Professional Documents
Culture Documents
January 2012
Systems Operation
Testing and Adjusting
3500C Engines
LLA1-Up (Engine)
R1A1-Up (Engine)
LLB1-Up (Engine)
LLC1-Up (Engine)
C8E1-Up (Engine)
LLE1-Up (Engine)
LLF1-Up (Engine)
SBG1-Up (Generator Set)
SBJ1-Up (Generator Set)
C8K1-Up (Engine)
LLK1-Up (Engine)
SBK1-Up (Generator Set)
SBM1-Up (Generator Set)
PES1-Up (Engine)
R1S1-Up (Engine)
RMS1-Up (Generator Set)
LLT1-Up (Generator Set)
R1T1-Up (Engine)
T2X1-Up (Engine)
SAFETY.CAT.COM
i03991620
RENR9363-08
3
Table of Contents
Table of Contents
13
15
16
17
Lubrication System
Lubrication System Operation .............................. 18
Metal Particle Detector ......................................... 21
Fumes Disposal System ....................................... 22
Cooling System
Jacket Water Cooling Circuit ................................. 23
Separate Circuit Cooling System .......................... 24
Basic Engine
Cylinder Block, Liners and Heads .........................
Pistons, Rings and Connecting Rods (One-Piece
Piston) .................................................................
Pistons, Rings and Connecting Rods (Two-Piece
Piston) .................................................................
Crankshaft ...........................................................
Camshaft .............................................................
24
25
26
26
26
33
33
34
35
35
36
36
36
37
Fuel System
General Information (Fuel System) ....................... 39
Fuel System Inspection ........................................ 39
Checking Engine Cylinders ................................... 39
Checking Engine Cylinders with an Electronic Service
Tool ..................................................................... 39
Fuel Pressure ....................................................... 40
Engine Rotation .................................................... 40
Finding the Top Center Position for the No. 1
Piston .................................................................. 40
Camshaft Timing ................................................... 41
Fuel Injector Adjustment ....................................... 44
Crankshaft Position for Fuel Injector Adjustment and
Valve Lash Setting .............................................. 47
Crankshaft Position for Fuel Injector Adjustment and
Valve Lash Setting .............................................. 48
Air Inlet and Exhaust System
Restriction of Air Inlet and Exhaust .......................
Measuring Inlet Manifold Pressure .......................
Measuring Exhaust Temperature ..........................
Crankcase Pressure .............................................
Valve Lash - Adjust ...............................................
50
50
50
50
51
Lubrication System
General Information (Lubrication System) ............ 53
Engine Oil Pressure - Test .................................... 53
Metal Particle Detector - Test ................................ 53
Cooling System
General Information (Cooling System) .................
Visual Inspection ...................................................
Test Tools for the Cooling System ........................
Radiator and Cooling System - Test .....................
Coolant Temperature Sensor - Test ......................
Water Temperature Regulator - Test .....................
55
55
57
58
59
60
Basic Engine
Connecting Rod Bearings .....................................
Main Bearings .......................................................
Cylinder Block .......................................................
Cylinder Head .......................................................
Cylinder Liner Projection .......................................
Flywheel - Inspect .................................................
Flywheel Housing - Inspect ...................................
Vibration Damper ..................................................
61
61
61
61
62
63
65
66
4
Table of Contents
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71
71
71
72
72
73
Index Section
Index ..................................................................... 77
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Systems Operation Section
Illustration 1
g00769594
30 C (86 F).
i02217884
ON.
6
Systems Operation Section
RENR9363-08
ENABLE.
Wiring harness
Engine speed/timing sensor
63 C (145 F).
Temperature sensors
Pressure sensors
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7
Systems Operation Section
i02388972
g00669770
Illustration 2
Electronic Controls
The electronic system consists of the following
components: the ECM, the mechanically actuated
electronically controlled unit injectors (MEUI), the
wiring harness, the switches, and the sensors. The
ECM is the computer. The flash file is the software
for the computer. The flash file contains the operating
maps. The operating maps define the following
characteristics of the engine:
Horsepower
Torque curves
The ECM determines the timing and the amount of
fuel that is delivered to the cylinders. These decisions
are based on the actual conditions and/or the desired
conditions at any given time.
The ECM compares the desired engine speed to
the actual engine speed. The actual engine speed
is determined through a signal from the engine
speed/timing sensor. The desired engine speed is
determined through the following items:
8
Systems Operation Section
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Fuel Injection
Aftercooler temperature
Programmable Parameters
Certain parameters that affect the engine operation
may be changed with the Caterpillar Electronic
Technician (ET). The parameters are stored in the
ECM, and some parameters are protected from
unauthorized changes by passwords.
Passwords
Oil pressure
Percent throttle position
Rated fuel limit
Timing cal enable/status
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Systems Operation Section
i01941448
g01235068
Typical example
(1) ECM
(2) Auxiliary drive
Coolant flow
10
Systems Operation Section
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i01944995
System Configuration
Parameters
Engine derate
Engine protection shutdown
i02388138
Histogramming
SMCS Code: 1901
Histogram data can be displayed via the Caterpillar
Electronic Technician (ET) in order to show the
trends of performance for the engine. This is used to
improve the overall performance of the engine.
Historical performance data is stored in a format
that can be used to construct histograms via the Cat
ET. Data is available for speed, load, and exhaust
temperature.
i01970428
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Systems Operation Section
i02217900
Fuel System
i04019269
Illustration 4
g02192355
12
Systems Operation Section
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Fuel Injector
SMCS Code: 1290
Illustration 5
g01188814
Adjusting nut
Rocker arm assembly
Electronic fuel injector
Pushrod
Cylinder head
Camshaft
Lifter
Illustration 6
Fuel injector
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Plunger
Pumping chamber
High pressure fuel passage
Cartridge valve
Low pressure fuel passage
Needle valve
Valve chamber
g01009248
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Systems Operation Section
Illustration 7
g01188937
Exhaust manifold
Aftercooler
Engine cylinder
Air inlet
Turbocharger compressor wheel
Turbocharger turbine wheel
Exhaust outlet
14
Systems Operation Section
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Systems Operation Section
i03949571
Aftercooler
(Air-to-Air Aftercooler)
SMCS Code: 1063
S/N: SBG1-Up
S/N: SBJ1-Up
S/N: LLK1-Up
S/N: SBK1-Up
S/N: SBM1-Up
S/N: R1S1-Up
S/N: LLT1-Up
S/N: T2X1-Up
g02158315
Illustration 8
The dashed lines with arrows represent air flow and the solid lines with arrows represent coolant flow.
(1) Air cleaner
(2) Engine
(3) Turbocharger compressor
(7) Radiator
16
Systems Operation Section
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Valve Mechanism
SMCS Code: 1102
The valve system components control the flow of the
inlet air and the exhaust gases into the cylinders and
out of the cylinders during engine operation.
The crankshaft gear drives the camshaft gears
through idlers. Both camshafts must be timed to the
crankshaft in order to get the correct relation between
the piston and the valve movement.
The camshafts have three lobes for each cylinder.
Two lobes operate the valves and one operates the
fuel injector.
Illustration 9
g01042301
Rocker arm
Bridge
Rotocoil
Valve spring
Pushrod
Lifter
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17
Systems Operation Section
i02388169
Turbocharger
SMCS Code: 1052
Rear Mounted
Illustration 10
g01192255
Center Mounted
Illustration 12
g01192313
Illustration 11
Turbocharger (typical example)
(4)
(5)
(6)
(7)
(8)
(9)
Compressor wheel
Bearing
Oil inlet port
Bearing
Turbine wheel
Oil outlet port
g01192286
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Systems Operation Section
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Lubrication System
i02389290
Illustration 13
g01192286
Compressor wheel
Bearing
Oil inlet port
Turbine wheel
Bearing
Oil outlet port
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Systems Operation Section
g01192996
Illustration 14
Main oil pump and lubrication system schematic (typical example)
(1)
(2)
(3)
(4)
(5)
(6)
(13)
(14)
(15)
(16)
(17)
20
Systems Operation Section
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Illustration 15
g00281794
Illustration 16
g01193001
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21
Systems Operation Section
i04398016
g01193018
S/N: LLF1-Up
S/N: SBJ1-Up
S/N: C8K1-Up
S/N: LLK1-Up
S/N: PES1-Up
S/N: RMS1-Up
S/N: LLT1-Up
Illustration 18
g02576878
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Systems Operation Section
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i02595783
Illustration 19
g00866265
Illustration 20
(1)
(2)
(3)
(4)
(5)
g01299277
Crankcase breather
Restriction indicator
Line to air cleaner
Fumes disposal filter
Drain line to crankcase
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Systems Operation Section
Cooling System
i04007209
g02180915
Illustration 21
(1) Jacket water pump
(2) Engine oil cooler
(3) Block
(7) Tube
(8) Bypass tube
(8) Radiator or heat exchanger
24
Systems Operation Section
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(1)
(2)
(3)
(4)
Basic Engine
i02388283
Illustration 22
g02181053
Aftercooler
Thermostatic valve
Source of the coolant
Separate circuit water pump
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Systems Operation Section
S/N: PES1-Up
S/N: R1S1-Up
S/N: RMS1-Up
S/N: LLT1-Up
S/N: R1T1-Up
S/N: T2X1-Up
Illustration 23
g01192345
Illustration 24
(1)
(2)
(3)
(4)
(5)
(6)
g01084288
Top ring
Intermediate ring
Oil control ring
Piston pin bore
Piston pin
Piston pin retainer
26
Systems Operation Section
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i04008992
i02391905
Crankshaft
SMCS Code: 1202
The crankshaft changes the combustion forces in
the cylinder into usable rotating torque. A vibration
damper is used at the front of the crankshaft in order
to reduce torsional vibrations (twist) that can cause
damage to the engine.
The crankshaft drives a group of gears that are on
the front of the engine and on the rear of the engine.
The gear group on the front of the engine drives the
oil pump, the jacket water pump, the fuel transfer
pump, and the accessory drives.
The rear gear group, which is also driven by the
crankshaft, drives the camshafts and the accessory
drives.
Illustration 25
(1)
(2)
(3)
(4)
(5)
(6)
g02182227
Top ring
Intermediate ring
Oil control ring
Piston pin bore
Piston pin
Piston pin retainer
Camshaft
SMCS Code: 1210
There is one camshaft assembly per side. The
3508 camshaft is supported by five bearings. The
3512 camshaft is supported by seven bearings. The
3516 camshaft is supported by nine bearings. Each
camshaft is driven by the rear gear group.
As the camshaft turns, each lobe moves a lifter.
There are three lifters for each cylinder. Each outside
lifter moves a pushrod and two valves. The valves
can be inlet valves or exhaust valves. The center
lifter moves a pushrod that operates the unit injector.
The camshafts must be in time with the crankshaft.
The relation of the camshaft lobes to the crankshaft
position causes the valves and unit injectors in each
cylinder to operate at the correct time.
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27
Systems Operation Section
g01013593
Illustration 26
Air starting system (typical example)
(1) Relay valve
(2) Hose
g01192361
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Systems Operation Section
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29
Systems Operation Section
g00826581
Illustration 28
Trailer mounted pumper
(1) Quick disconnects
(2) Solenoid operated valve
30
Systems Operation Section
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g00853405
Illustration 29
Truck mounted pumper
(3) Hydraulic motor
Illustration 30
Hydraulic starting motor
(3) Hydraulic motor
(4) Starter motor
(5) Pinion
g00822762
Illustration 31
g00824836
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Systems Operation Section
g02665740
Illustration 32
Hydraulic starting system diagram (typical example)
(6) Reservoir.
(7) Low-pressure filter
(8) Hand pump
32
Systems Operation Section
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g02666296
Illustration 33
Hydraulic Starting Motor
(15) Rotor
(16) Pistons
Electrical System
i01253714
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Systems Operation Section
i02130651
i02475511
Grounding Practices
Charging System
NOTICE
Never operate the alternator without the battery in the
circuit. Making or breaking an alternator connection
with heavy load on the circuit can cause damage to
the regulator.
Alternator
Illustration 34
g01192436
NOTICE
When boost starting an engine, follow the instructions
in Operation and Maintenance Manual, Engine Starting to properly start the engine.
This engine is equipped with a 24 volt starting system.
Use only equal voltage for boost starting.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Regulator
Roller bearing
Stator winding
Ball bearing
Rectifier bridge
Field winding
Rotor assembly
Fan
34
Systems Operation Section
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i04384794
Starting System
SMCS Code: 1450
Starting solenoid
A solenoid is an electromagnetic switch that does
two basic operations.
Starting Motor
The starting motor is used to turn the engine flywheel
in order to get the engine running.
Illustration 35
g00285112
Solenoid (typical)
Illustration 36
Cross section of the starting motor (typical example)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Field
Solenoid
Clutch
Pinion
Commutator
Brush assembly
Armature
g01192489
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35
Systems Operation Section
Circuit Breaker
SMCS Code: 1420
Illustration 37
g01192553
36
Testing and Adjusting Section
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i01938925
Calibration
SMCS Code: 1901
Configuration Parameters
SMCS Code: 1901
Configuration parameters are those parameters
that affect engine power or various engine features.
The configuration parameters for the crank duration
and the maximum number of cycles must be
reprogrammed from the factory settings before the
engine will start.
The configuration parameters may be programmed
with the Caterpillar Electronic Technician (ET). Refer
to Troubleshooting for additional information in order
to program the configuration parameters.
Some parameters may not be available on all
applications. If a parameter is unavailable the Cat
ET will indicate unavailable when the parameter is
selected. The Electronic Control Module (ECM) must
be programmed. Make sure that the Air Shutoff,
the Ether Control and the Plt Hse EMS Status
parameters are ENABLED/ON if the engine is
equipped with these attachments. Make sure that
the DISABLED/OFF is used if the engine is not
equipped. The Eng. Prelube Duration must be
programmed to a value that is not zero seconds if
the engine is equipped with the prelube. The prelube
motor will not run if this value is not programmed. If
the engine is not equipped with the prelube then the
parameter must be programmed to 0. The correct
configuration for the aftercooling system must be
programmed.
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37
Testing and Adjusting Section
i01946291
Parameter
Valid Range
0 - 39999
Governor Minimum
Stability Factor
0 - 39999
Governor Maximum
Stability Factor
0 - 39999
Tuning Procedure
1. Turn the Engine Control Switch (ECS) to the
COOLDOWN/STOP position. Connect the
Caterpillar Electronic Technician (ET). Enable
the engine overspeed protection prior to the
adjustment procedure. Adjusting governor gain
parameters without engine overspeed protection
can result in serious engine damage. Ensure
that engine overspeed protection is ON. Engine
overspeed is configured on the setup screen of
Service Monitoring System in Cat ET.
Gain Explanations
Governor Gain Factor
The Governor Gain Factor is multiplied by the
engine speed error. This value is derived by
calculating the difference between the desired speed
and the actual speed.
38
Testing and Adjusting Section
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39
Testing and Adjusting Section
Fuel System
i02672579
i04007910
i02391941
40
Testing and Adjusting Section
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i01433473
Fuel Pressure
SMCS Code: 1250-081
The 1U-5470 Engine Pressure Group can be used
in order to check the engine's fuel pressures.
g00284798
Illustration 40
Illustration 38
g00284796
Pressure indicators
Zero adjustment screw
Pressure indicator
Pressure tap
Pressure indicator
Engine Rotation
SMCS Code: 1000
Illustration 39
g00284797
i02389395
Tools Needed
9S-9082 Engine Turning Tool
Quantity
1
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41
Testing and Adjusting Section
Illustration 41
g01193047
i04007489
Camshaft Timing
1. Remove cover (1) and plug (3) from the right front
side of the flywheel housing.
Timing Check
Table 3
Tools Needed
9S-9082 Engine Turning Tool
Illustration 42
Quantity
1
g01193048
Illustration 43
g00793695
42
Testing and Adjusting Section
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Timing Adjustment
Table 4
Tools Needed
Quantity
8S-9089 Bolts
Illustration 44
g00793673
Illustration 45
g00284803
Illustration 46
Camshaft drive gears (RH side)
(3) Drive gear
(4) Plate
(5) Bolt
g00284804
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43
Testing and Adjusting Section
Illustration 49
g00793706
Illustration 47
g00793811
Illustration 48
g00793793
44
Testing and Adjusting Section
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Tools Needed
Illustration 50
g01226674
Vertical line
Quantity
NOTICE
The camshafts must be correctly timed with the crankshaft before an adjustment of the unit injector lash
is made. The timing pins must be removed from the
camshafts before the crankshaft is turned or damage
to the cylinder block will be the result.
Illustration 51
g01226685
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45
Testing and Adjusting Section
g00284808
Illustration 54
g00284831
Illustration 53
Adjustment of the fuel timing tools
(1)
(2)
(4)
(5)
g00284810
46
Testing and Adjusting Section
Illustration 55
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g00284832
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47
Testing and Adjusting Section
i02708199
3508
3512
3516
(1)
Inlet Valves
Exhaust Valves
Injectors
Compression
1-2-6-8
1-2-3-7
2-3-4-7
Exhaust
3-4-5-7
4-5-6-8
1-5-6-8
Compression
1-3-6-7-10-12
1-4-5-6-9-12
2-4-5-8-9-11
Exhaust
2-4-5-8-9-11
2-3-7-8-10-11
1-3-6-7-10-12
Compression
1-2-5-7-8-12-13-14
1-2-3-4-5-6-8-9
3-4-6-9-10-11-15-16
Exhaust
3-4-6-9-10-11-15-16
7-10-11-12-13-14-15-16
1-2-5-7-8-12-13-14
Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, Finding the Top Center
Position for the No 1 Piston. Find the top center position for a particular stroke and make the adjustment for the correct cylinders. Remove
the timing bolt . Turn the flywheel by 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center
(TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.
48
Testing and Adjusting Section
RENR9363-08
Table 7
3508
3512
3516
(1)
Inlet Valves
Exhaust Valves
Injectors
Compression
1-3-4-8
1-2-7-8
2-6-7-8
Exhaust
2-5-6-7
3-4-5-6
1-3-4-5
Compression
1-3-4-6-7-12
1-4-5-8-9-12
2-5-8-9-10-11
Exhaust
2-5-8-9-10-11
2-3-6-7-10-11
1-3-4-6-7-12
Compression
1-2-5-6-7-8-13-14
1-2-3-4-5-6-9-10
3-4-9-10-11-12-15-16
Exhaust
3-4-9-10-11-12-15-16
7-8-11-12-13-14-15-16
1-2-5-6-7-8-13-14
Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, Finding the Top Center
Position for the No 1 Piston. Find the top center position for a particular stroke and make the adjustment for the correct cylinders. Remove
the timing bolt . Turn the flywheel by 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center
(TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.
i02713567
3512
(1)
Inlet Valves
Exhaust Valves
Injectors
Compression
1-2-3-4-7-8
1-2-5-8-9-10
5-6-9-10-11-12
Exhaust
5-6-9-10-11-12
3-4-6-7-11-12
1-2-3-4-7-8
Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, Finding the Top Center
Position for the No 1 Piston. Find the top center position for a particular stroke and make the adjustment for the correct cylinders. Remove
the timing bolt . Turn the flywheel by 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center
(TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.
RENR9363-08
49
Testing and Adjusting Section
Table 9
3512
(1)
Inlet Valves
Exhaust Valves
Injectors
Compression
1-2-3-7-8-10
1-2-5-6-9-10
4-5-6-9-11-12
Exhaust
4-5-6-9-11-12
3-4-7-8-11-12
1-2-3-7-8-10
Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, Finding the Top Center
Position for the No 1 Piston. Find the top center position for a particular stroke and make the adjustment for the correct cylinders. Remove
the timing bolt . Turn the flywheel by 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center
(TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments for the cylinders that remain.
50
Testing and Adjusting Section
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i04331949
Measuring Exhaust
Temperature
SMCS Code: 1088-082
Table 10
Tools Needed
Qty
Crankcase Pressure
SMCS Code: 1215; 1317-082
The Caterpillar Electronic Technician (ET) can be
used to measure crankcase pressure. Crankcase
pressure is given on the display status screen
in Cat ET. The Electronic Control Module (ECM)
will perform any of the following functions if the
crankcase pressure is high in the engine: warning,
derate, and shutdown. The response will depend on
the programming and the availability of the parameter
of the monitoring system.
Pistons or rings that have damage can be the cause
of too much pressure in the crankcase. This condition
will cause the engine to run rough. There will be
more than the normal amount of fumes coming from
the crankcase breather. This crankcase pressure can
also cause the element for the crankcase breather to
have a restriction in a very short time. This crankcase
pressure can also be the cause of any oil leakage at
the gaskets and at the seals.
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51
Testing and Adjusting Section
i02160604
g00286271
Illustration 56
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
147-2060
147-2059
148-7211
145-5191
147-2056
147-5536
147-2057
147-2058
Wrench
Torque Wrench
Bridge Nut Socket
Gauge Support
Dial Indicator
Indicator Contact Point
Indicator Contact Point
Indicator Extension
Gauge Dimension
Inlet
Exhaust
Table 11
Tools Needed
Valves
Quantity
147-2060 Wrench
Illustration 57
g00286365
52
Testing and Adjusting Section
Illustration 58
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g00286366
Illustration 59
g00286367
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53
Testing and Adjusting Section
Lubrication System
i01574160
General Information
(Lubrication System)
i04398118
S/N: LLA1-Up
S/N: LLB1-Up
S/N: LLC1-Up
S/N: C8E1-Up
S/N: LLE1-Up
S/N: LLF1-Up
i01727818
S/N: SBJ1-Up
S/N: C8K1-Up
S/N: LLK1-Up
S/N: PES1-Up
S/N: RMS1-Up
S/N: LLT1-Up
Perform this test with the engine stopped.
1. Turn the switch for the fuel control OFF.
Illustration 60
g00285344
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Dealer Service Tool Catalog for tools and supplies suitable to
collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
54
Testing and Adjusting Section
RENR9363-08
Illustration 61
g02576878
RENR9363-08
55
Testing and Adjusting Section
Cooling System
Overcooling
i02225295
Illustration 62
g00286266
Overheating
Coolant loss
Visual Inspection
SMCS Code: 1350-535
Perform a visual inspection of the cooling system
before a test is made with test equipment.
56
Testing and Adjusting Section
RENR9363-08
Bent fins
Debris between the folded cores
Damaged fan blades
5. Check the heat exchanger (if equipped) for
internal blockage. Make sure that the filters for the
water are not clogged.
RENR9363-08
57
Testing and Adjusting Section
i04317197
Tools Needed
Part
Number
Part Name
Quantity
348-5430
Multi-Tool Gp
9S-8140
Pressurizing Pump
245-5829
Coolant/Battery Tester Gp
Illustration 64
g00286369
Illustration 63
348-5430 Multi-Tool Gp
g02167834
58
Testing and Adjusting Section
RENR9363-08
Illustration 65
245-5829 Coolant/Battery Tester Gp
Tools Needed
Quantity
Illustration 67
9S-8140 Pressurizing Pump
(3) Release valve
(4) Adapter
(5) Hose
g01024208
g00286374
RENR9363-08
59
Testing and Adjusting Section
Illustration 68
g00286375
Tools Needed
Quantity
2F-7112 Thermometer
Illustration 69
g00769081
Test location
(1) Plug
60
Testing and Adjusting Section
RENR9363-08
RENR9363-08
61
Testing and Adjusting Section
Basic Engine
i01220459
Illustration 70
g00285686
i04317277
i01220466
Main Bearings
Cylinder Head
SMCS Code: 1100-040
Cylinder Block
SMCS Code: 1201-040
If the main bearing caps are installed without
bearings, the bore in the block for the main bearings
can be checked. Tighten the nuts that hold the caps
to the torque that is shown in the Specifications.
Alignment error in the bores must not be more than
0.08 mm (0.003 inch). Refer to Special Instruction,
SMHS7606 for the use of the 1P-4000 Line Boring
Tool Group for the alignment of the main bearing
bores. The 1P-3537 Dial Bore Gauge Group can
be used to check the size of the bores. The Special
Instruction, GMG00981 is with the group.
Valves
The removal and the installation of the valves
is easier with use of the 1P-3527 Valve Spring
Compressor.
Valve Guides
The tools for the removal and for the installation
of the valve guides are the 5P-1729 Valve Guide
Bushing and the 7M-3975 Valve Guide Driver. The
counterbore in the driver bushing installs the guide to
the correct height.
62
Testing and Adjusting Section
RENR9363-08
g02247495
Illustration 72
g00285313
Illustration 71
Bridge Dowels
Use a 5P-0944 Dowel Puller Group and a 5P-0942
Dowel Extractor. Remove the bridge dowels. Install a
new bridge dowel with a 6V-4009 Dowel Driver. This
dowel driver installs the bridge dowel to the correct
height.
Liner Projection = Z - X - Y
110-6994 Spacer Plate
i04093691
Table 16
Liner
Projection
Range
Tools Needed
Quantity
1U-9895 Crossblock
6V-7059 Micrometer
Liner
Projection
Range
Table 18
Liner Projection = Z - X - Y
362-9677 Spacer Plate
RENR9363-08
63
Testing and Adjusting Section
Illustration 73
g01192749
Flywheel - Inspect
SMCS Code: 1156-040
Table 19
Tools Needed
Part
Number
8T-5096
Part Name
Dial Indicator Gp
Quantity
1
64
Testing and Adjusting Section
RENR9363-08
Illustration 74
g00286049
g01193057
Illustration 75
Checking bore runout of the flywheel
(1)
(2)
(3)
(4)
7H-1945
7H-1645
7H-1942
7H-1940
Holding Rod
Holding Rod
Dial Indicator
Universal Attachment
RENR9363-08
65
Testing and Adjusting Section
g00286058
Illustration 76
Flywheel clutch pilot bearing bore
Tools Needed
8T-5096
Dial Indicator Gp
Quantity
1
Illustration 77
g00285931
Illustration 78
g00285932
Illustration 79
g00285934
66
Testing and Adjusting Section
RENR9363-08
Illustration 80
g00285936
Illustration 82
g00286046
(1)
(2)
(3)
(4)
Illustration 81
g00285932
Vibration Damper
RENR9363-08
67
Testing and Adjusting Section
General Information
(Air/Electric Starting System)
SMCS Code: 1450; 1451; 1462
This starting system uses an electric solenoid to
position an air valve in order to activate the air
starting motor. If the starting motor does not function,
do the procedure that follows:
1. Check the indicator reading for the air pressure.
2. If the reading is not acceptable then use a remote
source to charge the system.
3. If the reading is acceptable then open the main
tank drain valve for a moment. Verify the pressure
that is shown on the pressure indicator. Listen for
the sound of the high pressure from the discharge.
Illustration 84
g00286937
Illustration 83
Control Valve
Typical Example
(1) Control valve. (2) Connector.
g00286936
68
Testing and Adjusting Section
RENR9363-08
RENR9363-08
69
Testing and Adjusting Section
Electrical System
i03439502
Tools Needed
Quantity
4C-4911
271-8590
Starting/Charging Analyzer Gp
225-8266
Ammeter Tool Gp
146-4080
or
257-9140
Digital Multimeter Gp
271-8590 Starting/Charging
Analyzer Gp
Illustration 86
Illustration 85
4C-4911 Battery Load Tester
g00283565
g01789234
70
Testing and Adjusting Section
RENR9363-08
Illustration 88
g01015638
Illustration 87
g01012117
Amperage
Capacitance
Frequency
Pulse Width Modulation (PWM)
Resistance
Temperature
Voltage
The multimeter has an instant ohms indicator that
permits the checking of continuity for fast circuit
inspection. Temperature measurements can be taken
by using the adapter for type K thermocouples. An
RS-232 interface adaptor can be used to interface
with other electronic tools and displays.
Note: Refer to multimeter's Operator's Manual for
complete information that is related to the use of the
multimeter. The operator's manual is packaged with
the unit.
RENR9363-08
71
Testing and Adjusting Section
i01305428
Battery
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel 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 in operation. 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.
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.
Alternator Regulator
SMCS Code: 1405-081
The charging rate of the alternator should be
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.
i01223618
Charging System
SMCS Code: 1406-081
The condition of charge in the battery at each regular
inspection will show if the charging system operates
correctly. An adjustment is necessary when the
battery is constantly in a low condition of charge or
a large amount of water is needed. A large amount
of water would be more than one ounce of water per
cell per week or per every 100 service hours.
When it is possible, make a test of the charging
unit and voltage regulator on the engine, and use
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.
72
Testing and Adjusting Section
RENR9363-08
Illustration 89
g01192754
Tighten the nut that holds the pulley with the tools
shown. Refer to the Specifications module for the
torque.
i04641151
A short circuit
Loose connections
i02388967
RENR9363-08
73
Testing and Adjusting Section
Illustration 90
g01192756
Illustration 91
g01192757
74
Testing and Adjusting Section
RENR9363-08
g01413664
Illustration 92
(1) Select Monitoring System.
RENR9363-08
75
Testing and Adjusting Section
Illustration 93
g01413665
76
Testing and Adjusting Section
RENR9363-08
g01413666
Illustration 94
(4) Double click on Engine Overspeed Test
Illustration 95
g01413667
RENR9363-08
77
Index Section
Index
Numerics
A
Aftercooler (Air-to-Air Aftercooler) ......................... 15
Air Inlet and Exhaust System .......................... 13, 50
Air Inlet and Exhaust System Operation................ 13
Air Starting System................................................ 27
Air/Electric Starting System ................................... 67
Alternator Regulator .............................................. 71
Tightening the Alternator Pulley Nut .................. 72
B
Basic Engine.................................................... 24, 61
Battery ................................................................... 71
C
Calibration ............................................................. 36
Calibration for Electronic Injection Timing with the
Electronic Service Tool..................................... 36
Camshaft ............................................................... 26
Camshaft Timing ................................................... 41
Timing Adjustment ............................................. 42
Timing Check ..................................................... 41
CAN Data Link......................................................... 9
Cat Data Link........................................................... 8
Charging System ............................................. 33, 71
Alternator ........................................................... 33
Checking Engine Cylinders ................................... 39
Checking Engine Cylinders with an Electronic Service
Tool ...................................................................... 39
Circuit Breaker....................................................... 35
Cold Cylinder Cutout ............................................... 5
Configuration Parameters...................................... 36
Connecting Rod Bearings...................................... 61
Coolant Temperature Sensor - Test....................... 59
Cooling System ............................................... 23, 55
Crankcase Pressure .............................................. 50
Crankshaft ............................................................. 26
Crankshaft Position for Fuel Injector Adjustment and
Valve Lash Setting ......................................... 4748
Cylinder Block........................................................ 61
Cylinder Block, Liners and Heads ......................... 24
Cylinder Head........................................................ 61
Bridge Dowels.................................................... 62
Checking Valve Guide Bores ............................. 61
Valve Guides...................................................... 61
Valve Seat Inserts .............................................. 61
Valves ................................................................ 61
Cylinder Liner Projection ....................................... 62
Cylinder Liner In the Cylinder Block................... 63
Cylinder Liner Out of the Cylinder Block ............ 62
F
Finding the Top Center Position for the No. 1
Piston................................................................... 40
Flywheel - Inspect.................................................. 63
Bore Runout (Radial Eccentricity) of the
Flywheel ........................................................... 64
Face Runout (Axial Eccentricity) of the
Flywheel ........................................................... 64
Flywheel Housing - Inspect ................................... 65
Bore Runout (Radial Eccentricity) of the Flywheel
Housing ............................................................ 65
Face Runout (Axial Eccentricity) of the Flywheel
Housing ............................................................ 65
Fuel Injector........................................................... 12
Fuel Injector Adjustment........................................ 44
Fuel Injector Mechanism ....................................... 12
Fuel Pressure ........................................................ 40
Fuel Rate Scaling (Fuel Correction Factor) ........... 10
Fuel System...................................................... 11, 39
Fuel System Inspection ......................................... 39
Fuel System Operation........................................... 11
Fumes Disposal System........................................ 22
G
General Information (Air/Electric Starting
System)................................................................
Air Side Of The System .....................................
Electrical Side Of The System ...........................
General Information (Cooling System) ..................
General Information (Fuel System) .......................
67
67
67
55
39
78
Index Section
RENR9363-08
Table of Contents..................................................... 3
Test Tools for the Cooling System ......................... 57
Test Tools for the Electrical System....................... 69
146-4080 Digital Multimeter Gp ....................... 70
225-8266 Ammeter Tool Gp............................. 70
271-8590 Starting/Charging Analyzer Gp........ 69
4C-4911 Battery Load Tester............................ 69
Testing and Adjusting Section ............................... 36
Turbocharger ......................................................... 17
Center Mounted ................................................. 17
Rear Mounted .................................................... 17
I
Important Safety Information ................................... 2
J
Jacket Water Cooling Circuit ................................. 23
M
Main Bearings........................................................
Measuring Exhaust Temperature...........................
Measuring Inlet Manifold Pressure ........................
Metal Particle Detector ..........................................
Metal Particle Detector - Test ................................
Monitoring System Parameters .............................
61
50
50
21
53
36
O
Overspeed Verification Test................................... 73
Performing the Procedure with Cat ET .............. 76
Performing the Procedure with the Junction
Box ................................................................... 75
P
Pinion Clearance Adjustment ................................ 72
Pistons, Rings and Connecting Rods (One-Piece
Piston).................................................................. 25
Pistons, Rings and Connecting Rods (Two-Piece
Piston).................................................................. 26
R
Radiator and Cooling System - Test ...................... 58
Restriction of Air Inlet and Exhaust ....................... 50
S
Separate Circuit Cooling System........................... 24
51
51
16
66
55
W
Water Temperature Regulator - Test ..................... 60
RENR9363-08
79
Index Section
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