 20.050 0.015 mm (.7894 .0006 inch)
i00924288 (6) Valve lifter

Valve Mechanism
i00956795
SMCS Code: 1102
Valve Mechanism
S/N: 3CS1-Up
SMCS Code: 1102
S/N: CPD1-Up
S/N: 2KS1-Up
g00280461
Illustration 16
(2) Valve lash (engine stopped) Illustration 17 g00280461

(.025 .003 inch) (2) Valve lash (engine stopped)
Valve lash for the engine compression Inlet valves .. 0.38 0.08 mm (.015 .003 inch)
brake .......... .64 .08 mm (0.025 0.003 inch)
Note: After setting the valve lash, tighten the (.025 .003 inch)
adjusting screw locknut. Recheck the valve lash. Valve lash for the engine compression
brake .......... 1.02 0.08 mm (.040 .003 inch)
Torque for the adjusting screw locknut .. 25 7 Nm
(18 5 lb ft) Note: After setting the valve lash, tighten the
Diameter of new rocker arm Torque for the adjusting screw locknut .. 25 7 Nm
shaft .................................... 34.000 0.010 mm (18 5 lb ft)
(1.3386 .0004 inch)
(4) Valve bridge
Diameter of new rocker arm
shaft .................................... 34.000 0.010 mm
(5) Lifter group shaft (1.3386 .0004 inch)
10
(4) Valve bridge i00573207
(5) Lifter group shaft Valve Mechanism Cover

Diameter of new lifter group SMCS Code: 1107
shaft .. 20.000 0.010 mm (.7874 .0004 inch)
lifter ... 20.050 0.015 mm (.7894 .0006 inch)
(6) Valve lifter
i01013543
Valve Rocker Arm

SMCS Code: 1123
g00280491
Illustration 19
(1) Seal
Cut the seal to length for each of the three valve

mechanism covers. Coat the joint surface with
3S-6252 Sealant.
(2) Cover
g00280477
Illustration 18

inlet valve. Tighten the locknut to the following
torque. ........................ 25 7 Nm (18 5 lb ft)
Inlet valve lash (engine stopped) .............. 0.38 mm

(.015 inch)

exhaust valve. Tighten the locknut to the
g00280493
Illustration 20
Exhaust valve lash (engine stopped) ........ 0.64 mm
(.025 inch) (3) Tighten bolts 1 through 6 in a numerical
sequence to the following torque. ... 12 3 Nm
(3) Support assembly (9 2 lb ft)
(4) The dowel extends below the surface of the Again tighten bolts 1 through 6 in a numerical
support assembly. Distance ........ 5.0 0.5 mm sequence to the following torque. ......... 12 3 Nm
(.20 .02 inch) (9 2 lb ft)
(4) Breather assembly
The conditions that follow will allow the crankcase

pressure to be less than 0.4 kPa (0.06 psi).
Inside diameter of fumes disposal
tube ................................... 31.8 mm (1.25 inch)
Blowby per hour .................. 19.82 cubic meters
11
(5) Cylinder head Outside diameter ............. 23.24 mm (.915 inch)
(6) New valve stem diameter .... 9.441 0.008 mm

i00953496
(.3717 .0003 inch)
Cylinder Head Valves The valves can be reused if the minimum
SMCS Code: 1105 dimensions for the valve stems are met.
Inlet ................................ 9.408 mm (.3704 inch)
Exhaust .......................... 9.408 mm (.3704 inch)
Specifications for the valve guides

After installation into the cylinder head,
the valve guide bore is the following
value. .. 9.484 0.026 mm (.3734 .0010 inch)
The valve guide can be reused. The valve
guide bore must not be larger than the following
value. ............................. 9.538 mm (.3755 inch)
(7) Diameter of valve head

Inlet valve ............................... 45.00 0.13 mm
(1.772 .005 inch)
Exhaust valve ......................... 42.00 0.13 mm
(1.654 .005 inch)
(8) Angle of face of valve seat insert
g00448911
Inlet valve ......................... 29 3/4 1/4 degrees
Illustration 21 Exhaust valve ................... 44 3/4 1/4 degrees
Note: Coat the inlet valve stems and the exhaust
valve stems with 8T-2998 Lubricant prior to
installation into the cylinder head.
(1) Inlet valve
(2) Exhaust valve
(3) Height to the step that is in the valve

guide ........ 22.00 0.50 mm (.866 .020 inch)
(4) 7W-7082 Spring

Assembled Length ........ 51.69 mm (2.035 inch)
Load at assembled length ............... 240 24 N Illustration 22
g00282169
(54 5 lb)
Operating length (minimum) .............. 37.72 mm (9) Depth of the bore in the cylinder head for the
(1.485 inch) valve seat insert
(146 7 lb) Inlet ........... 15.00 0.05 mm (.591 .004 inch)
Free length after test ..... 59.89 mm (2.358 inch) Exhaust ..... 14.10 0.05 mm (.555 .004 inch)
Outside diameter ........... 34.00 mm (1.339 inch)
Note: Shrink the valve seat inserts by reducing the
(5) 7W-7083 Spring temperature. Shrinking the valve seat inserts allows
placement into the counterbore.
Assembled Length ........ 49.19 mm (1.937 inch)
Load at assembled length ............... 136 14 N (10) Valve seat insert
(31 3 lb)
Operating length (minimum) .............. 35.22 mm Diameter of valve seat insert (inlet
(1.387 inch) valve) .................................. 46.025 0.013 mm
Load at minimum operating length .. 292 15 N (1.8120 .0005 inch)
(66 3 lb)
Free length after test ..... 61.39 mm (2.417 inch)
12
Bore in cylinder head for valve seat insert (inlet

valve) .................................. 45.961 0.013 mm
(1.8095 .0005 inch)
Diameter of valve seat insert (exhaust
valve) .................................. 43.390 0.015 mm
(1.7083 .0006 inch)
Bore in cylinder head for valve seat insert
(exhaust valve) ................... 43.320 0.025 mm
(1.7055 .0010 inch)
(11) Angle of valve face

Angle of the face of the inlet
valve ................................. 29 1/4 1/4 degrees
Angle of the face of the exhaust
valve ................................. 44 1/4 1/4 degrees
(12) Minimum thickness of the valve lip

Inlet valve .......................... 2.51 mm (.099 inch)
Exhaust valve .................... 2.03 mm (.080 inch)
g00472047
Illustration 23
(13) Maximum variation of the valve stem length

Inlet valve to inlet valve ..... 0.66 mm (.026 inch)
Exhaust valve to exhaust valve ............ 0.66 mm
(.026 inch)
13
i01234015
Cylinder Head
SMCS Code: 1100
g00280510
Illustration 24
Note: Lubricate the bolt threads, the underside of 6. Tighten bolt (1) through bolt (26) again in a
the bolt heads, and the washers with 6V-4876 numerical sequence.
Lubricant prior to assembly.
Tighten the bolts again to the following
Use the following procedure in order to tighten the torque. .................. 160 15 Nm (120 11 lb ft)
cylinder head bolts:
1. Tighten bolt (1) through bolt (26) in a numerical Rotate bolt (1) through bolt (26) in a numerical
sequence. sequence.
Tighten the bolts to the following Rotate the bolts in the clockwise
torque. .................. 160 15 Nm (120 11 lb ft) direction. ............................ 90 degrees (1/4 turn)
2. Tighten bolt (1) through bolt (26) again in a 8. Tighten bolt (27) through bolt (33) in a numerical
numerical sequence. sequence.
Tighten the bolts again to the following Tighten the bolts to the following
torque. .................. 160 15 Nm (120 11 lb ft) torque. .......................... 28 7 Nm (20 5 lb ft)

Rotate bolt (1) through bolt (26) in a numerical
sequence.

direction. ............................ 90 degrees (1/4 turn)
4. Loosen bolt (1) through bolt (26) until the

5. Tighten bolt (1) through bolt (26) in a numerical

sequence.

g00284618
torque. .................. 160 15 Nm (120 11 lb ft) Illustration 25
View A-A
14
(34) The cup plugs are measured from the head

face to the top edge of the plug. Depth of
installation ................................. 1.25 0.25 mm
(0.049 0.010 inch)
Height of new cylinder head ...... 105.00 0.15 mm

(4.134 0.006 inch)
Minimum permissible thickness of cylinder

head ................................... 104.35 mm (4.108 inch)
Note: The flatness of the cylinder head should be

within 0.15 mm (0.006 inch). The flatness should
also be a maximum of 0.05 mm (0.002 inch) for any
150.00 mm (5.906 inch) span.
i01532595
Compression Brake
SMCS Code: 1119; 1129
g00517803
Illustration 27
(2) Locknut
torque. ........................ 35 8 Nm (26 6 lb ft)
(3) Slave piston adjustment screw
(4) Hold-down nut

Tighten the hold-down nuts to the following
torque. .................... 80 15 Nm (60 11 lb ft)
g00517802
Illustration 26
(5) Stud
Tighten the studs to the following
torque. .................. 100 20 Nm (75 15 lb ft)
Note: Prior to installation of the compression

recommended torque.
(6) Slave piston
(7) Slave piston lash setting
Note: The valve lash must be adjusted before

adjusting the slave piston lash.
15
Table 1 (17) Inlet valve bridge

C-10 0.64 mm (.025 inch)
C-12 1.02 mm (.040 inch) i00996636
Adjust the slave piston lash while the engine is

Turbocharger
stopped and the exhaust valves are closed. SMCS Code: 1052
Refer to the Testing and Adjusting, Compression S/N: 3CS1-Up
(9) Screw assembly

Apply 4C-9507 Retaining Compound to the
threads of the screw assembly.
torque. ........................ 25 7 Nm (18 5 lb ft)
(10) Exhaust valves
(11) Solenoid valve

There are two different designs of solenoid Illustration 28
g00509170
valves. The difference can be determined by the
Typical example of a turbocharger with a wastegate
number of points on the head of the solenoid
(1) Clamps
solenoid valve.
Tighten the solenoid valve with a twelve point To tighten clamps (1) on the turbocharger, use the
head to the following torque. .. 12.5 Nm (9 lb ft) following procedure:
Tighten the solenoid valve with a six point head
to the following torque. ........... 20 Nm (15 lb ft) 1. Tighten the clamp.
(12) Bolt Tighten the clamp to the following

torque. .......................... 14 1 Nm (10 1 lb ft)
torque. ...................... 55 10 Nm (41 7 lb ft) 2. Gently tap the clamp with a soft faced hammer.
(13) Spacer 3. Again tighten the clamp.
torque. .................. 100 20 Nm (75 15 lb ft) Tighten the clamp to the following
torque. .......................... 14 1 Nm (10 1 lb ft)
(14) Bolt
(2) Wastegate
torque. .................. 100 20 Nm (75 15 lb ft) Opening pressure of the
wastegate .................. 165 3 kPa (24 .5 psi)
(15) Head bolt stud
Refer to the Specifications, Cylinder Head topic

for the tightening procedure.
(16) Locknut
Tighten the locknut on the rocker arm
for the exhaust valve to the following
torque. ........................ 25 7 Nm (18 5 lb ft)
Tighten the locknut on the rocker arm for the
inlet valve to the following torque. ... 25 7 Nm
(18 5 lb ft)
16
i01530963 i00996812
Turbocharger Turbocharger
S/N: 3CS1-Up S/N: 2KS1-Up
g00403599 g00403601
Typical example Typical example of a turbocharger with a wastegate
(1) Clamp (1) Clamp
To tighten the clamp (1) on the turbocharger, use To tighten the clamp (1) on the turbocharger, use
the procedure that follows. the procedure that follows.
1. Tighten the clamp bolts. 1. Tighten the clamp.
Tighten the clamp bolts to the following Tighten the clamp to the following
torque. .......................... 14 1 Nm (10 1 lb ft) torque. ....................................... 18 Nm (13 lb ft)
2. Gently tap the clamps with a soft faced hammer. 2. Loosen the clamp.
3. Again tighten the clamp bolts. Loosen the clamp to the following torque. .. 6 Nm
(4 lb ft)
Tighten the clamp bolts to the following
torque. .......................... 14 1 Nm (10 1 lb ft) 3. Tighten the clamp.

torque. .......................... 14 1 Nm (10 1 lb ft)
(2) Clamp
torque. ........................ 14 1 Nm (10 1 lb ft)
(3) Waste gate

Opening pressure of the waste
gate ........................ 156 3 kPa (22.6 .5 psi)
17
i01529586 i01193540
Turbocharger Inlet Manifold

S/N: CPD1-Up
g00638757
Illustration 32
g00403599
(1) Air inlet manifold
Illustration 31 (2) Long bolts
Typical example (3) Short bolts
(1) Clamp Two different lengths of mounting bolts are used.

There are six long bolts and six shorter bolts that
To tighten the clamp (1) on the turbocharger, use are used on this engine. Be sure that the correct
the procedure that follows. length of bolt is installed in the correct hole.
1. Tighten the clamp. Tighten the mounting bolts to the following

torque: ............................ 55 10 Nm (40 7 lb ft)
torque. ....................................... 18 Nm (13 lb ft) i00816699
2. Loosen the clamp. Exhaust Manifold

Loosen the clamp to the following torque. .. 6 Nm SMCS Code: 1059
(4 lb ft)

torque. .......................... 14 1 Nm (10 1 lb ft)
g00389694
Illustration 33
Engine exhaust flange that utilizes four studs

stud threads. Tighten the studs to the following
torque. ........................ 35 5 Nm (26 4 lb ft)

torque. ...................... 55 10 Nm (41 7 lb ft)
18
(3) Apply 5P-3931 Anti-Seize Compound to the Inlet lobe ...................... 11.371 mm (.4477 inch)
stud threads. Tighten the studs to the following Injector lobe ................ 11.023 mm (.4340 inch)
torque. ........................ 35 5 Nm (26 4 lb ft)
i00816918
(8) Base circle
Camshaft Specified base circle (8)
SMCS Code: 1210 Exhaust lobe ... 55.0 0.4 mm (2.17 .02 inch)
S/N: 3CS1-Up Inlet lobe ......... 51.0 0.4 mm (2.01 .02 inch)


camshaft ............................... 0.13 mm (.005 inch)
g00466006
Illustration 34
i00816964
Camshaft
journals ............................... 74.850 0.025 mm SMCS Code: 1210
(2.9468 .0010 inch)
S/N: CPD1-Up
(3) Key
S/N: 2KS1-Up
(4) Part number
(5) Gear
g00466006
Illustration 36

g00466107
Illustration 35
journals ............................... 74.850 0.025 mm
(2.9468 .0010 inch)
(3) Key
19
(4) Part number
(5) Gear
g00466107
Illustration 37

(8) Base circle
Specified base circle (8)



camshaft ............................... 0.13 mm (.005 inch)
20
i01529498
Engine Oil Filter Base

SMCS Code: 1306
g00793983
Illustration 38
(1) Cover Load at assembled length ........ 39.7 N (8.92 lb)

(2) Oil filter base Outside diameter ................. 20.6 mm (.81 inch)
(3) Oil filter (7) Seal
(4) Bolts (six total) (8) Plunger
Apply 9S-3263 Thread Lock to each of the six (9) Seal

bolts.
(10) Stud
Tighten the stud that holds the oil filter to the oil
filter base to the following torque. ... 68 7 Nm
(50 5 lb ft)
g00473681
Illustration 39
Section A-A
(5) Seal
g00473768
(6) 8M-3182 Spring Illustration 40
Section B-B
21
(11) 2N-6005 Spring

Load at assembled length ...... 92.5 N (20.80 lb)
Minimum operating length ................... 45.7 mm
(1.80 inch)
Load at minimum operating length ....... 257.6 N
(57.91 lb)
Free length after test ....... 124.7 mm (4.91 inch)
(12) Valve
(13) Seal
g00794005
(14) Seal Illustration 42
Section D-D
(18) 8M-3182 Spring

Load at assembled length ........ 39.7 N (8.92 lb)
(19) Plunger
(20) Seal
i01532602
g00473770
Illustration 41 Engine Oil Filter
Section C-C
SMCS Code: 1318
Relief pressure ............................. 696 kPa (101 psi)
(15) Spacer
(16) 1A-2170 Spring
Assembled length ............... 21.4 mm (.84 inch)

Load at assembled length ......... 198.0 13.4 N
(45 3.5 lb)
(17) Seal
g00795574
Illustration 43
Check that the adapter (2) is still secure in the oil

filter base (1).
Lubricate the seal (3) of the new engine oil filter (4)
with clean engine oil. Ensure that the engine oil filter
is threaded squarely on the adapter (2). The engine
oil filter is hand tightened only.
22
i01532604
Engine Centrifugal Oil Filter

SMCS Code: 1328
g00795578
Illustration 44
(1) Centrifugal oil filter
(2) Adapter assembly

Tighten the adapter assembly to the following
torque. ........................ 47 7 Nm (35 5 lb ft)
(3) Cover assembly

Tighten the cover assembly to the following
torque. ........................ 20 3 Nm (15 2 lb ft)
i01532608
Engine Oil Cooler

SMCS Code: 1378
g00795586
Illustration 45
23
(1) Apply 5P-3413 Pipe Sealant to the plug

threads.
(2) Water pump
(3) Core assembly
g00534649
Illustration 48
Detail B
The oil flow rate through the cooler assembly is

123 L/min (32 US gpm). The maximum water
flow through the cooler assembly is 262 L/min
g00534638
Illustration 46 (69 US gpm).
Section A-A
Lubricate the core with engine oil. Press the core
(4) Install the hose clamps at the following into the housing to the following dimensions at both
angle. ......................................... 30 5 degrees ends.
(6) The depth of the plate is the following

value. .............. 5.5 0.5 mm (0.22 0.02 inch)
(7) The depth of the tube is the following

value. .............. 1.5 0.5 mm (0.06 0.02 inch)
i01039752
Engine Oil Pump

SMCS Code: 1304
g00534648
Illustration 47
(5) Core assembly
g00280778
Illustration 49
NOTICE
Before operating the engine, the oil pump must be
lubricated with clean engine oil. The oil pump must
turn freely by hand. Damage to the drive gear and
internal pump damage can occur if the oil pump is not
lubricated with clean engine oil.
24
Engine oil pump Minimum engine oil pressure at low idle (600 rpm to
800 rpm) .......................................... 68 kPa (10 psi)
Oil type ................................................... SAE 30
Oil temperature .............................. 50C (122F)
Pump speed ........................................ 3000 rpm i00887123
Oil pressure ............................. 359 kPa (52 psi)
Minimum oil flow ........... 185 L/min (49 US gpm) Engine Oil Pan
(1) Diameter of two shafts ....... 18.000 0.005 mm SMCS Code: 1302
(.7087 .0002 inch)
Bores in pump body for two

shafts ...... 18.050 0.010 mm (.7106 .0004 inch)
(2) Seal groove
Prior to installation, lubricate the bore in the engine

front cover. This will allow the seal groove and the
seal to slide.
(3) Drive gear

In order to install the drive gear, heat the drive
gear to the following temperature. .......... 316 C g00280790
(600 F) Illustration 50
Center Sump
(4) Pump gears
(1) Oil pan
In order to install the pump gears, heat the pump
gears to the following temperature. ........ 316 C (2) Tighten the plugs to the following
(600 F) torque. .................... 70 15 Nm (50 11 lb ft)
Length of new gears .......... 50.000 0.025 mm (3) Apply 9S-3263 Thread Lock Compound to
(1.9685 .0010 inch) plug threads. Tighten the plug to the following
Depth of bores in pump body for the torque. ...................... 80 11 Nm (60 8 lb ft)
gears ...... 50.13 0.02 mm (1.974 .001 inch)
i00947454
(5) Seal
Engine Oil Pan
(6) Distance between front face of gear and
housing ... 29.40 0.50 mm (1.158 .020 inch) SMCS Code: 1302
i00817005
Engine Oil Pressure

SMCS Code: 1924
Operate the engine in order to achieve the normal

operating temperature. When the engine has
achieved the normal operating temperature, the
engine oil temperature should be no greater than
110C (230F). The engine oil temperature should
be measured after the engine oil has passed
through the engine oil cooler.
g00483624
Illustration 51
Check the engine oil pressure in the oil gallery that
Shallow Front Sump
is located on the right side of the cylinder block.
Engine oil pressure under full load conditions (1400 (1) Engine oil pan
rpm to 1800 rpm) ...... 275 to 414 kPa (40 to 60 psi)
25
(2) Tighten the plugs to the following (1) Engine oil pan
torque. .................... 70 15 Nm (50 11 lb ft)
(2) Tighten the plugs to the following
(3) Apply 9S-3263 Thread Lock Compound to the torque. .................... 70 15 Nm (50 11 lb ft)
torque. ...................... 80 11 Nm (60 8 lb ft) (3) Apply 9S-3263 Thread Lock Compound to the
torque. ...................... 80 11 Nm (60 8 lb ft)
i00817425
Engine Oil Pan i01335616
SMCS Code: 1302 Crankcase Breather

SMCS Code: 1317
g00390433
Illustration 52
Rear Sump
g00638734
Illustration 54
(1) Engine oil pan
(1) Tighten the hose clamp to the following
(2) Apply 9S-3263 Thread Lock Compound to the torque. ................... 3.0 0.5 Nm (27 4 lb in)
torque. ...................... 80 11 Nm (60 8 lb ft) (2) Tighten the bolts for the crankcase breather
cover to the following torque. .......... 12 3 Nm
(3) Tighten the plugs to the following (9 2 lb ft)
torque. .................... 70 15 Nm (50 11 lb ft)
(3) Crankcase breather cover
i00947495
Engine Oil Pan

SMCS Code: 1302
g00390460
Illustration 53
Deep Front Sump
26
i00818610 i00817649
Coolant Conditioner Base Water Temperature Regulator

g00391440 g00390592
(1) Apply 9S-3263 Thread Lock Compound on (1) Install the lip type seal into the water temperature
the tapered end of the stud to the following regulator housing. Lubricate the sealing lip
distance. ................................ 7.6 mm (.30 inch) on the lip type seal with a small amount of
antifreeze.
(2) Tighten the stud to the following
torque. ........................ 60 7 Nm (44 5 lb ft) (2) Minimum stroke of the water temperature
(0.41 inch)
(3) Fully open temperature of the water temperature

regulator ......................................... 98C (208F)
i01529173
Water Pump
SMCS Code: 1361
g00639752
Illustration 57
27
(1) Tighten the bolt to the following (1) The dowels extend past the end of the cylinder
torque: ...................... 55 10 Nm (41 7 lb ft) block by the following distance. ... 10 0.5 mm
(.39 .02 inch)
(2) Bearing retaining ring
(3) Bearings block by the following distance. .. 10.0 0.5 mm
(.39 .02 inch)
(4) Water pump drive gear
(3) Cylinder liner
(5) Water pump housing
(6) Impeller cover

Tighten the bolts for the impeller cover to the
following torque: ......... 18 3 Nm (13 2 lb ft)
(7) Impeller
Note: The impeller is pressed onto shaft (8). The

face of the impeller is flush to the end of the shaft.
(8) Shaft
(9) The clearance between the impeller and the

impeller cover Illustration 59
g00488509
Section A-A
(10) The clearance between the impeller and
the water pump housing is the following Bore diameters in the cylinder block for the cylinder
dimension: ................................ 0.94 0.47 mm block liners:
(0.037 0.019 inch)
Position (A) ........................... 151.50 0.03 mm
Note: Clearance (9) and clearance (10) are preset (5.965 .001 inch)
once the impeller is pressed onto the shaft. Position (B) ............................... 149.8 0.3 mm
(5.898 0.012 inch)
(11) The clearance between the water pump Position (C) ........................... 148.00 0.03 mm
housing and the water pump drive gear is the (5.827 .001 inch)
following dimension: ............ 2.8 mm (0.11 inch) Position (D) ........................... 141.90 0.15 mm
(5.587 .006 inch)
Note: Clearance (11) is preset once the bearings
are tightened against the water pump drive gear.
i00961882
Cylinder Block
SMCS Code: 1201
g00488517
Illustration 60
g00488511
Illustration 58
28
(4) The dowels extend past the top surface (11) Bore in the cylinder block for the seven main
of the cylinder block by the following bearings ........................... 116.000 0.013 mm
distance. ........... 10.0 0.5 mm (.39 .02 inch) (4.5669 .0005 inch)

bore to the top surface of the cylinder
block .......................... 387.00 mm (15.236 inch)
(6) Diameter of the camshaft

bores .................................. 81.000 0.015 mm
(3.1890 .0006 inch)
(7) Bolt
Tighten the bolt that holds the piston cooling jet
to the following torque. .................... 35 3 Nm
(26 2 lb ft)
The flatness of the top contact surface of the Illustration 61 g00283161

cylinder block must be within 0.05 mm (.002 inch) View B-B
for any 150 mm (5.9 inch) section of the surface.
The camshaft bearings are installed into the cylinder
(8) Width of the main bearing block at the values that follow.
cap ................................... 175.000 0.020 mm
(6.8898 .0008 inch) Position (A) .................... 35.20 mm (1.386 inch)
Position (B) .................. 191.20 mm (7.528 inch)
Width in cylinder block for the main bearing Position (C) ................ 347.20 mm (13.669 inch)
cap ...... 175.000 0.018 mm (6.8898 .0007 inch) Position (D) ................ 503.20 mm (19.811 inch)
Position (E) ................ 659.20 mm (29.953 inch)
(9) Distance from the centerline of the crankshaft Position (F) ................ 815.20 mm (32.094 inch)
to the bottom surface of the cylinder Position (G) ................ 954.10 mm (37.563 inch)
block ................................ 120.0 mm (4.72 inch)
NOTICE
(10) Main bearing cap bolts
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
Use the following procedure in order to install the
main bearing cap bolts:
1. Orient the main bearing cap correctly. The part

number on the main bearing cap must face to
the right and to the front face of the block. Also,
the tab slots that are in the block and the main
bearing caps must be adjacent.
Note: The main bearing caps are marked with

identification numbers 1 through 7. Install the main
bearing caps into the correct positions.
2. Lubricate the main bearing cap bolts. Use SAE

30W oil or molybdenum grease to lubricate the
threads and the washer face.
g00283162
Illustration 62
3. Tighten the main bearing cap bolts. View C-C
Tighten bolts to the following torque. .. 95 5 Nm Note: Illustration 62 represents camshaft bearing 7.
(70 4 lb ft)
(12) Bearing joint
4. Put an alignment mark on each cap and bolt.
(A) Bearing oil hole at a 45 degree angle
direction. ..................................... 90 5 degrees
29
i01009618
Cylinder Liner
SMCS Code: 1216
S/N: 3CS1-Up
g00391637
Illustration 63
View D-D
Note: Illustration 63 represents camshaft bearings 2

through 6.
(13) Bearing joint
(14) Oil hole
g00517737
Illustration 65
Outside diameters of the cylinder liner

Position (A) ........................... 151.25 0.05 mm
(5.955 .002 inch)
Position (B) ........................... 147.90 0.03 mm
(5.823 .001 inch)
Position (C) ........................... 141.38 0.08 mm
(5.566 .003 inch)
g00391638 Bore diameter for the cylinder
Illustration 64
View E-E liner ..... 125.037 0.037 mm (4.9227 .0015 inch)
Note: Illustration 64 represents camshaft bearing 1. Note: Apply 5P-3975 Rubber Lubricant to the
cylinder liner seal prior to assembly.
(15) Bearing joint
(16) Oil hole
Note: The width of the number 1 through number 6

camshaft bearing is 33.4 0.5 mm (1.32 .02 inch).
The width of the number 7 camshaft bearing is
28.0 0.5 mm (1.10 .02 inch). The number
1 camshaft bearing has a 5.0 0.5 mm
(.20 .02 inch) wide single groove on the inside
diameter of the camshaft bearing. The width of
the single groove on the outside diameter of
camshaft bearings 2 through 6 is 8.0 0.5 mm
(.32 .02 inch). A single groove is on the outside
diameter of the number 7 camshaft bearing.
30
i01009387 i00819393
Cylinder Liner Cylinder Liner Projection

S/N: CPD1-Up Table 2
S/N: 2KS1-Up Specifications

Liner Projection 0.040 to 0.200 mm
(.0016 to .0079 inch)
Maximum Variation in Each
0.050 mm (.0020 inch)
Liner
Maximum Average
Variation Between 0.050 mm (.0020 inch)
Adjacent Liners
Maximum Variation
0.100 mm (.0040 inch)
Between All Liners
For more information on the cylinder liner projection,

refer to Testing and Adjusting, Basic Block.
i01532691
Crankshaft
SMCS Code: 1202
g00517737
Illustration 66
Outside diameters of the cylinder liner

Position (A) ........................... 151.25 0.05 mm
(5.955 .002 inch)
Position (B) ........................... 147.90 0.03 mm
(5.823 .001 inch)
Position (C) ........................... 141.38 0.08 mm
(5.566 .003 inch)
Bore diameter for the cylinder

liner ..... 130.037 0.037 mm (5.1196 .0015 inch)
g00632466
Note: Apply 5P-3975 Rubber Lubricant to the Illustration 67
cylinder liner seal prior to assembly. 3CS1-11999 and 2KS1-39999
31
i00959950
Crankshaft Seals
SMCS Code: 1160; 1161
g00632462
Illustration 68
3CS12000-UP, 2KS40000-UP, and CPD1-UP
(1) Main bearing journals

g00281016
The thrust plate is used on the center main bearing Illustration 69
only. (A) Rear
(B) Front
(2) Connecting rod bearing journals
(3) Gear
In order to install the gear, heat the gear to the
following temperature. ............... 210 C (410 F)
Note: Heat the gear for no more than one hour.
(4) Average diameter of gear after

assembly .............................. 136.20 0.11 mm
(5.362 .004 inch)
Maximum diameter of gear after

assembly ........................... 136.36 mm (5.368 inch)
g00489560
Illustration 70
Note: After the crankshaft is assembled into Rear seal group
the block, the crankshaft end play should be a
maximum of 0.50 mm (.020 inch) and a minimum Note: Install the front crankshaft seals and the rear
of 0.10 mm (.004 inch). crankshaft seals dry.
(5) Plate assembly (sensor) (1) Flywheel housing
Note: The crankshaft for Engines (S/N: 3CS1-11999) (2) Seal group cover
and (S/N: 2KS1-39999) has a sensor plate that is
attached to the crankshaft gear. (3) Seal group
(4) Crankshaft
(5) Rear face of cylinder block
(6) Bolt

torque. ................................ 12 3 Nm (9 2 lb ft)
(7) O-ring seal

32
Lightly lubricate the O-ring seal. Use the lubricant i01003510

i00826094
Journal
Vibration Damper and Pulley SMCS Code: 1202; 1219; 1225
SMCS Code: 1205 S/N: 3CS1-Up

Table 3
Connecting Rod Bearing Journal
(3.2283 .0008 inch)
0.508 mm (.0200 inch) (3.2083 .0008 inch)
0.762 mm (.0300 inch) (3.1983 .0008 inch)

(.0018 to .0046 inch)
i01003512

Journal
g00398558
Illustration 71 SMCS Code: 1202; 1219; 1225
Typical Example
S/N: CPD1-Up
(1) Damper assembly
S/N: 2KS1-Up
(2) Pulley Table 4
(3) Crankshaft Connecting Rod Bearing Journal

(4) Tighten the bolts to the following (3.5039 .0008 inch)
torque. ................ 240 40 Nm (175 30 lb ft)
0.508 mm (.0200 inch) (3.4839 .0008 inch)
torque. ...................... 55 10 Nm (41 7 lb ft) Undersize journal 87.238 0.020 mm
0.762 mm (.0300 inch) (3.4346 .0008 inch)

(.0024 to .0052 inch)
33
i00819737 i00962517
Main Bearing Journal Connecting Rod

SMCS Code: 1202; 1203 SMCS Code: 1218
Table 5 S/N: 3CS1-Up
(4.2520 .0008 inch)
0.508 mm (.0200 inch) (4.2320 .0008 inch)
0.762 mm (.0300 inch) (4.2220 .0008 inch)

(.0032 to .0071 inch)
Table 6
Main Bearing Bore
Main bearing bore (original 116.000 0.013 mm
size) (4.5669 .0005 inch)
Oversize bore in block 116.508 0.013 mm
0.508 mm (.0200 inch) (4.5869 .0005 inch)
g00490254
Illustration 72

bearing ............................... 55.435 0.013 mm
(2.1825 .0005 inch)

a torch.

rod ..................................... 85.0 mm (3.35 inch)

pin ... 50.830 0.008 mm (2.0012 .0003 inch)
Diameter of the piston pin ........ 50.795 0.005 mm

(2.0000 .0002 inch)
34
Thoroughly lubricate the piston pin with clean i00962529

engine oil prior to assembly of the piston and
connecting rod. Connecting Rod
(4) The bearing joint must be within 10 degrees SMCS Code: 1218
of either location.
S/N: CPD1-Up
(5) Distance between the center of the S/N: 2KS1-Up
bearings ...................... 247.00 mm (9.724 inch)



1. Before installing the connecting rod bolts,

lubricate the bolt threads and the seating faces
of the caps with 4C-5593 Anti-Seize Compound.
2. Tighten the connecting rod bolts.

torque. ........................ 130 7 Nm (95 5 lb ft)
3. Tighten each connecting rod bolt for an

additional amount.

direction. .............. 60 5 degrees (1/6 of a turn)
(8) Bore in the connecting rod for the crankshaft

bearing ............................... 86.800 0.013 mm
(3.4173 .0005 inch)
g00490254
Illustration 73

bearing ............................... 57.810 0.013 mm
(2.2760 .0005 inch)

a torch.

rod ..................................... 85.0 mm (3.35 inch)

pin ... 53.205 0.008 mm (2.0947 .0003 inch)
35

(2.0933 .0002 inch)
Piston and Rings
engine oil prior to assembly of the piston and SMCS Code: 1214; 1215
connecting rod.
S/N: 3CS1-Up
of either location.

bearings ...................... 242.50 mm (9.547 inch)


g00283705
Illustration 74
NOTICE
1. Before installing the connecting rod bolts, The piston pin plug prevents the piston pin from scuff-
lubricate the bolt threads and the seating faces ing the cylinder wall. The piston pin plug does not re-
of the caps with 4C-5593 Anti-Seize Compound. tain the piston pin into the assembly. Once the piston
assembly is removed from the cylinder liner, the pis-
2. Tighten the connecting rod bolts. ton pin is free to fall out of the piston assembly at any
time.
torque. ........................ 130 7 Nm (95 5 lb ft) (1) The piston is symmetrical with a center crater.
3. Tighten each connecting rod bolt for an Lubricate the entire piston in zone (A) prior to
additional amount. assembly into the cylinder block. Use clean engine
oil.
direction. .............. 60 5 degrees (1/6 of a turn) (2) Top piston ring
(8) Bore in the connecting rod for the crankshaft Install the piston ring with the side marked
bearing ............................... 93.800 0.013 mm UP-1 toward the top of the piston. The red
(3.6929 .0005 inch) stripe faces to the right of the piston ring end
gap.
Clearance ............................. 0.625 0.185 mm
(.0250 .0073 inch)
(.004 inch)
the top ring ........................ 5.43 mm (.214 inch)
(3) Intermediate piston ring

36
Install the piston ring with the side marked Piston pin bore diameter that is in the bearing of the
UP-2 toward the top of the piston. The blue crown assembly ....................... 50.830 0.008 mm
stripe faces to the right of the piston ring end (2.0012 .0003 inch)
gap.
Width of groove in new piston for intermediate Thoroughly lubricate the piston pin with clean
piston ring ............................ 3.061 0.013 mm engine oil prior to assembly.
(.1205 .0005 inch)
Minimum depth of groove in new piston for (7) Piston skirt
Thickness of new intermediate piston i00959202
ring ..... 2.988 0.013 mm (.1176 .0005 inch)
Clearance between groove and intermediate Piston and Rings
piston ring ............................ 0.047 to 0.099 mm
(.0019 to .0039 inch) SMCS Code: 1214; 1215
when the piston ring is installed in a cylinder S/N: CPD1-Up
S/N: 2KS1-Up
Clearance ............................. 0.625 0.125 mm
(.0246 .0049 inch)
(.004 inch)

assembled. The orange colored portion of the
Width of groove in new piston for oil control
piston ring ............................ 4.033 0.013 mm Illustration 75 g00283705
(.1588 .0005 inch)
Minimum depth of groove in new piston for oil
NOTICE
control piston ring ......... 3.727 mm (.1467 inch)
The piston pin plug prevents the piston pin from scuff-
Thickness of new oil control piston
ing the cylinder wall. The piston pin plug does not re-
ring ..... 3.987 0.013 mm (.1570 .0005 inch)
tain the piston pin into the assembly. Once the piston
Clearance between groove and oil control piston
assembly is removed from the cylinder, the piston pin
ring .... 0.020 to 0.072 mm (.0008 to .0028 inch)
is free to fall out of the piston assembly at any time.
liner with a bore of 125.000 mm (4.9213 inch). (1) The piston is symmetrical with a center crater.
Clearance ... 0.44 0.15 mm (.017 .006 inch)
The piston ring has an increase in clearance Lubricate the entire piston in zone (A) prior to
for each 0.03 mm (0.001 inch) increase in the assembly into the cylinder block. Use clean engine
cylinder liner bore. Increase ................ 0.09 mm oil.
(.004 inch)
(2) Top piston ring
piston rings so that the end gaps are 120 degrees Install the piston ring with the side marked
from each other. UP-1 toward the top of the piston. The green
(5) Crown assembly gap.
(6) Piston pin bore diameter that is in the piston when the piston ring is installed in a cylinder
skirt .. 50.815 0.005 mm (2.0006 .0002 inch) liner with a bore of 130.000 mm (5.1181 inch).
Clearance ............................. 0.520 0.125 mm
(.0205 .0049 inch)
37
The piston ring has an increase in clearance (6) Piston pin bore diameter that is in the piston
for each 0.03 mm (.001 inch) increase in the skirt .. 53.190 0.005 mm (2.0941 .0002 inch)
(.004 inch) Piston pin bore diameter that is in the bearing of the
Minimum depth of the groove in new piston for crown assembly ....................... 53.205 0.010 mm
the top ring ........................ 5.43 mm (.214 inch) (2.0947 .0004 inch)
(3) Intermediate piston ring Thoroughly lubricate the piston pin with clean
Install the piston ring with the side marked
UP-2 toward the top of the piston. The red (7) Piston skirt
gap.
i01196515
Width of groove in new piston for intermediate
piston ring ............................ 3.052 0.013 mm
(.1202 .0005 inch)
Piston Cooling Jet
Minimum depth of groove in new piston for SMCS Code: 1331
Thickness of new intermediate piston
ring ..... 2.950 0.013 mm (.1161 .0005 inch)
Clearance between groove and intermediate
piston ring ............................ 0.076 to 0.128 mm
(.0030 to .0050 inch)
Clearance ............................. 0.625 0.125 mm
(.0246 .0049 inch)
(.004 inch)
g00640160
Illustration 76
(1) Piston cooling jet
be a distance of 180 degrees from the ring The piston cooling jets (1) must be checked for the
end gap when the oil control piston ring is location of the stream of oil. Insert a drill rod with a
assembled. The white colored portion of the diameter of 2 mm (0.08 inch) into the orifice. This
piston ring must be visible at the ring end gap. drill rod simulates the stream of oil under normal
Width of groove in new piston for oil control operating pressure. The drill rod must pass through
piston ring ............................ 4.042 0.012 mm a circle with a diameter of 10 mm (0.40 inch) at
(.1591 .0005 inch) point (A). Place the drill rod in the second orifice.
Minimum depth of groove in new piston for oil The drill rod must pass through a circle with a
control piston ring ......... 3.727 mm (.1467 inch) diameter of 10 mm (0.40 inch) at point (B). The
Thickness of new oil control piston circles are located at dimension (F).
ring ..... 3.987 0.013 mm (.1570 .0005 inch)
Clearance between groove and oil control piston Use the following dimensions in order to locate
ring .... 0.030 to 0.080 mm (.0012 to .0031 inch) point (A) and point (B).
when the piston ring is installed in a cylinder Dimension (C) ...................... 53 mm (2.09 inch)
liner with a bore of 130.000 mm (5.1181 inch). Dimension (D) ...................... 10 mm (0.40 inch)
Clearance ... 0.44 0.15 mm (.017 .006 inch) Dimension (E) ....................... 29 mm (1.14 inch)
The piston ring has an increase in clearance Dimension (F) ....................... 162 mm (6.4 inch)
for each 0.03 mm (.001 inch) increase in the Dimension (G) ..................... 4.4 mm (0.17 inch)
(.004 inch)

piston rings so that the end gaps are 120 degrees
from each other.
(5) Crown assembly

38
i01181482
Housing (Front)
SMCS Code: 1151
g00640162
Illustration 77

torque: ........................ 35 3 Nm (26 2 lb ft)
i01532015
Accessory Drive (Air

Compressor) Illustration 79 g00281150
3CS1-11999 and 2KS1-39999

SMCS Code: 1207
g00795314
Illustration 78
(1) Air compressor
(2) Accessory drive gear (Air compressor)
(3) Tighten the air compressor shaft nut to the Illustration 80

g00632577
following torque. .. 460 60 Nm (340 44 lb ft) 3CS12000-UP and 2KS40000-UP
(4) Air compressor gear holder (1) Bolt

torque. ........................ 28 7 Nm (20 5 lb ft)
(2) Bolt
Tighten the 13 bolts to the following
torque. ........................ 35 8 Nm (26 6 lb ft)
39
(3) O-ring seal and crankshaft front seal
The O-ring seal and the crankshaft front seal are

part of the front housing. Lubricate the O-ring seal
lightly. Use the lubricant that is being sealed.
(4) Accessory drive assembly
g00281151
Illustration 81
View A-A

distance. ............. 5.0 0.5 mm (.20 .02 inch)
g00281152
Illustration 82
View B-B

distance. ........... 10.0 0.5 mm (.39 .02 inch)
Note: Apply 8T-9022 Silicone Gasket in order to

fill the space at the connecting joint of the front
housing, engine oil pan, and cylinder block.
40
i00820827
Gear Group (Front)

SMCS Code: 1206
g00281161
Illustration 83
(1) Diameter of gear bore for (8) Front face of the block
bearing ............................... 60.163 0.015 mm
(2.3686 .0006 inch) (9) Camshaft idler gear
Diameter of shaft for idler gear .. 55.047 0.020 mm Diameter of gear bore for
(2.1672 .0008 inch) bearing .. 74.452 0.015 mm (2.9312 .0006 inch)
(2) Idler gear Diameter of shaft for idler gear .. 69.141 0.008 mm
(2.7221 .0003 inch)
(3) Front face of the block
(10) Crankshaft gear
(4) Camshaft gear
(11) Crankshaft
(5) Front timing gear housing
(6) Tighten the bolts to the following torque. .................. 100 20 Nm (75 15 lb ft)
torque. ................ 240 40 Nm (175 30 lb ft)
(13) Align the timing marks that are on the idler
(7) Camshaft gear with the timing marks that are on the
crankshaft gear and the camshaft gear.
41
i00962846

SMCS Code: 1165-RE
g00281162
Illustration 84
Typical example of the gear assembly for the idler gears
(14) Inside diameter of bearing that is installed in

idler gear (2) ...................... 55.163 0.041 mm
(2.1718 .0016 inch)
Inside diameter of bearing that is installed in

camshaft idler gear (9) ............. 69.205 0.013 mm
(2.7246 .0005 inch)
(15) Bearing
(16) Install the bearing in the idler gear (2) to the

following depth. ........................ 1.00 0.25 mm
(.039 .010 inch)
Install the bearing in the camshaft idler gear (9) to g00490893

the following depth. ........................ 1.00 0.25 mm Illustration 85
(.039 .010 inch)
g00403946
Illustration 86
(1) Output shaft (PTO)

Diameter of the output shaft
(A) ... 60.245 0.025 mm (2.3718 .0010 inch)
End play of the output shaft .... 0.97 0.43 mm
(.038 .017 inch)
(2) Carrier bearing housing
(3) Carrier bearing

42
The carrier bearing should be installed to

the following depth (B) in the carrier bearing
housing. .............. 1.6 0.5 mm (.06 .02 inch)
When the engine is viewed from the rear,
the split in the bearing should be located
counterclockwise from the center of the top bolt
at the following angle. ........... 112 10 degrees
(4) Drive gear

Inside diameter of the drive
gear .................................... 60.320 0.025 mm
(2.3750 .0010 inch)
The clearance between the output shaft (1) and
the drive gear (4) ................. 0.025 to 0.125 mm
g00490894
(.0010 to .0050 inch) Illustration 87
(5) Bearing (11) Bearing
(6) Thrust washer The bearing must not extend beyond either face
of the idler gear.
Thickness of the thrust The relief groove in the bearing must line up
washer .................................. 4.690 0.025 mm with the relief grooves in the idler gear within
(.1846 .0010 inch) the following value. ............................ 2 degrees
(7) Thrust plate
i01012861
Thickness of the thrust plate ................ 6.75 mm
(.266 inch) Flywheel
(8) Thrust washer SMCS Code: 1156
Thickness of the thrust Part No.: 123-0816
washer .................................. 4.690 0.025 mm
(.1846 .0010 inch)
(9) Idler gear

Inside diameter of the idler
gear .... 88.90 0.013 mm (3.500 .0005 inch)
(10) Seal
Lubricate the sealing lip lightly with the lubricant
Install the seal to the following
depth. ................... 2.5 0.5 mm (.1 .02 inch)
g00394357
Illustration 88
43
Refer to the Testing And Adjusting, Basic Block (3) Bolt

topic for the proper procedure to check flywheel
runout. Apply 7M-7456 Compound to the bolt threads.
(1) Flywheel ring gear torque. ................ 300 40 Nm (220 30 lb ft)
The flywheel ring gear must be assembled
against the shoulder (A) of the flywheel. The i00971025
installation .................................. 300 C (572 F) Flywheel Housing
(2) Flywheel SMCS Code: 1157
(3) Bolt
torque. ................ 300 40 Nm (220 30 lb ft)
i01401694
Flywheel
SMCS Code: 1156
Part No.: 117-2774, 123-0815
g00494785
Illustration 90
(2) Apply 1U-8846 Sealant on the gasket surface

of the flywheel housing. Assemble the flywheel
housing to the cylinder block and tighten within
ten minutes of applying the sealant.
(3) Cylinder block
g00738537
Illustration 89
Typical Example

topic for the proper procedure to check flywheel
runout.
(1) Flywheel ring gear

The flywheel ring gear must be assembled
against shoulder (A) of the flywheel. The
installation .................................. 315 C (599 F)
(2) Flywheel
44
i00971769
Flywheel Housing
(Rear Power Take-Off (RPTO))
SMCS Code: 1157
g00496481
Illustration 93
Section B-B
Apply 1U-8846 Sealant on the gasket surface of

the flywheel housing except in area (E). Assemble
the flywheel housing to the cylinder block and
tighten within ten minutes of applying the sealant.
i00826037
Engine to Transmission
g00495004
Adapter
Illustration 91
SMCS Code: 1001
g00496522
Illustration 92
Section A-A
(1) Bearing
The split in the bearing should be located at
angle (A). ................................. 23 10 degrees
The bearing should be installed to depth
g00398205
(C). ...................... 1.5 0.5 mm (.06 .02 inch) Illustration 94
Typical Example
(1) Flywheel
(3) Dowel
(2) Adapter
The dowels should extend beyond the
surface of the flywheel housing by distance (3) Apply 9S-3263 Thread Lock Compound to
(D). ...................... 3.0 0.2 mm (.12 .01 inch) the bolts. Tighten the bolts to the following
torque. ................ 300 40 Nm (220 30 lb ft)
45

torque. .................... 70 15 Nm (51 11 lb ft)
i01211708
Belt Tension Chart

SMCS Code: 1357
Table 7
Belt Tension Chart
Borroughs Gauge
Gauge Reading
Numbers
Belt
of the Old the New
Initial(1) Used(2)
Gauge Gauge
46
i00970973 i00817864
Belt Tensioner Belt Tensioner

g00390952
Illustration 96
Use the following procedure in order to adjust the

belt tensioner:
1. Remove the belt so that there is no tension on

g00494780 the belt tensioner.
Illustration 95
Typical example 2. Align the thick black line on 134-1018 Film (1)
with shoulder (2) of the tensioners arm (3).
(1) Idler pulley assembly
3. Install the belt. Shoulder (2) should be in the
Tighten the idler pulley assembly to the following
green zone of 134-1018 Film (1).
torque. ........................ 50 5 Nm (37 4 lb ft)
(2) Belt tensioner i00817913
(3) Idler pulley assembly Belt Tensioner

Tighten the idler pulley assembly to the following SMCS Code: 1358
torque. ........................ 50 5 Nm (37 4 lb ft)
g00390992
Illustration 97
(1) Plate
Note: Install plate (1) with SIDE A toward the front

of the engine.
47
(2) Tighten the bolts to the following i01176753

torque. ........................ 85 5 Nm (65 4 lb ft)
Belt Tightener
(3) Damper
SMCS Code: 1358
i00972031
Belt Tensioner
SMCS Code: 1358
g00391337
Illustration 99

torque. ........................ 85 5 Nm (65 4 lb ft)
g00495198
(1) Belt tensioner Auxiliary Drive Pulley

Tighten the bolt that fastens the belt tensioner to SMCS Code: 1205
the bracket to the following torque. .. 50 5 Nm
(37 4 lb ft)
(2) Idler pulley assembly

Tighten the idler pulley assembly to the following
torque. ........................ 50 5 Nm (37 4 lb ft)
g00398438
Illustration 100
Typical Example
(1) Damper assembly

48
(2) Pulley i00826442
(3) Adapter Alternator and Regulator

(4) Crankshaft SMCS Code: 1405; 1410

torque. ................ 300 40 Nm (220 30 lb ft)

torque. .................... 70 15 Nm (50 11 lb ft)
i00820881
Engine Support (Front)

SMCS Code: 1153; 1154
g00289617
Illustration 102
g00393398
Illustration 101
Typical Example
g00289618
(1) Tighten the bolts to the following Illustration 103
torque. .................. 120 20 Nm (90 15 lb ft)
(2) Front housing group Battery Load Tester in order to get the maximum
alternator output.
Polarity ........................................... Negative Ground
Rotation ..................................................... Clockwise
Minimum full load current at 5000 rpm ..... 107 Amp
Minimum full load current at 1500 rpm ....... 45 Amp
Output voltage ...................................... 14.0 0.5 V
(1) Shaft nut torque ........ 102 7 Nm (75 5 lb ft)
(2) Positive terminal torque .............. 11.3 2.3 Nm

(100 20 lb in)
(3) Negative terminal torque .............. 6.2 0.6 Nm

(55 5 lb in)
(4) Regulator
49
Voltage setting .................................. No Adjustment Tighten the nut on the ground terminal to the
Permissible voltage range ................. 13.5 to 14.5 V
(3) Ground terminal
i00969807 Tighten the nut on the ground terminal to the
Electric Starting Motor (20 2 lb in)
SMCS Code: 1453 (4) Switch terminal
Part No.: 8C-3592 Tighten the nut on the switch terminal to the
(20 2 lb in)
(5) Motor terminal



housing ........................................ 9.1 mm (.36 inch)
g00282744
Illustration 104
Typical Example Solenoid
Hold-in windings ................... 23 Amp maximum
i00970021

SMCS Code: 1453
Part No.: 6V-5540
g00493900
Illustration 105


Speed ..................................... 6900 1800 rpm
Current draw ......................... 127.5 27.5 amp
Voltage ......................................................... 11 V

A maximum of three cable or wire terminals Illustration 106
g00400230
(2) Ground terminal

50

(22 3 lb ft)

housing .................... 8.3 to 9.9 mm (.33 to .39 inch)
Solenoid
Pull-in windings ..................................... 51 Amp
Hold-in windings ..................... 7 Amp maximum
g00494106
Illustration 107
i00970077
the pinion end, the motor rotates in the following Electric Starting Motor
SMCS Code: 1453

No load conditions at 25 C (77 F) Part No.: 6V-5582
Speed .................................. 5500 rpm minimum
Current draw ....................... 140 amp maximum
Voltage ......................................................... 24 V

(2) Ground terminal

following torque. ... 30.5 3.5 Nm (22 3 lb ft) g00282453
Illustration 108
(3) Ground terminal

(20 2 lb in)
(4) Switch terminal

(20 2 lb in)
g00494167
Illustration 109
(5) Motor terminal
Tighten the nut on the motor terminal to the When the electric starting motor is viewed from
following torque. ... 30.5 3.5 Nm (22 3 lb ft) the drive end, the motor rotates in the following
Minimum speed with no load .............. 3300 rpm
51
Maximum current with no load .............. 80 amp i00970013

Voltage ...................................................... 23.5 V
SMCS Code: 1453
should be between the nuts. Part No.: 106-8554
(2) Ground terminal

following torque. .... 1.5 0.5 Nm (13 4 lb in)
(3) Ground terminal

(4) Switch terminal

g00282688
The wire terminal that is on the switch terminal Illustration 110
(20 2 lb in)
(5) Motor terminal


g00493900
(13 2 lb ft) Illustration 111

Solenoid the drive end, the motor rotates in the following
Pull-in windings ................................... 103 Amp No load conditions at 25 C (77 F)
Hold-in windings ................... 19 Amp maximum Speed ..................................... 7643 1683 rpm
Current draw ............................. 67.5 7.5 amp
Voltage ......................................................... 23 V

(2) Ground terminal

(3) Ground terminal

52
Tighten the nut on the ground terminal to the (2) Cylinder block
(20 2 lb in)
i01199473
(4) Switch terminal Coolant Temperature Sensor

must be insulated with heat shrink tubing. Do SMCS Code: 1906
(20 2 lb in)
(5) Motor terminal



housing ........................................ 9.1 mm (.36 inch)
Solenoid
Current draw at 20 V and 25 C (77 F) g00641792
Illustration 113
(1) Pin 1
Hold-in windings ................ 14.6 Amp maximum
(2) Pin 2
i01193848
(3) Sensor assembly
Electrical Ground Stud Tighten the sensor assembly to the following
SMCS Code: 1408 torque. ........................ 20 5 Nm (15 4 lb ft)
i00968767
Fuel Temperature Sensor

SMCS Code: 1922
g00638966
Illustration 112
The electrical grounding stud is located on the left side of the
engine.
(1) Nut
Tighten the outer nut on the ground stud to the Illustration 114
g00493454
following torque. ...... 10 3 Nm (89 27 lb in)
53
(1) Pin 1 Tighten sensor assembly to the following

torque. ........................... 10 2 Nm (88 18 lb in)
(2) Pin 2
(2) Receptacle
(3) Sensor assembly
Tighten the sensor assembly to the following i00961856
torque. ........................ 20 5 Nm (15 4 lb ft)
Boost Pressure Sensor
i01375942 SMCS Code: 1917
Fuel Pressure Sensor
SMCS Code: 1718
g00490140
Illustration 117
(1) Sensor assembly

g00726672
Illustration 115 Tighten the sensor assembly to the following
torque. ..................... 10 2 Nm (88 18 lb in)
(1) Sensor assembly
(2) Plug with socket A, socket B, and socket C
torque. ........................... 10 2 Nm (90 18 lb in)
i00974651
(2) Plug Atmospheric Pressure Sensor

i00627515 SMCS Code: 1923
Engine Oil Pressure Sensor

SMCS Code: 1924
g00281665
Illustration 118
(1) Sensor assembly
Illustration 116
g00286048 Tighten the sensor assembly to the following
torque. ..................... 10 2 Nm (88 18 lb in)
(1) Sensor assembly
54
i00970150 Ensure that the bracket is installed in the orientation

that is shown.
Inlet Air Temperature Sensor
SMCS Code: 1921 torque: ........................ 28 7 Nm (21 5 lb ft)
Ensure that the sensor is seated before the bolt is

tightened.
Crankshaft Position Sensor
g00526991
Illustration 119
(1) Pin 1
(2) Pin 2
g00640259
(3) Sensor assembly Illustration 121
Crankshaft position sensor
torque. ........................ 20 5 Nm (15 4 lb ft) (1) Sensor
i01197625
(2) Bracket
Speed and Timing Sensor Ensure that the bracket is installed in the orientation
that is shown.
SMCS Code: 1907; 1912
torque: ........................ 28 7 Nm (21 5 lb ft)
Camshaft Position Sensor
Ensure that the sensor is seated before the bolt is
tightened.
g00640258
Illustration 120
Camshaft position sensor
(1) Sensor
(2) Bracket
55
i00996748 i01193346
Accelerator Pedal Position Air Compressor

Sensor SMCS Code: 1803
SMCS Code: 1913
g00638646
Illustration 124
g00496388
Illustration 122
(1) Air compressor
(1) Sensor assembly
(2) Bolts
Apply 9S-3263 Thread Lock Compound to the
threads of the bolts. Tighten the bolts to the
i01528644 following torque. ......... 100 20 Nm (75 15 lb ft)
Engine Control Module (3) Bolts
SMCS Code: 1901 Tighten the bolts to the following

torque. ............................ 55 10 Nm (41 7 lb ft)
g00732425
Illustration 123
Engine Control Module
(1) Bolt
Tighten bolt (1) on the wiring harness to the

following torque. ................ 6 1 Nm (53 9 lb in)
56
Index Section
Index
A F
Accelerator Pedal Position Sensor ........................ 55 Flywheel .......................................................... 4243

Accessory Drive (Air Compressor) ........................ 38 Flywheel Housing .................................................. 43
Air Compressor...................................................... 55 Flywheel Housing (Rear Power Take-Off (RPTO)).. 44
Alternator and Regulator ....................................... 48 Fuel Filter (Primary)................................................. 6
Atmospheric Pressure Sensor............................... 53 Fuel Filter and Water Separator .............................. 6
Auxiliary Drive Pulley ............................................. 47 Fuel Lines ................................................................ 5
Fuel Pressure Sensor............................................ 53
Fuel Priming Pump and Primary Fuel Filter ............ 6
B Fuel Temperature Sensor ...................................... 52
Fuel Transfer Pump ................................................. 5
Belt Tension Chart ................................................. 45
Belt Tensioner.................................................. 4647
Belt Tightener ........................................................ 47 G
Boost Pressure Sensor.......................................... 53
Gear Group (Front)................................................ 40
C
H
Camshaft ............................................................... 18
Compression Brake ............................................... 14 Housing (Front)...................................................... 38
Connecting Rod............................................... 3334
Coolant Conditioner Base...................................... 26 I
Coolant Temperature Sensor................................. 52
Crankcase Breather............................................... 25 Important Safety Information ................................... 2
Crankshaft ............................................................ 30 Inlet Air Temperature Sensor................................. 54
Crankshaft Seals ................................................... 31 Inlet Manifold ......................................................... 17
Cylinder Block........................................................ 27
Cylinder Head........................................................ 13
Cylinder Head Valves ............................................ 11 L
Cylinder Liner .................................................. 2930
Cylinder Liner Projection ....................................... 30 Lifter Group.............................................................. 8
E M
Electric Starting Motor ..................................... 4951 Main Bearing Journal ............................................ 33

Solenoid ....................................................... 4952
Electrical Ground Stud .......................................... 52
Electronic Unit Injector............................................. 6 P
Electronic Unit Injector Mechanism ......................... 7
Electronic Unit Injector Rocker Arm......................... 7 Piston and Rings ............................................. 3536
Electronic Unit Injector Wiring ................................. 8 Piston Cooling Jet.................................................. 37
Engine Centrifugal Oil Filter .................................. 22
Engine Control Module .......................................... 55
Engine Design ......................................................... 4 R
Engine Oil Cooler .................................................. 22
Engine Oil Filter ..................................................... 21 Rear Power Take-Off (RPTO) ................................ 41
Engine Oil Filter Base............................................ 20 Rocker Shaft............................................................ 8
Engine Oil Pan................................................. 2425
Engine Oil Pressure............................................... 24
Engine Oil Pressure Sensor .................................. 53 S
Engine Oil Pump.................................................... 23
Engine Support (Front) .......................................... 48 Specifications Section ............................................. 4
Engine to Transmission Adapter............................ 44
Exhaust Manifold ................................................... 17
57
Index Section
Speed and Timing Sensor ..................................... 54

Camshaft Position Sensor ................................. 54
Crankshaft Position Sensor................................ 54
Turbocharger ................................................... 1517
Valve Mechanism .................................................... 9

Valve Rocker Arm .................................................. 10
Vibration Damper and Pulley................................. 32
Water Pump........................................................... 26
Water Temperature Regulator ............................... 26
58
Index Section
59
Index Section
2001 Caterpillar
RENR2235-03
April 2001
Systems Operation
CPD1-Up (Engine)
2KS1-Up (Engine)
3CS1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Flywheel - Inspect ................................................. 84

Flywheel Housing - Inspect ................................... 85
Vibration Damper - Check ..................................... 87
Systems Operation Section Compression Brake
Slave Piston Lash - Adjust .................................... 88
Engine Design ....................................................... 4
Control Valve (Compression Brake) - Test ............ 89
Engine Design ....................................................... 4
Solenoid Valve (Compression Brake) - Test ......... 90
Glossary of Electronic Control Terms ..................... 6
Electrical System
Battery - Test ......................................................... 93
Fuel System ......................................................... 12
Belt Tension Chart ................................................ 93
Charging System - Test ........................................ 94
Electric Starting System - Test .............................. 96
Cooling System .................................................... 33
Engine Oil Pressure Sensor - Test ........................ 96
Basic Engine ......................................................... 36
Pinion Clearance - Adjust ..................................... 96
Electrical System ................................................. 41 Index Section
Index ..................................................................... 98
Fuel System
Fuel System - Inspect ........................................... 46
Air in Fuel - Test .................................................... 46
Electronic Unit Injector - Adjust ............................. 47
Electronic Unit Injector - Test ................................ 48
Finding Top Center Position for No. 1 Piston ........ 49
Fuel Quality - Test ................................................. 50
Fuel System - Prime ............................................. 51
Fuel System Pressure - Test ................................. 52
Gear Group (Front) - Time .................................... 56

Air Inlet and Exhaust System - Inspect ................. 58
Turbocharger - Inspect .......................................... 60
Inlet Manifold Pressure - Test ............................... 62
Exhaust Temperature - Test .................................. 63
Engine Crankcase Pressure (Blowby) - Test ........ 66
Compression - Test ............................................... 67
Engine Valve Lash - Inspect/Adjust ...................... 67
Lubrication System
Engine Oil Pressure - Test .................................... 70
Engine Oil Pump - Inspect .................................... 72
Excessive Bearing Wear - Inspect ........................ 73
Excessive Engine Oil Consumption - Inspect ....... 73
Increased Engine Oil Temperature - Inspect ........ 73
Cooling System
Cooling System - Check (Overheating) ................ 74
Cooling System - Inspect ...................................... 76
Cooling System - Test ........................................... 76
Water Temperature Regulator - Test ..................... 80
Water Pump - Test ................................................ 81
Basic Engine
Piston Ring Groove - Inspect ................................ 82
Connecting Rod Bearings - Inspect ...................... 82
Main Bearings - Inspect ........................................ 82
Cylinder Block - Inspect ........................................ 82
Cylinder Liner Projection - Inspect ........................ 83
4
Systems Operation Section Note: The front end of the engine is opposite of
the flywheel end of the engine. The left side of the
i00980518 from the flywheel end of the engine. The No. 1
Engine Design
SMCS Code: 1000 i00980375
S/N: 3CS1-Up Engine Design

SMCS Code: 1000
S/N: CPD1-Up
S/N: 2KS1-Up
g00386924
Illustration 1
(A) Exhaust valves
(B) Inlet valves
Bore ....................................... 125.0 mm (4.92 inch) g00386924

Illustration 2
Stroke ..................................... 140.0 mm (5.51 inch) (A) Exhaust valves
(B) Inlet valves
3
Displacement ................................... 10.3 L (629 in )
Bore ....................................... 130.0 mm (5.12 inch)
Stroke ..................................... 150.0 mm (5.91 inch)
the engine must be cold and the engine must be Cylinder arrangement ..................................... In-line
Inlet .................................... 0.38 mm (.015 inch)
Exhaust .............................. 0.64 mm (.025 inch)
Engine compression brake .................. 0.64 mm
the engine must be cold and the engine must be
(.025 inch)
Type of combustion .......................... Direct Injection Inlet .................................... 0.38 mm (.015 inch)
Exhaust .............................. 0.64 mm (.025 inch)
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4 Engine compression brake .................. 1.02 mm
(.040 inch)
flywheel end of the engine. Crankshaft Type of combustion .......................... Direct Injection
Firing Order ................................ 1 - 5 - 3 - 6 - 2 - 4

5
Note: The front end of the engine is opposite of Starting The Engine
the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed The engines ECM will automatically provide the
from the flywheel end of the engine. The No. 1 correct amount of fuel in order to start the engine.
cylinder is the front cylinder. 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
i01532990
to cool for two minutes before the starting motor
General Information is used again.
SMCS Code: 1000 NOTICE

Excessive ether (starting fluid) can cause piston and
C-10 Truck Engines and C-12 Truck Engines are ring damage. Use ether for cold weather starting pur-
in-line six cylinder arrangements. C-10 Truck poses only.
Engines have a bore of 125.0 mm (4.92 inch) and a
stroke of 140.0 mm (5.51 inch). The displacement
is 10.3 L (629 in3). C-12 Truck Engines have a bore Cold Mode Operation
of 130.0 mm (5.12 inch) and a stroke of 150.0 mm
(5.91 inch). The displacement is 12 L (732 in3). The ECM will set the cold start strategy when the
Both engines have a firing order sequence:1, 5, coolant temperature is below 18 C (64 F).
3, 6, 2, and 4. The rotation of these engines is
counterclockwise when the engine is viewed from When the cold start strategy is activated, low idle
the flywheel end of the engine. These engines utilize rpm will be increased to 1000 rpm and the engines
a turbocharger and an air-to-air aftercooler. power will be limited.
The Electronic Unit Injector system (EUI) eliminates Cold mode operation will be deactivated when any
many of the mechanical components that are of the following conditions have been met:
traditionally used in the fuel injector assembly. The
EUI also provides increased control of the timing Coolant temperature reaches 18 C (64 F).
and increased control of the fuel air mixture. The
timing advance is achieved by precise control of The engine has been running for fourteen
the fuel injection timing. Engine rpm is controlled by minutes.
adjusting the injection duration.
Cold mode operation varies the fuel injection amount
Engines (S/N: 3CS1-11999) and (S/N: 2KS1-39999) for white smoke cleanup. Cold mode operation
have a special pulse wheel, which is mounted to the also varies the timing for white smoke cleanup. The
crankshaft gear. The special pulse wheel provides engine operating temperature is usually reached
information to the Electronic Control Module (ECM) before the walk-around inspection is completed.
for detection of cylinder position and engine rpm. The engine will idle at the programmed low idle rpm
in order to be put in gear.
Engines (S/N: 3CS12000-UP), (S/N: 2KS40000-UP),
and (S/N: CPD1-UP) have a special crankshaft gear
that provides information to the Electronic Control NOTICE
Module (ECM) for detection of cylinder position and Do not move the vehicle with the engine in the cold
engine rpm. mode condition. Engine power could be noticeably re-
duced. At a vehicle speed above 8 km/h (5 mph), low
The engine has built-in diagnostics in order to idle rpm will be reduced to the customer programmed
ensure that all of the components are operating low idle and the power will still be reduced.
properly. In the event of a system component
failure, the operator will be alerted to the condition After the cold mode is completed, the engine
by a check engine light. The check engine light is should be operated at low rpm until normal
located on the dashboard. An electronic service operating temperature is reached. The engine will
tool can be used to read the numerical code of reach normal operating temperature faster when
the faulty component or condition. Also, the cruise the engine is operated at low rpm and low power
control switches can be used to flash the code on demand. Typically, the engine should be up to
the check engine light. Intermittent faults are logged operating temperature by just driving the vehicle
and stored in memory. through the yard toward the open road.
6
Customer Specified Parameters Atmospheric Pressure Sensor This sensor

measures atmospheric air pressure in the
The engine is capable of being programmed for crankcase. The sensor sends the signal to the
several customer specified parameters. For a brief electronic control module (ECM).
explanation of each of the customer specified
parameters, see the Operation and Maintenance Before Top Center (BTC) The 180 degrees of
Manual. crankshaft rotation before the piston reaches the top
center position in the normal direction of rotation.
i01220826
Boost Pressure Sensor This sensor measures
Glossary of Electronic Control inlet manifold air pressure. The sensor sends the
signal to the ECM.
Terms
Brake Pedal Position Switch This switch is
SMCS Code: 1900 supplied and installed by the OEM. The switch is
typically a pressure switch. The switch is normally
Accelerator Pedal Position The accelerator pedal closed when the pedal is released. Depressing the
position is the interpretation from the ECM of the brake will open the circuit.
signal from the Accelerator Pedal Position Sensor.
Bypass Circuit This circuit substitutes an existing
Accelerator Pedal Position Sensor This is circuit. The circuit is usually a temporary circuit. The
an electronic sensor that is connected to the circuit is used for testing.
accelerator pedal. The sensor sends a Pulse Width
Modulated Signal to the ECM. The ECM will then Calibration Calibration is an electronic adjustment
vary the duty cycle according to the pedal position. of a sensor signal.
ATA Data Link The data link is an electrical Camshaft Position Sensor This sensor provides a
connection for communication with other devices Pulse Width Modulated (PWM) signal to the ECM.
that are based on the microprocessor. These The ECM interprets this signal as the camshaft
devices are compatible with the ATA (American position in order to determine the top center position
Trucking Association) and with SAE Standards, of cylinder number 1.
Section J1587 and Section J1708. These devices
include trip recorders, electronic dashboards Caterpillar Engine Monitoring The part of the
and maintenance systems. The data link is also Caterpillar Electronic Engine Control that monitors
the medium for communication that is used Coolant Temperature, Oil Pressure, Intake Manifold
for programming and troubleshooting with the Air Temperature and Coolant Level. This will alert
Caterpillar electronic service tool. the operator of detected problems. The Coolant
Temperature, Intake Manifold Air Temperature, and
After Market Device The customer or the machine Oil Pressure Sensors are supplied by Caterpillar
(OEM) installs these devices or accessories. and monitored by the ECM. The Coolant Level
This installation is completed after the engine is Sensor is installed by the OEM and monitored by
delivered. the ECM. An aftermarket Engine Monitoring System
does not interface with the Caterpillar Electronic
Air-to-Air Aftercooler (ATAAC) This is the method Engine Control.
of using ambient air to cool intake air after the intake
air has been through the turbocharger. The intake Check Engine Lamp This is used to warn the
air is then passed through an aftercooler (heat operator of the presence of an active diagnostic
exchanger) before going to the intake manifold. The code. This is also called the Diagnostic Lamp.
aftercooler is mounted in the front of the radiator.
Clutch Pedal Position Switch This switch is
Alternating Current (AC) The direction of current supplied and installed by the OEM. The switch
flow changes. The current flow alternates constantly. is an adjustable limit switch that is mounted near
the pedal. The switch is normally closed when the
American Wire Gauge (AWG) This is the pedal is released. Depressing the clutch will open
measurement of the diameter of electrical wire. This the circuit.
is also the measurement of the ability of electrical
wire to carry current. A smaller AWG number Coolant Level Sensor This sensor detects the
reflects a larger wire. absence or presence of coolant at the probe. The
sensor sends the signal to the ECM. This sensor
is installed by the OEM.
7
Cooling Fan Relay This relay is supplied and Diagnostic Fault Code These codes indicate an
installed by the OEM. The relay is controlled by the electronic system malfunction which will indicate a
ECM. problem with the electronic system.
Coolant Temperature Sensor This sensor detects Diagnostic Flash Code This code indicates a
the engine coolant temperature for Cold Mode malfunction of the electronic system. This code
operation and Caterpillar Engine Monitoring. If can also indicate an event that is detected by the
Engine Monitoring has been programmed to be electronic system. The code is indicated on the
OFF the sensor will not detect the engine coolant Check Engine/Diagnostic Lamp.
temperature.
Diagnostic Lamp This is used to warn the operator
Crankshaft Position Sensor This sensor provides of the presence of an active diagnostic code.
a Pulse Width Modulated signal to the ECM. The Another name for this lamp is the Check Engine
ECM interprets this signal as the crankshaft position Lamp.
in order to determine the top center position of
cylinder number 1. Direct Current (DC) Direct current is the type of
Cruise Control Range The cruise control operates
within this range. The cruise control range is usually Duty Cycle See Pulse Width Modulation.
limited to the speed range that is anticipated for
the application. The cruise control range may be Electronic Control Module (ECM) The ECM is the
programmable by using the Low Cruise Limits and engines control computer. The ECM provides power
the High Cruise Limits. to the electronics for the system. The ECM monitors
the information that is input by the system. The ECM
Custom Data This allows the owner to specify acts as a governor in order to control engine rpm.
the operating parameters of the engine application
while the engine is in service. This data is for Electronic Control Module (ECM) Fan Control The
monitoring purposes. Custom Data is a part of the ECM may control the cooling fan through a relay
ECM fleet trip data. that is installed by the OEM. The ECM controls
the relay that is based on coolant temperature,
Customer Specified Parameter The customer can inlet manifold air temperature, and boost pressure.
set this parameter value. The parameter value may The relay can also be controlled by the ECM when
be protected by Customer Passwords. the following switches are installed by the OEM:air
conditioning high pressure switch, PTO ON/OFF,
Data Link The data link is an electrical manual fan override switch, and retarder solenoid
connection for communication with other onboard
microprocessor based devices that use the data Electronic Engine Control The electronic engine
link. These devices are compatible with SAE control is a complete electronic system. The
Standards. These devices include trip recorders, electronic engine control monitors the engine
electronic dashboards and maintenance systems. operation under all conditions. The electronic
The data link is also the medium for communication engine control also controls the engine operation
that is used for programming and troubleshooting under all conditions.
with the Caterpillar electronic service tool.
Electronic Technician (ET) Electronic Technician
Desired rpm The desired engine speed (rpm) is is a Caterpillar electronic service tool. ET is used
input to the electronic governor within the ECM. The for diagnostics and for programming a variety of
following criteria are used in order to determine the electronic controls.
desired engine speed (rpm): the Accelerator Pedal
Position Sensor, the Crankshaft Position Sensor, and Electronic Unit Injector (EUI) The injection pump
the Customer Parameters. is a mechanically actuated, electronically controlled
unit injector. The EUI combines the pumping,
Desired Timing Advance The fuel injection timing electronic fuel metering, and injecting elements into
advance is calculated by the ECM. The calculation a single unit.
is used to meet emission and performance
specifications. Engine Retarder Solenoids The Engine Retarder
is installed by Caterpillar. The solenoids are driven
Diagnostic Code A diagnostic code is an directly from the ECM instead of being driven
indication of a problem or event in the electronic through a relay that is installed by the OEM.
system.
Estimated Dynamic Timing This is the estimated
Diagnostic Event Code These codes indicate an calculation of actual injection timing by the ECM.
event. The codes are not necessarily an indication
of a problem within the electronic system.
8
Failure Mode Identifier (FMI) This identifies Integrated Electronic Controls The engine is
the type of failure that was experienced by the designed with the electronic controls as a necessary
component. This was adopted from SAE Standards, part of the system. The engine will not operate
Section J1587 diagnostics. without the electronic controls.
Flash Code (FC) A flash code is a Caterpillar Oil Pressure Sensor This sensor measures engine
proprietary code number which is flashed on the oil pressure. The sensor sends a signal to the ECM
diagnostic lamp. as part of the Caterpillar Engine Monitoring.
Fuel Ratio Control (FRC) The FRC is a limit that Open Circuit An open circuit is a broken electrical
is based on the control of the fuel to air ratio. The connection. The signal or the supply voltage cannot
FRC is used for emission control. When the ECM reach the intended destination.
senses a higher turbocharger outlet pressure, the
ECM increases the limit for the FRC in order to allow Original Equipment Manufacturer (OEM) An OEM
more fuel into the cylinders. is an equipment manufacturer that uses Caterpillar
engines to power vehicles that are produced.
Fuel Position The fuel position is a signal within
the ECM. The signal is from the electronic governor. Parameter A parameter is a programmable value
The signal goes to the fuel injection control. The which affects the characteristics or the behavior of
signal is based on the desired engine speed, the the engine and/or machine.
FRC, the rated position and engine speed.
Parameter Identifier (PID) This is the two or three
Fuel Temperature Sensor This sensor detects digit code which is assigned to each component.
the fuel temperature. The ECM monitors the fuel
temperature. The ECM adjusts the calculated fuel Passive Magnetic Speed Sensor This speed
rate accordingly. sensor does not require a power connection and a
ground connection. This speed sensor produces a
Full Load Setting (FLS) This is the fuel system signal that is based on the change in the magnetic
adjustment that is made at the factory. The flux of a ferrous metal gear that is near the sensing
adjustment is used to fine tune the fuel system. The tip.
correct value for this parameter is stamped on the
9L-6531 Information Plate. This parameter must be Password A password is a group of numeric
programmed. If the parameter is not programmed, characters or alphanumeric characters. A password
a Diagnostic Code 253-02 Check Customer or a is designed to restrict the changing of information
System Parameters Fault Code 56 will be generated. in the ECM. The EUI system requires correct factory
passwords in order to clear certain logged events.
Full Torque Setting (FTS) This is similar to Full Factory passwords are also required in order to
Load Setting. The parameter for full torque setting change the engine rating.
must be programmed or a Diagnostic Code 253-02
Check Customer or a System Parameters Fault Personality Module Or Ratings Personality Module
Code 56 will be generated. A personality module refers to the software that is
downloaded into the ECM. The module contains
Gear Down Protection This is a Programmable all the instructions (software) for the ECM and
High Gear Limit. This is used to promote driving in performance maps for a specific horsepower family.
higher gears for increased fuel economy.
Power Take-Off (PTO) This requires a dedicated
Harness The harness is the bundle of wiring that PTO switch with ON/OFF positions. This mode
connects all the components of the EUI system. permits setting an engine rpm with the following
functions: cruise Set/Resume Switch, remote
Hertz (Hz) Hertz is the measure of frequency in PTO Set/Resume Switch, remote accelerator, cab
cycles per second. accelerator, and programmable values.
Histogram The histogram is a bar graph. This bar Pro-Link The Pro-Link is a hand-held service tool
graph indicates the relative frequency of engine that is electronic. The Pro-Link is manufactured
operation within specific operating ranges. by Micro Processor Systems, Inc. (MPSI). This is
available with a Caterpillar cartridge in order to
Inlet Air Temperature Sensor This sensor detects service Caterpillar electronic engines.
the inlet air temperature. The ECM monitors the inlet
air temperature and the coolant temperature. The
inlet air temperature sensor is a part of Caterpillar
Engine Monitoring.
9
Pulse Width Modulation (PWM) A PWM is a digital Total Tattletale The total tattletale is the total
type of an electronic signal that corresponds to a number of changes to all system parameters.
measured variable. The length of the pulse (signal)
is controlled by the measured variable. The variable Transducer A transducer is a device which
is quantified by a certain ratio. This ratio is the converts a mechanical signal to an electrical signal.
percent of TIME-ON that is divided by the percent
of TIME-OFF. The PWM is also known as the Duty Trip Recorder This device records the operating
Cycle. parameters of the vehicle and the engine while the
vehicle is in service. The data from the trip recorder
Rated Fuel Position The rated fuel position is used to analyze operating habits. The data from
indicates the maximum allowable fuel position. The the trip recorder is used to develop operating logs.
rated fuel position will produce rated power for this
engine configuration. Vehicle Speed Circuit This circuit includes the
vehicle speed sensor, the harness and the ECM.
Reference Voltage The reference voltage is a
regulated voltage that is used by the sensor in order Vehicle Speed Sensor This is an electromagnetic
to generate a signal voltage. pickup that measures vehicle speed from the
rotation of gear teeth in the drive train of the vehicle.
Sensor A sensor is used to detect a change in
the pressure, in the temperature, or in mechanical Warning Lamp This is used to warn the operator
movement. When any of these changes are of the presence of a Caterpillar Engine Monitoring
detected, a sensor converts the change into an detected problem.
electrical signal.
Short Circuit A short circuit is an electrical circuit

that is mistakenly connected to an undesirable
point. For example, an electrical contact is made
with the frame whenever an exposed wire rubs
against a vehicles frame.
Signal A signal is a voltage or a wave that is

used to transmit information that is typically from a
sensor to the ECM.
Speed Burp A speed burp is a sudden brief

change in engine speed.
Speed Circuit This is the circuit that includes the

speed sensor, the harness and the ECM.
Speed Sensor The speed sensor is an

electromagnetic pickup that measures speed from
the rotation of gear teeth in the drive train.
Standard SAE Diagnostic Communications Data

Link Refer to the ATA Data Link.
Subsystem A subsystem is part of the EUI system

that relates to a particular function.
Supply Voltage Supply voltage is a constant

voltage that is supplied to a component in order
voltage may be generated by the ECM. The supply
voltage may also be the battery voltage that is
supplied by the vehicle wiring.
T Harness This harness is a test harness that

is designed to permit normal circuit operation and
the measurement of the voltage simultaneously.
Typically, the harness is inserted between the two
10
i00980925

Components
SMCS Code: 1900
g00499282
Illustration 3
Top view
11
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 engines fuel system and the engines 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
is achieved by precise control of injector firing change in some specific system of the vehicle.
time, and engine rpm is controlled by adjusting the The electronic control module sees the input
firing duration. The ECM energizes the solenoid sensor signal as information about the condition,
in the unit injector in order to start the injection of environment, or operation of the vehicle.
fuel. Also, the ECM de-energizes the unit injector
solenoids in order to stop injection of fuel. Refer to A control component (ECM) receives the input
the Systems Operation, Fuel System topic for a signals. Electronic circuits inside the control
complete 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
An input component is one that sends an electrical one of two ways. The output component can use
signal to the ECM. The signal that is sent varies in that electrical energy in order to perform work. The
one of the following ways: output component can use that electrical energy in
12
1. As an example, a moving solenoid plunger i01532739

will perform work. By performing work, the
component has functioned in order to regulate Fuel System
the vehicle.
SMCS Code: 1250
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
13
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 Electronic Unit Injectors
the 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.
14
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.
g00647032
Illustration 6
15
(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
system has three basic functions: air from the system when a fuel filter has been
changed or a unit injector has been changed. The
The low pressure fuel system supplies fuel to the priming pump pulls fuel from the tank, around the
injectors for combustion. transfer pump and into the filter. The transfer pump
pushes fuel through the supply passage in the
The low pressure fuel system supplies fuel to the cylinder head 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 60 PSI, the check valve closes. The check valve
consist 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
primary fuel filter or water separator engine functions. Sensors are electronic devices
that monitor engine performance parameters. The
fuel transfer pump pressure sensor, the temperature sensor and the
speed sensor provide information to the electronic
secondary fuel filter control module by a signal voltage. Actuators are
electronic devices which use electrical currents
fuel priming pump from the electronic control module to change engine
performance. An example of an actuator is an
fuel pressure regulator valve injector solenoid.
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.
16
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 These features result in the following items: precise
conditions. This information is sent to the Electronic engine speed control, very little smoke, faster cold
Control Module. The ECM has three main functions. starting, and built-in engine protection.
The 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
rpm. The ECM stores active faults, logged faults, control module and the personality module.
and logged events. The Personality Module is the
software in the ECM which contains the specific The ECM is a computer and the personality module
maps that define power, torque, and RPM of the is the software for the computer. The personality
engine. The ECM sends electrical current to the module contains the operating maps. The operating
output components in order to control engine maps define the following characteristics of the
operation. The ECM has the following connectors: engine:
two 70 pin harness connectors, one engine harness
connector, and one vehicle harness connector. The Horsepower
vehicle harness connects the ECM to the engine
control portion of the vehicle harness. The engine Torque curves
control 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
cooling fan solenoid varying the signals to the unit injectors. The unit
injectors will inject fuel ONLY if the unit injector
The following list of features are part of the solenoid is energized. The ECM sends a 90 volt
electronic control system: signal to the solenoid for energizing the solenoid.
By controlling the timing of the 90 volt signal, the
cold start strategy ECM controls injection timing. By controlling the
duration of the 90 volt signal, the ECM controls the
oil pressure injected fuel amount.
coolant temperature warning indicator

17
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.
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.
18
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.
19
g00660656
Illustration 9
Pre-injection
(A) Fuel supply pressure
(B) Injection pressure
(C) Moving parts
(D) Mechanical movement
(E) Fuel movement.
20
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.
21
g00660658
Illustration 10
Injection
(A) Fuel supply pressure.
(C) Moving parts
(E) Fuel movement.
22
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.
23
g00660660
Illustration 11
End of injection
(A) Fuel supply pressure (C) Moving parts
24
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.
25
g00795649
Illustration 12
Fill
(A) Fuel supply pressure
(C) Moving parts
(E) Fuel movement.
26
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
27
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 vehicles forward
g00294193
motion moves ambient air across both cores. This Illustration 14
cools the turbocharged inlet air and the engine Turbocharger
coolant. (1) Air inlet
(2) Compressor housing
From the aftercooler, air is forced into inlet manifold (3) Compressor wheel
(8). Air flow from the inlet chambers into the (4) Bearing
cylinders is controlled by inlet valves (4). There (5) Oil Inlet port
(6) Bearing
are two inlet valves and two exhaust valves (5) (7) Turbine housing
for each cylinder. The inlet valves open when the (8) Turbine wheel
piston moves down on the intake stroke. When (9) Exhaust outlet
the inlet valves open, cooled compressed air from (10) Oil outlet port
(11) Exhaust inlet
the inlet port is pulled into the cylinder. The inlet
valves close and the piston begins to move up on
the compression stroke. The air in the cylinder is The turbocharger is installed on the center section
compressed. When the piston is near the top of the of the exhaust manifold. All the exhaust gases
compression stroke, fuel is injected into the cylinder. from the engine go through the turbocharger. The
The fuel mixes with the air and combustion starts. compressor side of the turbocharger is connected
During the power stroke, the combustion force to the aftercooler by pipe.
pushes the piston downward. The exhaust valves
open and the exhaust gases are pushed through The exhaust gases enter turbine housing (7) through
the exhaust port into exhaust manifold (9) as the exhaust inlet (11). The exhaust gases then push the
piston rises on the exhaust stroke. After the exhaust blades of turbine wheel (8). The turbine wheel is
stroke, the exhaust valves close and the cycle starts connected by a shaft to compressor wheel (3).
again. The complete cycle consists of four strokes:
Inlet
28
Clean air from the air cleaners is pulled through Note: The turbocharger with a wastegate is preset
compressor housing air inlet (1) by the rotation of at the factory and no adjustment can be made.
compressor wheel (3). The action of the compressor
wheel blades causes a compression of the inlet air. Bearings (4) and (6) for the turbocharger use
This compression gives the engine more power by engine oil under pressure for lubrication. The oil
allowing the engine to burn more air and more fuel comes in through oil inlet port (5). The oil then goes
during combustion. through passages in the center section in order to
lubricate the bearings. Oil from the turbocharger
When the load on the engine increases, more fuel goes out through oil outlet port (10) in the bottom
is injected into the cylinders. The combustion of of the center section. The oil then goes back to the
this additional fuel produces more exhaust gases. engine lubrication system.
The additional exhaust gases cause the turbine
and the compressor wheels of the turbocharger to Valve System Components
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
Illustration 15
Typical example of a turbocharger with a wastegate
g00411726
(12) Canister Illustration 16
(13) Actuating lever Valve system components
(1) Valve bridge
Some turbochargers use a wastegate. The (2) Valve rotator
wastegate is controlled by boost pressure. At (3) Rocker arm
high boost pressures, the wastegate opens. The (4) Pushrod
(5) Valve springs
wastegate closes in order to increase boost (6) Valves
pressure. With this arrangement, the turbocharger (7) Valve guide
can be designed to be more effective at lower (8) Camshaft
engine speeds. (9) Lifter
When the engine is operating under conditions The valve system components control the flow of
of low boost, a spring pushes on a diaphragm in inlet air into the cylinders during engine operation.
canister (12). This action moves actuating lever (13) The valve system components also control the flow
in order to close the valve of the wastegate. Closing of exhaust gases out of the cylinders during engine
the valve of the wastegate allows the turbocharger operation.
to operate at maximum performance.
The crankshaft gear drives the camshaft gear
As the boost pressure increases against the through an idler gear. Camshaft (8) must be timed
diaphragm in canister (12), the valve of the to the crankshaft in order to get the correct relation
wastegate is opened. When the valve of the between the piston movement and the valve
wastegate is opened, the rpm of the turbocharger is movement.
limited by bypassing a portion of the exhaust gases
around the turbine wheel of the turbocharger.
29
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.
i00982190
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
30
g00421818
Illustration 18
Right side of engine
(9) Primary engine oil filter
(10) Engine oil pump
(11) Secondary oil filter (not shown)
(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) is thermostatically

controlled in order to maintain engine oil to bearing
temperature of 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.
31
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

front gear train on the lower right hand side of the
engine. The engine oil pump is driven by an idler
gear from the crankshaft gear. Oil is pulled from
the sump through oil pump bypass valve (15) on
the way to the engine oil cooler. The bypass valve
controls the oil pressure from the engine oil pump.
The engine oil pump can supply excess oil for the
lubricating system. When this situation is present,
the oil pressure increases and the bypass valve
opens. The open bypass valve allows the excess
oil to return to the sump.
32
High pressure relief valve (6) regulates high Filtered oil flows through main oil gallery (2) in the
pressure in the system. The high pressure relief cylinder block to the following components:
valve will allow the oil to return to the sump when
the oil pressure reaches 695 kPa (100 psi). The oil Piston cooling jets (18)
then flows through the engine oil cooler. The engine
oil cooler uses engine coolant in order to cool the Valve mechanism
oil. Oil cooler bypass valve (14) is thermostatically
controlled. The oil cooler bypass valve directs the Camshaft bearings
oil flow through the engine oil cooler when the oil
temperature reaches 100 to 103 C (212 to 217 F). Crankshaft main bearings
A failsafe activation temperature of 127 C (260 F),
which is incorporated in the oil cooler bypass valve, Turbocharger
will close the valve. Closing the valve directs oil flow
to the engine oil cooler. The valve will remain closed An oil cooling chamber is formed by the following
if the valve fails. The oil cooler bypass valve is also pieces: the lip forge at the top of the skirt of the
activated by pressure. If the oil pressure differential piston (19) and the cavity behind the ring grooves in
across the engine oil cooler reaches 155 17 kPa the crown. Oil flow from the piston cooling jet enters
(22 3 psi), the valve will open. Opening the valve the cooling chamber through a drilled passage in
allows the oil to bypass the engine oil cooler. the skirt. The oil then returns to the sump through
the clearance gap between the crown and the skirt.
Approximately five percent of the oil flow is directed Four holes that are drilled from the piston oil ring
through an orificed passage that leads to secondary groove to the interior of the piston drain excess oil
oil filter (17) (if equipped). The oil flows through the from the oil ring.
bypass filter and to the engine oil sump. The main
oil flow now flows toward the primary engine oil
filter. 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
g00481403
Note: Refer to Specifications, Engine Oil Filter Illustration 21
Base for a cross section of the valves in the engine Left front side of engine
oil filter base. (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
(19) Piston
(20) Connecting rod
33
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
g00423399
Illustration 23
Typical right side of engine
(4) Water pump
g00423398
Illustration 22
Cooling system schematic
(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 of radiator (2) by using the impellers rotation. The
pump is located on the right hand side of the water pump is located on the right hand side of the
engine. The water pump supplies the coolant for front timing gear housing.
the engine cooling system. The coolant is supplied
to the following components:
Engine oil cooler (5)

Cylinder head (8)
34
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 Typical right front side of engine
liner to the cylinder head. The cylinder head is (1) Temperature regulator housing
divided into single cylinder cooling sections. In the (2) Coolant temperature sensor
cylinder head, 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 g00423403
remainder flows directly to the cylinder head. Illustration 26
Temperature regulator housing
(3) Return manifold
(4) Coolant temperature regulator
35
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.
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.
36
Coolant conditioner element (7) is a spin-on Coolant for Air Compressor

element 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
g00501085
mixed to the correct concentration. Two basic Illustration 28
types of elements are used for the cooling system, Typical air compressor
the precharge and the maintenance elements. (1) Outlet hose
Each type of element has a specific use. Each (2) Inlet hose
type of element must be used correctly to get (3) Air compressor
the necessary concentration for cooling system
protection. The elements also contain a filter. Even The coolant that is used for air compressor (3)
after the conditioner material is dispersed, the comes from the cylinder head through inlet hose
elements should be left in the system so the coolant (2). The coolant exits the air compressor through
flows through the filter. outlet hose (1) and flows back to the cylinder head.
The precharge coolant conditioner element has

more than the normal amount of corrosion inhibitor. i01459203
The precharge coolant conditioner element is used Basic Engine

when a system is first filled with new coolant. This
element must add enough corrosion inhibitor in SMCS Code: 1200
order to bring the complete cooling system up to
the correct concentration.
Cylinder Block
The maintenance elements have a normal amount
of inhibitor and the maintenance elements are The cylinder block is a unique design with a deep
installed at each change interval. The maintenance counterbore that supports the cylinder liner. The
elements provide enough inhibitor in order to keep cylinder block also forms the coolant jacket. Two
the corrosion protection at an acceptable level. In oil manifolds are provided in the cylinder block
order to provide the cooling system with protection, for engine lubrication. The manifold on the lower
maintenance elements are installed at specific right side of the cylinder block provides oil to the
intervals. 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.
37
The piston is a two-piece articulated piston. The

piston has a forged steel crown (5) and a forged
aluminum skirt (6). Both parts are retained by the
piston pin to the small end of the connecting rod.
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
Illustration 29 g00762739 and a chrome finish.
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 is the head gasket which is
above the coolant jacket.
The cylinder block has seven main bearings in

order to support the crankshaft. The main bearing g00762786
Illustration 31
caps are fastened to the cylinder block with two
bolts per cap.
Connecting rod (8) is a conventional design. The
cap is fastened to the shank by two bolts (9) that are
Pistons, Rings, and Connecting threaded into the shank. Each side of the small end
Rods of the connecting rod (7) is machined at an angle
of 12 degrees in order to fit within the piston cavity.
This allows a larger surface area on the piston, and
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
g00762765 Water pump

Illustration 30
Engine oil pump
Air compressor
38
Fuel transfer pump Vibration Damper

Accessory drive The force from combustion in the cylinders and from
driveline components will cause the crankshaft to
The crankshaft is held in place by seven main twist. This is called torsional vibration. If the vibration
bearings. The oil holes and the oil grooves in is too great, the crankshaft will be damaged.
the shell of the upper bearing supply oil to the Driveline components can excite torsional stress.
connecting rod bearings. The oil holes for the This stress will cause damage to components. The
connecting rod bearings are located at the following vibration damper limits the torsional vibrations to an
main bearing journals: 2, 3, 5, and 6. acceptable amount in order to prevent damage to
the crankshaft.
crankshaft to control oil leakage. The hydrodynamic The viscous vibration damper is installed on the
grooves in the seal lip move lubrication oil back into front of the crankshaft. The viscous vibration
the crankcase as the crankshaft turns. The front damper has a weight in a case. The space between
seal is located in the front housing. The rear seal is the weight and the case is filled with a viscous fluid.
installed in the flywheel housing. The weight moves in the case in order to limit the
torsional vibration.
Camshaft
i00984742

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

of the flywheel housing. The rear power take-off
provides continuous live power through the following
direct drive gears:
Crankshaft gear
Idler gear
g00762808
Illustration 32 Output shaft gear
The camshaft has three lobes at each cylinder These gears are driven off the rear of the crankshaft.
in order to operate the unit injector, the exhaust
valves, and the inlet valves. Seven bearings support
the camshaft. The camshaft is driven by an idler i00984766
gear that is turned by the crankshaft in the front
gear train. Each bearing journal is lubricated from
Compression Brake
the oil manifold in the cylinder block. A thrust pin
SMCS Code: 1119; 1129
that is located at the rear of the block positions
the camshaft through a circumferential groove. The
The compression brake is powered from the
groove is machined at the rear of the camshaft.
Electronic Control Module (ECM). The compression
Timing of the camshaft is accomplished by aligning
brake helps the operator to slow the vehicle
marks on the crankshaft gear, idler gear, and
on grades, in curves, or for a necessary speed
camshaft gear with each other.
reduction. The service brakes should not be
used continuously on long descending grades.
The compression brake gives the vehicle some
braking power without using the service brakes.
The engine crankshaft is turned by the rear wheels
during downhill operation or during any slow down
condition. The engine crankshaft is turned through
the differential, through the drive shaft, through the
transmission, and through the clutch. An application
of a braking force can be made to the engine piston
in order to reduce the speed of the vehicle.
39
When the compression brake is activated, braking The control circuit for the compression brake
power is accomplished by opening the engines permits the operation of either one, two, or all three
exhaust valves. The exhaust valves are opened of the compression brake housing assemblies. This
near the top of the compression stroke in order provides progressive braking capabilities with the
to release the highly compressed air into the retarding effect of two cylinders, of four cylinders,
exhaust system. The compression brake can only or of all six cylinders in the engine.
be activated when the engine is in the no-fuel
position. Thus, combustion does not occur and
no positive force is produced on the piston. The
Performance of the Compression
compressed air pressure that is released to the Brake
atmosphere prevents the energy from 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.
g00427859
g00501265
Illustration 34
Illustration 33
Performance of the compression brake
Compression brake
(1) Control valve The performance of the compression brake, which
(2) Lead wire is shown in the graph, represents an engine with
(3) Bolt assembly
(4) Slave piston the three housing assemblies that are activated in
(5) Solenoid valve order to stop the vehicle. The compression brake
(6) Master piston should not be activated when the engine rpm is
(7) Stud and nut above 2300. The maximum engine power rating
is 2100 rpm. At this level, the amount of braking
The compression brake consists of three identical that is produced by the compression brake is
housing assemblies. A housing assembly is installed approximately 315 to 325 horsepower.
in each of the valve mechanism compartments
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).
40
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 operates by using 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
41
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 passage (15) is opened. This allows oil to drain from
(15) to engine oil pan (11) to be closed. At the underneath control valve (5). This also allows spring
same time, low pressure oil passage (16) to control (4) to push the control valve to the bottom of the
valve (5) is opened. As low pressure oil passage chamber. This position allows oil from high pressure
(16) is filled with engine oil, the control valve is oil passage (6) to drain into the chamber above the
pushed upward in the chamber against the force of control valves piston. This chamber vents to the
spring (4). At this position, a groove in control valve outside of the compression brake housing. Spring
(5) is in alignment with high pressure oil passage (10) now moves master piston (8) to the retracted
(6). Slave piston (14) and master piston (8) are position away from fuel injector rocker arm (12).
supplied by the high pressure oil passage. Engine The time that is necessary for the system to stop
oil pressure will now lift ball check valve (17). High operation is approximately 1/10 of a second. The
pressure oil passage (6) and the chambers behind compression brake will not be able to operate until
the slave pistons and behind the master pistons solenoid (2) is activated again.
will be filled with engine oil pressure. This pressure
moves the master piston downward until contact
i01459456
is made with fuel injector rocker arm (12). When
upward motion is initiated on the master piston, the
pressure increases above the current level of the
Electrical System
engine supply pressure. This causes ball check SMCS Code: 1400; 1550; 1900
valve (17) to seat. The system is now operating
in conjunction with the exhaust valve and with the
injector rocker mechanism. When the solenoid is Grounding Practices
activated, the compression brake could be operable
within 1/5 of a second. Proper grounding for the machine electrical
system and engine electrical systems is necessary
Fuel injector pushrod (13) will begin to move for proper machine performance and reliability.
upward on the pumping stroke of the electronically Improper grounding will result in uncontrolled
controlled unit injector. When this occurs, fuel electrical circuit paths and unreliable electrical
injector rocker arm (12) makes contact with circuit paths.
extending master piston (8). As the master piston
begins to move upward, the oil pressure increases Uncontrolled engine electrical circuit paths can
in high pressure oil passage (6). This happens result in damage to main bearings, crankshaft
because ball check valve (17) will not allow oil to bearing journal surfaces, and aluminum
exit. The upward movement of the fuel injector components.
rocker arm creates a constant increase in pressure.
This forces the slave piston downward against the To ensure proper functioning of the vehicle and
screw assembly in exhaust bridge assembly (20). engine electrical systems, an engine-to-frame
The slave piston moves downward with enough ground strap with a direct path to the negative
force to open exhaust valve (19). battery post must be used. This may be provided by
way of a starting motor ground, a frame to starting
Note: Only one of the two exhaust valves for each motor 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
This master-slave circuit is designed so that master to the frame of the vehicle and to the negative
piston (8) is moved only when the engine cylinder battery post.
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.
42
g00766579 g00766660
Grounding Stud To Battery Ground (-) Alternate Grounding Stud To Battery Ground (-)
The engine must have a wire ground to the battery.
Ground wires or ground straps should be combined

at ground studs that are only for ground use. All of
the grounds should be tight and free of corrosion.
All of the ground paths must be capable of carrying

any likely current faults. An AWG #0 or larger wire
is recommended for the grounding strap to the
cylinder head.
The engine alternator should be battery ground with

a wire size that is capable of managing the full
charging current of the alternator.
NOTICE
tems Operation, Engine Starting should be followed
in order to properly start the engine.
This engine may be equipped with a 12 volt starting

for boost starting should be used. The use of a higher

connected at the J1/P1 and J2/P2 locations before
welding on the vehicle.
43
The engine has several input components which are The alternator design has no need for slip rings
electronic. These components require an operating and the only part that has movement is the rotor
voltage. assembly. All conductors that carry current are
stationary. The following conductors are in the
Unlike many electronic systems of the past, this circuit:
engine is tolerant to common external sources of
electrical noise. Buzzers that use electrical energy Field winding
can cause disruptions in the power supply. If
buzzers are used anywhere on the machine, the Stator windings
engine electronics should be powered directly from
the battery system through a dedicated relay. The Six rectifying diodes
engine electronics should not be powered through a
common power bus with other key switch activated Regulator circuit components
devices.
The rotor assembly has many magnetic poles
Engine Electrical System that look like fingers with air space between each
of the opposite poles. The poles have residual
magnetism. The residual magnetism produces a
The electrical system has the following separate
circuits: small magnetic field between the poles. As the
rotor assembly begins to turn between the field
winding and the stator windings, a small amount
Charging of alternating current (AC) is produced. The AC
current is produced in the stator windings from the
Starting (If equipped) small magnetic field. The AC current is changed
to direct current (DC) when the AC current passes
Low amperage accessories through the diodes of the rectifier bridge. The
current is used for the following applications:
Some of the electrical system components are used
in more than one circuit. The following components
are common in more than one circuit: Charging the battery
Battery or batteries Supplying the low amperage accessory circuit
Circuit breakers Strengthening the magnetic field

The first two applications use the majority of the
Battery cables current. As the DC current increases through the
field windings, the strength of the magnetic field is
Ammeter increased. As the magnetic field becomes stronger,
more AC current is produced in the stator windings.
The charging circuit is in operation when the engine
is running. An alternator makes electricity for the The increased speed of the rotor assembly also
increases the current and voltage output of the
alternator.
controls the electrical output in order to keep the
battery at full charge.
switch. The voltage regulator senses the voltage in
The starting circuit is activated only when the start
switch is activated. the system. The voltage regulator switches ON and
OFF many times per second in order to control the
field current for the alternator. The alternator uses
The low amperage accessory circuit and the
charging circuit are connected through the ammeter. the field current in order to generate the required
voltage output.
The starting circuit is not connected through the
ammeter.
NOTICE
Never operate the alternator without the battery in the
Charging System Components circuit. Making or breaking an alternator connection
with heavy load on the circuit can cause damage to
Alternator the regulator.
The alternator is driven by a belt from the crankshaft
pulley. This alternator is a three-phase, self-rectifying
charging unit, and the regulator is part of the
alternator.
44
g00425518 g00425521
Typical alternator components Typical starting motor components
(1) Regulator (1) Field
(2) Roller bearing (2) Solenoid
(3) Stator winding (3) Clutch
(4) Ball bearing (4) Pinion
(5) Rectifier bridge (5) Commutator
(6) Field winding (6) Brush assembly
(7) Rotor assembly (7) Armature
(8) Fan
The starting solenoid (2) is an electromagnetic
Starting System Components switch that performs the following basic operations:
Starting Solenoid 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
g00317613 then makes contact across the battery and motor
Illustration 39
terminals of solenoid (2). Next, the starting motor
Typical starting solenoid 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.
45

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
off through the pull-in windings. At this point, only
the smaller hold-in windings are in operation. The
hold-in windings operate for the duration of time
that is required in order to start the engine. Solenoid
(2) will now draw less current from the battery, and
the heat that is generated by solenoid (2) will be
kept at an acceptable level.
46
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
i01459350
Relief valves
Fuel System - Inspect Check valves
SMCS Code: 1250-040
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.
the vent in the fuel cap is not filled with dirt. When possible, operate the engine under the
conditions which have been suspect of air in the
2. Check all fuel lines for fuel leakage. The fuel lines fuel.
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.

Prime.
g00578151
Illustration 41
2P-8278 Fuel Flow Tube (Sight Gauge)
i01459442
(1) A steady stream of small bubbles with a diameter of
Air in Fuel - Test approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
SMCS Code: 1280-081 are also acceptable if there is two seconds to three seconds
intervals between bubbles.
This procedure checks for air in the fuel. This (3) Excessive air bubbles in the fuel are not acceptable.
procedure also assists in finding the source of the
air.
1. Examine the fuel system for leaks. Ensure that

the fuel line fittings are properly tightened. Check
the fuel level in the fuel tank. Air can enter the
fuel system on the suction side between the fuel
transfer pump and the fuel tank.
47
3. If excessive air is seen in the sight gauge in the i01456781

fuel return line, install a second sight gauge at
the inlet to the fuel transfer pump. If a second Electronic Unit Injector - Adjust
sight gauge is not available, move the sight
gauge from the fuel return line and install the SMCS Code: 1290-025
sight gauge at the inlet to the fuel transfer pump.
Look for air bubbles in the fuel. If the engine
starts, check for air in the fuel at varying engine
speeds.
If excessive air is not seen at the inlet to the fuel

transfer pump, the air is entering the system after
the fuel transfer pump. Proceed to Step 6.
If excessive air is seen at the inlet to the fuel

transfer pump, air is entering through the suction
side of the fuel system.
g00481504
Illustration 42
Injector Mechanism
To avoid personal injury, always wear eye and face (1) Rocker arm
protection when using pressurized air. (2) Adjusting screw
(3) Locknut
NOTICE To make an adjustment to the unit injectors on

To avoid damage, do not use more than 55 kPa (8 psi) cylinders 3, 5, and 6 use the following procedure:
to pressurize the fuel tank.
on the compression stroke. Refer to Systems
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not
Operation/Testing and Adjusting, Finding Top
use more than 55 kPa (8 psi) in order to avoid
Center Position for No. 1 Piston.
damage to the fuel tank. Check for leaks in the
fuel lines between the fuel tank and the fuel
2. Start with cylinder number (3). Turn unit injector
transfer pump. Repair any leaks that are found.
adjusting screw (2) clockwise until contact is
Check the fuel pressure in order to ensure that
made with the unit injector.
the fuel transfer pump is operating properly. For
information about checking the fuel pressure, see
3. Turn the unit injector adjusting screw through
Testing and Adjusting, Fuel System Pressure
180 degrees in a clockwise direction.
- Test.
4. Hold the adjusting screw in this position and
5. If the source of the air is not found, disconnect
tighten locknut (3) to a torque of 55 10 Nm
the supply line from the fuel tank and connect an
(41 7 lb ft).
external fuel supply to the inlet of the fuel transfer
pump. If this corrects the problem, repair the fuel
5. Repeat Steps 2 through 4 for cylinders 5 and 6.
tank or the stand pipe in the fuel tank.
6. To make an adjustment to the unit injectors on
6. If the injector sleeve is worn or damaged,
cylinders 1, 2, and 4, remove the timing bolt. Turn
combustion gases may be leaking into the
the flywheel by 360 degrees in the direction of
fuel system. Also, if the O-rings on the injector
engine rotation. The direction of engine rotation
sleeves are worn, missing, or damaged,
is counterclockwise, as the engine is viewed
combustion gases may leak into the fuel system.
from the flywheel end. This will put the number 1
piston at the top center position on the exhaust
stroke.
7. Repeat Steps 2 through 4 for cylinders 1, 2, and

4.
8. Remove the timing bolt from the flywheel after all

the unit injector adjustments have been made.
48
Checking Engine Cylinders 2. Remove the valve cover and look for broken
parts. Repair any broken parts or replace any
Separately broken parts that are found. Inspect all wiring to
Table 2 the solenoids. Look for loose connections. Also
look for frayed wires or broken wires. Ensure
Tools Needed that the connector for the unit injector solenoid
Part is properly connected. Perform a pull test on
Part Name Quantity each of the wires. Refer to Troubleshooting
Number
Guide, P-501: Inspecting Electrical Connectors.
123-6700 Laser Infrared Thermometer 1 Inspect the posts of the solenoid for arcing. If
arcing or evidence of arcing is found, remove
When the engine runs at low idle, the temperature the cap assembly. Refer to Disassembly and
of an exhaust manifold port can be an indication Assembly Manual, Electronic Unit Injector -
of the condition of a unit injector. Low temperature Remove. Clean the connecting posts. Reinstall
at an exhaust manifold port is an indication of no the cap assembly and tighten the solenoid nuts
fuel to the cylinder. This could be caused by an to a torque of 2.5 0.25 Nm (22 2 lb in).
inoperative unit injector. Extra high temperature at Refer to Disassembly and Assembly Manual,
an exhaust manifold port can be an indication of Electronic Unit Injector - Install.
too much fuel to the cylinder. This is caused by a
malfunctioning unit injector. 3. Check the valve lash setting for the cylinder of
the suspect unit injector. Refer to Testing and
Use the 123-6700 Laser Infrared Thermometer to Adjusting, Engine Valve Lash - Inspect/Adjust.
Laser Infrared Thermometer II with laser Sighting 4. Ensure that the bolt that holds the unit injector
for the 123-6700 Laser Infrared Thermometer is tightened to the proper torque. If necessary,
gives the complete operating and maintenance loosen the bolt that holds the unit injector and
instructions for the tool. tighten the bolt to a torque of 30 7 Nm
(22 5 lb ft).
i01459364 5. Remove the suspect unit injector and check the
unit injector for signs of exposure to coolant.
Electronic Unit Injector - Test Refer to Disassembly and Assembly Manual,
Electronic Unit Injector - Remove. Exposure to
SMCS Code: 1290-081
coolant will cause rust to form on the injector.
If the unit injector shows signs of exposure to
This procedure assists in identifying the cause for
coolant, remove the injector sleeve and inspect
an injector misfiring. Perform this procedure only
the injector sleeve. Refer to Disassembly and
after performing the Cylinder Cutout Test. Refer to
Assembly Manual, Electronic Unit Injector
Troubleshooting for more information.
Sleeve - Remove. Replace the injector sleeve if
the injector sleeve is damaged. Check the unit
1. Check for air in the fuel, if this procedure has not
injector for an excessive brown discoloration that
already been performed. Refer to Testing and
extends beyond the injector tip. If excessive
Adjusting, Air in Fuel - Test.
discoloration is found, check the quality of the
fuel. Refer to Testing and Adjusting, Fuel Quality
- Test. Replace the seals on the injector and
reinstall the injector. Refer to Disassembly and
Electrical shock hazard. The electronic unit injec- Assembly Manual, Electronic Unit Injector -
tor system uses 90-120 volts. Install. Also refer to Disassembly and Assembly
Manual, Electronic Unit Injector Sleeves -
Install.
6. If the problem is not resolved, replace the

suspect injector with a new injector.
49
i01503660 Note: If the flywheel is turned beyond the point of

engagement, the flywheel must be turned in the
Finding Top Center Position direction that is reverse of normal engine rotation.
for No. 1 Piston Turn the flywheel by approximately 30 degrees.
Then turn the flywheel in the direction of normal
SMCS Code: 1105-531 rotation until the Timing Pin engages with the hole
in the flywheel. This procedure removes the play
Table 3 from the gears when the No. 1 piston is at the top
center position.
Tools Needed
Part 3. Remove the front valve mechanism cover from
Part Name Quantity
Number the engine.
1U-7115 Reverse Ratchet 1
4. The inlet and exhaust valves for the No. 1
9S-9082 Engine Turning Tool 1 cylinder are fully closed if No. 1 piston is on the
136-4632 Timing Pin 1
moved by hand. If the rocker arms cannot be
139-7063 Timing Pin Adapter 1 moved and the valves are slightly open, the No.
1 piston is on the exhaust stroke.
139-7064 Timing Pin Adapter 1
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.
Note: Never turn the engine by the crankshaft

vibration damper. The crankshaft vibration damper
is a precision part. Major engine failure may be
caused by damage to the crankshaft vibration
damper.
PROCEDURE FOR ENGINES THAT HAVE A REAR

POWER TAKE-OFF
g00780199
Illustration 43
Table 4
(1) Flywheel Housing Tools Needed
(2) Timing Hole Plug Part Number Part Name Quantity
1U-7115 Reverse Ratchet 1
(3) Cover Bolt
5P-7306 Gear Shaft Housing 1
(4) Cover Assembly
9U-6943 Gear Shaft Housing 1
1. Remove two bolts (3) and remove cover (4) from Assembly
flywheel housing (1) in order to open the turning
hole. 9U-7336 Gear Shaft Housing 1
Assembly
2. Thread the 136-4632 Timing Pin with the 5P-7305 Engine Turning Gear 1
proper Timing Pin Adapter into the timing
hole. The timing hole is located approximately 136-4632 Timing Pin 1
127 to 152 mm (5.0 to 6.0 inch) above the 139-7063 Timing Pin Adapter 1
turning hole for the engine turning tool in the
flywheel housing. Use the 9S-9082 Engine 139-7064 Timing Pin Adapter 1
Turning Tool and a 1U-7115 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.
50
4. The inlet and exhaust valves for the No. 1

cylinder are fully closed if No. 1 piston is on the
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.

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.
g00780201
Note: Never turn the engine by the crankshaft
Illustration 44 vibration damper. The crankshaft vibration damper
Typical Rear Power Take-Off is a precision part. Major engine failure may be
caused by damage to the crankshaft vibration
(1) Flywheel Housing damper.
(2) Timing Hole Plug

Checking and Calibrating the
1. Remove (2) Timing Hole Plug and remove the Electronic Injection Timing With
cover for the bore in the flywheel housing for the
starter motor or the starter motor from flywheel
the Electronic Service Tool
housing (1) in order to gain access to the
Refer to Electronic Troubleshooting, PC-32: Engine
flywheel gear.
Speed/Timing Calibration for the proper procedure
to calibrate the electronic injection timing.
2. Thread the 136-4632 Timing Pin with the proper
Timing Pin Adapter into the timing hole of the
flywheel housing. The timing hole is located i01370330
approximately 127 to 152 mm (5.0 to 6.0 inch)
above the bore for the starter motor in the Fuel Quality - Test
flywheel housing. Each different Gear Shaft
Housing Assembly is used in order to fit different SMCS Code: 1280-081
bore diameters for the starter motors. Use the
5P-7305 Engine Turning Gear with the proper This test checks for problems regarding fuel quality.
Gear Shaft Housing Assembly and a 1U-7115 Refer to Diesel Fuels and Your Engine, SEBD0717
Reverse Ratchet to turn the engine flywheel. for additional details.
Turn the flywheel in the direction of engine
rotation. The direction of engine rotation is Use the following procedure to test for problems
counterclockwise, as the engine is viewed from regarding fuel quality:
the flywheel end. Turn the flywheel until the
Timing Pin engages with the hole in the flywheel. 1. Determine if water and/or contaminants are
present in the fuel. Check the water separator (if
Note: If the flywheel is turned beyond the point of equipped). If a water separator is not present,
engagement, the flywheel must be turned in the proceed to Step 2. Drain the water separator, if
direction that is reverse of normal engine rotation. necessary. A full fuel tank minimizes the potential
Turn the flywheel by approximately 30 degrees. for overnight condensation.
Then turn the flywheel in the direction of normal
rotation until the Timing Pin engages with the hole Note: A water separator can appear to be full of fuel
in the flywheel. This procedure removes the play when the water separator is actually full of water.
from the gears when the No. 1 piston is at the top
center position.
3. Remove the front valve mechanism cover from

the engine.
51
2. Determine if contaminants are present in the i01180507

fuel. Remove a sample of fuel from the bottom
of the fuel tank. Visually inspect the fuel sample Fuel System - Prime
for contaminants. The color of the fuel is not
necessarily an indication of fuel quality. However, SMCS Code: 1258-548
fuel that is black, brown, and/or similar to sludge
can be an indication of the growth of bacteria or
oil contamination. In cold temperatures, cloudy
fuel indicates that the fuel may not be suitable Fuel leaked or spilled onto hot surfaces or elec-
for operating conditions. The following methods trical components can cause a fire. To help pre-
can be used to prevent wax from clogging the vent possible injury, turn the start switch off when
fuel filter: changing fuel filters or water separator elements.
Clean up fuel spills immediately.
Fuel heaters
Blending fuel with additives NOTICE
Use a suitable container to catch any fuel that might
Utilizing fuel with a low cloud point such as spill. Clean up any spilled fuel immediately.
kerosene
Refer to Operation and Maintenance Manual, NOTICE

Fuel Recommendations for more information. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
3. Check fuel API with a 9U-7840 Fluid and Fuel will be disconnected. Fit a suitable cover over discon-
Calibration Gp for low power complaints. The nected fuel system component.
acceptable range of the fuel API is 30 to 45
when the API is measured at 15 C (60 F), but If the fuel system runs out of fuel or if air is
there is a significant difference in energy within introduced into the fuel system the following
this range. Refer to Tool Operating Manual, procedure may be followed.
NEHS0607 for API correction factors when a low
power problem is present and API is high. 1. Turn the ignition switch to the OFF position.
Note: A correction factor that is greater than 1.000 2. Fill the fuel tank(s) with clean diesel fuel.
may be the cause of low power and/or poor fuel
consumption.
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

g00474457
Illustration 45
Air in the fuel Typical example
(1) Air bleed screw
Other fuel characteristics (2) Fuel priming pump (IF EQUIPPED)
3. Open air bleed screw (1) for the fuel filter three
full turns. Do not remove the air bleed screw.
NOTICE
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.
52
4. Crank the engine for 30 seconds. Use a suitable Note: Failure to tighten all fittings could result in
container to catch the fuel while you crank the serious fuel leaks.
engine. Allow the starter motor to cool for 2
minutes. c. Clean any residual fuel from the engine
components.
Note: After four or five cranking intervals, most of
the air should be purged from the system. d. Continue to operate the fuel priming pump
until a strong resistance is felt. Listen for an
5. Crank the engine for 30 seconds. Allow the audible click from the fuel manifold. The click
starter motor to cool for 2 minutes. will indicate that the valve has opened and
the fuel system is pressurized. Lock the fuel
6. Repeat Step 5 until the engine starts and runs. If priming pump.
the engine runs rough, continue to operate the
engine at low idle until the engine runs smoothly. NOTICE
Do not crank the engine for more than 30 seconds.
7. Observe air bleed screw (1). When a small drop Allow the starting motor to cool for two minutes before
of fuel appears at the threads of the air bleed cranking again.
screw, close and tighten air bleed screw (1).
Note: Failure to tighten all fittings could result in e. Crank the engine. If the engine starts but
serious fuel leaks. the engine runs rough, continue to operate
the engine at low idle until the engine runs
8. Clean any residual fuel from the engine smoothly.
components.
Note: If the engine will not start, further priming
9. Once the engine runs smoothly, stop the engine. is necessary. If the engine starts but the engine
Turn the ignition switch to the OFF position. continues to misfire or smoke, further priming is
necessary.
Note: You may use the hand priming pump for the
fuel filter (if equipped) instead of starting engine
i01360235
and running the engine. Perform the following
procedure when the hand priming pump is used: Fuel System Pressure - Test
SMCS Code: 1250-081; 1256-081
Low Fuel Pressure

Low fuel pressure can cause low power. Low fuel
pressure can also cause cavitation of the fuel
which can damage the fuel injectors. The following
conditions can cause low fuel pressure:
Plugged fuel filters

Debris in the check valves for the fuel priming
pump
g00474457
Illustration 46
C-10 and C-12 Truck Engine Sticking or worn fuel pressure regulating valve in
(1) Air bleed screw
the fuel transfer pump
(2) Fuel priming pump (IF EQUIPPED)
Severe wear on return fuel pressure regulating
a. Open air bleed screw (1) for the fuel filter valve in the fuel filter base
three full turns. Do not remove the air bleed
screw. Worn gears in the fuel transfer pump
b. While you operate the hand priming pump, Pinched fuel lines or undersized fuel lines
observe air bleed screw (1). When a small
drop of fuel appears at the threads of the Old fuel lines that have a reduced interior
air bleed screw, close and tighten air bleed diameter that was caused by swelling
screw (1).
53
Fuel lines with deteriorating interior surfaces

NOTICE
Pinched fuel line fittings or undersized fuel line Keep all parts clean from contaminants.
fittings
Debris in the fuel tank, fuel lines, or fuel system component life.
components that create restrictions
NOTICE
High Fuel Pressure Care must be taken to ensure that fluids are contained
Excessive fuel pressure can cause fuel filter gaskets during performance of inspection, maintenance, test-
to rupture. The following conditions can cause high
fuel pressure: collect the fluid with suitable containers before open-
Plugged orifices in the fuel pressure regulating
valve
Stuck fuel pressure regulating valve in the fuel suitable to collect and contain fluids on Caterpillar
transfer pump
products.
Pinched fuel return line Dispose of all fluids according to local regulations and
mandates.
Checking Fuel Pressure
Table 5 1. Use the following procedure in order to measure
the fuel pressure that is after the secondary filter:
Tools Needed
Part Note: Fuel pressure readings near the fuel supply
Part Name Quantity manifold have pressure spikes. The pressure spikes
Number
are caused by excess fuel that is returning to the
1U-5470 Engine Pressure Group 1 fuel system from the injectors. Excessive needle
movement at the gauge may be present. Connect
the gauge with a section of suitable hose. The air
in the hose absorbs the spikes. This achieves an
average reading and a steady needle. Keep the
gauge above the measuring point.
g00293196
Illustration 47
Refer to Special Instruction, SEHS8907, Using The

g00597253
Illustration 48
Standard secondary fuel filter base
(1) Preferred port
(2) Alternative port
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. Clean up fuel
a. If the fuel filter base is mounted on the fuel
spills immediately.
supply manifold, install the 1U-5470 Engine
Pressure Group into port (1). This port is the
preferred test port. An alternative port (2) is
located on top of the fuel filter base.
54
g00597254 g00597851
Fuel filter base (remote mount) Secondary fuel filter base (remote mount)
(3) Fuel manifold adapter (7) Fuel line fitting
(4) Fuel filter base (remote mount)
(5) Test port
b. If the secondary fuel filter base is a remote
mount, remove the fuel line. Install a tee at
b. If the fuel filter base is a remote mount, install fuel line fitting (7). Reinstall the fuel line. Install
the 1U-5470 Engine Pressure Group into port the 1U-5470 Engine Pressure Group into the
(4) that is on the top of the fuel filter base. empty tee connection.
c. Adjust the engine speed to 1800 rpm with no c. Adjust the engine speed to 1800 rpm with no
load. load.
d. The fuel pressure should be 586 kPa (85 psi) d. If the pressure is more than 35 kPa (5 psi)
nominal. Record the pressure. above the reading recorded after the
secondary filter, the secondary filter is
e. If excessive pressure is found, check the plugged or the priming pump is plugged.
conditions that are listed under the High Fuel
Pressure heading. e. Replace the secondary filter and check the
pressure again. Inspect the priming pump
2. Use the following procedure in order to measure for debris if the pressure remains more than
the fuel pressure that is before the secondary 35 kPa (5 psi) above the reading recorded
filter: after the secondary filter. Replace the priming
pump, if necessary.
f. If fuel pressure is low both before the

secondary fuel filter and after the secondary
fuel filter, the primary fuel filter is suspect.
If the primary filter has not been replaced
yet, change the filter and check the pressure
again.
g. If the pressure is still low, continue to Step 3.
3. Use the following procedure to check the output

of the fuel transfer pump:
Illustration 50
g00597849 a. Remove the return fuel line. Remove the return
fuel line fitting. This return fuel line fitting is
Standard fuel filter base
located on the standard secondary fuel filter
(6) Port base. The return fuel line fitting is located on
the fuel manifold adapter if the secondary fuel
a. If the fuel filter base is mounted on the fuel filter base is a remote mount.
supply manifold, install the 1U-5470 Engine
Pressure Group into port (6).
55
b. Install the 1U-5470 Engine Pressure Group

into the port that contained the return fuel
line fitting.
c. Adjust the engine speed to 600 rpm with no

load.
d. The fuel pressure should be 690 kPa (100 psi)

to 724 kPa (105 psi).
e. If the fuel pressure is within the specified

range, proceed to Step 4.
g00598160
Illustration 53
Standard secondary fuel filter base
(9) Return fuel pressure regulating valve
(10) Spring
g00597852
Illustration 52
Fuel transfer pump (side view)
(8) Access plug
f. If the pressure is less than 655 kPa (95 psi),

the fuel transfer pump is weak. The pressure
regulating valve in the pump may be stuck or g00598162
Illustration 54
worn. The pressure regulating valve is located
under access plug (8). Remove the access Fuel manifold adapter
plug. Remove the pressure regulating valve, (9) Return fuel pressure regulating valve
the spring, and the pin. Replace the fuel (10) Spring
transfer pump if the pressure regulating valve
is significantly worn and no debris is found. If a. Return fuel pressure regulating valve (9) is
debris is found, clean the valve assembly and located behind the return fuel line fitting.
reinstall the valve assembly. Reinstall access Remove the return fuel pressure regulating
plug (8). valve and remove spring (10).
g. Check the fuel pressure again. Replace the b. Inspect return fuel pressure regulating valve
fuel transfer pump if the fuel pressure still (9) for wear. Replace the valve if the taper
measures less than 655 kPa (95 psi). The fuel exceeds 0.13 mm (0.005 inch).
transfer pump is operating properly if the fuel
pressure measures at least 690 kPa (100 psi) c. Inspect the return fuel line fitting. The return
to 724 kPa (105 psi). fuel pressure regulating valve shifts against
the return fuel line fitting. The movement of
h. Once the fuel transfer pump has been the valve will cause the return line fitting to
confirmed as properly operating, check the wear over time. Replace the fitting if there is
fuel pressure again at the secondary fuel filter evidence of significant wear.
base. Refer to step 2. If the fuel pressure is
not at the nominal specification, continue to d. Reinstall the spring and the return fuel
Step 4. pressure regulating valve. Reinstall the return
fuel line fitting and reinstall the return fuel line.
4. Use the following procedure to inspect the
return fuel pressure regulating valve:
56
e. Check the fuel pressure again at the i01096903

secondary fuel filter base. Refer to Step 2.
If the fuel pressure is not up to 586 kPa Gear Group (Front) - Time
(85 psi), then perform Step 5. If the primary
filter is sized correctly and the fuel lines are SMCS Code: 1206-531
sized correctly, replace the secondary fuel
filter base. If the secondary fuel filter base
is a remote mount, replace the fuel manifold
adapter.
5. Use the following procedure to measure the

vacuum at the primary filter:
a. Adjust the engine speed to 1800 rpm with no

load.
b. Measure the vacuum at the outlet of the

primary filter.
c. The vacuum should be 10.14 kPa (3 in Hg) to

13.52 kPa (4 in Hg). If the vacuum is more
than 30.42 kPa (9 in Hg), measure the vacuum
at the inlet of the primary filter. The differential
across the primary filter should be less than
3.38 kPa (1 in Hg) with a new filter installed.
If the differential is higher by more than
3.38 kPa (1 in Hg), the filter is undersized. g00430184
Illustration 55
The filter should be rated at 341 L (90 US gal) Front Gear Group
per hour. If the filter is sized correctly, ensure (1) Camshaft gear and timing reference ring
that the fittings and lines are correctly sized. (2) Timing marks
The fuel lines should be 12.7 mm (0.5 inch). (3) Idler gear
Also check for debris in the fuel tank that may (4) Crankshaft gear
be plugging the supply tube.
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.
57
Note: The electronic injection timing must be

Refer to Electronic Troubleshooting, PC-32: Engine
Speed/Timing Calibration.
58
Air Inlet and Exhaust

System Hot engine components can cause injury from
burns. Before performing maintenance on the
i01098617
cool.
- Inspect
SMCS Code: 1050-040 Making contact with a running engine can cause
Air Inlet Restriction rotating parts.
There will be a reduction in the performance of the When working on an engine that is running, avoid
engine if there is a restriction in the air inlet system contact with hot parts and rotating parts.
or the exhaust system.
Table 6
4. Use the differential pressure gauge of the
Tools Needed
Part
Part Name Quantity
Number
g00293196
Illustration 56
1U-5470 Engine Pressure Group Illustration 57 g00580368
(1) Air cleaner

Refer to Special Instruction, SEHS8907, Using (2) Test location
instructions that are needed to use the 1U-5470 a. Connect the vacuum port of the differential
Engine Pressure Group. pressure gauge to test location (2). Test
location (2) can be located anywhere along
1. Inspect the engine air cleaner inlet and ducting the air inlet piping after the engine air cleaner
in order to ensure that the passageway is not but before the turbocharger.
blocked or collapsed.
b. Leave the pressure port of the differential
2. Inspect the engine air cleaner element. Replace pressure gauge open to the atmosphere.
a dirty engine air cleaner element with a clean
engine air cleaner element. c. Start the engine. Run the engine in the
no-load condition at high idle.
3. Check for dirt tracks on the clean side of the
engine air cleaner element. If dirt tracks are d. Record the value.
observed, contaminants are flowing past the
engine air cleaner element and/or the seal for e. Multiply the value from Step 4.d by 1.8.
the engine air cleaner element.
59
f. Compare the result from Step 4.e to the

appropriate values that follow.
The air flow through a used engine air cleaner
may have a restriction. The air flow through a
rotating parts.
plugged engine air cleaner will be restricted to
some magnitude. In either case, the restriction must
not be more than the following amount:
Maximum restriction ........ 6.2 kPa (25 in of H2O)
Use the differential pressure gauge of the 1U-5470
The air flow through a new engine air cleaner Engine Pressure Group in order to measure back
element must not have a restriction of more than pressure from the exhaust. Use the following
the following amount: procedure in order to measure back pressure from
Maximum restriction ........ 3.7 kPa (15 in of H2O) the exhaust:
Exhaust Restriction
between the exhaust at the outlet elbow and the
atmospheric air.
Table 7
Tools Needed
Part
Part Name Quantity
Number
g00583322
Illustration 59
(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
Illustration 58 muffler.
2. Leave the vacuum port of the differential pressure
Refer to Special Instruction, SEHS8907, Using gauge open to the atmosphere.
instructions that are needed to use the 1U-5470 3. Start the engine. Run the engine in the no-load
Engine Pressure Group. condition at high idle.
4. Record the value.
5. Multiply the value from Step 4 by 1.8.

Hot engine components can cause injury from
burns. Before performing maintenance on the 6. Compare the result from Step 5 to the value that
engine, allow the engine and the components to follows.
cool.
Back pressure from the exhaust must not be more
than the following amount:
60
Maximum back pressure ...................... 10.0 kPa Before you begin inspection of the turbocharger,
(40 in of H2O) be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the
exhaust system restriction is within the specifications
i01460199
for your engine. Refer to Systems Operation/Testing
Turbocharger - Inspect and Adjusting, Air Inlet and Exhaust System -
Inspect.
SMCS Code: 1052-040
The condition of the turbocharger will have definite
effects on engine performance. Use the following
inspections and procedures to determine the
condition of the turbocharger.
Hot engine components can cause injury from
burns. Before performing maintenance on the Inspection of the Compressor and the Compressor
engine, allow the engine and the components to Housing
cool.
Inspection of the Turbine Wheel and the Turbine
Housing

Personal injury can result from rotating and mov-
ing parts.
Inspection of the Compressor and
Stay clear of all rotating and moving parts. the Compressor Housing
Never attempt adjustments while the machine is Remove air piping from the compressor inlet.
moving or the engine is running unless otherwise
specified. 1. Inspect the compressor wheel for damage from a
foreign object. If there is damage, determine the
The machine must be parked on a level surface source of the foreign object. As required, clean
and the engine stopped. the inlet system and repair the intake system.
Replace the turbocharger. If there is no damage,
go to Step 3.
NOTICE
Keep all parts clean from contaminants. 2. Clean the compressor wheel and clean the
compressor housing if you find buildup of foreign
Contaminants may cause rapid wear and shortened material. If there is no buildup of foreign material,
component life. go to Step 3.
NOTICE 3. Turn the rotating assembly by hand. While you

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

If restriction is found, correct the problem.
61
c. Inspect the engine crankcase breather. Clean 3. Turn the rotating assembly by hand. While you
the engine crankcase breather or replace turn the assembly, push the assembly sideways.
the engine crankcase breather if the engine The assembly should turn freely. Turbine wheel
crankcase breather is plugged. (2) should not rub turbine wheel housing (1).
Replace turbocharger (3) if turbine wheel (2)
d. Remove the turbocharger oil drain line. rubs turbine housing (1). If there is no rubbing or
Inspect the drain opening. Inspect the oil scraping, go to Step 4.
drain line. Inspect the area between the
bearings of the rotating assembly shaft. Look 4. Inspect the turbine and turbine housing (1) for
for oil sludge. Inspect the oil drain hole for oil leakage. Inspect the turbine and turbine
oil sludge. Inspect the oil drain line for oil housing (1)for oil coking. Some oil coking may
sludge in the drain line. If necessary, clean be cleaned. Heavy oil coking may require
the rotating assembly shaft. If necessary, replacement of the turbocharger. If the oil is
clean the oil drain hole. If necessary, clean coming from the turbocharger center housing go
the oil drain line. to Step 4.a. Otherwise go to Inspection of the
Wastegate.
source of the oil leakage, the turbocharger has a. Remove the turbocharger oil drain line.
internal damage. Replace 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
Inspection of the Turbine Wheel hole for oil sludge. Inspect the oil drain line
and the Turbine Housing for oil sludge. If necessary, clean the rotating
assembly shaft. If necessary, clean the drain
Remove the air piping from the turbine housing. 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 the oil drain line is not too close to
the engine exhaust manifold.

source of the oil leakage, turbocharger (3) has
internal damage. Replace turbocharger (3).
Illustration 60
g00763164
(1) Turbine Housing
(2) Turbine Wheel Note: All engines are not equipped with waste
(3) Turbocharger gates.
1. Inspect the turbine for damage by a foreign The wastegate controls the amount of exhaust gas
object. If there is damage, determine the source that is allowed to bypass the turbine side of the
of the foreign object. Replace turbocharger (3). turbocharger. This valve then controls the rpm of
If there is no damage, go to Step 2. the turbocharger.
2. Inspect turbine wheel (2) for buildup of carbon When the engine operates in conditions of low
and other foreign material. Inspect turbine boost (lug), a spring presses against a diaphragm
housing (1) for buildup of carbon and foreign in the canister. The actuating rod will move and the
material. Clean turbine wheel (2) and clean wastegate will close. Then, the turbocharger can
turbine housing (1) if you find buildup of carbon operate at maximum performance.
or foreign material. If there is no buildup of
carbon or foreign material, go to Step 3.
62
When the boost pressure increases against the The correct pressure for the inlet manifold is listed
diaphragm in the canister, the wastegate will open. in the TMI (Technical Marketing Information). The
The rpm of the turbocharger becomes limited. The correct pressure is also on the Fuel Setting And the
rpm limitation occurs because a portion of the related Service Information System. Development of
exhaust gases bypass the turbine wheel of the this information is performed under the following
turbocharger. conditions:
The following levels of boost pressure indicate a 99 kPa (29.7 in Hg) dry barometric pressure
problem with the wastegate:
29 C (85 F) outside air temperature
too high at full load conditions
35 API rated fuel
too low at all lug conditions
On a turbocharged, aftercooled engine, a change in
Note: The housing assembly for the wastegate is the fuel rating will change the horsepower. A change
preset at the factory and no adjustments can be in the fuel rating will change the inlet manifold
made. pressure. If the fuel is rated above 35 API, the inlet
manifold pressure can be less than the pressure
NOTICE given in the TMI (Technical Marketing Information).
If the high idle rpm or the engine rating is higher than The pressure will also be less than the pressure that
given in the Technical Marketing Information (TMI) is listed on the Fuel Setting And the Related Service
for the height above sea level at which the engine is Information System. If the fuel is rated below 35
operated, there can be damage to engine or to tur- API, the inlet manifold pressure can be more than
bocharger parts. Damage will result when increased the pressure listed in the TMI (Technical Marketing
heat and/or friction due to the higher engine output Information). The pressure will also be more than
goes beyond the engine cooling and lubrication the pressure that is listed on the Fuel Setting And
systems abilities. the Related Service Information System.
Note: Ensure that the air inlet and the exhaust are
The boost pressure controls the maximum rpm of the not restricted when you are checking the inlet
turbocharger, because the boost pressure controls manifold pressure.
the position of the wastegate. The following factors
also affect the maximum rpm of the turbocharger:
the engine rating

the horsepower demand on the engine
the high idle rpm
the height above sea level for engine operation
inlet air restriction
exhaust system restriction
g00434159
Illustration 61
i01461897
Pressure test location on inlet manifold
Inlet Manifold Pressure - Test (1) Plug

Tools Needed
The efficiency of an engine can be checked by
making a comparison of the pressure in the inlet Part
Part Name Quantity
manifold with the information given in the TMI Number
(Technical Marketing Information). The information 1U-5470 Engine Pressure Group 1
is also listed on the Fuel Setting and the Service
Information System. This test is used when there
is a decrease of horsepower from the engine, yet
there is no real sign of a problem with the engine.
63
A very high temperature can indicate that too much

fuel is flowing to the cylinder. A malfunctioning
fuel injection nozzle could cause this very high
temperature.
Use the 123-6700 Laser Infrared Thermometer to

NEHS0630 contains the complete operating and
maintenance instructions for the 123-6700 Laser
Infrared Thermometer.
i01099953
Aftercooler - Test
g00293196
Illustration 62
SMCS Code: 1063-081
Table 10
Refer to Special Instruction, SEHS8907, Using
the 1U-5470 Engine Pressure Group for the Tools Needed
instructions that are needed to use the 1U-5470 Part
Engine Pressure Group. Part Name Quantity
Number
Use the following procedure in order to measure the 1U-5470 Engine Pressure Group 1
inlet manifold pressure: FT-1984 Aftercooler Testing Group 1
1. Remove plug (1) from the inlet manifold. FT-1438 Aftercooler (Dynamometer 1
Test)
2. Connect the 1U-5470 Engine Pressure Group to
the inlet manifold at the pressure test location.
Visual Inspection
4. Compare the value that was recorded in Step 3
to the pressure that is given in the TMI (Technical Air lines
Marketing Information). The correct pressure
is also given in the Fuel Setting And Related Hoses
Information Microfiche.
Gasket joints
i01460255
Exhaust Temperature - Test

Pressurized air can cause personal injury. When
SMCS Code: 1088-081 pressurized air is used for cleaning, wear a protec-
tive face shield, protective clothing, and protective
Table 9 shoes.
Tools Needed
Ensure that the constant torque hose clamps are
Part
Part Name Quantity tightened to the correct torque. Check the truck
Number
manufacturers specifications for the correct torque.
123-6700 Laser Infrared Thermometer 1 Check the welded joints for cracks. Ensure that
When the engine runs at low idle, the temperature of Ensure that the brackets are in good condition. Use
an exhaust manifold port can indicate the condition compressed air to clean any debris or any dust
of a fuel injection nozzle. from the aftercooler core assembly. Inspect the
cooler core fins for the following conditions:
A low temperature indicates that no fuel is flowing
to the cylinder. An inoperative fuel injection nozzle Damage
or a problem with the fuel injection pump could
cause this low temperature. Debris
Corrosion
64
Use a stainless steel brush to remove any corrosion. Aftercooler Core Leakage
Ensure that you use soap and water.

system are repaired, a leak test is recommended.
When parts of the air-to-air aftercooler system are
replaced, a leak test is recommended.
The use of winter fronts or shutters is discouraged

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
the truck manufacturer about the use of both winter
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

g00295702
manifold temperature can be caused by any of the Illustration 63
following conditions: FT-1984 Aftercooler Testing Group
Plugged air cleaner Clean the air cleaner or (2) Nipple
replace the air cleaner, as required. Refer to the (3) Relief valve
Operation and Maintenance Manual, Engine Air (4) Tee
(5) Coupler
Cleaner Element - Clean/Replace. (6) Aftercooler
(7) Dust plug
Blockage in the air lines Blockage in the air lines (8) Dust plug
between the air cleaner and the turbocharger must (9) Chain
be removed.
A low power problem in the engine can be the result
Aftercooler core leakage Aftercooler core leakage of aftercooler leakage. Aftercooler system leakage
should be pressure tested. Refer to Aftercooler can result in the following problems:
Core Leakage topic for the testing procedure.
Low power
Leakage of the induction system Any leakage from
the pressure side of the induction system should Low boost pressure
be repaired.
Black smoke
Inlet manifold leak An inlet manifold leak can be
caused by the following conditions: loose fittings High exhaust temperature
and plugs, missing fittings and plugs, damaged
fittings and plugs, and leaking inlet manifold gasket. NOTICE
Remove all air leaks from the system to prevent engine
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
65
A large leak of the aftercooler core can often be Air System Restriction


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
being pressurized. Illustration 64
Pressure measurements should be taken at the inlet

NOTICE manifold (1) and at the turbocharger outlet (2).
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 in order to measure the restriction of the aftercooler:
Also, attach the air supply. 1. Connect the vacuum port of the differential
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
5. Inspect all connection points for air leakage.
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:
check all areas for leakage. Look for air bubbles Air flow is at a maximum level.
aftercooler core, or repair the aftercooler core, Total air pressure drop of the charged system
as needed. 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 Clean
removed, relieve all pressure in the system slowly
by using an air regulator and a valve assembly. Repair
8. After the testing, remove the FT-1984 Aftercooler Replacement

Testing Group. Reconnect the air pipes on both
sides of the aftercooler core assembly.
66
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 11
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

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 restricted in a very short time, causing oil leakage
and blow dry the aftercooler with compressed air. at gaskets and seals that would not normally have
Blow dry the assembly in the reverse direction of leakage. Blowby can also be caused by worn valve
normal air flow. To make sure that the whole system guides or by a failed turbocharger seal.
is clean, 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 g00286269
Illustration 65
system. Therefore, the jacket water cooling systems 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
Barometric pressure
With dynamometer tests for engines, use the
FT-1438 Aftercooler (Dynamometer Test). This tool
provides a water cooled aftercooler in order to
control the inlet air temperature to 43 C (110 F).
67
i01120286 Table 12
Compression - Test Valve Lash Check (Stopped Engine)

0.30 to 0.46 mm
SMCS Code: 1215 Inlet
(0.012 to 0.018 inch)
An engine that runs roughly can have a leak at the 0.56 to 0.72 mm
Exhaust
(0.022 to 0.028 inch)
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 If the measurement is not within this range, an
necessary to find those small defects that would adjustment is necessary. Refer to Valve Lash
not normally cause problems. Repairs of these Adjustment for the proper procedure.
problems are normally performed when you are
reconditioning the engine. Valve Lash Adjustment
Table 13
i01460266
Valve Lash Setting (Stopped Engine)
Engine Valve Lash -
Inlet 0.38 mm (0.015 inch)
Inspect/Adjust
Exhaust 0.64 mm (0.025 inch)
SMCS Code: 1102-025


This engine uses high voltage to control the fuel g00386924

Illustration 66
injectors.
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- Use the following procedure to adjust the valve lash:
Note: Valve lash is measured between the rocker Adjusting, Finding Top Center Position for No.
arm and the valve bridge. All measurements and 1 Piston.
adjustments must be made with the engine stopped
and the valves fully closed.
Valve Lash Check

An adjustment is NOT NECESSARY if the
range in Table 12.
68
g00481639 g00481645
Adjustment of the inlet valve Adjustment of the exhaust valve
(1) Inlet rocker arm (3) Exhaust rocker arm
(2) Adjustment locknut (4) Adjustment locknut
2. Adjust the valve lash on the inlet valves for 3. Adjust the valve lash on the exhaust valves for
cylinders 1, 2, and 4. cylinders 1, 3, and 5.
a. Lightly tap the rocker arm at the top of the a. Lightly tap the rocker arm at the top of the
adjustment screw with a soft mallet. This will adjustment screw with a soft mallet. This will
ensure that the lifter roller seats against the ensure that the lifter roller seats against the
camshafts base circle. camshafts base circle.
b. Loosen adjustment locknut (2). b. Loosen adjustment locknut (4).
c. Place the appropriate feeler gauge between c. Place the appropriate feeler gauge between
inlet rocker arm (1) and the inlet valve exhaust rocker arm (3) and the exhaust valve
bridge. Then, turn the adjustment screw in a bridge. Then, turn the adjustment screw in a
clockwise direction. Slide the feeler gauge clockwise direction. Slide the feeler gauge
between the rocker arm and the valve bridge. between the rocker arm and the valve bridge.
Continue turning the adjustment screw until a Continue turning the adjustment screw until a
slight drag is felt on the feeler gauge. Remove slight drag is felt on the feeler gauge. Remove
the feeler gauge. the feeler gauge.
d. Tighten adjustment locknut (2) to a torque d. Tighten adjustment locknut (4) to a torque
of 25 7 Nm (18 5 lb ft). Do not allow of 25 7 Nm (18 5 lb ft). Do not allow
the adjustment screw to turn while you are the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck tightening the adjustment locknut. Recheck
the valve lash after tightening the adjustment the valve lash after tightening the adjustment
locknut. locknut.

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
5. Adjust the valve lash on the inlet valves for

cylinders 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
camshafts base circle.
b. Loosen adjustment locknut (2).

69
c. Place the appropriate feeler gauge between

inlet rocker arm (1) and the inlet valve
bridge. Then, turn the adjustment screw in a
clockwise direction. Slide the feeler gauge
between the rocker arm and the valve bridge.
Continue turning the adjustment screw until a
slight drag is felt on the feeler gauge. Remove
the feeler gauge.
d. Tighten adjustment locknut (2) to a torque

of 25 7 Nm (18 5 lb ft). Do not allow
the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck
the valve lash after tightening the adjustment
locknut.
6. Adjust the valve lash on the exhaust valves for

cylinders 2, 4, 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
camshafts base circle.
b. Loosen adjustment locknut (4).
c. Place the appropriate feeler gauge between

exhaust rocker arm (3) and the exhaust valve
bridge. Then, turn the adjustment screw in a
clockwise direction. Slide the feeler gauge
between the rocker arm and the valve bridge.
Continue turning the adjustment screw until a
slight drag is felt on the feeler gauge. Remove
the feeler gauge.
d. Tighten adjustment locknut (4) to a torque

of 25 7 Nm (18 5 lb ft). Do not allow
the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck
the valve lash after tightening the adjustment
locknut.
7. Remove the timing bolt from the flywheel after all

adjustments to the valve lash have been made.
Refer to Testing and Adjusting, Slave Piston Lash -

Adjust.

adjusting the compression brake, if equipped.
Refer to Testing and Adjusting, Electronic Unit

Injector - Adjust.
70
Lubrication System
i01103330
Engine Oil Pressure - Test

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

electronically by using the electronic technician
(ET). 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 69
oil pressure in the system. This engine tool group
can read the oil pressure inside the oil manifold.
Engine parts that are hot, or parts that are moving, Note: Refer to Special Instruction, SEHS8907,
can cause personal injury. Using the 1U-5470 Engine Pressure Group for
more information.
NOTICE

component life.
NOTICE
g00437624
Illustration 70
Refer to Special Publication, NENG2500, Caterpillar Oil gallery plug
Tools and Shop Products Guide for tools and supplies (1) Plug
products. 1. Install the 1U-5470 Engine Pressure Group into
oil gallery plug (1).
mandates. Note: Engine oil pressure to the camshaft and main
bearings should be checked on each side of the
Table 14 cylinder block at oil gallery plug (1).
Tools Needed
2. Start the engine. Run the engine with SAE 15W40
Part Number Part Name Quantity oil. Refer to Operation and Maintenance Manual,
1U-5470 Engine Pressure Group 1 Engine Oil for the recommendations of engine
oil.
3. Record the value of the engine oil pressure when

the engine is at operating temperature 100 C
(212 F).
71
The minimum engine oil pressure at 1800 The oil pickup tube has a leak or a restricted inlet
rpm should be approximately 275 to 414 kPa screen. Refer to Step 5.
(40 to 59 psi). Minimum engine oil pressure
at low idle rpm (600 to 800 rpm) should be The engine oil pump is faulty. Refer to Step 6.
Engine Bearings have excessive clearance. Refer
4. Compare the recorded engine oil pressure with to Step 7.
the oil pressure indicators on the instrument
panel and the engine oil pressure that is 1. Check the engine oil level in the crankcase.
displayed on the electronic service tool. The oil level can possibly be too far below the
oil pump supply tube. This will cause the oil
5. An engine oil pressure indicator that has a pump not to have the ability to supply enough
defect or an engine oil pressure sensor that lubrication to the engine components. If the
has a defect can give a false indication of a engine oil level is low add engine oil in order
low oil pressure or a high oil pressure. If there to obtain the correct engine oil level. Refer to
is a notable difference between the engine oil Operation and Maintenance Manual, Engine Oil
pressure readings make necessary repairs. for the recommendations of engine oil.
6. If the engine oil pressure is determined to be low, 2. Engine oil that is contaminated with fuel or
refer to Reasons for Low Engine Oil Pressure. coolant will cause low engine oil pressure.
High engine oil level in the crankcase can be
7. If the engine oil pressure is determined to be an indication of contamination. Determine the
high, refer to Reason for High Engine Oil reason for contamination of the engine oil and
Pressure. make the necessary repairs. Replace the engine
oil with the approved grade of engine oil. Refer
to Operation and Maintenance Manual, Engine
Reasons for Low Engine Oil Oil for the recommendations of engine oil.
Pressure
NOTICE
NOTICE Caterpillar oil filters are built to Caterpillar speci-
Keep all parts clean from contaminants. fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
Contaminants may cause rapid wear and shortened the engine bearings, crankshaft, etc., as a result of
component life. the larger waste particles from unfiltered oil entering
recommended by Caterpillar.
NOTICE
during performance of inspection, maintenance, test- 3. If the engine oil bypass valves are held in the
ing, adjusting and repair of the product. Be prepared to open position, a reduction in the oil pressure can
collect the fluid with suitable containers before open- be the result. This may be due to debris in the
ing any compartment or disassembling any compo- engine oil. If the engine oil bypass valves are
nent containing fluids. stuck in the open position, remove each engine
oil bypass valve and clean each bypass valve
Refer to Special Publication, NENG2500, Caterpillar in order to correct this problem. You must also
Tools and Shop Products Guide for tools and supplies clean each bypass valve bore. Install new engine
suitable to collect and contain fluids on Caterpillar oil filters. New engine oil filters will prevent more
products. debris from causing this problem. For information
on the repair of the engine oil bypass valves,
Dispose of all fluids according to local regulations and refer to Disassembly and Assembly, Engine Oil
mandates. Filter Base - Disassemble.
4. An oil line or an oil passage that is open,

Engine oil level is low. Refer to Step 1. broken, or disconnected will cause low engine
oil pressure. An open lubrication system could
Engine oil is contaminated. Refer to Step 2. be caused by a piston cooling jet that is missing
or damaged. Determine the reason for an open
The engine oil bypass valves are open. Refer to lubrication system of the engine and make the
Step 3.
necessary repairs.
The engine lubrication system is open. Refer to
Step 4.
72
Note: The piston cooling jets direct engine oil toward

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

SMCS Code: 1304-040
component life. The inlet screen of the supply tube for the engine
oil pump can have a restriction. This will cause
cavitation and a loss of oil pressure. Air leakage
in the supply side of the engine oil pump will also
cause cavitation and loss of oil pressure. If the
bypass valve for the engine oil pump is held in
the open position, the lubrication system cannot
achieve maximum pressure. Oil pump gears that
have too much wear will cause a reduction in the
oil pressure.
73
If any part of the engine oil pump is worn enough Oil leakage past the seal rings in the impeller end
in order to affect the performance of the engine oil of the turbocharger shaft
pump, the engine oil pump must be replaced. Refer
to Specifications, Engine Oil Pump for clearances. Overfilling of the crankcase
Wrong dipstick or guide tube
i01126690
Excessive Bearing Wear - Excessive oil consumption can also be the result if
oil with the wrong viscosity is used. Oil with a thin
Inspect viscosity can be caused by fuel leakage into the
crankcase or by increased engine temperature.
SMCS Code: 1203-040; 1211-040; 1219-040
When some components of the engine show i01366050

restriction in an oil passage.
Increased Engine Oil
Temperature - Inspect
An engine oil pressure indicator may show that there
is enough oil pressure, but a component is worn SMCS Code: 1348-040
the passage for the oil supply to the component. A When the engine is at operating temperature and
restriction in an oil supply passage will not allow the engine is using SAE 15W40 oil, the maximum
enough lubrication to reach a component. This will oil temperature should be 110 C (230 F). This is
result in early wear. the temperature of the oil after passing through the
oil cooler.
i01461992
If the oil temperature is high, then check for a
Excessive Engine Oil restriction in the oil passages of the oil cooler. A
restriction in the oil cooler will not cause low oil
Consumption - Inspect pressure in the engine.
SMCS Code: 1348-040 Determine if the oil cooler bypass valve is held in
the open position. This condition will allow the oil to
Oil Leakage On Outside Of Engine pass through the valve instead of the oil cooler. The
oil temperature will increase.
Check for leakage at the seals at each end of the
crankshaft. Look for leakage at the oil pan gasket
and all lubrication system connections. Look for any
oil that may be leaking from the crankcase breather.
This can be caused by combustion gas leakage
around the pistons. A dirty crankcase breather
crankcase breather will cause the gaskets and the
seals to leak.
Oil Leakage Into Combustion Area

Of Cylinders
Oil leakage into the combustion area of the cylinders
can be the cause of blue smoke. There are six
possible ways for oil leakage into the combustion
area of the cylinders:
Oil leakage between worn valve guides and valve

stems
Worn components or damaged components

Incorrect installation of the compression ring

74
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
Cooling System - Check coolant not to cool to the proper temperature
(Overheating) differential.
SMCS Code: 1350-535 5. Check the water temperature gauge. A water

temperature gauge which does not work
Above normal coolant temperatures can be caused correctly will not show the correct temperature.
by many conditions. Use the following procedure Refer to Testing and Adjusting, Cooling System
to determine the cause of above normal coolant - Inspect.
temperatures:
6. Check the sending unit. In some conditions, the
temperature sensor in the engine sends signals
to a sending unit. The sending unit converts
these signals to an electrical impulse which is
Personal injury can result from escaping fluid unused by a mounted gauge. If the sending unit
der pressure. malfunctions, the gauge can show an incorrect
reading. Also if the electric wire breaks or if the
If a pressure indication is shown on the indicator, electric wire shorts out, the gauge can show an
push the release valve in order to relieve pressure incorrect reading.
7. Check the radiator.
a. Check the radiator for a restriction to coolant
flow. Check the radiator for debris, dirt, or
Cooling System Coolant Level - Check. If
deposits on the inside of the radiator core.
the coolant level is too low, air will get into the
Debris, dirt, or deposits will restrict the flow of
cooling system. Air in the cooling system will
coolant through the radiator.
cause a reduction in coolant flow and bubbles
in the coolant. Air bubbles will keep coolant
b. Check for debris or damage between the fins
away from the engine parts, which will prevent
of the radiator core. Debris between the fins of
the transfer of heat to the coolant. Low coolant
the radiator core restricts air flow through the
level is caused by leaks or incorrectly filling the
radiator core. Refer to Testing and Adjusting,
radiator.
Cooling System - Inspect.
2. Check the mixture of antifreeze and water. The
c. Ensure that the radiator size is according
mixture should be approximately 50 percent
to the OEMs specifications. An undersized
water and 50 percent antifreeze with 3 to 6
radiator does not have enough area for the
percent coolant conditioner. Refer to Operation
effective release of heat. This may cause
and Maintenance Manual, General Coolant
the engine to run at a temperature that is
Information. If the coolant mixture is incorrect,
higher than normal. The normal temperature
drain the system. Put the correct mixture of
is dependent on the ambient temperature.
water, antifreeze and coolant conditioner in the
cooling system.
8. Check the filler cap. A pressure drop in the
radiator can cause the boiling point to be lower.
3. Check for air in the cooling system. Air can enter
This can cause the cooling system to boil. Refer
the cooling system in different ways. The most
to Testing and Adjusting, Cooling System - Test.
common causes of air in the cooling system
are not filling the cooling system correctly and
9. Check the fan and/or the fan shroud.
combustion gas leakage into the cooling system.
Combustion gas can get into the system through
a. The fan must be large enough to send air
inside cracks, a damaged cylinder head, or a
through most of the area of the radiator
damaged cylinder head gasket. Air in the cooling
core. Ensure that the size of the fan and the
system causes a reduction in coolant flow and
position of the fan are according to the OEM
bubbles in the coolant. Air bubbles keep coolant
specifications.
away from the engine parts, which prevents the
transfer of heat to the coolant.
75
b. The fan shroud must be the proper size and b. If the measured restriction is higher than the
the fan shroud must be positioned correctly. maximum permissible restriction, there is a
Ensure that the size of the fan shroud and the restriction in the exhaust system. Repair the
position of the fan shroud are according to exhaust system, as required.
the OEM specifications.
14. Check the shunt line, if the shunt system is
10. Check for loose drive belts. A loose fan drive used. The shunt line must be submerged in the
belt will cause a reduction in the air flow across expansion tank. A restriction of the shunt line
the radiator. Check the fan drive belt for proper from the radiator top tank to the engine water
belt tension. Adjust the tension of the fan pump inlet will cause a reduction in water pump
drive belt, if necessary. Refer to Operation and efficiency. A reduction in water pump efficiency
Maintenance Manual, Belt - Inspect. will result in low coolant flow and overheating.
11. Check the cooling system hoses and clamps. 15. Check the water temperature regulator. A water
Damaged hoses with leaks can normally be temperature regulator that does not open, or
seen. Hoses that have no visual leaks can soften a water temperature regulator that only opens
during operation. The soft areas of the hose can part of the way can cause overheating. Refer
become kinked or crushed during operation. to Testing and Adjusting, Water Temperature
These areas of the hose can cause a restriction Regulator - Test.
in the coolant flow. Hoses become soft and/or
get cracks after a period of time. The inside of a 16. Check the water pump. A water pump with
hose can deteriorate, and the loose particles of a damaged impeller does not pump enough
the hose can cause a restriction of the coolant coolant for correct engine cooling. Remove
flow. Refer to Operation and Maintenance the water pump and check for damage to the
Manual, Hoses and Clamps - Inspect/Replace. 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)
foreign material from the engine air cleaner can cause overheating. Check for debris or
element or install a new engine air cleaner deposits which would prevent the free flow of
element. Refer to Operation and Maintenance air through the aftercooler. Refer to Testing and
Manual, Engine Air Cleaner Element - Adjusting, 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
engine can cause high cylinder temperatures. to keep the coolant from boiling must be used.
a. Make a visual inspection of the exhaust

system. Check for damage to exhaust piping
or for a damaged muffler. If no damage
is found, check the exhaust system for a
restriction. Refer to Testing and Adjusting, Air
Inlet and Exhaust System - Inspect.
76
21. The engine may be running in the lug condition. Note: A small amount of coolant leakage across
When the load that is applied to the engine is the surface of the water pump seals is normal.
too large, the engine will run in the lug condition. This leakage is required in order to provide
When the engine is running in the lug condition, lubrication for this type of seal. A hole is provided
engine rpm does not increase with an increase in the water pump housing in order to allow this
of fuel. This lower engine rpm causes a reduction coolant/seal lubricant to drain from the pump
in air flow through the radiator. This lower engine housing. Intermittent leakage of small amounts of
rpm also causes a reduction in coolant flow coolant from this hole is not an indication of water
through the system. This combination of less air pump seal failure.
and less coolant flow during high input of fuel
will cause above normal heating. 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,
i01390078
look for debris between the folded cores of the
Cooling System - Inspect radiator.
SMCS Code: 1350-040 5. Inspect the drive belts for the fan.
Cooling systems that are not regularly inspected are 6. Check for damage to the fan blades.
the cause for increased engine temperatures. Make
a visual inspection of the cooling system before any 7. Look for air or combustion gas in the cooling
tests are performed. system.
8. Inspect the filler cap, and check the surface that

seals the filler cap. This surface must be clean.

i01532788
der pressure.

Cooling System - Test
push the release valve in order to relieve pressure SMCS Code: 1350-040; 1350-081
This engine has a pressure type cooling system. A
1. Check the coolant level in the cooling system. pressure type cooling system has two advantages.
Refer to Operation and Maintenance Manual, The cooling system can be operated in a safe
Cooling System Coolant Level - Check. manner at a temperature higher than the normal
boiling point (steam) of water.
2. Check the quality of the coolant. The coolant
should have the following properties: This type of system prevents cavitation in the water
Color that is similar to new coolant bubbles in liquids that are caused by mechanical
forces. It is more difficult to create an air pocket or
Odor that is similar to new coolant a steam pocket with this type of cooling system.
Free from dirt and debris

If the coolant does not have these properties,
the cooling system with the correct mixture of
water, antifreeze, and coolant conditioner. Refer
to Operation and Maintenance Manual, General
3. Look for leaks in the system.
g00286266
Illustration 71
Boiling point of water
77
Remember that temperature and pressure work

together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
effect on the cooling system temperature. For an
rotating parts.
example, refer to Illustration 71. This will show the
effect of pressure on the boiling point (steam) of
water. This will also show the effect of height above
sea level.

and alkali.


g00286267
Illustration 72
4C-6500 Digital Thermometer
The 4C-6500 Digital Thermometer is used in the
The coolant level must be to the correct level in diagnosis of overheating conditions and in the
order to check the coolant system. The engine must diagnosis of overcooling conditions. This group can
be cold and the engine must not be running. be used to check temperatures in several different
parts of the cooling system. Refer to Operating
After the engine is cool, loosen the pressure cap Manual, NEHS0554, 4C-6500 Digital Thermometer
in order to relieve the pressure out of the cooling Group for the testing procedure.
system. Then remove the pressure cap.
The level of the coolant should not be more than

13 mm (0.5 inch) from the bottom of the filler pipe.
If the cooling system is equipped with a sight glass,
the coolant should be to the proper level in the
sight glass.
Test Tools For Cooling System

Table 15
Tools Needed
Part
Part Name Quantity
Number
g00286269
Illustration 73
check the air flow through the radiator core. Refer to
9U-7400 Multitach Tool Group 1 Special Instruction, SEHS8712, Using the 8T-2700
Blowby/Air Flow Indicator for the test procedure
1U-7297 1
for checking blowby.
or Coolant/Battery Tester
1U-7298
78
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
g00286276
the cooling system top-off is an unacceptable
Illustration 74 practice. Adding pure antifreeze increases the
9U-7400 Multitach concentration of antifreeze in the cooling system.
This increases the concentration of the dissolved
The 9U-7400 Multitach Tool Group is used to solids and the undissolved chemical inhibitors in
check the fan speed. Refer to Operating Manual, the cooling system. Add the coolant/water mixture
NEHS0605, 9U-7400 Multitach Tool Group for to the same freeze protection as your cooling
the testing procedure. system. The following chart assists in determining
the concentration of antifreeze to use. Refer to
Operation and Maintenance Manual, General
Table 16
Antifreeze Concentrations
Temperature Concentration
30% antifreeze and
Protection to 15 C (5 F)
70% water
(10 F) 60% water
(34 F) 50% water
g00286369
Illustration 75
(60 F) 40% water
The 9S-8140 Pressurizing Pump is used to test the
filler caps. This pressurizing pump is also used to Checking the Filler Cap
Table 17
Tools Needed
Part
Part Name Quantity
Number
One cause for a pressure loss in the cooling system

can be a damaged seal on the radiator filler cap.
g00439083
Illustration 76
1U-7297 Coolant/Battery Tester or 1U-7298 Coolant/Battery
Tester
79
4. Compare the gauges reading with the opening

pressure that is listed on the filler cap.
5. If the filler cap is damaged, replace the filler cap.

System For Leaks
Table 18
Tools Needed
Part
Part Name Quantity
Number
g00296067 9S-8140 Pressurizing Pump 1

Illustration 77
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.
To check for the amount of pressure that opens the

1. After the engine is cool, loosen the filler cap
slowly and allow pressure out of the cooling
system. Then remove the filler cap from the
1. After the engine cools, carefully loosen the filler
radiator.
cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap.
2. Ensure that the radiator is full of coolant.
Carefully inspect the filler cap. Look for any
3. Install the 9S-8140 Pressurizing Pump onto the
damage to the seals and to the sealing surface.
radiator.
Inspect the following components for any foreign
substances:
4. Take the pressure reading on the gauge to
20 kPa (3 psi) more than the pressure on the
Filler cap filler cap. The pressure on a typical filler cap is
48.3 kPa (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
items.
2. Install the filler cap on the 9S-8140 Pressurizing
Pump.
3. Look at the gauge for the exact pressure that You do NOT observe any outside leakage.
opens the filler cap.
80
The reading remains steady after five minutes. Coolant temperature can also be read on the
display screens of the Electronic Service Tool.
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:

Evidence of coolant on the engine oil gauge.
Test For The Water Temperature Illustration 78

g00438983
Gauge Typical example

(1) Ports
Table 19
Tools Needed Remove the plug from one of ports (1). Install one
Part of the following thermometers in the open port:
Part Name Quantity
Number
The 4C-6500 Digital Thermometer
or or
2F-7112 Thermometer
A temperature indicator of known accuracy can
also be used to make this check.

der pressure.
cover over part of 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.
i01461401
burns from hot parts and can cause injury from Water Temperature Regulator
rotating parts.
- Test
SMCS Code: 1355-081; 1355-081-ON
Check the accuracy of the coolant temperature

indicator or coolant temperature sensor if you find
either of the following conditions:
der pressure.
The engine runs at a temperature that is too hot, If a pressure indication is shown on the indicator,
but a normal temperature is indicated. A loss of
coolant is found.
hot temperature is indicated. No loss of coolant 1. Remove the coolant temperature regulator from
is found. the engine.
81
2. Heat water in a pan until the temperature is

98 C (208 F).
3. Hang the coolant temperature regulator in the
pan of water. The coolant temperature regulator
rotating parts.
must be below the surface of the coolant and
away from the sides and the bottom of the pan.
4. Keep the coolant at the correct temperature for
ten minutes.
Perform the following procedure in order to
5. After ten minutes, remove the coolant determine if the water pump is operating correctly:
temperature regulator. Check the opening in the
housing for the coolant temperature regulator. 1. Remove the plug from port (1).
If the distance is less than the specified distance 2. Install the 6V-7775 Air Pressure Gauge in port
in the Specification manual, replace the coolant (1).
temperature regulator. Refer to Specifications,
Water Temperature Regulator. 3. Start the engine. Run the engine until the coolant
is at operating temperature.
i01467399
4. Note the water pump pressure. The water pump
Water Pump - Test pressure should be 100 to 125 kPa (15 to 18 psi).
SMCS Code: 1361-040; 1361-081

Table 20
Tools Needed
Part
Part Name Quantity
Number
g00439003
Illustration 79
Typical example
(1) Port
(3) Water manifold assembly
(4) Water outlet
(5) Coolant temperature regulator
(6) Bypass line
(7) Water pump
(8) Port
82
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
i01124208 Line Boring Tool Group. The 1P-4000 Line Boring
Tool Group is used in order to check the alignment
Piston Ring Groove - Inspect of the main bearing bores. The 1P-3537 Dial
Bore Gauge Group can be used to check the
SMCS Code: 1214-040 size of the bore. Refer to Special Instruction,
GMG00981, 1P-3537 Dial Bore Gauge Group for
The pistons of the engine have a keystone design the instructions that are needed to use the 1P-3537
ring groove. The piston rings are a keystone Dial Bore Gauge Group.
available to check the top ring groove in the piston.
Use the 8T-3149 Plug Gauge that is part of this i01160522
Gauge Group to check the top ring groove on the
piston. Refer to the instruction card for correct use Cylinder Block - Inspect
of the 1U-6431 Piston Ring Groove Gauge.
SMCS Code: 1201-040
i01460477 Table 21
Tools Needed
Part
Inspect Number
Part Name Quantity
SMCS Code: 1219-040 1P-3537 Dial Bore Gauge Group 1
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
or refer to the Guideline For Reusable Parts,
SEBF0531, 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.
g00285686
Illustration 80
1P-3537 Dial Bore Gauge Group
i01125517
Main Bearings - Inspect If the main bearing caps are installed without
bearings, the bore in the block for the main bearings
SMCS Code: 1203-040 can be checked. Tighten the nuts on the bearing
caps to the torque that is given in Specifications,
Main bearings are available with 0.508 mm Cylinder Block. Alignment error in the bores must
(0.0200 inch) and a 0.762 mm (0.0300 inch) smaller not be more than 0.08 mm (0.003 inch).
These bearings are for crankshafts that have been The 1P-3537 Dial Bore Gauge Group can be used
ground. to check the size of the bore. Refer to Special
Instruction, GMG00981, 1P-3537 Dial Bore Gauge
Main bearings are also available with a larger Group for the instructions that are needed to use
outside diameter than the original size bearings. the 1P-3537 Dial Bore Gauge Group.
These bearings are used for the cylinder blocks
the bores original size. The size that is available
has a 0.508 mm (0.0200 inch) outside diameter that
is larger than the original size bearings.
83
i01398911 3. Tighten bolts (1) evenly according to the

Cylinder Liner Projection -
Inspect First tighten each bolt to the following
torque. ....................................... 27 Nm (20 lb ft)
SMCS Code: 1216-040
Then tighten each bolt to the following
Table 22 torque. ....................................... 54 Nm (40 lb ft)
Tools Needed
Then tighten each bolt to the following
Part torque. ....................................... 68 Nm (50 lb ft)
Part Name Quantity
Number
8T-0455 Liner Projection Tool Group 1
Again tighten each bolt to the following
torque. ....................................... 68 Nm (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 23
Needed 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 82
4 7K-1977 Washer 6 36 (5) Bolt

(6) Dial indicator
(7) Gauge body
(8) Gauge block

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 indicator.
g00441535
Illustration 81
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 81. 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.
84
i01461420
Flywheel - Inspect
SMCS Code: 1156-040
Table 25
Required Tools
Part
Description Qty
Number
g00326384
Illustration 83
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
to find the amount of liner projection. Check the
projection at four locations (every 90 degrees)
around each cylinder liner.
Table 24
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 84
0.100 mm (0.0040 inch)
Between Liners Checking face runout of the flywheel
7. If a liner does not meet the recommended 1. Refer to Illustration 84 and install the dial
cylinder liner projection specification, check the indicator. Always put a force on the crankshaft
following parts: in the same direction before the dial indicator
The depth of the cylinder block bore should be clearance.
100.00 0.03 mm (3.937 0.001 inch).
The liner flange should be 100.12 0.03 mm
(3.942 0.001 inch). 3. Turn the flywheel at intervals of 90 degrees and
read the dial indicator. Refer to Testing and
If the depth of the cylinder block bore is out of Adjusting, Finding Top Center Position for No.
specification, replace the cylinder block. Then 1 Piston.
the liner flange is out of specification, replace 4. Take the measurements at all four points. The
the liner. Then repeat the liner projection difference between the lower measurements and
measurements. the higher measurements that are performed at
face runout (axial eccentricity) of the flywheel.
85
Bore Runout (Radial Eccentricity)

of the Flywheel
g00286058
Illustration 86
Flywheel clutch pilot bearing bore

6. The runout (eccentricity) of the bore for the pilot

(0.005 inch).
g00286054
Illustration 85
Checking bore runout of the flywheel i01461438
(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 26
adjustment of 7H-1940 Universal Attachment
(4) so the dial indicator makes contact on the Tools Needed
flywheel. Part
Part Name Quantity
Number
read the dial indicator.
4. Take the measurements at all four points. The the Flywheel Housing
difference between the lower measurements and
g00285931
Illustration 87
86
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.

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 90
Checking bore runout of the flywheel housing
g00285932
Illustration 88
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

g00763974
and the higher measurements that are performed Illustration 91
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
face runout (axial eccentricity) of the flywheel location (C) adjust the dial indicator to 0.0 mm
housing. (0.00 inch). Push the crankshaft upward against
the top of the bearing. Refer to Illustration 91.
Write the measurement for bearing clearance on
Bore Runout (Radial Eccentricity) line 1 in column (C).
of the Flywheel Housing
Note: Write the measurements for the dial indicator
3. Divide the measurement from Step 2 by two.

Write this number on line 1 in columns (B) and
(D).

at position (A). Adjust the dial indicator to 0.0 mm
(0.00 inch).

put the dial indicator at position (B). Write the
measurements in the chart.
g00285934
Illustration 89
87
6. Turn the flywheel counterclockwise in order to i01148031

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.

g00398558
Illustration 93
Vibration damper and pulley
Typical example
(1) Damper assembly
(2) Pulley
(3) Crankshaft
(4) Bolt
(5) Bolt
The vibration damper is installed on the front of

g00286046 crankshaft (3). Vibration damper (1) has a weight
Illustration 92
in a case. The space between the weight and the
Graph for total eccentricity case is filled with viscous fluid. The weight moves
(1) Total vertical eccentricity in the case in order to limit the torsional vibration.
(2) Total horizontal eccentricity
(4) Unacceptable value
conditions exist:
10. Find the intersection of the eccentricity lines
(vertical and horizontal) in Illustration 92. The damper is dented, cracked, or leaking.
11. If the point of the intersection is in the The paint on the damper is discolored from heat.
Acceptable range, the bore is in alignment. If
the point of intersection is in the Not acceptable There is a large amount of gear train wear that is
range, the flywheel housing must be changed. not caused by lack of oil.
Analysis of the oil has revealed that the front main

bearing is badly worn.
The engine has had a failure because of a broken

crankshaft.
NOTICE
Inspect the viscous vibration damper for signs of leak-
88
Compression Brake
i01532801
Slave Piston Lash - Adjust

SMCS Code: 1119-025

Hot engine components can cause burns. Allow Illustration 94 g00481680

Compression brake
(1) Adjusting screw and locknut
(2) Slave piston
(3) Screw assembly
2. Loosen adjustment locknut (1).

This engine uses high voltage to control the fuel
injectors.
3. Place the appropriate feeler gauge between
slave piston (2) and screw assembly (3).
Disconnect electronic fuel injector enable circuit
Then, turn the adjustment screw in a clockwise
connector to prevent personal injury.
direction. Slide the feeler gauge between the
slave piston and the screw assembly. Continue
Do not come in contact with the fuel injector ter-
turning the adjustment screw until a slight drag
is felt on the feeler gauge. Remove the feeler
gauge.
adjusting the slave piston lash. 4. Tighten adjustment locknut (1) to a torque of
35 Nm (25 lb ft). Recheck the slave piston lash
Table 27 after tightening the locknut.
Engine Setting Feeler Gauge 360 degrees in the direction of engine rotation.
0.64 mm This will put the No. 6 piston at the top center
C-10 149-6114 position on the compression stroke. Install the
(0.025 inch)
1.02 mm
C-12 150-7227
(0.040 inch) To adjust the slave piston lash on cylinders 2, 4,
and 6, perform Steps 2 through 4.
Refer to Testing and Adjusting, Engine Valve Lash
- Inspect/Adjust. 6. Remove the timing bolt from the flywheel after
all adjustments have been performed. Reinstall
Note: Slave piston lash is measured between the the timing cover.
slave piston and the screw assembly in the exhaust
valve bridge. Make all adjustments while the engine Refer to Electronic Troubleshooting, PB-18:
is stopped and the exhaust valves are closed. Retarder Solenoid Circuits Test.
Use the following procedure to adjust the slave Refer to Testing and Adjusting, Electronic Unit
piston lash on cylinders 1, 3, and 5: Injector - Adjust.

Adjusting, Finding Top Center Position for No.
1 Piston.
89
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
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 g00514378
Illustration 95
panel does not provide the same information as
the oil pressure reading at the compression brake 149-6111 Oil Pressure Test Kit
housings. (1) Pressure gauge
(2) Seals
(3) Control valve removal tool
Low oil pressure in the compression brake housings (4) Control valve test body
may cause weak braking or no braking at all. If the (5) Control valve adapter
oil pressure in the compression brake housings is (6) Solenoid valve adapter
too high, the compression brake may not operate
at all. High oil pressure may also prevent the 1. Assemble pressure gauge (1), control valve test
compression brake from shutting off. body (4), and control valve adapter (5). Hand
tighten the adapter assembly.
Oil Pressure Test at Control Valve
2. While the engine is not running, remove
the control valve. Refer to Disassembly and
Assembly, Compression Brake - Disassemble.
Table 28
Tools Needed
Part
Part Name Quantity
Number
149-6111 Oil Pressure Test Kit 1
g00514468
Illustration 96
90
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 Solenoid Valve (Compression
the bottom of the bore in order to allow the oil to
enter the adapter assembly.
Brake) - Test
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
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
g00514472 the oil pressure reading at the compression brake
Illustration 97
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
Note: Hold the solenoid on only long enough to too high, the compression brake may not operate
obtain the oil pressure reading. The oil pressure at all. High oil pressure may also prevent the
may be too low at idle in order to operate the compression brake from shutting off.
compression 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.
8. Stop the engine. Install the control valve. Refer
to Disassembly and Assembly, Compression
Brake - Assemble.
Table 29
The oil pressure readings at the control valve Tools Needed
above 1000 rpm should be 275 105 kPa
(40 15 psi). Part
Part Name Quantity
Number
If the oil pressure readings at the control 149-6111 Oil Pressure Test Kit 1
valve are within the specified range, there
is not a 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
91
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

Illustration 98 g00514378 solenoid valve to the oil pressure readings
149-6111 Oil Pressure Test Kit
from the Testing and Adjusting, Control Valve
(Compression Brake) - Test.
(1) Pressure gauge
(2) Seals
(3) Control valve removal tool If the oil pressure at the solenoid valve is
(4) Control valve test body higher than the oil pressure at the control
(5) Control valve adapter valve, continue with Steps 10 through 15.
(6) Solenoid valve adapter
If the oil pressure at the solenoid valve is
1. Attach pressure gauge (1) to solenoid valve the same pressure as the oil pressure at
adapter (6). the control valve, the oil pressure to the
compression brake is too low. Refer to Testing
2. Remove the solenoid valve and the three seals and Adjusting, Engine Oil Pressure - Test.
from the compression brake housing. Refer
to Disassembly and Assembly, Compression 10. Start the engine.
Brake - Disassemble.
11. Disconnect the wires from each solenoid valve
3. Install three seals (2), which are included in except for the solenoid valve that is being tested
the 149-6111 Oil Pressure Test Kit. Place the in order to check each solenoid valve individually.
smallest seal in the bottom of the bore for the
solenoid. Install the other two seals on solenoid
valve adapter (6).
g00514472
Illustration 100
g00514470
12. Turn the switch for the compression brake to the
Illustration 99 ON position. Observe the movement of solenoid
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.
92
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.
93
Electrical System
i01126605
Battery - Test
SMCS Code: 1401-081
Most of the tests of the electrical system can be

in good condition. The wire and cable connections
must be clean, and both components must be tight.
Never disconnect any charging unit circuit or bat-

tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec-
trolyte through the battery outlets. Injury to per-
sonnel can be the result.
The battery circuit is an electrical load on the

charging 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
test the battery. This publication also contains the
specifications to use when you test the battery.
i01286614
Belt Tension Chart

SMCS Code: 1357
94
Table 30
Belt Tension Chart
Borroughs Gauge
Gauge Reading
Numbers
Belt
of the Old the New
Initial(1) Used(2)
Gauge Gauge
i01380929 Test Tools For The Charging

Charging System - Test System
Tools Needed
regular inspection will show if the charging system Part
Part Name Quantity
is operating correctly. An adjustment is necessary Number
when the battery is constantly in a low condition 8T-0900 Ammeter 1
A large amount of water would be more than one 6V-7070 Digital Multimeter 1
ounce of water per cell per week or per every 100
service hours.
8T-0900 Ammeter
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 the
system. Off-engine testing or bench testing will give
a test of the charging unit and voltage regulator
operation. This testing will give an indication of
needed repair. After repairs are made, perform
repaired to the original condition of operation.
g00296441
Illustration 101
8T-0900 Ammeter
95
The 8T-0900 Ammeter is completely portable. The 6V-7070 Digital Multimeter is a hand-held
This ammeter is a self-contained instrument that service tool with a digital display, that is completely
measures electrical currents without breaking the portable. This multimeter is built with extra protection
circuit and without disturbing the conductors against damage in field applications. The multimeter
insulation. is equipped with 7 functions and 29 ranges. The
The ammeter contains a digital display that is used indicator. This indicator permits checking continuity
to monitor current directly within a range between 1 for a fast inspection of the circuits. The multimeter
ampere and 1200 amperes. If an optional 6V-6014 can also be used for troubleshooting capacitors
Cable is connected between this ammeter and a that have small values.
directly from the display of the multimeter. This can Note: Refer to Special Instruction, SEHS7734 for
be accomplished under only one condition: complete information for the use of the 6V-7070
Digital Multimeter.
A lever opens the ammeters jaws over a conductor.
The conductors diameter can not be larger than
19 mm (0.75 inch). checked when an alternator is charging the battery
too much. The charging rate of the alternator should
The spring loaded jaws close around the conductor
be checked when an alternator is not charging the
for measuring the current. A trigger switch controls battery enough.
the ammeter. The trigger switch can be locked into
the ON position or into the OFF position.
After the trigger has been working and the trigger is
turned to the OFF position, the reading appears in
the digital display for five seconds. This accurately
measures currents in areas with a limited access.
See Special Instruction, REHS0354, Charging
For example, these areas include areas that are
System Troubleshooting for the correct procedures
beyond the operators sight. For DC operation, an to use to test the charging system. This publication
ammeter contains a zero control, and batteries
also contains the specifications to use when you
inside the handle supply the power.
test the charging system.
for more information about using the 8T-0900
Ammeter.
g00283566
Illustration 102
96
Tightening The Alternator Pulley Trouble with the starting system could be caused by
the battery or by charging system problems. If the
Nut 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

Test
SMCS Code: 1924-081
Refer to the Troubleshooting, RENR2238, Engine

Oil Pressure Sensor Open Or Short Circuit Test for
information on checking the engine oil pressure
sensor.
i01530581
Illustration 103 g00283568 Pinion Clearance - Adjust

Tools For Tightening The Alternator Pulley Nut SMCS Code: 1454-025
(1) 8T-9293 Torque Wrench. (2) 8S-1588 Adapter (1/2 inch
female to 3/8 inch male). (3) 2P-8267 Socket Assembly. (4)
8H-8517 Combination Wrench (1-1/8 inch). (5) 8T-5314 Socket. Electric Starting Motor
Tighten the nut that holds the pulley with the tools When the solenoid is installed, make an adjustment
shown. Refer to the Specifications module for the of the pinion clearance. The adjustment can be
torque. made with the starting motor removed.
i01113572
Electric Starting System - Test

SMCS Code: 1450-081
Most of the tests of the electrical system can be

in good condition. The wire and cable connections
must be clean, and both components must be tight.
The battery must be fully charged. If the on-engine
test shows a defect in a component, remove the
component for more testing.
g00301360
Illustration 104
The starting system consists of the following four
components: Connection for checking pinion clearance
(1) Connector to the motor
(2) Switch terminal
keyswitch (3) Ground terminal
start relay 1. Install the solenoid without connector (1) from the
MOTOR connections (terminal) on the solenoid
starting motor solenoid to the motor.
starting motor 2. Connect a battery, that has the same voltage as
the solenoid, to the SW terminal (2).
97
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
g00283574
Illustration 105
Typical example
(4) Shaft nut
(5) Pinion
(6) Pinion clearance
5. Push the pinion toward the end with the

commutator in order to remove free movement.
6. Pinion clearance (6) must be 9.1 mm (0.36 inch).


plug over the nut (4) and install the connector
(3) between the MOTOR terminal on the solenoid
and the starter motor.
98
Index Section
Index
A Cylinder Liner Projection - Inspect......................... 83

Aftercooler Core Leakage .................................. 64 E
Air System Restriction ....................................... 65
Dynamometer Test............................................. 66 Electric Starting System - Test .............................. 96
Turbocharger Failure .......................................... 66 Electrical System............................................. 41, 93
Visual Inspection................................................ 63 Charging System Components .......................... 43
Air in Fuel - Test..................................................... 46 Engine Electrical System ................................... 43
Air Inlet and Exhaust System .......................... 26, 58 Grounding Practices .......................................... 41
Turbocharger...................................................... 27 Starting System Components ............................ 44
Valve System Components................................ 28 Electronic Control System Components................ 10
Air Inlet and Exhaust System - Inspect.................. 58 Electronic Unit Injector - Adjust ............................. 47
Air Inlet Restriction............................................. 58 Checking Engine Cylinders Separately.............. 48
Exhaust Restriction............................................ 59 Electronic Unit Injector - Test................................. 48
Engine Crankcase Pressure (Blowby) - Test ......... 66
Engine Design ......................................................... 4
B Engine Oil Pressure - Test..................................... 70
Measuring Engine Oil Pressure ......................... 70
Basic Engine.................................................... 36, 82 Reason for High Engine Oil Pressure ................ 72
Camshaft............................................................ 38 Reasons for Low Engine Oil Pressure ............... 71
Crankshaft.......................................................... 37 Engine Oil Pressure Sensor - Test ........................ 96
Cylinder Block .................................................... 36 Engine Oil Pump - Inspect..................................... 72
Pistons, Rings, and Connecting Rods ............... 37 Engine Valve Lash - Inspect/Adjust ....................... 67
Vibration Damper ............................................... 38 Valve Lash Adjustment ...................................... 67
Battery - Test ......................................................... 93 Valve Lash Check .............................................. 67
Belt Tension Chart ................................................. 93 Excessive Bearing Wear - Inspect......................... 73
Excessive Engine Oil Consumption - Inspect ........ 73
Oil Leakage Into Combustion Area Of
C Cylinders .......................................................... 73
Oil Leakage On Outside Of Engine.................... 73
Charging System - Test ......................................... 94 Exhaust Temperature - Test................................... 63
Alternator Regulator........................................... 95
Test Tools For The Charging System ................. 94
Tightening The Alternator Pulley Nut ................. 96 F
Compression - Test................................................ 67
Compression Brake ......................................... 38, 88 Finding Top Center Position for No. 1 Piston ......... 49
Operation of the Compression Brake................. 40 Checking and Calibrating the Electronic Injection
Performance of the Compression Brake ............ 39 Timing With the Electronic Service Tool........... 50
Connecting Rod Bearings - Inspect....................... 82 Flywheel - Inspect.................................................. 84
Control Valve (Compression Brake) - Test............. 89 Bore Runout (Radial Eccentricity) of the
Oil Pressure Test................................................ 89 Flywheel ........................................................... 85
Cooling System ............................................... 33, 74 Face Runout (Axial Eccentricity) of the
Coolant Conditioner (If Equipped)...................... 35 Flywheel ........................................................... 84
Coolant Flow ...................................................... 33 Flywheel Housing - Inspect ................................... 85
Coolant for Air Compressor ............................... 36 Bore Runout (Radial Eccentricity) of the Flywheel
Supply Manifold ................................................. 34 Housing ............................................................ 86
Temperature Regulator Housing ........................ 34 Face Runout (Axial Eccentricity) of the Flywheel
Cooling System - Check (Overheating) ................. 74 Housing ............................................................ 85
Cooling System - Inspect....................................... 76 Fuel Quality - Test.................................................. 50
Cooling System - Test............................................ 76 Fuel System..................................................... 12, 46
Checking the Filler Cap...................................... 78 Electronic Controls............................................. 16
Making the Correct Antifreeze Mixtures............. 78 Injection Actuation System................................. 17
Test For The Water Temperature Gauge ........... 80 Low Pressure Fuel System ................................ 14
Test Tools For Cooling System .......................... 77 Operation of the Fuel Injector ............................ 18
Testing The Radiator And Cooling System For Unit Injector........................................................ 18
Leaks................................................................ 79 Unit Injector Mechanism .................................... 17
Cylinder Block - Inspect......................................... 82 Fuel System - Inspect............................................ 46
99
Index Section
Fuel System - Prime.............................................. 51 Turbocharger - Inspect........................................... 60

Fuel System Pressure - Test ................................. 52 Inspection of the Compressor and the Compressor
Checking Fuel Pressure..................................... 53 Housing ............................................................ 60
High Fuel Pressure ............................................ 53 Inspection of the Turbine Wheel and the Turbine
Low Fuel Pressure ............................................. 52 Housing ............................................................ 61
Inspection of the Wastegate .............................. 61
G
V
Gear Group (Front) - Time..................................... 56
General Information................................................. 5 Vibration Damper - Check ..................................... 87
Cold Mode Operation........................................... 5
Customer Specified Parameters .......................... 6
Starting The Engine ............................................. 5 W
Glossary of Electronic Control Terms ...................... 6
Water Pump - Test ................................................. 81
Water Temperature Regulator - Test...................... 80
I

Increased Engine Oil Temperature - Inspect ......... 73
Inlet Manifold Pressure - Test ................................ 62

Oil Flow Through The Lubrication System......... 31
Main Bearings - Inspect......................................... 82
Pinion Clearance - Adjust ...................................... 96

Electric Starting Motor ....................................... 96
Piston Ring Groove - Inspect................................. 82
Slave Piston Lash - Adjust..................................... 88

Solenoid Valve (Compression Brake) - Test .......... 90
Oil Pressure Test................................................ 90
2001 Caterpillar
RENR2236-03
April 2001
Disassembly and
Assembly
CPD1-Up (Engine)
2KS1-Up (Engine)
3CS1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents Gear Group (Front) - Remove ............................... 59

Disassembly and Assembly Section Accessory Drive - Remove ................................... 62
Accessory Drive - Disassemble ........................... 63
Fuel Priming Pump - Remove and Install .............. 5
Accessory Drive - Assemble ................................ 63
Accessory Drive - Install ....................................... 64
Fuel Manifold - Remove .......................................... 8
Install ................................................................... 66
Fuel Manifold - Install .............................................. 8
Compression Brake - Remove .............................. 67
Electronic Unit Injector - Remove ........................... 9
Electronic Unit Injector - Install ............................. 10
Compression Brake - Assemble ........................... 71
Electronic Unit Injector Sleeve - Remove .............. 12
Compression Brake - Install .................................. 74
Electronic Unit Injector Sleeve - Install ................. 12
Inlet Manifold - Remove ....................................... 15
Inlet Manifold - Install ........................................... 16
Camshaft - Remove .............................................. 83
Inlet and Exhaust Valve Springs - Remove and
Install ................................................................... 16
Camshaft Bearings - Remove ............................... 86
Camshaft Bearings - Install ................................... 87
Install ................................................................... 20
Install ................................................................... 21
Engine Centrifugal Oil Filter - Remove and
Cylinder Liner - Install ........................................... 92
Install ................................................................... 22
Connecting Rod Bearings - Remove .................... 98
Connecting Rod Bearings - Install ........................ 99
Crankshaft Main Bearings - Install ...................... 101
Crankshaft - Remove .......................................... 102
Crankshaft - Install .............................................. 103
Crankshaft Gear - Remove and Install ............... 104
Bearing Clearance - Check ................................. 107
Camshaft Position Sensor - Remove and Install .. 107
Install ................................................................. 108
............................................................................. 41
Water Outlet Manifold - Remove ........................... 44
Install ................................................................. 109
Flywheel - Remove ............................................... 45
........................................................................... 110
Fuel Pressure Sensor - Remove and Install ....... 111
Boost Pressure Sensor - Remove and Install ..... 112
Engine Control Module - Remove and Install ..... 114
Install ................................................................... 47
Rear Power Take-Off (RPTO) - Remove ............... 50
Air Conditioner Support Bracket - Remove and
Install ................................................................. 116
............................................................................. 55
Front Cover - Remove ........................................... 57
4
Table of Contents
Index Section
Index ................................................................... 120
5
Disassembly and Assembly Installation Procedure

Section NOTICE
i01468998
Fuel Priming Pump - Remove component life.
and Install
SMCS Code: 1258-010
Removal Procedure
NOTICE

component life.
NOTICE
Illustration 2
during performance of inspection, maintenance, test- Typical example
collect the fluid with suitable containers before open- 1. Inspect the condition of the gasket. Replace the
ing any compartment or disassembling any compo- gasket, if necessary.
2. Ensure that both valve assemblies are located in
Refer to Special Publication, NENG2500, Caterpillar the correct position in the fuel priming pump.
suitable to collect and contain fluids on Caterpillar 3. Install the gasket and fuel priming pump (2) on
products. the fuel filter base.
Dispose of all fluids according to local regulations and 4. Install the washers and bolts (1).
mandates.
5. Check the operation of the fuel priming pump.
i01015037
Fuel Filter Base - Remove and

Install
SMCS Code: 1262-010
Removal Procedure
Table 1
Required Tools
g00511626
Illustration 1 Part
2. Remove fuel priming pump (2) and the gasket NOTICE

from the fuel filter base. Keep all parts clean from contaminants.

component life.
6
5. Disconnect hose assembly (3). Plug all openings

NOTICE immediately.
during performance of inspection, maintenance, test- 6. Remove two bolts (4) and the washers.
to collect the fluid with suitable containers before 7. Remove fuel filter base (5) and the two O-ring
opening any compartment or disassembling any seals.
8. Remove the fuel filter mounting stud from the fuel
Refer to Special Publication, NENG2500, Caterpillar filter base, if necessary.
plies suitable to collect and contain fluids in Caterpillar Installation Procedure
machines.
Table 2
Required Tools
mandates.
Part
Number
NOTICE

component life.

threads of the fuel filter mounting stud. Apply
the compound to the tapered end of the stud no
Illustration 3
g00519561 more than 7.6 mm (.30 inch) from the end.
1. Remove plug (1) and drain fuel into a suitable 2. Install the stud and tighten to a torque of
container for storage or disposal. 70 15 Nm (50 11 lb ft).
3. Inspect the condition of the two O-ring seals.

Replace the seals, if necessary.
g00520760
Illustration 4
Typical example
g00520760
Illustration 5
2. Use Tool (A) to remove fuel filter (6).
Typical example
3. Disconnect the sensor connector from fuel
temperature sensor (2). 4. Install the two O-rings on fuel filter base (5).
4. Remove fuel temperature sensor (2). 5. Install fuel filter base (5) on the fuel manifold with
two bolts (4) and the washers.
7
6. Connect hose assembly (3).
7. Install fuel temperature sensor (2). Connect the

sensor connector to fuel temperature sensor (2).
8. Use Tool (A) in order to install new fuel filter (6).

Follow the instructions on the fuel filter.
g00511822
Illustration 7
1. Disconnect tube assembly (3). Cover all

openings immediately.
2. Remove two bolts (2) and the seal washers.

g00519561 3. Remove fuel transfer pump (1) and the gasket.
Illustration 6
9. Install plug (1).

i00999918
i00999915
Fuel Transfer Pump - Remove SMCS Code: 1256-012
SMCS Code: 1256-011 Installation Procedure

Removal Procedure NOTICE
NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened
component life.
component life.
NOTICE

machines. g00511822
Illustration 8
Dispose of all fluids according to local regulations and 1. Inspect the condition of the gasket. Replace the
mandates.
2. Position the fuel transfer pump (1) and the gasket

on the front housing cover.

washers during installation.
8
3. Install bolts (2) and the new seal washers. 1. Remove bolt (2) and move the wiring harness
Tighten the bolts to a torque of 55 10 Nm out of the way.
(41 7 lb ft).
4. Connect tube assembly (3).
3. Remove fuel manifold (1).
i01533776
Fuel Manifold - Remove

SMCS Code: 1702-011
Removal Procedure
Start By:

Install.
g00519417
4. Remove six O-ring seals (4).
component life. 5. Remove plugs (5) and the O-ring seals, if
necessary.
NOTICE
i01533793
during performance of inspection, maintenance, test- Fuel Manifold - Install
collect the fluid with suitable containers before open- SMCS Code: 1702-012
Tools and Shop Products Guide for tools and supplies NOTICE
suitable to collect and contain fluids on Caterpillar Keep all parts clean from contaminants.
products.
Dispose of all fluids according to local regulations and component life.
mandates.
g00519376
Illustration 9
Typical example
9
i01463268
Electronic Unit Injector -

Remove
SMCS Code: 1290-011
Removal Procedure
Table 3
Required Tools
Part
Number
g00519417
Illustration 11 A 5F-4764 Pry Bar 1
2. Install plugs (5) and the O-ring seals.

Start By:
3. Install six O-ring seals (4) on fuel manifold (1).
a. Remove the rocker shaft and the push rods.
NOTICE

component life.
NOTICE
g00519376 collect the fluid with suitable containers before open-
Illustration 12
4. Install fuel manifold (1) on the cylinder head with nent containing fluids.
bolts (3) and the washers.
5. Install the wiring harness with bolt (2). Tighten Tools and Shop Products Guide for tools and supplies
all of the bolts to a torque of 28 7 Nm suitable to collect and contain fluids on Caterpillar
(21 5 lb ft). products.
End By: Dispose of all fluids according to local regulations and

mandates.
Install.
g00511865
Illustration 13
10
1. Remove plug (1) from the fuel manifold. i01463359
2. Drain the fuel from the cylinder head assembly Electronic Unit Injector - Install
into a suitable container for storage or disposal.
SMCS Code: 1290-012
Table 4
Required Tools
Number
9U-6682 Tapered Brush 1
A
9U-6863 Small Bore Brush 1
B
g00511868
Illustration 14
3. Mark bridge assemblies (4) for reference during NOTICE

installation. Keep all parts clean from contaminants.
4. Loosen two nuts (3) and remove cap assembly Contaminants may cause rapid wear and shortened
(2). component life.
5. Remove bolt (5) and spacer assembly (6) that

holds the unit injector in place.
g00764868
Illustration 15
6. Position Tool (A) under hold-down (8). Carefully

pry unit injector (7) out of the cylinder head
assembly. Remove unit injector (7).
g00511917
Illustration 16
(1) Injector seating
(2) Tip bore
1. Use Tool (A) to clean injector seating (1).
2. Use Tool (B) to clean tip bore (2).

11
g00511927 g00511936
Note: Do not reuse seals (4). Use new seals for 8. Install plug (11) in the fuel manifold.
installation.
g00511929
Illustration 18
3. Lubricate the bore lightly with a 50/50 mix of

clean engine oil and 8T-2998 Lubricant.
4. Position the unit injector (3) in the cylinder head g00529729

assembly. Place the hold down clamp (10) at Illustration 20
the base of the unit injector. Push down on the (12) Electronic injector code
return spring of the unit injector in order to seat
the unit injector. NOTICE
When a fuel injector group is serviced, the new fuel
5. Install spacer assembly (9) and bolt (8) that injector groups electronic injector code must be pro-
holds the unit injector in place. grammed into the engines personality module soft-
ware by using the calibration menu on the Electronic
6. Pull the unit injector completely into the bore. Service Tool. If the new fuel injector groups electronic
Tighten the bolt to a torque of 30 Nm (22 lb ft). code is not entered, the previous fuel injector groups
characteristics are assumed.
7. Install cap assembly (5). Tighten nuts (6) to a
torque of 2.5 0.25 Nm (22 2 lb in). If it is not possible to immediately reprogram the elec-
tronic injector code of the injector into the personal-
ity module software, the engine will not be severely
harmed. The new electronic injector code should be
reprogrammed as quickly as possible in order to opti-
mize engine performance.
9. If a new unit injector or a different unit injector is

installed, program the electronic injector code.
12
End By: 1. Install the puller stud from Tool (A) into the unit
injector sleeve.
i01465373

- Remove
SMCS Code: 1713-011
Removal Procedure
Table 5 g00512002
Illustration 22
Required Tools
Part 2. Install the following parts from Tool (A) over the
Tool Part Description Qty stud: bridge puller, thrust bearing, hard washer,
Number
and nut. See Step 1.
9U-7259 Puller Stud 1
128-7889 Bridge Puller 1 3. Tighten the nut until the unit injector sleeve is
pulled free of the cylinder head assembly.
A(1) 9U-6877 Thrust Bearing 1
5P-8247 Hard Washer 1 4. Remove Tool (A) from the unit injector sleeve.
4K-0367 Nut 1 5. Repeat Steps 1 through 4 in order to remove the
(1) The tools that are listed in the chart are part of the 9U-6891 remaining unit injector sleeves.
Injector Tool Group.
Start By: i01465344
a. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, Electronic Unit - Install
Injector - Remove.
SMCS Code: 1713-012
NOTICE
Keep all parts clean from contaminants. Installation Procedure
Contaminants may cause rapid wear and shortened Table 6
component life. Required Tools
Part
Number
A 4C-5552 Large Bore Brush 1
B
9U-7244 End Brush 1
C 9U-7258 Driver Cap 1
NOTICE

component life.
g00512128
Illustration 21
Typical example
13
5. Repeat Step 1 through Step 4 in order to install

the remaining unit injector sleeves.
End By:
a. Install the electronic unit injectors. Refer to

Disassembly and Assembly, Electronic Unit
Injector - Install.
i01469974
SMCS Code: 1052-011
Removal Procedure
NOTICE

g00512115
Illustration 23 suitable to collect and contain fluids on Caterpillar
products.
1. Use Tool (A) to clean the unit injector bore.
2. Use Tool (B) to clean the unit injector seat. mandates.
Note: Check the fuel passage in the cylinder head
assembly. Remove any debris left from the use of
Tool (A) and Tool (B).
3. Apply 4C-9507 Retaining Compound to upper

land (1) and lower land (2) on the unit injector
sleeve.
g00766939
Illustration 25
Typical Example
g00512116
Illustration 24
4. Position the unit injector sleeve in the cylinder

head assembly. Use Tool (C) and a hammer to
seat the sleeve.
14
g00521930 g00521930
1. Remove two bolts (3) and washers (4).
2. Remove bolt (8) with the nut and the washer.

Remove saddle clamp (7).
4. Remove oil supply tube (2) and the gasket.
6. Remove oil drain tube (6). Remove the O-ring

seal and the gasket from oil drain tube (6).
g00766939
7. Remove four nuts (11). Illustration 28
Typical Example
8. Remove turbocharger (1) and gasket (10) from
the exhaust manifold. Note: Refer to the Specifications Manual for the
tightening procedure of the clamps on specific
turbochargers.
i01470033
Turbocharger - Install 2. Place clean engine oil in the oil supply port of
the turbocharger prior to installation. The oil will
SMCS Code: 1052-012 provide lubrication during starting and protection
during storage.
Installation Procedure 3. Apply 5P-3931 Anti-Seize Compound to the
turbocharger mounting studs on the exhaust
1. Inspect the condition of the gasket between the manifold.
turbocharger and the exhaust manifold and the
O-ring seals. Replace the O-ring seals and the 4. Install turbocharger (1) and gasket (10) on the
gaskets, if necessary. exhaust manifold. Install four nuts (11). Tighten
the nuts to a torque of 70 Nm (52 lb ft).
5. Place the gasket and the O-ring seal on oil drain

tube (6).
6. Install oil drain tube (6) with two bolts (5) and
the washers.

15
8. Install oil supply tube (2) and the gasket on

turbocharger (1). Install two bolts (3) and
washers (4).
9. Install bolt (8) and saddle clamp (7).
i01465377
Exhaust Manifold - Remove

and Install
SMCS Code: 1059-010
Typical example
Start By:
4. Position the gaskets with the tabs in the upward
a. Remove the turbocharger. Refer to Disassembly
position. Install exhaust manifold (2).
5. Apply 5P-3931 Anti-Seize Compound to
locknuts (1). Install locknuts (1) with the washers
and spacers. Tighten the locknuts to a torque of
55 10 Nm (41 7 lb ft).

threads of studs (3).
7. Install studs (3) in exhaust manifold (2). Tighten

the studs to a torque of 35 5 Nm (26 4 lb ft).
End By:

Illustration 29 g00512515 and Assembly, Turbocharger - Install.
Typical example
i01337457
1. Remove locknuts (1) with the washers and
spacers. Inlet Manifold - Remove
2. Remove exhaust manifold (2) and the gaskets. SMCS Code: 1058-011
3. Remove the studs that hold the exhaust manifold Removal Procedure
to the cylinder head assembly.
NOTICE
4. Remove studs (3) from the exhaust manifold, if
necessary.
Installation Procedure component life.


threads of the studs that hold the exhaust
manifold to the cylinder head assembly.
3. Install the studs for the cylinder head assembly.

Tighten the studs to a torque of 35 5 Nm
(26 4 lb ft).
16

2. Position air inlet manifold (6) and the three

gaskets on the cylinder head.
3. Install bolts (7) and the washers. Tighten bolts

4. Install hose assembly (5).
6. Install clip (4) and bolt (1). Tighten bolt (1) to a

g00707340
Illustration 31
Typical example 7. Connect sensor connector (3).
1. Disconnect sensor connector (3).

i01463575
2. Remove bolt (1) and clip (4).
Inlet and Exhaust Valve
3. Disconnect sensor connector (2). Springs - Remove and Install
4. Remove hose assembly (5). SMCS Code: 1108-010
5. Remove bolts (7) and the washers. Remove air

inlet manifold (6) and the three gaskets.
Removal Procedure
Table 7
i01337547 Required Tools
Inlet Manifold - Install Tool

Part
Number
SMCS Code: 1058-012 A 4C-6726 Valve Spring Compressor 1
Installation Procedure Start By:
NOTICE a. Remove the valve mechanism cover. Refer to

Keep all parts clean from contaminants. Disassembly and Assembly, Valve Mechanism
component life. b. Remove the electronic unit injector. Refer to
Injector - Remove.
NOTICE

component life.
Note: The following procedure is for the removal

of the inlet valve springs and the exhaust valve
springs without removing the cylinder head. This
procedure can be performed on only one cylinder
at a time. This will prevent the inlet valves and the
Illustration 32 g00707340 exhaust valves from falling into the cylinder.
Typical example
17
1. Rotate the crankshaft in order to bring the piston

to the top center position in the cylinder.
g00526804
Illustration 36
Illustration 33
g00526801 7. Remove valve rotators (4).
2. Place the bottom portion of Tool (A) on the 8. Remove the inlet valve springs and the exhaust
cylinder head. Install the hold down bolt (1) . valve springs (5) from each valve.
g00526802 g00526805
3. Install the remainder of Tool (A). 9. Remove bases (6) from the cylinder head.
10. Install the inlet valve springs and the exhaust

valve springs before you rotate the crankshaft.
Table 8
Required Tools
Part
Number
NOTICE
g00526803
Illustration 35 Keep all parts clean from contaminants.
4. Tighten the nut on Tool (A) in order to compress Contaminants may cause rapid wear and shortened
the inlet valve springs and the exhaust valve component life.
springs (2).
5. Remove retainer locks (3). Note: Ensure that the piston is at the top center
position in order to install the inlet valve springs and
6. Remove Tool (A). the exhaust valve springs.
18
5. Tighten the nut on Tool (A) in order to compress

the inlet valve springs and the exhaust valve
springs (2).
6. Install retainer locks (3).
7. Remove Tool (A).
End By:
a. Install the electronic unit injector. Refer to

Injector - Install.
g00526805
b. Install the valve mechanism cover. Refer to
Illustration 38 Disassembly and Assembly, Valve Mechanism
1. Install bases (6) for the inlet valve springs and
i01463658
Inlet and Exhaust Valves -

Remove and Install
SMCS Code: 1105-010
Removal Procedure
Table 9
Required Tools
Part
Number
g00526804 A 5S-1330 Valve Spring Compressor 1
Illustration 39
2. Install the inlet valve springs and the exhaust Start By:
valve springs (5).
a. Remove the cylinder head. Refer to Disassembly
3. Install valve rotators (4). and Assembly, Cylinder Head - Remove.
NOTICE

component life.
g00526803
Illustration 40

19
g00513273
Illustration 41
1. Place the cylinder head assembly in an upright

position. See Illustration 41.
2. Use Tool (A) to compress valve springs (3) and

valve spring (5). Remove retainer locks (1).
3. Remove Tool (A). Remove valve rotator (2), valve

springs (3) and valve spring (5).
4. Repeat Steps 2 and 3 in order to remove valve

springs (3), valve spring (5) and bridge supports
(6). g00513277
Illustration 42
5. Remove valves (4) from the cylinder head. 1. Lubricate the inlet valve (7) and the exhaust
valve (8) with clean engine oil. Install the inlet
6. Repeat Steps 2 through 5 in order to remove the valves and exhaust valves in the cylinder head
remaining inlet valves and exhaust valves. assembly.
Table 10
Required Tools when the valve spring compressor is released. En-
Part
sure that the valve keepers are properly installed
Tool Part Description Qty on the valve stem. To help prevent personal injury,
Number
A 5S-1330 Valve Spring Compressor 1 valve springs during the installation of the valves.

2. Place the following items on valve stem (4):

bridge support (6), valve springs (3), valve
spring (5), and valve rotators (2).
3. Use Tool (A) to compress valve springs (3) and

(5). Install retainer locks (1).

End By:
a. Install the cylinder head. Refer to Disassembly

20
i01463690
NOTICE
Inlet and Exhaust Valve Guides Keep all parts clean from contaminants.
SMCS Code: 1104-010 component life.
Removal Procedure
Table 11
Required Tools
Part
Number
A 1U-9654 1
Group
Start By:

NOTICE

component life.
g00513519
Illustration 44
1. Position the valve guide and tap on the top of

the valve guide. This is done in order to start the
valve guide into the cylinder head assembly.
2. Use Tool (A) to install the valve guides. Install the

valve guides until the protrusion is 22.0 0.5 mm
(.87 .02 inch) above the cylinder head
assembly.
g00513516
Illustration 43
Typical example
End By:
1. Use Tool (A) to remove the valve guides from the a. Install the inlet valves and exhaust valves.
cylinder head assembly. Refer to Disassembly and Assembly, Inlet and
Exhaust Valves- Remove and Install.
Table 12
Required Tools
Part
Number
A 1U-9654 1
Group
21
i01463695 1. Use Tool (A) to remove valve seat inserts (1).

Inlet and Exhaust Valve Seat Installation Procedure
Table 14
SMCS Code: 1103-010 Required Tools
Part
Removal Procedure Tool
Number
Table 13 Valve Guide and Seat Tool

A 1U-9654 1
Group
Required Tools
Part
Tool Part Description Qty NOTICE
Number
A 1U-9654 1
Group
component life.
Start By:
a. Remove the inlet and exhaust valves. Refer to

NOTICE

component life.
g00513645
Illustration 47
Typical example
g00513641
Illustration 45
Typical example
g00513644
Illustration 48
1. Lower the temperature of new valve seat insert

(1).
2. Use Tool (A) to install the new valve seat insert

in the cylinder head assembly.
g00513644
Illustration 46
22
End By:
a. Install the inlet and exhaust valves. Refer to

i01234011
Engine Centrifugal Oil Filter -

Remove and Install
SMCS Code: 1328-010
Table 15
1. Remove filter cover assembly (3) and filter rotor
Required Tools assembly (1) from the body of the filter assembly.
Part
Tool Part Description Qty 2. Remove two bolts (2) and the washers. Remove
Number
the body of the filter assembly.
NOTICE

component life.
NOTICE
ing any compartment or disassembling any compo- g00512750
Illustration 50
Refer to Special Publication, NENG2500, Caterpillar 3. Remove filter rotor assembly (4) from filter cover
Tools and Shop Products Guide for tools and supplies assembly (3).
products.

mandates.
g00512752
Illustration 51
4. Use Tool (A) to remove retaining ring (5) from

filter cover assembly (3).
23
g00512754 g00512755
5. Remove the following items from filter cover (7): 8. Remove O-ring seal (12) from filter adapter
filter cover bolt (9), O-ring seal (8), and seal (6). assembly (11).
Table 16
Required Tools
Part
Number
NOTICE
g00512845 Contaminants may cause rapid wear and shortened

Illustration 53
component life.
6. Remove seal (10) from the body of the filter
assembly (1). 1. Inspect the condition of the O-ring seals. Replace
g00512756
Illustration 54
g00512755
Illustration 56
7. Remove filter adapter assembly (11) from the
oil filter base. 2. Install O-ring seal (12) onto filter adapter
assembly (11).
24
g00512756 g00512750
3. Place the filter adapter assembly (11) on the oil 7. Place filter rotor assembly (4) on filter cover
filter base. Tighten the adapter to a torque of assembly (3).
47 7 Nm (35 5 lb ft).
g00512749
Illustration 61
g00512754
Illustration 58
8. Install filter cover assembly (4) in the body of
4. Install O-ring seal (8) on filter cover bolt (9). filter assembly (1). Tighten the filter body bolt to
9. Install the O-ring seal on the body of filter

assembly (1).
10. Install the body of filter assembly (1) with two

g00512752
Illustration 59
5. Install filter cover bolt (9) in filter cover (6) with

retaining ring (5).
6. Install seal (7) on filter cover (6).

25
i01001046

Remove
SMCS Code: 1306-011
Removal Procedure
Table 17
Required Tools
Part
Number
g00512861
A 2P-8250 Strap Wrench Assembly 1 Illustration 63

NOTICE
Keep all parts clean from contaminants. 3. Remove four bolts (3) and the washers.
Contaminants may cause rapid wear and shortened Note: Two bolts (6) that hold the oil filter base
component life. assembly to the cylinder block are marked. This is
done for installation purposes.
NOTICE 4. Remove six bolts (2) and the washers.
during performance of inspection, maintenance, test- 5. Remove oil filter base assembly (4) and the
ing, adjusting and repair of the machine. Be prepared O-ring seals.
component containing fluids. i01465384
Refer to Special Publication, NENG2500, Caterpillar Engine Oil Filter Base -

Tools and Shop Products Guide, for tools and sup- Disassemble
machines. SMCS Code: 1306-015
mandates. Disassembly Procedure
Start By:

Base - Remove .
NOTICE

component life.
g00512858
Illustration 62

26
c. Remove spacer (7) from bolt (6).

NOTICE

products.

mandates. g00513077
Illustration 66
Typical example

valve (12).
4. Remove valve (12) and O-ring seal (10) from oil

filter base (8).

cover (13).
6. Remove the following items from oil filter base

(8): cover (13), O-ring seal (14), spring (11), and
oil pump bypass valve (9).
g00513002
Illustration 64
1. Remove three O-ring seals (1) from the oil filter

base.
g00513080
Illustration 67
Typical example
7. Remove the following items from oil filter base

g00513037
Illustration 65 (8): plug (18), O-ring seal (17), spring (16), and
Typical example relief valve plunger (15).
2. Remove relief valve assembly (2): 8. Remove the stud that holds the oil filter to the oil
filter base, if necessary.
a. Loosen bolt (6) slowly in order to release the
compression on the spring (4).
b. Remove the following items from the oil filter

base: bolt (6), seat of the relief valve spring
(5), spring (4), and retainer (3).
27
i01463705 5. Install the following items in oil filter base (8): oil
pump bypass valve (9), spring (11), and O-ring
Engine Oil Filter Base - seal (14).
Assemble 6. Install cover (13) and the two bolts with washers
SMCS Code: 1306-016 that hold the cover in place.
7. Install O-ring seal (10) and valve (12) in oil filter

Assembly Procedure base (8).
NOTICE 8. Install the two bolts with washers that hold valve
Keep all parts clean from contaminants. (12) in place.

component life.

2. Install the stud that holds the oil filter to the

oil filter base. Tighten the stud to a torque of
68 7 Nm (50 5 lb ft).
g00764949
Illustration 70
9. Install the following items in oil filter base (8):

retainer (3), retainer spring (4), seat of the relief
valve spring (5), and spacer (7).
10. Install bolt (6).
g00513080
Illustration 68
Typical example
3. Install relief valve plunger (15) and spring (16)

into oil filter base (8).
4. Place O-ring seal (17)on plug (18) and install the

plug in oil filter base (8).
g00513002
Illustration 71
11. Install relief valve assembly (2).
12. Install three O-ring seals (1) in the oil filter base
assembly.
End By:

Base - Install.
g00764944
Illustration 69
28
i01001095
Engine Oil Filter Base - Install

SMCS Code: 1306-012
Table 18
Required Tools
Part
Number
g00512858
Illustration 73
NOTICE
Keep all parts clean from contaminants. 6. Install oil filter assembly (1) with Tool (A). Follow
the instructions with the oil filter assembly for the
Contaminants may cause rapid wear and shortened correct installation.
component life.
i01463799
1. Inspect the condition of the O-ring seals. Replace Engine Oil Cooler - Remove
SMCS Code: 1378-011
Note: Place all O-ring seals and install all bolts
finger tight before tightening to the standard torque.
Removal Procedure

and alkali.


g00512861 cooling system pressure cap is cool enough to
Illustration 72
2. Install the O-ring seals in oil filter base assembly Do not attempt to tighten hose connections when
(4). Position the oil filter base assembly on the the coolant is hot, the hose can come off causing
cylinder block. Apply 9S-3263 Thread Lock burns.
Compound to bolts (6) that are marked.
3. Install four bolts (2) and the washers. Avoid contact with skin and eyes.
NOTICE
5. Install two bolts (5) and the washers. Keep all parts clean from contaminants.

component life.
29

NOTICE
Care must be taken to ensure that fluids are contained 6. Remove two bolts (6) and the washers.
ing, adjusting and repair of the product. Be prepared to 7. Remove engine oil cooler (4) and the two O-ring
collect the fluid with suitable containers before open- seals from the oil filter base.

products.

mandates.

g00513712
Illustration 76
Typical example
8. Loosen hose clamp (7) on hose (8). Remove

engine oil cooler bonnet (10) and O-ring seal (9).
g00513708
Illustration 74
Typical example
3. Remove elbow (1) of the engine oil cooler and

the O-ring seals. g00513713
Illustration 77
Typical example
4. Remove two bolts (3) from the core of engine
oil cooler (4). 9. Clean the cooler tube bundles in engine oil.
Clean cooler core (4) with a rod that has a
suitable diameter. Thoroughly clean the tube
bundles. Check the oil cooler for cracks or leaks.
g00513711
Illustration 75
Typical example
30
i01002243

SMCS Code: 1378-012
NOTICE

component life.
g00513708
1. Inspect the condition of the O-ring seals. Replace Illustration 80
the seals, if necessary. Typical example
3. Install the two O-ring seals on the oil filter base.

Position the oil cooler (4) on the oil filter base.
4. Install two bolts (6) with washers and two bolts

(3) with washers.
5. Install three bolts (5) with washers. Tighten hose

clamp (7).
6. Install the O-ring seals on elbow (1) of the engine

oil cooler.
7. Lubricate the bore lightly with glycerin. Position

the elbow of the engine oil cooler on engine oil
g00513712 cooler core (4).
Illustration 78
Typical example
8. Install three bolts (2) and the washers.
2. Install O-ring seal (9). Position engine oil cooler
bonnet (10) in hose (8). 9. Fill the cooling system with coolant to the correct
level. Refer to Operation and Maintenance
i01000454

SMCS Code: 1304-011
Removal Procedure
NOTICE
g00513711 Contaminants may cause rapid wear and shortened
Illustration 79
Typical example component life.
31
i01465390
NOTICE
Care must be taken to ensure that fluids are contained Engine Oil Pump - Disassemble
SMCS Code: 1304-015
opening any compartment or disassembling any Disassembly Procedure
Table 19
plies suitable to collect and contain fluids in Caterpillar Part
machines. Number
5F-7344 Block-Puller 1
mandates. A 7S-7786 Puller Leg 1
5F-7345 Screw 1
Start By:

Remove .
NOTICE

component life.
g00512289
Illustration 81
NOTICE
1. Remove bolts (1) and the washers that hold the Care must be taken to ensure that fluids are contained
tube to the elbow of the oil pump. during performance of inspection, maintenance, test-
2. Remove bolts (2) and the washers that hold the collect the fluid with suitable containers before open-
elbow of oil pump (3) to the cylinder block. ing any compartment or disassembling any compo-

products.

mandates.
g00512297
Illustration 82

engine oil pump to the front housing. Remove
the engine oil pump and the elbow as a unit.
4. Remove the two O-ring seals. One O-ring seal is

on the connection of the tube to the elbow. The
second O-ring seal is on the engine oil pump. g00512335
Illustration 83
32
1. Remove elbow (1) from the engine oil pump.
2. Remove the two O-ring seals from the elbow of

the engine oil pump.
4. Remove cover (3) from the pump housing.
g00766947
Illustration 85
2. Install drive shaft (1) in the pump housing.
Note: Heat gear (4) to a maximum temperature of

316 C (600 F).
3. Install gear (4) on the end of drive shaft (1).

Illustration 84 g00512369 Position the gear so the distance between
the outside face of the gear and the step
5. Remove O-ring seal (4) and idler gear (5) from face on the pump body is 29.40 0.50 mm
the cover. (1.158 .020 inch).
6. Use Tool (A) to remove gear (6) from drive shaft 4. Install idler gear (5) in the pump housing.
(7).
5. Install O-ring seal (6) in cover (3).
NOTICE 6. Install cover (3) and four bolts (2) with the
Before removing the drive shaft from the pump hous- washers.
7. Remove drive shaft (7) from the pump housing.
i01465392

SMCS Code: 1304-016
Assembly Procedure
g00512488
Illustration 86
NOTICE
Keep all parts clean from contaminants. 7. Lubricate the two O-ring seals. Install the two
O-ring seals on elbow (7) of the oil pump.
component life. 8. Install the elbow on the engine oil pump.
1. Inspect the condition of the O-rings. Replace NOTICE

O-rings, if necessary. The pump must rotate freely by hand after assembly.

33
End By:

i01000464

SMCS Code: 1304-012
NOTICE g00512305
Illustration 88
Contaminants may cause rapid wear and shortened 4. Install two bolts (3) that hold the elbow of oil
component life. pump (4) to the cylinder block.
5. Install two bolts (2) and the washers that hold the
tube to the elbow of the oil pump.
i01463822
Water Pump - Remove

SMCS Code: 1361-011
Removal Procedure
Start By:
a. Remove the alternator. Refer to Disassembly and

g00512304
Illustration 87 Assembly , Alternator - Remove and Install.
1. Inspect the condition of the O-ring seals. There b. Remove the belt tensioner. Refer to Disassembly
is one O-ring seal on the connection of the tube and Assembly, Belt Tensioner - Remove and
to the elbow. The second O-ring seal is on the Install.
engine oil pump. Replace the seals, if necessary.
c. Remove the engine oil cooler. Refer to
2. Install the O-ring seals. Place the engine oil Disassembly and Assembly, Engine Oil Cooler
pump in the correct position in the front housing. - Remove.
Note: Lubricate the bore in the front housing with

clean engine oil.
3. Install bolts (1) and the washers that hold the

engine oil pump to the front housing.
34

and alkali.


g00513750
Illustration 89
the coolant is hot, the hose can come off causing 2. Remove two bolts (4) and the washers from tube
burns. assembly (5).
Cooling System Coolant Additive contains alkali. 3. Cut plastic tie (3) from tube assembly (5).
4. Loosen hose clamp (2) and remove hose (1).
NOTICE 5. Remove bolt (8) and the washer.
6. Remove dipstick tube (6) with the O-ring seal.
component life. 7. Remove two bolts (9) and the washers from the
alternator bracket.
NOTICE

products.

mandates. Illustration 90 g00513753
1. Drain the coolant from the system into a suitable 8. Remove two bolts (10) and the washers.
9. Remove water pump (7) and the tube assembly.
Remove the flange gasket and the O-ring seal.
10. Remove the tube assembly and O-ring seals

from the water pump, if necessary.
35
i01528851
Water Pump - Disassemble

SMCS Code: 1361-015
Table 20
Required Tools
Number
A 5F-7344 Puller 1
Block(1)
5F-7345 Screw(1) 1
7S-7789 Bumper(1) 2
B 1P-1861 Retaining 1
Ring Pliers
8S-2264 1 g00793641
C Puller Illustration 91
Group (3) Cover bolts
(1) Part of 8B-7554 Bearing Cup Puller (4) Nut
(5) Bolt
(6) Bearing
Start By: (7) Gear
(8) Retaining ring
a. Remove the water pump. Refer to Disassembly (9) Impeller
and Assembly, Water Pump - Remove. The (10) Shaft
(11) Water seal
information is in this manual. (12) Oil seal
NOTICE

component life.
g00718976
Illustration 92
1. Remove water pump elbow (1). Remove elbow

(2).
36
g00718982 g00719029
2. Remove cover bolts (3). Carefully separate the 4. Remove bearing (6).
housing from the cover.
g00719007
Illustration 97
g00718996
Illustration 94
5. Use Tool (A) to remove gear (7).
g00718989
Illustration 95
g00719327
Illustration 98
3. Hold nut (4). Remove hex socket head bolt (5).
6. Use Tool (B) to remove retaining ring (8). Remove
inner bearing.
37
g00719369 g00719396
7. Use Tool (C) to remove impeller (9). 10. Remove oil seal (12).
i01529028

SMCS Code: 1361-016
Assembly Procedure
Table 21
Required Tools
Number
g00719348
Illustration 100 A 1P-0766 Seal Guide 1
B 183-4028 Seal Guide 1
8. Use a hydraulic press and remove shaft
assembly (10). C 6V-2012 Depth 1
Micrometer
NOTICE

component life.
g00719377
Illustration 101
9. Remove water seal (11).

38
g00719459
Illustration 105
g00793641
Illustration 103
(3) Cover bolts
(4) Nut
(5) Bolt
(6) Bearing
(7) Gear
(8) Retaining ring
(9) Impeller
(10) Shaft
(11) Water seal
(12) Oil seal g00719465
Illustration 106
1. Use 4C-9500 Quick Cure Primer to clean the
shaft assembly and the counterbore in the 3. Use a hydraulic press with Tool (B) to install
housing. water seal (3) onto shaft assembly (4). Install the
water seal with the part number upward. Ensure
that the water seal is flush against the base of
the shaft assembly. Do not lubricate the seal.
g00719452
Illustration 104
2. Use Tool (A) to install oil seal (1) into water pump g00719486
Illustration 107
housing (2). Install the oil seal with the part
number toward the housing. Ensure that the oil
seal is flush with the housing. Do not lubricate 4. Use a hydraulic press with Tool (B) to install
the seal. shaft assembly (4) into water pump housing (2).
Ensure that there is clearance under the shaft
assembly before the shaft assembly is pressed
into position.
39
g00719546 g00719554
Dimension A is 29.3 mm (1.15 inch).
5. Install bearing (5).
7. Use a hydraulic press to install gear (7). Install
the gear to a height of 29.3 mm (1.15 inch).
g00719522
Illustration 109
6. Use retaining ring pliers to install retaining ring Illustration 112 g00719589
(6).
g00719597
Illustration 113
g00719552
Illustration 110
8. Use a hydraulic press to install impeller (8) onto
the shaft assembly. The impeller should be flush
with the top of the shaft assembly.
40
g00719600 g00719692
9. Install bearing (9). Ensure that the bearing is 12. Install a new gasket and water pump elbow (13).
flush with the gear. Install a new gasket and elbow (14).
End By:
a. Install the water pump. Refer to Disassembly

and Assembly, Water Pump - Install. The
information is in this manual.
i01463891

SMCS Code: 1361-012
g00719613
Illustration 115
NOTICE
10. Install nut (10) and hex socket head bolt (11). Keep all parts clean from contaminants.

component life.
1. Inspect the condition of the O-ring seals and the

flange gasket. Replace the seals and the gasket,
if necessary.
g00719691
Illustration 116
11. Install a new gasket and the cover. Tighten bolts

g00513750
Illustration 118
41
i01002312

Remove and Install
SMCS Code: 1355-010
Removal Procedure

and alkali.
g00513753
Illustration 119
2. Install the O-ring seal on water pump (7).
Lubricate the bore lightly with clean engine oil.
3. Lubricate the O-ring seals with coolant and install
the O-ring seals on tube assembly (5). Install
tube assembly (5) on water pump (7).
4. Position water pump (7) and tube assembly (5)
in the front housing. Install two bolts (10) and
the washers. Tighten the bolts to a torque of
28 7 Nm (21 5 lb ft).
burns.
5. Position the flange gasket between tube
assembly (5) and the water temperature regulator
housing. Install two bolts (4) and the washers.
(21 5 lb ft). NOTICE
6. Install hose (1) and tighten hose clamp (2).
7. Put new plastic tie (3) on tube assembly (5) in component life.
order to hold the wiring.
8. Install two bolts (9) and washers into the NOTICE

alternator bracket. Care must be taken to ensure that fluids are contained
9. Install dipstick tube (6) with bolt (8) and the ing, adjusting and repair of the machine. Be prepared
washer. to collect the fluid with suitable containers before
10. Fill the cooling system with coolant to the correct component containing fluids.
Manual for the correct filling procedure. Refer to Special Publication, NENG2500, Caterpillar
End By: plies suitable to collect and contain fluids in Caterpillar
machines.
a. Install the engine oil cooler. Refer to Disassembly
and Assembly, Engine Oil Cooler Install. Dispose of all fluids according to local regulations and
mandates.
b. Install the belt tensioner. Refer to Disassembly
1. Drain the coolant from the system into a suitable
Install.
c. Install the alternator. Refer to Disassembly and
Assembly, Alternator - Remove and Install .
42
g00513801
Illustration 120
Typical example
2. Remove four nuts (1) and the washers from

3. Remove regulator housing (2). Remove four

studs (3), if necessary.
4. Remove pipe plug (4), if necessary.
g00513806
Illustration 123
6. Remove water temperature regulator (6). Remove

pipe plug (7), if necessary.
7. Remove lip seal (8) from regulator housing (2).
Table 22
Required Tools
g00513802
Illustration 121 Part
5. Remove gasket (5).
NOTICE

component life.
g00513803
Illustration 122
43
g00513801
Illustration 124
Typical example
g00513806
Illustration 126
2. Position the seal with the lip toward the inside of

the housing. Lubricate the lip of the seal with
g00513802
Illustration 125 glycerin. Install lip seal (8) in regulator housing
Typical example (2) with Tool (A). Install the seal until contact with
the counterbore in the housing.
1. Install studs (3) in the water outlet manifold.
Position gasket (5) on studs (3).
g00513803
Illustration 127
3. Install pipe plug (4) and (7) with 5P-3413 Pipe

Sealant.
4. Position water temperature regulator (6) in

5. Install regulator housing (2) with two nuts (1) and

the washers.
44
6. Fill the cooling system with coolant to the correct 1. Drain the level of the coolant below the water
level. Refer to the Operation and Maintenance outlet manifold. Drain the coolant into a suitable
Manual for the correct filling procedure. container for storage or disposal.
i01005442
Water Outlet Manifold -

Remove
SMCS Code: 1362-011
Removal Procedure

and alkali. g00515792
Illustration 128
At operating temperature, engine coolant is hot 2. Remove two bolts (6) and the washers that hold
and under pressure. The radiator and all lines tube (5) to water outlet manifold (3).
steam. Any contact can cause severe burns. 3. Disconnect sensor connector (2) and lay wiring
harness (1) aside.

burns.

NOTICE
g00515793
Illustration 129
Contaminants may cause rapid wear and shortened The air inlet manifold has been removed for photo purposes.
component life.
NOTICE
Care must be taken to ensure that fluids are contained 5. Remove water outlet manifold (3) and water
during performance of inspection, maintenance, test- temperature regulator housing (4) as a unit from
ing, adjusting and repair of the machine. Be prepared the cylinder head. Remove the gaskets.
opening any compartment or disassembling any 6. Remove plugs (7), if necessary.

machines.

mandates.
45
i01005443 7. Fill the cooling system with coolant to the correct

Water Outlet Manifold - Install Manual for the correct filling procedure.
SMCS Code: 1362-012
i01002432
Installation Procedure Flywheel - Remove


Removal Procedure
component life. Table 23
Required Tools
Part
Number

lifting device.
g00515793
Illustration 130
The air inlet manifold has been removed for photo purposes.

2. Install the gaskets and position water outlet

manifold (3) on the cylinder head.
g00513879
Illustration 132
3. Install bolts (8) and the washers.
4. Apply 5P-3413 Pipe Sealant to the threads of lifting device to the flywheel.
plugs (7). Install plugs (7).
the flywheel. The weight of the flywheel is 57 kg
(125 lb).

remove the ring gear.
g00515792
Illustration 131

46
i01183069 6. Check the flywheel runout. Refer to Testing

and Adjusting, Basic Engine for the correct
Flywheel - Install procedure.
SMCS Code: 1156-012
i01465394
Installation Procedure Crankshaft Rear Seal - Remove

Table 24
SMCS Code: 1161-011
Required Tools
Tool
Part
Removal Procedure
Number
Start By:
Assembly, Flywheel - Remove.
Always wear protective gloves when handling NOTICE

parts that have been heated. Care must be taken to ensure that fluids are contained
1. Heat the ring gear to a maximum temperature
of 315 C (599 F). Install the ring gear on the
flywheel. Position the ring gear with the part
number toward the crankshaft. Allow the ring
gear to cool. Use a soft hammer in order to seat
the ring gear against the shoulder of the flywheel.
products.

mandates.
g00513879
Illustration 133

3. Place the flywheel in the original position on the g00514081

crankshaft. Align the arrows on the flywheel and Illustration 134
the crankshaft.
4. Apply 7M-7456 Compound to the threads of

eight bolts (1).
5. Install eight bolts (1) and the washers. Tighten

the bolts evenly to a torque of 300 40 Nm
(221 30 lb ft).
47
g00514082 g00514081
1. Remove six nuts (1) and three bolts (2). 2. Clean the seal surface of the crankshaft.
Lubricate O-ring seal (4) with clean engine oil.
2. Use a screwdriver to remove crankshaft rear seal Position O-ring seal (4) on the back of crankshaft
(3). rear seal (3).
3. Remove O-ring seal (4). The O-ring seal is 3. Position the crankshaft rear seal (3) on the
located behind the crankshaft rear seal (3). crankshaft and the studs. Push crankshaft rear
seal (3) in place. This will dislodge the shipping
sleeve.
i01465396
Crankshaft Rear Seal - Install 4. Install the six nuts (1) and the washers.
SMCS Code: 1161-012 5. Apply 7M-7456 Compound to the threads of

three bolts (2). Install three bolts (2) at the bottom
of crankshaft rear seal (3). Tighten the bolts to a
Installation Procedure torque of 12 3 Nm (9 2 lb ft).
Note: Leave the shipping sleeve in place in order to End By:
install the crankshaft rear seal. The crankshaft rear
seal must be installed dry. a. Install the flywheel. Refer to Disassembly and
the seal, if necessary.
i01533804

Remove and Install
Removal Procedure
Table 25
Required Tools
Part
Number
g00514082 A 5F-4764 Pry Bar 1
Illustration 136
Start By:

48
1. Place a new gasket over dowels (3).
g00521945
Illustration 138
g00521970
Illustration 141
1. Remove four bolts (1) and the washers that hold
crankshaft rear seal carrier (2) to the cylinder
block.
g00521945
Illustration 142
g00521947
2. Place crankshaft rear seal carrier (2) on the
Illustration 139 crankshaft.
2. Use Tool (A) to carefully pry crankshaft rear seal 3. Install four bolts (1) and the washers.
carrier (2) from the crankshaft.
End By:
3. Remove the gasket between the cylinder block
and crankshaft rear seal carrier (2). a. Install the flywheel housing. Refer to Disassembly
Installation Procedure Install.
i01463915

and Install
SMCS Code: 1157-010
Removal Procedure
Start By:

g00521969 Assembly, Flyheel - Remove.
Illustration 140
49
b. Remove the crankshaft rear seal. Refer to

Seal - Remove.
NOTICE

suitable to collect and contain fluids on Caterpillar Illustration 144 g00514037
products.
5. Remove O-ring seal (4) from rear seal carrier (5).
mandates.
lifting device.
g00514040
Illustration 145
g00514036
1. Apply 1U-6396 O-Ring Assembly Compound to
Illustration 143 O-ring seal (4). Install O-ring (4).
2. Remove twelve bolts (1) and the washers. 2. Apply 1U-8846 Sealant to the face of the
cylinder block.
3. Attach a suitable lifting device to flywheel
housing (2).
4. Lift flywheel housing (2) away from dowel pins

(3). The weight of flywheel housing (2) is 23 kg
(50 lb).
g00514036
Illustration 146
3. Position flywheel housing (2) on the rear of the

cylinder block. Install twelve bolts (1) and the
washers.
50
End By: 3. Remove bolts (3), cover (4), and the gasket.
Inspect the condition of the gasket. Replace the
a. Install the crankshaft rear seal. Refer to gasket, if necessary.
Seal - Install .
b. Install the flywheel. Refer to Disassembly and

i01464030

Remove
Table 26
4. Remove crankshaft gear (5) from the crankshaft.
Required Tools Remove the O-ring seal from crankshaft gear (5).
Part
Tool Number Part Description Qty 5. Remove Tool (A).
A 8T-0514 Guide Bolt 2
6. Remove bolts (6) that fasten shaft (7) to the
B 1P-0520 Driver Group 1 flywheel housing.
Start By:

Assembly, Flywheel - Remove.
NOTICE

component life.
g00520763
Illustration 149
7. Use a pry bar in order to remove shaft (7) and

gear assembly (8).
g00520761
Illustration 147
1. Install Tool (A) in the crankshaft.
2. Remove bolts (1) and crankshaft seal (2).

51

necessary, use Tool (B) to remove bearing (14)
g00520764
Illustration 150
8. Inspect the condition of the bearing in gear

assembly (8). If necessary, remove bearing (9) Illustration 153
g00520769
from the gear with Tool (B).
g00520770
Illustration 154
g00520766
Illustration 151
12. Remove bolts (16), cover assembly (17), and
9. Remove bolts (10) that fasten carrier assembly thrust washer (18). Replace the O-ring seal.
(11) to the flywheel housing. Install two bolts
(10) opposite each other at location (12). Use 13. Inspect the condition of thrust washer (18).
these bolts as forcing screws in order to remove Replace thrust washer (18), if necessary.
carrier assembly (11).
washer (18) is 4.665 mm (.1837 inch).

washer (18) in cover assembly (17). Remove the
g00765120
Illustration 152
10. Remove O-ring seal (15) and lip type seal (13)
52
g00520771 g00520774
15. Remove bolts (19) and thrust plate (20) from the 18. Remove thrust washer (24) from the flywheel
output shaft. housing.
19. Inspect the condition of thrust washer (24).

Replace thrust washer (24), if necessary.

washer (24) is 4.665 mm (0.1837 inch).

washer (24) in the flywheel housing. Remove the

necessary, remove bearing (25) from the flywheel
housing with Tool (B).
g00520772
Illustration 156
i01465400

Install
Table 27
Required Tools
Part
g00520773 A 8T-0514 Guide Bolt 2
Illustration 157
16. Remove hex socket head bolts (21) that fasten
gear (23) to output shaft (22).
NOTICE
17. Remove output shaft (22) from gear (23). Keep all parts clean from contaminants.
Remove gear (23) from the flywheel housing.
component life.
53
g00520774 g00520773
g00520772
Illustration 162
4. Hold gear (23) in the flywheel housing and install

output shaft (22) in gear (23).
5. Fasten gear (23) to output shaft (22) with hex

g00520775 socket head bolts (21).
Illustration 160
1. Install bearing (25) in the flywheel housing with

Tool (B).

at angle (XX), which is 23 10 degrees from
the horizontal centerline. The bearing should be
installed to depth (YY), which is 1.5 0.5 mm
(0.06 0.02 inch).
2. Install the dowels for thrust washer (24) in the

flywheel housing.

surface of the flywheel housing by a distance of Illustration 163 g00520771
3.0 0.2 mm (0.12 0.01 inch).
6. Fasten thrust plate (20) to the output shaft with
3. Install thrust washer (24) on the dowels in the bolts (19).
flywheel housing.
54
g00520770 g00520768
9. Install bearing (14) in the carrier assembly with

Tool (B).

at angle (X), which is 112 10 degrees from the
centerline in the upper bolt hole in the carrier
assembly . The bearing should be installed to depth
(Y), which is 1.6 0.5 mm (0.06 0.02 inch).
10. Install O-ring seal (15) and lip type seal (13) in
the carrier assembly. Lubricate lip type seal (13)
lightly with the lubricant that is being sealed.
g00520769
Note: Lip type seal (13) should be installed to a
Illustration 165 depth of 2.5 0.5 mm (0.1 0.02 inch).
7. Install the dowels for thrust washer (18) in cover 11. Install the carrier assembly in the flywheel
assembly (17). housing. Install bolts (10).
surface of cover assembly (17) by a distance of
3.0 0.2 mm (0.12 0.01 inch).
8. Install thrust washer (18) on the dowels in cover

assembly (17). Fasten cover assembly (17) to
the flywheel housing with bolts (16).
g00520764
Illustration 168
g00520767
Illustration 166
55
Note: Some flywheel housings have locating dowels

for cover (4). If the flywheel housing does not have
these locating dowels, care must be taken in order
to ensure that the cover is properly aligned. Ensure
that the gap between the dust lip and the crankshaft
gear is uniform in order to avoid damage to the
crankshaft seal.
16. Hold cover (4) and the gasket in position on the

flywheel housing and install bolts (3).
17. Install crankshaft seal (2) and bolts (1).
18. Remove Tool (A) from the crankshaft.

g00520765
Illustration 169 End By:
12. Install bearing (9) in gear (8) with Tool (B). a. Install the flywheel. Refer to Disassembly and
relief groove in gear (8) within two degrees. Bearing
(9) must not extend beyond either face of gear (8). i01464063

Remove and Install
SMCS Code: 1205-010
Removal Procedure
1. Relieve the tension on the belt tensioner and
remove the drive belts.
g00520762
Illustration 170
13. Install shaft (7) and gear assembly (8) in the

flywheel housing. Fasten shaft (7) to the flywheel
housing with bolts (6).
14. Install Tool (A) in the crankshaft. Install a new

O-ring seal on crankshaft gear (5).
15. Install crankshaft gear (5).

g00514208
Illustration 172
3. Remove the following items from the end of the

crankshaft: vibration damper (2), pulley (3), and
adapter (4).
4. Remove eight bolts (5).
g00520761
Illustration 171
56
1. Place adapter (4) and pulley (3) on vibration

damper (2). Install eight bolts (5). Tighten the
2. Install bolts (1) and the washers. Tighten all

bolts evenly to a torque of 240 40 Nm
(175 30 lb ft).
3. Install the drive belt and apply the correct

tension.
i01464074

g00514209
Illustration 173 Remove
5. Separate pulley (3) and adapter (4) from vibration SMCS Code: 1160-011
damper (2).
Removal Procedure
Start By:

NOTICE

component life.
g00514210
Illustration 174
g00514250
Illustration 176
1. Remove nuts (2) and the washers.
2. Remove crankshaft front seal (1).
g00514211
Illustration 175
57
i01464078 b. Remove the belt tensioner. Refer to Disassembly

Crankshaft Front Seal - Install Install.
SMCS Code: 1160-012 c. Remove the crankshaft front seal. Refer to
Installation Procedure Seal - Remove.
NOTICE d. Remove the fuel transfer pump. Refer to

Keep all parts clean from contaminants. Disassembly and Assembly, Fuel Transfer Pump
- Remove.
component life. NOTICE
Note: Leave the shipping sleeve in place in order to Contaminants may cause rapid wear and shortened
install the crankshaft front seal. The crankshaft front component life.
seal must be installed dry.
1. Clean the seal surface on the crankshaft and NOTICE

the front cover. Care must be taken to ensure that fluids are contained

products.

mandates.
g00514250
Illustration 177
2. Place crankshaft front seal (1) on the crankshaft.

Push the crankshaft front seal in place. This will
dislodge the shipping sleeve.
3. Install nuts (2) and the washers.
End By:

Damper - Remove and Install.
g00514870
Illustration 178
i01464100 Typical example
Front Cover - Remove 1. Remove studs (1) with the nuts and the seal
washers.
SMCS Code: 1166-011
Removal Procedure
3. Remove bolt (5).
Start By:
4. Remove cover (3).
a. Remove the alternator. Refer to Disassembly and
Assembly, Alternator Remove and Install .
58
g00514872 g00514870
5. Remove housing cover gasket (4). Note: Bolt (5) is a through bolt. Apply 9S-3263
Thread Lock Compound to threads prior to
installation.
i01464118
Front Cover - Install 3. Install the following items on the front housing:
front cover (3), bolts (2), bolt (5), and the
SMCS Code: 1166-012 washers.

Installation Procedure washers for installation.
NOTICE 4. Install studs (1) with new seal washers and the
Keep all parts clean from contaminants. nuts.
Contaminants may cause rapid wear and shortened End By:

component life.
a. Install the fuel transfer pump. Refer to
Disassembly and Assembly, Fuel Transfer Pump
Note: The rear face of the cover and the front face - Install.
of the housing must be clean.
1. Inspect the condition of the housing cover Disassembly and Assembly, Crankshaft Front
gasket. Replace the gasket, if necessary. Seal - Install.
c. Install the belt tensioner. Refer to Disassembly

Install.
d. Install the alternator. Refer to Disassembly and

Assembly, Alternator - Remove and Install .
g00514872
Illustration 180
Typical example
2. Install housing cover gasket (4).

59
i01533820
NOTICE
Gear Group (Front) - Remove Care must be taken to ensure that fluids are contained
SMCS Code: 1206-011
Removal Procedure ing any compartment or disassembling any compo-
Table 28
Required Tools Refer to Special Publication, NENG2500, Caterpillar
Part suitable to collect and contain fluids on Caterpillar
Tool Number Part Description Qty products.
A 6V-8214 Bolt 4
mandates.
Start By:
a. Remove the water pump. Refer to Disassembly

b. Remove the engine oil pump. Refer to

Remove.
c. Remove the air compressor. Refer to Disassembly

Install.
d. Remove the alternator. Refer to Disassembly and

g00522893
Illustration 182
e. Remove the camshaft position sensor. Refer to
Disassembly and Assembly, Camshaft Position
Note: The sensor plate must be removed from the
Sensor - Remove and Install.
crankshaft gear for Engines (S/N: 3CS1-11999)
and (S/N: 2KS1-39999) in order to remove the front
f. Remove the crankshaft position sensor. Refer to
gear group. The sensor plate can have either two
Disassembly and Assembly, Crankshaft Position
threaded holes to aid in the removal of the sensor
plate or the sensor plate can have four threaded
holes.
g. Remove the camshaft. Refer to Disassembly and
1. Install Tool (A) in bolt holes (X). Turn the bolts
evenly in order to separate the sensor plate from
NOTICE the crankshaft gear.
Note: Align the timing marks on the idler gear with
Contaminants may cause rapid wear and shortened the marks on the crankshaft gear and the camshaft
component life. gear before removal.
60
1. Hold accessory drive (8) in position and install

two bolts (7). Tighten the bolts to a torque of
100 20 Nm (75 15 lb ft).

(175 30 lb ft).

(175 30 lb ft).
g00522192
Note: Ensure that the timing marks on the gears are
Illustration 183 in alignment.
2. Remove the following items from the front
housing: bolt (1), shaft (2), gear (3), and the
bearing.
3. Next, remove the following items from the front parts that have been heated.
housing: bolt (4), shaft (5), gear (6), and the
bearing.
4. Heat the sensor plate to a temperature of 210 C
(410 F) for no more than 20 minutes.
Note: During installation, it is possible to install the
accessory drive incorrectly. Before removal, mark
accessory drive (8) for correct orientation.
4. Remove bolts (7) and accessory drive (8).
i01533832
Gear Group (Front) - Install

SMCS Code: 1206-012
g00523036
5. Position the hot sensor plate so that the tab on
Contaminants may cause rapid wear and shortened the sensor plate aligns with groove (X) on the
component life. crankshaft gear.
6. Push the sensor plate onto the crankshaft gear

until the back of the sensor plate contacts the
front of the crankshaft gear. Hold the sensor
plate on the crankshaft gear in this position until
the sensor plate cools and the sensor plate is
properly seated.
7. Use a feeler gauge in order to measure the

clearance between the back of the sensor
plate and the front of the crankshaft gear. The
measurement should be taken in three places
and the clearance should not exceed 0.25 mm
(0.010 inch).
g00522192
Illustration 184
61
Note: Steps 4 through 7 are for Engines (S/N:

3CS1-11999) and (S/N: 2KS1-39999) that have the
sensor plate.
End By:

b. Install the camshaft position sensor. Refer to

c. Install the crankshaft position sensor. Refer to

Disassembly and Assembly, Crankshaft Position g00514280
Sensor - Remove and Install. Illustration 186
d. Install the alternator. Refer to Disassembly and 1. Remove thirteen bolts (1) and the washers.
2. Remove front housing (2) and the gasket.
e. Install the air compressor. Refer to Disassembly
and Assembly, Air Compressor - Remove and i01464330
Install.
f. Install the engine oil pump. Refer to Disassembly
and Assembly, Engine Oil Pump - Install. SMCS Code: 1151-012
g. Install the water pump. Refer to Disassembly and

Note: The face of the housing and the face of the
i01464328 block must be clean prior to installation.

SMCS Code: 1151-011
Removal Procedure
Start By:

- Remove.
NOTICE
Care must be taken to ensure that fluids are contained Illustration 187
g00514286
Typical example
1. Apply a bead of 8T-9022 Silicone Gasket to the
nent containing fluids. lower edges (5) of the cylinder block.

products.

mandates.
62
4. Remove the excess 8T-9022 Silicone Gasket

from the face seal joints at the following locations:
cylinder block, front housing, and oil pan. Use a
suitable sized flat tool such as a putty knife in
order to remove the excess sealant.
NOTICE
Do not use fingers or towels in order to remove the
excess 8T-9022 Silicone Gasket. The use of fingers
or towels will not leave a flat sealing surface. A leak
may develop.
End By:
g00514307
Illustration 188 a. Install the front gear group. Refer to Disassembly
Typical example and Assembly, Gear Group Front - Install .
2. Install gasket (3). Apply a bead of 8T-9022

i01464331
Silicone Gasket to lower edges (4) of gasket (3).
Accessory Drive - Remove
SMCS Code: 1207-011
Removal Procedure
Start By:

Install.
b. Remove the front cover. Refer to Disassembly

g00514280
Illustration 189
3. Install front housing (2) and thirteen bolts (1)

with the washers. Tighten the bolts to a torque of
35 8 Nm (26 6 lb ft).
g00515001
Illustration 191
Typical example

g00514308
Illustration 190 2. Remove accessory drive (2).
63
i01467325
Accessory Drive - Disassemble

SMCS Code: 1207-015
Table 29
Required Tools
Part
Number
3H-0468 Puller Plate 4
g00521983
9S-9155 Spacer 1 Illustration 193
8B-7550 Push-Puller Leg 2 2. Use Tool (A) to remove two bearings (2) from
A
5F-7344 Block Puller 1 gear and shaft (1).
8H-0663 Bearing Puller 1
5F-7345 Screw 1
Start By:
a. Remove the accessory drive. Refer to

Disassembly and Assembly, Accessory Drive -
Remove.
g00521986
Illustration 194
3. Use Tool (B) to remove snap ring (4) from

i01467334
Accessory Drive - Assemble

SMCS Code: 1207-016
g00521981
Illustration 192
Assembly Procedure
1. Remove gear and shaft (1) with two bearings (2)
Table 30
from accessory drive housing (3).
Required Tools
Note: One end of the gear shaft is longer than the
Part
opposite end. Prior to assembly, ensure that the Tool
Number
gear shaft is in the correct position.
64
g00522020 g00522024
1. Lower the temperature of gear and shaft (1). 5. Install gear and shaft (1) with bearings (2) into
End By:
Always wear protective gloves when handling a. Install the accessory drive. Refer to Disassembly
parts that have been heated. and Assembly, Accessory Drive - Install.
2. Heat two bearings (2) in an oven to a temperature

of 100 C (212 F).
i01464334
Accessory Drive - Install

3. Place bearings (2) in the original location on
gear and shaft (1). SMCS Code: 1207-012
g00522021
Illustration 196
4. Use Tool (A) to install snap ring (4) into accessory g00515001
Illustration 198
drive housing (3).
Typical example
1. Install accessory drive (2).
2. Install two bolts (1) and the washers. Tighten the

End By:

65
b. Install the belt tensioner. Refer to Disassembly Note: Spacer (5) is used on engines that are
and Assembly, Belt Tensioner - Remove and equipped with a compression brake.
Install.
head: valve cover (2), spacer (5), and seals (4).
i01004798
Valve Mechanism Cover - Installation Procedure

Remove and Install
NOTICE
SMCS Code: 1107-010 Keep all parts clean from contaminants.

Removal Procedure component life.
NOTICE
Keep all parts clean from contaminants. 1. Cut seals (4) to the correct length for the valve
cover and spacer. Apply 3S-6252 Sealant to
Contaminants may cause rapid wear and shortened each joint surface after installation.
component life.
2. Place the following items on the valve cover
base: seals (4), spacer (5), and valve cover (2).
NOTICE
Care must be taken to ensure that fluids are contained 3. Place clip (3) on the valve cover.

machines.

mandates.
g00280493
Illustration 200
4. Install bolts (1) and the washers. Use the

following procedure in order to tighten the bolts:
a. Tighten bolts in a numerical sequence to a

b. Tighten bolts again in a numerical sequence

to a torque of 12 3 Nm (9 2 lb ft).
g00515241
Illustration 199
Typical example
1. Remove the bolt and the washer that holds clip

(3) to the valve cover base.
2. Move clip (3) and the wiring harness out of the

way.

66
i01465407

Remove and Install
SMCS Code: 1120-010
Removal Procedure
Start By:
a. Remove the valve mechanism covers. Refer to

g00515303
Illustration 202
NOTICE
Keep all parts clean from contaminants. 2. Remove bolts (4) and washers (6).
Contaminants may cause rapid wear and shortened 3. Remove isolators (7) and isolator sleeves (8).
component life.
4. Remove valve cover base (5) and base gasket
(9).
NOTICE
products.

mandates.
g00515303
Illustration 203
1. Install base gasket (9) and valve cover base (5)

on the cylinder head.
2. Install isolator sleeves (8) and isolators (7).

g00668535
Illustration 201
3. Install washers (6) and bolts (4).
1. Disconnect wiring harness (2) and the clips.
Loosen clamp (1) and disconnect the hose from
the side of the valve cover base. Disconnect
sensor (3) from the valve cover base.
67
NOTICE

products.

Illustration 204
mandates.
4. Install sensor (3).
5. Connect wiring harness (2) and the clips.
6. Connect the hose to the side of the valve cover

base and tighten clamp (1).
End By:
a. Install the valve mechanism covers. Refer to

i01464340
g00521562
Illustration 205
Compression Brake - Remove
1. Disconnect wires (2) from the solenoid valve.
SMCS Code: 1119-011
2. Remove two nuts (1) and bolt (3).
Removal Procedure
3. Remove compression brake housing (4).
Start By:
i01465421
a. Remove the valve mechanism covers. Refer to
Disassembly and Assembly, Valve Mechanism Compression Brake -
Disassemble
NOTICE
SMCS Code: 1119-015
Contaminants may cause rapid wear and shortened Disassembly Procedure

component life.
Table 31
Required Tools
Part
68
Start By:
a. Remove the compression brake. Refer to

Remove accumulator covers carefully. The accu-
Disassembly and Assembly, Compression
mulator covers are under load from the accumu-
Brake - Remove.
lator springs. Remove with care to avoid personal
injury.
NOTICE
1. Apply downward pressure to accumulator cover
Contaminants may cause rapid wear and shortened (2) with a punch of suitable size. Remove
component life. retaining ring (1) with Tool (A).
2. Slowly release the pressure from accumulator

NOTICE cover (2) until the spring pressure ceases.
Care must be taken to ensure that fluids are contained Remove accumulator cover (2) and spring (3).
ing, adjusting and repair of the product. Be prepared to 3. Use a magnet or needle nose pliers to remove
collect the fluid with suitable containers before open- accumulator piston (4) from the bore in
ing any compartment or disassembling any compo- compression brake housing (5).

products.

mandates.
g00523476
Illustration 208
g00523471
Illustration 206
g00524780
Illustration 209
Remove control valve covers carefully. Control

valve spring covers are under load from the
control valve springs. Remove with care to avoid
personal injury.
g00523472
Illustration 207
69
4. Apply downward pressure to control valve

cover (6) with a punch of suitable size. Remove
5. Slowly release the pressure from control valve

cover (6) until the spring pressure ceases.
Remove control valve cover (6) and two control
valve springs (8).
g00523482
Illustration 212
Typical example
8. Remove three O-ring seals (11) from solenoid

valve (10). Discard the O-ring seals.
Note: The lower O-ring may stay in the bore in the

compression brake housing. If this is the case,
g00524781 use a seal pick to remove the O-ring from the
Illustration 210
6. Use a magnet or needle nose pliers in order to
reach into the bore and remove control valve (9)
from compression brake housing (5).

control valve.
g00523483
Illustration 213
NOTICE
Do not diassemble or tamper with slave piston adjust-
ing screw. Engine damage could result.
g00523481
Illustration 211
9. Remove slave piston adjustment screw locknut
NOTICE (12).
Do not disassemble or tamper with the solenoid valve.
Engine damage could result.
7. Unscrew solenoid valve (10) from the

70
g00523484 g00524782
10. Loosen slave piston adjustment screw (13) until

the slave piston is fully retracted.
Remove slave pistons carefully. The slave pistons
are under spring pressure. Remove with care to
avoid personal injury.
11. Place Tool (C) over slave piston adjustment

screw (13). Turn the handle on Tool (C) until
spring retainer (14) is depressed approximately
1.0 mm (.04 inch) in order to relieve the pressure
from retaining ring (15).
12. Remove retaining ring (15) with Tool (A). Slowly

back out the handle on Tool (C) until the spring
pressure ceases. Remove Tool (C).
g00524785
Illustration 215 13. Remove spring retainer (14), springs (16), and
slave piston (17).

slave piston.
g00523486
Illustration 216
g00524783
Illustration 218
71
g00524784
Illustration 219
Remove master pistons carefully. The master pis-

ton is under spring pressure. Remove with care to
avoid personal injury.
14. Apply downward pressure to retaining washer

(19) with a punch of suitable size. Remove
15. Slowly release the pressure from retaining Illustration 220 g00523650
washer (19) until the spring pressure ceases.
Remove retaining washer (19), two springs (20), 1. Inspect the condition of the bores in the
and master piston (21). compression brake housing. The bores must be
free of wear and score marks.
master piston.
i01533855
Compression Brake -
Assemble
SMCS Code: 1119-016
Assembly Procedure
Table 32
Required Tools Illustration 221
g00524784
Part
NOTICE

component life.
72
g00524783 g00523486
2. Inspect the condition of master piston (20). The 4. Inspect the condition of slave piston (17). The
master piston must be free of wear and score slave piston must be free of wear and score
marks. Replace master piston (21), if necessary. marks. Replace slave piston (17), if necessary.
3. Install master piston (21) in the bore. Install 5. Install slave piston (17), springs (16), spring
the small end of spring (20) in the bore. Install retainer (14), and retaining ring (15) in the bore.
retaining washer (19), and retaining ring (18)
over master piston (21) and compress until
retaining washer (19) is below the retaining ring
groove. Install retaining ring (18) with Tool (B).
Ensure that retaining ring (18) is fully seated in
the groove.

master piston.
g00524785
Illustration 225
6. Place Tool (C) over slave piston adjustment

screw (13) and spring retainer (14). Turn the
handle on Tool (C) until spring retainer (14)
is approximately 1.0 mm (.04 inch) below the
retaining ring groove. Install retaining ring (15)
with Tool (A).
g00524782
Illustration 223 7. Remove Tool (C) slowly in order to ensure that
retaining ring (15) is properly seated in the
groove.

slave piston.
73
10. Coat three new O-ring seals (11) with clean

engine oil. Install the upper O-ring seal and the
center O-ring seal on solenoid valve (10). Install
the small O-ring seal in the bottom of the bore in
the compression brake housing.
Note: Ensure that O-ring seals (11) are seated

properly on solenoid valve (10). Do not twist the
seals or unseat the seals during installation of the
solenoid valve.
g00523484
Illustration 226
8. Screw in slave piston adjustment screw (13) until

contact is made with the slave piston.
g00523481
Illustration 229
11. Carefully install solenoid valve (10) in the

There are two different designs of solenoid

valves. The difference can be determined by the
number of points on the head of the solenoid
g00523483
Illustration 227 solenoid valve.
9. Install slave piston adjustment screw locknut Tighten the solenoid valve with a twelve point
(12). head to the following torque. ......... 12.5 Nm
(9 lb ft)
Note: Repeat Steps 8 and 9 for the remaining slave Tighten the solenoid valve with a six point
piston adjustment screw. head to the following torque. ............ 20 Nm
(15 lb ft)
g00523482
Illustration 228
g00524781
Typical example Illustration 230
74
g00524780 g00523471
12. Inspect the condition of control valve (9). Insert a 15. Inspect the condition of accumulator piston
wire into the hole in the base of control valve (9) (4). The accumulator piston should be free of
until the wire contacts the check ball. The check wear and score marks. Apply clean engine oil to
ball should rise with light pressure on the wire. If accumulator piston (4).
the check ball is stuck, replace control valve (9).
Apply clean engine oil to control valve (9). 16. Install accumulator piston (4), spring (3), and
accumulator cover (2) in the bore in compression
13. Install control valve (9), two control valve springs brake housing (5).
(8), and control valve cover (6) in compression
brake housing (5). 17. Apply downward pressure to accumulator cover
(2) with a punch of suitable size. Install retaining
14. Apply downward pressure to control valve cover ring (1) with Tool (A). Slowly release the pressure
(6) with a punch of suitable size. Install retaining from accumulator cover (2) in order to ensure
ring (7) with Tool (B). Slowly release the pressure that retaining ring (1) is fully seated in the groove.
from control valve cover (6) in order to ensure
that retaining ring (7) is fully seated in the groove. End By:
Note: Repeat Steps 12 through 14 for the remaining a. Install the compression brake. Refer to
control valve. Disassembly and Assembly, Compression
Brake - Install.
i01018713
Compression Brake - Install

SMCS Code: 1119-012
NOTICE
g00523472
75
NOTICE

component life.
NOTICE
g00521562
Illustration 234
1. Position compression brake housing (4) on the Tools and Shop Products Guide for tools and supplies
two studs. suitable to collect and contain fluids on Caterpillar
products.
2. Install two nuts (1) and tighten to a torque of
80 15 Nm (60 11 lb ft). Dispose of all fluids according to local regulations and
mandates.
3. Install bolt (3) and tighten to a torque of
55 10 Nm (41 7 lb ft).
4. Connect wires (2) to the solenoid valve on the

compression brake.

adjusting the slave piston lash.
End By:
a. Adjust the valve lash. Refer to the Testing and

Adjusting, Air Inlet and Exhaust System topic
for the correct procedure.
b. Adjust the slave piston lash. Refer to the Testing g00524203

Illustration 235
and Adjusting, Compression Brake topic for
the correct procedure. Typical example
c. Install the valve mechanism covers. 1. Put identification marks on each rocker arm in
for installation.
i01464346
2. Remove bolt (1) and stud (3).
Remove 3. Remove rocker arm assembly (2) and the push
rods. Keep each push rod with the respective
SMCS Code: 1102-011; 1208-011 rocker arm.
Removal Procedure
Start By:

76
g00524205 g00524203
4. Remove valve bridge assemblies (4). 3. Install the push rods in the original location in
the engine.
i01464353
4. Position rocker arm assembly (2) in the original
Rocker Shaft and Pushrod - location on the engine. Install stud (3) and bolt
(1). Tighten stud (3) and bolt (1) to a torque of
Install 100 20 Nm (75 15 lb ft).
SMCS Code: 1102-012; 1208-012 End By:
Installation Procedure a. Install the valve mechanism cover. Refer to

NOTICE
Keep all parts clean from contaminants. b. Adjust the engine valve lash. Refer to Systems
Operation Testing and Adjusting, Engine Valve
Contaminants may cause rapid wear and shortened Lash - Inspect/Adjust.
component life.
i01464358
1. Inspect the condition of the following items:
rocker arm assemblies, valve bridge assemblies, Cylinder Head - Remove
and push rods. Replace the parts, if necessary.
SMCS Code: 1100-011
Removal Procedure
Table 33
Required Tools
Part
Start By:
g00524205 a. Remove the valve cover base. Refer to

Illustration 237 Disassembly and Assembly, Valve Mechanism
Cover Base - Remove and Install.
2. Install valve bridge assemblies (4). Apply clean
engine oil to the top surface of the valve bridge b. Remove the rocker shaft and the push rods.
assemblies. Refer to Disassembly and Assembly, Rocker
Shaft and Pushrods - Remove .
77
3. Remove the bolt and the clip from tube assembly

NOTICE (3) and (5). Remove two bolts (4) and the
Keep all parts clean from contaminants. washers. Remove tube assembly (3) and the
O-ring seal.
component life. 4. Remove two bolts (6) and the washers. Remove
tube assembly (5) and the O-ring seals.
NOTICE

products.

g00524537
mandates. Illustration 241
Typical example
suitable container for storage or disposal. 5. Remove two nuts (7), the bolts, and the washers.
6. Remove hose (8).
7. Use tool (A) to remove fuel filter (10). Disconnect

hose (9). Plug all openings immediately.
8. Remove bolt (11), the washer, and the clip.
9. Disconnect sensor connector (12) and cut tie

straps (13).
g00524436
Illustration 239
2. Disconnect sensor connector (2). Lay wiring

harness (1) out of the way.
g00524775
Illustration 242
10. Remove nut (14), the washer, and the clip.
11. Loosen bolt (15) until wiring harness (16) can be

disconnected. Disconnect wiring harness (16).
Lay the wiring harness away from the cylinder
head.
g00525386
Illustration 240
Typical example
78
Note: Engines that are equipped with a compression

brake will have three head bolt studs. The three
head bolt studs are installed in place of head bolts.
Remove the head bolt studs with the head bolts.
15. Remove head bolts (23) and the head bolt

studs, if equipped.
16. Remove four gaskets (24) from cylinder head

(25).
g00707634
Illustration 243
Typical example
12. Disconnect fittings (17). Remove bolts (18) and

the washers. Remove line (19).
g00525775
Illustration 246
Typical example
17. Attach a suitable lifting device to cylinder head

(25). Ensure that all wires, lines, and hoses are
free from the cylinder head.
18. Carefully remove cylinder head (25) from the

cylinder block. The weight of cylinder head (25)
g00525468
Illustration 244
Typical example 19. Remove cylinder head gasket (26) and O-ring
seals (27) from the cylinder block.
13. Remove bolts (20) and the washers. Remove
water outlet manifold (21).
14. Remove spacers (22) from the head bolt studs.
g00525534
Illustration 245
Typical example
79
i01530771 6. If a damaged head bolt thread is observed,

repair the damaged head bolt thread with a
Cylinder Head - Install Heli-Coil thread repair kit.
SMCS Code: 1100-012 7. Inspect the cylinder head and the cylinder block
for flatness. Use a straightedge and a 8H-8581
Installation Procedure Feeler Gauge. The flatness for the cylinder head
and the cylinder block should be a maximum of
Table 34 0.05 mm (0.002 inch) within a span of 150 mm
Required Tools (6 inch). The flatness for the cylinder head
should be a maximum of 0.15 mm (0.006 inch)
Part within a span of 600 mm (24 inch).
A 2P-8250 Strap Wrench Assembly 1 Note: To avoid damage to the cylinder head gasket,
cylinder head.
NOTICE
Keep all parts clean from contaminants. 8. Use a suitable lifting device to install the cylinder
head on the cylinder block.
component life.

cylinder head and the cylinder block.
g00525534
Illustration 248
9. Install four gaskets (24) on cylinder head (25).
10. Install new cylinder head bolts (23). If the engine

g00525775 is equipped with a compression brake, then
Illustration 247
install new studs.
2. Determine the correct cylinder head gasket to 11. Lubricate the following components with
use. Refer to Truck Engine News, SEBD6730, 6V-4876 Lubricant: the bolt threads, the
December 2000, New Cylinder Head Gasket underside of the bolt heads, and the washers.
for C-10 and C-12 Truck Engines. Install a new Install cylinder head bolts and the head bolt
cylinder head gasket (26) and new O-ring seals studs. Follow Step 12 for the correct tightening
(27) on the cylinder block. Inspect the condition procedure.
of the remaining gaskets. Replace the gaskets,
if necessary.
3. Clean all 26 head bolt holes on the cylinder

block with a 8T-3096 plug tap.
4. After cleaning the threads, remove any debris

from the head bolt holes on the cylinder block
with a vacuum line.
5. Visually inspect the head bolt holes on the

cylinder block for thread damage.
80
g00517501
Illustration 249
Note: Engines that are equipped with a compression h. Tighten bolt (27) through bolt (33) in a
brake will have three head bolt studs. Install the numerical sequence to a torque of 28 7 Nm
head bolt studs in positions (2), (8), and (10). (20 5 lb ft).
Tighten the head bolt studs in sequence with the
head bolts.


(120 11 lb ft).

160 15 Nm (120 11 lb ft).
c. Place an index mark on each bolt head.

g00525468
Turn bolt (1) through bolt (26) in a numerical Illustration 250
turn). 13. Install spacers (22) on the three head bolt studs.
Tighten spacers (22) to a torque of 100 20 Nm
d. Loosen bolt (1) through bolt (26) until the (75 15 lb ft).
14. Install water outlet manifold (21) and bolts (20).
e. Tighten bolt (1) through bolt (26) in a numerical
(120 11 lb ft).
f. Tighten bolt (1) through bolt (26) again

160 15 Nm (120 11 lb ft).
g. Place an index mark on each bolt head.

Turn bolt (1) through bolt (26) in a numerical
turn).
81
21. Install hose (8).
22. Install the bolts, the washers, and two nuts (7).
g00707634
Illustration 251
15. Hold line (19) in position and connect fittings

(17). Install bolts (18).
g00525386
Illustration 254
23. Install tube assembly (5) with the O-ring seals,

24. Install tube assembly (3) with the O-ring seal,

two bolts (4), and the washers. Install the clip
and the bolt to tube assembly (5) and (3).
g00524775
Illustration 252
16. Connect wiring harness (16). Tighten bolt (15) to

a torque of 6 1 Nm (53 9 lb in).
17. Install the clip, the washer, and nut (14).
g00524436
Illustration 255
25. Route wiring harness (1) accordingly and

connect sensor connector (2).

End By:
g00524537
Illustration 253 to Disassembly and Assembly, Rocker Shaft
and Pushrods - Install.
18. Connect sensor connector (12). Install the clip,
the washer, and bolt (11). Secure the wiring b. Install the valve cover base. Refer to Disassembly
harness with tie straps (13). and Assembly, Valve Mechanism Cover Base
19. Install fuel filter (10) with Tool (A). Follow the
instructions on the fuel filter.
82
i01464393

Install
SMCS Code: 1209-010
Removal Procedure
Start By:

and Assembly, Cylinder Head - Remove.
g00515668
Illustration 257
NOTICE
2. Remove the following items from the right end of
lifter shaft (5): bracket assembly (6), valve lifters
(8), and unit injector lifter (9).
component life.
3. Remove the following items from the middle of
NOTICE lifter shaft (5): valve lifters (8) and unit injector
Care must be taken to ensure that fluids are contained lifter (9).
ing, adjusting and repair of the product. Be prepared to 4. Remove the following items from the left end of
collect the fluid with suitable containers before open- lifter shaft (5): bracket assembly (7), valve lifters
ing any compartment or disassembling any compo- (8), and unit injector lifter (9).
5. Remove dowel (4) and cap plug (3) from lifter
Refer to Special Publication, NENG2500, Caterpillar shaft (5).
suitable to collect and contain fluids on Caterpillar 6. Remove the spring pin from bracket (7), if
products. necessary.

mandates.
g00515670
Illustration 258
Typical example
Illustration 256
g00515645 7. Remove dowel (10) from bracket (6), if necessary.
1. Remove bolts (1) and lifter assembly (2). The

lifter assembly can be removed in two sections.
83
NOTICE

component life.
g00515645
Illustration 261
Note: Immerse the entire lifter assembly in clean

engine oil prior to installation on the engine.
6. Place the lifter assembly (2) on the engine and

install bolts (1). Tighten the bolts to a torque of
30 3 Nm (22 2 lb ft).
g00515670
Illustration 259
Typical example End By:
1. Install the spring pin and dowel (10) in bracket a. Install the cylinder head. Refer to Disassembly
(7). and Assembly, Cylinder Head - Remove.
i01464398
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 35
Required Tools
Part
g00515668
Illustration 260 A 131-1525 Camshaft Pilot 1
2. Install dowel (4) and cap plug (3) in lifter shaft

Start By:
(5). Lubricate the lifter shaft with clean engine oil
prior to assembly.
a. Remove the rocker shaft and the push rods.
3. Install the following items on the left end of lifter
Shaft and Pushrod - Remove .
shaft (5): bracket (7), valve lifters (8), and unit
injector lifter (9).
b. Remove the front cover. Refer to Disassembly
4. Install the following items on the middle of lifter
shaft (5): valve lifters (8) and unit injector lifter (9).
c. Remove the camshaft position sensor. Refer to
5. Install the following items on the right end of
lifter shaft (5): bracket (6), valve lifters (8), and
unit injector lifter (9).
84
NOTICE

component life.
NOTICE
Illustration 263
Tools and Shop Products Guide for tools and supplies 4. Remove thrust pin (1).
products.

mandates.

installation.

g00765230
Illustration 264
5. Install Tool (A) into camshaft (2).
Note: Lubricate Tool (A) for easier removal of the

camshaft. Lubrication also prevents damaging the
camshaft lobes and the camshaft bearings.
6. Carefully remove camshaft (2) from the engine.
g00529917
Illustration 262
Note: It is not necessary to remove the cylinder

head for removal of the camshaft.

See Illustration 262.
85
i01464414
Camshaft - Install
SMCS Code: 1210-012
Table 36
Required Tools
Part
g00516008
Illustration 266

g00516006
Illustration 265
Typical example
Note: Ensure that camshaft (2) and Tool (A) are

clean. Apply clean engine oil to the lobes and
journals of camshaft (2) and Tool (A).
Note: During installation of camshaft (2), rotate the

camshaft in both directions in order to prevent
binding in the camshaft bearing bores. g00516004
Illustration 267
2. Carefully install camshaft (2) in the engine.

4. Install thrust pin (1). Tighten thrust pin (1) to a
torque of 28 7 Nm (20 5 lb ft). Remove the
NOTICE wires that were used to hold the valve lifters.
ber one cylinder is at top center of the compression End By:
camshaft timing is very important. The timing mark a. Install the camshaft position sensor. Refer to
on the camshaft drive gear must line up with the tim- Disassembly and Assembly, Camshaft Position
ing mark on the idler gear. Refer to the Specifications Sensor - Remove and Install.
b. Install the front cover. Refer to Disassembly and
c. Install the rocker shaft and the pushrods. Refer

86

Install
Removal Procedure
Start By:
a. Remove the camshaft. Refer to Disassembly and


g00522082
order to prevent damage to the camshaft. Illustration 269
1. Install woodruff key (2) in camshaft (3).
2. Heat drive gear (1) to a temperature of 300 C

(572 F) for 30 minutes.
3. Install drive gear (1) on the end of camshaft (3).
4. Ensure that woodruff key (2) is aligned. Also

ensure that drive gear (1) makes contact with the
shoulder on the end of camshaft (3).
End By:

g00522082
Illustration 268 Assembly, Camshaft - Install.
NOTICE
i01533953
Do not allow the camshaft to fall to the floor when
pressing it from the drive gear. Also make sure that Camshaft Bearings - Remove
SMCS Code: 1211-011
2. Place camshaft (3) and drive gear (1) in a
suitable press. Press camshaft (3) from drive Removal Procedure
gear (1).
Table 37
3. Remove woodruff key (2) from camshaft (3). Required Tools
Part
Number
A
6F-7032 Bolt 1
87
Start By:
a. Remove the lifter group. Refer to Disassembly

Install.
b. Remove the camshaft. Refer to Disassembly and

NOTICE
g00516211
Illustration 271
component life. 1. Install Tool (A). Apply Anti-Seize Compound on
the threads.
NOTICE 2. Remove camshaft bearings (1).
ing, adjusting and repair of the product. Be prepared to i01533955
ing any compartment or disassembling any compo- Camshaft Bearings - Install
SMCS Code: 1211-012
Tools and Shop Products Guide for tools and supplies Installation Procedure
products. Table 38
Required Tools
mandates. Part
Number
A
6F-7032 Bolt 1
Illustration 270
g00516210 NOTICE

component life.
88
NOTICE

component life.
NOTICE
g00516213
Illustration 272
1. Position new bearing (2) in Tool (A) and install the Tools and Shop Products Guide for tools and supplies
bearing from the rear to the front of the engine. suitable to collect and contain fluids on Caterpillar
products.
NOTICE
Location of the camshaft bearing lubrication holes is Dispose of all fluids according to local regulations and
critical. Position the clinch butt joint up for all seven mandates.
camshaft bearings. The No. 1 camshaft bearing oil
hole is located 115 degrees counter clockwise from 1. Drain the engine oil into a suitable container for
top center to align with the oil supply passage in the storage or disposal.
block. Camshaft bearings No. 2 through No. 7 are in-
stalled with the oil hole 45 degrees clockwise from
top center. All are viewed from the front of the en-
gine. Camshaft bearings 1,2,3,4,5, and 6 are the same
width. Camshaft bearing No. 7 has a smaller width.
Refer to the Specifications Manual for more informa-
tion.
End By:

b. Install the lifter group. Refer to Disassembly and

Assembly, Lifter Group - Remove and Install.
g00516290
Illustration 273
Typical example
i01183159
Engine Oil Pan - Remove and 2. Remove six bolts (2) and the washers. Remove
sound suppression cover (1), if equipped.
Install
SMCS Code: 1302-010
Removal Procedure

jury.

89
3. Place the gasket and engine oil pan (6) on the

cylinder block.
4. Install the following items: isolator sleeves,

isolators, bolts (5), and the washers.
Note: Perform the following procedure in order to

eliminate the possibility of an oil leak from the bolt
for the engine oil pan:
Note: The path of the oil leak is through the threads

of the bolt for the engine oil pan. The third bolt from
the front of the engine block on the right side of the
engine is the suspect bolt.
g00516292
Illustration 274
Typical example

block: fourteen bolts (5), the washers, the
isolators, and the isolator sleeves.
4. Remove engine oil pan (6) and the gasket.
5. Remove pipe plug (3) and drain plug (4) with the
O-ring seal, if necessary.
NOTICE

component life.
g00633606
Illustration 276
Typical example
(1) Front face of the engine block
(2) Bolt threads
a. Clean the bolt hole and dry the bolt hole.
Note: Apply 8T-9022 Silicone Gasket to the right
b. Clean the oil pan bolt and dry the oil pan bolt.
and the left edges of the cylinder block prior to
installation.
c. Apply 4C-4030 Thread Lock Compound or
9S-3263 Thread Lock Compound to the
threads of the bolt.
d. Install the oil pan bolt and tighten the bolt to a

5. Wipe off excess 8T-9022 Silicone Gasket from

all gasket joints. Use a flat, straight tool in order
to remove the sealant.
6. Apply 9S-3263 Thread Lock Compound to pipe

plug (3). Install pipe plug (3). Tighten the plug to
Illustration 275
g00516292 7. Install drain plug (4) and the O-ring seal. Tighten
Typical example
the plug to a torque of 70 15 Nm (50 11 lb ft).
90
NOTICE

products.

Illustration 277
mandates.
Typical example
8. Position the sound suppression cover (1) on the

engine oil pan and install six bolts (2) with the
washers.
9. Fill the engine with oil to the correct level. See

i01533962

SMCS Code: 1216-011
g00474523
Illustration 278
S/N: 3CS1-Up
Removal Procedure each connecting rod. Remove connecting rod
caps (4).
Table 39
Required Tools 2. Tap connecting rod (3) away from the crankshaft
with a soft hammer. Remove the top half of
Tool Part Number Part Description Qty connecting rod bearing (1).
1U-9593 Cylinder Pack Puller 1
A 1U-9897 Bridge Group 1
1U-6319 Socket 1
Start By:

b. Remove the piston cooling jets. Refer to

g00516411

component life.
91
NOTICE NOTICE
When removing the cylinder liner, watch the rod, and Keep all parts clean from contaminants.
block as it comes out. Contaminants may cause rapid wear and shortened
component life.
NOTICE
4. Remove Tool (A) from the cylinder liner. Care must be taken to ensure that fluids are contained

products.

mandates.
g00516413
Illustration 280

the cylinder liner. Remove seal (6) from the
cylinder liner.
i01533964

SMCS Code: 1216-011
S/N: CPD1-Up
g00474523
S/N: 2KS1-Up Illustration 281

Removal Procedure each connecting rod. Remove connecting rod
caps (4).
Table 40
Required Tools 2. Tap connecting rod (3) away from the crankshaft
Tool Part Number Part Description Qty with a soft hammer. Remove the top half of
connecting bearing (1).
129-6675 Cylinder Pack Puller 1
A 1U-9897 Bridge Group 1
1U-6319 Socket 1
Start By:

b. Remove the piston cooling jets. Refer to

g00516411
Illustration 282
92
NOTICE
When removing the cylinder liner, watch the rod, and
block as it comes out.
4. Remove Tool (A) from the cylinder liner.
g00516413
Illustration 284
1. Apply 5P-3975 Rubber Lubricant to the new

seal. Install new seal (6) in the machined groove
on the cylinder liner.

g00516413
Illustration 283 the connecting rod must be on the right side of the
the cylinder liner. Remove seal (6) from the 2. Lubricate the lower portion of the cylinder
cylinder liner. liner with clean engine oil. Ensure that the
corresponding crankshaft throw is at bottom
center. Position the cylinder liner and guide the
i01464667
connecting rod in place. Use Tool (B) to press
Cylinder Liner - Install the cylinder liner in place.
SMCS Code: 1216-012 Note: Refer to the Testing and Adjusting, Cylinder
Liner Projection topic in order to check the cylinder
liner projection.
Table 41
Required Tools
Part
Tool Part Description 1
Number
Cylinder Liner Installation
A 2P-8260 1
Group
NOTICE

component life. g00474523
Illustration 285
93
3. Install the upper half of connecting rod bearing

(1) in connecting rod (3). Ensure that the bearing NOTICE
tab engages with the slot in the connecting rod. Care must be taken to ensure that fluids are contained
Lubricate the bearing surface with clean engine during performance of inspection, maintenance, test-
oil. Tap the piston with a soft hammer until the ing, adjusting and repair of the product. Be prepared to
connecting rod bearing makes contact with the collect the fluid with suitable containers before open-
crankshaft. ing any compartment or disassembling any compo-
4. Install connecting rod cap (4). Lubricate
connecting rod cap bolts (2) with 4C-5593 Refer to Special Publication, NENG2500, Caterpillar
Anti-Seize Compound. Install connecting rod Tools and Shop Products Guide for tools and supplies
cap bolts (2). suitable to collect and contain fluids on Caterpillar
products.
(95 5 lb ft). Dispose of all fluids according to local regulations and
mandates.
turn).
End By:
a. Install the piston cooling jets. Refer to

b. Install the cylinder head. Refer to Disassembly

i01464716
Piston Cooling Jets - Remove Illustration 286

g00516600
and Install 1. Remove bolt (1) and piston cooling jet (2) from
each cylinder.
SMCS Code: 1331-010
Start By: NOTICE

a. Remove the engine oil pan. Refer to Disassembly
and Assembly, Engine Oil Pan - Remove and Contaminants may cause rapid wear and shortened
Install. component life.
NOTICE

component life.
g00516600
Illustration 287
94
1. Position piston cooling jet (2) and install bolt (1) 2. Inspect the connecting rod and connecting
in each cylinder. Tighten the bolt to a torque of rod cap (3) for the proper identification mark.
35 3 Nm (26 2 lb ft). The connecting rod and connecting rod cap
End By: that is toward the right side of the engine. The
a. Install the engine oil pan. Refer to Disassembly bearing retainer notch should also be on the right
and Assembly, Engine Oil Pan - Remove and side. Mark the connecting rod and connecting
Install. rod cap (3), if necessary.
3. Remove connecting rod cap bolts (2) and

i01464749
connecting rod cap (3). Remove the lower half of
Pistons and Connecting Rods the bearing from connecting rod cap (3).
- Remove
SMCS Code: 1225-011
Removal Procedure
Start By:

b. Remove the engine oil pan. Refer to Disassembly

Install. g00516604
Illustration 289
Typical example
NOTICE
4. Push the piston and connecting rod (4) away
from the crankshaft. Remove the upper half of
component life.
5. Remove the piston and connecting rod (4) from
the cylinder block.

g00516602
Illustration 288
1. Remove the bolts that hold piston cooling jets (1)

in position. Remove piston cooling jets (1).
95
i01465424

- Disassemble
SMCS Code: 1225-015
Table 42
Required Tools
Part
Number
g00516777
A 4C-3601 Piston Ring Expander 1 Illustration 291
5P-8639 Hydraulic Press 1 2. Remove plug (3) and the piston pin.
8F-0024 Hose Assembly 1
3. Separate piston crown (2) from piston skirt (4)
1P-2375 Connecting Coupler 1 and connecting rod (5).
1P-2376 Connecting Coupler 1
B
5P-9725 Hydraulic Cylinder 1
5P-8651 Spacer 1
5P-8649 Adapter 1
5P-8650 Adapter 1
Start By:
a. Remove the pistons and the connecting rods.

Connecting Rods - Remove .
g00516784
NOTICE
Contaminants may cause rapid wear and shortened The connecting rod must be heated for the installation
component life. of the piston pin bearing. Do not use a torch.
4. Heat connecting rod (5) in the indicated area

(7). The maximum distance of area (7) is 85 mm
(3.35 inch). The temperature should be between
175 C (347 F) and 260 C (500 F).
5. Use Tool (B) in order to remove old bearing (6)

and install new bearing (6) at the same time.
6. The bearing joint must be within 10 degrees of

one of the locations that are indicated by the
arrows.
g00516756
Illustration 290
1. Use Tool (A) in order to remove piston rings (1)

from piston crown (2).
96
i01464769

- Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 43
Required Tools
Part
Number
g00765257
A 4C-3601 Piston Ring Expander 1 Illustration 293
1. Place piston crown (2) in piston skirt (4). Place

NOTICE the piston assembly on connecting rod (5). Put
Keep all parts clean from contaminants. clean engine oil on piston pin (7) and install the
pin. Install new plug (3).
component life. 2. Check the clearance between the ends of the
piston rings. See the Specifications Manual,
Pistons and Rings topic.
NOTICE
Verify correct assembly of the pistons and the con- Note: The oil ring must be installed over the spring
necting rods. Ensure that the etched numbers on the with the end gap 180 degrees from the oil ring
rod and the rod cap are in the correct positions. The spring joint.
to the cylinder in which it should be installed. 3. Install the oil control piston ring. The ends of the
spring should be rotated 180 degrees from the
ring end gap. The white colored portion of the
NOTICE
spring must be visible at the ring end gap.
Do not use a hard surfaced tool to install plug. Do not
strike or impact plug during installation. If the plug is
dropped, replace the plug with another new plug.

when the piston is installed. The etched number
on the connecting rod must be on the right side of
the engine in the corresponding cylinder. Ensure
that the piston crown and the etched number are
correctly positioned.
g00516756
Illustration 294


97
6. After installation, all three of the piston rings Note: The word FRONT may be stamped on the
should be placed 120 degrees away from each crown of the pistons in some engines. Ensure that
other. the word FRONT is toward the front of the engine
End By: the connecting rod must be on the right side of the
i01464785

- Install
SMCS Code: 1225-012
Table 44
g00516604
Illustration 296
Required Tools
Part 4. Line up the piston and connecting rod (4) with
Tool Part Description Qty the crankshaft. Use a soft hammer and tap the
Number
A 1U-6684 Piston Ring Compressor 1 off of the piston.
NOTICE 5. Before the connecting rod comes in contact

Keep all parts clean from contaminants. with the crankshaft, install the upper half
of connecting rod bearing (5). Ensure that
Contaminants may cause rapid wear and shortened the bearing tab engages with the slot in the
component life. connecting rod.

1. Place clean engine oil on the following items: the upper half of connecting rod bearing (5). Use a
pistons, the piston rings, and the cylinder bore. soft hammer in order to tap the piston into the
cylinder bore while you guide the connecting rod
onto the crankshaft.
g00516632
Illustration 295
g00516602
2. Install Tool (A) in order to compress the piston Illustration 297
rings.
7. Place the lower half of connecting rod bearing
3. With the number one crankshaft throw at the (5) in corresponding connecting rod cap (3).
bottom center, install the piston and connecting Ensure that the bearing tab engages with the
rod in the engine. Ensure that the proper piston groove in connecting rod cap (3).
98

lower half of connecting rod bearing (5).
Install connecting rod bearing cap (3) on the
connecting rod. Ensure that the number on
number on the connecting rod. Ensure that the

10. Install connecting rod cap bolts (2). Tighten the

11. Place an index mark on each bolt head. Tighten g00522734

each bolt for an additional 60 5 degrees (1/6 Illustration 298
turn).
1. Inspect the connecting rod and connecting
12. Repeat Steps 1 through 11 for the remaining rod cap (2) for the proper identification mark.
pistons and connecting rods. The connecting rod and connecting rod cap
13. Install piston cooling jets (1) and the bolts. that is toward the right side of the engine. The
Tighten the bolts to a torque of 35 3 Nm number should match the cylinder number. The
(26 2 lb ft). bearing retainer notch should also be on the right
side. Mark the connecting rod and connecting
End By: rod cap (2), if necessary.
a. Install the engine oil pan. Refer to Disassembly 2. Remove connecting rod cap bolts (1) and
and Assembly, Engine Oil Pan - Remove and connecting rod cap (2).
Install.
3. Remove the lower half of the connecting rod
b. Install the cylinder head. Refer to Disassembly bearing from connecting rod cap (2).
i01464812

Remove
SMCS Code: 1219-011
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly Illustration 299

g00522735
Install. 4. Push connecting rod (3) away from the
crankshaft. Remove the upper half of connecting
NOTICE rod bearing (4).
Contaminants may cause rapid wear and shortened remaining connecting rod bearings.
component life.
99
i01464817 5. Place clean engine oil on the surface of the lower

half of the connecting rod bearing.
Install 6. Install connecting rod cap (2) on the
corresponding connecting rod. Ensure that the
SMCS Code: 1219-012 numbers are on the same side.

Installation Procedure 4C-5593 Anti-Seize Compound.
NOTICE 8. Install connecting rod cap bolts (1). Tighten the

Keep all parts clean from contaminants. bolts to a torque of 130 7 Nm (95 5 lb ft).
Contaminants may cause rapid wear and shortened 9. Place an index mark on each bolt head. Tighten
component life. each bolt for an additional 60 5 degrees (1/6
turn).

End By:
a. Install the engine oil pan. Refer to Disassembly

Install.
i01464829

Illustration 300 g00522735 Remove
1. Install the upper half of connecting rod bearing SMCS Code: 1203-011
(4) into connecting rod (3). Ensure that the
bearing tab engages with the slot in the Removal Procedure
connecting rod.
Table 45
2. Place clean engine oil on the surface of the Required Tools
upper half of connecting rod bearing (4).
Part
3. Position connecting rod (3) and connecting rod Number
bearing (4) on the crankshaft. A 2P-5518 Bearing Tool 1
Start By:
a. Remove the oil pan. Refer to Disassembly and

Assembly, Engine Oil Pan - Remove and Install.
NOTICE

component life.
g00522734
Illustration 301
4. Install the lower half of the connecting rod

bearing in corresponding connecting rod cap
100
g00516918
Illustration 302
1. Remove bolts (1) that hold crankshaft main

bearing cap (2). Remove crankshaft main
bearing cap (2).
2. Remove the lower half of the crankshaft main g00516919

Illustration 304
bearing from crankshaft main bearing cap (2).
upper half of crankshaft main bearings (3):

(A).


Illustration 303
g00516920 Parts, SEBF8009, Main and Connecting
Typical example
Connecting Rod Bearings.
NOTICE
If the crankshaft is turned in the wrong direction, the 4. Remove thrust plate (4).
tab of the crankshaft main bearing will be pushed be-
cause damage to either or both the crankshaft and the
cylinder block.
101
i01465185

Install
SMCS Code: 1203-012
Table 46
Required Tools
Part
Number
NOTICE
g00516919
Illustration 306
component life. 1. Use Tool (A) and install the new upper halves
of crankshaft main bearings (3) in the cylinder
Note: Place clean engine oil on the crankshaft main block. This half of the bearing has an oil hole. Do
bearings prior to assembly. Ensure that the tabs on not put oil on the back of the crankshaft main
the back side of the crankshaft main bearings fit in bearing.
the grooves of the crankshaft main bearing caps
NOTICE
Ensure that the crankshaft main bearings are installed
in the correct locations. Two different part numbers are
used in quantities of three and four. The part number
having the quantity of four is to be installed on crank-
shaft main bearings 2, 3, 5, and 6. The part number
having the quantity of three is to be installed on crank-
shaft bearing 1, 4, and 7. The thrust plate is to be in-
stalled on the center crankshaft main bearing only.
g00516918
Illustration 307
2. Install the new lower halves of the crankshaft

main bearings in crankshaft main bearing caps
(2). Do not put oil on the back of the crankshaft
main bearing.
NOTICE
Crankshaft main bearing caps should be installed with
the part number toward the right side of the engine.
Crankshaft main bearing caps are to be identified by
g00516920
Illustration 305 shaft main bearing only.

the washer face. Install bolts (1).
102

(70 4 lb ft). Place an index mark on each bolt NOTICE
head. Tighten each bolt for an additional 90 5 Keep all parts clean from contaminants.
degrees (1/4 turn).
component life.
g00517003
Illustration 308
5. Check the end play of the crankshaft with Tool g00517115

Illustration 309
(B). The end play must be 0.10 mm (.004 inch)
to 0.50 mm (.020 inch).
1. Remove bolts (1).
Note: The crankshaft end play is controlled by
crankshaft thrust bearings (4). Thrust bearings (4) 2. Remove crankshaft main bearing caps (2).
are located at the center of the crankshaft.
3. Remove crankshaft thrust bearings (3).
End By:
Note: Crankshaft main bearing caps (2) are marked
a. Install the oil pan. Refer to Disassembly and with the numbers 1 through 7. Crankshaft main
Assembly, Engine Oil Pan - Remove and Install bearing caps (2) that are not marked should be
. marked with the corresponding cylinder number on
the side that is toward the right side of the engine.
i01465195
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Start By:

Disassembly and Assembly, Engine Oil Pan -
Remove and Install.
g00517116
b. Remove the front housing. Refer to Disassembly Illustration 310
4. Install a suitable bolt into each end of the
c. Remove the flywheel housing. Refer to crankshaft. Fasten suitable lifting device (4) to the
Disassembly and Assembly, Flywheel Housing bolts in the crankshaft. Remove the crankshaft.
- Remove and Install. The weight of the crankshaft is 129 kg (285 lb).
d. Remove the pistons and connecting rods. Refer 5. Remove the upper halves of the crankshaft main
to Disassembly and Assembly, Pistons and bearings.
Connecting Rods - Remove.
103
i01465227
SMCS Code: 1202-012
Table 47
Required Tools
Part
Number
g00517179
Illustration 312
NOTICE
Keep all parts clean from contaminants. 3. Install crankshaft thrust bearings (3).

component life.
NOTICE
Ensure that the crankshaft main bearing tabs engage
bearing cap.
1. Place the upper halves of the crankshaft main

bearings in the cylinder block. Place the lower
halves of the crankshaft main bearings in
crankshaft main bearing caps.
g00517115
Illustration 313
4. Install crankshaft main bearing caps (2) with

the part numbers toward the right hand side of
the cylinder block. Ensure that crankshaft main
bearing caps (2) have numbers 1 through 7. The
numbers should start at the front of the engine.
threads and the washers. Install bolts (1). Tighten
the bolts to a torque of 95 5 Nm (70 4 lb ft).
5. Place an index mark on each bolt head. Turn the

bolts for an additional 90 5 degrees (1/4 turn).
g00517116
Illustration 311
2. Fasten suitable lifting device (4) to the crankshaft

and place the crankshaft in the cylinder block.
g00517182
Illustration 314
104
6. Check the end play of the crankshaft with Tool

(A). The end play must be 0.10 mm (.004 inch)
to 0.50 mm (.020 inch).
End By:
a. Install the pistons and connecting rods. Refer

to Disassembly and Assembly, Piston and
Connecting Rods - Install .
b. Install the flywheel housing. Refer to Disassembly

Install.
c. Install the front housing. Refer to Disassembly g00522193

and Assembly, Housing (Front) - Install . Illustration 315
d. Install the engine oil pump. Refer to Disassembly 1. Place the following items from Tool (D) around the
and Assembly, Engine Oil Pump - Install. finished end of the crankshaft in order to prevent
damage: paper towels, shim stock, and clamp.
i01465251 2. Use paper towels in order to plug all openings

in the cylinder block and prevent debris from
Crankshaft Gear - Remove and entering the cylinder block.
Install
Removal Procedure
Table 48
Required Tools
Part
Number
9U-6232 Wheel Grinder 1
A
1U-6801 Cutoff Wheel 1
1F-1161 1 g00522199
Cold Chisel Illustration 316
B
1U-7237 Hammer 1
3. Use Tool (E) for added protection on the front
C 5F-4764 Pry Bar 2 of the engine.
5P-0598 Clamp 1
D 1U-9579 Paper Towels 1
- Shim Stock 1 Wear eye protection in order to prevent possible
- personal injury while performing the following
E Plastic Sheeting 1
steps.
Start By:

- Remove.
105
g00522197 g00522200
5. Use Tool (B) to make a crack in crankshaft gear

(1).
6. Remove Tool (D) from the crankshaft.
g00522195
Illustration 318
NOTICE
Do not cut all the way through crankshaft gear. Keep at
least 1.5 mm (.06 inch) from the end of the crankshaft.
g00522201
Stay away from the hose clamp and the shim stock. Illustration 320
7. Use Tool (C) to pry crankshaft gear (1) loose

NOTICE from the end of the crankshaft.
Do not nick or gouge the front face of the cylinder
block with the cutoff wheel while grinding through the 8. Remove crankshaft gear (1).
crankshaft gear.
Note: Remove paper towels and Tool (E) from the
cylinder block.
4. Use Tool (A) to make a cut through the root
diameter of crankshaft gear (1). Keep at least
1.5 mm (.06 inch) from the finished end of Installation Procedure
crankshaft.
Table 49
Required Tools
Part
Number
A 6V-2098 Press Sleeve 1
B 8H-8581 Gauge 1
106
g00522202 g00522205
1. Rotate the crankshaft in order to get drive pin 4. Use Tool (A) to seat crankshaft gear (1) against
(2) at top center. the shoulder of the crankshaft.
g00522204 g00522206
5. Use Tool (B) to ensure that crankshaft gear (1) is

seated against the shoulder on the crankshaft.
Always wear protective gloves when handling Note: Check the crankshaft gear in three places
parts that have been heated. with Tool (B).
2. Heat crankshaft gear to a temperature of 210 C End By:

(410 F) for no more than one hour.
a. Install the front gear group. Refer to Disassembly
Note: Heating the gear for more than one hour may and Assembly, Gear Group (Front) - Install.
change the hardness of the gear.
3. Install crankshaft gear (1) on the end of the

crankshaft. Ensure that slot (3) in crankshaft gear
(1) is aligned with drive pin (2).
107
i01410976 Note: Do not allow Tool (A) to extend over the edge
of the bearing.
Bearing Clearance - Check
SMCS Code: 1203-535; 1219-535 order to install the bearing cap. Do not use an
Table 50 Note: Do not turn the crankshaft when Tool (A) is

Part
A - Plastigage -
NOTICE

component life.

small engines. This is because of the possibility of g00473227
Illustration 325
obtaining inaccurate results and the possibility of Typical example
Caterpillar engine bearing is quality checked for 3. Carefully remove the cap, but do not remove
specific wall thickness. Tool (A). Measure the width of Tool (A) while Tool
(A) is in the bearing cap or on the crankshaft
Note: The measurements should be within journal. Refer to Illustration 325.
specifications and the correct bearings should
be used. If the crankshaft journals and the bores 4. Remove all of Tool (A) before you install the
for the block and the rods were measured during bearing cap.
However, if the technician still wants to measure Note: When Tool (A) is used, the readings can
the bearing clearances, Tool (A) is an acceptable sometimes be unclear. For example, all parts of
method. Tool (A) is less accurate on journals with Tool (A) are not the same width. Measure the major
small diameters if clearances are less than 0.10 mm width in order to ensure that the parts are within
(0.004 inch). the specification range. Refer to Specifications,
Crankshaft for the correct clearances.
NOTICE
i01016545
Camshaft Position Sensor -
The technician must be very careful to use Tool (A) Remove and Install
correctly. The following points must be remembered:
SMCS Code: 1912-010
Removal Procedure
seated in the tab grooves. NOTICE
points of Tool (A). Contaminants may cause rapid wear and shortened
component life.
108

i01018581
Crankshaft Position Sensor -

Remove and Install
SMCS Code: 1912-010
Removal Procedure
NOTICE
g00521613 Keep all parts clean from contaminants.
Illustration 326
1. Disconnect sensor connector (4) from camshaft Contaminants may cause rapid wear and shortened
position sensor (3). component life.

NOTICE
3. Remove camshaft position sensor (3) and Care must be taken to ensure that fluids are contained
bracket (2) as a unit from the front housing. during performance of inspection, maintenance, test-
4. Inspect the condition of the O-ring seal on to collect the fluid with suitable containers before
camshaft position sensor (3). Replace the O-ring opening any compartment or disassembling any
seal, if necessary. component containing fluids.

Installation Procedure Tools and Shop Products Guide, for tools and sup-
NOTICE machines.
Contaminants may cause rapid wear and shortened mandates.
component life.
g00522655
Illustration 328
g00521613
Illustration 327 The vibration damper and the front engine support have been
1. Install camshaft position sensor (3) and bracket
(2) as a unit into the front housing. 1. Disconnect sensor connector (4) from crankshaft
3. Connect sensor connector (4) to camshaft
109
3. Remove crankshaft position sensor (2) and i01014165

bracket (3) as a unit from the front housing.
4. Inspect the condition of the O-ring seal on
crankshaft position sensor (2). Replace the
Remove and Install
O-ring seal, if necessary. SMCS Code: 1906-010
Installation Procedure Removal Procedure

NOTICE
and alkali.
component life.


burns.

g00522655
Illustration 329 Avoid contact with skin and eyes.
The vibration damper and the front engine support have been
NOTICE
1. Install crankshaft position sensor (2) and bracket Keep all parts clean from contaminants.
2. Install bolt (1) and the washer. component life.
3. Connect sensor connector (4) to crankshaft

position sensor (2). NOTICE
4. Calibrate the engine speed-timing. Refer to during performance of inspection, maintenance, test-
Electronic Troubleshooting for more information. ing, adjusting and repair of the machine. Be prepared

machines.

mandates.
110
i01000174

Remove and Install
SMCS Code: 1924-010
Removal Procedure
NOTICE

g00520237
component life.
Illustration 330
1. Drain the level of the coolant below the coolant NOTICE

temperature sensor. Drain the coolant into a Care must be taken to ensure that fluids are contained
suitable container for storage or disposal. during performance of inspection, maintenance, test-
2. Disconnect sensor connector (1) from coolant to collect the fluid with suitable containers before
temperature sensor (2). opening any compartment or disassembling any
3. Remove coolant temperature sensor (2).
Installation Procedure Tools and Shop Products Guide, for tools and sup-
machines.
NOTICE
Keep all parts clean from contaminants. Dispose of all fluids according to local regulations and
mandates.
component life.
g00512032
Illustration 332
g00520237
Illustration 331 1. Disconnect sensor connector (1). Cut the wire
ties that secure the sensor wiring to the engine.
1. Install coolant temperature sensor (2). Tighten
coolant temperature sensor (2) to a torque of 2. Remove engine oil pressure sensor (2).
20 5 Nm (15 4 lb ft).
2. Connect sensor connector (1) to coolant

temperature sensor (2).

Manual for the correct procedure.
111
NOTICE
NOTICE Care must be taken to ensure that fluids are contained
Keep all parts clean from contaminants. during performance of inspection, maintenance, test-
Contaminants may cause rapid wear and shortened collect the fluid with suitable containers before open-
component life. ing any compartment or disassembling any compo-

products.

mandates.
g00512032
Illustration 333

10 2 Nm (88 18 lb in).
2. Connect sensor connector (1). Secure the sensor

wiring to the engine with wire ties.
g00748139
Illustration 334
i01428365
1. Disconnect wiring harness connector (1) from
Fuel Pressure Sensor - fuel pressure sensor (2).
Remove and Install
2. Remove fuel pressure sensor (2) from fuel
SMCS Code: 7414-010 transfer pump (3).
NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
g00748139
Illustration 335
112
1. Install fuel pressure sensor (2). Tighten fuel 2. Remove boost pressure sensor (2) and the
pressure sensor (2) to a torque of 10 2 Nm O-ring seal.
(7.3 1.4 lb ft).
2. Connect wiring harness connector (1) to fuel
pressure sensor (2).
NOTICE
i01426862
Boost Pressure Sensor - component life.
Remove and Install
SMCS Code: 1917-010
Removal Procedure
NOTICE

component life.
NOTICE
Care must be taken to ensure that fluids are contained Illustration 337
g00636492
ing, adjusting and repair of the product. Be prepared to Note: Check the condition of the O-ring seal. If the
collect the fluid with suitable containers before open- O-ring seal is worn or damaged, use a new part
ing any compartment or disassembling any compo- for replacement.
1. Install the O-ring seal on boost pressure sensor
Refer to Special Publication, NENG2500, Caterpillar (2).
suitable to collect and contain fluids on Caterpillar 2. Install boost pressure sensor (2). Tighten boost
products. pressure sensor (2) to a torque of 10 2 Nm
(88 18 lb in).
mandates. 3. Connect wiring harness (1) to boost pressure
sensor (2).
g00636492
Illustration 336
1. Disconnect wiring harness (1) from boost

pressure sensor (2).
113
i01190887

Install
SMCS Code: 1358-010
Removal Procedure
g00519256
Illustration 340
2. Install support (3) on the front housing with three

3. Install belt tightener (1) with bolt (4) and

the washer. Tighten the bolt to a torque of
g00519255
55 10 Nm (41 7 lb ft).
Illustration 338
4. Install the drive belt. Use a breaker bar to place
1. Use a breaker bar to release the tension on belt the original amount of tension on the belt.
tightener (1). Remove the drive belt.
g00519259
Illustration 341
g00519256
Illustration 339
5. If the alternator is equipped with an adjustable
2. Remove bolt (4) and the washer. support strap, adjust the position of the alternator
until the indicator edge (5) is aligned with the
3. Remove belt tightener (1). green area of the indicator decal.
5. Remove support (3).
1. Inspect the condition of the belt tightener and
the drive belt. Replace the tightener and the belt,
if necessary.
114
i01533573 3. Install hose (5) and plate (4). Install three nuts
(6).
Engine Control Module -
Remove and Install 4. Connect wiring harness (8). Tighten bolt (7) to a
torque of 6 1 Nm (53 9 lb in).
SMCS Code: 1901-010
5. Install clip (3), the washer, and nut (1).
Removal Procedure
i01012735
Alternator - Remove and Install

SMCS Code: 1405-010
Removal Procedure
1. Remove the drive belt from the drive pulley on
the alternator.

the electrical wires from the alternator.
g00523113
Illustration 342
1. Remove nut (1), the washer, and clip (3).
2. Loosen bolt (7) until wiring harness (8) can be

disconnected. Disconnect wiring harness (8).
3. Remove three nuts (6) and the washers. Move

hose (5) out of the way. Remove plate (4).
4. Remove bolt (9) and the washer. Remove three

studs (2) and the washers. Remove the electronic
control module from the engine.
g00519357
Installation procedure Illustration 344
Typical example
4. Remove nut (2) with the washer and bolt (3) from
mounting bracket (4).
5. Remove the alternator.
g00523113
Illustration 343
1. Position the electronic control module on the

engine and install three studs (2) and the
washers.

115
g00519372
Illustration 346
g00519357
Typical example
1. Place the alternator on mounting bracket (4). starting motor.
Install bolt (3) with the washer and nut (2). Hand
tighten nut (2). 3. Remove three bolts (1).
2. Install bolt (1) and the washer. Do not tighten. 4. Remove the electric starting motor and the
3. Install the drive belt on the drive pulley of the the electric starting motor is 29 kg (65 lb).
alternator.
4. Adjust the tension on the drive belt. Refer to

the Operation and Maintenance Manual for the 1. Inspect the condition of the gasket. Replace the
correct adjusting procedure. gasket, if necessary.
5. Tighten bolt (1). 2. Install the gasket on the electric starting motor.
6. Tighten nut (2).
7. Connect all wires to the alternator. Use the index

marks to correctly connect the wires.
i01012803

Remove and Install
SMCS Code: 1453-010

Illustration 347
1. Place an index mark on all of the electrical wires Typical example
Disconnect the electrical wires from the electric 3. Fasten a suitable lifting device to the electric
starting motor. starting motor.


116
i01024767
Air Conditioner Support

Bracket - Remove and Install
SMCS Code: 1802-010
Removal Procedure
g00526793
Illustration 349
Typical example
1. Install air conditioner support bracket (3) with

the following procedure.
a. Install two bolts (1) with the nuts and the

washers. Finger tighten the bolts.
g00526793
Illustration 348
b. Install two bolts (2) and the washers. Finger
Typical example tighten the bolts.
1. Remove two bolts (1) with the nuts and the
washers. NOTICE
Ensure that there is no gap between the air condition-
2. Remove two bolts (2) and the washers. er compressor support bracket and the engine front
housing. Ensure that there is no gap between the air
3. Remove air conditioner compressor support conditioner support bracket and the cylinder head.
bracket (3). Reposition the air conditioner compressor support
bracket in order to eliminate the gap.
c. Lightly tighten bolts (1) and bolts (2).
NOTICE
d. Ensure that air conditioner support bracket (3)
The air conditioner support bracket provides addition-
al support for the mounting pad on the engine front remains tight against the engine front housing
housing. However, due to the increased stiffness of
this bracket, extra care is needed when installing the
air conditioner compressor support bracket on the en- e. Tighten the bolts to a torque of 47 9 Nm
(35 7 lb ft).
gine. Following the correct installation procedure will
avoid applying assembly stresses to the engine front
housing mounting pad which may lead to a crack.
117
i00999511

Install
SMCS Code: 1803-010
Removal Procedure
Table 51
Required Tools
Number
g00511527
A 138-7573 Link Bracket 1 Illustration 350
2. Remove bolt (6). Disconnect fittings (3) and

remove tube (5).
Do not disconnect the air lines until the air pres- 3. Disconnect hose (1) from the air compressor.
ed under pressure it can cause personal injury. 4. Loosen clamps on hose (2) and remove hose (2).
NOTICE

component life.
NOTICE
component containing fluids. Illustration 351
g00511528
Refer to Special Publication, NENG2500, Caterpillar 5. Install Tool (A) and a proper lifting device to the
Tools and Shop Products Guide, for tools and sup- air compressor. The weight of the air compressor
plies suitable to collect and contain fluids in Caterpillar is approximately 27 kg (60 lb).
machines.
6. Disconnect hose (9) from the air compressor.
mandates. 7. Remove three bolts (7) and the washers.
1. Remove the air pressure from the air tank and 8. Apply tension to the lifting device and remove
drain the coolant from the cooling system. two bolts (8) and the washers. Remove air
compressor (4) and the gasket from the engine.
Table 52
Required Tools
Number
118
7. Install tube (5) and connect fittings (3).

NOTICE
Keep all parts clean from contaminants. 8. Install bolt (6).
Contaminants may cause rapid wear and shortened 9. Connect hose (2) and tighten the clamps.
component life.
1. Inspect the condition of the gasket. Replace the 11. Fill the cooling system with coolant to the correct
gasket, if necessary. level. Refer to the Operation and Maintenance
i01465301

Remove
Removal Procedure
Table 53
Required Tools
g00511528
Illustration 352
Part
air compressor. The weight of the air compressor Holding Fixture (Air
A 132-5451 1
is approximately 27 kg (60 lb). Compressor Drive Gear)
3. Position air compressor (4) in the front housing. Start By:

with the gear in the front housing. a. Remove the air compressor. Refer to Disassembly
4. Apply 9S-3263 Thread Lock Compound to the Install.
threads of three bolts (7). Install three bolts (7)
and the washers. Tighten bolts (7) to a torque of NOTICE
100 20 Nm (75 15 lb ft). Keep all parts clean from contaminants.
5. Install two bolts (8) and the washers. Tighten Contaminants may cause rapid wear and shortened
bolts (8) to a torque of 55 10 Nm (41 7 lb ft). component life.
Remove the lifting device and Tool (A).
g00524786
Illustration 354
Typical example
g00511527
Illustration 353
119
1. Mount air compressor (1) in a bench vise. 6. Remove Tool (A).
2. Install Tool (A) on air compressor (1), as shown. End By:
3. Remove nut (2). a. Install the air compressor. Refer to Disassembly

4. Remove Tool (A) and air compressor drive gear Install .
(3).
i01534044

Install
Table 54
Required Tools
Part
Holding Fixture (Air
A 132-5451 1
Compressor Drive Gear)
NOTICE

component life.
g00524786
Illustration 355
Typical example
2. Install air compressor drive gear (3) on the air

3. Install nut (2).
4. Install Tool (A) on air compressor (1), as shown.

(340 44 lb ft).
120
Index Section
Index
A Compression Brake - Install .................................. 74
Accessory Drive - Assemble.................................. 63 Compression Brake - Remove............................... 67
Assembly Procedure.......................................... 63 Removal Procedure ........................................... 67
Accessory Drive - Disassemble............................. 63 Connecting Rod Bearings - Install ......................... 99
Accessory Drive - Install........................................ 64 Connecting Rod Bearings - Remove ..................... 98
Accessory Drive - Remove .................................... 62 Coolant Temperature Sensor - Remove and
Removal Procedure ........................................... 62 Install ................................................................. 109
Air Compressor - Remove and Install.................. 117 Installation Procedure ...................................... 110
Installation Procedure ...................................... 117 Removal Procedure ......................................... 109
Removal Procedure ......................................... 117 Crankshaft - Install............................................... 103
Air Compressor Drive Gear - Install..................... 119 Installation Procedure ...................................... 103
Installation Procedure ...................................... 119 Crankshaft - Remove........................................... 102
Air Compressor Drive Gear - Remove................. 118 Removal Procedure ......................................... 102
Removal Procedure ......................................... 118 Crankshaft Front Seal - Install ............................... 57
Air Conditioner Support Bracket - Remove and Installation Procedure ........................................ 57
Install ................................................................. 116 Crankshaft Front Seal - Remove ........................... 56
Removal Procedure ......................................... 116 Crankshaft Gear - Remove and Install ................ 104
Alternator - Remove and Install ........................... 114 Installation Procedure ...................................... 105
Installation Procedure ...................................... 115 Removal Procedure ......................................... 104
Removal Procedure ......................................... 114 Crankshaft Main Bearings - Install....................... 101
Crankshaft Main Bearings - Remove..................... 99
B Removal Procedure ........................................... 99
Bearing Clearance - Check ................................. 107 Install ................................................................. 108
Measurement Procedure ................................. 107 Installation Procedure ...................................... 109
Belt Tensioner - Remove and Install .................... 113 Removal Procedure ......................................... 108
Installation Procedure ...................................... 113 Crankshaft Rear Seal - Install................................ 47
Boost Pressure Sensor - Remove and Install...... 112 Crankshaft Rear Seal - Remove............................ 46
Install ................................................................... 47
C Installation Procedure ........................................ 48
Camshaft - Install................................................... 85 Cylinder Head - Install ........................................... 79
Camshaft - Remove............................................... 83 Cylinder Head - Remove ....................................... 76
Camshaft Bearings - Install ................................... 87 Cylinder Liner - Install............................................ 92
Camshaft Bearings - Remove ............................... 86 Cylinder Liner - Remove .................................. 9091
Removal Procedure ........................................... 86 Removal Procedure ..................................... 9091
Camshaft Gear - Remove and Install .................... 86
Removal Procedure ........................................... 86 D
Camshaft Position Sensor - Remove and Install.. 107
Installation Procedure ...................................... 108 Disassembly and Assembly Section........................ 5
Compression Brake - Assemble ............................ 71
121
Index Section
E Front Cover - Remove ........................................... 57

Electric Starting Motor - Remove and Install ....... 115 Fuel Filter Base - Remove and Install ..................... 5
Installation Procedure ...................................... 115 Installation Procedure .......................................... 6
Removal Procedure ......................................... 115 Removal Procedure ............................................. 5
Electronic Unit Injector - Install .............................. 10 Fuel Manifold - Install .............................................. 8
Installation Procedure ........................................ 10 Installation Procedure .......................................... 8
Electronic Unit Injector - Remove ............................ 9 Fuel Manifold - Remove........................................... 8
Removal Procedure ............................................. 9 Removal Procedure ............................................. 8
Electronic Unit Injector Sleeve - Install .................. 12 Fuel Pressure Sensor - Remove and Install ........ 111
Installation Procedure ........................................ 12 Removal Procedure ......................................... 111
Electronic Unit Injector Sleeve - Remove .............. 12 Fuel Priming Pump - Remove and Install ................ 5
Engine Centrifugal Oil Filter - Remove and Install.. 22 Removal Procedure ............................................. 5
Installation Procedure ........................................ 23 Fuel Transfer Pump - Install..................................... 7
Engine Control Module - Remove and Install ...... 114 Fuel Transfer Pump - Remove ................................. 7
Installation procedure....................................... 114 Removal Procedure ............................................. 7
Engine Oil Cooler - Install...................................... 30
Installation Procedure ........................................ 30 G
Engine Oil Cooler - Remove .................................. 28
Removal Procedure ........................................... 28 Gear Group (Front) - Install ................................... 60
Engine Oil Filter Base - Assemble......................... 27 Installation Procedure ........................................ 60
Assembly Procedure.......................................... 27 Gear Group (Front) - Remove ............................... 59
Engine Oil Filter Base - Disassemble .................... 25 Removal Procedure ........................................... 59
Engine Oil Filter Base - Install ............................... 28
Installation Procedure ........................................ 28 H
Removal Procedure ........................................... 25 Housing (Front) - Install ......................................... 61
Engine Oil Pan - Remove and Install ..................... 88 Installation Procedure ........................................ 61
Installation Procedure ........................................ 89 Housing (Front) - Remove ..................................... 61
Engine Oil Pressure Sensor - Remove and
Install ................................................................. 110
Installation Procedure ...................................... 111 I
Engine Oil Pump - Assemble................................. 32 Important Safety Information ................................... 2
Assembly Procedure.......................................... 32 Inlet and Exhaust Valve Guides - Remove and
Engine Oil Pump - Disassemble............................ 31 Install ................................................................... 20
Engine Oil Pump - Remove ................................... 30 Install ................................................................... 21
Exhaust Manifold - Remove and Install ................. 15 Removal Procedure ........................................... 21
Installation Procedure ........................................ 15 Inlet and Exhaust Valve Springs - Remove and
F Inlet and Exhaust Valves - Remove and Install ..... 18
Installation Procedure ........................................ 46 Inlet Manifold - Install............................................. 16
Flywheel - Remove................................................ 45 Installation Procedure ........................................ 16
Removal Procedure ........................................... 45 Inlet Manifold - Remove......................................... 15
Flywheel Housing - Remove and Install ................ 48 Removal Procedure ........................................... 15
122
Index Section
L W
Lifter Group - Remove and Install.......................... 82 Water Outlet Manifold - Install ............................... 45
Removal Procedure ........................................... 82 Water Outlet Manifold - Remove............................ 44
Water Pump - Assemble........................................ 37
P Assembly Procedure.......................................... 37
Water Pump - Disassemble ................................... 35
Piston Cooling Jets - Remove and Install .............. 93 Disassembly Procedure ..................................... 35
Installation Procedure ........................................ 93 Water Pump - Install .............................................. 40
Pistons and Connecting Rods - Assemble ............ 96 Water Pump - Remove .......................................... 33
Assembly Procedure.......................................... 96 Removal Procedure ........................................... 33
Pistons and Connecting Rods - Disassemble ....... 95 Water Temperature Regulator - Remove and
Disassembly Procedure ..................................... 95 Install ................................................................... 41
Pistons and Connecting Rods - Install................... 97 Installation Procedure ........................................ 42
Pistons and Connecting Rods - Remove............... 94

Rear Power Take-Off (RPTO) - Remove................ 50
Rocker Shaft and Pushrod - Install ........................ 76
Rocker Shaft and Pushrod - Remove .................... 75

Install ................................................................... 66
Vibration Damper and Pulley - Remove and
Install ................................................................... 55
123
Index Section
2001 Caterpillar
RENR1289
January 2001
Service Manual
C-10, C-12, 3406E, C-15 and C-16
Engines - Electronic PTO Installation
and Applications
1MM1-Up (Engine)
2KS1-Up (Engine)
2WS1-Up (Engine)
3CS1-Up (Engine)
6NZ1-Up (Engine)
7CZ1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents
Switches ................................................................. 4
Component Installation ........................................... 8

Programmable Parameters ................................... 38
0030-08 Invalid PTO Throttle Signal (29) .............. 43

PTO Shutdown Timer - Test .................................. 45
PTO Switch Circuit - Test ...................................... 47
PTO Switch ON Lamp Circuit - Test ...................... 59
Test ..................................................................... 63

PTO Parameters - Program .................................. 72
PTO Configurations - Test ..................................... 74
Index Section
Index ................................................................... 112
4
Switches
i01219566
SMCS Code: 1011-ZS
General Information
Switch Electrical Specifications
SMCS Code: 1000; 1165
The plating that is on the switch should not corrode
This manual explains the different options and and the plating should not oxidize. Gold plated
applications for the installation of the electronics for contacts are recommended. All switches should be
the PTO. Different switches and components are an environmentally sealed unit. All switches should
shown in different applications in this manual. be protected according to the requirements of the
application.
Once the installation is complete, ensure that the
operator of the PTO understands the operation of Normally, the applied voltage to the switches will not
the PTO. Fully explain the different applications and exceed 11.5 Volts. The normal current draw through
components of the installation. Ensure that the Truck the switches will not exceed 0.0065 Amp (6.5 mA).
Installation Diagram is completed and ensure that
the Truck Installation Diagram is explained to the The chatter (momentary opening and closing) of
operator of the PTO. the contacts should not exceed a duration of 0.1
seconds (100 milliseconds). The switches should
This manual has been created in different sections. not open and the switches should not close due to
The Specifications section explains the selection of a vibration or shock. Closure of an installed switch
the different components that may be needed for must short the circuit. The input will short to the
the installation. Schematics and configurations for Input Sensor Common 1 (terminal 18) or to the
the switches and components are provided. The Input Sensor Common 2 (terminal 3) of the ECM
schematics and configurations are for the different Vehicle Harness Connector J1/P1.
installations.
The Systems Operation section explains the Voltage Thresholds (Measurement at the
operation of the PTO once the switches and ECM)
components have been installed. More detail is
given on the different types of installations. Voltage Input of Less Than 0.9 Volts When the
switch contacts close, the voltage that is across the
The Testing and Adjusting section explains the following items must be less than 0.9 Volts between
operation of the system once the system has been the respective control input and the sensor common
installed. All of the different types of installation connection: difference of the ground potential, drop
arrangements are explained in full operation. A in switch voltage, and drop in voltage for the wiring
diagram of the position of the tachometer, the harness.
switches, and the accelerator pedal is given for
each step for a quick reference. Voltage Input Equal To or Greater Than 4.0 Volts
When the switch contacts open, the following items
Finally, the Troubleshooting section explains the must not result in an effective resistance of less than
diagnostics and the correction of any problems 5,000 Ohms from the respective control input to the
with the installation. For more information on sensor common connection: the pin to pin leakage
troubleshooting, always refer to the Troubleshooting paths in connectors, harnesses, and switches.
Guide for your engine.
Note: The following terminals are designated as
the Sensor Common connection J1/P1: Terminal 3
(Input Sensor Common 2) and terminal 18 (Input
Sensor Common 1). OEM installed switches that
are input into the ECM must not be connected to
the vehicle or to the cab ground. The OEM installed
switches must be grounded to the Sensor Common
by using a dedicated return line to ECM Vehicle
5
Selecting a Switch Type Electrical Specifications for the

The type of switch that is required depends on
Remote Accelerator Pedal Position
the type of application that is required. The Cruise Sensor
Control Set/Resume or the RPM Increase/RPM
Decrease Switch is typically a three-position
momentary switch. A spring is used in order to
return the switch to the OFF position.
The PTO On/Off Switch can be an On/Off or a

two-position switch. The switch can be actuated by
one of the following operations:
Manual
Air
Hydraulic
g00622029
The Interlock Switches for the PTO are typically Illustration 2
actuated by air. The Interlock Switches for the 161-8906 Accelerator Pedal Position Sensor
PTO are also in the normally closed position. The
switches are connected into the air lines for the The 161-8906 Position Sensor is required. The
Parking Brake or connected to the air lines for sensor is supplied with a Deutsch HD connector.
the Transmission. All switches may be controlled The Deutsch part number is HD16-3-96S. The
hydraulically or the switches may be limit switches. Caterpillar part number is 8T-8731 Connector Plug.
All switches that are located outside the cab should The connecting harness will require a Deutsch HD
be environmentally sealed and protected. receptacle connection. The Deutsch part number
is HD14-3-96P. The Caterpillar part number is
Switches That Are Available from 8T-8732 .
Caterpillar Note: The 161-8906 Position Sensor can not be
powered by the 8 Volt power supply from the ECM.
A 112-4073 Pressure Switch Assembly is available. The 161-8906 Position Sensor must be connected
The switch has the following features: single pole, and powered by 12/24 Volt battery voltage.
single throw, and actuated by air.
Mounting the Accelerator Pedal Position
Sensor
g00621900
Illustration 1
Schematic for the 112-4073 Pressure Switch Assembly
The actuation pressure for the switch is the following value: Illustration 3 g00638606
330 kPa (48 psi)
107-2281 Mounting Block
The handle is not included.
6
The 161-8906 Position Sensor can be attached to Specifications for the Harness
either an accelerator pedal assembly or a 107-2281
Mounting Block. The PTO Accelerator Assembly The harness should be protected from the
does not include the handle. A mechanical linkage environment by using a conduit that is plastic or
can also be used in the application. Contact the by other means. All of the wire for the harness
vehicle OEM in order to obtain information on the should be 18 AWG or the wire should be larger.
part number for the accelerator pedal assembly. The wire for the harness should be SAE J1128. The
wire for the harness should be SXL or GXL. Use
an equivalent wire for the harness if one of the
types is not available. The acceptable range for
wire insulation outside diameter is 2.26 to 3.33 mm
(0.089 to 0.131 inch). All ring terminals and all
splices that are connected to the harness must be
sealed. All ring terminals and all splices that are
routed to the engine ECM must be sealed. Seal the
terminals and splices with Raychem ES2000 shrink
tubing or the equivalent in order to seal the ring
terminals and the splices.
g00638604
Illustration 4
Williams Controls, Inc. Pedal assembly
Table 1
Williams Controls, Inc. Part Numbers for
Pedal Assemblies
Supplier Part Number Pedal Angle
350415 28 degrees
350416 35 degrees
350417 45 degrees
Note: The 161-8906 Position Sensor provides a

Pulse Width Modulated signal to the ECM that is
constant frequency. The duty cycle varies with the
position of the accelerator pedal. The ECM Remote
Throttle input cannot be used with a vernier control
cable assembly or as an input for the throttle switch.
The ECM Remote Throttle input must receive the
correct PWM signal during any of the following
conditions: The ECM is in the ON position., The
Throttle., and A diagnostic code is the result.
7
Table 2
Components for the 70 Terminal Connector for the ECM
Vendor and Vendor Part
Description Usage Caterpillar Part Number
Number
70 Terminal Connector Vehicle Harness for the OEM AMP/776241-1 160-7689
The AMP terminal is a Number 16 and Number 18 AMP/776093-1 126-1766
gold socket contact that is AWG SXL Wire
stamped and formed. Number 14, Number 16, and
Number 18 AWG GXL wire
The Deutsch terminal is a Number 14 AWG SXL wire Deutsch-0462-209-1631 126-1768
gold socket contact that is and Number 14 AWG GXL
machined for field service. wire
The Deutsch terminal is a Number 16 and Number 18 Deutsch-0462-201-1631 9X-3402
Gold Socket Contact that is AWG SXL wire
machined for field service. Number 16 and Number 18
AWG GXL wire
Sealing Plug for Number 14 Unused Connector Slots PEI Genesis-225-0093-000 9G-3695
AWG to Number 18 AWG
Sealing Plug for Number 14 Unused Connector Slots Deutsch-114017 8T-8737
AWG to 18 AWG
Hand Crimp Tool The tool crimps the following Deutsch-HDT-48-00 1U-5804
wire: Number 14, Number
16, and Number 18 AWG
Wire Removal Tool SXL and GXL Wire AMP 776106 151-6320
g00622240
Illustration 5
(1) Contact Pin
(2) Machined socket contact
(3) Stamped and forged socket contact
(4) Sealing plug
8
i01357284
Component Installation
SMCS Code: 1000; 1900
g00725429
Illustration 6
The left side of the C-15 truck engine is shown.
(1) Vehicle harness connector J1/P1 (5) Side view of vehicle harness connector
(2) Engine harness connector J2/P2 P1
(3) Engine Control Module (ECM) (6) Harness side of vehicle harness
(4) ECM side of vehicle harness connector connector P1
P1
9
Considerations for the Installation The PTO Configuration is Programmed

to Remote Switches or to Remote
Throttle
The switches labeled PTO Interlock in the The components that follow are ignored when
schematics are redundant and should be added the PTO On/Off circuit is in the ON position. The
to ensure the engine is put in PTO mode only PTO Configuration must also be programmed
when the vehicle and operator are prepared for to Remote Switches or to Remote Throttle:
safe PTO operation. The interlocks must pre- accelerator pedal position sensor for the cab, clutch
vent operation of the engine PTO until the PTO switch, service brake switch, and cruise control
operator is expecting it and is prepared. These switches. A PTO Switch On lamp is recommended
switch(es) may be (parking brake switch or other in both the cab and at the remote station in order
switches) available as an interlock and are re- to indicate when the PTO On/Off circuit is ON. The
quired for the application. Parking Brake Switch and/or a Transmission Neutral
Switch causes the engine to return to the Low
Idle Engine RPM. The engine will return to the
NOTICE Low Idle Engine RPM if someone tries to move
It is the installer and the vehicle owners responsibil- the vehicle and the operator of the PTO is at the
ity to determine the necessary interlocks for the the remote location. The Idle/PTO Vehicle Speed Limit
PTO system and to provide the PTO operator with the should also be programmed to the minimum 1 km/h
operating instructions. Failure to do so may cause ve- (1 mph) in order to cause the engine to return to
hicle/equipment damage. low idle if the vehicle is moved.
PTO Switch On Lamp Engine Shutdown Switch
The PTO switch On lamp should be installed in the If an engine shutdown switch is desired, then the
cab. If the PTO operating station is outside of the switch should be connected to a Normally Closed
cab, a lamp should also be installed at the operating Relay. Refer to Schematic 7 for an example. The
station. This lamp will provide an indication to the actual location of the switch should be readily
driver/PTO operator when the PTO On/Off circuit accessible to the operator of the PTO during PTO
is ON. Refer to the appropriate diagrams for the operation.
application. The PTO switch On lamp parameter
must be programmed to J1/P1:30 in order for
Output 1 to illuminate the PTO switch On lamp
when the PTO On/Off switch is in the ON position.
If the PTO Configuration is programmed to Cab
Switches, then refer to Illustrations 9 and 10. If the
Switches, then refer to Illustrations 11 and 12. If
the PTO Configuration is programmed to Remote
Throttle, then refer to Illustrations 13 and 14.
10
Schematic for the Engine Shutdown Switch
g00627399
Illustration 7
Schematic for the engine shutdown switch for a full feature system
PTO Interlocks for Transmission Driven

PTO
Any PTO Configuration
Vehicles that use a transmission driven PTO require

an additional Parking Brake Interlock Switch for the
PTO On/Off circuit. The interlock will prevent PTO
operation if the Parking Brake is not set.
11
g00716284
Illustration 8
Schematic for the PTO Interlock for transmission driven PTO
Installation for Three PTO The Set position becomes the RPM increase
Configurations RPM decrease position if the PTO Engine RPM Set
The PTO configuration provides three
programmable options:
Cab switches provide either the DECEL function or the ACCEL
Remote switches by the Idle/PTO Bump RPM parameter.
Remote throttle Note: A Neutral Switch (Input 12, J1/P1 terminal-62)
is required for PTO operation if the PTO
The information in this section provides details on
the installation of the necessary components that
are required for the various options for the PTO and the Transmission Style is programmed to one
of the following options: Automatic Option 3 and
configuration.
Automatic Option 4.
Cab Switches PTO Configuration
No splicing into the existing cab wiring is necessary.
The Cruise Control Set/Resume Switch is used
for PTO Operation, Cruise Control, and Extended
Idle. The function of the Set position and Resume
position is determined by the programming of
the following parameters: PTO Engine RPM Set
Speed, Cruise/Idle/PTO Switch Configuration,
and Idle/PTO Bump RPM
12
g00717912
Illustration 9
Cab Switches for PTO Configuration
(A) Set/Resume switch (E) Harness side of vehicle harness
(D) ECM side of vehicle harness connector (30) Output 1 (PTO Switch On lamp)
J1 (56) Input 1 (PTO On/Off switch)
13
g00716285
Illustration 10
Schematic for Cab Switches for PTO Configuration
Remote Switches PTO Configuration

The Cruise Control Set/Resume switch that is
in the cab is not used. Remote switches PTO
configuration requires the installation of a remote
set switch and the installation of a remote resume
switch. While the PTO is in operation, all of the cab
controls will be ignored.
The function of the Set position and Resume

position is determined by the programming of the
PTO Engine RPM Set Speed, Cruise/Idle/PTO
Switch Configuration, and the Idle/PTO Bump
RPM parameters.
The Set position becomes the RPM increase

RPM decrease position if the PTO Engine RPM Set
provide either the DECEL function or the ACCEL
by the Idle/PTO Bump RPM parameter.
14
g00716286
Illustration 11
Remote Switches for PTO Configuration
15
(A) PTO On/Off Switch (C) PTO Switch On lamp (3) Input sensor common 2
(B) The PTO Set/Resume switch may (D) PTO Switch On lamp (30) Output 1 (PTO switch On lamp)
be located in the cab or in a remote (E) ECM side of the vehicle harness (56) Input 1 (PTO On/Off switch)
location. The operation of the PTO connector J1 (58) Input 2 (PTO set switch)
Set/Resume switch is dependent upon (F) Harness side of the vehicle harness (60) Input 3 (PTO resume switch)
the programming. connector P1
g00716287
Illustration 12
Schematic for Remote Switches for PTO Configuration
Remote Throttle PTO Configuration

The ECM monitors the Remote Accelerator Position
Sensor when the PTO On/Off switch and the PTO
Interlock switches are closed. The PTO Set switch
can be used to set engine rpm and the PTO
Resume switch is available to resume a previously
set RPM. The switch will go to the ACCEL position
or the switch will go to the DECEL position from
the current set speed if the PTO Set switch is held
in position or the PTO Resume switch is held in
position. This is based on the programming for the
customer specified parameter.
16
g00716289
Illustration 13
Remote Throttle for PTO Configuration
17
(A) PTO Switch On lamp (D) PTO Switch On lamp (30) Output 1 (PTO switch On lamp)
(B) PTO On/Off Switch (E) PTO accelerator assembly (56) Input 1 (PTO On/Off switch)
(C) The PTO Set/Resume switch may (F) ECM side of the vehicle harness (58) Input 2 (PTO set switch)
be located in the cab or in a remote connector J1 (60) Input 3 (PTO resume switch)
location. The operation of the PTO (G) Harness side of the vehicle harness (68) Input 8 (remote accelerator)
Set/Resume switch is dependent upon connector P1
the programming. (3) Input sensor common 2
g00716290
Illustration 14
Schematic for the Remote Throttle for PTO Configuration
Cab Switches with Torque Limit Switch

When the Torque Limit switch is in the ON position,
the Torque Limit is applicable. The Torque Limit
is used when the Torque Limit has a programmed
value and the PTO On/Off switch is in the ON
position. The Torque Limit is operational when
driving the vehicle and the PTO On/Off switch is in
the OFF position. For example, this is useful when
the transmission provides deep reduction gears
that require reduced torque levels for the driveline.
This feature should only be used for temporary
protection of the equipment. To enable this feature,
Input 4 must be programmed to Torque Limit
Switch. The default is None.
18
g00716420
Illustration 15
Configuration of the Cab Switches with torque limit switch
(A) PTO Set/Resume switch (E) ECM side of the vehicle harness (3) Input sensor common 2
(B) PTO On/Off Switch connector J1 (7) Input 4 (torque limit switch)
(C) PTO Switch On lamp (F) Harness side of the vehicle harness (30) Output 1 (PTO switch On lamp)
(D) Torque limit switch connector P1 (56) Input 1 (PTO On/Off switch)
19
g00716421
Illustration 16
Schematic for the Cab Switches with torque limit switch
Cab Switches with Ignore Brake/Clutch

Switch
The Ignore Brake/Clutch switch is intended for
applications that require mobile use of the vehicle
with a set engine rpm. The PTO will disengage if the
brake is depressed or if the clutch is depressed.
The Ignore Brake/Clutch switch prevents the
clutch or the brake from disengaging the PTO set
speed. This is useful for the following applications:
fire truck, cement pavement, and curb pouring
operations. In order to enable this feature, Input
5 must be programmed to Ignore Brake/Clutch
Switch. The default is None.
Note: If the Transmission Style is programmed to

Automatic Option 3 or to Automatic Option 4,
then provisions must be taken in order to prevent
the neutral switch from disengaging the PTO when
the transmission is in gear.
20
g00716434
Illustration 17
Configuration of the Cab Switches with ignore brake/clutch switch
(A) PTO Set/Resume switch (E) ECM side of the vehicle harness (3) Input sensor common 2
(B) PTO On/Off Switch connector J1 (30) Output 1 (PTO switch On lamp)
(C) PTO Switch On lamp (F) Harness side of the vehicle harness (47) Input 5 (ignore brake/clutch switch)
(D) Ignore brake/clutch switch connector P1 (56) Input 1 (PTO On/Off switch)
21
g00716435
Illustration 18
Schematic for Cab Switches with ignore brake/clutch switch
Remote Switches with Torque Limit

Switch
The Torque Limit is used when the Torque Limit
has a programmed value and the PTO On/Off
switch is in the ON position. The diagrams illustrate
the connection of a second switch in order to
provide the Torque Limit under certain conditions.
The Torque Limit is operational when driving
and the PTO On/Off switch is in the OFF position.
None.
22
g00716422
Illustration 19
Configuration for Remote Switches with torque limit switch
(A) PTO On/Off Switch (F) ECM side of the vehicle harness (7) Input 4 (torque limit switch)
(B) PTO Set/Resume switch connector J1 (30) Output 1 (PTO switch On lamp)
(C) PTO Switch On lamp (G) Harness side of the vehicle harness (56) Input 1 (PTO On/Off switch)
(D) PTO Switch On lamp connector P1 (58) Input 2 (PTO set switch)
(E) Torque limit switch (3) Input sensor common 2 (60) Input 3 (PTO resume switch)
23
g00716424
Illustration 20
Schematic for Remote Switches with torque limit switch
Remote Switches with Ignore

Brake/Clutch Switch
All inputs from the cab are ignored when
the Remote Switches PTO Configuration is
programmed. The Ignore Brake/Clutch switch is
used to ignore the following inputs: brake and
clutch. The inputs are ignored while in idle mode.
This is for applications that require mobile use of
the vehicle with a set engine rpm that does not
require the brake or clutch to disengage the idle set
speed. To enable this feature, Input 5 must be
programmed to Ignore Brake Clutch Switch.
If the PTO On/Off switch is OFF, then the ECM

considers the closure of the ignore brake/clutch
switch as a request to prevent the disengagement
of the idle set speed. The vehicle speed must be
below the programmable Idle Vehicle Speed Limit
and an engine rpm must be set for the feature to be
applicable. The ignore brake/clutch switch is not
required when the PTO On/Off switch is in the ON
position. All cab inputs are ignored.
Note: If the Transmission Style is programmed to

Automatic Option 3 or to Automatic Option 4,
then provisions must be taken in order to prevent
the neutral switch from disengaging the idle set
speed when the transmission is in gear.
24
g00716427
Illustration 21
Configuration for Remote Switches with ignore brake/clutch switch
25
(A) PTO On/Off Switch (H) Harness side of the vehicle harness
(B) PTO Set/Resume switch connector P1
(D) PTO Switch On lamp (30) Output 1 (PTO switch On lamp)
(E) Torque limit switch (47) Input 5 (Ignore Brake/Clutch switch)
(F) Ignore Brake/Clutch switch (56) Input 1 (PTO On/Off switch)
(G) ECM side of the vehicle harness (58) Input 2 (PTO set switch)
connector J1 (60) Input 3 (PTO resume switch)
g00716429
Illustration 22
Schematic for Remote Switches with Ignore Brake/Clutch switch
Idle Shutdown is Disabled with the PTO Multiple Speed PTO Operation That
Switch ON Uses The PTO Engine RPM Set Speed
Input A and The PTO Engine RPM Set
The ECM will disable the Idle Shutdown Timer
when the circuit for the PTO On/Off switch is in Speed Input B
the ON position. This will prevent shutdowns that
The Multiple Speed PTO Operation that uses the
are unwanted when the PTO mode is active. The
PTO Shutdown Timer can be used to shut down PTO Engine RPM Set Speed Input A and the PTO
Engine RPM Set Speed Input B is available for use
the engine. This shutdown can be used if the
with all three PTO configurations. The engine will
driver/operator is using the PTO mode in order to
prevent idle shutdown. The PTO Shutdown Timer operate at the programmed PTO Engine RPM Set
Speed A when the PTO Engine RPM Set Speed
will shut down the engine but the PTO Shutdown
Input A switch (Input 7) and the PTO On/Off switch
Timer will not disable the ECM.
are ON. The engine will operate at the PTO Engine
RPM Set Speed B when the PTO Engine RPM
Note: It is critical that the operator of the PTO
Set Speed Input B switch (Input 19) and the PTO
knows the arrangement. The operator must fully
understand the setup of the PTO system. It is also On/Off switch are ON. The PTO Engine RPM Set
Speed B will not operate unless the PTO Engine
critical that the operator of the PTO understands the
RPM Set Speed A switch is OFF. The PTO Engine
operation of the system.
RPM Set Speed Input A and the PTO Engine RPM
Set Speed Input B have priority over all of the
other features that are used to control the engine
speed during PTO operation. The exception is any
circumstance that causes the PTO operation to be
disabled.
26
g00719704
Illustration 23
Configuration for the Multiple Speed PTO Operation that uses the PTO Engine RPM Set Speed Input A and the PTO Engine RPM Set
Speed Input B
27
(A) PTO Set/Resume switch (G) Harness side of the vehicle harness
(B) PTO On/Off Switch connector P1
(D) PTO Engine RPM Set Speed B On/Off (23) Input 19 (PTO Engine RPM Set Speed
Switch B switch)
(E) PTO Engine RPM Set Speed A On/Off (30) Output 1 (PTO switch On lamp)
Switch (46) Input 7 (PTO Engine RPM Set Speed
(F) ECM side of the vehicle harness A switch)
connector J1 (56) Input 1 (PTO On/Off switch)
g00719705
Illustration 24
Schematic for the Multiple Speed PTO Operation that uses the PTO Engine RPM Set Speed Input A and the PTO Engine RPM Set
Speed Input B
28
Systems Operation Section The dedicated PTO has two speed controls
with three circuits. The three circuits are the
programmed low idle, the PTO preset set
i01362474 speed, and the PTO TEL.
General Information The accelerator pedal in the cab can be disabled

without altering the cab wiring.
SMCS Code: 1000; 1165
The dedicated PTO provides an rpm limit for
Advantages of a Dedicated PTO the accelerator pedal in the cab and the cab
switches.
The ECM provides several options in order to
enhance vehicles that require control of the engine The dedicated PTO has additional inputs for the
speed for vocational applications. The vocational remote accelerator position sensor. The remote
applications include the following applications: accelerator position sensor provides control of
cement mixers, refuse packers, bulk haulers, utility the engine rpm on the outside of the cab.
trucks, fire trucks, and applications that require
the control of the engine rpm for the operation of The dedicated PTO has additional Set/Resume
specialized equipment. inputs for control of the engine rpm. The inputs
can be remote. An example would be outside of
There are 15 dedicated PTO parameters. The the cab.
dedicated PTO has seven inputs and one output.
The features of the dedicated PTO provide a Engine set speeds that are lower can be used to
significant increase in the capability of the engine reduce the level of engine noise during dedicated
and of the usage of the engine. PTO operation. Engine set speeds can be lower
than a mechanical engine.
An electronically controlled engine eliminates the
need for the following items: mechanical control The ECM controlled Engine Retarder is disabled
cables, air cylinders, electric solenoids, and when the PTO On/Off switch is in the ON position.
linkages and connections. The dedicated PTO
provides a simple installation. The Cruise Control The idle shutdown feature is disabled when the
switches that are in the cab and the circuit for the PTO On/Off switch is in the ON position.
accelerator pedal position are left unaffected.
The dedicated PTO provides a programmable
PTO shutdown time in order to reduce driver
Features of the Dedicated PTO abuse. Driver abuse is placing the truck in
dedicated PTO mode in order to disable the idle
There are several features of the dedicated PTO: shutdown timer.
The dedicated PTO reduces the alteration of the The cab clutch inputs and the service brake
cab wiring or the dedicated PTO eliminates the inputs can be prevented from disengaging
alteration of the cab wiring. an engine set speed during dedicated PTO
operation. Slow moving vehicle operations require
The dedicated PTO has multiple speed control by control of the engine rpm from the cab. An
using the PTO Engine RPM Set Speed A and example would be a curb pouring cement truck.
PTO Engine RPM Set Speed B.
The dedicated PTO has two speed controls that engine torque limit.
require the PTO On/Off circuit.
The dedicated PTO provides three different PTO engine rpm acceleration/deceleration ramp rate
configurations which determine the operation of and a programmable engine rpm bump rate.
the dedicated PTO.
The dedicated PTO requires an OFF and ON
The dedicated PTO has one speed control that transition of the PTO On/Off switch in order to
has a programmed low idle to PTO set speed for begin dedicated PTO operation.
engine rpm with one circuit.
The dedicated PTO provides the ability to keep
the ECM controlled cooling fan ON during
dedicated PTO operation.
29
Customer Programmable Parameter PTO Shutdown Time The PTO Shutdown Time
Options is a programmable time. If the engine is in PTO
mode, then the PTO Shutdown Time will shut
There are many customer programmable parameter down the engine when the time limit expires.
options:
PTO Activates Cooling Fan The PTO Activates
PTO Configuration The PTO Configuration Cooling Fan can be programmed so that the
determines the input/output configuration that is cooling fan will operate during PTO operation.
Input 4 Input 4 provides a parameter for a
PTO TEL The PTO TEL provides a parameter Torque Limit Switch when torque limiting is desired
in order to limit the engine rpm during PTO for temporary protection of equipment. This is
operation. regardless of the position of the PTO On/Off switch.
MAR98 or later Personality Modules
PTO Engine RPM Set Speed The PTO Engine
RPM Set Speed provides a set point for the engine Input 5 Input 5 provides a parameter for an
rpm for the PTO. Ignore Brake/Clutch Switch when mobile use of
PTO Engine RPM Set Speed A This provides brake and the clutch are not required in order to
a programmable engine speed set point that disengage the engine rpm set speed. MAR98 or
is actuated by a dedicated switch circuit. The later Personality Modules
dedicated switch circuit is Input 7.
Input 7 Input 7 can be programmed to PTO
PTO Engine RPM Set Speed B This provides a Engine RPM Set Speed A in order to provide
second programmable engine speed set point that a dedicated circuit for the PTO operation at a
is actuated by a second dedicated switch circuit. programmed speed when the PTO On/Off Switch is
The dedicated switch circuit is Input 19. ON. JUL99 or later Personality Modules
PTO to Set Speed The PTO to Set Speed Input 19 Input 19 is programmable to PTO
function requires only one circuit (PTO On/Off Engine RPM Set Speed B in order to provide a
Switch) to provide two speed controls. The PTO second dedicated circuit for the operation at a
to Set Speed function provides three-speed programmed speed when PTO Engine RPM Set
controls by using the PTO On/Off Switch and the Speed A is OFF and the PTO On/Off switch is ON.
Set/Resume Switch. JUL99 or later Personality Modules
PTO Cab Controls RPM Limit The PTO Cab Torque Limit Switch The torque limit switch
Controls RPM Limit provides a parameter in order parameter limits torque regardless of PTO operation.
to limit the rpm from the accelerator pedal position
sensor in the cab during PTO operation. The PTO Ignore Brake/Clutch Switch The ignore
Cab Controls RPM Limit can be used in order brake/clutch switch parameter allows mobile use
to exceed the programmed PTO TEL with the of the vehicle during PTO operation. The ignore
accelerator pedal that is in the cab. brake/clutch switch parameter allows mobile use
of the vehicle when an engine rpm set speed is
Torque Limit The torque limit reduces the required and the brake or the clutch is not required
engine torque during PTO operation. The torque in order to disable the engine rpm set speed.
limit will also reduce the engine torque when
the Torque Limit Switch is in the ON position for Cruise/Idle/PTO Switch Configuration The
temporary protection of equipment. Cruise/Idle/PTO switch configuration determines if
the set switch or the resume switch will function as
PTO Vehicle Speed Limit The PTO Vehicle the ACCEL or the DECEL function.
Speed Limit determines the operating range of the
vehicle speed during PTO operation. PTO Switch On Lamp The PTO switch On lamp
parameter allows a lamp to illuminate when the PTO
Idle/PTO RPM Ramp Rate The Idle/PTO RPM On/Off switch is in the ON position.
Ramp Rate determines the rate of acceleration
and deceleration. Additional Features of the Dedicated PTO
Idle/PTO Bump RPM The Idle/PTO Bump RPM When the PTO On/Off switch is in the ON position,
determines the amount of change in the engine rpm the Idle Shutdown feature is disabled.
30
Two terminal connector and wiring is standard for

the PTO On/Off Switch. Two terminal connector
and wiring is standard for the PTO Interlock
Switches.

Driver abuse is placing the truck in PTO mode in
order to disable the idle shutdown time.
Definition of Power Take-Off (PTO)

The dedicated PTO is an engine rpm control that
is initiated through an On/Off circuit. The circuit
Vehicle Harness Connector J1/P1. Engine rpm
control that is initiated through the Cruise Control
On/Off switch is referred to as Extended Idle.
Idle Enable Switch is referred to as Fast Idle.
The Four Programmable PTO

Configurations
Off The functions for the dedicated PTO are
not available.
Cab Switches The cruise control Set/Resume

switch and the Accelerator Pedal are used to control
the engine rpm. A dedicated PTO On/Off switch is
Remote Switches The Set/Resume switch for the

remote PTO is used to control the engine rpm. The
Remote Switches configuration ignores all of the
cab controls. An On/Off switch for the dedicated
PTO is required. Refer to Illustration 26.
Remote Throttle The Remote Throttle

configuration is used in order to control the engine
rpm. The Remote Throttle configuration will ignore
all of the cab controls. An On/Off switch for the
dedicated PTO is required. Refer to Illustration 27.
31
g00625394
Illustration 25
Cab Switches PTO configuration
g00625393
Illustration 26
Remote Switches PTO configuration
32
g00625391
Illustration 27
Remote Throttle PTO configuration
One Speed Control with One Circuit Variable Speed Control that uses an
Two Speed Control with Three Circuits that is equipped with an Accelerator Position Sensor
Speed and the PTO TEL. The following components Dedicated Switch Inputs
are required: PTO On/Off Switch, PTO Interlock
Switches, Cruise Control or Remote Set/Resume This function can be used in conjunction with other
Switch, and PTO Switch On Lamp(s). features that are used to control engine speed. The
Variable Speed Control that uses
Remote Switches switch for the PTO Engine RPM Set Speed A.
The switch for the PTO Engine RPM Set Speed B
The following components are required: PTO On/Off can be used in addition to the switch for the PTO
switch, PTO interlock switches, PTO Set/Resume Engine RPM Set Speed A.
switch, and PTO switch On lamp
33
Engine RPM Control That Uses Switches Installation Questionnaire

Instead of a Control That Uses An
Refer to the C-10, C-12, 3406E, C-15, C-16 Truck
Accelerator Position Sensor Engines Electronic PTO Installation and Applications
Service Manual, PTO Parameters - Program for
This function uses switches in order to control
the installation and programming that is based on
engine rpm. Switches are also recommended if
the information on the Questionnaire Response.
the operator of the PTO will be frequently varying
the engine rpm. Switches are recommended if the
operator of the PTO will not have a free hand or a
free foot in order to operate the accelerator.
Recommended Information for

Operator of the PTO
of the engine and the components for the PTO
operation. Ensure that the operator understands the
operation before attempting to install the switches
before the parameters are programmed. The
installation questionnaire will make the installation
easier to understand. The installation questionnaire
are needed.
Question (1) through question (8) should be

The remaining questions may be asked after the
installation is completed. This will help to fine tune
Refer to the information for programmable
parameters that is found in Programmable
Parameters Available Ranges, Options, and
Default Settings. For more information, refer to
Electronic Truck Engines. Also refer to Special
Publication, LEBT9390, Electrical and Electronic
Application and Installation Guide.
Complete the following information once the

installation is complete:

Operator of the PTO

The information that is recorded should be explained

recorded should be left in the cab glove box. This
will allow the operator of the PTO to review the
configuration of the truck and the PTO. This will
allow the service technician to troubleshoot any
suspected problems that relate to the installation.
34
Table 3
Questions Response
PTO.
the PTO.
varying engine rpm.
be used.
required.
to the ON position.
equipment.
problems.

(continued)
35

Truck Manufacturer Input Number 5 (Ignore
JUL99 and newer Brake/Clutch Switch)
Personality Modules
Input Number 7 (PTO
Vehicle Speed Parameters Engine RPM Set Speed
A)
Vehicle Speed Limit
Input Number 19 (PTO
Cruise Control Parameters Engine RPM Set Speed
Low Cruise Control Speed B)
Set Limit
High Cruise Control
Speed Set Limit
Configuration
Idle Parameters
Idle RPM Limit
(rpm/sec)
Idle/PTO Bump RPM
Fast Idle RPM 1
Fast Idle RPM 2
PTO Configuration
PTO TEL
PTO Engine RPM Set
Speed
PTO Engine RPM Set
Speed A
PTO Engine RPM Set
Speed B
PTO to Set Speed
PTO Cab Controls RPM
Limit
Torque Limit
PTO Shutdown Time
Fan

TEL
Low Idle Engine RPM
Transmission Style
Input Selections
Input Number 4 (Torque
Limit Switch)
(continued)
36

PTO
Table 5
Question Response
operation.
return to low idle.
the switch.
necessary.
position.
is active.
Refer to the C-10, C-12, 3406E, C-15, and
C-16 Truck Engines Electronic PTO Installation
complete: and Applications Service Manual, The Four
Programmable PTO Configurations for the
installation and programming that is based on
the information on the Questionnaire Response.

37
g00720254
Illustration 28
(1) Torque limit switch (5) PTO Set RPM Increase/Set RPM (8) PTO Engine RPM Set Speed A On/Off
(2) Ignore/Normal Brake/Clutch switch Decrease switch switch
(3) PTO On/Off switch (6) PTO accelerator assembly (9) PTO Engine RPM Set Speed B On/Off
(4) PTO switch On lamp (7) PTO switch On lamp switch
38
i01362670
SMCS Code: 1000
Understanding Programmable
Engine RPM Limits
There are three programmable engine rpm limits
that are available.
Top Engine Limit (TEL) The TEL is used while

the vehicle is being driven on the road. The TEL
determines the maximum rpm when the PTO On/Off
Switch is in the OFF position.
Idle RPM Limit The Idle RPM Limit is the

maximum of the engine rpm limit if the engine rpm
is established by using the Cruise Control On/Off
Switch and the Cruise Control Set/Resume Switch.
The programmable range of the Idle RPM Limit is
from 700 rpm to the TEL in one rpm increments.
The minimum programmable Idle RPM Limit is
determined by the programmed Low Idle Engine
RPM. The maximum programmable Idle RPM Limit
is limited by the TEL.
PTO TEL The PTO TEL is the maximum engine

rpm limit when the PTO On/Off switch is ON. The
PTO TEL has a programmable range from 700 rpm
to the TEL in one rpm increments. The minimum
programmable PTO TEL is actually determined
by the programmed Low Idle Engine RPM. The
maximum programmable PTO TEL is the TEL.
Available Ranges, Options,

and Default Settings for the
Table 6
Rating Number Engine Power Dependent -

Vehicle ID 17 Characters are Available. 00000000000000000
ECM Wireless Comunications Enable NO or YES NO
Vehicle Speed Calibration 2485 to 93226 pulses/km 8696 pulses/km (14000 pulses/mile)
(4000 to 150000 pulses/mile) The value is not programmed.
Vehicle Speed Limit 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
(continued)
39
(Table 6, contd)
VSL Protection 1300 to the TEL TEL
Tachometer Calibration 12.0 to 500.0 134.0
pulse/revolution pulse/revolution
Soft Vehicle Speed Limit NO or YES NO
Low Cruise Control Speed Set Limit 24 to 204 km/h (15 to 127 mph) 204 km/h (127 mph)
High Cruise Control Speed Set Limit 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
Engine Retarder Mode Coast, Latch, or Manual Manual
Engine Retarder Minimum VSL Type Hard Limit or Soft Limit Hard Limit
Engine Retarder Minimum Vehicle 0 to 204 km/h (0 to 127 mph) 0 km/h (0 mph)
Speed
Auto Retarder in Cruise 0 to 16 km/h (0 to 10 mph) 0 km/h (0 mph)
0 km/h (0 mph) is OFF.
Auto Retarder in Cruise Increment 0 to 8 km/h (0 to 5 mph) 3 km/h (2 mph)
Cruise/Idle/PTO Switch Configuration Set/Accel or Set/Decel Set/Accel
SoftCruise Control YES or NO YES
Idle Parameters
Idle RPM Limit 600 to TEL TEL
Idle/PTO RPM Ramp Rate 5 to 1000 50 rpm/sec
rpm/sec
PTO Configuration OFF OFF
Cab Switches
Remote Throttle
Cab Switches
Remote Switches
PTO TEL 600 rpm to TEL TEL
PTO Engine RPM Set Speed Low Idle to PTO TEL 0 rpm
0 rpm is OFF.
PTO Engine RPM Set Speed A Low Idle to PTO TEL 0 RPM
PTO Engine RPM Set Speed B Low Idle to PTO TEL 0 RPM
PTO Cab Controls RPM Limit TEL TEL
Low Idle
PTO TEL
Torque Limit 270 Nm (200 lb ft) To Rated Torque 3400 Nm (2500 lb ft)
0 rpm is OFF.
(continued)
40
(Table 6, contd)
Lower Gears Engine RPM Limit 1100 rpm to TEL TEL
Intermediate Gears Engine RPM Limit 1100 rpm to TEL TEL
Gear Down Protection RPM Limit 1300 rpm to TEL TEL
Gear Down Protection Turn On Speed 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
TEL Dependent upon the Engine and the Dependent upon the Engine and the
Rating Rating
TEL with Droop NO or YES NO
Transmission Style Manual Manual
Automatic Option 1
Automatic Option 2
Automatic Option 3
Automatic Option 4
Eaton Top 2
Eaton Top 2 Override with Cruise NO or YES NO
Switch
Top Gear Ratio 0.000 to 3.750 0.000
Top Gear Minus One Ratio 0.000 to 3.750 0.000
Top Gear Minus Two Ratio 0.000 to 3.750 0.000
Timer Parameters
Idle Shutdown Time 3 to 1440 minutes 0 minutes
0 is OFF.
Allow Idle Shutdown Override YES YES
NO
Outside Temp Based
J1587 Outside Temp Based
Minimum Idle Shutdown Outside Temp 40 to 49C (40 to 120F) 49C (120F)
Maximum Idle Shutdown Outside 40 to 49C (40 to 120F) 49C (120F)
Temp
A/C Switch Fan On-Time 1 to 600 seconds 0 seconds
0 is OFF.
Fan with Engine Retarder in High YES or NO NO
Mode
Engine Retarder Delay 0.0 to 3.0 seconds 0.0 seconds
Engine Monitoring Mode OFF Warning
Warning
Derate
Shutdown
Coolant Level Sensor NO NO
4-Pin
Engine Oil Pressure Sensor Installed Not Installed
Not Installed
Maintenance Indicator Parameters
(continued)
41
(Table 6, contd)
Maintenance Indicator Mode OFF OFF
Manual distance
Manual hour
Automatic distance
Automatic hour
PM1 Interval 8050 to 56325 Kilometers 24140 Kilometers (15000 Miles)
Refer to the Operation and Maintenance (5000 to 35000 Miles) 300 Hours
Manual, Maintenance Schedule. 100 to 750 Hours
Engine Oil Capacity 19 to 57 L (20 to 60 qt) C-10: 34 L (36 qt)
C-12: 34 L (36 qt)
3406E: 38 L (40 qt)
C-15: 38 L (40 qt)
C-16: 38 L (40 qt)
Trip Parameters
Fuel Correction Factor -63.5 to 63.5 0
Dash-Change Fuel Correction Factor YES or NO NO
Dash-PM1 Reset YES or NO NO
Dash-Fleet Trip Reset YES or NO NO
Dash-State Selection YES or NO YES
Theft Deterrent System Control YES or NO NO
Theft Deterrent Password Four Characters
(The characters must be uppercase
letters.)
Quick Stop Rate 5 to 24 km/h/s 0 km/h/s
(0 is OFF.) (3 to 15 mph/s) (0 mph/s)
Input Selections
Fan Override Switch None None
J1/P1:7, J1/P1:47, J1/P1:6, J1/P1:46
Ignore Brake/Clutch Switch None None
J1/P1:47
Torque Limit Switch None None
J1/P1:7
Diagnostic Enable None None
J1/P1:47
Remote PTO Set Switch None J1/P1:58
J1/P1:58
Remote PTO Resume Switch None J1/P1:58
J1/P1:60
Two Speed Axle Switch None None
J1/P1:6
Cruise Control On/Off Switch J1/P1:59 J1/P1:59
Cruise Control Set/Resume Switch J1/P1:35 and J1/P1:44 J1/P1:35 and J1/P1:44
Clutch Pedal Position Switch J1/P1:22 J1/P1:22
Retarder Off/Low/Medium/High Switch J1/P1:23 and J1/P1:40 J1/P1:23 and J1/P1:40
Service Brake Pedal Position Switch 1 J1/P1:45 J1/P1:45
Accelerator Pedal Position J1/P1:66 J1/P1:66
Output Selections
(continued)
42
(Table 6, contd)
Engine Running Output None None
J1/P1:10, J1/P1:12, J1/P1:13
Engine Shutdown Output None None
J1/P1:10, J1/P1:12, J1/P1:13
Auxiliary Brake None None
J1/P1:12
PTO Switch On Lamp J1/P1:30 J1/P1:30
Fan Control Type On/Off None
NONE
Passwords
Customer Password 1 8 Characters are available.
Customer Password 2 8 Characters are available.
Data Link Paramters
Powertrain Data Link OFF OFF
J1922, J1939
J1922 and J1939
43
Troubleshooting Section i01368633
0030-13 PTO Throttle Sensor

Calibration (29)
Troubleshooting with a
SMCS Code: 1913-038; 1913
Diagnostic Code
i01368614
The PTO Configuration is a Customer Parameter.
0030-08 Invalid PTO Throttle The PTO Configuration is programmed to Remote
Throttle. The duty cycle of the PTO Accelerator
Signal (29) signal is less than 5 percent or more than 95
percent.
SMCS Code: 1913-038; 1913
System Response:
The PTO Configuration is a Customer Parameter. engine to low idle when the problem is detected.
Throttle. The ECM is not receiving a correct PTO Service Tool Display or Lamps The Service Tool
accelerator signal. will indicate 0 percent Throttle Position for the PTO
Note: If the PTO Configuration is programmed to Diagnostic Code is Active.
signal from the Remote Accelerator Position Sensor Engine Response The engine will remain at low
at all times. The remote throttle signal must be idle while the Diagnostic Code is Active.
the OFF position. Troubleshooting:
System Response: Note: The Remote Accelerator Pedal Position
Sensor can not be calibrated.
engine to low idle when the problem is detected. Perform the following diagnostic procedure:
Service Tool Display or Lamps The Service Tool Test
Accelerator Sensor Status parameter while the Results:
OK STOP.
i01225477
Troubleshooting:
0071-14 PTO Shutdown Timer
The diagnostic code is probably caused by an Occurrence (47)
open circuit in the Accelerator Pedal Position Signal
circuit or an open circuit in the 12 volt sensor supply SMCS Code: 1900
frequency can also cause this code. Conditions Which Generate This Code:
Perform the following diagnostic procedure: The timer for the PTO has expired and the engine
Remote PTO Accelerator Position Sensor Circuit - has shut down.
Test
Results: does not represent an Electronic System fault.
OK STOP. System Response:
Electronic System Response The ECM remains

44

code.
Troubleshooting:

Shutdown Timer - Test
Results:
OK STOP.
45
Diagnostic Functional With OCT99 and newer Personality Modules, an

additional parameter can be programmed to allow
Tests the timer to be reset above a specified engine
speed. When the parameter for the PTO Shutdown
Timer Maximum RPM is programmed to a value
i01328987 below the Top Engine Limit, the timer can be reset
PTO Shutdown Timer - Test by increasing engine rpm above a programmed
limit. The timer will stay reset until engine rpm drops
below the programmed value. At this point, the timer
SMCS Code: 1900-038
will begin to count again. The factory default setting
of 2120 rpm (Top Engine Limit) disables this feature.
Use this procedure under the following situation: Test Step 1. Verify Activation Of The PTO
Shutdown Timer.
Shutdown is operating correctly. A. Connect an Electronic Service Tool to the Cab
Data Link Connector.
to this procedure: B. Access the Customer Parameters on the
PTO Shutdown Timer display screens in order:
A programmable parameter for the PTO Shutdown Service

Timer is provided. This timer will shut down the
engine when all of the following conditions are met: Configuration
a. Record the programmed PTO Shutdown Time.
The PTO Shutdown Time that is programmed The PTO Shutdown Time must be between 3
has expired.
and 1440 minutes. If the PTO Shutdown Time
Parameters.
C. Start the engine. Allow the engine to warm up
The PTO On/Off Switch is ON and the ECM is in Allow the engine to operate at the programmed
the Dedicated PTO Mode.
devices.
The engine is not in the Cold Mode.
During the last 90 seconds of the PTO Shutdown D. Ensure that all unnecessary loads are turned
Timer, the Check Engine Lamp will begin flashing. OFF.
If the vehicle is equipped with a PTO Switch On
Lamp, the PTO Switch On Lamp will begin flashing E. Use the following procedure in order to check
during the last 90 seconds. the operation of the PTO Shutdown:
If the PTO Shutdown Timer is activated and the a. Park the vehicle.
timer stops the engine, the following event code
will be generated. b. Ensure that the PTO Configuration is
71-14 PTO Shutdown Timer Occurrence (47)
Note: Fuel rates are not monitored while the PTO c. Ensure that the status of the PTO On/Off
Shutdown Timer is active. Shutdown will occur Switch is ON.
regardless of load. Unlike the Idle Shutdown Timer,
the PTO Shutdown Timer cannot be overridden by d. Observe the status of the PTO Shutdown.
using the clutch pedal or the brake pedal.
Note: With OCT99 and Newer Personality Modules,
a PTO Shutdown Timer Maximum RPM can be
programmed in order to allow the timer to be reset
by increasing engine RPM above the programmed
limit. Ensure that the accelerator is not being
depressed in order to increase rpm beyond the
programmed limit.
46
Result 1 The status of the parameter for PTO Result 1 The Driver Alert Function of the PTO
Shutdown indicates COUNTING. Shutdown operates in the manner that is described
above.
conditions for activation of the timer. Result 2 The PTO Switch ON Lamp did not Flash.
Results: Result 3 The Check Engine Lamp did not Flash.
Result 1 The ECM is reading the proper Results:

conditions for the activation of the PTO Shutdown
Timer. Proceed to test step 2. Result 1 The PTO Shutdown timer is operating
properly. Clear all diagnostic codes. STOP.
Result 2 PTO Switch ON Lamp did not flash
Test Step 2. Verify The Driver Alert during the driver alert.
Function Of The PTO Shutdown.
A. Connect an Electronic Service Tool to the Cab procedure: Troubleshooting, PTO Switch ON
Data Link Connector. Lamp Circuit - Test
B. Use the following procedure in order to activate STOP.

the PTO Shutdown Timer:
Result 3 The Check Engine Lamp did not flash
a. Access the Customer Parameters on the during the driver alert.
display screens in order: Repair: Perform the following diagnostic
procedure:
Service
Configuration Test
b. Record the programmed PTO Shutdown Time. STOP.

The PTO Shutdown Time must be between 3
and 1440 minutes. If the PTO Shutdown Time Test Step 3. Check The State Of The
is programmed to 0, the timer is disabled. Related Conditions When The Vehicle Is
Parked.
c. Reprogram the PTO Shutdown Time to 3
minutes for this test. A. Check the state of the following related conditions
when the vehicle is parked:
C. Observe the following items during the 90 second
period before the programmed shutdown time: a. Ensure that the vehicle speed is 0 km/h
(0 mph) on the Electronic Service Tool or the
Check Engine Lamp Dash Display.
Status of the PTO Shutdown Timer b. Ensure that the engine is not in Cold Mode.
PTO Switch ON Lamp Note: The Electronic Service Tool Status Screen will
indicate if the Cold Mode is Active.
During the 90 second period before the
scheduled shutdown, the status should change c. Ensure that the PTO On/Off Switch is ON.
Check Engine Lamp and the PTO Switch On Expected Result:
Lamp should flash rapidly.
Result 1 Vehicle speed is not indicated as 0 km/h
Note: A PTO Switch ON Lamp is an optional feature (0 mph).
and the PTO Switch ON Lamp may not be installed.
Result 2 The Electronic Service Tool Status Screen
D. Reprogram the PTO Shutdown Timer to the value indicates that the engine is in the Cold Mode.
that was recorded earlier for this test.
47
Result 3 The PTO On/Off Switch is not ON. When the ECM is in the Dedicated PTO mode the
Exhaust Brake is disabled and the PTO Top Engine
Results: Limit (TEL) and the torque limit are activated. The
engine may proceed directly to the PTO Engine
Result 1 Continue by testing the Vehicle Speed rpm Set Speed if the parameter is programmed. If a
Circuit. PTO Switch ON Lamp is connected to the OUTPUT
1, the PTO Switch ON Lamp will turn ON whenever
Repair: Perform the following diagnostic the PTO On/Off circuit is ON.
Circuit - Test With OCT99 and newer Personality Modules,
OUTPUT 1 can also be selected for use as a Low
STOP. Coolant Level Warning Lamp. If OUTPUT 1 is used
for a Warning Lamp, OUTPUT 1 will not be used for
Result 2 The engine must not be in Cold Mode the PTO. Refer to Troubleshooting, Warning Lamp
operation while this test procedure is being Circuit - Test for details.
performed. Allow the engine to run until the
coolant temperature exceeds 38 C (100 F). If the problem is with undetermined PTO kickouts,
Troubleshoot and repair any related conditions. use the following procedure:
STOP.
Operate the vehicle in PTO mode.
Result 3 Continue by testing the PTO On/Off
Switch Circuit. After the kickout, review the Electronic Service
Repair: Perform the following diagnostic kickout status parameter indicates the cause. This
procedure: Troubleshooting, PTO Switch Circuit - must be performed before the Ignition Key Switch
Test is turned OFF. It is important to remember that the
STOP. the ECM has been powered by the Ignition Key
Switch Input.
i01353186
PTO Switch Circuit - Test powered up. If this parameter is blank, No
SMCS Code: 1165-081-ZS blank until the ECM detects the use of the PTO
Mode. Also, this parameter remains blank until the
System Operation Description: ECM detects the disengagement of PTO Mode.
Refer to table 7 in order to interpret the status
Use this procedure under the following situation: screen kickout status parameter.
Use this procedure to determine that the vehicle The following kickout status parameter is available:
wiring and the ECM are functioning properly for the
features of Dedicated PTO. PTO Kickout
The following background information is related PTO Interlocks may also be connected in series with
to this procedure: the PTO On/Off switch. The Interlocks are intended
to prevent the PTO On/Off circuit from activating
INPUT 1 unless certain conditions are met.
The INPUT 1 is used for the PTO On/Off Switch INPUT 2

circuit when the PTO Configuration is programmed
to Cab Switches, Remote Switches or Remote The INPUT 2 is used for the PTO SET/RPM Increase
Throttle. Switch when the PTO Configuration is programmed
When the PTO On/Off circuit is ON, the ECM will be
in Dedicated PTO mode. INPUT 3
The INPUT 3 is used for the PTO Resume/RPM

Decrease Switch when the PTO Configuration
is programmed to Remote Switches or Remote
Throttle.
The PTO Configuration Is Set To Cab Switches.

48
When the PTO Configuration is programmed to Cab The AP Sensor/Switch Sensor Common is
Switches and the PTO On/Off switch is ON, the terminal 5.
following circuits can be used to interrupt a set rpm:
Cruise Control Set/Resume Switch

Service Brake Pedal Position Switch 1
Clutch Pedal Position Switch
Neutral Switch
Cab Switches and the PTO On/Off switch is ON,
the Cab Accelerator Pedal Position Sensor can be
PTO Cab Throttle RPM Limit parameter:
Low Idle
Top Engine Limit
The PTO Configuration Is Set To Remote

Remote Switches or Remote Throttle and the PTO
On/Off switch is ON, the following circuits are
ignored:

Clutch Pedal Position Switch
Neutral Switch
Cab Accelerator Pedal Position Sensor
Cab Cruise Control Set/Resume Switch
A Remote Accelerator Pedal Position Sensor
is connected to the INPUT 8 when the PTO

within the ECM:

49
Table 7
No Engine Speed
Switch Turned Off
circuit condition.
Clutch
No Occurrence
g00644420
Illustration 29
50
g00644427
Illustration 30
g00644448
Illustration 31
Test Step 1. Check The Programming Of Expected Result:

The Dedicated PTO Customer Parameter.
The PTO Configuration is programmed to either Cab
A. Connect an Electronic Service Tool. Switches, Remote Switches, or Remote Throttle.
B. Turn the Ignition Key Switch to the ON position. Results:
C. Access the Dedicated PTO Customer Yes Proceed to test step 2.

the programming of the PTO Configuration
Parameter.
51
No The Dedicated PTO features are not

programmed for this engine. If PTO operation
is desired, the PTO configuration must be
programmed to either Cab Switches, Remote

Installation Setup.
B. Check the cab glove box for any information

regarding the installation of the PTO. It is
function of the PTO Interlocks that are used in
the installation.

necessary.
D. Determine the Schematic that most closely

matches the installation. Review the Schematics
specific PTO Configuration of the truck.
E. Record the PTO Configuration.
Expected Result:
The requirements for the Installation and the

Application have been reviewed.
Results:

52

And Wiring.
g00713728
Illustration 32
A. Thoroughly inspect ECM Connector J1/P1, Terminal 68

connectors that are used by the PTO. Refer to Illustration 32.
Refer to Troubleshooting, Inspecting Electrical C. Check the ECM Connector (Allen Head Screw)
Connectors for details. for the proper torque of 6.0 Nm (55 lb in).
wires in the ECM Connector that are associated pinch points from the sensor to the ECM.
connections should be tested if the connections Expected Result:
are used:
Terminal 3 completely coupled and/or inserted and the harness
Terminal 5 or pinch points.
Terminal 30 Results:
Terminal 35 OK Proceed to test step 4.

Terminal 44 Not OK
Terminal 56 Repair: Perform the following diagnostic
procedure:
Terminal 58
Terminal 60
53
Repair the connectors or wiring and/or replace Result 3 Proceed to Test Step 6.
seals are properly in place and ensure that the Test Step 5. Check Status Of The
connectors are completely coupled. Set/Resume Input On The Electronic
Service Tool.
Note: The Set/Resume Input increases the engine
STOP. rpm and the Set/Resume Input decreases the
engine rpm.
Test Step 4. Check The PTO On/Off
Switch Circuit With An Electronic Service A. Find the PTO Set/Resume Switch. If the PTO
Tool. Configuration is programmed to Cab Switches,
the Cruise Control Set/Resume Switch will be
A. Turn the Ignition Key Switch to the ON position. used. If the PTO Configuration is programmed
to Remote Switches or Remote Throttle, a
B. For the INPUT 1 (PTO On/Off Switch), Access dedicated PTO Set/Resume Switch will be used.
the Electronic Service Tool Status screens that
display the following status parameters: The PTO Configuration is programmed to
Cab Switches.
PTO Configuration
Look at the status of the Cruise Control
PTO ON/OFF Switch Set/Resume Switch parameter on the Electronic
Service Tool. The parameter is located on the
C. Verify that each of the PTO Interlocks are set. same status screen as the Cruise/Idle Switch.
Then, while the Electronic Service Tool status
screen is being monitored turn ON the PTO B. While the Electronic Service Tool status screen
On/Off switch and turn OFF the PTO On/Off for the switch is being monitored, perform the
switch. following procedure in order:
An example of a PTO Interlock would be a Put the Cruise Control Set/Resume Switch in
parking brake that is intended to allow PTO the Set position.
Engine control under specific conditions.
Release the Cruise Control Set/Resume Switch
Expected Result: from the Set position.
Result 1 The status of the PTO On/Off Switch on Put the Cruise Control Set/Resume Switch in
the Electronic Service Tool changes from OFF to the Resume position.
ON when the PTO On/Off Switch is turned OFF and
ON, but the Set/Resume Switch is not operating Release the Cruise Control Set/Resume Switch
correctly. from the Resume position.
Result 2 The status of the PTO On/Off Switch on The PTO Configuration is programmed to
the Electronic Service Tool changes from OFF to ON Remote Switches or Remote Throttle.
when the PTO On/Off Switch is turned OFF and ON.
However, the Remote Accelerator is not operating View the status parameter on the Electronic
correctly. Service Tool for the Remote PTO Set Switch
Result 3 The status of the PTO On/Off Switch on
the Electronic Service Tool DOES NOT change from C. While the Electronic Service Tool status screen
OFF to ON when the PTO On/Off Switch is turned for the switch is being monitored, perform the
OFF and ON. following procedure in order:
Results: Put the Remote PTO Set/Resume Switch in the

Set position.
Release the Remote PTO Set/Resume Switch
Result 2 from the Set position.
Repair: Perform the following diagnostic Put the Remote PTO Set/Resume Switch in the
procedure: Troubleshooting, Remote PTO Resume position.
Accelerator Position Sensor Circuit - Test
Release the Remote PTO Set/Resume Switch
STOP. from the Resume position.
54
Expected Result:

Cab Switches, the status parameter for the Cruise
Control Set/Resume Switch on the Electronic
Service Tool behaves in the following manner:
The status of the Cruise Control Set/Resume

Switch will display OFF when the Set Switch is
released.

Switch changes from OFF to Set Switch ON
when the Switch is moved to the SET position.

Switch changes from Set Switch ON to Resume
Switch ON when the Resume Switch is moved to
the RESUME position.

parameter for the Remote PTO Set Switch behaves
The status of the Remote PTO Set Switch displays

OFF when the Remote PTO Set Switch is released.
The status of the Remote PTO Resume Switch

displays OFF when the Remote PTO Resume
Switch is released.
The status of the Remote PTO Set Switch changes

from OFF to Set Switch ON when the Remote PTO
Set Switch is moved to the SET position.
The status of the Remote PTO Resume Switch

changes from OFF to Resume Switch ON when
the Remote PTO Resume Switch is moved to the
RESUME position.
Results:
Yes The Set circuit and the Resume circuit

No (Programmed to Cab Switches) The PTO

No (Programmed to Remote Switches or Remote

Throttle) The PTO Configuration is programmed
to Remote Switches or Remote Throttle. Proceed
to test step 8.
55
Test Step 6. Check The Status Of The

Service Tool.
g00644480
Illustration 33
A. Turn the ignition key switch to the OFF position. Results:
B. Fabricate a jumper wire 100 mm (4 inch) long. Yes The INPUT 1 (PTO On/Off Switch) of the
Crimp a Deutsch Pin to both ends of the wire. ECM is functioning correctly. The problem is in
C. Disconnect Vehicle Harness Connector P1 from the wiring of the vehicle.
the ECM.
D. Connect a 70-Termial Breakout T to ECM following options:
Connector J1 and connect P1 to the Breakout T.
E. Connect an Electronic Service Tool to the Cab
data link connector. Send the vehicle to the OEM dealer for repair.
F. Turn the ignition key switch to the ON position. Verify that the repair eliminates the problem.
G. Access the PTO On/Off Switch status on the STOP.

H. While the switch status is being observed on the change.
Breakout T in order to connect terminal 56 (Input Repair: Perform the following diagnostic
1) to terminal 3 (Input Sensor Common #2). procedure:
The Input 1 is the PTO On/Off Switch. 1. Temporarily connect a test ECM.
Refer to Illustration 33. 2. Ensure that the PTO Configuration of the test
Expected Result: suspect ECM.
The switch status of the PTO On/Off Switch on 3. Remove all jumpers and replace all connectors.
manner: 4. Recheck the system for Active diagnostic
codes.
The switch status is OFF when the jumper is
removed. 5. Repeat the test step.
The switch status changes from OFF to ON when 6. If the problem is resolved with the test ECM,
the jumper is in place. reconnect the suspect ECM.

replace the ECM.
56
STOP.

Cruise Control Set/Resume Switch On
g00713811
Illustration 34
A. Turn the ignition key switch to the OFF position. I. While the switch status is being observed on the
Electronic Service Tool, install the jumper into the
B. Fabricate a jumper wire 100 mm (4 inch) long. Breakout T. This connects terminal 44 (RESUME)
Crimp a Deutsch Pin to both ends of the wire. to terminal 5 (AP SENSOR/SWITCH SENSOR
COMMON). Also, while the switch status is
C. Disconnect Vehicle Harness Connector P1 from being observed on the Electronic Service Tool,
the ECM. remove the jumper from the Breakout T. This will
disconnect terminal 44 (RESUME) from terminal
D. Connect a 70-Termial Breakout T to ECM 5 (AP SENSOR/SWITCH SENSOR COMMON).
Connector J1 and connect P1 to the Breakout T.
E. Connect an Electronic Service Tool to the Cab
data link connector. Expected Result:
F. Turn the ignition key switch to the ON position, The switch status of the Cruise Control Set/Resume
while the engine is OFF. Switch on the Electronic Service Tool behaves in
G. Access the Cruise Control Set/Resume Switch
status on the Electronic Service Tool. The switch status of the Cruise Control
Set/Resume Switch is OFF when the jumper is
H. While the switch status is being observed on the removed.
Breakout T in order to connect terminal 35 (SET) The switch status of the Cruise Control
to terminal 5 (AP SENSOR/SWITCH SENSOR Set/Resume Switch changes from OFF to Set
COMMON). Also, while the switch status is Switch ON when the jumper is connected
being observed on the Electronic Service Tool from terminal 35 (SET) to terminal 5 (AP
remove the jumper from the Breakout T in order SENSOR/SWITCH SENSOR COMMON).
to disconnect terminal 35 (SET) from terminal 5
(AP SENSOR/SWITCH SENSOR COMMON). The switch status of the Cruise Control
Set/Resume Switch changes from OFF to Resume
Switch ON when the jumper is connected from
terminal 44 (SWITCH RESUME TERMINAL)
to terminal 5 (AP SENSOR/SWITCH SENSOR
COMMON).
57
Results:
Yes The Set Input and the Resume Input of the


following options:

STOP.

change.

procedure:

suspect ECM.
4. Recheck the system for Active diagnostic

codes.


replace the ECM.
STOP.

Remote PTO Set Switch And The Remote
58
PTO Resume Switch On The Electronic

Service Tool.
g00644513
Illustration 35
A. Turn the ignition key switch to the OFF position. The Input 2 is the set switch for the PTO and the
Input 3 is the resume switch for the PTO.
Crimp a Deutsch Pin to both ends of the wire. Refer to Illustration 35.
C. Disconnect Vehicle Harness Connector P1 from Expected Result:

the ECM.
D. Connect a 70-Termial Breakout T to ECM the Electronic Service Tool behaves in the following
Connector J1 and connect P1 to the Breakout T. manner:
E. Connect an Electronic Service Tool to the Cab The switch status of the Remote PTO Set Switch
data link connector. is OFF when the jumper is removed.
F. Turn the ignition key switch to the ON position. The switch status of the Remote PTO Set Switch
changes from OFF to Set Switch ON when the
G. Access the Remote PTO Set Switch and Remote jumper is connected from terminal 58 (INPUT 2)
PTO Resume Switch status on the Electronic to terminal 3 (INPUT SENSOR COMMON #2).
Service Tool.
H. While the Remote PTO Set Switch status is Switch on the Electronic Service Tool behaves in
being observed on the Electronic Service Tool, the following manner:
install the jumper into the Breakout T in order
to connect terminal 58 (INPUT 2) to terminal The switch status of the Remote PTO Resume
3 (INPUT SENSOR COMMON #2). Also, while Switch is OFF when the jumper is removed.
the switch status is being observed on the
Electronic Service Tool remove the jumper from The switch status of the Remote PTO Resume
the Breakout T in order to disconnect terminal Switch changes from OFF to Resume Switch
58 (INPUT 2) from terminal 3 (INPUT SENSOR ON when the jumper is connected from terminal
COMMON #2). 60 (INPUT 3) to terminal 3 (INPUT SENSOR
COMMON #2).
I. While the Remote PTO Resume Switch status is
being observed on the Electronic Service Tool, Results:
install the jumper into the Breakout T in order
to connect terminal 60 (INPUT 3) to terminal Yes The Input 2 (Remote PTO Set) and the
3 (INPUT SENSOR COMMON #2). Also, while Input 3 (Remote PTO Resume) of the ECM
the switch status is being observed on the are functioning correctly. The problem is in the
Electronic Service Tool remove the jumper from switches of the vehicle or the problem is in the
the Breakout T in order to disconnect terminal wiring of the vehicle.
60 (INPUT 3) from terminal 3 (INPUT SENSOR
COMMON #2).
59
Repair: Inspect the wiring. Select one of the Output 1 (terminal 30) is dedicated for use as
following options: a PTO Switch ON Lamp output with Personality
Modules that are older than OCT99. If the PTO
Repair the wiring or replace the wiring. Configuration is programmed to Cab switches,
Remote Switches, or Remote Throttle, the Output
Send the vehicle to the OEM dealer for repair. will turn the lamp ON whenever the PTO Switch
Circuit is turned ON.
With OCT99 and newer Personality Modules, the
STOP. Output 1 (terminal 30) can be used as a PTO Switch
On Lamp output or a Low Coolant Level Warning
No The ECM is not reading the switch status Lamp output. Customer parameter programming
change. determines the desired usage. If the Engine
Monitoring Lamps parameter is programmed to
Repair: Perform the following diagnostic Option 1 and the Coolant Level Sensor parameter
procedure: is programmed to 4-Pin, then Output 1 is used as a
Low Coolant Level Warning Lamp output. Otherwise,
1. Temporarily connect a test ECM. Output 1 can be used as a PTO Switch On Lamp
output. This output was used with Personality
2. Ensure that the PTO Configuration of the test Modules that are older than OCT99.
suspect ECM. Electrical Connection of Lamps
3. Remove all jumpers and replace all connectors. One terminal of the PTO Switch ON Lamp must be
connected to battery voltage through the vehicle
4. Recheck the system for Active diagnostic wiring. The other terminal is connected to the ECM
codes. at the Vehicle Harness Connector J1/P1 at terminal
30.
6. If the problem is resolved with the test ECM, the lamp ON.

replace the ECM.
STOP.
i01329182

- Test
SMCS Code: 7431-081

60
g00703413
Illustration 36
g00668646
Illustration 37
Test Step 1. Inspect Electrical Connectors Refer to Illustration 37.

And Wiring.
A. Thoroughly inspect ECM Vehicle Harness for the proper torque of 6.0 Nm (55 lb in).
Connector J1/P1, the firewall bulkhead
connector, or the PTO Switch ON Lamp. D. Check the harness and wiring for abrasion and
Refer to Troubleshooting, Inspecting Electrical pinch points from the battery to the ECM.

with the PTO Switch ON Lamp.
61
Expected Result:

or pinch points.
Results:

Not OK
STOP.

Of The PTO Switch ON Lamp.
A. Use the following procedure for the Output 1
(PTO Switch ON Lamp).
Connect an Electronic Service Tool. Access

the status screen that displays the PTO
Configuration and the PTO ON/OFF Switch. The
PTO Configuration must indicate Cab Switches,
Remote Switches, or Remote Throttle. The PTO
Configuration is not programmed to turn the
PTO Switch ON Lamp to the ON position if the
PTO Configuration indicates OFF.
If the Engine Monitoring Lamps parameter is

programmed to Option 1 and the Coolant Level
Lamp parameter is programmed to 4-Pin, then
Output 1 will not function as a PTO Switch On
Lamp. Refer to Troubleshooting, Warning Lamp
Circuit - Test.
While the PTO Switch ON Lamp and the status

of PTO ON/OFF Switch is being watched on
the Electronic Service Tool, turn the PTO On/Off
The PTO Switch ON Lamp should turn ON when
the PTO Switch ON Lamp should turn Off when
Expected Result:
The Lamp turns ON and the Lamp turns OFF per

the above description.
Results:

at this time. STOP.
No Proceed to test step 3.

62

Lamp Circuit.
g00668711
Illustration 38
A. Disconnect ECM Vehicle Harness Connector Result 2 The lamp did not turn ON. The
J1/P1. vehicles lamp circuit is not functioning properly.
B. Fabricate a jumper wire 100 mm (4 inch) long. problem in the wiring from the cab to either the
Crimp a Deutsch Pin to both ends of the wire. ECM or the +Battery connection. Repair the lamp
C. Insert the jumper into terminal 30 of connector repairs. STOP.
P1.
Result 3
terminal 65 (-BATTERY). Repair: Perform the following diagnostic
procedure:
E. Turn the Ignition Key Switch to the ON position.
F. While the lamp is being watched, insert the shorted to chassis ground. Repair the circuit or
jumper wire and remove the jumper wire. send the vehicle to the OEM dealer for repairs.
Refer to Illustration 38. STOP.
Expected Result:
Result 1 The PTO Switch On Lamp turns ON while

the jumper is connected to both sockets. Also, the
PTO Switch On Lamp turns OFF when the jumper is
Result 2 The suspect lamp does not turn ON while

Result 3 The lamp will stay ON while the ECM

Results:
Result 1 The PTO Switch ON Lamp circuit is

63

PTO Switch On Lamp.
g00642533
Illustration 39
A. Disconnect ECM Vehicle Harness Connector Results:

J1/P1.
B. Insert a 70-Terminal Breakout T between ECM problem in the vehicle wiring or the lamp. STOP.
Vehicle Harness Connector J1 and ECM Vehicle
Harness Connector P1. No
C. Connect one probe of the voltage test lamp Repair: Temporarily connect a test ECM. Ensure
to terminal 65 (-BATTERY). Connect the other that the PTO Configuration of the test ECM
probe of the voltage test lamp to terminal 52 matches the PTO Configuration of the suspect
(UNSWITCHED +BATTERY) of the Breakout T. ECM. Check the ECM operation of the PTO Switch
ON Lamp when the test ECM is installed. If the
D. The test lamp should turn ON. If the test lamp problem is resolved with the test ECM, reconnect
does not turn on, either the test lamp is faulty or the suspect ECM. If the problem returns with the
the wiring to the ECM is faulty. Continue with this suspect ECM, replace the ECM.
STOP.
E. Leave the voltage test lamp probe connected to
terminal 52 (UNSWITCHED +BATTERY).
i01334712

terminal 30 (Output 1) of the Breakout T.
Remote PTO Accelerator
SMCS Code: 1913
following display screens in order: System Operation Description:
Diagnostics Use this procedure under the following situation:
Diagnostic Test Use this procedure if any of the following Diagnostic

Codes are indicated:
Special Test
30-08 Invalid PTO Throttle Signal (29)
Lamp. Observe the voltage test lamp. The lamp 30-13 PTO Throttle Sensor Calibration (29)
should turn ON when the test is Active. Also, the
lamp should turn OFF when the test is inactive. Also, use this procedure if the Remote PTO
Accelerator Position Sensor is suspected of
Expected Result: improper operation.
The test lamp turns ON and the test lamp turns OFF Remote PTO Accelerator Position Sensor
64
Position Sensor must be used for the Remote PTO This prevents the engine from experiencing
Accelerator Position Sensor, and the +8 V version unexpected acceleration or sudden acceleration
for the Cab Accelerator Pedal Position Sensor. when the PTO ON/OFF circuit is turned ON. The
The ECM will not respond to the Remote PTO Idle before the ECM will respond. The ECM must
Accelerator Position Sensor if there is a 253-02 also see a transition from the OFF position to the ON
Check Customer or System Parameters (56) Active position in the PTO ON/OFF Switch in order to allow
Diagnostic Code under some conditions. Refer to the other PTO speed control functions to operate. If
Troubleshooting, ECM Memory - Test if there is a the engine is started with the PTO ON/OFF Switch
253-02 Check Customer or System Parameters (56) in the ON position, the accelerator will respond. The
Active Diagnostic Code. response will occur only if the accelerator pedal
The Remote Accelerator Pedal Position Sensor is speed control functions will not respond.
used to provide a throttle position signal to the ECM.



Sensor can be replaced separately from the Pedal
must be replaced.
If the vehicle is using the ECM Dedicated PTO

mode and the PTO Configuration is programmed
to the following setting:
Remote Throttle
65
g00642017
Illustration 40
66
g00642018
Illustration 41
Sensor:
D. Check the ECM Connector (Allen Head Screw)

67
Repair the connectors or wiring and/or replace Test Step 3. Check the Supply Voltage
the connectors or wiring. Ensure that all of the for the Remote PTO Accelerator Position
seals are properly in place and ensure that the Sensor.
B. Measure the voltage at terminal A (+12 V) with
STOP. reference to terminal B (sensor common) at the
connector J406. This connector is for the Remote
Test Step 2. Check for Active Diagnostic PTO Accelerator Position Sensor.
Codes.
Expected Result:
Data Link Connector. The measured voltage is between 11.0 VDC and
13.5 VDC.
Results:
C. Monitor the Active Diagnostic Code Screen of
the Electronic Service Tool. Check and record OK Proceed to test step 4.
Active Diagnostic Codes.
Not OK The vehicle wiring or the battery is
Note: When the ECM automatically calibrates new causing the problem. Repair the wiring or the
duty cycle values for the low idle throttle position battery. Replace the wiring or the battery. Perform
and the high idle throttle position the ECM assumes the repair that is necessary. Verify that the repair
22 percent duty cycle at low idle and 75 percent has fixed the problem. STOP.
duty cycle at high idle. As a result, you may notice
that the PTO Throttle Position Status reaches 100 Test Step 4. Check The Duty Cycle Of The
percent well before the remote PTO accelerator Accelerator Pedal Position Sensor.
pedal is fully depressed. This is normal. After
some cycling of the accelerator pedal to the high A. Turn the Ignition Key Switch to the ON position.
idle position, the ECM will adjust the calibration
automatically. The ECM will adjust the calibration B. Monitor the Duty Cycle of the PTO Throttle
automatically provided that the high idle stop Sensor on the Electronic Service Tool. Access
position is within the 75 to 90 percent duty cycle the following display screen in order:
range, and the low idle is in the 10 to 22 percent
duty cycle range. During normal operation, you Service
may notice that more movement of the remote PTO
accelerator pedal is required for the PTO Throttle Calibrations
Position status to increase above 3 percent. You
may also observe that the status reaches the 100 Monitor Throttle Position Sensor
percent value prior to the limit of the high idle
position. This is done in order to ensure that the Expected Result:
accelerator reaches these two critical points for
engine operation. The Duty Cycle is between 10 and 22 percent with
Result 1 Diagnostic Code 30-08 or 30-13 is Active. High Idle position.
Result 2 There are NO Active Diagnostic Codes that Results:

are related to the Accelerator Pedal Position Sensor
Circuit at this time, but a problem is suspected with Yes The Remote PTO Accelerator Pedal
operation of the Remote PTO Accelerator Pedal Position Sensor is operating correctly. Proceed
Position Sensor Circuit. to test step 5.
Results: No The Remote PTO Accelerator Pedal Position

Sensor Circuit is not operating correctly. Proceed
Result 1 Proceed to test step 3. to test step 6.

68
High Idle position.
At The ECM.

69
Assembly.
Expected Result:

High Idle position.
Results:




of abrasion.

of the Breakout T.

Illustration 42.
70
g00642019
Illustration 42


replacement of the Accelerator Assembly. STOP.
71
B. Remove the signal wire for the remote PTO

C. Remove terminal C (Accelerator Pedal Position)

Connector.
D. Route new wiring from the ECM to the Remote

F. Check the Duty Cycle of the Remote PTO

Accelerator Position Sensor with an Electronic
Service Tool while the accelerator pedal
Expected Result:

High Idle position.
Results:

Pedal Position Sensor appears faulty. Permanently
the problem. STOP.
No Double check the wiring, the ECM Vehicle

Connector. If a problem still exists, restart the test
procedure. STOP.
72

Section

i01366850
PTO Parameters - Program

SMCS Code: 1000-591
Installation and Programming That

Is Based on The Questionnaire
Response
Table 8
Question Response
The operator of the PTO needs to control the engine rpm. If the operator of the PTO will be operating the PTO from the
Determine the location on the vehicle. cab, then program the PTO configuration to cab switches.
Determine if the operator of the PTO needs to continually If the operator of the PTO will be outside of the cab,
vary the engine rpm. then program the PTO configuration to either remote
Determine if a foot accelerator is necessary. Determine if a switches or to remote throttle. If the operator of the PTO
hand accelerator is necessary. will be continually varying the engine rpm by using a foot
This determines the programming of the PTO configuration. accelerator or a hand accelerator, then program the PTO
configuration to remote throttle. Otherwise, program the
PTO configuration to remote switches.
If operation of the PTO in the cab or out side of the cab is
required, then the following components are used for the
control of the PTO in the cab: The Cruise Control On/Off
switch, the Cruise Control Set/Resume switch, the Cab
Accelerator Pedal, or the Fast Idle switch are needed.
The remote PTO configuration should be used for outside
cab control. The PTO configuration should be programmed
to either remote switches or remote throttle.
Determine the maximum vehicle speed for the PTO operation. Program the PTO Vehicle Speed Limit to the value that
Determine if the PTO operation requires the use of the clutch is needed. If the PTO is driven by the transmission and
and the service brakes without changing the engine rpm. a high vehicle speed results, then this parameter can be
This determines the programming of the PTO Vehicle set to avoid a disconnection of the vehicle speed circuit.
Speed Limit. This also determines if an additional switch is Refer to the appropriate diagrams for the application if the
necessary in order to prevent the movement of the brake operation requires feathering out the service brakes or the
pedal and the movement of the clutch from returning the clutch in order to adjust the vehicle speed. A set engine
engine rpm to programmed low idle rpm. rpm is also maintained at the same time. Refer to the PTO
Service Manual, Cab Switches with Torque Limiting and
Ignore Brake/Clutch Switch for more information if the
PTO configuration is programmed to cab switches. If the
transmission style is programmed to Automatic Option 3
and Automatic Option 4, and a neutral switch is used, then
necessary measures must be taken in order to prevent the
neutral switch from disengaging the PTO operation when
the transmission is in gear.
Determine the torque value that is maximum for the Program the parameter for the Torque Limit to this value.
equipment when the circuit for the PTO is ON. NOTE: The programmed torque limit is an estimate. To
This determines the programming of the torque limit. determine actual torque output, test the engine on a
dynamometer.
(continued)
73
(Table 8, contd)
Determine if a torque limit is also required for the temporary Refer to the appropriate schematic for the application
protection of equipment. This is determined for the instance if the torque limit is required. This may be required for
when the PTO On/Off Circuit is in the OFF position. the instance when the PTO is OFF. Refer to the PTO
This determines if a Torque Limit switch is necessary. Service Manual, Cab Switches with Torque Limiting and
Ignore Brake/Clutch Switch if the PTO configuration is
programmed to cab switches. If the PTO configuration
is programmed to Remote Switches, then refer to PTO
Service Manual, Remote Switches with Torque Limiting and
Ignore Brake/Clutch Switch.
Determine if one or more fixed engine rpm above low idle is If only one rpm above low idle is required, program the PTO
required. TEL and PTO Engine RPM Set Speed to the same rpm.
Determine the first engine rpm. If two rpm are desired, then program the PTO Engine RPM
Determine the second engine rpm. Set Speed to the first rpm value. Program the PTO TEL to
This determines the programming of the PTO Engine RPM the second rpm.
Set Speed and the PTO TEL parameters for a dedicated Program the PTO to Set Speed to YES if the engine should
PTO. accelerate to the first engine rpm point. This occurs when the
Determine that the engine rpm needs to accelerate to the PTO On/Off switch is turned ON.
first engine rpm at the instant when the PTO On/Off switch NOTE: The PTO Engine RPM Set Speed A and the PTO
is turned ON. Engine RPM Set Speed B is another option. Refer to PTO
This determines the programming of the PTO in relation to Service Manual, Multiple Speed PTO Operation for more
the Set Speed parameter for a dedicated PTO. This also information.
determines if a second switch is required for control of the
engine rpm.
Determine if the control for the engine rpm is required from This requires the use of parameters for a Dedicated PTO
both the cab and outside of the cab. that is operated outside of the cab. The accelerator position
Determine the points for operating speed if control for the sensor that is in the cab, the Cruise Control On/Off Switch,
engine rpm is required in both locations. and the Cruise Control Set/Resume Switch are also needed
for operation from the cab.
Program the Idle RPM Limit for the use of the Cruise
Control Switches. Program the Dedicated PTO parameters
for operation outside the cab.
Determine the engine rpm that is maximum for the PTO in Program the Top PTO Engine RPM Limit to this rpm.
operating conditions. The answer to this question will determine whether the PTO
Determine if the accelerator pedal should have limited rpm. Cab Controls RPM Limit should be programmed to Low
This determines the programming of the Top PTO Engine Idle, TEL, or PTO TEL if the PTO Configuration is
RPM Limit and the PTO Cab Controls RPM Limit. programmed to the Cab Switches.
NOTE: The accelerator pedal is ignored in the PTO.
Determine the necessary time in order for the engine to This parameter may be programmed after demonstrating
accelerate and decelerate to the engine rpm set points and some different settings to the customer.
from the engine rpm set points.
NOTE: Acceleration rates and deceleration rates are
measured in rpm/sec.
This determines the programming of the Idle/PTO Ramp
Rate that is measured in rpm/sec.
Programming the Parameters Programming Provisions

Programming the parameters requires an Electronic The following parameters or the operation of
Service Tool. Customer Passwords are required to the following parameters are affected by other
change the current settings for the programmable parameters.
parameters if the customer passwords have been
set. Availability of some of the parameters depends PTO Configuration The Parameter for the PTO
on the programming of other parameters. Program Configuration must be programmed first in order
the Parameter for the PTO Configuration before to meet the requirements for the PTO Parameters
attempting to program any of the Dedicated PTO that are Dedicated. No other parameter can be
parameters. Failure to program the Parameter programmed first in order to allow programming of
for the PTO Configuration first will cause the other Dedicated PTO Parameters.
remaining Dedicated PTO parameters to display
Unavailable on the Electronic Service Tool PTO TEL The PTO TEL should be programmed
Configuration Screen. above the programmed Low Idle.
74
PTO Engine RPM Set Speed The PTO Engine i01367002

RPM Set Speed disables the Idle/PTO Bump RPM
for the PTO operation. PTO Configurations - Test
PTO Engine RPM Set Speed A Input 7 must SMCS Code: 1000-081; 1165-081
be programmed to PTO Engine RPM Set Speed A
and a dedicated switch must be installed in order The tables that follow list the following information:
for the engine to operate at the desired speed for Sequence of events, Action that is taken by the
this parameter. Operator of the PTO, and Position of the controlling
equipment. The positions produce the resultant
PTO Engine RPM Set Speed B Input 19 must engine RPM within a specific programmed limit. The
be programmed to PTO Engine RPM Set Speed B following components are used in order to provide a
and a dedicated switch must be installed in order demonstration of the interaction of different systems:
for the engine to operate at the desired speed for Cruise Control On/Off switch, PTO On/Off switch,
this parameter. Set/Resume switch, Fast Idle On/Off switch, and
Accelerator Pedal. Most systems will require only
PTO to Set Speed The PTO to Set Speed some of the components.
requires the PTO Engine RPM Set Speed to be
programmed to an engine rpm above low idle. The Note: Before performing each test, reset the
PTO Configuration must be programmed to Cab parameters to the factory defaults. This will ensure
Switches or to Remote Switches. that a parameter that was used for one test is not
active for another test. The parameters that are
PTO Cab Controls RPM Limit The PTO Cab given in the tables must be programmed in order to
Controls RPM Limit is used only if the PTO perform the tests.
The cab accelerator position sensor is always
limited to low idle when the PTO On/Off circuit is ON
and the PTO Configuration has been programmed
Torque Limit The Torque Limit can be

programmed to values above the Rated Torque
of the engine. However, the Rated Torque of the
engine is the maximum torque of the engine.
Cruise/Idle/PTO Switch Configuration The

Set/Resume switch operates as an RPM
Increase/RPM Decrease switch when the PTO
On/Off switch is ON and the parameter for the PTO
Engine RPM Set Speed is programmed. Placing
the switch in the Set position will signal the ECM to
increase the engine rpm. Placing the switch in the
Resume position will signal the ECM to decrease
the engine rpm.
PTO Vehicle Speed Limit The park brake switch

and the interlocks for the neutral switch are required
in the circuit for the PTO On/Off Switch if the
parameter for the PTO Vehicle Speed Limit is used
in order to avoid the disconnection of the vehicle
speed circuit. The requirement is because of the
fact that the PTO is driven by the transmission in
this instance.
PTO Shutdown Time The timer will become

active when the PTO is switched ON. The timer
cannot be overridden if the PTO Shutdown Time
has been programmed properly. The engine will
shut down regardless of the load when the elapsed
time equals the programmed value .
75
The Three Programmable Engine

Limits
Table 9
Parameter Programming for the Three Programmable Engine Limits
PTO TEL 2000 rpm
PTO Cab Controls RPM Limit PTO TEL
Low Idle Engine RPM 600 rpm
Idle RPM Limit 900 rpm
TEL 2120 rpm
g00721156
Illustration 43
Table 10
The Three Programmable Engine Limits
Frame 1
The Cruise Control switch is Park the vehicle with the The engine is at the
OFF. The PTO switch is OFF. engine at idle. programmed Low Idle
The Set/Resume switch is Engine RPM. 600 rpm
is not depressed.
g00721158
Illustration 44
76
Table 11
Frame 2
The Cruise Control switch is Fully depress the accelerator The engine is limited by the
OFF. The PTO switch is OFF. pedal. programmed TEL. The TEL
The Set/Resume switch is in this instance is 2120 rpm. 2120 rpm
is fully depressed.
g00721159
Illustration 45
Table 12
Frame 3
The Cruise Control switch Place the Cruise Control The engine is limited by the
is ON. The PTO switch is switch to the ON position. programmed TEL which is
OFF. The Set/Resume switch Place the Set/Resume switch 2120 rpm.
2120 rpm
is in the Set position. The to the Set position.
depressed.
g00721160
Illustration 46
77
Table 13
Frame 4
The Cruise Control switch is Release the Accelerator The engine is at the
ON. The PTO switch is OFF. Pedal. Release the programmed idle RPM
The Set/Resume switch is Set/Resume switch from Limit which is 900 rpm. 900 rpm
OFF. The Accelerator Pedal the Set position.
is released.
g00721161
Illustration 47
Table 14
Frame 5
The Cruise Control switch is Turn the PTO On/Off switch The engine will return to Low
ON. The PTO switch is ON. to ON. Idle Engine RPM because a
The Set/Resume switch is PTO rpm has not been set.
OFF. The Accelerator Pedal The PTO On/Off switch will
is released. override the Cruise Control 600 rpm
On/Off switch. The PTO
Vehicle Speed Limit must be
higher than the actual vehicle
speed.
g00721162
Illustration 48
78
Table 15
Frame 6
The Cruise Control switch Place the Set/Resume switch The engine is at the PTO TEL
is ON. The PTO switch is in the Set position and fully which is 2000 rpm.
ON. The Set/Resume switch depress the accelerator
2000 rpm
is in the Set position. The pedal.
depressed.
g00721163
Illustration 49
Table 16
Frame 7
The Cruise Control switch is Release the Set/Resume The engine will remain at the
ON. The PTO switch is ON. switch. Release the PTO TEL which is 2000 rpm.
The Set/Resume switch is accelerator pedal. 2000 rpm
is released.
g00721165
Illustration 50
79
Table 17
Frame 8
The Cruise Control switch is Turn the Cruise Control The engine will return to the
OFF. The PTO switch is OFF. On/Off switch to the OFF Low Idle Engine RPM which
The Set/Resume switch is position. Turn the PTO is 600 rpm. 600 rpm
OFF. The Accelerator Pedal On/Off switch to the OFF
is released. position.
Engine Operation with PTO Engine

RPM Set Speed
The parameter for the PTO Engine RPM Set Speed
is useful only if one or two specific engine rpm
above low idle is required. Program this parameter
to the same value as the PTO TEL if ONLY one
specific engine rpm above low idle is required.
This parameter determines the amount of engine

rpm when the PTO On/Off switch is turned to the
ON position. The parameter for the PTO to Set
Speed must also be programmed to YES. If the
PTO to Set Speed is programmed to NO, then
this speed can be achieved by using the RPM
Increase/RPM Decrease switch.
NOTE: The parameter for the PTO Engine RPM

Set Speed can override the parameter for the
Idle/PTO Bump RPM. If the PTO Engine RPM
Set Speed is programmed above 0 rpm, then
the Set/Resume switch will function as the RPM
Increase/RPM Decrease switch. This occurs when
the PTO On/Off switch is ON.
Example 1 illustrates PTO operation with two

specific engine rpm above low idle. Example 1
also illustrates the PTO Engine RPM Set Speed. In
this example, the PTO Engine RPM Set Speed is
for applications that require engine operation at low
idle, at an intermediate rpm, and at the PTO TEL.
Example 2 illustrates PTO operation with one

specific engine rpm above low idle.
Example 1
Table 18
PTO TEL 2000 rpm
80
g00721167
Illustration 51
Table 19
Frame 1
is ON. The RPM to the ON position and leave idle, which is 600 rpm.
600 rpm
Increase/Decrease switch is the throttle at the low idle
OFF. position.
g00721170
Illustration 52
81
Table 20
Frame 2
released.
g00646885
Illustration 53
Table 21
Frame 3
Increase/Decrease switch is Speed which is 1500 rpm.
1500 rpm
switch is released.
g00646886
Illustration 54
82
Table 22
Frame 4
released.
g00721172
Illustration 55
Table 23
Frame 5
The PTO On/Off Switch Release the RPM The engine will ramp up
is ON. The RPM Increase/Decrease switch. to the PTO TEL, which
Increase/Decrease switch is is 2000 rpm. This will
2000 rpm
released.
g00721174
Illustration 56
83
Table 24
Frame 6
released.
g00646889
Illustration 57
Table 25
Frame 7
The PTO On/Off Switch Release the RPM The engine will ramp to
1500 rpm
switch is released.
g00646890
Illustration 58
84
Table 26
Frame 8
released.
g00721176
Illustration 59
Table 27
Frame 9
The PTO On/Off switch is ON. Release the RPM The engine will ramp to the
The RPM Increase/Decrease Increase/Decrease switch. programmed Low Idle Engine
switch is released. RPM, which is 600 rpm.
600 rpm
This will happen only after
switch is released.
Example 2
Table 28
PTO to Set Speed NO
PTO TEL 1500 rpm
85
g00721177
Illustration 60
Table 29
Frame 1
is ON. The RPM to the ON position. idle, which is 600 rpm.
600 rpm
OFF.
g00721178
Illustration 61
86
Table 30
Frame 2
released.
g00646896
Illustration 62
Table 31
Frame 3
1500 rpm
switch is released.
g00646898
Illustration 63
87
Table 32
Frame 4
set to Increase. programmed. The engine will 1500 rpm
not respond until the RPM
released.
g00646897
Illustration 64
Table 33
Frame 5
The PTO On/Off Switch Release the RPM There should be no change in
is ON. The RPM Increase/Decrease switch. engine rpm. The PTO TEL
Increase/Decrease switch is is programmed to the same
1500 rpm
released. rpm as the PTO Engine
RPM Set Speed, which is
1500 rpm.
g00646899
Illustration 65
88
Table 34
Frame 6
released.
g00721180
Illustration 66
Table 35
Frame 7
The PTO On/Off Switch Release the RPM The engine will ramp to the
is ON. The RPM Increase/Decrease switch. programmed Low Idle Engine
Increase/Decrease switch is RPM, which is 600 rpm.
600 rpm
switch is released.
Engine Operation with PTO to Set

Speed
The engine will accelerate to the PTO Engine RPM
Set Speed when the PTO to Set Speed parameter
is programmed to YES. The PTO On/Off switch must
be ON. This is useful for applications that require
only one specific engine rpm above low idle. Only
one circuit is required.
89
Table 36
Parameter Programming for PTO to Set Speed Engine Operation
PTO to Set Speed YES
g00721181
Illustration 67
Table 37
Frame 1
The PTO On/Off switch is Start the engine. The engine is at the
OFF. The Set/Resume switch programmed low idle of 600 rpm
is set to OFF. 600 rpm.
g00646904
Illustration 68
90
Table 38
Frame 2
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine will ramp to the
ON. The Set/Resume switch to the ON position. programmed PTO Engine 1500 rpm
is set to OFF. RPM Set Speed.
Multiple Speed PTO Operation by

Using the PTO Engine RPM Set
Speed A and PTO Engine RPM
Set Speed B
Input 7 and Input 19 are provided for the
connection of the dedicated switches for the
multiple speed PTO operation. Input 7 can be
programmed to PTO Engine RPM Set Speed A.
Input 19 can be programmed to PTO Engine
RPM Set Speed B. A desired engine rpm can then
be programmed for each input (PTO Engine RPM
Set Speed A and PTO Engine RPM Set Speed B).
Perform the following functions so that the engine

will proceed to the corresponding rpm that is
programmed for the PTO Engine RPM Set Speed
A or PTO Engine RPM Set Speed B:
Turn the PTO On/Off Switch to the ON position.

Turn the switch for the PTO Engine RPM Set
Speed A or the PTO Engine RPM Set Speed B
to the ON position.
If both switches are ON, the engine will proceed

to PTO Engine RPM Set Speed A because the
PTO Engine RPM Set Speed A has priority over
PTO Engine RPM Set Speed B. If switch A is
then turned OFF, the engine will proceed to the
programmed PTO Engine RPM Set Speed B. If
switch A is then turned ON, then the engine will
proceed back to the PTO Engine RPM Set Speed
A. If both switches are in the OFF position, then
the engine will return to Low Idle.
Example 1
Table 39
Example 1 of the Parameter Programming for the Multiple Speed
PTO Operation by Using the PTO Engine RPM Set Speed A
and PTO Engine RPM Set Speed B
91
g00721184
Illustration 69
Table 40
A and PTO Engine RPM Set Speed B
Frame 1
The PTO On/Off Switch is Start the engine. The engine is at the
B is OFF.
g00721185
Illustration 70
92
Table 41
Frame 2
ON. The PTO Engine RPM to the ON position. programmed low idle of
B is OFF.
g00648610
Illustration 71
Table 42
Frame 3
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine is now at the
ON. The PTO Engine RPM to the ON position. Turn the programmed PTO Engine
Set Speed A is ON. The PTO Engine RPM Set Speed RPM Set Speed A. 1500 rpm
PTO Engine RPM Set Speed A to the ON position.
B is OFF.
g00648612
Illustration 72
93
Table 43
Frame 4
1500 rpm
B.
g00648614
Illustration 73
Table 44
Frame 5
Set Speed A is OFF. The position. RPM Set Speed B. 1200 rpm
B is ON.
g00648617
Illustration 74
94
Table 45
Frame 6
ON. The PTO Engine RPM Set Speed A to the ON PTO Engine RPM Set Speed
Set Speed A is ON. The position. A.
1500 rpm
B.
g00721612
Illustration 75
Table 46
Frame 7
Set Speed A is ON. The 600 rpm. 600 rpm
B is ON.
g00648618
Illustration 76
95
Table 47
Frame 8
ON. The PTO Engine RPM to the ON position. PTO Engine RPM Set Speed
Set Speed A is ON. The A.
1500 rpm
B.
Example 2
The switches for the PTO Engine RPM Set Speed
A or PTO Engine RPM Set Speed B can also be
used in conjunction with other features that control
engine speed during PTO operation. Set Speed A
and Set Speed B have priority over all of the other
features that are used to adjust engine rpm. Table
48 describes the interaction between the parameter
for the PTO to Set Speed and the parameter for the
PTO Engine RPM Set Speed. The parameter for the
PTO to Set Speed is programmed to YES.
Note: The feature for the PTO Engine RPM Set

Speed is not available for the Remote Throttle
PTO Configuration. The PTO Engine RPM Set
Speed A and the PTO Engine RPM Set Speed B
are available for all three PTO configurations.
Table 48
Example 2 for the Parameter Programming for the Multiple Speed
PTO Operation by Using the PTO Engine RPM Set Speed A
and PTO Engine RPM Set Speed B
PTO to Set Speed Yes
g00721613
Illustration 77
96
Table 49
Example 2 for the Multiple Speed PTO Operation by Using the PTO Engine RPM Set
Speed A and PTO Engine RPM Set Speed B
Frame 1
The PTO On/Off Switch is Start the Engine. The engine is at the
B is OFF.
g00648654
Illustration 78
Table 50
Frame 2
ON. The PTO Engine RPM to the ON position. programmed PTO Engine
Set Speed A is OFF. The RPM Set Speed of 1000 rpm. 1000 rpm
B is OFF.
g00648656
Illustration 79
97
Table 51
Frame 3
The PTO On/Off Switch is Turn the PTO Engine RPM The engine is now at the
ON. The PTO Engine RPM Set Speed A to the ON programmed PTO Engine
1500 rpm
B is OFF. priority over Set Speed
B. Set Speed A also
to Set Speed.
g00648657
Illustration 80
Table 52
Frame 4
1500 rpm
B. Set Speed A also
to Set Speed.
98
g00648658
Illustration 81
Table 53
Frame 5
Set Speed A is OFF. The position. RPM Set Speed B.
1200 rpm
PTO Engine RPM Set Speed NOTE: Set Speed B has
B is ON. priority over the PTO to Set
Speed.
g00648659
Illustration 82
99
Table 54
Frame 6
ON. The PTO Engine RPM Set Speed B to the OFF PTO Engine RPM Set Speed.
Set Speed A is OFF. The position. 1000 rpm
B is OFF.
g00721614
Illustration 83
Table 55
Frame 7
B is OFF.
g00648661
Illustration 84
100
Table 56
Frame 8
ON. The PTO Engine RPM to the ON position. Turn PTO Engine RPM Set Speed
Set Speed A is OFF. The the PTO Engine RPM Set B. 1200 rpm
PTO Engine RPM Set Speed Speed B to the ON position.
B is ON.
Programmable Torque Limit

Programming the parameter for the Torque Limit
provides an engine torque limit for PTO operation
or other special situations. This feature should only
The programmable range for this parameter is
270 to 3400 Nm (200 to 2500 lb ft). The range is in
1 Nm (1 lb ft) increments. Programming the Torque
Limit above the rated torque of the engine will not
provide additional torque. The engine will operate
using the normal torque curve whenever the normal
torque is less than the programmed value of the
Torque Limit.
g00621329
The tables demonstrate the Torque Limit for the Illustration 85
PTO. The tables also demonstrate the Torque (1) Engine Speed (RPM)
Limit when the PTO is OFF. The Torque Limit (2) Torque
(3) Normal Engine Torque Curve
operates when the PTO On/Off switch is ON. When (4) Programmed Torque Limit
the PTO On/Off switch is OFF and the Torque
Limit Switch is ON, the Torque Limit will operate.
Refer to C-10, C-12, 3406E, C-15, and C-16 Truck
Engine Electronic PTO Installation and Applications
Manual, Cab Switches with Torque Limiting and
Ignore Brake/Clutch Switch for more information
if the configuration for the PTO is programmed to
Cab Switches. Refer to C-10, C-12, 3406E, C-15,
and C-16 Truck Engine Electronic PTO Installation
and Applications Manual, Remote Switches with
more information if the configuration for the PTO is
programmed to Remote Switches. The Torque Limit
switch should be part of the system that requires
the torque limit. Program the Torque Limit to the
torque that is rated for the device that is protected Illustration 86
g00621335
by the Torque Limit. (1) Engine Speed (RPM)
(2) Torque
NOTE: The programmed torque level is an estimate. (4) Programmed Torque Limit
To achieve precise torque limiting, a chassis
dynamometer may be required.
101
Operation of the Torque Limit With PTO

On/Off Switch
Table 57
Remote Throttle
g00721947
Illustration 87
Table 58
Operation of the Torque Limit With PTO On/Off Switch
Frame 1
Operator of the PTO
The Torque Limit switch is OFF. The Start the engine. The normal engine torque is used.
PTO On/Off switch is OFF. Refer to Illustration 85.
g00721950
Illustration 88
102
Table 59
Frame 2
Operator of the PTO
The Torque Limit switch is OFF. The Turn the PTO On/Off switch to the ON The normal engine torque is used.
PTO On/Off switch is ON. position. Refer to Illustration 85.
g00721951
Illustration 89
Table 60
Frame 3
Operator of the PTO
The Torque Limit switch is ON. The PTO Turn the Torque Limit switch to the ON The Torque Limit that has been
On/Off switch is ON. position. Turn the PTO On/Off switch to programmed is activated. This will
the ON position. reduce the torque that is available.
g00721952
Illustration 90
103
Table 61
Frame 4
Operator of the PTO
The Torque Limit switch is ON. The PTO Turn the Torque Limit switch to the ON The Torque Limit that has been
On/Off switch is OFF. position. Turn the PTO On/Off switch to programmed is activated. This will
the OFF position. reduce the torque that is available.
PTO Cab Controls RPM Limit

The PTO Cab Controls RPM Limit is active when
the PTO Configuration is programmed to Cab
Switches. The accelerator in the cab is always
limited to low idle when the PTO Configuration is
programmed to Remote Switches. The accelerator
position sensor that is in the cab is limited to the
value of the PTO Cab Controls RPM Limit only
when the PTO On/Off circuit is in the ON position.
This is useful for applications with equipment that
may be damaged by engine overspeed. This
parameter has three programmable choices. The
following items are the three programmable choices:
Low Idle, TEL, and PTO TEL.
If the PTO Cab Controls RPM Limit is

programmed to Low Idle, then the engine will
not exceed the programmed Low Idle when the
accelerator pedal is depressed. The PTO On/Off
circuit must also be in the ON position. The
accelerator pedal is ignored.
If PTO Cab Controls RPM Limit is programmed

to the TEL, then depressing the accelerator
pedal will allow the engine to achieve the
programmed TEL.
If PTO Cab Controls RPM Limit is programmed

to the PTO TEL, then depressing the accelerator
pedal will allow the engine to reach the
programmed PTO TEL. The PTO On/Off circuit
must also be in the ON position.
The next three tables describe each of the three

options that are for this parameter.
104
PTO Cab Controls RPM Limit That is

Programmed to Low Idle
Table 62
Parameter Programming for PTO Cab Controls RPM Limit
That is Programmed to Low Idle
PTO TEL 2000 rpm
PTO Cab Throttle Limit Low Idle
TEL 2120 rpm
g00721615
Illustration 91
Table 63
PTO Cab Controls RPM Limit That is Programmed to Low Idle
Frame 1
OFF. The Accelerator Pedal Pedal. the programmed TEL of 2120 rpm
is fully depressed. 2120 rpm.
g00721617
Illustration 92
105
Table 64
PTO Cab Controls RPM Limit That is Programmed to Low Idle
Frame 2
The PTO On/Off switch is Turn the PTO On/Off Switch The engine will return to the
ON. The Accelerator Pedal is to the ON position. Low Idle Engine RPM of 600. 600 rpm
fully depressed.

Programmed to The TEL
Table 65
Parameter Programming for Cab Throttle RPM Limit That
is Programmed to The TEL
PTO TEL 2000 rpm
PTO Cab Throttle Limit TEL
TEL 2120 rpm
g00721629
Illustration 93
Table 66
Cab Throttle RPM Limit That is Programmed to The TEL
Frame 1
OFF. The Accelerator Pedal Pedal. the programmed TEL of 2120 rpm
106
g00721630
Illustration 94
Table 67
Cab Throttle RPM Limit That is Programmed to The TEL
Frame 2
ON. The Accelerator Pedal is to the ON position. TEL of 2120 rpm. 2120 rpm
fully depressed.

Programmed to The PTO TEL
Table 68
Parameter Programming for Cab Throttle RPM Limit That
is Programmed to The PTO TEL
PTO TEL 2000 rpm
PTO Cab Throttle Limit PTO TEL
TEL 2120 rpm
g00721631
Illustration 95
107
Table 69
Cab Throttle RPM Limit That is Programmed to The PTO TEL
Frame 1
The PTO On/Off switch is Fully depress the Accelerator The engine will accelerate
OFF. The Accelerator Pedal Pedal. to the programmed TEL of 2120 rpm
g00721632
Illustration 96
Table 70
Cab Throttle RPM Limit That is Programmed to The PTO TEL
Frame 2
The PTO On/Off Switch is Turn the PTO On/Off Switch The engine will decelerate to
ON. The Accelerator Pedal is to the ON position. the PTO TEL of 2000 rpm. 2000 rpm
fully depressed.
Idle/PTO RPM Ramp Rate Idle/PTO Bump RPM

The Idle/PTO RPM Ramp Rate determines the rate The Idle/PTO Bump RPM can be programmed to
of acceleration and deceleration of the engine when change the engine rpm when the Set/Resume switch
the engine rpm is changing. This happens because is toggled. This parameter determines the change
of the actuation of the following items: Set/Resume in rpm when the Set/Resume switch is toggled. If
switch, Idle/PTO Bump RPM, PTO to Set Speed, the PTO Engine RPM Set Speed is programmed to
and parameters for the PTO Engine RPM Set one rpm or above, then the parameter is overridden.
Speed. The Idle/PTO RPM Ramp Rate is not
applicable to the acceleration and the deceleration Note: The Idle/PTO Bump RPM can not be used
of the engine due to an accelerator position sensor. with the Fast Idle operation. The Fast Idle RPM
is not set or changed with the Cruise Control
The parameter is programmed in one rpm per Set/Resume switch.
second increments from 5 to 1000 rpm per second.
This parameter should be programmed in order
to match the application. Some applications have
a reduced cycle time that is critical. This will
provide reduced cycle times for those applications.
Programming excessive ramp rates may stress the
driven equipment.
108
Table 71
Parameter Programming for Idle/PTO Bump RPM
PTO to Set Speed NO

Cruise/Idle/PTO Switch Set/Accelerate
Configuration
Idle/PTO Bump RPM 400 rpm
PTO TEL 1800 rpm
g00721633
Illustration 97
Table 72
Idle/PTO Bump RPM
Frame 1
The PTO On/Off Switch is Start the engine. The engine will remain at the
OFF. The Set/Resume Switch low idle of 600 rpm. 600 rpm
is OFF.
g00721635
Illustration 98
109
Table 73
Idle/PTO Bump RPM
Frame 2
ON. The Set/Resume Switch to the ON position. low idle of 600 rpm because
600 rpm
is OFF. the PTO to Set Speed is
programmed to NO.
g00721638
Illustration 99
Table 74
Idle/PTO Bump RPM
Frame 3
1000 rpm
g00721639
Illustration 100
110
Table 75
Idle/PTO Bump RPM
Frame 4
1400 rpm
g00743956
Illustration 101
Table 76
Idle/PTO Bump RPM
Frame 5
is in the SET position. the SET position and then Bump RPM value. The 1800 rpm
release. engine rpm is now 1800,
which is the PTO TEL.
PTO Vehicle Speed Limit Note: A PTO that is driven by the transmission
will produce a vehicle speed signal. Program the
The parameter for the PTO Vehicle Speed Limit parameter for the PTO Vehicle Speed Limit to the
is used to disable a PTO Set Speed when maximum value of 204 km/h (127 mph) instead of
the vehicle speed exceeds the programmed disconnecting the vehicle speed circuit during the
limit. The PTO On/Off switch operates the PTO operation of the PTO. This will ensure that the PTO
Vehicle Speed Limit. The programmable range is Set Speed will not be disabled due to vehicle
2 to 204 km/h (1 to 127 mph) in increments of one. speed.
By programming the parameter to one, the PTO Set
RPM will be disabled while the vehicle is moving.
The following item will cause disengagement of an
active set rpm: exceeding the PTO Vehicle Speed
Limit.
111
Note: In some instances, a false vehicle signal can

be produced during the operation of the PTO due
to the movement of the drive train. If the parameter
for the PTO Vehicle Speed Limit is programmed
to a very low value, then the operation of the PTO
will abort when the false vehicle speed exceeds the
programmed limit. It may be necessary to isolate
the source of the false speed signal. The PTO
Vehicle Speed Limit can also be programmed to
a higher value.
Configuration
This parameter will determine the ACCEL and
DECEL function of both the Cruise Control On/Off
switch and the PTO On/Off switch. The switch can
be used for the Set/Resume switch or the switch
can be held in position for a constant acceleration.
The default positions follow: The Set position is the
ACCEL position and the Resume position is the
DECEL position. This can be changed by using the
Caterpillar Electronic Service Tool.
Note: The Set Switch serves as the RPM Increase

position and the Resume Switch serves as the RPM
Decrease position under the following conditions:
The PTO On/Off Switch is in the ON position. and
The PTO Engine RPM Set Speed is programmed
to one rpm or more. This is regardless of the
programmed setting for the Cruise/Idle/PTO
Switch configuration.
Engine Monitoring
An engine monitoring function is available for the
C-10, C-12, 3406E, C-15, and C-16 Truck engines.
The parameter can be programmed to Off, Warning,
Derate or Shutdown. Refer to the engine Operation
and Maintenance Manual for additional information
regarding this feature.
If Engine Monitoring is programmed to Derate

or Shutdown, and one of the monitored condi-
tions is exceeded, then the engine will derate or
shutdown. This should be considered especially if
derating or shutting the engine down during PTO
operation. This could present a problem for the ve-
hicle or possible injury to the operator.
112
Index Section
Index
Numerics PTO Configurations - Test ..................................... 74
Cruise/Idle/PTO Switch Configuration ........... 111
0030-08 Invalid PTO Throttle Signal (29) .............. 43 Engine Monitoring ......................................... 111
0030-13 PTO Throttle Sensor Calibration (29) ...... 43 Engine Operation with PTO Engine RPM Set
0071-14 PTO Shutdown Timer Occurrence (47) ... 43 Speed.............................................................. 79
Engine Operation with PTO to Set Speed ....... 88
Idle/PTO Bump RPM ..................................... 107
C Idle/PTO RPM Ramp Rate ............................ 107
Multiple Speed PTO Operation by Using the PTO
Component Installation............................................ 8 Engine RPM Set Speed A and PTO Engine
Considerations for the Installation........................ 9 RPM Set Speed B........................................... 90
Installation for Three PTO Configurations .......... 11 Programmable Torque Limit........................... 100
PTO Cab Controls RPM Limit........................ 103
PTO Vehicle Speed Limit............................... 110
D The Three Programmable Engine Limits ........... 75
PTO Parameters - Program ................................... 72
Diagnostic Functional Tests................................... 45 Installation and Programming That Is Based on
The Questionnaire Response .......................... 72
Programming the Parameters ............................ 73
G PTO Shutdown Timer - Test .................................. 45
PTO Switch Circuit - Test....................................... 47
General Information........................................... 4, 28 PTO Switch ON Lamp Circuit - Test ...................... 59
Advantages of a Dedicated PTO........................ 28
Definition of Power Take-Off (PTO).................... 30
Installation Questionnaire .................................. 33 R
Instructions for the Operator of the PTO ............ 36
Programmed Parameter Information Sheet for the Remote PTO Accelerator Position Sensor Circuit -
Operator of the PTO......................................... 34 Test ...................................................................... 63
PTO.................................................................. 33
Truck Installation Diagram for The Switches and S
The Components.............................................. 36
Specifications Section ............................................. 4
Switches .................................................................. 4
I Electrical Specifications for the Remote Accelerator
Pedal Position Sensor ........................................ 5
Important Safety Information ................................... 2 Selecting a Switch Type....................................... 5
Specifications for the Harness ............................. 6
Switch Electrical Specifications ........................... 4
P Systems Operation Section ................................... 28
Programmable Parameters.................................... 38
Available Ranges, Options, and Default Settings for T
the Programmable Parameters ........................ 38
Understanding Programmable Engine RPM Table of Contents..................................................... 3
Limits................................................................ 38 Testing and Adjusting ............................................ 72
Troubleshooting Section ........................................ 43
Troubleshooting with a Diagnostic Code ............... 43
2001 Caterpillar
RENR2238-03
April 2001
Troubleshooting
C-10, C-12, 3406E, C-15 and C-16 Truck
Engines
CPD1-Up (Engine)
1MM1-Up (Engine)
2KS1-Up (Engine)
2WS1-Up (Engine)
3CS1-Up (Engine)
6NZ1-Up (Engine)
7CZ1-Up (Engine)
i01097883


this publication.


death.
3
Table of Contents
Table of Contents No Diagnostic Code Detected (55) ..................... 116

0001-11 Cylinder 1 Fault (72) ............................. 116
0002-11 Cylinder 2 Fault (72) ............................. 116
0003-11 Cylinder 3 Fault (73) ............................. 117
Troubleshooting Section 0004-11 Cylinder 4 Fault (73) ............................. 117
0005-11 Cylinder 5 Fault (74) ............................. 117
0006-11 Cylinder 6 Fault (74) ............................. 118
System Overview .................................................... 5
0022-11 Cam Sensor to Crank Sensor Calibration
Glossary ............................................................... 16
(42) .................................................................... 118
Component Diagram ............................................. 24
0022-13 Check Timing Sensor Calibration (42) .. 119
Electronic Service Tools ........................................ 25
0030-08 Invalid PTO Throttle Signal (29) ............ 119
0030-13 PTO Throttle Sensor Calibration (29) ... 119
Electrical Connectors and Functions .................... 33
0041-03 8 Volt Supply Above Normal (21) .......... 120
Engine Wiring Harness Diagram .......................... 34
0041-04 8 Volt Supply Below Normal (21) .......... 120
Vehicle Wiring Harness Diagram .......................... 35
0043-02 Ignition Key Switch Fault (71) ............... 120
0054-05 Output #6 Open Circuit (66) ................. 121
Programming Parameters
0054-06 Output #6 Short Circuit (66) ................. 121
Programming Parameters ..................................... 36
0055-05 Output #7 Open Circuit (67) ................. 121
Customer Passwords ............................................ 38
0055-06 Output #7 Short Circuit (67) ................. 122
Customer Specified Parameters ........................... 38
0064-12 Loss of Engine Cam Sensor RPM Signal
Customer Specified Parameters Table ................. 62
(34) .................................................................... 122
Customer Specified Parameters Worksheet ......... 66
0071-00 Idle Shutdown Override (01) ................. 122
ECM Date/Time Stamped Information .................. 69
0071-01 Idle Shutdown Occurrence (47) ............ 123
ECM Snapshot ...................................................... 70
0071-14 PTO Shutdown Timer Occurrence
Electronic Technician (ET) .................................... 72
(47) .................................................................... 123
Factory Passwords ................................................ 73
0084-00 Vehicle Overspeed Warning (41) .......... 123
Factory Passwords Worksheet ............................. 74
0084-01 Loss of Vehicle Speed Signal (31) ........ 124
Flash Programming .............................................. 75
0084-02 Invalid Vehicle Speed Signal (36) ......... 124
System Configuration Parameters ........................ 76
0084-08 Vehicle Speed Out of Range (36) ......... 124
0084-10 Vehicle Speed Rate of Change (36) ..... 125
0084-14 Quick Stop Occurrence ........................ 125
Troubleshooting without a Diagnostic Code
Can Not Reach Top Engine RPM ......................... 78
0091-13 Throttle Sensor Calibration (28) ........... 126
Can Not Reach Vehicle Speed Limit ..................... 79
0100-01 Low Oil Pressure Warning (46) ............. 126
Check Engine Lamp or Warning Lamp Is
0100-03 Oil Pressure Sensor Open Circuit (24) .. 127
Malfunctioning ..................................................... 81
0100-04 Oil Pressure Sensor Short Circuit (24) .. 127
Cooling Fan Is Always ON .................................... 82
0100-11 Very Low Oil Pressure (46) ................... 127
Cruise Control, Idle, or PTO Can Not Be Set ........ 83
0102-00 Boost Pressure Reading Stuck High
Driver Questionnaire ............................................. 84
(25) .................................................................... 128
Driver Questionnaire Response ............................ 86
0102-03 Boost Pressure Sensor Open Circuit
ECM Will Not Accept Factory Passwords ............. 87
(25) .................................................................... 128
Electronic Service Tool Will Not Communicate with
0102-04 Boost Pressure Sensor Short Circuit
ECM .................................................................... 89
(25) .................................................................... 128
Engine Cranks but Will Not Start .......................... 90
0105-00 High Inlet Manifold Temp Warning (64) .. 129
Engine Misfires, Runs Rough or Is Unstable ........ 93
Engine Retarder (Compression Brake) Will Not Turn
(38) .................................................................... 129
ON ....................................................................... 94
0105-04 Inlet Manifold Temp Sensor Short Circuit
Engine Vibration ................................................... 96
(38) .................................................................... 130
Engine Will Not Crank ........................................... 97
0105-11 Very High Inlet Manifold Temp (64) ....... 130
Excessive Black Smoke ........................................ 98
Excessive Fuel Consumption ............................. 100
(26) .................................................................... 130
Excessive White Smoke ..................................... 100
0108-04 Atmospheric Pr Sensor Short Circuit
Intermittent Cruise Control, Idle, or PTO
(26) .................................................................... 131
Kickout .............................................................. 102
0110-00 High Coolant Temperature Warning
Intermittent Engine Shutdown ............................. 103
(61) .................................................................... 131
Intermittent Low Power or Power Cutout ............. 104
0110-03 Coolant Temp Sensor Open Circuit
Low Power/Poor or No Response to Throttle ...... 106
(27) .................................................................... 131
Poor Acceleration or Response .......................... 108
Possible Performance Effect of Active Diagnostic
(27) .................................................................... 132
Codes ................................................................ 110
0110-11 Very High Coolant Temperature (61) .... 132
0111-02 Coolant Level Sensor Fault (12) ........... 133
Diagnostic Codes ................................................ 113
4
Table of Contents
0121-05 Retarder Solenoid Low/High Open Circuit Engine Temperature Sensor Open or Short Circuit -
(14) .................................................................... 134 Test ................................................................... 268
0121-06 Retarder Solenoid Low/High Short Circuit Event Codes - Test .............................................. 277
(14) .................................................................... 134 Fan Override Switch Circuit - Test ...................... 281
0122-05 Retarder Solenoid Med/High Open Circuit Idle Shutdown Timer - Test ................................. 285
(14) .................................................................... 135 Ignition Key Switch Circuit and Battery Supply Circuit
0122-06 Retarder Solenoid Med/High Short Circuit - Test ................................................................. 288
(14) .................................................................... 135 Ignore Brake/Clutch Switch Circuit - Test ............ 295
0168-02 Intermittent Battery (51) ........................ 135 Injector Solenoid Circuit - Test ............................ 299
0171-03 Outside Air Temp Sensor Open Circuit Multi-Torque - Test .............................................. 311
........................................................................... 135 Neutral Switch Circuit - Test ................................ 312
0171-04 Outside Air Temp Sensor Short Circuit .. 136 Powertrain Data Link Circuit - Test ...................... 323
0171-11 No Ambient Air Temperature Data ........ 136 PTO Engine RPM Set Speed (Input A and Input B)
0174-00 High Fuel Temperature Warning (65) ... 136 Circuit - Test ...................................................... 331
0174-03 Fuel Temperature Sensor Open Circuit PTO Shutdown Timer - Test ................................ 335
(13) .................................................................... 137 PTO Switch Circuit - Test .................................... 338
0174-04 Fuel Temperature Sensor Short Circuit PTO Switch ON Lamp Circuit - Test .................... 349
(13) .................................................................... 137 Remote PTO Accelerator Position Sensor Circuit -
0190-00 Engine Overspeed Warning (35) .......... 137 Test ................................................................... 353
0190-12 Loss of Engine Crank Sensor RPM Signal Retarder (Compression Brake) Solenoid Circuit -
(34) .................................................................... 138 Test ................................................................... 361
0191-07 Transmission Not Responding (68) ...... 138 Service Brake Pedal Position (Switch 1) Circuit -
0224-11 Theft Deterrent Active (00) ................... 138 Test ................................................................... 371
0224-14 Engine Cranking with Theft Deterrent Active Service Brake Pedal Position (Switch 2) Circuit -
(00) .................................................................... 139 Test ................................................................... 382
0231-11 J1939 Data Link Fault (58) ................... 139 Starting Aid Switch Circuit - Test ........................ 387
0232-03 5 Volt Supply Above Normal (21) .......... 140 Starting Aid Output Circuit - Test ........................ 391
0232-04 5 Volt Supply Below Normal (21) .......... 140 Tachometer Circuit - Test .................................... 395
0246-11 Brake Switch #1 .................................... 141 Torque Limit Switch Circuit - Test ........................ 400
0247-11 Brake Switch #2 ................................... 141 Two Speed Axle Switch Circuit - Test .................. 404
0249-11 J1922 Data Link Fault (58) ................... 141 Vehicle Speed and Speedometer Circuit - Test .. 408
0252-11 Incorrect Engine Software (59) ............. 142 Warning Lamp Circuit - Test ............................... 417
(56) .................................................................... 142 Calibration Procedures
0253-11 Check Transmission Customer Parameters Engine Speed/Timing Sensor - Calibrate ........... 423
(56) .................................................................... 142 Vehicle Speed Circuit - Calibrate ........................ 425
Diagnostic Functional Tests Index Section

5 Volt Engine Pressure Sensor Supply Circuit -
Test ................................................................... 144 Index ................................................................... 428
Accelerator Pedal (Throttle) Position Sensor Circuit -
Test ................................................................... 150
ATA (SAE J1587 / J1708) Data Link Circuit -
Test ................................................................... 158
Auxiliary Brake Circuit - Test ............................... 165
Check Engine Lamp Circuit - Test ....................... 170
Clutch Pedal Position Switch Circuit - Test ......... 174
Coolant Level Sensor Circuit - Test ..................... 185
Cooling Fan Circuit and A/C High Pressure Switch
Circuit - Test ...................................................... 193
Cruise Control Switch Circuit - Test .................... 213
Diagnostic Enable Switch Circuit - Test .............. 223
Eaton Top 2 Transmission Circuit - Test .............. 227
ECM Memory - Test ............................................ 235
Electrical Connectors - Inspect ........................... 238
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 245
Engine Running Output Circuit - Test ................. 253
Engine Shutdown Output Circuit - Test ............... 256
Engine Speed/Timing Sensor Circuit - Test ........ 259
5
Troubleshooting Section The governor uses the Accelerator Pedal Position

Sensor to determine the desired engine speed. The
governor compares the desired engine speed to the
actual engine speed. The actual engine speed is
Electronic Troubleshooting determined through the Crankshaft Position Sensor.
If the desired engine speed is greater than the
actual engine speed, the governor injects more fuel
i01501196 in order to increase engine speed.
System Overview
SMCS Code: 1900
System Operation
The C-10, C-12, 3406E, C-15 and C-16 Truck
Engines were designed for electronic control. The
injection pump, the fuel lines and the nozzles
that are used in mechanical engines have been
replaced with an electronic unit injector in each
cylinder. A solenoid on each injector controls the
amount of fuel that is delivered by the injector. An
Engine Control Module (ECM) sends a signal to
each injector solenoid in order to provide complete
control of the engine.
Electronic Controls
The C-10, C-12, 3406E, C-15 and C-16 Truck
Engines electronic system consists of the Engine g00628869
Illustration 1
Control Module (ECM), the Engine Sensors and the (1) Accelerator pedal
Vehicle Interface. The ECM is the computer. The (2) Fuel injector
personality module is the software for the computer. (3) Crankshaft position sensor
The personality module contains the operating (4) Engine Control Module (ECM)
maps. The operating maps define the following
characteristics of the engine: The desired engine speed is typically determined
by one of the following conditions:
Horsepower
The position of the accelerator pedal
Torque curves
The desired vehicle speed in cruise control
RPM
The desired engine rpm in PTO control
Other characteristics
Timing Considerations
Engine Governor
Once the governor has determined the amount of
The Electronic Controls on the engine serves as the fuel that is required, the governor must determine
engine governor. the timing of the fuel injection. Fuel injection timing
is determined by the ECM after considering input
The Electronic Controls determine the timing and from the following components:
the amount of fuel that is delivered to the cylinders.
These decisions are based on the actual conditions Coolant Temperature Sensor
and the desired conditions at any given time.
Inlet Manifold Air Temperature Sensor
Boost Pressure Sensor
6
At start-up, the ECM determines the top center The Personality Module inside the ECM sets certain
position of the number 1 cylinder from the Camshaft limits on the amount of fuel that can be injected.
Position Sensors signal. After start-up, the ECM The FRC Fuel Limit is a limit that is based on the
determines the top center position of the number 1 boost pressure. The FRC Fuel Limit is used to
cylinder from the crankshaft position sensor. The control the air/fuel ratio for control of emissions.
ECM decides when fuel injection should occur When the ECM senses a higher boost pressure,
relative to the top center position and the ECM the ECM increases the FRC Fuel Limit . A higher
provides the signal to the injector at the desired boost pressure indicates that there is more air in
time. The ECM adjusts timing for the best engine the cylinder. When the ECM increases the FRC Fuel
performance, the best fuel economy and the best Limit, the ECM allows more fuel into the cylinder.
control of white smoke. Actual Timing cannot be
viewed with an Electronic Service Tool, and Desired The Rated Fuel Limit is a limit that is based on the
Timing cannot be viewed with an Electronic Service power rating of the engine and engine rpm. The
Tool. Rated Fuel Limit is similar to the rack stops and the
torque spring on a mechanically governed engine.
The Rated Fuel Limit provides the power curves
and the torque curves for a specific engine family
and a specific engine rating. All of these limits
are determined at the factory. These limits are in
the Personality Module and these limits cannot be
changed.
g00628870
Illustration 3
(1) Accelerator pedal
(2) Fuel injector (1) TC reference
(3) Camshaft position sensor (2) Speed-timing signal
(4) Crankshaft position sensor (3) Electrical current to injector solenoid
(5) Engine Control Module (ECM) (4) Injection pressure curve
Note: The signals and the timing of Illustration 3 are

Fuel Injection not to scale.
The ECM controls the amount of fuel that is injected
by varying the signals to the injectors. The injectors
will pump fuel only if the injector solenoid is
energized. The ECM sends a high voltage signal
to the solenoid. This high voltage signal energizes
the solenoid. By controlling the timing and the
duration of the high voltage signal, the ECM can
control injection timing and the ECM can control the
amount of fuel that is injected.
7
Customer Parameters And Engine Speed For example, if DERATE Mode was selected, the
Governing engine will derate engine power and vehicle speed.
The engine will derate engine power and vehicle
A unique feature with Electronic Engines is speed if the Coolant Temperature Sensor, the
Customer Specified Parameters. These parameters Oil Pressure Sensor or the Coolant Level Sensor
allow the vehicle owner to fine tune the ECM for detects conditions that exceed acceptable limits.
engine operation. Fine tuning the ECM for engine
operation allows the vehicle owner to accommodate An excessive Inlet Manifold Air Temperature will not
the typical usage of the vehicle and the power train derate the engine. Also, an excessive Inlet Manifold
of the vehicle. Air Temperature will not shut down the engine.
Many of the Customer Parameters provide additional Caterpillar Engine Monitoring

restrictions on the actions that will be performed
by the ECM in response to the drivers input. For OFF
example, the PTO Top Engine Limit is an engine
rpm limit. The PTO Top Engine Limit is an engine If Caterpillar Engine Monitoring is programmed
rpm limit that is used by the ECM as a cutoff for to OFF, the ECM will not flag low oil pressure,
the fuel. The ECM will not fuel the injectors above high coolant temperature, and low coolant level.
this rpm. No warnings will occur even though conditions
that could cause the ECM to take action (Engine
Some parameters are intended to notify the driver Monitoring) are exceeded.
of potential engine damage (Engine Monitoring
Parameters). Some parameters enhance fuel The ECM still uses these sensors for engine
economy (Vehicle Speed, Cruise Control, operation. As an example, the Coolant Temperature
Engine/Gear Speed Limit Parameter and Idle Sensor is still used for Cold Mode operation.
Shutdown Parameters). Other parameters are used
to enhance the engine installation into the vehicle. WARNING Operation
Other parameters are also used to provide engine
operating information to the truck engine owner. If the system is programmed to WARNING, the ECM
causes the Warning Lamp to turn on. This will also
cause the Check Engine Lamp to flash because
Engine Monitoring of the Active Diagnostic Code. The flashing Check
Engine Lamp indicates that a problem has been
Caterpillar provides a factory installed Engine
detected by the Engine Monitoring System. No
Monitoring system. The Caterpillar Engine
further action by the ECM or action by the engine
Monitoring system monitors engine oil pressure,
occurs if the ECM is programmed to WARNING.
coolant temperature, inlet manifold air temperature,
and coolant level (optional device). Optional
devices are OEM installed. If the problem is due to one of the following
conditions, the ECM will cause the Warning lamp to
turn ON and the ECM will cause the Check Engine
The Oil Pressure, Inlet Manifold Air Temperature,
and Coolant Temperature Sensors are standard on Lamp to flash:
all engines. The Vehicle OEM installs the coolant
level sensor and the associated harness. The Low Coolant Level
Coolant Level Sensor is the only optional component
of Caterpillar Engine Monitoring. Coolant Level High Coolant Temperature
is selected through a Customer Programmable
Parameter. High Inlet Manifold Air Temperature
Caterpillar Engine Monitoring can be programmed Low Oil Pressure

to four different modes. These four modes of
DERATE Operation
programming are the following modes: OFF,
WARNING, DERATE, and SHUTDOWN. The Coolant
Temperature Sensor, the Oil Pressure Sensor and If the system is programmed to DERATE, the ECM
causes the Warning Lamp to turn ON. The Warning
the Coolant Level Sensor (optional device) will
Lamp does not flash. Also, the ECM begins flashing
operate in the Engine Monitoring Mode that is
selected. the Check Engine Lamp. The flashing Check Engine
Lamp indicates that a problem has been detected
by the Engine Monitoring System.
This response is identical to the response when the

system is in the WARNING Mode.
8
The DERATE Mode alters the engine performance

when any of the following conditions exist:
Oil pressure becomes Very Low Oil Pressure.

Coolant level becomes Very Low Coolant Level.
Coolant temperature becomes High Coolant
Temperature.
Coolant temperature becomes Very High Coolant

Temperature.
Whenever the Warning Lamp is flashing, the ECM

is limiting or derating the engine. g00628179
Illustration 4
The ECM limits the maximum vehicle speed and the Graph of engine monitoring coolant temperature
ECM reduces the available power when any of the (1) Start or Restart warning derate
following conditions exist: (2) The maximum rate will not exceed 10 percent per second.
(3) Shutdown
High Coolant Temperature
Very High Coolant Temperature
Very Low Coolant Level
If the ECM detects Very Low Oil Pressure, the ECM
limits the following parameters:
Maximum vehicle speed

Available power
Engine rpm
g00628181
Illustration 5
This derating of engine performance is provided in
order to get the drivers attention so the driver can C-10 and C-12 Graph of engine monitoring coolant temperature
take action in order to avoid engine damage. (1) Shutdown
SHUTDOWN Operation
If the system is programmed to SHUTDOWN, the

ECM takes all the action that is indicated for the
DERATE Mode and the ECM will eventually shut
down the engine under some conditions.
The SHUTDOWN Mode will shut the engine OFF

when any of the following conditions exist:
Oil pressure becomes Very Low Oil Pressure.

Coolant level becomes Very Low Coolant Level.
g00628184
Coolant temperature becomes Very High Coolant Illustration 6
Temperature. 3406E, C-15 and C-16 Graph of engine monitoring coolant
temperature
(1) Shutdown
9
g00628189
Illustration 7
Graph of engine monitoring coolant level
(1) Warning derate
(2) The maximum rate will not exceed 10 percent per second.
(3) Shutdown
g00732031
Illustration 9
C-10 and C-12 Graph of low oil pressure for OCT99 and newer
Personality Modules
(1) Low Oil Pressure
(2) Very Low Oil Pressure
g00628190
Illustration 8
Graph of engine monitoring coolant level time
(1) Start or Restart warning tripped
(2) Shutdown
g00628191
Illustration 10
C-10 and C-12 Graph of low oil pressure for JUL99 and older
Personality Modules
(1) Low oil pressure
(2) Very low oil pressure
10
Other ECM Functions Of

Performance
The ECM also provides enhanced control of the
engine for vehicle functions such as retarding
the engine and controlling the cooling fan. Refer
to Troubleshooting, Component Diagram for
supplemental information about the systems that
can be monitored by the ECM in order to provide
enhanced vehicle performance, fuel economy and
convenience for the driver.
Self-Diagnostics
The C-10, C-12, 3406E, C-15 and C-16 electronic
system has the ability to diagnose problems.
When a problem is detected, a diagnostic code is
generated and the Check Engine/Diagnostic Lamp
may be turned ON. In most cases, the code is
also stored in permanent memory or logged in the
Illustration 11 g00628192 Engine Control Module (ECM).
3406E, C-15 and C-16 Graph of low oil pressure
When diagnostic codes occur, the diagnostic
(1) Low oil pressure codes are called Active diagnostic codes. Active
(2) Very low oil pressure
diagnostic codes indicate that a problem of some
kind currently exists. Active diagnostic codes
should always be serviced before any other work is
performed. If a truck is brought in with an Active
Code, find the code in this manual and proceed
to diagnose the cause.
Diagnostic codes that are stored in memory are

called Logged diagnostic codes. Logged diagnostic
codes do not necessarily indicate that something
needs to be repaired. The problem may have been
temporary, or the problem may have been repaired
since the problem was logged. Logged diagnostic
codes are instead meant to be an indication of
probable causes for intermittent problems.
g00628193
Illustration 12
Diagnostic Codes that identify operating conditions
Graph of Very low oil pressure start-up or restart
outside the normal operating range are called
(1) Warning derate Events. Event codes are not typically an indication
(2) Shutdown
of an electronic system problem.
Monitoring Fuel Temperature Some of the diagnostic codes require passwords to
be cleared from memory. Diagnostic codes that do
The Fuel Temperature Sensor monitors the fuel not require passwords to be cleared from memory
temperature. The fuel rate that is calculated by are automatically deleted after 100 hours of engine
the ECM is adjusted in order to compensate for operation.
changes in fuel temperature. The fuel rate is
also adjusted for constant power. The sensor is
also used to warn the operator of excessive fuel
temperature with a Diagnostic Event Code because
excessive fuel temperatures can adversely affect
engine performance. An Electronic Service Tool
can be used to temporarily disable the adjustment
of Fuel Temperature. This could be necessary
for testing a vehicle on a dynamometer with fuel
temperature compensation.
11
Engine Snapshot Data There are several occurrences of the diagnostic

code in a very short period of time.
Whenever most diagnostic codes occur, the ECM
records the time in engine hours of the occurrence. The ECM is indicating an Active Code at the
Also, the ECM records the operating parameters of present time.
the engine for 9.6 seconds before the diagnostic
code and 3.4 seconds after the diagnostic code. Diagnostic Event Codes
The operating parameters of the engine that are
recorded are similar to the operating parameters of Diagnostic Event Codes are used to indicate that
the engine that are displayed in the status screens some operational problem has been detected in
of the Electronic Technician. Not all of the status the engine or in the truck by the ECM. Usually, this
screens of the Electronic Technician or parameters does not indicate an electronic malfunction.
are recorded. The Engine Snapshot can also be
triggered from the Cruise Control Set/Resume The ECM also provides an ECM date/time clock
switch. In order to trigger the Engine Snapshot that is used to time stamp the following diagnostic
from the Cruise Control Set/Resume switch, quickly event codes:
toggle the switch to the Set position. Then, quickly
toggle the switch to the Resume position. You can 84-00 Vehicle Overspeed Warning (41)
also toggle the Cruise Control Set/Resume switch
from the Resume position to the Set position. The 84-14 Quick Stop Occurrence (00)
Engine Snapshot can also be triggered from the
Electronic Technician. 100-11 Very Low Oil Pressure (46)
Effect Of Diagnostic Codes On 105-11 Very High Inlet Manifold Air Temperature
(64)
Engine Performance
110-11 Very High Coolant Temperature (61)
The discussion on Engine Monitoring mentions that
the Check Engine Lamp flashes when a specific 111-11 Very Low Coolant Level (62)
condition exists. When the ECM detects the engine
problem, the ECM generates an Active Diagnostic 190-00 Engine Overspeed Warning (35)
Code. Also, the ECM Logs the diagnostic code
in order to indicate the time of the problems Refer to Troubleshooting, Possible Performance
occurrence. The ECM also Logs the number of Effect of Active Diagnostic Codes for a listing of all
occurrences of the problem. There are two types of the PID-FMI Diagnostic codes.
of Diagnostic Codes. There are Fault Codes and
Event Codes.
ECM Lifetime Totals
Diagnostic Fault Codes The ECM maintains total data of the engine for the
following parameters:
Diagnostic Fault Codes are provided in order to
indicate that an electrical problem or an electronic
problem has been detected by the ECM. In some Total Time (Engine Hours)
cases, the engine performance can be affected
when the condition that is causing the code exists. Total Distance
More frequently, the driver cannot detect any
difference in the engine performance. PTO Time and PTO Fuel
If the check engine lamp is flashing and the driver Idle Time and Idle Fuel
indicates that a performance problem occurs, the
Diagnostic Code may indicate the cause of the Average Load Factor (Engine)
problem. The problem should be corrected.
Total Fuel
If the driver does not indicate a problem with
the engine performance and a Diagnostic Code Total Max Fuel
is logged by the ECM, the situation indicates
The total time is the engines operating hours.
that the ECM detected an abnormal condition,
The engine hours do not include operating time
but the abnormal condition did not affect engine
when the ECM is powered ON but the engine is
performance.
not running.
In this situation, the system has no faults except
when either of the following conditions exist:
12
Total Distance Data requires a vehicle speed Total Time

sensor or an electronic vehicle speed source to be
connected to the ECM. The same sensor is used for Driving Time
ECM vehicle speed. Distance can be displayed in
miles or kilometers. Distance
PTO Time and PTO Fuel are logged when Fuel
engine rpm is set by using the Cruise switches and
the engine is operating under some load. Also, Overall Fuel Economy
PTO Time and PTO Fuel are logged when the
PTO On/Off Switch is in the ON position and vehicle Driving Fuel Economy
speed is within the range of the PTO Vehicle Speed
Limit Parameter. Idle Time
Idle Time and Idle Fuel can include operating Idle Fuel
time when all of the following conditions are met:
Percent Idle Time
When engine speed is set by using the Cruise
switches and the vehicle speed is within the PTO Time
range of the Idle Vehicle Speed Limit Parameter.
PTO Fuel
The engine is not operating under a load.
Percent PTO Time
Fuel Information can be displayed in US Gallons
or liters. Average Load Factor
Total Fuel is the total amount of fuel that is Average Vehicle Speed
consumed by the engine during operation.
Average Driving Speed
Total Max Fuel is the maximum amount of fuel that
could have been consumed by the engine during Maximum Vehicle Speed
operation.
Maximum Engine Speed
Average Load Factor provides relative engine
operating information. Average Load Factor Start Time
compares actual engine operation information to
the maximum engine operation that is available. End Time
Average Load Factor is determined by using Total
Max Fuel, Idle Fuel, and Total Fuel. All of these Start Odometer
parameters are available by using an Electronic
Service Tool. These parameters are available within End Odometer
the menu for Current Totals.
A Driver Trip Segment can be reset by using
an Electronic Service Tool or a Caterpillar Driver
Trip Data That Is Stored In The ECM Information Display (CAT ID).
The Trip data allows the tracking of engine operation
When the data is reset, the ECM stores the Current
by the vehicle owner over intervals that are defined
Totals at the time of the reset. This data is used
by the vehicle owner. Two types of Trip Data are
stored in the ECM, Driver Trip Data and Fleet Trip as the starting point for the Driver Trip Data. The
Electronic Service Tool or the CAT ID accesses this
Data. All of the Trip Data is stored in memory and
starting point and the Current Totals from the ECM
the Trip Data is maintained through the Unswitched
Battery Lines when the ignition switch is OFF. An in order to calculate the data for the Driver Trip
Segment. Resetting the Driver Trip Segment does
internal battery will maintain this information while
not require passwords.
the Unswitched Battery Lines are disconnected.
Driver Trip Data

Driver Trip Data is known as the Driver Trip
Segment. The Driver Trip Segment includes data for
the following parameters:
13
Fleet Trip Data

Fleet Trip Data includes a Fleet Trip Segment,
Histograms, and Custom Data. The Fleet Trip
Segment records the same parameters as the Driver
Trip Segment except that the Fleet Trip Segment can
be reset independently of the Driver Trip Segment.
Three histograms are available. One histogram

records engine hours versus the engine speed. The
second histogram records engine hours versus
vehicle speed. The third histogram records engine
hours versus engine speed and vehicle speed.
The Electronic Service Tool calculates the g00628194

percentage of time that is spent in each of the Illustration 13
engine rpm or vehicle speed ranges. Custom Data Basic Program
is available. Custom Data allows the recording of
engine parameters that are specified by the vehicle The following list defines the options for Variable
owner. The ECM records the Custom Data. 1 of the basic program:
A reset of the Fleet Trip Data which includes the Engine Hours
Fleet Trip Segment, the Histograms, and the Custom
Data can be done in several ways. The following Distance Traveled
tools can be used to reset the Fleet Trip Data:
Fuel Burned
An Electronic Service Tool which may require
Customer Passwords Occurrences
Caterpillar Fleet Information Software (FIS) Refer to the following list for information regarding
the options that are available for Variable 2 and
CAT ID which requires Customer Parameters Variable 5.
Programming to provide access
Variables 3, 4, 6, and 7 define the minimum range
When the data is reset, the ECM records the Current and the maximum range of variables 2 and 5.
Totals at the time of the reset. These Totals are used
as the starting point for the Fleet Trip. The following Engine RPM
tools access the recorded starting point:
Vehicle Speed
An Electronic Service Tool
Fuel Rate
Caterpillar Fleet Information Software (FIS)
Load Factor
CAT ID
Coolant Temperature
The tool then subtracts the recorded starting point
from the Current Totals in the ECM in order to Oil Pressure
calculate the Fleet Trip Data. Resetting the Fleet Trip
Data requires Customer passwords if the passwords Fuel Temperature
are programmed.
Fleet Trip Custom Data
Cruise
Fleet Trip Custom Data is part of the Fleet Trip
Segment. Fleet Trip Custom Data allows the owner PTO
of the vehicle to set five customized methods of
recording data for the vehicle. Refer to Illustration Engine Retarder
13 for the basic program.
Throttle Position
Brake
14
Refer to the example of a Custom Data program, as If the PM1 is programmed to the automatic mode,
shown below. the ECM calculates the next point of maintenance
by considering the history of the vehicles operation
Fuel Burned when Fuel Temperature is between from the previous maintenance interval. If the
7 and 67 C (45 and 120 F) and Vehicle Speed vehicle has a history of poor fuel economy the
is between 87 and 137 km/h (55 and 85 mph) maintenance indicator parameter will occur sooner
than a vehicle with better fuel economy.
The Custom Data programs are protected by
Customer Passwords. The programs are stored in The ECM also uses the Engine Oil Capacity.
permanent memory. The programs are not reset A larger engine oil capacity provides a longer
when the Fleet Trip Segment is reset, but the data maintenance interval. The Engine Oil Capacity is
that is recorded for the Trip is reset. programmed into the ECM in liters or quarts. If
the PM1 is programmed to the Manual mode, the
Fuel Correction Factor owner can program the ECM in the owners specific
maintenance interval. The maintenance interval can
A Fuel Correction Factor is available for fine be programmed to the owners specific interval
tuning the calculations for fuel consumption. The that is based on mileage or time. The interval for
Fuel Correction Factor is protected by Customer the PM2 and the interval for the Cooling System
Passwords. The Fuel Correction Factor enhances Clean/Flush are established by the factory.
the accuracy of the calculation for fuel consumption.
Altering the Fuel Correction Factor does not affect CAT ID
data that is already stored in the ECM. Altering
the Fuel Correction Factor only affects data that is The Caterpillar Driver Information Display (CAT ID)
stored in the ECM after the Fuel Correction Factor is available to provide engine operating information
is entered. to the driver. The Driver Trip Segment, the Fleet Trip
Segment, and the Maintenance Indicator data can
Note: The Fuel Correction Factor should be adjusted be viewed. However, the Fleet Trip Histograms and
by using a long interval, data from the fuel tank and the Custom Data cannot be viewed from the display.
recorded data in the ECM.
The CAT ID provides the ability to enter an ID code
Quick Stop Rate for a driver in order to divide the Fleet Trip Segment
for two drivers. If the driver enters the information
A Customer Parameter is available in order to regarding the state of travel, the Fleet Trip Segment
record the Quick Stop occurrences. The Parameter can be tagged by the state of travel.
determines the rate of change in vehicle speed that
is used by the ECM in order to record a Quick Stop The CAT ID can be used in order to tag portions
Event Code and a Quick Stop Snapshot. Refer to of the Fleet Trip Segment into two ID codes. The
Troubleshooting, ECM Snapshot. CAT ID can also be used in order to tag portions of
the Fleet Trip Segment into the state of travel. The
ID code and the information regarding the state of
Maintenance Indicator Data travel cannot be viewed from the display. Only the
Caterpillar Fleet Information Software (FIS) can view
The ECM records the Current Totals when a reset
this information. The ability to reset any of these
occurs for the following three levels of maintenance:
parameters is dependent on Customer Parameters
in the ECM.
PM1
The CAT ID will also display engine operating
PM2 parameters such as engine rpm, coolant
temperature, boost pressure and many other
Cooling System Clean/Flush parameters.
The ECM uses the previous point of maintenance in
The CAT ID will also display engine diagnostic
order to calculate the timing of the next scheduled
codes. The CAT ID will also display a brief text
maintenance work. description of the diagnostic codes.
The maintenance Indicator mode is programmable
to hours or distance. The PM1 maintenance is
programmable to the Off, Automatic Distance,
Automatic Hours, Manual Distance, or Manual
Hours setting.
15
An available feature of the CAT ID is the Theft Driver Reward Feature

Deterrent. The Theft Deterrent allows the driver
to input a password prior to shutdown. The Theft The Driver Reward Feature automatically adjusts the
Deterrent will prevent the engine from restarting VSL as a reward to the driver for operating a truck
until the password is successfully entered. The CAT in a manner that meets the truck engine owners
ID must have the version of software that is capable specifications. Several parameters are monitored in
of supporting this feature. order to evaluate a drivers operating technique.
Weighting factors are applied to the parameters that
An Auto-Enable option is available as a Theft reflect the operating techniques that are desired
Deterrent on Personality Modules which are dated and the operating techniques that are expected.
OCT99 and newer. If this option is selected, If the operating techniques meet the owners
the Theft Deterrent Feature will automatically be specifications or the operating techniques exceed
activated when the engine is shut down. The driver the owners specifications, the VSL is automatically
must input the correct password in order to start increased as a reward. The VSL will decrease when
the engine. the operating techniques do not meet the owners
specifications.
Secure Idle is another Theft Deterrent Feature.
This allows the driver to bring the engine to an idle The CAT ID can be used to monitor parameters that
condition. The driver then enters the password. The affect the Driver Reward, which allows the driver to
engine will remain at low idle until the password is adjust the operating techniques, as required.
re-entered. If the engine is shutdown, a password
will be required to go above low idle after start-up. Wireless Communication Enable
Fleet Information Software (FIS) The Wireless Communication Enable parameter in
the ECM allows the ECM to communicate through
The Caterpillar Fleet Information Software (FIS) is the SAE J1587 Data Link with certain systems
another method that can be used to review the trip of communication. Programming this parameter
information. The entire Fleet Trip Segment, which requires Factory Passwords.
includes the following elements of data can be
accessed with the Caterpillar FIS: With this system, the customer can remotely change
the following parameters by using the Caterpillar
Histograms FIS:
Custom Data Fuel Correction Factor

Information that is tagged by the ID code Custom Data
Information that is tagged by the state of travel Maintenance Indicator Data
Maintenance Indicator information can also be With this system, the customer can remotely extract
accessed by using the Caterpillar FIS. the following information from the ECM:
When the Caterpillar FIS downloads the information, Current Totals

the Caterpillar FIS also resets the ECM in order to
prepare the ECM for the next trip. The information Reports on Custom Data
can be downloaded to a computer with the
Caterpillar FIS program, or the information can be Fleet Trip Data
downloaded to an Argo Mobile Data Tool (MDT).
The Argo Mobile Data Tool (MDT) is then connected Economy Model
to a computer in order to download the information.
Maintenance Information
Settings for Customer Parameters
The reports are processed for the owner of the fleet
by using the Caterpillar FIS. The frequency and
the timing of the downloading of the information
can be at set intervals or the downloading of the
information can be done manually.
16
Programmable Parameters Customer Parameters can be protected by

Customer Passwords. The Customer Passwords are
Certain parameters that affect the C-10, C-12, programmed by the customer. Factory Passwords
3406E, C-15 and C-16 Truck Engine operation can be used to change Customer Passwords if
may be changed with electronic service tools. Customer Passwords are lost.
The parameters are stored in the ECM, and the
parameters are protected from unauthorized Refer to Troubleshooting, Customer Passwords
changes by passwords. These parameters are and Troubleshooting, Factory Passwords.
either System Configuration Parameters or Customer
Parameters.
i01510440
System Configuration Parameters are set at the

factory. System Configuration Parameters affect
Glossary
emissions or power ratings within an engine family. SMCS Code: 1000
Factory Passwords must be obtained and factory
Passwords must be used to change the System A/C High Pressure Switch The A/C High Pressure
Configuration Parameters. Switch senses refrigerant pressure in the air
conditioning system. The A/C High Pressure Switch
Customer Parameters are variable. Customer opens the electrical contacts and the A/C High
Parameters can be used to affect the following Pressure Switch closes the electrical contacts.
characteristics of the engine within the limits that The opening and closing of the electrical contacts
are set by the factory, Caterpillar Engine Monitoring, depends on the pressure in the system in order
and PTO operation: to turn ON the cooling fan. This switch may be
connected to the ECM in some applications.
Cruise control
Accelerator Pedal Position The Accelerator Pedal
Vehicle speed limits Position is the interpretation by the ECM of the
signal from the Accelerator Pedal Position Sensor.
Progressive shifting
Accelerator Pedal Position Sensor The accelerator
RPM ratings pedal position sensor is an electronic sensor
that is connected to the accelerator pedal. The
Power ratings accelerator pedal position sensor sends a Pulse
Width Modulated Signal to the ECM.
Customer Passwords may be required to change
Customer Specified Parameters. Active Diagnostic Code An Active Diagnostic
Code describes a condition that is currently present
Some of the parameters may affect engine operation in order to alert the driver or the service technician
in an unusual way. A driver might not expect this of an abnormal parameter of engine operation.
type of effect. Without adequate training, these Refer to a Diagnostic Fault Code.
parameters may lead to power complaints or
performance complaints even though the engines Aftermarket Device An aftermarket device is a
performance is to the specification. device or an accessory that is installed by the
customer after the vehicle is delivered.
Parameters. Air-To-Air Aftercooler An air-to-air aftercooler is
a device that is used on turbocharged engines
Passwords in order to cool inlet air that has undergone
compression. The inlet air is cooled after the inlet
System Configuration Parameters are protected air passes through the turbocharger. The inlet air
by Factory Passwords. Factory passwords are is passed through an aftercooler (heat exchanger)
calculated on a computer system that is available that uses ambient air for cooling. The inlet air that
only to Caterpillar dealers. Since factory passwords has been cooled advances to the inlet manifold.
contain alphabetic characters, only an electronic
service tool may change System Configuration Alternating Current (AC) Alternating Current is an
Parameters. System Configuration Parameters affect electric current that reverses direction at a regular
the power rating family or emissions. interval that is reoccurring.
17
American Wire Gauge (AWG) AWG is a measure Boost The difference between the turbocharger
of the diameter of electrical wire. AWG is also outlet pressure and the atmospheric pressure is
a measure of the current carrying capacity of commonly referred to as boost.
electrical wire. When the AWG number is smaller,
the diameter of the wire is larger. When the AWG Boost Pressure Sensor The boost pressure sensor
number is larger, the diameter of the wire is smaller. measures inlet manifold air pressure. The boost
pressure sensor sends a signal to the Electronic
Analog Sensors Analog sensors produce a DC Control Module (ECM).
output signal. The sensors are used in order to
detect a change in temperature or pressure. The Bypass Circuit A bypass circuit is a circuit that is
change is converted by the sensor to an electrical used as a substitute circuit for an existing circuit. A
signal. bypass circuit is typically used as a test circuit.
Analog Sensor Return The common line (ground) Calibration Calibration is an electronic adjustment
for the analog sensor from the ECM is used as a of a sensor signal.
ground for the analog sensors.
CAT Data Link (CDL) The CAT Data Link (CDL)
Analog Sensor Supply The +5 VDC supply from is a serial communications system that is used for
the ECM is used in order to power the analog communication with other microprocessor based
sensors. devices. The CDL is a proprietary Data Link that
is used for Caterpillar equipment. The CDL is not
Anti-Lock Brake System (ABS) An Anti-Lock Brake used in truck applications. The electronic monitoring
System is a brake system that attempts to reduce a system utilizes the CDL for communication. The
skid during brake operation. A power train electronic CDL is also used for communication with ET.
control can turn off the engine retarder, if necessary.
Also, a power train electronic control can signal the Caterpillar Driver Information Display (CAT ID)
engine ECM to deactivate the engine retarder. The Caterpillar Driver Information Display is a
digital readout of the performance parameters of
ATA Data Link (American Trucking Association) the vehicle and performance parameters that are
The ATA Data Link is a two wire electrical connection monitored by the ECM. This definition is intended
for communication with other microprocessor for truck applications and Challengers applications.
based devices. These devices are compatible with
Standards for the American Trucking Association Caterpillar Engine Monitoring Caterpillar Engine
and Standards for the SAE (J1587 and J1708) such Monitoring is the part of the Caterpillar Electronic
as trip recorders, electronic dashboards, power Engine Control that monitors Coolant Temperature,
train controls, and maintenance systems. The Data Oil Pressure, Inlet Manifold Air Temperature and
Link is also the serial communication medium Coolant Level. The monitoring alerts the operator of
that is used for programming and troubleshooting detected problems. Coolant Temperature, Intake
Caterpillar truck engines. Manifold Air Temperature, and Oil Pressure Sensors
are supplied by Caterpillar and monitored by
Atmospheric Pressure Sensor The atmospheric the ECM. The Coolant Level Sensor is installed
pressure sensor measures barometric pressure. by the Vehicle OEM but still monitored by the
The sensor sends a signal to the electronic control ECM. Aftermarket engine monitoring systems
module (ECM). The signal is used in engine control do not interface with the Caterpillar Electronic
and in engine operation. Engine Control. This definition is intended for truck
applications.
Auxiliary Pressure Sensor This sensor is an
additional pressure sensor that is installed by the Caterpillar Monitoring System The Caterpillar
engine owner. Monitoring System is a modular electronic display.
The Caterpillar Monitoring System can communicate
Auxiliary Retarder Relay The brakes solenoids with the ECM via the CAT Data Link.
are driven by an OEM installed relay, which is driven
by the ECM. Check Engine Lamp The Check Engine Lamp is
sometimes referred to as the Diagnostic Lamp. The
Auxiliary Temperature Sensor This sensor is an Check Engine Lamp is used to alert the operator
additional temperature sensor that is installed by of the presence of an active event. The lamp then
the engine owner. flashes a diagnostic code.
Before Top Center (BTC) BTC is the 180 degrees

of crankshaft rotation before the piston reaches
rotation.
18
Clutch Pedal Position Switch The switch is Crankshaft Position Sensor The crankshaft
typically supplied and installed by the OEM. This position sensor measures the crankshaft position,
switch is typically a limit switch that is mounted near the direction of rotation, and the engine rpm. The
the clutch pedal. The switch is usually adjustable. sensor sends the signals to the ECM.
This switch is in the normally closed position when
the clutch pedal is released. Depressing the clutch Cruise Control Range The cruise control range
pedal will open the circuit. is the speed range that is monitored by the cruise
control. This speed range is typically the anticipated
Code Refer to the Diagnostic Fault Code and the speed range on the open road. The Cruise Control
Diagnostic Event Code. Range is programmable by using the Low Cruise
Limit and the High Cruise Limit. This definition is
Cold Mode Cold mode is a mode for cold starting intended for truck applications.
and for cold engine operation that includes timing
that is retarded and low idle that is raised. This Custom Data Custom Data is part of the fleet trip
mode is used for engine protection, reduced smoke data that is stored in the ECM. This capability allows
emissions and faster warm up time. the vehicle owner to specify operating parameters
for monitoring purposes while the engine is in
Component Identifier (CID) The CID is a number service.
that identifies the specific component of the
electronic control system that has experienced a Customer Specified Parameter A Customer
diagnostic code. This is part of the CDL. Specified Parameter is a value that can be set and
changed by the customer. The parameters can be
Communication Adapter Tool The communication protected by Customer Passwords.
adapter provides a communication link between the
ECM and an Electronic Service Tool. Desired Engine Speed The desired engine speed
is input to the electronic governor within the ECM.
Control Area Network (CAN) Data Link The CAN The electronic governor uses the signal from the
Data Link is a serial communications port that is Throttle Position Sensor, the Engine Speed Sensor,
used for communication with other microprocessor the Cruise Control, and the Customer Parameters in
based devices. This is also referred to as the J1939 order to determine desired speed.
Data Link.
Desired RPM The desired rpm is input to the
Coolant Level Sensor This OEM installed sensor electronic governor within the ECM. The electronic
detects the absence or presence of coolant at the governor uses the signal from the Accelerator
probe. The sensor then sends a signal to the ECM. Pedal Position Sensor, the Engine Speed Sensor,
This definition is intended for truck applications. the Cruise Control, and the Customer Parameters
in order to determine desired rpm. This definition is
Coolant Temperature Sensor This sensor detects intended for truck applications.
the engine coolant temperature for Cold Mode
operation and the Caterpillar Engine Monitoring. Diagnostic Event Code These codes indicate an
The Caterpillar Engine Monitoring must be enabled event that describes an abnormal engine condition
for the coolant temperature sensor to be used for such as a High Coolant Temperature. These codes
monitoring purposes. are not necessarily an indication of problems within
the Electronic System.
Cooling Fan Override Switch This switch overrides
control of the cooling fan relay so the cooling fan Diagnostic Fault Code A Diagnostic Fault Code
operates continuously. This switch is supplied and is sometimes referred to as a fault code. These
installed by the OEM. This definition is intended for codes indicate an electronic system malfunction or
truck applications. abnormal operating conditions.
Cooling Fan Relay This relay is controlled by Diagnostic Flash Code The Diagnostic Flash
the ECM which uses information from the coolant Codes are flashed on the Check Engine Lamp.
temperature sensor, the engine retarder and the These flash codes indicate a malfunction in the
air conditioning high pressure switch. The air electronic system or an event that is detected by
conditioning high pressure switch is not always the ECM.
installed. The relay and the air conditioning high
pressure switch is supplied and installed by Diagnostic Lamp A diagnostic lamp is sometimes
the OEM. This definition is intended for truck called the check engine lamp. The diagnostic lamp
applications. is used to warn the operator of the presence of an
active diagnostic code.
19
Digital Sensors Digital sensors produce an ON or Engine Monitoring System The Engine Monitoring
OFF type of signal. Some sensors vary the ON or System is a programmable system that allows the
OFF time which is referred to as PWM Pulse Width ECM to take actions if an engine parameter is
Modulated. out of range. The actions are Warning, Derate,
and Shutdown. This definition is intended for truck
Digital Sensor Return The common line (ground) applications.
from the ECM is used as a ground for the digital
sensors. Engine Oil Pressure Sensor This sensor measures
engine oil pressure and the sensor sends a signal
Digital Sensor Supply The supply from the ECM is to the ECM.
used in order to power the digital sensors.
Engine Retarder Solenoids The Engine Retarder
Direct Current (DC) Direct current is the type of Solenoids are installed by Caterpillar and the
current that flows consistently in only one direction. solenoids are driven by the ECM. These solenoids
are used in place of relays such as the Auxiliary
DT, DT Connector, or Deutsch DT This is a type Brake that is installed by the OEM. This definition
of connector that is used on CAT machines and is intended for truck applications.
truck engines. The connectors are manufactured
by Deutsch. Engine Speed/Timing Sensor This sensor provides
a variable amplitude and Pulse Width Modulated
Dual Coil Vehicle Speed Sensor The Dual Coil Signal to the ECM. The ECM interprets this signal
Vehicle Speed Sensor is a magnetic pickup that as the crankshaft position and the engine speed.
senses movement of the teeth on the output shaft
of the transmission. The sensor contains two coils. EPROM An EPROM is a type of computer memory
This sensor provides two differential output signals. chip. An EPROM is a computer memory chip that
has an Erasable Programmable Read Only Memory.
Duty Cycle Refer to Pulse Width Modulation.
Estimated Dynamic Timing The estimated dynamic
Electronic Control Module (ECM) The ECM is timing is the estimate that is provided by the ECM
the engines control computer. The ECM provides of the actual injection timing.
power to the electronics. The ECM monitors data
that is input from the engines sensors. The ECM Ether Relay The ether relay is used in order to
acts as a governor in order to control engine rpm. actuate the ether injection system. The relay is
Refer to Engine Control Module. controlled by the ECM.
Electronic Engine Control The electronic engine Event Events indicate an event that describes an
control is a complete electronic system. The abnormal engine condition. These codes are not
electronic engine control monitors the engine necessarily an indication of problems within the
operation under all conditions. The electronic electronic system.
engine control also controls the engine operation
under all conditions. Failure Mode Identifier (FMI) This Identifier
indicates the type of failure that has been
Electronic Technician (ET) ET is a service tool experienced by the component. The FMI has
that uses a software program in order to run on a been adopted from the SAE practice of J1587
personal computer (PC). This program has replaced diagnostics. The FMI follows the PID or CID in the
the ECAP tool. descriptions of the Fault Code . The descriptions for
the FMIs are shown in the following list:
Electronically Controlled Unit Injector The
Electronically Controlled Unit Injector is an 0 The data is valid but the data is above the
injection pump which is a mechanically actuated, normal operational range
electronically controlled unit injector. This unit
combines the pumping, electronic fuel metering 1 The data is valid but the data is below the
and injecting elements in a single unit. normal operational range
EMS Display Modules Refer to the Caterpillar 2 The data is erratic, intermittent, or incorrect.
Monitoring System.
3 The voltage is above normal or the voltage is
Engine Control Module (ECM) The ECM is the shorted high
engines control computer. The ECM provides power
to the electronics. The ECM monitors data that is 4 The voltage is below normal or the voltage is
input from the engines sensors. The ECM acts as a shorted low
governor in order to control engine rpm.
20
5 The current is below normal or the circuit is Fuel Temperature Sensor This sensor detects
open the fuel temperature. The ECM monitors the fuel
temperature and the ECM adjusts the calculated
6 The current is above normal or the circuit is fuel rate accordingly.
grounded
Full Load Setting (FLS) The FLS is the number
7 The mechanical system is not responding that represents the fuel system adjustment. This
properly adjustment is made at the factory in order to help
ensure the maximum fuel delivery of the fuel system.
8 Abnormal frequency, pulse width, or period The correct value for this parameter is stamped on
the engine information ratings plate. This parameter
9 Abnormal update must be programmed. If the parameters are not
programmed, the diagnostic code that is 253-02
10 Abnormal rate of change Check Customer or System Parameters will be
active.
11 The failure mode is not identifiable
Full Torque Setting (FTS) The FTS is similar to
12 Damaged device or component the Full Load Setting. This parameter must be
programmed. If the parameters are not programmed
13 The device or the component is not calibrated the diagnostic code that is 253-02 Check Customer
or System Parameters will be active.
14 and 15 These locations are reserved for a
future assignment Gear Down Protection This feature consists of the
High Gear Limits that are programmable. High Gear
Flash Code (FC) The Flash Codes are proprietary Limits are used in order to promote driving in higher
Caterpillar code numbers that are flashed on the gears for increased fuel economy. This definition is
diagnostic lamp. The Flash Codes are flashed on intended for truck applications.
the Check Engine Lamp. These flash codes indicate
a malfunction in the electronic system or an event Harness The Harness is the bundle of wiring
that is detected by the ECM. (loom) that connects all components of the
Electronic System.
Flash Programming Flash programming is the
method of programming or updating an ECM with Hertz (Hz) Hertz is the measure of electrical
an Electronic Service Tool over the data link instead frequency in cycles per second.
of replacing components. Flash Programming
installs the specific Personality Module that is used Histogram The histogram is a bar graph which
to control the engine. The Personality Module may indicate the relative frequency of vehicle
contains specific performance maps and features operation in specific operating ranges. A histogram
for a selected rating. can be used to show many relationships.
Fleet Information Software (FIS) FIS is a software Hydraulically Actuated Electronically Controlled Unit
program that operates on a personal computer Injector (HEUI) The HEUI is an injection pump
(PC). This program allows the user to review the which is a hydraulically actuated, electronically
trip information. The program also allows the user controlled unit injector. This injector uses hydraulic
to reset the trip information which includes the forces to produce the high injection pressure.
Maintenance Indicator information. This definition is This unit combines the pumping, electronic fuel
intended for truck applications. metering, and injecting elements in a single unit.
Fuel Position This is an internal signal within Injector Codes The Injector Codes or injector trim
the ECM. The signal comes from the Electronic codes are numeric codes or alphanumeric codes
Governor and the signal then goes to the Fuel that are etched or stamped on individual injectors.
Injection Control. The information that is gathered These codes are used to fine tune the fuel delivery.
is based on the Desired RPM, the FRC Limit, the
Rated Fuel Limit, and the actual engine rpm. Inlet Air Temperature Sensor This sensor detects
the air inlet temperature. The ECM monitors the inlet
Fuel Ratio Control (FRC) The FRC is a limit that air temperature and other data in order to adjust
is based on the control of the fuel to air ratio. The injection timing and other performance functions.
FRC is used for purposes of emission control. When
the ECM senses a higher boost pressure (more air
into the cylinder), the FRC increases the FRC Limit
(more fuel into the cylinder).
21
Integrated Electronic Controls The engine is Open Circuit An open circuit is a condition that is
designed with the electronic controls as a necessary caused by an open switch, or an electrical wire or
part of the system. The engine will not operate a connection is broken. When this condition exists,
without the electronic controls. the signal or the supply voltage can no longer reach
the intended destination.
J1922 Data Link This data link is an SAE
diagnostic communications data link that is used Original Equipment Manufacturer (OEM) The
to communicate between the electronic engine OEM is the manufacturer of a vehicle that uses
and the power train components. Examples of a Caterpillar engine for the power source. This
power train components are the ABS/traction definition is intended for truck applications.
control system and the transmissions. This allows
the power train component to control the engine Overspeed Verify This feature is used to test the
during reduced traction or transmission shifts. This Overspeed Shutoff Circuit. The shutoff circuit is
definition is intended for truck applications. tripped at 75% of the Overspeed Shutoff Limit.
J1939 Data Link This data link is an SAE Parameter A parameter is a value or a limit that
diagnostic communications data link that is used to is programmable. This helps determine specific
communicate between the electronic engine, the characteristics or behaviors of the engine and/or
transmission, instrument clusters, and/or the power vehicle.
train controls.
Parameter Identifier (PID) The PID is a two digit
Keyswitch Input When the input is energized, the code or a three digit code which is assigned to
ECM is powered up. each component in order to identify data via the
data link to the ECM.
Kickout Switch This term refers to the service
brake switch and the clutch switch. These switches Passive Magnetic Speed Sensor This sensor is a
are used as an exit or a kickout for the cruise speed sensor that does not require a power and a
control set speed, the idle speed setting, or the ground connection. The sensor produces a signal
PTO/Idle set speed. This definition is intended for that is based on the change in magnetic flux of a
truck applications. ferrous metal gear near the sensing tip.
Logged Diagnostic Codes Logged diagnostic Password A password is a group of numeric

codes are codes which are stored in memory. characters or a group of alphanumeric characters
These codes are meant to be an indicator of that is designed to restrict access to parameters.
possible causes for intermittent problems. Refer to The electronic system requires correct passwords
the Diagnostic Fault Code for more information. in order to change Customer Specified Parameters
(Customer Passwords) or certain engine
Maintenance Clear Switch The maintenance specifications (Factory Passwords). Passwords are
clear switch is required to reset the PM1 Interval also required to clear certain diagnostic codes.
diagnostic after maintenance on the engine
is performed. This reset is necessary for the Personality Module or Ratings Personality Module
maintenance indicator to function. This module is attached to the inside of the
ECM. The module contains all the instructions
Maintenance Overdue Lamp This lamp will turn (software) for the ECM and the module contains the
ON when the preventive Maintenance interval performance maps for a specific horsepower family.
occurs such as PM1 Interval.
Power Cycled Power cycled happens when
Mechanically Actuated Electronically Controlled Unit power to the ECM is cycled: on, off, and on. Power
Injector (MEUI) The MEUI is an injection pump cycled refers to the action of cycling the keyswitch
which is a mechanically actuated, electronically from any position to the OFF position, and to the
controlled unit injector. Mechanical forces that are START/RUN position.
produced from the camshaft are used to produce
the high injection pressures. This unit combines the Power Take-Off (PTO) The PTO operates with
pumping, electronic fuel metering, and injecting the cruise control switches and the dedicated
elements in a single unit. PTO On/Off switch. This mode permits the setting
of constant engine speeds or the mode permits
Oil Pressure Sensor This sensor measures engine varying the speed with either the accelerator pedal
oil pressure and the sensor signals the ECM. in the cab or a remote accelerator.
Power Train Data Link Refer to J1922 Data Link.

22
Powered Down Powered down occurs when Reference Voltage The Reference Voltage is a
power is removed from the ECM. Powered down regulated voltage and a steady voltage that is
refers to the action of cycling the keyswitch from supplied by the ECM to a sensor. The reference
any position to the OFF/RESET position. voltage is used by the sensor to generate a signal
voltage.
Powered Up Powered up occurs when power
is applied to the ECM. Powered up refers to the Remote Shutdown The ECM disables the fuel
action of cycling the keyswitch from the OFF/RESET injection signal when the Remote Shutdown Switch
position to the START position. is closed. This causes the ECM to shut down the
engine. However, the ECM remains active. The air
Pro-Link Pro-Link is an electronic service tool that shutoff solenoid is not activated when the remote
is hand-held. The tool is manufactured by Micro shutdown switch is activated.
Processor Systems, Inc. (MPSI). This tool is supplied
with a Caterpillar cartridge in order to service a Remote Station Operation This is a location that
Caterpillar engine that is electronically controlled. is outside of the vehicle cab. The functions such
as the engine speed control are typically used for
Progressive Shifting This is a method of upshifting some type of PTO operation that is for pumping
through the lower gears quickly and not using or for some other application that uses the engine
excessive engine rpm in each gear. Shifts are made power. These functions are controlled from the
above peak torque but below rated rpm. Using remote station.
excessively high engine rpm ranges before shifting
to the next gear wastes fuel. Using the excessively Retarder Enable Signal The retarder enable signal
high engine rpm ranges also fails to take advantage interfaces the ECM to the engine retarder. This
of the torque rise of the engine. The two steps LoGr will restrict operation of the engine brake during
1 and LoGr 2give the opportunity for progressive undesirable engine operating conditions. One
shifting. LoGr 1 is typically setat no lower than peak operating condition is at a time when the engine
torque plus 200 rpm. LoGr 2 is typically set at a is being fueled.
point that is midway between the LoGr 1 rpm limit
and the Top Engine Limit. This definition is intended Retarder Solenoids This refers to the Engine
for truck applications. Retarder that is installed by Caterpillar. The
solenoids are driven directly by the Caterpillar
PTO Configuration This is a programmable ECM. The solenoids are not driven through an OEM
parameter that determines the best use of the ECM installed relay such as the Auxiliary Retarder. This
input and the ECM output for PTO applications. definition is intended for truck applications.
Pulse Width Modulation (PWM) The PWM is a Sensor The sensor is a device that is used
signal that consists of pulses that are of variable to detect a change in pressure, temperature, or
width. These pulses occur at fixed intervals. The mechanical movement. The information that is
ratio of TIME ON versus total TIME OFF can be detected is converted into an electrical signal.
varied. This ratio is also referred to as a duty cycle.
Service Brake Pedal Position Switch This switch
is typically a pressure switch that is supplied and
installed by the OEM. This switch is normally closed
when the brake pedal is in the released position.
Depressing the brake will open the circuit. This
definition is intended for truck applications.
Short Circuit A short circuit is a condition that has

an electrical circuit that is inadvertently connected
to an undesirable point. An example of a short
circuit is a wire which rubs against a vehicle frame
and this rubbing eventually wears off the wire
insulation. Electrical contact with the frame is made
and a short circuit results.
g00284479
Illustration 14 Signal The signal is a voltage or a waveform that
is used in order to transmit information typically
Rated Fuel Limit This term indicates the maximum from a sensor to the ECM.
allowable fuel position (longest injection pulse). This
position will produce rated power for this engine Speed Burp A Speed Burp is a sudden, brief,
configuration. unwanted change in the engine rpm.
23
Standard SAE Diagnostic Communications Data Timing Calibration The timing calibration is the
Link Refer to the ATA Data Link. adjustment of an electrical signal. This adjustment
is made in order to correct the timing error
Starting Aid Switch This switch is used for injection between the crankshaft and the crankshaft position
of a starting aid in cold weather. An example of a sensor or between the crankshaft and the engine
starting aid is ether. speed/timing sensor.
Static Timing Static timing is the basis for correct Top Center This refers to the crankshaft position
fuel timing and valve mechanism operation. Static when the engine piston position is at the highest
timing is determined by the timing ring and the point of travel. The engine must be turned in the
alignment of the rear gear group. normal direction of rotation in order to reach this
point.
Subsystem A Subsystem that is used in this
application is a part of the Electronic System that Torque Limit This is a programmable parameter
relates to a particular function. An example of a that limits the maximum torque which is based on
subsystem is the throttle subsystem. the PTO configuration and PTO operation.
Supply Voltage The Supply Voltage is a constant Total Tattletale The Total Tattletale is the total
voltage that is supplied to a component in order number of changes to all the Customer Specified
to provide electrical power that is required for Parameters that are stored in the ECM.
the component to operate. The power may be
generated by the ECM or the power may be battery Transducer (Timing Calibration Probe) This is
voltage that is supplied by the vehicle wiring. a device that converts a mechanical signal to
an electrical signal. This probe requires a power
Suspect Parameter Number (SPN) The SPN source in order to operate.
is a three digit code which is assigned to each
component in order to identify data via the data link Trip Recorder The Trip Recorder is an after
to the ECM. This is used for J1939 diagnostics. market device that is dedicated to recording the
parameters of the vehicle and the parameters of the
System Configuration Parameters System operating engine during the vehicle service. The
Configuration Parameters are Parameters that affect Trip Recorder is used to analyze the driving habits
the power rating family or emissions. and the recorder is used in order to produce the
logs of the driver.
T-Harness The T-Harness is a test harness that is
designed to connect into the vehicle harness or the Turbocharger Inlet Pressure Sensor This analog
engine harness. This connection allows a normal sensor measures the pressure of the inlet air to the
circuit operation and the connection simultaneously turbocharger compressor.
provides a breakout T in order to measure the
signals. Turbocharger Outlet Pressure Sensor This analog
sensor measures the pressure of the air at the outlet
Terminating Resistor This is used to terminate of the turbocharger compressor.
the J1939 CAN Data Link. Refer to the installation
procedures. Vehicle Speed Sensor The Vehicle Speed Sensor
is an electromagnetic pickup that measures vehicle
Theft Deterrent This feature uses a four digit speed from the rotation of gear teeth in the drive
code in order to prevent the engine from starting. train of the vehicle.
The feature requires a password to be entered via
the CAT ID. This definition is intended for truck
applications.
Throttle Position The Throttle Position is the

interpretation by the ECM of the signal from the
Throttle Position Sensor.
Throttle Position Sensor This sensor is an

electronic sensor that is connected to an
accelerator pedal or a hand lever. This sensor
sends a PWM signal to the ECM. For on-highway
truck applications, refer to the Accelerator Pedal
Position Sensor.
24
i01246095
Component Diagram
SMCS Code: 1400-035; 1900-035
g00664863
Illustration 15
The diagram of components for the following engines C-10, C-12, 3406E, C-15, and C-16
25
i01501293 Snapshot Recorder

Electronic Service Tools The Electronic Control Analyzer Programmer ECAP
can also be used in a limited capacity. However, the
SMCS Code: 1900 ECAP is no longer supported. The ECAP uses small
plug-in modules. These modules are called Service
The Caterpillar Electronic Service Tools for the Program Modules. The modules are used to adapt
C-10, C-12, 3406E, C-15 and C-16 Electronic the basic tool to a specific Caterpillar electronic
Control system are designed to help the service control application.
technician analyze faults or problems within the
system. The Caterpillar Electronic Service Tools There are several adapter cables, breakout T
are required to perform some sensor calibrations cables, probes, and other miscellaneous items
electronically. The Caterpillar Electronic Service that are used in order to access measurements of
Tools are required to read engine parameters and signals. A heavy duty multimeter is suitable in order
the Caterpillar Electronic Service Tools are required to make the necessary measurements. A multimeter
to change engine parameters. The Caterpillar that has the ability to measure the Duty Cycle may
Electronic Technician (ET) requires a personal also be required. Special Tools that are used to
computer with ET software that is installed and the measure pressure and temperature may be needed.
Caterpillar Electronic Technician (ET) also requires
either a Caterpillar Communication Adapter or a
MPSI Pro-Link. The MPSI Pro-Link must include the
Caterpillar Cartridge in order to translate from the
Vehicles ATA Data Link to the computers RS-232
port.
The ET can be used to display the following

information:
Programmable Parameter Settings

Active Diagnostic Codes and Logged Diagnostic
Codes
Logged Events
Engine Rating History
Driver and Fleet Trip Segments
Histograms
Custom Data
ECM Date/Time Clock
Maintenance Intervals
The ET can also be used to perform the following
functions:
Diagnostic Tests
Sensor Calibrations
Flash Programming
Copy Configuration for ECM Replacement
Data Logging
Real Time Graphing
26
C-10, C-12, 3406E, C-15 And C-16 C-10, C-12, 3406E, C-15 And C-16
Service Tools Service Tools That Are Optional
Table 1 Table 2
Part Number Description Part Number Description
Caterpillar Electronic Technician 7X-1425 Data Link Cable ( 7X-1701
Communication Adapter to PC)
JERD2124 Single Use Program License
175-3700 Connector Repair Kit
JERD2125 Data Subscription (Truck Engine)
7X-6370 Adapter Cable (3 Pin DT Breakout T)
or
8T-8726 Adapter Cable (3 Pin HD Breakout T)
JERD2128 Data Subscription (Truck and
Commercial Engine) 7X-1710 Multimeter Probe (Spoons)
or 1U-5718 Vacuum Pump
JERD2129 Data Subscription (All Engine and 1U-8757 Tube (Attachment for Vacuum Pump)
Machine)
1U-5814 Bottle Assembly (Vacuum Pump)
5P-7277 Voltage Tester (Test Lamp)
9U-5103 Socket (Coolant Temperature Sensor
Removal) 1U-5470 Engine Pressure Group
6V-2197 Magnetic Transducer (Timing 6V-9130 Temperature Adapter
Calibration Probe)
124-5643 Cable (3 Pin Packard Breakout T)
7X-1171 Transducer Adapter (Timing Probe
Adapter) 125-3662 Cable (3 Pin DT Bypass T)
7X-1695 Cable (Timing Probe Cable) 157-4829 Cable Adapter (9 Pin J1939 Dash)
171-4400 Communication Adapter Gp (Support 7X-1403 Adapter Cable (9 Pin Navistar Dash)
for J1939 Flash) 7X-1686 Cable Adapter (6 Pin Dash)
1U-5804 Crimp Tool 139-4166 Data Link Cable As (Communication
1U-5805 Wire Removal Tool (14 AWG Wire) Adapter to Dash Connector)
151-6320 Wire Removal Tool (16 and 18 AWG 7X-1412 Adapter Cable (9 Pin Service Tool
Wire) Breakout T)
167-9225 Harness (Bypass for Service Tool)

140-2266 Harness (Breakout T for ECM)
9U-7330 Digital Multimeter
27
i01176159
Sensors and Electrical

Connectors
SMCS Code: 1900-035
C-10 and C-12 Engines
g00629193
Illustration 16
Left side view
(1) Fuel temperature sensor (5) Engine ground stud (9) Crankshaft position sensor
(2) Electronic unit injector connector (6) Camshaft position sensor (10) Engine harness connector (J2/P2)
(3) Atmospheric pressure sensor (7) Engine Control Module (ECM) (11) Engine ground stud
(4) Oil pressure sensor (8) OEM vehicle harness connector (J1/P1)
28
g00629198
Illustration 17
Front views
(3) Atmospheric pressure sensor (13) Inlet manifold air temperature sensor
(12) Coolant temperature sensor (14) Boost pressure sensor
29
3406E Engine
g00629427
Illustration 18
Left side view
(1) Boost pressure sensor (5) Camshaft position sensor (9) Atmospheric pressure sensor
(2) Electronic unit injector connector (6) Engine Control Module (ECM) (10) Crankshaft position sensor
(3) Inlet manifold air temperature sensor (7) Fuel temperature sensor (11) Engine harness connector (J2/P2)
(4) Engine ground stud (8) OEM vehicle harness connector (J1/P1)
30
g00629430
Illustration 19
Other views
(12) Oil pressure sensor (13) Coolant temperature sensor
31
C-15 and C-16 Engines
g00638128
Illustration 20
Left Side View
(1) Boost pressure sensor (5) Camshaft position sensor (9) Crankshaft position sensor
(2) Electronic unit injector connector (6) Engine Control Module (ECM) (10) Atmospheric pressure sensor
(3) Inlet manifold air temperature sensor (7) OEM vehicle harness connector (J1/P1) (11) Oil Pressure sensor
(4) Engine ground stud (8) Engine harness connector (J2/P2)
32
g00638129
Illustration 21
Top view
(3) Inlet manifold air temperature sensor (12) Coolant temperature sensor (13) Fuel temperature sensor
33
i01259168
Electrical Connectors and

Functions
SMCS Code: 1900
Table 3
Connector Function
J1/P1 ECM Connector (70-Pin OEM
Harness)
J2/P2 ECM Connector (70-Pin Engine
Harness)
J100/P100 Coolant Temperature Sensor (2-Pin
Connector)
J103/P103 Inlet Manifold Air Temperature
J105/P105 Fuel Temperature Sensor (2-Pin
Connector)
J200/P200 Boost Pressure Sensor (3-Pin
Connector)
J201/P201 Engine Oil Pressure Sensor (3-Pin
Connector)
J203/P203 Atmospheric Pressure Sensor
Connector (3-Pin Connector)
J300/P300 Injector Solenoid Harness (12-Pin
Connector)
J400/P400 Engine Timing Calibration Probe
(2-Pin Connector)
J401/P401 Crankshaft Position Sensor (2-Pin
Connector)
J402/P402 Camshaft Position Sensor (2-Pin
Connector)
J403/P403 Accelerator Pedal Position Sensor
(3-Pin Connector)
34
i01246696
Engine Wiring Harness

Diagram
SMCS Code: 1408-035
g00665178
Illustration 22
35
i01248643
Vehicle Wiring Harness

Diagram
SMCS Code: 1408-035
g00665578
Illustration 23
36
Programming Parameters Replacing The ECM With the Use Of

The ECM Replacement Feature From
Caterpillar Electronic Technician (ET)
i01181843
Programming Parameters 1. Ensure that the ECM is the problem by first

SMCS Code: 1900 connection. Hang the test ECM on the side of the
Many programmable parameters affect the Engine Module that was used in the suspect ECM
operation. These parameters may be changed by into the test ECM. Use the ECM Replacement
using Electronic Service Tools. The parameters are Feature that is in the ET in order to copy the
stored in the ECM. The parameters are NOT stored parameters from the ECM that is suspect. Copy
in the personality module. Any parameter can be these parameters into the test ECM. Ensure that
read. However, passwords protect parameters from the parameters in the test ECM are equal to the
unauthorized changes. parameters in the suspect ECM.
Two categories contain various parameters, System 2. If the test ECM repairs the problem, reconnect
Configuration Parameters and Customer Specified the suspect ECM. Verify that the problem returns
Parameters. System Configuration Parameters can when the suspect ECM is reconnected.
be altered only with the proper factory passwords
by using the Caterpillar Electronic Technician (ET). 3. Select the ECM Replacement Feature under the
Service/Copy Configuration menu and load the
Customer Specified Parameters can be changed by parameters from the failed ECM.
using an Electronic Service Tool only with the proper
customer passwords. Refer to Troubleshooting, 4. Temporarily connect the new ECM by connecting
Customer Passwords and Troubleshooting, both ECM Connectors. Do not mount the ECM
Factory Passwords for additional information. on the engine yet.

Programming a New ECM new ECM if the personality module is not already
The Engine Control Module or the ECM is the Personality Module.
brain of the system. So when a problem occurs,
it is easy to assume that the ECM is responsible. 6. Use the ECM Replacement Feature in the ET to
This is usually the wrong assumption. Most failures program the new ECM.
occur at the wiring and connectors or at a sensor
input or sensor output. Follow the procedures in 7. Enter the parameter for the Rating Number into
the troubleshooting guide, and do not replace the new ECM.
an ECM on an assumption. However, when your
troubleshooting indicates that a failure has in fact 8. Check for Active Codes. Program any required
occurred in the ECM, use the following procedure parameters that have not been programmed.
to replace a faulty ECM.
Note: On initial powerup of a new ECM, the
Note: If a replacement for the ECM is required, the parameter for the Rating Number must be
following information can be transferred from the programmed to avoid a 253-02 Check Customer Or
suspect ECM to the replacement ECM: customer System Parameters (56) Diagnostic Code.
parameters, injector trim codes, and timing
calibration.Timing calibration will NOT be necessary. 9. If a 22-13 Check Timing Sensor Calibration
This feature requires the Caterpillar Electronic Diagnostic Code is not Active, install the new
Technician (ET) and this feature is only possible if ECM on the engine. Otherwise, perform a timing
the suspect ECM can communicate with the ET. calibration first.
37
Replacing The ECM Without the Use Of Note: The following parameters can be programmed
The ECM Replacement Feature From on a new ECM without factory passwords: Full Load
Setting (FLS), Full Torque Setting (FTS), and Engine
Caterpillar Electronic Technician (ET) Serial Number. System Configuration parameters
must be entered before the Customer Specified
1. Ensure that the ECM is the problem by first
Parameters are entered. If Customer Parameters
are entered before the System Configuration
connection. Hang the test ECM on the side of the Parameters, the Total Tattletale will change. It will
then be necessary to obtain another set of Factory
Module that was used in the suspect ECM into
Passwords in order to access System Configuration
the test ECM. Program any parameters that Parameters.
are necessary to use the ECM for the test. For
example, Vehicle Speed Parameters need to be
8. Perform the following operations.
programmed to check the vehicle speed circuit.
Program the parameters in the test ECM to be
a. Use the Troubleshooting, Factory Passwords
equal to the parameters in the suspect ECM.
Worksheet to record the following information
from the Engine Information Plate: Full Load
2. If the test ECM repairs the problem, reconnect
the suspect ECM. Verify that the problem returns
when the suspect ECM is reconnected.
b. Record the mileage from the vehicle odometer.
3. Obtain customer parameters from the failed
Use the ET to access System Configuration
ECM. Parameters. When the Factory Specified
Passwords screen appears, record the
a. Obtain the Customer Passwords and
following information: ECM Serial Number,
record the Customer Passwords. If the Engine Serial Number, ET Serial Number, Total
customer (owner) has lost the passwords
Tattletale, and Reason Code.
or if the customer (owner) has forgotten the
passwords, proceed to Troubleshooting, c. Leave the ET on the Factory Specified
Customer Passwords for more details.
Passwords screen and obtain the Factory
Passwords. Complete the Troubleshooting,
b. Use the ET to access Customer Specified Factory Passwords Worksheet.
Parameters from the ECM that is being
replaced. If the ECM does not communicate
9. Program the new ECM.
with the Electronic Service Tool, obtain the
required Parameter List from the OEM.
Note: On initial powerup of a new ECM, the following
six parameters must be programmed to avoid a
c. Use the Troubleshooting, Customer Specified 253-02 Check Customer Or System Parameters
Parameters Worksheet to record the customer
(56) Diagnostic Code: Full Load Setting (FLS), Full
parameters.
Torque Setting (FTS), Vehicle Speed Calibration
(ppm), Rating Number, Engine Serial Number, and
4. Record ECM lifetime Totals.
Injector Trim Codes.
a. Use the Troubleshooting, Customer Specified a. Use the ET to access System Configuration
Parameters Worksheet (Current Totals
Parameters. Enter the following parameters
Worksheet) to record the old ECM Current
that are recorded on the worksheet: Full Load
Totals.
5. Temporarily connect the new ECM by connecting
both ECM Connectors. Do not mount the ECM to
b. Use the ET to access Customer Specified
the engine until the timing calibration has been
Parameters. Enter the Customer Specified
performed.
Parameters and the original Customer
Passwords that are recorded on the
worksheet.
new ECM if the Personality Module is not already
c. Use the ET to access Current Totals from
Personality Module.
the Read/Change Current Totals main
menu. Record the information by using
7. Obtain the Factory Passwords when the
the Troubleshooting, Factory Passwords
passwords are required.
Worksheet to obtain the Factory Passwords.
Enter the Totals from the original ECM that are
recorded on the worksheet.
38
d. Select the following screens in order i01501310

to calibrate the engine timing: Service,
Calibrations, and Timing Calibration. Calibrate Customer Specified
the timing. Refer to Troubleshooting, Engine
Speed/Timing Circuit - Test.
Parameters
SMCS Code: 1901
10. Install the new ECM on the engine.
Customer Specified Parameters allow the vehicle
i01267637
owner to influence the operating technique of
a driver. Some parameters may affect engine
Customer Passwords operation in a way that would not be expected by
an inadequately trained driver. These parameters
SMCS Code: 1901 may lead to power or performance complaints
even though the engines performance is within the
If Customer Passwords have been entered, then engines specification.
the Customer Passwords are required to change
ANY customer parameter. Customer Parameters Customer parameters may be changed repeatedly
are those parameters that affect the vehicle speed as a customers operation changes or as new
limits, the power rating within an engine family drivers are assigned to a truck. Customer Passwords
and the PTO operation. Refer to Troubleshooting, are required to change these parameters.
Customer Specified Parameters for more detail on
parameters that are customer programmable. The following information is a brief description of
the Customer Specified Parameters. The following
An ET or a MPSI Pro-Link with the Caterpillar parameter values are included with the descriptions:
Cartridge may change Customer Parameters. To
obtain customer passwords, contact the owner Minimum
of the vehicle. If the owner has lost the owners
passwords, customer passwords may be read by Maximum
using an ET.
Default
Note: Factory passwords are required in order to
read customer passwords. Note: Parameter values that are shown in bold text
are programmed settings that disable the feature.
Use the following procedure in order to read
customer passwords with an ET: The tables show values in an approximate range for
metric units that is followed by the metric conversion
1. Use the ET to access the Utilities Menu. Then to English units. The exact range of the parameter
access View Passwords under the Utilities Menu. in metric units depends on the Service Tool that is
being used. Each Tool may use slightly different
2. When the Factory Password screen appears, conversion factors.
record the information that is listed on the C-10,
C-12, 3406E, C-15 and C-16 Factory Passwords Customer Parameter Lockout
Worksheet. Refer to Troubleshooting, Factory
Passwords Worksheet. The Customer Parameter Lockout is available in
order to restrict access to changing some of the
3. Obtain the factory passwords. The information available parameters. Locking out a parameter
that is recorded on the Factory Passwords requires Customer Passwords (if used). Once a
Worksheet must be provided. When the factory parameter is locked out, Factory Passwords are
passwords are obtained, a permanent record of required to change the parameter. Also, once a
the access is generated at Caterpillar. parameter is locked out, Factory Passwords are
required to unlock the parameter.
4. From the Factory Password screen, enter the
Factory Passwords. If a lockable parameter is not locked out, Factory
Passwords are not required. A locked out parameter
5. When the Read Customer Passwords screen restricts the parameter from being changed directly
appears, record the Customer Passwords. The by the operator. This helps vehicle owners that
Customer Passwords may then be used to are encountering problems with operators that are
change Customer Parameters. obtaining Customer Passwords and altering some
of these parameters.
39
A locked out parameter also provides an audit Selected Engine Rating

trail. The audit trail can be used to determine the
following information: Rating Number
Time of change The Rating Number is the selected Rating within a
power rating family. The Personality Module defines
Operator during change the power rating family (242 kW (325 hp)) and the
Personality Module may contain only one or several
The following Customer Parameters are available ratings. The rating number defines the power rating
for Lockout: that is used within the power rating family. The
following list illustrates examples of the power rating:
Vehicle Speed Limit
324 kW (435 hp) at a Governed Engine Speed of
VSL Protection 1800 rpm
Driver Reward Enable (MAR99 and Newer 324 kW (435 hp) at a Governed Engine Speed of
Personality Modules) 2100 rpm
High Cruise Control Set Speed Limit Both ratings will be displayed for Multi-Torque
applications.
Top Engine Limit
Transmission Style Multi-Torque Ratio
This parameter is used to select the desired
Soft Vehicle Speed Limit Multitorque trip point. Multitorque ratings allow the
engine to provide additional torque, additional
Engine Monitoring Lamps (NOV99 and Newer horsepower, and torque when the transmission is
Personality Modules)
operating in higher gear. The additional torque
allows the truck to crest a hill without downshifting
A/C Switch Fan On-Time and increases fuel economy. The Multi-Torque
feature also helps to reduce wear. The trip point
Low Speed Range Axle Ratio is determined by a ratio of engine speed versus
vehicle speed. The three programmable options
High Speed Range Axle Ratio represent the different trip point values that are
listed below.
Multi-Torque Ratio (OCT99 and Newer
Personality Modules)
Top Gear Ratio

Top Gear Minus One Ratio
Top Gear Minus Two Ratio
Vehicle Speed Calibration
Engine Retarder Delay
Fan Control Type
When an attempt to change a locked out parameter
occurs, the Factory Password screen will come up.
If changing the parameter is required, follow the
instructions on the Service Tool display.
Factory Passwords are also required to change a

parameter from a locked parameter to an unlocked
parameter. If more than one parameter is locked
out, and each one needs to be unlocked, one
Factory Password is required.
40
Table 4
Programmable Option Turn On Ratio (RPM to MPH) Gear Range
MT-4 71.5 Top 4 Gears
MT-2 37.6 Top 2 Gears
MT-1 27.9 Top 1 Gear
Note: This feature is not used with standard engine

ratings. This feature is only available for Multitorque
ratings.
Table 5
Type of Engine Rating Alternatives Default
Standard Ratings Unavailable Unavailable
Multitorque Ratings MT-2, MT-1 MT-4
ECM Identification Parameters Vehicle Speed Parameters

Vehicle ID Vehicle Speed Calibration
Vehicle ID is the identification of the vehicle that The Vehicle Speed Calibration is the value that is
is assigned by the customer. Vehicle ID is used used by the ECM in order to translate the vehicle
only for the customers reference. Vehicle ID is speed signal into kilometers per hour (miles per
not required by the ECM. hour). This parameter is programmed in pulses per
kilometer (PPKM) or pulses per mile (PPM). This
Security Access Parameters parameter must be programmed. If this parameter
is not programmed, the Diagnostic Code 253-02
that is Check Customer or System Parameters
ECM Wireless Communication Enable (56) will occur. This parameter affects the cruise
control and the ECM speedometer signal. Also, this
The ECM Wireless Communication Enable parameter can affect the PTO operation, extended
determines if the ECM will transfer information idle and trip totals.
over the data link through remote communications
systems for customers. Table 7
The parameter will default out of Caterpillar to no
access. The parameter can only be enabled by 2485 PPKM 93226 PPKM 8696 PPKM
getting Factory Passwords. This feature can only (4000 PPM) (150000 PPM) (14000 PPM)
be enabled after the truck has been delivered to
the customer. Refer to Troubleshooting, System
Overview for additional information. Vehicle Speed Limit (VSL)
Table 6 The Vehicle Speed Limit (VSL) is the maximum
vehicle speed that is allowed by the ECM. The ECM
Alternative Default
will shut off fuel above this speed. An inexperienced
Yes No driver may think that something is wrong with the
engine because the ECM will not fuel the engine
above this vehicle speed limit. Vehicle speed
limiting allows the implementation of a gear fast/run
slow specification for the truck. The gear fast/run
slow specification for the truck improves fuel
economy while the parameter for the vehicle speed
limit limits the maximum vehicle speed of the truck.
Note: The Driver Incentive Feature can be used

to automatically adjust the VSL according to the
drivers operating techniques.
41
Table 8 Low Speed Range Axle Ratio

The Low Speed Range Axle Ratio must be
48 km/h (30 mph)
204 km/h 204 km/h programmed when a Two-Speed Axle On/Off Switch
(127 mph) (127 mph) is used by the ECM to adjust the vehicle speed
calibration. When a two-speed axle is used, the
change in gear ratios from the high speed range
VSL Protection to the low speed range alters the calibration of
the vehicle speed signal. Since the vehicle speed
The VSL Protection is the maximum engine rpm signal has been altered, a calibration adjustment is
when there is a problem with the vehicle speed required to ensure that the ECM driven speedometer
signal that is detected by the ECM. The ECM limits and the information that is stored in the ECM
the engine to this engine rpm when the ECM senses correctly reflect the actual vehicle speed. This
no vehicle speed signal, and a load on the engine. parameter should be programmed to the Low
This is a feature that is used to prevent tampering by Speed Range Axle Ratio. This parameter only
running without a Vehicle Speed input to the ECM. requires programming when the Two-Speed Axle
Switch parameter is enabled. The Two-Speed Axle
Note: When this parameter is programmed to the Switch Parameter is enabled when the parameter
2120 rpm, the ECM disables the Diagnostic Code is programmed to J1/P1:7, J1/P1:47, J1/P1:6, or
84-01 that is Loss Of Vehicle Speed Signal (31) J1/P1:46.
and 84-10 that is Vehicle Speed Rate of Change
(36) and the VSL Protection can be exceeded by Table 12
disconnecting the Vehicle Speed Sensor.
Table 9 1.00 19.99 1.00
1300 rpm 2120 rpm 2120 rpm High Speed Range Axle Ratio
The High Speed Range Axle Ratio must be
Tachometer Calibration programmed when a Two-Speed Axle On/Off Switch
is used by the ECM to adjust the vehicle speed
The Tachometer Calibration is used by the ECM calibration. When a two-speed axle is used, the
to translate the engine speed signal into revolutions change in gear ratios from the high speed range
per minute for a tachometer. The Tachometer to the low speed range alters the calibration of
Calibration is programmed in pulses per revolution the vehicle speed signal. Since the vehicle speed
(PPR). The programmable range is from 12.0 PPR signal has been altered, a calibration adjustment is
to 500.0 PPR in 0.1 PPR increments. required to ensure that the ECM driven speedometer
Table 10
and the information that is stored in the ECM
correctly reflect the actual vehicle speed. This
Minimum Maximum Default parameter should be programmed to the High
12.0 PPR 500.0 PPR 113.0 PPR Speed Range Axle Ratio. This parameter only
requires programming when the Two-Speed Axle
Switch parameter is enabled. The Two-Speed Axle
Soft Vehicle Speed Limit Switch parameter is enabled when the parameter
is programmed to J1/P1:7, J1/P1:47, J1/P1:6, or
The Soft Vehicle Speed Limit operates in J1/P1:46.
conjunction with the Vehicle Speed Limit. The
Soft Vehicle Speed Limit limits the vehicle speed Table 13
within the following range: Minimum Maximum Default
1.00 9.99 1.00
The minimum value is 4 km/h (2.5 mph) below the
programmed Vehicle Speed Limit at full load.
The maximum value is 4 km/h (2.5 mph) above Cruise Control Parameters
the selected Vehicle Speed Limit at no load.
Table 11
Alternative Default The Low Cruise Control Speed Set Limit sets
the lowest vehicle speed that will allow the cruise
YES NO control to be set. Programming this parameter to
the maximum value disables cruise control.
42
Table 14 The engine retarder switch is in the ON position.

The engine rpm is greater than 800 rpm.
204 km/h 204 km/h
24 km/h (15 mph)
(127 mph) (127 mph) The engine is not being fueled.
Table 16
Alternative Default
The High Cruise Control Speed Set Limit sets Coast or Latch Manual
the highest vehicle speed that will allow the cruise
control to be set. If a driver attempts to set a
vehicle speed higher than this limit, the High
Cruise Control Speed Set Limit will be the cruise
set speed. If the High Cruise Control Speed Set
Limit is programmed to a value that is greater than
the Vehicle Speed Limit, the cruise control switches
can be used to exceed the programmed Vehicle
Speed Limit.
Table 15
204 km/h 204 km/h
48 km/h (30 mph)
(127 mph) (127 mph)
Engine Retarder Mode

Engine Retarder Mode determines the operation
of the Auxiliary Retarder Output and the Exhaust
Retarder Output while the cruise control On/Off
switch is in the ON position but the engine is not g00631045
Illustration 24
in cruise control. This does not determine engine
retarder operation while the engine is in cruise Coast and latch of engine retarder mode
control. Also, this does not allow engine retarder
operation while the engine is in cruise control. Engine Retarder Minimum VSL Type
The following modes are allowable options: The Engine Retarder Minimum VSL Type defines
the use of the Engine Retarder Minimum Vehicle
Coast Speed parameter. The Engine Retarder Minimum
VSL Type provides the following two options:
Latch
Hard Limit
Manual
Soft Limit
When the Engine Retarder Mode is programmed
to the Coast mode, the engine retarder is enabled If the Engine Retarder Minimum VSL Type is
only while the service brakes are being applied. programmed to the Hard Limit, the engine retarder
When the ECM is programmed to the Latch mode, will turn off when the value that is programmed
the engine retarder stays enabled after the service into the Engine Retarder Minimum Vehicle Speed
brakes are released. A direct, immediate pressure is reached.
on the brake pedal latches the engine retarder in
the ON position and the engine retarder will remain If the Engine Retarder Minimum VSL Type is
in the ON position until the accelerator pedal is programmed to the Soft Limit, the engine retarder
depressed. will remain on and the retarder will have a value that
is below the value that is programmed in the Engine
When the ECM is programmed to the Manual mode, Retarder Minimum Vehicle Speed. The engine
the cruise control switch is not required to be in the retarder will remain on until the parameters that
ON position. When the ECM is programmed to the would normally turn off the engine retarder are met.
Manual mode, the engine retarder will activate when
all of the following conditions are met:
43
In both cases, the engine retarder will remain off Engine Retarder Minimum Vehicle
until vehicle speed is higher than the programmed Speed
value of the Engine Retarder Minimum Vehicle
Speed and the engine retarder has been engaged Engine Retarder Minimum Vehicle Speed determines
again. the minimum vehicle speed limit for the engine
retarders to turn ON. Below this vehicle speed, the
The following diagram illustrates the Engine ECM will not turn on the engine retarder unless the
Retarder operation for both options of the Engine vehicle is stationary. If the vehicle is stationary, the
Retarder Minimum VSL Type. The Engine Retarder vehicle speed is 0 km/h (0 mph). If the vehicle
parameter is programmed to MANUAL and the speed signal was not being read by the ECM, the
parameter for the Engine Retarder Minimum Vehicle vehicle could be moving but the vehicle speed
Speed is programmed to 48 km/h (30 mph). signal would be 0 km/h (0 mph). If Engine Retarder
Minimum Vehicle Speed is programmed to 0 km/h
(0 mph) the engine retarder will operate at all
vehicle speeds. This parameter affects both the
engine retarder and any auxiliary retarder such as
a BrakeSaver.
Table 18
204 km/h
0 km/h (0 mph) 0 km/h (0 mph)
(127 mph)
Auto Retarder in Cruise

The Auto Retarder in Cruise determines the
vehicle speed in kilometers per hour (km/h) or
miles per hour (mph) above the cruise set speed
when the engine retarder will be activated. The
engine retarder switch must be in the ON position
and the cruise control must be set for this feature
to operate. Programming the Auto Retarder in
g00631048
Illustration 25 Cruise parameter to zero disables this feature.
This parameter affects the engine while the cruise
Note: When the vehicle speed drops below the control is activated.
Engine Retarder Minimum Vehicle Speed and the
parameter is programmed to the Hard limit, the Note: This parameter only affects the Factory
Engine retarder turns OFF. When the vehicle speed installed engine retarder (compression brake). This
drops below the Engine Retarder Minimum Vehicle parameter does not affect an auxiliary braking
Speed and the parameter is programmed to the device or Brakesaver.
Soft limit, the Engine retarder remains on.
The actual level of braking is limited by the settings
If the Engine Retarder Minimum Vehicle Speed of the retarder switch. For example, the retarder will
has been programmed to 0 km/h (0 mph), the not come ON if the retarder is switched OFF.
programming of the parameter for the Engine
Retarder Minimum VSL Type does not affect the If Soft Cruise Control is programmed to YES, the
operation of the Engine Retarder. retarder will not come on until the vehicle speed
is 5 km/h (3 mph) above the cruise set speed. An
Table 17 Electronic Service Tool will change an attempt to
Alternative Default program 2 km/h (1 mph) or 3 km/h (2 mph) for this
parameter to 5 km/h (3 mph) if Soft Cruise Control
Soft Limit Hard Limit
is programmed to YES.
Table 19
0 km/h (0 mph) 16 km/h (10 mph) 0 km/h (0 mph)
44
Auto Retarder in Cruise Increment

Auto Retarder in Cruise Increment requires
the Auto Retarder in Cruise parameter to be
programmed above zero. Auto Retarder in Cruise
Increment determines the increment in kilometers
per hour (km/h) or miles per hour (mph) when the
Medium level of engine retarder will activate. Auto
Retarder in Cruise Increment also determines the
increment in kilometers per hour (km/h) or miles per
hour (mph) when the High level of engine retarder
will activate. Programming the parameter to zero
will allow the retarder to come on in the High mode
when the programmed Auto Retarder in Cruise
speed is reached. The Auto Retarder in Cruise
speed must be set above the cruise set speed.
This parameter affects the engine while the cruise
control is activated. The actual level of braking
is limited by the settings of the retarder switch.
For example, the retarder will not come ON if the
retarder is switched OFF.
g00670797
Illustration 26
Table 20
Minimum Maximum Default Table 22
0 km/h (0 mph) 8 km/h (5 mph) 3 km/h (2 mph) Alternative Default

NO YES
Cruise/Idle/PTO Switch Configuration defines the
Idle Parameters
function of the Set/Resume Switch for ACCEL
mode and DECEL mode. This parameter affects Idle Vehicle Speed Limit
cruise control mode, idle mode and PTO mode.
The Idle Vehicle Speed Limit is the maximum
Table 21 vehicle speed for setting or maintaining a set
engine rpm in the idle mode. In order to enter
Alternative Default
the idle mode, the engine rpm must be set by
Set/Decel-Res/Accel Set/Accel-Res/Decel the Set/Resume switch while the Cruise Control
On/Off switch is in the ON position. If the vehicle
speed signal exceeds this value, the engine will not
Soft Cruise Control maintain the set engine rpm.
Soft Cruise Control provides a 8 km/h (5 mph) Table 23
operating range around the cruise control set speed
in order to provide a smoother cruise control. Soft
Cruise Control controls the cruise speed within the 2 km/h (1 mph) 24 km/h (15 mph) 2 km/h (1 mph)
following range:
4 km/h (2.5 mph) below the set vehicle speed Idle RPM Limit
at full load
The Idle RPM Limit is the maximum engine rpm
4 km/h (2.5 mph) above the set vehicle speed in idle mode. The idle mode occurs if the engine
at no load rpm is set by using the Cruise Control On/Off switch
and the Set/Resume switch. Refer to Idle Vehicle
Speed Limit. The actual high limit of this parameter
is determined by the programmed Top Engine Limit.
The lower limit is determined by the programmed
Low Idle Engine rpm.
45
Programming this parameter to 600 rpm will prevent Dedicated PTO Parameters
the engine from idling at a constant rpm above the
programmed Low Idle rpm. PTO Configuration
Table 24
The PTO Configuration determines the features
Minimum Maximum Default that are available for Dedicated PTO applications
and the input signals that are used for Dedicated
PTO applications. When the PTO Configuration is
turned off, the application does not use the PTO.
Idle/PTO RPM Ramp Rate The remaining PTO programmable options require a
PTO On/Off circuit that is connected to ECM Input
The Idle/PTO RPM Ramp Rate determines the 1. A PTO Switch On Lamp can also be connected
rate of increase or decrease of engine rpm. This to Output 1 (ECM J1/P1 terminal 30).
parameter determines rates of increase or decrease
in engine rpm for the following functions: If the ECM is programmed to the Cab Switches,
the ECM will use the signals from the following two
Idle rpm switches for PTO Control and Cruise Control:
PTO rpm Cab Set switch (J1/P1 terminal 35)

The parameter can be set to a value between 5 rpm Resume switch (J1/P1 terminal 44)
and 1000 rpm in one rpm increments.
If the ECM is programmed to Remote Switches,
Note: The parameter affects both idle control and the ECM will monitor programmed signals such
PTO control. The idle mode occurs if the engine as the Remote Set switch and Remote Resume
rpm is set by using the Cruise Control On/Off switch switch. Signals from the cab controls will be ignored
and the Set/Resume switch. The PTO mode occurs when the PTO On/Off circuit is ON. The following
if the engine rpm is set by using the PTO On/Off components are cab controls:
switch and the Set/Resume switch.
Brake Switch
Table 25
Minimum Maximum Default Clutch Switch
5 rpm/sec 1000 rpm/sec 50 rpm/sec Accelerator
Cruise Control Switches
Idle/PTO Bump RPM
If the ECM is programmed to Remote Throttle,
The Idle/PTO Bump RPM determines the the ECM will monitor J1/P1 terminal 68 for the
increment or the decrement in engine rpm when remote accelerator pedal. The ECM will monitor
the ACCEL switch or the DECEL switch is briefly programmed signals and the ECM will ignore all
toggled. The Idle/PTO Bump RPM also pertains to cab controls when the PTO On/Off circuit is ON.
the dedicated PTO and idle. If a PTO Engine RPM
Set Speed has been programmed, the Idle/PTO Table 27
Bump RPM pertains only to the control of the
Alternative Default
engine rpm that is initiated by using the Cruise
Control On/Off input circuit. If a PTO Engine rpm Set Cab Switches, Remote
Speed has been programmed, the Idle/PTO Bump Switches or Remote OFF
RPM also pertains to the control of the engine rpm Throttle
that is initiated by using the PTO On/Off circuit.
Table 26 PTO Top Engine Limit
The PTO Top Engine Limit is the top engine limit
5 rpm 500 rpm 20 rpm that is available by using a PTO On/Off circuit that
is connected to Input 1 of ECM Connector J1/P1.
Note: The PTO Configuration must be programmed

to Cab Switches, Remote Switches, or Remote
Throttle before this parameter can be programmed.
46
Table 28 The ECM controls this engine rpm. This control

occurs when the PTO ON/OFF circuit and the PTO
Engine RPM Set Speed Input B switch is ON and
600 TEL rpm TEL rpm the PTO Engine RPM Set Speed A switch is OFF.
The RPM can be programmed to operate from Low
Idle up to the PTO Top Engine Limit RPM. While
PTO Engine RPM Set Speed A the engine is operating at this set speed, all other
inputs for speed control are ignored except for the
NOV99 and Newer Personality Modules PTO Engine RPM Set Speed A. The inputs for speed
control that are ignored include the Cab Throttle
The ECM controls this engine rpm. This control switch, the Remote Throttle switch, the Set/Accel
occurs when the PTO ON/OFF circuit is ON and switch, and the Resume/Decel switch. This feature
the PTO Engine RPM Set speed Input A switch is can also be used in conjunction with the PTO to Set
ON. The RPM can be programmed to operate from speed feature for multiple speed PTO operation.
Low Idle up to the PTO Top Engine Limit RPM. This feature can also override the PTO to Set
While the engine is operating at this set speed, speed feature for multiple speed PTO operation.
all other inputs for speed control are ignored. The
inputs for speed control that are ignored include the The engine will only operate at this programmed
Cab Throttle switch, the Remote Throttle switch, the speed when the PTO ON/OFF circuit and the PTO
Set/Accel switch, and the Resume/Decel switch. Engine RPM Set Speed Input B switch is ON and
This feature can also be used in conjunction with the PTO Engine RPM Set Speed A switch is OFF.
the PTO to Set speed feature and the PTO Engine The engine will operate at the programmed speed
RPM Set Speed B feature for multiple speed PTO unless a condition that causes PTO operation
operation. This feature can also override the PTO kickout occurs. The conditions that will cause
to Set speed feature and the PTO Engine RPM Set PTO operation kickout include the depression
Speed B feature for multiple speed PTO operation. of the brake pedal, the depression of the clutch
pedal, and the PTO Vehicle Speed Limit that is
The engine will only operate at this programmed exceeded. The engine will return to low idle if the
speed when the PTO ON/OFF circuit is ON and the PTO operation is kicked out.
PTO Engine RPM Set Speed Input A switch is ON.
The engine will operate at the programmed speed Note: The PTO Configuration parameter must be
unless a condition that causes PTO operation programmed to Cab Switches, Remote switches,
kickout occurs. The conditions that will cause or Remote Throttle and the PTO Engine RPM Set
PTO operation kickout include the depression Speed Input B parameter must be programmed
of the brake pedal, the depression of the clutch to a dedicated switch input (J1/P1:6, J1/P1:46,
pedal, and the PTO Vehicle Speed Limit that is J1/P1:58, or J1/P1:60) for this feature to function.
exceeded. The engine will return to low idle if the
PTO operation is kicked out. Table 30
Note: The PTO Configuration parameter must be
programmed to Cab Switches, Remote Switches, Low Idle rpm PTO TEL rpm 0 rpm
or Remote Throttle and the PTO Engine RPM Set
Speed Input A parameter must be programmed
to a dedicated switch input (J1/P1:6, J1/P1:46, PTO to Set Speed
J1/P1:58, or J1/P1:60) for this feature to function.
This parameter causes the ECM to proceed to
Table 29 the programmed PTO Engine RPM Set Speed
when the PTO ON/OFF switch is ON. PTO
Configuration must be programmed to Cab
Low Idle rpm PTO TEL rpm 0 rpm Switches or Remote Switches before this parameter
can be programmed.
PTO Engine RPM Set Speed Input B Note: This parameter is not available for PTO
Configuration Remote Throttle.
NOV99 and Newer Personality Modules
Table 31
Alternative Default
YES NO
47
PTO Cab Controls RPM Limit Torque Limit

This determines the engine rpm limit of the Cab
Accelerator Pedal Position Sensor when PTO
and the PTO On/Off circuit is ON. This parameter
is intended to prevent engine overspeed when
dedicated PTO is used.
If the parameter is programmed to Low Idle, the

Cab Controls are ignored.
If the parameter is programmed to Top Engine

Limit (TEL), the engine will operate to the
programmed Top Engine Limit.
g00628600
If the parameter is programmed to PTO TEL, the Illustration 27
engine will operate to the programmed PTO Top Operation of Torque limit
Engine Limit. (1) Programmed torque limit
Note: PTO Configuration must be programmed The parameter for the Torque Limit defines the
to Cab Switches for this parameter to take effect. maximum torque output of the engine during
If PTO Configuration is programmed to Remote Dedicated PTO operation. This parameter provides
Switches or Remote Throttle, the ECM will always temporary protection of equipment. The Torque
ignore the Cab Throttle when the PTO On/Off circuit limit of the engine is active when the circuit for the
is ON. Torque Limit Switch is ON. The maximum value
is the Rated Torque of the engine. The Torque
Table 32
Limit is programmable to Nm (lb ft) of torque.
Alternative Default Programming a value higher than the Rated Torque
Low Idle, TEL or PTO TEL TEL
is limited by the ECM to Rated Torque. The torque
limit is indicated by the dashed line in Illustration 27.
PTO Vehicle Speed Limit (VSL) Table 34

This is the maximum vehicle speed for setting or
270 Nm 3400 Nm 3400 Nm
maintaining a set engine rpm in PTO mode. PTO
(200 lb ft) (2500 lb ft) (2500 lb ft)
mode is entered if the PTO On/Off Switch is ON.
(This uses Input 1.) If the vehicle speed signal
exceeds this value, the engine will not maintain the PTO Shutdown Time
set engine rpm.
The PTO Shutdown Time is the time (minutes) of
Table 33
engine operation with the PTO On/Off circuit ON
Minimum Maximum Default and no vehicle speed before shutting down. The
timer will only count with no vehicle speed and the
204 km/h
2 km/h (1 mph)
(127 mph)
2 km/h (1 mph) PTO On/Off circuit ON. The PTO Shutdown Timer
will not begin counting if the engine is in Cold Mode.
This parameter requires the PTO Configuration to
be programmed to Cab Switches, Remote Switches
or Remote Throttle for the timer to function.
Note: This feature does not shut down the vehicles

power. The ECM and the vehicle remain powered.
Table 35
3 minutes 1440 minutes 0 minutes
PTO Shutdown Timer Maximum RPM

OCT99 and Newer Personality Modules
48
This parameter can be used to reset the PTO Table 37

Shutdown Timer if engine speed goes above the Range Default
programmed PTO Shutdown Timer Maximum RPM.
Programming this parameter to 2120 rpm disables Normal
Normal
this feature. If this parameter is programmed to a Continuous
value below 2120 rpm and the PTO Shutdown Timer
is used, the timer will be reset when the engine
RPM exceeds the programmed value. Engine/Gear Parameters
The engine will accelerate at a slower rate when this
limit is exceeded under normal driving conditions.
This parameter is used to encourage the driver to
shift to the next highest gear.
Table 38
Lower Gears Turn Off Speed

The Lower Gears Turn Off Speed parameter is
the vehicle speed when the Lower Gears Engine
RPM Limit is shut off. This must be matched with
the Lower Gears Engine RPM Limit to the specific
drive train for best performance.
g00671143 Table 39
Illustration 28
PTO Shutdown Timer Maximum RPM Graph Minimum Maximum Default
Table 36 5 km/h (3 mph) 48 km/h (30 mph) 5 km/h (3 mph)

600 rpm 2120 rpm 2120rpm
This parameter is similar to the Lower Gears
PTO Activates Cooling Fan Engine RPM Limit. The engine will accelerate at
a slower rate when this limit is exceeded under
This parameter requires the use of the ECM cooling normal driving conditions. This parameter is
fan circuit. When this parameter is programmed to typically programmed to a slightly higher rpm than
Continuous Mode, the ECM will signal the cooling the Lower Gears Engine RPM Limit.
fan to run continuously when the PTO On/Off circuit
is ON. The cooling fan runs continuously in order Table 40
to reduce changes in the load while the engine is Minimum Maximum Default
being used for dedicated PTO applications. When
this parameter is programmed to the normal mode,
the fan operates the same way with the PTO On/Off
circuit ON or OFF. In this mode, the operation of Intermediate Gears Turn Off Speed
the fan is based on coolant temperature, inlet air
temperature or air conditioning high head pressure. This parameter is similar to the Lower Gears Turn
The PTO Configuration must be programmed to Off Speed. This parameter is typically programmed
Cab Switches, Remote Switches or Remote Throttle to a slightly higher vehicle speed than the Lower
before this parameter can be programmed. The Fan Gears Turn Off Speed.
Control Type must be programmed to the On/Off
setting or the Three-Speed Fan Setting. Table 41
8 km/h (5 mph) 80 km/h (50 mph) 8 km/h (5 mph)
49
Gear Down Protection RPM Limit Table 45

Alternative Default
This parameter is the Engine RPM Limit when the
vehicle speed is above the Gear Down Protection Yes No
Turn On Speed. This is a hard limit. The ECM will
not allow fuel to the engine above this limit. This
parameter is used to encourage the driver to shift Low Idle Engine RPM
into overdrive or top gear.
The Low Idle Engine RPM is the minimum engine
Table 42 rpm.
Minimum Maximum Default Table 46
1300 rpm TEL rpm TEL rpm Minimum Maximum Default
600 rpm 750 rpm 600 rpm
Gear Down Protection Turn On Speed
This parameter is the Vehicle Speed when the Transmission Style
Gear Down Protection RPM Limit is turned on. This
must be matched to the specific drive train for This parameter indicates the type of transmission
best performance. Above this vehicle speed limit, configuration that is installed in the vehicle to the
the engine rpm will be limited by the Gear Down ECM. This parameter is used by the ECM to read
Protection RPM Limit. the signals from the following devices:
Table 43 Brake switch (No. 2)

Clutch Switch
204 km/h 204 km/h
48 km/h (30 mph)
(127 mph) (127 mph) Neutral switch
If an automatic transmission is installed, this
Top Engine Limit (TEL) parameter should be programmed to one of the
following options:
OCT99 and Older Personality Modules
Automatic Option 1
This parameter is the maximum engine rpm when
the engine is under load. The engine will still Automatic Option 2
achieve Rated rpm under no load conditions.
Automatic Option 3
Note: NOV99 and newer personality modules do not
allow the TEL to be adjusted. Automatic Option 4
Table 44
The Manual selection requires a clutch pedal
Minimum Maximum Default position switch to be connected to the ECM
Connector J1/P1 terminal 24. The transmission
This value is
dependent on selections with a neutral switch require a
1600 rpm 2120 rpm(1) transmission neutral switch to be connected to the
the Engine
Rating. ECM Connector J1/P1 terminal 62 . Terminal 62 is
(1)
the Input 12. The transmission selections with two
A limited number of special ratings have a Top Engine Limit
of 2150 rpm.
brake switches require a second brake switch to be
connected to the ECM Connector J1/P1 terminal 64.
Terminal 64 is the Input 13.
Top Engine Limit with Droop
The Eaton Top 2 transmission is a manual
OCT99 and Older Personality Modules transmission and the Eaton Top 2 transmission
requires a clutch switch. The ECM operates two
When the Top Engine Limit with Droop is selected, outputs in order to control shifting between the top
the engine can exceed the TEL with a partial load. two gears of an Eaton Top 2 transmission. A total
The rpm limit increases as load decreases to 150 of four parameters must be programmed for the
rpm above the selected limit for no load. system to operate correctly.
Note: NOV99 Personality Modules and newer
Personality Modules do not allow the droop option
to be selected.
50
Table 47
Transmission Style Use of Switch

Parameter Setting Service Brake No. 1 Service Brake No. 2 Clutch Neutral
Manual X X
Automatic Option 1 X
Automatic Option 2 X X
Automatic Option 3 X X X
Automatic Option 4 X X
Eaton Top 2 X X
Table 48 Top Gear Ratio

Alternative Default
The Top Gear Ratio identifies the highest gear
Automatic Option 1, ratio for an Eaton Top 2 Transmission. For example,
Automatic Option 2, tenth gear for an Eaton Super 10 Top 2 transmission
Automatic Option 3, Manual is the Top Gear. The programmable range is 0.000
Automatic Option 4, to 3.750 in 0.001 increments. The default is 0.000.
Eaton Top 2
Refer to Gear Ratios for Eaton Top 2 Transmission
for programmable values for each Eaton Top 2
Eaton Top 2 Override with Cruise transmission.
Control Switch Note: This parameter must be precisely programmed
to three decimal places to ensure the proper
If this parameter is programmed to YES the Cruise operation of the Eaton Top 2 and Caterpillar engine
Control On/Off switch can be used to disable Top 2 drive train in the top two gears.
mode. If the Cruise Control On/Off switch is turned
to the OFF position and the transmission is not Table 50
in Top 2 mode, the Top 2 mode will be disabled.
This condition is applicable to the manual mode of Minimum Maximum Default
operation only. If the Cruise Control On/Off switch is 0.000 3.750 0.000
turned to the ON position, the Top 2 mode will be
enabled and the transmission will be allowed to shift
automatically in the Top 2 gears. When the vehicle Top Gear Minus One Ratio
is operating in one of the Top 2 gears and the Top
2 mode is enabled, switching the Cruise Control The Top Gear Minus One Ratio identifies the
On/Off switch to the OFF position will place the second highest gear ratio for an Eaton Top 2
transmission in Hold mode. When the transmission Transmission. For example, ninth gear for an Eaton
is in the Hold mode, the transmission will not shift Super 10 Top 2 transmission is Top Gear Minus
out of the currently selected gear. When the Cruise One. The programmable range is 0.000 to 3.750
Control On/Off switch is returned to the ON position, in 0.001 increments. The default is 0.000. Refer
the transmission will return to Top 2 mode. When to Gear Ratios for Eaton Top 2 Transmission
the clutch is depressed and the transmission is in for programmable values for each Eaton Top 2
the Hold mode, the Manual mode will be enabled transmission.
and the Top 2 will be disabled.
Note: This parameter must be precisely programmed
Table 49 to three decimal places to ensure the proper
Alternative Default operation of the Eaton Top 2 and Caterpillar engine
drive train in the top two gears.
YES NO
Table 51
0.000 3.750 0.000
51
Top Gear Minus Two Ratio Timer Parameters

The Top Gear Minus Two Ratio identifies the third Idle Shutdown Time
highest gear ratio for an Eaton Top 2 Transmission.
For example, eighth gear for an Eaton Super The Idle Shutdown Time is the time (minutes) of
10 Top 2 transmission is Top Gear Minus Two. engine idle before shutting down. The engine will
The programmable range is 0.000 to 3.750 in only shut down if the ECM senses low engine load
0.001 increments. The default is 0.000. Refer and no vehicle speed. The Idle Shutdown Timer will
to Gear Ratios for Eaton Top 2 Transmission not begin counting if the engine is in Cold Mode. If
for programmable values for each Eaton Top 2 this parameter is programmed to zero, this feature is
transmission. disabled and the engine will idle until the keyswitch
for the ignition is in the OFF position.
Note: This parameter must be precisely programmed
to three decimal places to ensure the proper Note: This feature does not shut down the vehicles
operation of the Eaton Top 2 and Caterpillar engine power. The ECM and the vehicle remain powered.
drive train in the top two gears.
Table 54
Table 52
3 minutes 1440 minutes 0 minutes
0.000 3.750 0.000
Idle Shutdown Timer Maximum RPM

Gear Ratios for Eaton Top 2
Transmission NOV99 and Newer Personality Modules
Table 53 This parameter can be used to reset the Idle
Transmission Top Top Top Shutdown Timer if engine speed goes above
Model Gear Gear Gear the programmed Idle Shutdown Timer Maximum
Minus Minus Ratio RPM. Programming this parameter to 2120 rpm
Two One disables this feature. By disabling this feature,
Ratio Ratio the Idle Shutdown Timer can not be overridden
RTLO-XX610B-T2 1.352 1.000 0.741 by increasing the engine rpm. If this parameter is
programmed to a value below 2120 rpm and the
RTLO-XX710B-T2 1.825 1.351 1.000 PTO Shutdown Timer is used, the timer will be reset
RTLO-XX713A-T2 1.000 0.856 0.730 when the engine RPM exceeds the programmed
value.
RTLO-XX718B-T2 1.000 0.856 0.730
Table 55
Note: The XX that appears in the model number Minimum Maximum Default
of the transmission refers to the Nominal Torque 600 rpm 2120 rpm 2120 rpm
Capacity. XX times 100 equals the Nominal
Torque Capacity. For example, RTLO-14613A has
a Nominal Torque Capacity of 14 times 100 or Allow Idle Shutdown Override
1900 Nm (1400 lb ft).
This parameter determines if the clutch or the
The model designation of the transmission and service brake can be used to override the idle
other information are stamped on a tag on the shutdown timer during the driver alert. The driver
transmission. The tag is located on the lower left alert is the last 90 seconds when the Check Engine
side near the front of the transmission. Lamp begins flashing. This parameter requires the
Idle Shutdown Time to be programmed to 3 or more
minutes for the parameter to be enabled. When
the Idle Shutdown Time is programmed to 0, the
parameter is turned off.
In order to override the timer under the following

conditions, depress the clutch or the service
brake if the parameter is programmed to Outside
Temperature Based or J1587 Outside Temperature
Based and the driver alert is activated. Depression
of the clutch or the service brake will override the
timer:
52
The outside temperature is below the programmed

Minimum Idle Shutdown Outside Temperature.
The outside temperature is above the Maximum

Idle Shutdown Outside Temperature.
Note: When the timer is overridden, the engine will

not shut down.
If the outside temperature is between the Minimum

Idle Shutdown Outside Temperature and the
Maximum Idle Shutdown Outside Temperature,
the timer is not overridden and the engine will
shut down. If the Outside Temperature Based
option is programmed, an Air Temperature Sensor g00631057
must be installed in order to measure the outside Illustration 29
temperature. If the sensor is not installed, a The Allow Idle Shutdown Override is programmed to the Outside
171-03 Outside Air Temp Sensor Open Circuit Temperature Based option or the Outside Temperature Based
(J1587) option.
diagnostic code will be active. If the J1587 Outside
Temperature Based option is programmed and a
171-11 No Ambient Air Temperature Data active Maximum Idle Shutdown Outside
diagnostic code exists, the idle shutdown timer will Temperature
be disabled.
This parameter determines the upper outside
Table 56 temperature limit when the Allow Idle Shutdown
Alternative Default Override is programmed to one option of the
options that follow:
NO, Outside Temperature
Based, and (J1587)
Outside Temperature
YES Outside Temperature Based
Based
J1587 Outside Temperature Based
Minimum Idle Shutdown Outside Illustration 29 indicates that the Allow Idle
Temperature Shutdown Override is allowed in the final 90
seconds of the timers countdown. During the final
This parameter determines the lower outside 90 seconds, one of the following conditions must
temperature limit when the Allow Idle Shutdown exist in order for the engine to be shut down:
Override is programmed to one option of the
options that follow: The outside temperature is below the programmed
Minimum Idle Shutdown Outside Temperature.
Outside Temperature Based
The outside temperature is above the Maximum
Idle Shutdown Outside Temperature.
J1587 Outside Temperature Based
Table 58
Table 57

40 C (40 F) 49 C (120 F) 49 C (120 F)

40 C (40 F) 49 C (120 F) 49 C (120 F)
53
A/C Switch Fan On-Time This parameter is used to determine the voltage trip
point. Below this trip point, the Battery Monitor and
The input 11 to the ECM can be used for the the Engine Speed Control System will automatically
connection of a normally closed high pressure A/C elevate engine idle in order to maintain ideal battery
switch. The ECM has a built-in timer. The timer is system voltage. This feature is used to promote
used to prevent excessive cycling of the cooling fan additional battery life. The engine idle will only
clutch due to successive cycling of the A/C switch. be increased if the vehicle is stopped and the
Programming this parameter to 0 disables the transmission is out of gear. If these conditions
function. Programming depends on the refrigerant, are not met, the engine idle will not be adjusted.
and the design of the air conditioning system as This feature will not function when the engine is
well as the use of the signal input. Program the operating in dedicated PTO mode (PTO On/Off
timer to 1 second for the connection of this input to switch in the ON position).
another system. Programming the timer to 1 second
also provides a time delay. This feature requires the The recommended setting is 12.2 Volts for a 12 Volt
Fan Control Type to be programmed to the On/Off system, and 24.5 Volts for a 24 Volt system.
or the Three-Speed Fan.
Note: This feature requires the installation of a
Table 59 Neutral Switch on J1/P1. This is terminal 62 (Input
Minimum Maximum Default 12). Engine speed will only be elevated when the
transmission is in Neutral.
1 second 600 seconds 0 seconds
Table 62
Fan with Engine Retarder in High Mode Minimum Maximum Default

0 Volts 25.5 Volts 0 Volts
This parameter determines whether the Cooling Fan
will turn on when the Engine Brake has been active
for at least two seconds. This feature requires the Engine Monitoring Parameters
Fan Control Type to be programmed to the On/Off or
the Three-Speed Fan. An On/Off or a Three-Speed
Engine Monitoring Mode
Fan must be installed in order for this parameter
to function.
This parameter determines the level of action that
Table 60 will be taken by the ECM in response to a condition
that has the capability to damage the engine. The
Alternatives Default ECM reads the Caterpillar Coolant Temperature, Oil
NO YES Pressure and Inlet Manifold Air Temperature. If the
ECM has been programmed to monitor the OEM
Installed Coolant Level Sensor, the ECM will read
Engine Retarder Delay that sensor.
This parameter provides a programmable delay Table 63

after provisions to turn on the engine retarder or Alternative Default
the engine brake are met.
OFF, DERATE and
WARNING
Table 61 SHUTDOWN
0 seconds 3 seconds 0 seconds Engine Monitoring Lamps
Smart Idle Parameters
This parameter determines the lamp requirements
Battery Monitor and Engine Control Voltage for the Engine Monitoring System. If this parameter
is programmed to the Warning Lamp option, J1/P1
OCT99 and Newer Personality Modules (terminal 29) is available for the connection of a red
Warning Lamp. The Warning Lamp is used to alert
the operator that an engine problem is occurring.
The Warning Lamp also indicates when the engine
is being derated or the lamp will indicate that
shutdown will take place.
54
If this parameter is programmed to Option 1, there If Hour is selected, all maintenance indications on
will be up to three discrete lamp outputs that the service tool will be displayed in Hours. Typical
are available for use to indicate specific engine maintenance indications are PM 1, PM 2 and the
problems. Option 1 configures J1/P1 (terminal Cooling System Clean/Flush. The ECM provides
29) for the connection of a Low Oil Pressure PM 1 maintenance interval and last maintenance
Warning Lamp and Option 1 also configures J1/P1 information.
(terminal 31) for the connection of a High Coolant
Temperature Warning Lamp. If the parameter for the Table 66
Coolant Level Sensor is programmed to the 4 Pin Alternative Default
option, then J1/P1 (terminal 30) will also be available
for the connection of a Low Coolant Level Warning Manual Distance
Lamp. If the parameter for the Coolant Level Sensor Manual Hours
OFF
Automatic Distance
is programmed to Off, then J1/P1 (terminal 30) can
Automatic Hours
be used to connect a PTO Switch On Lamp.
Table 64
PM 1 Interval (Manual Maintenance
Alternative Default Indicator Mode)
Option 1 Warning Lamp
The PM 1 Interval allows a maintenance interval
(PM 1) to be specified by the user. This parameter
Note: The Engine Monitoring System must be (PM 1 Interval) must be programmed only when
programmed to one of the following items for the the Maintenance Indicator Mode is programmed to
Warning Lamp to function. a Manual Mode (Distance or Hours).
Warning Table 67
Manual Distance
Derate
Shutdown 8050 km 56325 km 24140 km
(5000 miles) (35000 miles) (15000 miles)
Coolant Level Sensor
Table 68
This parameter determines if the ECM monitors
the input signal of the Coolant Level Sensor. This Manual Hours
feature requires the Engine Monitoring Mode to be Minimum Maximum Default
programmed to one of the following modes:
100 750 300
Warning
Derate Engine Oil Capacity (Automatic
Maintenance Indicator Mode)
Shutdown
The PM 1 Interval can be determined by the
Table 65 ECM. The ECM bases the PM 1 Interval on
Alternative Default fuel usage. This parameter (PM 1 Interval) must
be programmed only when the Maintenance
4-pin NO Indicator Mode is programmed to an Automatic
Mode (Distance or Hours). Capacity of the Sump
influences the Maintenance Interval.
Table 69
Maintenance Indicator Mode Minimum Maximum Default
The ECM records data that is related to the 19 L (20 qt) 57 L (60 qt) Refer to Table 70.
vehicles maintenance. If Distance is selected, all
maintenance indications on the service tool will
be displayed in distance. Typical maintenance
indications are PM 1, PM 2 and the Cooling System
Clean/Flush.
55
Table 70
Engine Model Default
C-10 and C-12 34 L (36 qt)
3406E, C-15 and C-16 38 L (40 qt)
3406E, C-15 and C-16 with
38 L (40 qt)
a Rear Sump BreakSaver
3406E, C-15 and C-16 with
38 L (40 qt)(1)
a Front Sump BreakSaver
(1) The 3406E, C-15 and C-16 Engine with a Front Sump
BrakeSaver should be programmed to 49 L (52 qt).
Trip Parameters g00629939

Illustration 31
Fuel Correction Factor

The fuel correction factor is available to fine tune
all fuel data that will be stored in the future by The following parameters establish a security
the ECM. Caterpillar recommends changing this access for the Caterpillar Driver Information Display:
factor only after a significant operating interval that
includes a comparison of actual tank fuel economy Change Fuel Correction Factor
to the fuel economy that is recorded in the ECM.
The operating interval should also reflect a typical PM 1 Reset
route. The Fuel Correction Factor is a percentage
that is programmable in 0.5 percent increments. Fleet Trip Reset
Table 71 State Selection
These parameters require a Caterpillar Driver
63.5 +63.5 0 Information Display for access.
Calculating Fuel Correction Factor Change Fuel Correction Factor

The following formula should be used to determine This parameter allows the driver to adjust the Fuel
the new Fuel Correction Factor (NEW FCF). Correction Factor. An owner/operator would want
the driver to be able to change this information, but
a fleet operation might not want the driver to be
able to change this information.
Table 72
Alternative Default
YES NO
g00629908
Illustration 30
PM 1 Reset
OLD FCF Fuel Correction Factor in ECM
This parameter determines the drivers access for
TANK Actual Fuel Economy resetting the PM 1 (Maintenance) after the PM 1
has been performed. Maintenance Indicator Mode
ECM Fuel Economy in ECM Stored Trip Data cannot be programmed to OFF for the PM 1 Reset
parameter to take effect.
Refer to Illustration 31 as an example. The Actual
TANK fuel economy is 7.1 mpg. The Fuel Economy Table 73
in the ECM Stored Trip Data is 7.0 mpg over the Alternative Default
same distance with an OLD FCF of 2.5.
YES NO
56
Fleet Trip Reset Table 77

Alternative Default
This parameter determines the drivers access for
resetting the Fleet Trip Segment. Four Characters
A through Z 0000
Table 74 0 through 9
Alternative Default
YES NO Quick Stop Rate
This parameter determines the rate of vehicle speed
State Selection change that is used by the ECM to record a Quick
Stop Event Code and a Quick Stop Snapshot. This
Program this parameter to NO to disable this parameter is programmable from 5 kilometers per
function of the Cat ID. The Cat ID will not show hour per second (3 miles per hour per second) to 24
State Selection as an option to the driver. If this kilometers per hour per second (15 miles per hour
parameter is programmed to Yes (default) the Cat per second). This parameter is also programmable
ID will provide the feature of State Selection. to 0, which is the default value. Programming this
parameter to 0 will disable this feature and no
Programming this parameter to NO eliminates State Quick Stop Events will be logged. Each Quick
Selection. Therefore, the storage of the trip data Stop Snapshot contains 60 frames of information.
(State Selection) is eliminated. The no. 45 Frame is the Quick Stop occurrence.
The Quick Stop Snapshot also contains 44 frames
Table 75 before the Quick Stop occurrence and 15 frames
Alternative Default after the Quick Stop occurrence. Each frame is
separated by 1.0 second.
NO YES
Table 78
Theft Deterrent System Control ECM Snapshot Frame Data

Engine rpm Vehicle Speed
When this parameter is used with a Theft Deterrent Throttle Position Cruise Status
Password, this parameter prevents the engine from Clutch Switch Brake Switch
starting unless the password has been entered via
the dash display of the CAT ID. Before the operator
The most recent Quick Stop Snapshot is stored in
can use the feature of Theft Deterrent of the CAT
the ECM memory. When a Quick Stop Event occurs
ID, the system must be turned on. In order to turn
the ECM replaces the old Quick Stop Snapshot
on the theft deterrent, a service tool must be used
with the new Quick Stop Snapshot. The ECM also
to program the parameter for the theft deterrent to
logs a diagnostic event code for each Quick Stop
YES. The operator must first enter the password
Occurrence. The ECM stores a maximum of 255
before the engine is shut off. This will enable the
occurrences.
system. Enabling the system prevents the engine
from starting without re-entering the password on Table 79
the next attempted start.
Alternative Default
Table 76
5 kilometers per hour
Alternative Default per second ( 3 miles per
0 kilometers per hour
hour per second) to 24
YES, Auto-Enable(1) NO per second (0 miles per
kilometers per hour per
hour per second)
(1) NOV99 and Newer Personality Modules second (15 miles per
hour per second)
Theft Deterrent Password
Note: Programming the Quick Stop Rate too low
The Theft Deterrent Password is the password will cause an excessive number of Quick Stop Event
that is required by the ECM before the feature of Codes. A vehicle without a load or a trailer will be
Theft Deterrent is enabled. After the Theft Deterrent able to stop much more quickly than a vehicle with
is enabled, the Theft Deterrent Password is the a heavy load. If too many Quick Stop Event Codes
password that is required to restart the engine. All are being logged, the Quick Stop Rate should be
of the characters must be in the upper case. increased. This will improve the detection of the
exceptions when the exceptions occur.
57
Vehicle Activity Report J1/P1:47 (Input 5)

Minimum Idle Time J1/P1:6 (Input 6)
OCT99 and Newer Personality Modules J1/P1:46 (Input 7)
The Vehicle Activity Report provides a This switch will allow the operator to turn on the
chronological order log of engine operation. This cooling fan at any time for improved retarding and
report records the following items: vehicle starts, braking of the engine. This will also allow better
vehicle stops, idle time, driving time, and PTO time. engine cooling.
The Minimum Idle Time parameter can be used to
Table 82
adjust the recorded idle time. This is done in order
to remove the time for the following occurrences: Alternative Default
stopped in traffic, switching into PTO mode and
J1/P1:7
switching out of PTO mode, and idling for other J1/P1:47
brief periods of time. If the Minimum Idle Time is NONE
J1/P1:6
programmed to a value above 0 minutes (default), J1/P1:46
the previous mode of operation will be logged until
the idle time exceeds the programmed limit.
Table 80
Minimum Maximum Default The Input 5 to the ECM can be used to connect
an Ignore Brake/Clutch Switch. The Ignore
0 Minutes 1440 Minutes 0 Minutes Brake/Clutch Switch is used for applications that
require the mobile use of the vehicle with a set PTO
engine set rpm that does NOT require the Brake or
Driver Reward the Clutch to disengage the engines PTO operation.
This parameter (Ignore Brake/Clutch Switch) must
Driver Reward Enable be programmed to J1/P1:47 to enable this feature.
MAR99 and Newer Personality Modules Table 83

Alternative Default
Driver Reward is a feature that allows a truck
owner to place emphasis on certain factors J1/P1:47 NONE
for desired operating habits. If the vehicle is
operated in a manner that exceeds the owners
specifications, the maximum vehicle speed limit can
Torque Limit Switch
be automatically increased to a specified value as
The Input 4 to the ECM can be used to connect the
a reward to the driver. The Driver Reward Enable
Torque Limit Switch in order to limit the engine
parameter provides a means in order to disable
torque to a programmable value. This should only
the Driver Reward feature. This parameter also
provides a means in order to lock out the Driver
This parameter (Torque Limit Switch) must be
Reward feature. An Electronic Service Tool is used
programmed to J1/P1:7 to enable this feature.
for those areas with regulations that require a fixed
maximum Vehicle Speed Limit. Table 84

Alternatives Default J1/P1:7 NONE
Disabled Enabled
Diagnostic Enable Switch
Input Selections The Input 7 can be used to connect the Diagnostic
Enable Switch. This parameter (Diagnostic
Fan Override Switch Enable Switch) must be programmed to J1/P1:46.
Diagnostic flash codes can be prompted by using
Four input connections can be used in order to the Diagnostic Enable switch. To initiate the flash
connect the Fan Override Switch. The Fan codes, depress the momentary Diagnostic Enable
Override Switch can be programmed to the switch until the Check Engine Lamp begins to
following ECM pins: flash. Refer to Troubleshooting, Diagnostic Codes
for additional information regarding flash codes.
J1/P1:7 (Input 4)
58
Table 85 The PTO Engine RPM Set Speed Input B Switch

Alternative Default
can be connected to either J1/P1:6, J1/P1:46,
J1/P1:58, or J1/P1:60. If the PTO Engine RPM Set
J1/P1:46 NONE Speed Input B parameter is programmed to the
corresponding switch input option, the switch is
used to control engine speed during PTO operation.
Remote PTO Set Switch The PTO Configuration parameter must be
programmed to Cab Switches, Remote Switches or
The Input 2 can be used to connect the Remote Remote Throttle and the PTO Engine RPM Speed
PTO Set Switch. The Remote PTO Set Switch is Input B parameter must be programmed to a valid
used when the PTO Configuration is programmed speed.
to Remote Switches and the PTO On/Off switch is in
the ON position. This parameter (Remote PTO Set Table 89
Switch) must be programmed to J1/P1:58.
Table 86 J1/P1:6, J1/P1:46,
None
Alternative Default J1/P1:58, J1/P1:60
NONE J1/P1:58
Starting Aid On/Off Switch
Remote PTO Resume Switch OCT99 and Newer Personality Modules
The Input 3 can be used to connect the Remote The Starting Aid On/Off Switch can be connected
PTO Resume Switch. The Remote PTO Resume to either of the following locations: J1/P1:6, J1/P1:7,
Switch is used when the PTO Configuration J1/P1:46, and J1/P1:47. The Starting Aid System
is programmed to Remote Switches and the does not require a switch for Automatic operation. A
PTO On/Off switch is in the ON position. This switch can be installed in order to allow the operator
parameter (Remote PTO Resume Switch) must be to disable the Automatic Starting Aid. If a switch
programmed to J1/P1:60. is installed and the Starting Aid On/Off Switch
parameter is programmed to the corresponding
Table 87
switch input, the switch will control the Starting Aid
Alternative Default system. When the switch is in the ON position, the
Starting Aid System will automatically enable the
NONE J1/P1:60
Starting Aid Output when conditions require the
use of a starting aid. When the switch is in the Off
PTO Engine RPM Set Speed Input A position, the Starting Aid System will not function.
Table 90
The PTO Engine RPM Set Speed Input A Switch
J1/P1:6, J1/P1:7, J1/P1:46,
can be connected to either J1/P1:6, J1/P1:46, J1/P1:47
None
J1/P1:58, or J1/P1:60. If the PTO Engine RPM Set
Speed Input A parameter is programmed to the
corresponding switch input option, the switch is Two-Speed Axle Switch
used to control engine speed during PTO operation.
The PTO Configuration parameter must be The Input 6 to the ECM is used to connect the
programmed to Cab Switches, Remote Switches or Two-Speed Axle On/Off Switch. When a two-speed
Remote Throttle and the PTO Engine RPM Speed axle is used, the change in gear ratios from the
Input A parameter must be programmed to a valid high speed range to the low speed range alters
speed. the calibration of the vehicle speed signal. When
this parameter (Two-Speed Axle On/Off Switch)
Table 88 is programmed to J1/P1:6 and the switch is in the
Alternatives Default ON position the ECM automatically adjusts the
vehicle speed calibration. This will ensure that the
J1/P1:6, J1/P1:46, ECM driven speedometer and the information that
None
J1/P1:58, J1/P1:60
is stored in the ECM correctly reflect the actual
vehicle speed. The High Speed Range Axle Ratio
PTO Engine RPM Set Speed Input B and Low Speed Range Axle Ratio must also be
programmed for this feature to function correctly.
59
Table 91 Clutch Pedal Position Switch

Alternative Default
The Input for the Clutch Pedal Position Switch
J1/P1:6 NONE is available for the connection of a Clutch Pedal
Position Switch to ECM Connector J1/P1 terminal
22. This parameter (Clutch Pedal Position Switch)
Cruise Control On/Off Switch must be programmed to J1/P1:22. This input is
used when the Transmission Style is programmed
The Cruise Control On/Off Input Circuit is available to the Manual Mode. When the Transmission Style
for the connection of a Cruise Control On/Off is programmed to the Manual Mode, an input that is
Switch to ECM Connector J1/P1 terminal 59. This used to determine the position of the clutch pedal
parameter (Cruise Control On/Off Switch) must is required.
be programmed to J1/P1:59. This switch is used to
enable Cruise Control when the vehicle is moving. Table 94
Also, this switch is used to control the engine idle
Alternative Default
rpm when the vehicle is stationary.
J1/P1:22
Table 92
Alternative Default
Retarder Off/Low/Medium/High Switch
J1/P1:59
The input for the Retarder Solenoid Low/Hi Switch
and the input for the Retarder Solenoid Med/Hi
Cruise Control Set/Resume Switch Switch are available for the connection of an Engine
Retarder Solenoid Selection Switch. The Low/Hi
The Cruise Control Set/Resume Input Circuits are Input should be connected to ECM Connector
available for the connection of a Cruise Control J1/P1 terminal 23 and the Med/Hi Input should be
Set/Resume Switch. This parameter (Cruise Control connected to ECM Connector J1/P1 terminal 40.
Set/Resume Switch) must be programmed to This parameter (Retarder Off/Low/Medium/High
J1/P1:35 and J1/P1:44. The Set input should be Switch) must be programmed to J1/P1:23 and
connected to J1/P1 terminal 35 and the Resume J1/P1:40. This switch controls the operation of the
input should be connected to J1/P1 terminal 44. This Engine Retarder Solenoids.
switch is used in conjunction with the Cruise Control
On/Off Switch to perform the following functions: Table 95
Alternative Default
Control the operation of the cruise control while
the vehicle is moving. J1/P1:23 & 40
Adjust the engine idle rpm while the vehicle is

stationary. Service Brake Pedal Position Switch 1
Enable the Diagnostic Flash Codes on the Check The Input for Service Brake Pedal Position Switch
Engine Lamp. 1 is available for the connection of a Service
Brake Pedal Position Switch. The switch should
When the PTO Configuration is programmed to be connected to ECM Connector J1/P1 terminal
Cab Switches, the Cruise Control Set/Resume 45. This parameter (Service Brake Pedal Position
Switch is also used with the PTO On/Off Switch to Switch 1) must be programmed to J1/P1:45. The
control the engine rpm in PTO Mode. input is used to determine the position of the service
brake pedal. The position of the service brake pedal
Table 93 can affect the following functions:
Alternative Default
Cruise
J1/P1:35 & 44
Idle
PTO
Idle Shutdown
Table 96
Alternative Default
J1/P1:45
60
Accelerator Pedal Position Table 99

Alternative Default
The Input for the Accelerator Pedal Position is
available for the connection of an Accelerator Pedal J1/P1:10
Position Sensor. The Sensors signal line should be J1/P1:12 NONE
connected to ECM Connector J1/P1 terminal 66. J1/P1:13
This parameter (Accelerator Pedal Position) must
be programmed to J1/P1:66. The input is used to
determine the position of the Accelerator Pedal.
Auxiliary Brake
Table 97 The Auxiliary Brake Output is for use with a

BrakeSaver or other Aftermarket braking devices.
Alternative Default The Output 3 is available for the connection of an
J1/P1:66 auxiliary Brake Relay. This parameter (Auxiliary
Brake) must be programmed to J1/P1:12.
Operation of the auxiliary brake and the relay
Output Selections is inhibited during undesirable engine operating
conditions. The time period of fueling the engine is
an undesirable engine operating condition.
Engine Running Output
Table 100
The Output 2, Output 3 or Output 4 is available
for the connection of an Engine Running Output Alternative Default
Relay that is used to prevent engagement of the J1/P1:12 NONE
starter while the engine is running. The Engine
Running Output can be programmed to J1/P1:10,
J1/P1:12 or J1/P1:13. The Engine Running Output Starting Aid Output
comes on when the engine is running. The Engine
Running Output turns off when the engine rpm is NOV99 and Newer Personality Modules
0. The relay is normally closed so cranking can be
achieved immediately at powerup. During cranking, Output 2, Output 3 or Output 4 is available
the ECM energizes the Engine Running Output for the connection of the Starting Aid Output
once engine low idle rpm has been achieved. The Relay/Solenoid. If a Starting Aid Switch is not used,
relay is de-energized when the engine speed falls the Starting Aid Output will turn on automatically
by 100 rpm below the programmed low idle. The when operating conditions require the use of a
programmed low idle range is 600 rpm to 750 rpm. Starting Aid. If the Starting Aid On/Off Switch
parameter is programmed and a switch connected
Table 98 to the corresponding switch input, the Starting Aid
Alternative Default Output will not function when the switch is in the
OFF position.
J1/P1:10
J1/P1:12 NONE Table 101
J1/P1:13
J1/P1:10, J1/P1:12,
Engine Shutdown Output J1/P1:13
None
The Output 2, Output 3 or Output 4 is available for

the connection of an Engine Shutdown Output Relay Fan Control Type
that is used to shut down the vehicle electrical
system after the idle timer has expired. The Engine If the ECM is used to operate the cooling fan, this
Shutdown Output can be programmed to J1/P1:10, parameter must be programmed to the On/Off or
J1/P1:12 or J1/P1:13. The Engine Shutdown Three-Speed Fan. Options are NONE (default),
Output comes on after the engine runs for more On/Off and Three-Speed Fan. This parameter
than 3 seconds. The Engine Shutdown Output should be programmed to NONE if the ECM is
turns off when the engine rpm is at least 100 rpm not connected to the cooling fan relay or the
below the low idle rpm for more than 3 seconds. cooling fan solenoid. Also, this parameter should be
programmed to NONE if the ECM is not operating
the cooling fan relay or the cooling fan solenoid.
When this parameter is programmed to NONE, the
service technician can use an Electronic Service
Tool to determine that the ECM is not connected to
the fan circuit.
61
Table 102
Alternative Default
On/Off
NONE
Three-Speed Fan
Data Link Parameters

Power Train Data Link
This parameter (Power Train Data Link) determines
if the ECM will communicate to a power train device
by using the SAE J1922 data link or the J1939
data link. If the vehicle is not using the data link
for communication to the power train systems, this
parameter should be programmed to NONE. The
following systems are examples of power train
systems:
Traction control systems

Anti-lock brake systems
Electronically controlled transmissions
Note: In addition, the J1939 data link is sometimes
used for instrument cluster communications.
Table 103
Alternative Default
NONE
J1922
OFF
J1939
J1922 and J1939
Injector Codes
Injector Codes are etched on each injector for the
C-10, C-12, 3406E, C-15, and C-16 engines. The
Injector Codes can be viewed from an Electronic
Service Tool or the injector codes can be changed
from an Electronic Service Tool. The technician must
select the Service screen, the Calibration screen
and the Injector Codes Calibration screen in order
to view the injector codes. Also, the technician must
select the Service screen, the Calibration screen
and the Injector Codes Calibration screen in order
to change the injector codes. The injector code
must match the code on the corresponding injector.
When an injector is replaced, reprogram the new
code for the new injector.
62
i01501660
Customer Specified
Parameters Table
SMCS Code: 1901
Table 104
Table for Customer Specified Parameters
Rating Number Dependent on engine power
Multitorque Ratio (OCT99 and Newer Unavailable (Standard Ratings) Unavailable
Personality Modules) MT-1, MT-2, or MT-4 (Multi-Torque MT-4 (Multi-Torque)
Ratings)
Vehicle ID 17 Digits
Available characters are dependent all zeroes
on the service tools.
ECM Wireless Communication Enable YES or NO NO
Vehicle Speed Calibration 2485 to 93226 PPKM
8696 PPKM (14000 PPM)
(4000 to 15000 PPM)
Vehicle Speed Limit 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
VSL Protection 1300 to TEL rpm TEL rpm
Tachometer Calibration 12.0 to 500.0 pulses per revolution 113.0 pulses per revolution
Soft Vehicle Speed Limit YES or NO NO
Low Cruise Control Speed Set Limit 24 to 204 km/h (15 to 127 mph) 204 km/h (127 mph)
High Cruise Control Speed Set Limit 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
Engine Retarder Mode Coast, Latch or Manual Manual
Engine Retarder Minimum VSL Type Hard Limit or Soft Limit Hard Limit
Engine Retarder Minimum Vehicle
0 to 204 km/h (0 to 127 mph) 0 km/h (0 mph)
Speed
Auto Retarder in Cruise 0 to 16 km/h (0 to 10 mph) 0 km/h (0 mph)
Auto Retarder in Cruise Increment 0 to 8 km/h (0 to 5 mph) 3 km/h (2 mph)
Cruise/Idle/PTO Switch Configuration Set/Accel-Reset/Decel or
Set/Accel-Reset/Decel
Set/Decel-Reset/Accel
Soft Cruise Control YES or NO YES
Idle Parameters
Idle RPM Limit 600 rpm to TEL rpm TEL rpm
(continued)
63
(Table 104, contd)

Table for Customer Specified Parameters
Idle/PTO RPM Ramp Rate 5 to 1000 rpm/sec 50 rpm/sec
Cab Switches
OFF
Remote Switches
Remote Throttle
PTO Top Engine Limit 600 to TEL rpm TEL rpm
PTO Engine RPM Set Speed Low idle rpm to PTO TEL rpm 0
PTO Engine RPM Set Speed A Low Idle rpm to PTO TEL rpm
PTO Engine RPM Set Speed B Low Idle rpm to PTO TEL rpm None
PTO Cab Controls RPM Limit Low idle rpm, TEL rpm or PTO TEL rpm TEL rpm
Torque Limit 270 Nm (200 lb ft) to Rated Torque 3400 Nm (2500 lb ft)
PTO Shutdown Timer Maximum RPM
600 to 2120 rpm 2120 rpm
OCT99 and Newer Personality Modules
Lower Gears Engine RPM Limit 1100 to TEL rpm TEL rpm
Intermediate Gears Engine RPM Limit 1100 to TEL rpm TEL rpm
Gear Down Protection RPM Limit 1300 to TEL rpm TEL rpm
Gear Down Protection Turn On Speed 48 to 204 km/h (30 to 127 mph) 204 km/h (127 mph)
1600 to 2120 rpm Dependent on the engine rating
Top Engine Limit with Droop
YES or NO NO
Transmission Style Manual
Automatic Option 1
Automatic Option 2
Manual
Automatic Option 3
Automatic Option 4
Eaton Top 2
Eaton Top 2 Override

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SENR6553-02

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 Crankshaft Rear Seal - Remove ........................... 45

Disassembly and Assembly 2. Place an identification mark (5) on crankcase

3. Loosen clamp (2) and remove hose (7) from

Table 1 6. Remove four bolts (4) and the washers. Remove

2. Position the gasket and fuel filter base (9) on the

3. Install the washers and four bolts (4).

4. Connect tubes (6) and (8) to fuel filter base (9).

5. Install the O-ring seal and crankcase breather (3)

6. Install the washer and bolt (1). Tighten the bolt

i01153675 2. Cut nylon strap (2) that fastens the wiring

Contaminants may cause rapid wear and shortened

Refer to Special Publication, NENG2500, Caterpillar

Dispose of all fluids according to local regulations and

2. Install the O-ring seal (6).

Fuel Transfer Pump - Install

7. Secure the wiring harness to the fuel transfer

Fuel Pressure Regulator -

1. Ensure that the orifice in fuel pressure regulator

1. Remove fuel pressure regulator (1) from the rear

2. Install fuel pressure regulator (1) in the rear of

Unit Injector - Remove

Contaminants may cause rapid wear and shortened

Refer to Special Publication, NENG2500, Caterpillar

1. Disconnect wiring harness (1) from the unit

Unit Injector - Install

3. Lubricate the O-ring seals with clean engine oil. NOTICE

Refer to Special Publication, NENG2500, Caterpillar

Dispose of all fluids according to local regulations and

1. Inspect the injector sleeve for pitting and for

Unit Injector Sleeve - Install End By:

i01180574 3. Use Tool (A) and an extension in order to remove

NOTICE a. Remove the injection actuation pressure control

Contaminants may cause rapid wear and shortened

1. Disconnect wiring harness plug (2) from injection

1. Remove O-ring seals (1) and (4), and backup

Contaminants may cause rapid wear and shortened

1. Clean the injection actuation pressure control

1. Use Tool (A) in order to install the injection

2. Install new O-ring seals (1) and (4), and backup

Unit Injector Hydraulic Pump -

a. Remove the fuel transfer pump. Refer to

Refer to Special Publication, NENG2500, Caterpillar

Hot oil and components can cause personal in-

Do not allow hot oil or components to contact skin.

i01205479 5. Install the washers and three bolts (5).

Contaminants may cause rapid wear and shortened

1. Install gear (9) with the washer and bolt (8).

Refer to Special Publication, NENG2500, Caterpillar

Dispose of all fluids according to local regulations and

3. Install oil inlet port (2) in unit injector hydraulic

4. Install oil outlet port (3) in unit injector hydraulic

Contaminants may cause rapid wear and shortened

Dispose of all fluids according to local regulations and

2. Remove the bolts and the gasket in order to

1. Place alignment marks on the two housings and

2. Remove line (3) from compressor housing (6).

3. Remove clip (4) on waste gate (7).

4. Remove bolts (1) and waste gate (7) from turbine

5. Remove bolts (2) from compressor housing (6).