Caterpillar Operation And Testing

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RENR2307-02
September 2002

Systems Operation
Testing and Adjusting
C-15, C-16 and C-18 On-highway
Engines
W1A1-Up (Engine)
CJP1-Up (Engine)
MDP1-Up (Engine)
MEP1-Up (Engine)
6NZ1-Up (Engine)
7CZ1-Up (Engine)

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 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents Flywheel - Inspect ................................................. 87

Flywheel Housing - Inspect ................................... 88
Vibration Damper - Check ..................................... 91
Systems Operation Section Compression Brake
Slave Piston Lash - Adjust .................................... 92
Engine Design ....................................................... 4
Control Valve (Compression Brake) - Test ............ 94
Engine Design ....................................................... 4
Solenoid Valve (Compression Brake) - Test ......... 95
Engine Design ....................................................... 5
General Information ................................................ 5
Electrical System
Glossary of Electronic Control Terms ..................... 6
Battery - Test ......................................................... 98
Electronic Control System Components ............... 10
Charging System - Test ........................................ 98
Fuel System ......................................................... 16
Electric Starting System - Test .............................. 98
Air Inlet and Exhaust System ............................... 21
Pinion Clearance - Adjust ..................................... 99
Lubrication System .............................................. 25
Cooling System .................................................... 29
Basic Engine ......................................................... 33 Index Section
BrakeSaver ........................................................... 35
Compression Brake .............................................. 43 Index ................................................................... 101
Electrical System ................................................. 45

Testing and Adjusting Section

Fuel System
Fuel System - Inspect ........................................... 49
Air in Fuel - Test .................................................... 49
Finding Top Center Position for No. 1 Piston ........ 50
Fuel Quality - Test ................................................. 51
Fuel System - Prime ............................................. 52
Fuel System Pressure - Test ................................. 54
Gear Group (Front) - Time .................................... 55
Electronic Unit Injector - Adjust ............................. 57
Electronic Unit Injector - Test ................................ 58

Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 59
Turbocharger - Inspect .......................................... 61
Inlet Manifold Pressure - Test ............................... 63
Exhaust Temperature - Test .................................. 64
Aftercooler - Test ................................................... 64
Engine Crankcase Pressure (Blowby) - Test ........ 67
Compression - Test ............................................... 68
Engine Valve Lash - Inspect/Adjust ...................... 68

Lubrication System
Engine Oil Pressure - Test .................................... 71
Excessive Bearing Wear - Inspect ........................ 74
Excessive Engine Oil Consumption - Inspect ....... 74
Increased Engine Oil Temperature - Inspect ........ 75

Cooling System
Cooling System - Check (Overheating) ................ 76
Cooling System - Inspect ...................................... 77
Cooling System - Test ........................................... 78
Water Temperature Regulator - Test ..................... 82
Water Pump - Test ................................................ 83

Basic Engine
Piston Ring Groove - Inspect ................................ 84
Connecting Rod Bearings - Inspect ...................... 84
Main Bearings - Inspect ........................................ 84
Cylinder Block - Inspect ........................................ 84
Cylinder Liner Projection - Inspect ........................ 85
4
Systems Operation Section

Systems Operation Section i01811470

Engine Design
i01819103
SMCS Code: 1000
Engine Design S/N: W1A1-Up
SMCS Code: 1000 S/N: 7CZ1-Up
S/N: 6NZ1-Up
C-16
C-15

g00561261
Illustration 2
g00561261 Cylinder and valve location
Illustration 1
Cylinder and valve location (A) Inlet valves
(B) Exhaust valves
(A) Inlet valves (C) Left side of the engine
(B) Exhaust valves (D) Cylinder number
(C) Left side of the engine (E) Front of the engine
(D) Cylinder number (F) Right side of the engine
(E) Front of the engine (G) Flywheel
(F) Right side of the engine
(G) Flywheel
Bore ....................................... 140.0 mm (5.51 inch)
Bore ....................................... 137.0 mm (5.39 inch)
Stroke ..................................... 171.0 mm (6.73 inch)
Stroke ..................................... 165.0 mm (6.50 inch)
Displacement ................................... 15.8 L (964 in3)
Displacement ................................... 14.6 L (890 in3)
Cylinder arrangement ................. In-Line six cylinder
Cylinder arrangement ................. In-Line six cylinder
Valves per cylinder ................................................. 4
Valves per cylinder ................................................. 4
The adjustment for the inlet valve lash is the
The adjustment for the inlet valve lash is the following value. ...................... 0.38 mm (0.015 inch)
following value. ...................... 0.38 mm (0.015 inch)
The adjustment for the exhaust valve lash is the
The adjustment for the exhaust valve lash is the following value. ...................... 0.76 mm (0.030 inch)
following value. ...................... 0.76 mm (0.030 inch)
Firing order (Injection Sequence) ..... 1, 5, 3, 6, 2, 4
Firing order (Injection Sequence) ..... 1, 5, 3, 6, 2, 4
Crankshaft rotation is viewed from the flywheel.
Crankshaft rotation is viewed from the flywheel. Crankshaft rotation ....................... counterclockwise
Crankshaft rotation ....................... counterclockwise
Note: The front end of the engine is opposite the
Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the
flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1
engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.
cylinder is the front cylinder.
 5
Systems Operation Section

i01811642 i01815862

Engine Design General Information

SMCS Code: 1000 SMCS Code: 1000
S/N: CJP1-Up These engines are in-line six cylinder engines. The
S/N: MDP1-Up engines have a firing order sequence of 1, 5, 3, 6, 2,
4. The rotation of these engines is counterclockwise
S/N: MEP1-Up when the engine is viewed from the flywheel end of
the engine. These engines utilize a turbocharger
and an air-to-air aftercooler.
C-18
The Electronic Unit Injector system (EUI) eliminates
many of the mechanical components that are
traditionally used in the fuel injector assembly. The
EUI also provides increased control of the timing
and increased control of the fuel air mixture. The
timing advance is achieved by precise control of
the fuel injection timing. Engine speed is controlled
by adjusting the injection duration.

The engine has built-in diagnostics in order to

ensure that all of the components are operating
properly. In the event of a system component
failure, the operator will be alerted to the condition
by a check engine light. The check engine light is
Illustration 3 g00561261 located on the dashboard. An electronic service
tool can be used to read the numerical code of
Cylinder and valve location
the faulty component or condition. Also, the cruise
(A) Inlet valves control switches can be used to flash the code on
(B) Exhaust valves
(C) Left side of the engine
the check engine light. Intermittent faults are logged
(D) Cylinder number and stored in memory.
(E) Front of the engine
(F) Right side of the engine
(G) Flywheel Starting The Engine
Bore ....................................... 145.0 mm (5.71 inch) The engine’s ECM will automatically provide the
correct amount of fuel in order to start the engine.
Stroke ..................................... 183.0 mm (7.20 inch) Do not hold the throttle down while the engine is
cranking. If the engine fails to start in 30 seconds,
Displacement ................................. 18.0 L (1100 in3) release the starting switch. Allow the starting motor
to cool for two minutes before the starting motor
Cylinder arrangement ................. In-Line six cylinder is used again.

Valves per cylinder ................................................. 4 NOTICE

Excessive ether (starting fluid) can cause piston and
The adjustment for the inlet valve lash is the ring damage. Use ether for cold weather starting pur-
following value. ...................... 0.38 mm (0.015 inch) poses only.
The adjustment for the exhaust valve lash is the
following value. ...................... 0.76 mm (0.030 inch) Cold Mode Operation
Firing order (Injection Sequence) ..... 1, 5, 3, 6, 2, 4 The ECM will set cold mode when the coolant
temperature is below 18 C (64 F).
Crankshaft rotation is viewed from the flywheel.
Crankshaft rotation ....................... counterclockwise Cold mode is activated five seconds after the start
of the engine. During cold mode, low idle speed
Note: The front end of the engine is opposite the will be increased to 800 rpm. After 60 seconds, the
flywheel end. The left side and the right side of the engine speed is reduced to 600 rpm. Engine power
engine are viewed from the flywheel end. The No. 1 will be limited until cold mode is deactivated.
cylinder is the front cylinder.
6
Systems Operation Section

Cold mode will be deactivated when the coolant American Wire Gauge (AWG) – This is the
temperature reaches 18 C (64 F). measurement of the diameter of electrical wire. This
is also the measurement of the ability of electrical
Cold mode varies the amount of fuel that is injected wire to carry current. A smaller AWG number
for white smoke cleanup. Cold mode also varies reflects a larger wire.
the timing for white smoke cleanup. The engine
operating temperature is usually reached before the Atmospheric Pressure Sensor – This sensor
walk-around inspection is completed. measures atmospheric air pressure in the
crankcase. The sensor sends the signal to the
After cold mode is completed, the engine should electronic control module (ECM).
be operated at low speed until normal operating
temperature is reached. The engine will reach Before Top Center (BTC) – The 180 degrees of
normal operating temperature faster when the crankshaft rotation before the piston reaches the top
engine is operated at low speed and low power center position in the normal direction of rotation.
demand.
Boost Pressure Sensor – This sensor measures
inlet manifold air pressure. The sensor sends the
i01816763
signal to the ECM.
Glossary of Electronic Control Brake Pedal Position Switch – This switch is
Terms supplied and installed by the OEM. The switch is
typically a pressure switch. The switch is normally
SMCS Code: 1900 closed when the pedal is released. Depressing the
brake will open the circuit.
Accelerator Pedal Position – The accelerator pedal
position is the interpretation from the ECM of the Bypass Circuit – This circuit substitutes an existing
signal from the Accelerator Pedal Position Sensor. circuit. The circuit is usually a temporary circuit. The
circuit is used for testing.
Accelerator Pedal Position Sensor – This is
an electronic sensor that is connected to the Calibration – Calibration is an electronic adjustment
accelerator pedal. The sensor sends a Pulse Width of a sensor signal.
Modulated Signal to the ECM. The ECM will then
vary the duty cycle according to the pedal position. Camshaft Position Sensor – This sensor provides
a Pulse Width Modulated signal to the ECM. The
ATA Data Link – The data link is an electrical ECM interprets this signal as the camshaft position
connection for communication with other devices in order to determine the top center position of
that are based on the microprocessor. These cylinder number 1.
devices are compatible with the ATA (American
Trucking Association) and with SAE Standards, Caterpillar Engine Monitoring – The part of the
“Section J1587 and Section J1708”. These devices Caterpillar Electronic Engine Control that monitors
include trip recorders, electronic dashboards Coolant Temperature, Oil Pressure, Intake Manifold
and maintenance systems. The data link is also Air Temperature and Coolant Level. This will alert
the medium for communication that is used the operator of detected problems. The Coolant
for programming and troubleshooting with the Temperature, Intake Manifold Air Temperature, and
Caterpillar electronic service tool. Oil Pressure Sensors are supplied by Caterpillar
and monitored by the ECM. The Coolant Level
Aftermarket Device – The customer or the machine Sensor is installed by the OEM and monitored by
(OEM) installs these devices or accessories. the ECM. An aftermarket Engine Monitoring System
This installation is completed after the engine is does not interface with the Caterpillar Electronic
delivered. Engine Control.

Air-to-Air Aftercooler (ATAAC) – This device cools Check Engine Lamp – This is used to warn the
the intake air after the air is compressed by the operator of the presence of an active diagnostic
turbocharger. The intake air is then passed through code. This is also called the Diagnostic Lamp.
an aftercooler (heat exchanger) before going to the
intake manifold. The aftercooler is mounted in the Clutch Pedal Position Switch – This switch is
front of the radiator. supplied and installed by the OEM. The switch
is an adjustable limit switch that is mounted near
Alternating Current (AC) – The direction of current the pedal. The switch is normally closed when the
flow changes. The current flow alternates constantly. pedal is released. Depressing the clutch will open
the circuit.
 7
Systems Operation Section

Coolant Level Sensor – This sensor detects the Diagnostic Event Code – These codes indicate an
absence or presence of coolant at the probe. The event. The codes are not necessarily an indication
sensor sends the signal to the ECM. This sensor of a problem within the electronic system.
is installed by the OEM.
Diagnostic Fault Code – These codes indicate an
Cooling Fan Relay – This relay is supplied and electronic system malfunction which will indicate a
installed by the OEM. The relay is controlled by the problem with the electronic system.
ECM.
Diagnostic Flash Code – This code indicates a
Coolant Temperature Sensor – This sensor detects malfunction of the electronic system. This code
the engine coolant temperature for Cold Mode can also indicate an event that is detected by the
operation and Caterpillar Engine Monitoring. If electronic system. The code is indicated on the
Engine Monitoring has been programmed to be Check Engine/Diagnostic Lamp.
OFF the sensor will not detect the engine coolant
temperature. Diagnostic Lamp – This is used to warn the operator
of the presence of an active diagnostic code.
Crankshaft Position Sensor – This sensor provides Another name for this lamp is the Check Engine
a Pulse Width Modulated signal to the ECM. The Lamp.
ECM interprets this signal as the crankshaft position
in order to determine the top center position of Direct Current (DC) – Direct current is the type of
cylinder number 1. current that flows consistently in only one direction.

Cruise Control Range – The cruise control operates Duty Cycle – See Pulse Width Modulation.
within this range. The cruise control range is usually
limited to the speed range that is anticipated for Electronic Engine Control – The electronic engine
the application. control is a complete electronic system. The
electronic engine control monitors the engine
Custom Data – This allows the owner to specify operation under all conditions. The electronic
the operating parameters of the engine application engine control also controls the engine operation
while the engine is in service. This data is for under all conditions.
monitoring purposes. Custom Data is a part of the
ECM fleet trip data. Electronic Technician (ET) – Electronic Technician
is a Caterpillar electronic service tool. ET is used
Customer Specified Parameter – The customer can for diagnostics and for programming a variety of
set this parameter value. The parameter value may electronic controls.
be protected by Customer Passwords.
Electronic Unit Injector (EUI) – The injection pump
Data Link – The data link is an electrical is a mechanically actuated, electronically controlled
connection for communication with other onboard unit injector. The EUI combines the pumping,
microprocessor based devices that use the data electronic fuel metering, and injecting elements into
link. These devices are compatible with SAE a single unit.
Standards. These devices include trip recorders,
electronic dashboards and maintenance systems. Engine Control Module (ECM) – The ECM is the
The data link is also the medium for communication engine’s control computer. The ECM provides power
that is used for programming and troubleshooting to the electronics for the system. The ECM monitors
with the Caterpillar electronic service tool. the information that is input by the system. The ECM
acts as a governor in order to control engine rpm.
Desired rpm – The desired engine speed (rpm) is
input to the electronic governor within the ECM. The Engine Control Module (ECM) Fan Control – The
following criteria are used in order to determine the ECM may control the cooling fan through a relay
desired engine speed (rpm): the Accelerator Pedal that is installed by the OEM. The ECM controls
Position Sensor, the Crankshaft Position Sensor, and the relay that is based on coolant temperature,
the Customer Parameters. inlet manifold air temperature, and boost pressure.
The relay can also be controlled by the ECM when
Desired Timing Advance – The fuel injection timing the following switches are installed by the OEM:air
advance is calculated by the ECM. The calculation conditioning high pressure switch, PTO ON/OFF,
is used to meet emission and performance manual fan override switch, and retarder solenoid
specifications.
Engine Retarder Solenoids – The Engine Retarder
Diagnostic Code – A diagnostic code is an is installed by Caterpillar. The solenoids are driven
indication of a problem or event in the electronic directly from the ECM.
system.
8
Systems Operation Section

Estimated Dynamic Timing – This is the estimated Inlet Air Temperature Sensor – This sensor detects
calculation of actual injection timing by the ECM. the inlet air temperature. The ECM monitors the inlet
air temperature and the coolant temperature. The
Failure Mode Identifier (FMI) – This identifies inlet air temperature sensor is a part of Caterpillar
the type of failure that was experienced by the Engine Monitoring.
component. This was adopted from SAE Standards,
“Section J1587” diagnostics. Integrated Electronic Controls – The engine is
designed with the electronic controls as a necessary
Flash Code (FC) – A flash code is a Caterpillar part of the system. The engine will not operate
proprietary code number which is flashed on the without the electronic controls.
diagnostic lamp.
Oil Pressure Sensor – This sensor measures engine
Fuel Ratio Control (FRC) – The FRC is a limit that is oil pressure. The sensor sends a signal to the ECM
based on the control of the fuel to the air ratio. The as part of the Caterpillar Engine Monitoring.
FRC is used for emission control. When the ECM
senses a higher turbocharger outlet pressure, the Open Circuit – An open circuit is a broken electrical
ECM increases the limit for the FRC in order to allow connection. The signal or the supply voltage cannot
more fuel into the cylinders. reach the intended destination.

Fuel Position – The fuel position is a signal within Original Equipment Manufacturer (OEM) – An OEM
the ECM. The signal is from the electronic governor. is an equipment manufacturer that uses Caterpillar
The signal goes to the fuel injection control. The engines to power vehicles that are produced.
signal is based on the desired engine speed, the
FRC, the rated position and engine speed. Parameter – A parameter is a programmable value
which affects the characteristics or the behavior of
Fuel Temperature Sensor – This sensor detects the engine and/or machine.
the fuel temperature. The ECM monitors the fuel
temperature. The ECM adjusts the calculated fuel Parameter Identifier (PID) – This is the two or three
rate accordingly. digit code which is assigned to each component.

Full Load Setting (FLS) – This is the fuel system Passive Magnetic Speed Sensor – This speed
adjustment that is made at the factory. The sensor does not require a power connection and a
adjustment is used to fine tune the fuel system. The ground connection. This speed sensor produces a
correct value for this parameter is stamped on the signal that is based on the change in the magnetic
9L-6531 Information Plate. This parameter must be flux of a ferrous metal gear that is near the sensing
programmed. If the parameter is not programmed, tip.
a Diagnostic Code 253-02 Check Customer or a
System Parameters Fault Code 56 will be generated. Password – A password is a group of numeric
characters or alphanumeric characters. A password
Full Torque Setting (FTS) – This is similar to Full is designed to restrict the changing of information
Load Setting. The parameter for full torque setting in the ECM. The EUI system requires correct factory
must be programmed or a Diagnostic Code 253-02 passwords in order to clear certain logged events.
Check Customer or a System Parameters Fault Factory passwords are also required in order to
Code 56 will be generated. change the engine rating.

Gear Down Protection – This is a Programmable Personality Module Or Ratings Personality Module –
High Gear Limit. This is used to promote driving in A personality module refers to the software that is
higher gears for increased fuel economy. downloaded into the ECM. The module contains
all the instructions (software) for the ECM and
Harness – The harness is the bundle of wiring that performance maps for a specific horsepower family.
connects all the components of the EUI system.
Power Take-Off (PTO) – This requires a dedicated
Hertz (Hz) – Hertz is the measure of frequency in PTO switch with ON/OFF positions. This mode
cycles per second. permits setting an engine rpm with the following
functions: cruise Set/Resume Switch, remote
Histogram – The histogram is a bar graph. This bar PTO Set/Resume Switch, remote accelerator, cab
graph indicates the relative frequency of engine accelerator, and programmable values.
operation within specific operating ranges.
 9
Systems Operation Section

Pro-Link – The Pro-Link is a hand-held service tool “T” Harness – This harness is a test harness that
that is electronic. The Pro-Link is manufactured is designed to permit normal circuit operation and
by Micro Processor Systems, Inc. (MPSI). This is the measurement of the voltage simultaneously.
available with a Caterpillar cartridge in order to Typically, the harness is inserted between the two
service Caterpillar electronic engines. ends of a connector.

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
movement. When any of these changes are
detected, a sensor converts the change into an
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 vehicle’s 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
to provide electrical power for operation. Supply
voltage may be generated by the ECM. The supply
voltage may also be the battery voltage that is
supplied by the vehicle wiring.
Caterpillar Operation And Testing
10
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Systems Operation Section

i01816619

Electronic Control System

Components
SMCS Code: 1900

g00635162
Illustration 4
Typical example
(1) Camshaft position sensor (5) Ground point for the OEM (9) Atmospheric pressure sensor
(2) Boost pressure sensor (6) Engine Control Module (ECM) (10) Engine oil pressure sensor
(3) Connector for the electronic unit injector (7) Crankshaft position sensor (11) ECM connector that is for the engine
P300/J300 (8) Fuel temperature sensor (12) ECM connector that is for the OEM
(4) Inlet air temperature sensor

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