Engine Start

If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine
or move the controls. Consult with the person that attached the warning tag before the engine is
started.
 All protective guards and all protective covers must be installed if the engine must be
started in order to perform service procedures. To help prevent an accident that is caused by parts
in rotation, work around the parts carefully.
Start the engine from the operator's compartment or from the engine start switch.
 Always start
the engine according to the procedure that is described in the Operation and Maintenance Manual,
"Engine Starting" topic in the Operation Section. Knowing the correct procedure will help to
prevent major damage to the engine components. Knowing the procedure will also help to prevent
personal injury.
 To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if
equipped) is working correctly, check the water temperature gauge and/or the oil temperature
gauge during the heater operation.
 Engine exhaust contains products of combustion which can
be harmful to your health. Always start the engine and operate the engine in a well ventilated area.
If the engine is started in an enclosed area, vent the engine exhaust to the outside.
 Note: The
engine is equipped with a device for cold starting. If the engine will be operated in very cold
conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped
with the correct type of starting aid for your region of operation.
 These engines are equipped
with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve
starting.

Engine Stop
To avoid overheating of the engine and accelerated wear of the engine components, stop the engine
according to this Operation and Maintenance Manual, "Engine Stopping" topic (Operation
Section). Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. DO
NOT use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO
NOT start the engine until the problem that caused the emergency stop has been corrected.
On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop
the engine if an overspeed condition occurs.
 To stop an electronic controlled engine, cut the
power to the engine and/or the air supply to the engine.

Engine Electronics
This engine has a comprehensive, programmable Engine Monitoring System. The Electronic
Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the
engine parameters extend outside an allowable range, the ECM will initiate an immediate
action.
 The following actions are available for engine monitoring control:
Warning
Derate

Shutdown
The following monitored engine operating conditions have the ability to limit engine speed and/or
the engine power:
Engine Coolant Temperature

Engine Oil Pressure

Engine Speed
 Intake Manifold Air Temperature
The Engine Monitoring package can vary for different engine models and different engine
applications. However, the monitoring system and the engine monitoring control will be similar
for all engines.
 Note: Many of the engine control systems and display modules that are available
for Caterpillar Engines will work in unison with the Engine Monitoring System. Together, the two
controls will provide the engine monitoring function for the specific engine application. Refer to
the Troubleshooting for more information on the Engine Monitoring System.
Welding on Engine with Electronic Controls
Proper welding procedures are necessary in order to avoid damage to the engine's ECM,
sensors, and associated components. When possible, remove the component from the unit and then
weld the component. If removal of the component is not possible, the following procedure must
be followed when you weld on a unit that is equipped with the engine. The following procedure is
considered to be the safest procedure to weld on a component. This procedure should provide a
minimum risk of damage to electronic components.
NOTICE
Do not ground the welder to electrical components such as the ECM or sensors. Improper
grounding can cause damage to the drive train bearings, hydraulic components, electrical
components, and other components.
Clamp the ground cable from the welder to the component that will be welded. Place the clamp as
close as possible to the weld. This will help reduce the possibility of damage.
Stop the engine. Turn the switched power to the OFF position.
 Disconnect the negative battery
cable from the battery. If a battery disconnect switch is provided, open the switch.
 Disconnect
the J1/P1 and J2/P2 connectors from the ECM. Move the harness to a position that will not allow
the harness to accidentally move back and make contact with any of the ECM pins.

Connect the welding ground cable directly to the part that will be welded. Place the ground cable
as close as possible to the weld in order to reduce the possibility of welding current damage to
bearings, hydraulic components, electrical components, and ground straps.
 Note: If
electrical/electronic components are used as a ground for the welder, or electrical/electronic
components are located between the welder ground and the weld, current flow from the welder
could severely damage the component.
Protect the wiring harness from welding debris and spatter. Use standard welding practices to weld
the materials.

Engine Diagnostics
The engine has built-in diagnostics in order to ensure that the engine systems are functioning
correctly. The operator will be alerted to the condition by a "Stop or Warning" lamp. Under certain
conditions, the engine horsepower and the vehicle speed may be limited. The electronic service
tool may be used to display the diagnostic codes.
There are three types of diagnostic codes: active, logged and event.
 Most of the diagnostic codes
are logged and stored in the ECM. For additional information, refer to the Operation and
Maintenance Manual, "Engine Diagnostics" topic (Operation Section).
 The ECM provides an
electronic governor that controls the injector output in order to maintain the desired engine rpm.
Engine Cooling and Lubrication
The cooling system consists of the following components:

Gear-driven centrifugal water pump

Water temperature regulator which regulates the engine coolant temperature
Gear-driven rotor type oil pump

Oil cooler
The engine lubricating oil is supplied by a rotor type oil pump. The engine lubricating oil is cooled
and the engine lubricating oil is filtered. The bypass valve can provide unrestricted flow of
lubrication oil to the engine if the oil filter element should become plugged.
 Engine efficiency,
efficiency of emission controls, and engine performance depend on adherence to proper operation
and maintenance recommendations. Engine performance and efficiency also depend on the use of
recommended fuels, lubrication oils, and coolants. Refer to this Operation and Maintenance
Manual, "Maintenance Interval Schedule" for more information on maintenance items.
NOTICE
If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded,
STOP the engine. Engine damage can result.
A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes,
perform the following procedure:
Remove the load.
 Stop the engine.
 Check and maintain the oil level.
Engine Oil Pressure - The oil pressure should be greatest after a cold engine is started. The typical
engine oil pressure with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at rated rpm.

Jacket Water Coolant Temperature - Typical temperature range is 83° to 95°C (181.4° to
171°F). The maximum allowable temperature at sea level with the pressurized cooling system at
48 kPa (7 psi) is 103 °C (217.4 °F). Higher temperatures may occur under certain conditions. The
water temperature reading may vary according to load. The temperature reading should never
exceed 7 °C (44.6 °F) below the boiling point for the pressurized system that is being used.
A 100 kPa (14.5 psi) radiator cap may be installed on the cooling system. The temperature of this
cooling system must not exceed 112 °C (233.6 °F).
 If the engine is operating above the normal
range and steam becomes apparent, perform the following procedure:
Reduce the load and the engine rpm.
 Determine if the engine must be shut down immediately or
if the engine can be cooled by reducing the load.
 Inspect the cooling system for leaks.
Tachometer - This gauge indicates engine speed (rpm). When the throttle control lever is moved
to the full throttle position without load, the engine is running at high idle. The engine is running
at the full load rpm when the throttle control lever is at the full throttle position with maximum
rated load.
The following parameters are monitored:
Coolant temperature

Intake manifold air temperature

Intake manifold air pressure
Oil pressure

Pressure in the fuel rail
Engine speed/timing

"Warning"
The "Warning" lamp and the warning signal (orange lamp) turn "ON" and the warning signal is
activated continuously in order to alert the operator that one or more of the engine parameters is
not within normal operating range.
The "Diagnostic" lamp turns "ON" and the warning signal (red lamp) is activated. After the
warning, the engine power will be derated. The warning lamp will begin to flash when the derating
occurs.
 The engine will be derated if the engine exceeds preset operational limits. The engine
derate is achieved by restricting the amount of fuel that is available for each injection. The amount
of this reduction of fuel is dependent on the severity of the fault that has caused the engine derate,
typically up to a limit of 50%. This reduction in fuel results in a predetermined reduction in engine
power.
"Warning/Derate/Shutdown"
The "Diagnostic" lamp turns "ON" and the warning signal (red lamp) is activated. After the
warning, the engine power will be derated. The engine will continue at the rpm of the set derate
until a shutdown of the engine occurs. The engine can be restarted after a shutdown for use in an
emergency.
 A shutdown of the engine may occur in as little as 20 seconds. The engine can be
restarted after a shutdown for use in an emergency. However, the cause of the initial shutdown
may still exist. The engine may shut down again in as little as 20 seconds.
If there is a signal for low oil pressure or for coolant temperature, there will be a two second delay
in order to verify the condition.
 For each of the programmed modes, refer to Troubleshooting
Guide, "Indicator Lamps" for more information on Indicator Lamps.
For more information or assistance for repairs, consult your Caterpillar dealer.

"Warning/Derate"

Programmable Monitoring System (PMS)

The Programmable Monitoring System determines the level of action that is taken by the
Engine Control Module (ECM) (5) in response to a condition that can damage the engine. These
conditions are identified by the ECM from the signals that are produced from the following
sensors.
Coolant Temperature Sensor

Intake Manifold Air Temperature Sensor
Intake manifold Pressure Sensor

Fuel Pressure Sensor

Engine Oil Pressure Sensor

Primary Speed/Timing Sensor

Secondary Speed/Timing Sensor

Coolant Temperature Sensor 1

The coolant temperature sensor monitors engine coolant temperature. The output of the ECM (5)
can indicate a high coolant temperature through a relay or a lamp. The coolant temperature sensor
is used by the ECM to determine initiation of the Cold Start Condition.
The ECM (5) will detect a failure of the coolant temperature sensor. The diagnostic lamp will warn
the operator about the status of the coolant temperature sensor. A failure of the coolant temperature
sensor will not cause a shutdown of the engine or any horsepower change. In order to check the
correct operation of the sensor, refer to Troubleshooting, "Engine Temperature Sensor Circuit -
Test".

Intake Manifold Air Temperature Sensor 2

The intake manifold air temperature sensor measures the inlet air temperature. A signal is sent to
the electronic control module (ECM) (5). The intake manifold air temperature sensor is also used
by the ECM to determine initiation of the Cold Start Strategy.
 In order to check the correct
operation of the sensor, refer to Troubleshooting, "EngineTemperature Sensor Circuit - Test".

Intake Manifold Pressure Sensor 3

The intake manifold pressure sensor measures boost pressure in the inlet air manifold. A signal is
sent to the ECM (5) .

Fuel Pressure Sensor 4

The fuel pressure sensor measures the fuel pressure in the fuel manifold. A signal is sent to the
ECM (5) .

Electronic Control Module 5

The ECM is the control computer of the engine. The ECM provides power to the electronics. The
ECM monitors data that is input from the sensors of the engine. The ECM acts as a governor in
order to control the speed and the power of the engine.
 The ECM adjusts injection timing and
fuel pressure for the best engine performance, the best fuel economy and the best control of exhaust
emissions.

Engine Oil Pressure Sensor 6

The engine oil pressure sensor is an absolute pressure sensor that measures the engine oil pressure
in the main oil gallery. The engine oil pressure sensor detects engine oil pressure for diagnostic
purposes. The engine oil pressure sensor sends a signal to the ECM (5) .

Low Oil Pressure Warning

The setpoint for the low pressure warning is dependent upon the engine speed. The fault will be
active and logged only if the engine has been running for more than 8 seconds.

Very Low Oil Pressure Warning

The very low oil pressure setpoint is dependent upon the engine speed. If the DERATE mode of
the engine monitoring system is selected, the ECM (5) will derate the engine power. The engine
horsepower will be limited.

Failure of the Engine Oil Pressure Sensor

The ECM (5) will detect failure of the engine oil pressure sensor. The diagnostic lamp warns the
user about the status of the engine oil pressure sensor. The engine oil pressure related strategies
will be disabled in the event of a failure of the engine oil pressure sensor. A failure of the engine
oil pressure sensor will not cause a shutdown of the engine or any horsepower change. In order to
check the correct operation of the sensor, refer to Troubleshooting, "5 Volt Sensor Supply Circuit
- Test".
Primary Speed/Timing Sensor 7
If the ECM (5) does not receive a signal from the primary speed/timing sensor, the
"DIAGNOSTIC" lamp will indicate a diagnostic fault code which will be logged in the ECM
memory.
 If the ECM does not receive a signal from the primary speed/timing sensor (7), the
ECM will read the signal from the secondary speed/timing sensor (8). The ECM continually checks
in order to determine if there is a signal from both sensors.
Intermittent failure of the sensors will cause erratic engine control.
Failure of the Primary Speed/Timing Sensor
Correct operation of the primary speed/timing sensor is essential. Software in the ECM protects
against reverse running of the engine. If the primary speed/timing sensor fails there is no automatic
protection against reverse running. In some applications, it is possible for the transmission to run
the engine in reverse. In this event, Stop the engine immediately. Turn the keyswitch to the "OFF"
position.
In order to check the correct operation of the sensor, refer to Troubleshooting, "Engine
speed/Timing sensor - Test".
Secondary Speed/Timing Sensor 8
The signal from the secondary speed/timing sensor is used by the ECM (5) on engine start-up in
order to check the stroke of the pistons. The secondary speed/timing sensor may be used by the
ECM in order to operate the engine if the primary speed/timing sensor is faulty.
 In order to check
the correct operation of the sensor, refer to Troubleshooting, "Engine speed/Timing sensor-Test".

Engine Shutoffs and Engine Alarms Shutoffs

The shutoffs are electrically operated or mechanically operated. The electrically operated shutoffs
are controlled by the ECM.
 Shutoffs are set at critical levels for the following items:
Operating temperature Operating pressure
 Operating level
 Operating rpm
The particular shutoff may need to be reset before the engine will start.

Alarms
The alarms are electrically operated. The operation of the alarms are controlled by the ECM.
 The
alarm is operated by a sensor or by a switch. When the sensor or the switch is activated a signal is
sent to the ECM. An event code is created by the ECM. The ECM will send a signal in order to
illuminate the lamp.
 Your engine may be equipped with the following sensors or switches:

Coolant level - The low coolant level switch indicates when the coolant level is low.

Coolant temperature - The coolant temperature sensor indicates high jacket water coolant
temperature.
Intake manifold air temperature - The intake manifold air temperature sensor indicates high intake
air temperature.

Intake manifold pressure - The intake manifold pressure sensor checks the rated pressure in the
engine manifold.

Fuel rail pressure - The fuel rail pressure sensor checks for high pressure or low pressure in the
fuel rail.

Engine oil pressure - The engine oil pressure sensor indicates when oil pressure drops below rated
system pressure, at a set engine speed.

Engine overspeed - The primary speed/timing sensor checks the engine speed. The alarm is
activated at 3000 RPM.

Air filter restriction - The switch checks the air filter when the engine is operating.

User defined switch - This switch can shut down the engine remotely.

Water in fuel switch - This switch checks for water in the primary fuel filter when the engine is
operating.

Note: The sensing element of the coolant temperature switch must be submerged in coolant in
order to operate.
 Engines may be equipped with alarms in order to alert the operator when
undesirable operating conditions occur. If corrective measures are not taken within a reasonable
time, engine damage could result. The alarm will continue until the condition is corrected. The
alarm may need to be reset.

Overspeed
An overspeed condition is detected by the Electronic Control Module (ECM). The event code
E0190 will be logged if the engine speed exceeds 3300 rpm. The "DIAGNOSTIC" lamp will
indicate a diagnostic fault code. The diagnostic fault code will remain active until the engine speed
drops to 2800 rpm.