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Vol. 2, No. 1, 2006

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ENGINE

The 535C and 545C Wheel Skidders are equipped with the C7 ACERT® engine, serial number
prefix KHX.

The displacement of the C7 in the 535C has a displacement of 7.1 liters with a rated power of
163kW (218 hp) at 1800 rpm. The performance test specification for the C7 is 0K5892.

The displacement of the C7 in the 545C has a displacement of 7.1 liters with a rated power of
173kW (232 hp) at 1800 rpm. The performance test specification for the C7 is 0K5893.

The C7 utilizes the A4 Electronic Control Module (ECM) engine control and is equipped with
an Air To Air AfterCooler (ATAAC) intake air cooling system. The Engine ECM utilizes the
Advanced Diesel Engine Management (ADEM IV) to control the fuel injector solenoids and to
monitor fuel injection.

The C7 ACERT® engine meets U.S. Environmental Protection Agency (EPA) Tier III
Emissions Regulations for North America and Stage III European Emissions Regulations.

The components located on the left side of the machine are:

- Main disconnect switch (1)
- Coolant overflow and reservoir (2)
- Air filter housing (3)
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The fuel system is equipped with an electronic fuel priming pump (1). To prime the fuel
system, the fuel pump priming switch (not shown) must be held in the top position with the
main disconnect switch in the ON position.

Also shown is the Engine ECM (2).

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The engine components located on the right side of the machine are:

- Turbocharger (1)
- Alternator (2)
- Starter (3)
- Oil filter (4)
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The secondary fuel filter base (3) contains the fuel pressure differential switch (1) and a fuel
pressure sensor (2).

The fuel filter pressure differential switch compares the filter inlet pressure to the filter outlet
pressure. This switch is normally closed. When the difference in the inlet pressure and the
outlet pressure causes the switch to open, a fault will be logged in the Engine ECM.

When this event occurs, engine performance may be degraded when the fuel flow is restricted,
and the fuel injectors are starved of fuel. This condition, if ignored, could cause damage to the
fuel injectors.

The status of the sensor and the filter pressure differential switch may be viewed through
Caterpillar Electronic Technician (Cat ET).
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This view shows the side of the engine that is accessed from the right side of the machine.

Components which can be seen are:

- Injection Actuation Pressure (IAP) sensor (1)

- Air inlet heater relay (2)

- Intake air temperature sensor (3)

- Atmospheric pressure sensor (4)

- Intake air pressure sensor (5)

- Engine ECM (A4E4) (6)

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Some additional components that are located on the right side are:

- Speed sensors (1)

- Oil pressure sensor (2)

- Coolant temperature sensor (3)

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HYDRAULIC WINCH SYSTEM

The machines now features an electronically controlled hydraulic winch (1). The hydraulic
winch eliminates the need for the continuously rotating driveshaft.

The following switches are used to control the winch:

- Winch reel in switch (3)
- Winch reel out switch (4)
- Winch free spool switch (5)

Also shown is differential lock switch (2).