Cat C11-C13-C15-C18 MANUAL DE CALIBRACIONES
Cat C11-C13-C15-C18 MANUAL DE CALIBRACIONES
Cat C11-C13-C15-C18 MANUAL DE CALIBRACIONES
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Producto: EXCAVATOR
Modelo: 345C EXCAVATOR TAJ
Configuración: 345C Excavator TAJ00001-UP (MACHINE) POWERED
BY C13 Engine
Pruebas y Ajustes
C11 and C13 Engines for Caterpillar Built Machines
Número de medio -SENR9888-05 Fecha de publicación -01/10/2006 Fecha de actualización -27/10/2006
i02793330
To prevent possible injury, do not use the starter to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the engine to
cool before measuring valve clearance.
----------------------
Do not come in contact with the fuel injector terminals while the engine is
running.
----------------------
Note: Valve lash is measured between the rocker arm and the bridge for the inlet valves. Valve lash is measured between
the rocker arm and the valve stem for the exhaust valve. All of the clearance measurements and the adjustments must be
made with the engine stopped. The valves must be fully closed.
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 2.
If the measurement is not within this range adjustment is necessary. See Testing And Adjusting, "Valve Lash And Valve
Bridge Adjustment".
Illustration 1 g01193938
Cylinder and Valve location
Illustration 2 g01229786
(1) Exhaust rocker arm
(3) Rocker arm adjustment screw locknut for the exhaust rocker arm
(4) Rocker arm adjustment screw for the exhaust rocker arm
Table 2
Valve Lash
Adjust the valve lash while the engine is stopped. Use the following procedure to adjust the valves:
1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and Adjusting, "Finding
Top Center Position for No. 1 Piston".
Table 3
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 camshaft's base circle.
c. Place the appropriate feeler gauge between rocker arm and the 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 the adjustment locknut to a torque of 30 ± 7 N·m (22 ± 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.
3. 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 position on the compression stroke. Install the timing bolt in the flywheel.
Table 4
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 camshaft's base circle.
c. Place the appropriate feeler gauge between rocker arm and the 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 the adjustment locknut to a torque of 30 ± 7 N·m (22 ± 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.
5. Remove the timing bolt from the flywheel after all adjustments to the valve lash have been made. Reinstall the
timing cover.
Cerrar SIS
Pantalla anterior
Producto: EXCAVATOR
Modelo: 345C EXCAVATOR TAJ
Configuración: 345C Excavator TAJ00001-UP (MACHINE) POWERED
BY C13 Engine
Pruebas y Ajustes
C11 and C13 Engines for Caterpillar Built Machines
Número de medio -SENR9888-05 Fecha de publicación -01/10/2006 Fecha de actualización -27/10/2006
i02738289
Illustration 1 g01126970
Injector Mechanism
(3) Locknut
1. Put the No. 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".
c. Turn the adjustment screw until the screw makes contact with the electronic unit injector.
f. Turn the adjustment screw until the screw makes contact with the electronic unit injector.
2. Rotate the engine in the normal operating direction by 360 degrees. Cylinder 1 will now be on TC exhaust stroke.
c. Turn the adjustment screw until the screw makes contact with the electronic unit injector.
f. Turn the adjustment screw until the screw makes contact with the electronic unit injector.
Copyright 1993 - 2007 Caterpillar Inc. Sun Oct 21 09:30:04 EST 2007
Todos los derechos reservados.
Red privada para licenciados del SIS.
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Pantalla anterior
Producto: EXCAVATOR
Modelo: 345C EXCAVATOR TAJ
Configuración: 345C Excavator TAJ00001-UP (MACHINE) POWERED
BY C13 Engine
Pruebas y Ajustes
C11 and C13 Engines for Caterpillar Built Machines
Número de medio -SENR9888-05 Fecha de publicación -01/10/2006 Fecha de actualización -27/10/2006
i02232306
This procedure assists in identifying the cause for an injector misfiring. Perform this procedure only after performing the
Cylinder Cutout Test. Refer to Troubleshooting for more information.
1. Check for air in the fuel, if this procedure has not already been performed. Refer to Testing and Adjusting, "Air in
Fuel - Test".
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
2. Remove the valve cover and look for broken parts. Repair any broken parts or replace any broken parts that are
found. Inspect all wiring to the solenoids. Look for loose connections. Also look for frayed wires or broken wires.
Ensure that the connector for the unit injector solenoid is properly connected. Perform a pull test on each of the
wires. Refer to Troubleshooting, "Electrical Connectors - Inspect". Inspect the posts of the solenoid for arcing. If
arcing or evidence of arcing is found, remove the cap assembly. Refer to Disassembly and Assembly Manual,
"Electronic Unit Injector - Remove". Clean the connecting posts. Reinstall the cap assembly and tighten the solenoid
nuts to a torque of 2.5 ± 0.25 N·m (22 ± 2 lb in).
3. Check the valve lash setting for the cylinder of the suspect unit injector. Refer to Testing and Adjusting, "Engine
Valve Lash - Inspect/Adjust".
4. Ensure that the bolt that holds the unit injector is tightened to the proper torque. If necessary, loosen the bolt that
holds the unit injector and tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
5. Remove the suspect unit injector and check the unit injector for signs of exposure to coolant. Refer to Disassembly
and Assembly Manual, "Electronic Unit Injector - Remove". Exposure to coolant will cause rust to form on the
injector. If the unit injector shows signs of exposure to coolant, remove the injector sleeve and inspect the injector
sleeve. Refer to Disassembly and Assembly Manual, "Electronic Unit Injector Sleeve - Remove". Replace the
injector sleeve if the injector sleeve is damaged. Check the unit injector for an excessive brown discoloration that
extends beyond the injector tip. If excessive 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 Assembly Manual, "Electronic Unit Injector - Install". Also refer to Disassembly and Assembly
Manual, "Electronic Unit Injector Sleeve - Install".
Shutdown SIS
Previous Screen
i02230869
To prevent possible injury, do not use the starter to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve clearance.
Do not come in contact with the fuel injector terminals while the engine
is running.
Note: Valve lash is measured between the rocker arm and the valve bridge. All measurements and
adjustments must be made with the engine stopped and the valves fully closed.
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C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 2 of 5
Table 1
Valve Lash
Valves Acceptable Range for Valve Lash
Inlet
0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Exhaust
0.76 ± .08 mm (0.030 ± 0.003 inch)
If the measurement is not within this range adjustment is necessary. Refer to Testing And Adjusting,
"Valve Lash Adjustment".
Illustration 1 g01125936
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C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 3 of 5
Illustration 2 g01023432
Table 2
Valve Lash
Valves Lash Setting
Inlet
0.38 mm (0.015 inch)
Exhaust
0.76 mm (0.030 inch)
Adjust the valve lash while the engine is stopped. Use the following procedure in order to adjust the
valves:
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C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 4 of 5
1. Determine the style of variable valve actuator that is installed on the engine.
b. For the, MXS engines, it is not necessary to remove the variable valve actuators.
2. Put the No. 1 piston at the top center position. See Testing and Adjusting, "Finding Top Center
Position for No. 1 Piston" for further details.
Note: If the engine is equipped with an engine compression brake, loosen the adjustment screw
for the lash on the slave piston for the compression brake prior to adjusting the engine valve
lash. Refer to the Testing and Adjusting, "Slave Piston Lash - Adjust" topic in order to adjust
the slave piston lash.
3. With No. 1 piston at the top center position of the compression stroke, an adjustment can be
made to the valves.
Before any adjustments are made, lightly tap each rocker arm at the top of the adjustment
screw. Use a soft mallet to ensure that the lifter roller seats against the camshaft's base circle.
4. Make an adjustment to the valve lash on the inlet valves for cylinders 1, 2, and 4.
b. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve
bridge. Turn inlet adjustment screw (4) while valve adjustment locknut (3) is being held
from turning. Adjust the valve lash until the correct specification is achieved. Refer to
Table 2.
c. After each adjustment, tighten valve adjustment locknut (3) while valve adjustment screw
(4) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.
5. Make an adjustment to the valve lash on the exhaust valves for cylinders 1, 3, and 5.
b. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust
valve bridge. Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is
being held from turning. Adjust the valve lash until the correct specification is achieved.
Refer to Table 2.
c. After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw
(2) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.
6. Remove the timing bolt, and turn the flywheel by 360 degrees in the direction of engine
rotation. This will position the No. 6 piston at the top center on the compression stroke. Install
the timing bolt in the flywheel.
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C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 5 of 5
b. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve
bridge. Turn inlet adjustment screw (4) while valve adjustment locknut (3) is being held
from turning. Adjust the valve lash until the correct specification is achieved. Refer to
Table 2.
c. After each adjustment, tighten valve adjustment locknut (3) while valve adjustment screw
(4) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.
b. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust
valve bridge. Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is
being held from turning. Adjust the valve lash until the correct specification is achieved.
Refer to Table 2.
c. After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw
(2) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.
9. Remove the timing bolt from the flywheel after all valve lash adjustments have been made.
Refer to the Testing and Adjusting, "Slave Piston Lash - Adjust" topic for information on
adjusting the slave piston lash.
Note: The engine valve lash must be adjusted before you adjust the compression brake.
The lash must also be adjusted on the electronic unit injector. Refer to Testing and Adjusting,
"Electronic Unit Injector - Adjust" for more information.
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Page 1 of 8
To prevent possible injury, do not use the starter to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve clearance.
Do not come in contact with the fuel injector terminals while the engine
is running.
NOTICE
The engine valve lash and the injector lash must be within specifications prior to adjusting the
compression brake slave piston lash. Refer to Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust" for the correct procedure for inspection of the engine valve lash. Refer to Testing
and Adjusting, "Electronic Unit Injector - Adjust" for the proper procedure for inspection of the
injector lash adjustment.
Note: The slave piston lash adjustment must be performed while the engine is cold. If the
engine is warm, allow the engine to cool prior to performing the following adjustments.
Use the following procedure to adjust the slave piston lash on cylinders 1, 3, and 5:
Put the No. 1 piston at the top center position on the compression stroke. See Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston" for further details.
Illustration 1 g00596577
NOTICE
Prior to adjusting the lash setting for the engine compression brake,
check the identification plate that is on the compression brake casting
in order to determine the model that is installed on your engine. You
Page 3 of 8
must have this model number and the engine serial number prefixin
order to determine the lash setting for your engine.
Table 1
Slave Piston Lash Setting
Jake Brake Compression Brakes
6NZ1-UP
435 hp or more 0.84 ± 0.08 mm (0.033 ±
Jake Brake 340C
0.003 inch)
375/435 hp Multitorque
0.84 ± 0.08 mm (0.033 ±
rating
0.003 inch)
1MM1-UP
7CZ1-UP
All ratings 0.94 ± 0.08 mm (0.037 ±
5DS1-UP
0.003 inch)
Jake Brake 340C
5EK1-UP (2)
435 hp or more 0.68 ± 0.08 mm (0.027 ±
Jake Brake 340
0.003 inch)
1LW1-UP
6NZ1-UP
All ratings 0.64 ± 0.08 mm (0.025 ±
7CZ1-UP
0.003 inch)
Jake Brake 340D
CJP1-UP
MDP1-UP
MEP1-UP All ratings 1.02 ± 0.08 mm (0.040 ±
W1A1-UP 0.003 inch)
Jake Brake 340C
MBN1-UP
Jake Brake 340D All ratings 0.76 ± 0.08 mm (0.030 ±
0.003 inch)
BXS1-UP
All ratings 0.89 ± 0.08 mm (0.035 ±
Jake Brake 340C 0.003 inch)
BXS1-UP
All ratings 0.84 ± 0.08 mm (0.033 ±
Jake Brake 340E
0.003 inch)
(1)
Check the identification plate that is on the compression brake casting in order to determine the model that is
installed on your engine.
(2)
Some of the early 3406E Engines , 5EK1-01820 were built with either the 340 or the 340A compression brakes.
Note: The slave piston lash settings are specific to the model number of the compression brake
and to the serial number prefix of the engine. Use these settings only for the compression brakes
and serial number prefixes that are specified in the table.
2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 1 for the correct slave piston lash setting.
3. Turn the adjustment screw for the slave piston in a clockwise direction until the slave piston
tightens against the feeler gauge. A slight drag should be felt on the feeler gauge.
4. Tighten the adjustment locknut (1) to a torque of 34 ± 5 N·m (25 ± 4 lb ft). Recheck the
adjustment after you tighten the locknut. If necessary, repeat this procedure.
1. Loosen adjustment locknut (1) and back out the adjustment screw until the slave piston is
not in contact with the exhaust valve rocker arm.
2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 1 for the correct slave piston lash setting.
3. Turn the adjustment screw for the slave piston in a clockwise direction until the slave piston
tightens against the feeler gauge. Tighten the adjustment screw for one additional turn in the
clockwise direction. The valve spring should start to compress. Allow the oil to be purged
from the autolash assembly of the compression brake for 30 seconds.
Note: All of the oil must be allowed to drain from the autolash assembly of the compression
brake. If the temperature of the oil is below 16 °C (60 °F), allow the oil to be purged for an
additional 2 minutes. Serious engine damage may occur if the oil is not properly purged
from the autolash assembly.
4. Slowly turn the adjustment screw counterclockwise until the slave piston begins to loosen
against the feeler gauge. A slight drag should be felt on the feeler gauge when the
adjustment is correct.
Note: Do not overshoot the setting of the slave piston during adjustment. If you
overshoot the setting, this procedure must be repeated.
5. Tighten the adjustment locknut (1) to a torque of 34 ± 5 N·m (25 ± 4 lb ft). Recheck the
adjustment after tightening the locknut. If necessary, repeat the procedure.
Adjust the slave piston lash settings for cylinders 3 and 5 prior to rotating the engine.
After you adjust cylinders 1, 3, and 5, reset the timing pin and turn the flywheel for 360 degrees in
the direction of engine rotation. This will position the No. 6 piston at the top center on the
compression stroke. Ensure that the timing pin has located the timing hole that is in the flywheel.
Continue to perform the adjustment procedure for the slave piston lash settings on cylinders 2, 4,
and 6.
Remove the timing pin from the flywheel after all adjustments have been performed. Reinstall the
timing cover.
Illustration 2 g00975814
Table 2
Slave Piston Lash Setting
Pacbrake Compression Brakes
Serial Number Prefix and Model Horsepower
Slave Piston Lash Setting
Designation Rating
1LW1-UP
5DS1-UP All ratings 0.762 ± 0.076 mm (0.030 ±
Pacbrake P-39A 0.003 inch)
5EK1-UP
6TS1-UP
1LW1-UP
5DS1-UP
2WS1-UP All ratings 0.838 ± 0.076 mm (0.033 ±
1MM1-UP 0.003 inch)
6NZ1-UP
7CZ1-UP
Pacbrake P-39B
6NZ1-UP
7CZ1-UP N/A Product Campaign (1)
Pacbrake P-39C
Page 7 of 8
MBN1-UP
All ratings 0.97 ± 0.08 mm (0.038 ± 0.003
Pacbrake P-39D
inch)
BXS1-UP
All ratings 0.71 ± 0.08 mm (0.028 ± 0.003
Pacbrake P-39E (1)
inch)
(1)
Contact Pacbrake for information that relates to the product campaign.
(1)
C15 Engines only
Note: The slave piston lash settings are specific to the serial number of the engine. Ensure
that the slave piston lash setting that is being used is correct for the serial number of your
engine.
2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 2 for the correct slave piston lash settings.
3. Turn the adjustment screw for the slave piston in a clockwise direction. Tighten the
adjustment screw for the slave piston beyond the point of contact with the exhaust valve
rocker arm. This will allow the oil to be purged from the slave piston. Once the oil has been
purged from the piston, turn the adjustment screw for the slave piston in a counterclockwise
direction until the feeler gauge is loose between the adjustment screw and the rocker arm.
4. Again, turn the adjustment screw for the slave piston in a clockwise direction until a slight
drag is felt on the feeler gauge.
Adjust the slave piston lash settings for cylinders 3 and 5 prior to rotating the engine.
2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 2 for the correct slave piston lash settings.
3. Turn the adjustment screw for the slave piston in a clockwise direction until the slave piston
tightens against the feeler gauge. Tighten the adjustment screw for one additional turn in the
clockwise direction. The valve spring should start to compress. Allow the oil to be purged
from the components of the compression brake for 1 minute.
4. Slowly turn the adjustment screw counterclockwise until a slight drag is felt on the feeler
gauge.
Note: Do not overshoot the setting of the slave piston during this adjustment. If you
overshoot the setting, this procedure must be repeat.
Page 8 of 8
5. While you hold the screw of the adjuster, tighten the adjustment locknut (1) to a torque of
34 ± 5 N·m (25 ± 4 lb ft).
Note: Do not place excessive torque on the locknut that is on the adjustment screw. If
excessive torque is placed on the adjustment screw, damage to the components of the
compression brake may result.
6. Recheck the adjustment after tightening the locknut. If a slight drag is not felt on the feeler
gauge, repeat the adjustment procedure.
Adjust the slave piston lash settings for cylinders 3 and 5 prior to rotating the engine.
After you adjust cylinders 1, 3, and 5, reset the timing pin and turn the flywheel for 360 degrees in
the direction of engine rotation. This will position the No. 6 piston at the top center on the
compression stroke. Ensure that the timing pin has located the timing hole that is in the flywheel.
Continue to perform the adjustment procedure for the slave piston lash settings on cylinders 2, 4,
and 6.
Remove the timing pin from the flywheel after all adjustments have been performed. Reinstall the
timing cover.
C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 1 of 2
Shutdown SIS
Previous Screen
i02230867
Table 1
Required Tools
Part Number Part Name Quantity
9U-7227 Injector Height Gauge 1
Note: Determine the style of variable valve actuator that is installed on the engine. For the BXS engines,
remove the variable valve actuators. For the MXS engines, it is not necessary to remove the variable valve
actuators.
Illustration 1 g01023138
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C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 2 of 2
Injector Mechanism
(3) Locknut
To make an adjustment to the unit injectors on cylinders 3, 5, and 6 use the following procedure:
1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".
2. Injector height gauge (4) is used in order to obtain a dimension of 78.0 ± 0.2 mm (3.07 ± 0.01 inch).
The dimension is measured from the top of the unit injector to the machined ledge of the fuel injector
body.
3. Turn unit injector adjustment screw (2) clockwise until the correct height is obtained.
4. Hold the adjustment screw in this position and tighten locknut (3) to a torque of 100 ± 10 N·m (74 ± 7
lb ft).
5. To make an adjustment to the unit injectors on cylinders 1, 2, and 4, remove the timing bolt. Turn the
flywheel by 360 degrees in the direction of engine rotation. The direction of engine rotation is
counterclockwise, as the engine is viewed from the flywheel end. This will put the number 1 piston at
the top center position on the exhaust stroke.
7. Remove the timing bolt from the flywheel after all the unit injector adjustments have been made.
Reinstall the valve mechanism cover.
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C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 1 of 3
Shutdown SIS
Previous Screen
i02283578
S/N - MXS1-UP
S/N - NXS1-UP
NOTICE
Do not disassemble the Variable Valve Actuator. There are no
components of the Variable Valve Actuator that are serviceable. If the
Variable Valve Actuator is disassembled, the warranty will be void.
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C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 2 of 3
Illustration 1 g01102463
(1) Adjustment screw
1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".
2. Loosen adjustment screw locknut (2) and back out adjustment screw (1) until actuator rod (4) is not in
contact with intake rocker arm (3) .
Note: During this procedure, ensure that the intake rocker arm is in full contact with the valve
bridge.
3. Place the appropriate feeler gauge between the actuator rod and the intake rocker arm. Turn the
adjustment screw in a clockwise direction. Slide the feeler gauge between the actuator rod and the
intake rocker arm. Continue turning the adjustment screw until a slight drag is felt on the feeler gauge.
Remove the feeler gauge. Refer to Specifications, "Variable Valve Actuators" for the proper lash
setting.
4. Tighten the adjustment screw locknut. Refer to Specifications, "Variable Valve Actuators" for the
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C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 3 of 3
5. Recheck the lash setting after the adjustment screw locknut has been torqued.
7. Remove the timing bolt from the flywheel. Turn the crankshaft clockwise by 360 degrees. This will
position the No. 6 piston at the top center on the compression stroke. Install the timing bolt in the
flywheel.
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SENR9575-05 Harness And Wire Electrical Schematic Symbols
November 2007
P300
Symbols
UNIT INJECTOR
HARNESS CONNECTOR
INTAKE MANIFOLD Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
FUEL AIR TEMPERATURE No circle indicates that the wire cannot be disconnected from the component.
TEMPERATURE P103
SPLICE P105 FUEL
G833 PRESSURE ELECTRONIC
CONTROL MODULE Ground (Wired): This indicates that the component is connected to a grounded wire. The
J209 P2 grounded wire is fastened to the machine.
P300
UNIT INJECTOR
SPLICE
993
C-10, C-12, C-15 and C-16 Sender: A component that is used with a temperature or pressure gauge. The sender
measures the temperature or pressure. Its resistance changes to give an indication to
Industrial Engine
SECONDARY ENGINE
SPEED/TIMING HARNESS CONNECTOR T
the gauge of the temperature or pressure.
(CAMSHAFT)
P402
SPLICE
Electrical System
SPLICE Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
R993 997
It has a coil that makes an electromagnet when current flows through it. The
electromagnet can open or close the switch part of the relay.
ELECTRONIC
CONTROL MODULE
P2 Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
PRIMARY ENGINE ENGINE OIL PRIMARY ENGINE
SPEED/TIMING PRESSURE SPEED/TIMING coil that makes an electromagnet when current flows through it. The electromagnet
(CRANKSHAFT) P201 (CRANKSHAFT) can open or close a valve or move a piece of metal that can do work.
P401 P401
CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES Z2B1-UP
226-5758 AND 243-6620 (C-10/C-12) Z2C1-UP
MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is
activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
INTEGRAL SENSORS CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES that make electromagnet when current flows through them. It also has an internal switch that places
BDL1-UP the latch coil circuit open at the time the coil latches.
191-5204, 238-1773, AND 237-7595 (C-15/C-16)
BEM1-UP
Harness and Wire Symbols
BFM1-UP
BCX1-UP 1 Deutsch connector: Typical representation
of a Deutsch connector. The plug contains all
1 Sure-Seal connector: Typical representation
of a Sure-Seal connector. The plug and receptacle
2 sockets and the receptacle contains all pins. 2 contain both pins and sockets.
325-AG135 PK-14 1 5A
Pin Socket Fuse
Receptacle
Pin or Socket (5 Amps)
Single Wire
Number
9X-1123
Connector
Component
INTAKE MANIFOLD Plug
Part Number
AIR TEMPERATURE
P103 Harness identification code: 2 200-L32 BK-14
This example indicates wire
135 in harness "AG".
Ground Circuit Identification Wire Gauge
Connection Number Wire Color
SPLICE
997
ENGINE COOLANT
TEMPERATURE
P100
174-0502 160-7689
P300 A B
UNIT INJECTOR D788 D786 D788 D787 D788 D786
SECONDARY ENGINE HARNESS CONNECTOR
SPEED/TIMING
(CAMSHAFT) SPLICE
P402 D786 C
ENGINE OIL
PRESSURE INJECTOR
#5 INJECTOR INJECTOR INJECTOR
J201 INJECTOR INJECTOR
#3 #2 #1
#6 #4
A701
PRIMARY ENGINE SPLICE A702
3
5
1
6
4
A704 A703
SPEED/TIMING A706 A705 D790
(CRANKSHAFT) D790 D789 160-7690
P401 D791 D790 D789
D791 2 1
SENR9575-05
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 189-6594 (C-10/C-12)
PIGTAIL SENSORS
3E-3370
SPLICE SPLICE
SPLICE
D791 D789
D788
B A
1 5 6 10
155-2267 11 15 16 20
21 25 26 30
31 35 36 40
A B
CATERPILLAR SUPPLIED
ENGINE SERVICE
TOOL CONNECTOR C
J63
8T-8736
CUSTOMER 169-8670
CONNECTOR D
30 Page,
J61 E C
F A B
A B
INJECTOR HARNESS J
CONNECTOR G
J300
C H
SPLICE
120
SPLICE
892 SPLICE
893
SPLICE 155-2252
SPLICE
D788
D786
12 11 10 9 8 7
GROUND
229 1 2 3 4 5 6
SPLICE
A234 D788 D788 D788
K990
K900
TERMINATION
RESISTOR D791 D791 D789 D789 3E-7990
P154
A705
5
A706
1
6
A702 A701
1 2 3 4 5 6
CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES Related Electrical Service Manuals
D790 D790
INJECTOR INJECTOR INJECTOR INJECTOR
189-6596, 191-1531, 238-1774, 242-7248, AND 243-6618 (ALL) #6 #5 #2 #1 Title
Industrial
Form Number
ELECTRONIC Engine
3
4
A704 A703 12 11 10 9 8 7
CONTROL
Installation Guide C-10,C-12 REHS0871
MODULE
P1 System Operation
C-10,C-12 SENR9573
INJECTOR INJECTOR Test and Adjust
#4 #3 Troubleshooting C-10,C-12 SENR9576
Installation Guide C-15,C-16 REHS0871
3E-8969
System Operation
C-15,C-16 RENR2347
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 4P-9537 (C-10/C-12) Test and Adjust
Troubleshooting C-15,C-16 SENR9576
7 8 9 10 11 12
System Operation
C-10(Z2B),C-15(Z2C) SENR9953
Test and Adjust
Troubleshooting C-10(Z2B),C-15(Z2C) RENR5061
6 5 4 3 2 1
NOT NOT
Fuel
Customer Fuel Pressure Atmospheric
Engine Coolant
Connector Temperature Sensor Pressure
Temperature Service Tool
J61 Sensor J209 Sensor
Sensor Connector Electronics
P105 P203(J203)
P100 J63 Ground
Engine Control Module
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS Stud
(NOTE B) Primary Engine
CID Component Speed/Timing
1
2 INLET AIR SHUTOFF 0001 Injector #1
SOLENOID RELAY Sensor
INLET AIR SHUTOFF (NOTE V) 0002 Injector #2
SOLENOID (NOTE V) (Crankshaft)
0003 Injector #3
P401
0004 Injector #4
P142/J142 0005 Injector #5
AUXILIARY
A +8V
TEMPERATURE
B RETURN 0006 Injector #6
SENSOR
C SIGNAL
0022 Timing Sensor
P800/J800
BATTERY A +8V COOLANT LEVEL 0041 8 Volt DC Supply
B RETURN SENSOR
BATTERY OFF ENGINE 0091 Throttle Position
DISCONNECT C SIGNAL
SWITCH
0094 Fuel Pressure Secondary Engine
TERMINATION
RESISTOR
120
P220/J220 0100 Engine Oil Pressure Speed/Timing
J63 AUXILIARY
(134-2540)
ENGINE SERVICE
A +5V
PRESSURE
0110 Engine Coolant Temperature Sensor
(NOTE B&C) OPTIONAL B RETURN
TOOL CONNECTOR
BATTERY WIRING C SIGNAL SENSOR 0168 System Voltage (Camshaft) ECM
A B C 8T8736
P154 120/YL A (+)BATTERY 0172 Intake Manifold Air Temp P402 Ground
1740502
1297163
0320 Speed / Timing Sensor Event Codes For ADEM III ECM
CAT DATA LINK (-) 892/WH 120/YL 120/YL Control
(Dimensions: 39 inches x 28 inches)
9 P515
RETARDER LAMP 10 T936/GN ALTERNATOR 1552269 Event Code Condition
BK-18 0342 Loss of Secondary Engine Speed Module
INLET AIR SHUTOFF SOLENOID RELAY 11 G971/BR 1
12 A234/BK A234/BK BK-18 2 STARTING AID OVERRIDE SW 0545 Ether Start Relay E004 Engine Overspeed Shutdown
13
(ECM)
14 K990/GN K990/GN 1835 Auxiliary Pressure Sensor E005 Fuel Filter Restriction Derate Timing Calibration
AUXILIARY PRESSURE SENSOR 15 G469/BU
(TC) Probe Connector
16 K900/YL K900/YL MAINTENANCE DUE RESET SW
1836 Auxiliary Temperature Sensor E006 Fuel Filter Restriction Shutdown
ECM
17
18
¹ The CID is a diagnostic code that indicates which component is faulty. E015 High Engine Coolant Temperature Derate P400 Connector ECM
19 892/WH 892/WH ² The MID is a diagnostic code that indicates which electronic control module Engine Oil Connector
20 893/PK 893/PK J61 +BAT. (UNSWITCHED) 14 AWG E016 High Engine Coolant Temperature Shutdown P2/J2
TORQUE LIMIT SW Pressure
ETHER START VALVE
STARTING AID OVERRIDE SWITCH
21
22
382/PK
M910/OR M909/GN
9X1343
150/OR(48) 1
P61
+BAT. (UNSWITCHED)
+BAT. (UNSWITCHED)
+BAT. (UNSWITCHED)
14 AWG
14 AWG
diagnosed the fault.
E017 High Engine Coolant Temperature Warning Sensor
LEFT SIDE VIEW P1/J1
MAINTENANCE DUE RESET SWITCH 23 F426/BU T936/GN M909/GN 2 TORQUE LIMIT SW INLET AIR SHUTOFF SOLENOID RELAY
24 G971/BR T936/GN 3 RETARDER LAMP(NOTE M) SOLENOID COMMON REMOTE SHUTDOWN SW (NOTE K) Failure Mode Identifiers (FMI)¹ E025 High Inlet Air Temperature Derate P201(J201)
25 G969/YL G971/BR 4 INLET AIR SHUTOFF SOLENOID RELAY AUXILIARY TEMP SNSR
SENR9575-05
26 167/OR G969/YL 5 SOLENOID COMMON COOLANT LEVEL SNSR FMI No. Failure Description E027 High Inlet Air Temperature Warning
NOT USED 27 J983/YL A274/BK 892/WH 6 CAT DATA LINK - DIG SNSR PWR (+8V)
0 Data valid but above normal operational range. E039 Low Engine Oil Pressure Derate
DIAGNOSTIC LAMP 28 F404/RD A307/GY 893/PK 7 CAT DATA LINK + DIG SNSR RETURN INTERMEDIATE ENGINE SPEED SW
WARNING LAMP 29 F420/GN G488/GN 167/OR 8 DIG SNSR PWR (+8V) AUXILIARY PRESS. SNSR 1 Data valid but below normal operational range.
A274/BK 9 DIG SNSR RETURN THROTTLE POSITION SNSR
E040 Low Engine Oil Pressure Shutdown
MAINTENANCE DUE LAMP 30 F424/YL F426/BU
31 F424/YL A307/GY 10 THROTTLE POSITION SNSR ANLG SNSR PWR (+5V) 2 Data erratic, intermittent, or incorrect.
G488/GN 11 AUXILIARY TEMP SNSR ANLG SNSR RETURN
E054 High Fuel Temperature Derate
32 125/OR OVERSPEED VERIFY SW 3 Voltage above normal or shorted high.
33 T993/BR F426/BU 12 MAINTENANCE DUE RESET SW ETHER START VALVE NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST
F424/YL 13
E055 High Fuel Temperature Shutdown
M904/OR MAINTENANCE DUE LAMP STARTING AID OVERRIDE SW 4 Voltage below normal or shorted low.
J1939 DATA (-) 34 K990/GN HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS
382/PK 125/OR 14 ANLG SNSR PWR (+5V) MAINTENANCE DUE RESET SW (+) BATTERY
35
T993/BR 15 ANLG SNSR RETURN TORQUE LIMIT SW 5 Current below normal or open circuit. E056 High Fuel Temperature Warning CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL
36 F404/RD PTO INTERRUPT SW
37 F420/GN A234/BK 16 J1939 SHIELD REMOTE SHUTDOWN SW E057 Low Engine Coolant Level Derate
F716/WH K900/YL 17 J1939 DATA + INTERMEDIATE ENGINE SPEED SW
6 Current above normal or grounded circuit. (+) BATTERY SWITCHED NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL
TACHOMETER + 38 450/YL
451/BR G968/WH K990/GN 18 J1939 DATA - 75% OVERSPEED VERIFY SW 7 Mechanical system not responding properly. E058 Low Engine Coolant Level Shutdown INSTALLATION DETAILS
TACHOMETER - 39
TORQUE LIMIT SWITCH 40 M909/GN 381/PU M904/OR 19 PTO INTERRUPT SW PTO INTERRUPT SW PTO ENABLE SW
STARTING CIRCUIT
PTO INTERRUPT SWITCH 41 M904/OR G955/GN 450/YL 20 PTO ENABLE SW 8 Abnormal frequency, pulse width, or period. E059 Low Engine Coolant Level Warning NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR
J1939 SHIELD 42 A234/BK G469/BU 451/BR 21
9 Abnormal update. (-) BATTERY / SENSOR RETURN TO TERMINATION RESISTOR) IS 40 METERS
(NOT USED)NOTE Z 43 E798/PK H407/YL 382/PK 22 ETHER START VALVE PTO RAMP UP/SET SW E095 Fuel Filter Restriction Warning
E798/PK(H406/GY)NOTE Z J983/YL 23 PTO RAMP DOWN/RESUME SW 10 Abnormal rate of change. NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION
REMOTE SHUTDOWN SWITCH 44 F716/WH
INTERMEDIATE ENGINE SPEED SWITCH 45 G968/WH E452/WH F404/RD 24 DIAGNOSTIC LAMP MAINTENANCE DUE LAMP E096 High Fuel Pressure SENSOR / ACTUATOR SUPPLY NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939
COOLANT LEVEL SENSOR 46 E452/WH H405/BU F420/GN 25 WARNING LAMP DIAGNOSTIC LAMP 11 Failure mode not identifiable. SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS
RETARDER SOLENOID HI (NOTE M) 47 H405/BU M910/OR 120/YL 26 +BAT. (SWITCHED) WARNING LAMP E100 Low Engine Oil Pressure Warning SIGNAL PLUS TO ECM
F716/WH 27 REMOTE SHUTDOWN SW RETARDER LAMP(NOTE M) PTO RAMP
12 Bad device or component. NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR
+BATTERY (UNSWITCHED) 48 150/OR(48) G967/WH SIGNAL MINUS TO ECM
387/PK G968/WH 28 INTERMEDIATE ENGINE SPEED SW +BAT. (SWITCHED) 14 AWG UP/DOWN SWITCH E190 Engine Overspeed Warning MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION
RETARDER SOLENOID MED (NOTE M) 49 H406/GY 13 Out of calibration.
J1939 DATA (+) 50 K900/YL 150/OR(48) 381/PU 29 PTO ENABLE SW CAT DATA LINK -
51 150/OR(52) G955/GN 30 PTO RAMP UP/SET SW CAT DATA LINK + 14 Parameter failures. E443 High Auxiliary Pressure CONTROL PLUS FROM ECM NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING
+BATTERY (UNSWITCHED) 52 150/OR(52) 150/OR(53) 150/OR(52) 31 +BAT. (UNSWITCHED) MAINTENANCE CONTROL MINUS FROM ECM STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE
450/YL 150/OR(53) 32 +BAT. (UNSWITCHED)
CB DUE LAMP 15 Parameter failures. E445 High Auxiliary Temperature OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO
+BATTERY (UNSWITCHED) 53 150/OR(53)
75% OVERSPEED VERIFY SWITCH 54 387/PK 451/BR G469/BU 33 AUXILIARY PRESS. SNSR
MAX LENGTH 40 METERS 1A 16 Parameter not available. CAT DATA LINK A MAIN EMS MODULE
55 J983/YL H407/YL 34 RETARDER MED/LO/HI SW(NOTE M) J1939 SHIELD
NOTE Z E798/PK(H406/GY) 35 RETARDER MED SW(NOTE M) J1939 DATA + 17 Module not responding. J1939 DATA LINK NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS.
PTO ENABLE SWITCH 56 381/PU
57 E452/WH 36 COOLANT LEVEL SNSR J1939 DATA - DIAGNOSTIC LAMP
IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED.
H405/BU 37 RETARDER HI SW(NOTE M) (153-2707)
CB 18 Sensor supply fault. IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO
PTO RAMP UP/SET SWITCH 58 G955/GN
M910/OR 38 STARTING AID OVERRIDE SW (NOTES B & E) 1A 19 Condition not met. BATTERY (-) IS REQUIRED
30 Page, Color 2,
120 G Intake Manifold NOTE Y: HARNESSES 237-7595 -00 AND 238-1773 -00 HAVE WIRES J700/BR, J701/GN,
H
TERMINATION
(165-0200)
J
(Intake Air Temperature AND J702/BK INSTALLED. ALL OTHER C-15/C-16 ENGINE HARNESSES DO NOT INCLUDE
MAX LENGTH 1 METER
RESISTOR
(NOTE B) Manifold Air) THESE WIRES.
(174-3016)
DEVICE
(J66) Sensor NOTE Z: HARNESS 242-7248 -00 HAS WIRE H406/GY INSTALLED. ALL OTHER CUSTOMER
(NOTE B & C) CUSTOMER INSTALLED
SERVICE TOOL CONN
J200 P103 HARNESSES HAVE WIRE E798/PK INSTALLED. H406/GY TERMINATES AT P1/49 AND J61/35.
E798/PK TERMINATES AT P1/43 AND J61/35.
NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES
WITHOUT CATERPILLAR ENGINEERING APPROVAL
UNLESS OTHERWISE SPECIFIED:
ALL WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR
EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708
ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN
ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN
CONSIDERING COMPONENT REMOVAL
Secondary Engine
MAIN EMS MODULE
OPTIONAL EMS DISPLAY MODULES
Speed/Timing ABBREVIATION
(NOTE G)
Sensor ALT ALTERNATOR
ATA AMERICAN TRUCKING ASSOCIATION
TACHOMETER MODULE QUAD GAUGE MODULE
Engine Coolant (Camshaft) Timing Calibration CB CIRCUIT BREAKER
CAT DATA LINK +
CAT DATA LINK -
SCROLL BACKWARD
(NOTE G) (NOTE G)
SCROLL FORWARD
WARNING LAMP
DIG DIGITAL
MODULE LOAD
MODULE DATA
CAT DATA LINK +
CAT DATA LINK -
-BAT.
+BAT. (SWITCHED)
US/METRIC
10
15
20 Sensor
WARNING
-BAT
33
10
11
12
16
17
18
19
21
22
24
26
27
28
29
30
31
32
36
37
38
39
40
1
2
5
7
4
3
6
8
9
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Pressure
Sensor THIS SCHEMATIC IS FOR THE C-10, C-12, C-15, and C-16 INDUSTRIAL ENGINES
J203 WIRING DIAGRAMS- 201-0649 CHG04 AND 238-1775 CHG01
(NOTE F)
4P-9537 07 INJECTOR(C-10/C-12)
CAT DATA LINK +
CAT DATA LINK - 122-1486 10 INJECTOR(C-15/C-16)
-BAT.
(NOTES B & L) 132-3144 00 FUEL PRESSURE EXTENSION(C-10/C-12)
+BAT. (SWITCHED)