5 Engine Arrangement

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Product: TRACK-TYPE TRACTOR
Model: D6R II TRACK-TYPE TRACTOR AAX
Configuration: D6R SERIES II Track-Type Tractor XL Differential Steering AAX00001-UP (MACHINE) POWERED BY C-9 Engine
Troubleshooting
C-9 Engine for D6R Series II Track-Type Tractor
Media Number -SENR9503-13 Publication Date -01/07/2013 Date Updated -29/07/2013

i01914176
Engine Misfires, Runs Rough or Is Unstable

SMCS - 1000-035
Note: If the symptom is intermittent and the symptom cannot be repeated, refer to Troubleshooting,
"Intermittent Low Power or Power Cutout". If the symptom is consistent and the symptom can be
repeated, continue with this procedure.
Probable Causes
• Diagnostic codes
• Electrical connectors
• Starting aids
• Throttle signal
• Injection actuation pressure
• Unit injectors
• Fuel supply
• Air inlet and exhaust system
Recommended Actions
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under those conditions. Troubleshooting the symptom
under other conditions can give misleading results.
Diagnostic Codes
Check for active diagnostic codes on the Caterpillar Electronic Technician (Cat ET). Troubleshoot
any active diagnostic codes before continuing with this procedure.
Electrical Connectors
Check for correct installation of ECM connectors J1/P1 and J2/P2 and the unit injector connectors.
Refer to Troubleshooting, "Electrical Connectors - Inspect".
Starting Aids
Air Inlet Heater (If Equipped)
Ensure that the air inlet heater is programmed to "On". For additional information on the air inlet
heater, refer to Troubleshooting, "Air Inlet Heater Circuit - Test".
Ether Injection System (If Equipped)
Ensure that the ether injection system is programmed to "On". For additional information on the ether
injection system, refer to Troubleshooting, "Ether Injection System - Test".
Oil Grade Plugs
Ensure that the correct oil grade plug is installed. The oil grade plug should match with the oil that is
installed in the engine. Do not program the "Engine Oil Weight" with Cat ET.
Throttle Signal
Monitor the throttle signal on Cat ET. Verify that the throttle signal is stable. Move the throttle from
the low idle position to the high idle position in order to verify that the engine is able to reach high
idle.
Injection Actuation Pressure

Ensure that the injection actuation system is operating properly. Refer to Troubleshooting, "Injection
Actuation Pressure - Test".
Unit Injectors
1. Perform the Injector Solenoid Test on Cat ET in order to determine if all of the injector
solenoids are being energized by the ECM.
2. Perform the Cylinder Cutout Test on Cat ET in order to identify any misfiring cylinder(s). Refer
to Troubleshooting, "Injector Solenoid Circuit - Test" for more information.
Fuel Supply
1. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines.
If problems are found with the fuel lines, repair the lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may block the fuel supply.
3. Check for air in the low pressure fuel supply system if any of the following procedures have
been performed:
◦ Replacement of the fuel filters

◦ Service on the low pressure fuel supply circuit
◦ Replacement of unit injectors
4. Purge air from the low pressure fuel supply circuit. Refer to Testing and Adjusting, "Fuel
System - Prime" for the correct procedure.
Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel.
5. Check fuel quality. In temperatures below 0 °C (32 °F), check for solidified fuel (wax). Refer to
Special Publication, SEBD0717, "Diesel Fuels And Your Engine".
6. Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter.
Refer to Testing and Adjusting, "Fuel System" for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve.
Air Inlet and Exhaust System

1. Check for an air filter restriction. Clean plugged air filters or replace plugged air filters.
2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Testing and
Adjusting, "Air Inlet and Exhaust System".
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Troubleshooting

i05451609
Engine Stalls at Low RPM

SMCS - 1915-035
Note: Refer to Troubleshooting, "Cat ET Service Features" for information about service features.
Probable Causes
• Unit injectors
• Fuel supply
• Air supply
• Engine idle
• Accessory equipment
Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Unit Injectors Result: The J1/P1 and

J2/P2 connectors have
A. Check for correct installation of the J1/P1 and J2/P2 been installed correctly.
connectors for the Electronic Control Module (ECM).
Unit Result: The J300/P300
Injectors connectors have been
B. Check for correct installation of the J300/P300
connectors for the unit injectors. Refer to the diagnostic installed correctly.
functional test Troubleshooting, "Electrical Connectors
- Inspect". Proceed to Test Step 2.
Result: The connectors

have not been installed
properly.
Repair the connectors.
Result: The fuel lines are

OK.
Result: The fuel lines are

2. Fuel Supply
NOT OK.
A. Check the fuel pressure. Refer to Systems
Replace or repair the fuel
Operation/Testing and Adjusting.
lines.
B. Check the fuel lines for the following problems:
Result: The fuel tank
restrictions, collapsed lines and pinched lines.
does not have a blockage
of the fuel supply.
C. Check the fuel tank for foreign objects which may
block the fuel supply.
Result: The fuel tank has
a blockage of the fuel
Note: A sight glass in the low-pressure supply line is Fuel Supply
tank.
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting.
Repair the blockage in
the fuel tank.
D. Cold weather adversely affects the characteristics of
the fuel. Refer to the Operation and Maintenance
Result: The fuel pressure
Manual.
is OK.
E. Check the fuel pressure after the fuel filter while the
Proceed to Test Step 3.
engine is being cranked. For the correct pressure values,
refer to the Systems Operation/Testing and Adjusting
Result: The fuel pressure
manual.
is NOT OK.
Make the necessary

repairs.
Result: The are no

restrictions in the air inlet
system.
3. Air Supply Proceed to Test Step 4.

Air inlet
A. Check for restrictions in the air inlet system. Refer to system Result: There are
Systems Operation/Testing and Adjusting. restrictions in the air inlet
system.
Repair the restrictions in

the air inlet system.
Result: The low engine
idle parameters are OK.
4. Engine Idle Proceed to Test Step 5.
A. Check the parameter for the low engine idle (if Parameters Result: The low engine
applicable). Refer to Troubleshooting, "System idle parameters are NOT
Configuration Parameters". OK.
Repair the low engine

idle parameters.
Result: An engine
5. Engine Accessories accessory is creating an
Engine excessive load.
A. Inspect any engine accessories and the transmission accessories
(if applicable). Repair the engine
accessory.
Complete the procedure in the order in which the steps are listed.
The procedure corrected the issue. Return the engine to service.
The procedure did not correct the issue.
Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer
with the Dealer Solutions Network (DSN).
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Troubleshooting

i05451717
Engine Vibration
SMCS - 1000-035
Probable Causes
• Vibration damper
• Engine supports
• Driven equipment
• Engine misfiring or running rough
Recommended Actions
Table 1
Result: The vibration damper has

not been damaged.
1. Vibration Damper
A. Check the vibration damper for
Damage to Result: The vibration damper has
damage.
vibration damper been damaged.
B. Inspect the mounting bolts for damage
Replace the vibration damper.
and/or for wear.
Replace any damaged bolts. Refer
to the Disassembly and Assembly
manual.
2. Engine Supports Loose or broken Results: Mounts and brackets are

mounts not damaged.
A. Inspect the mounts and the brackets
while you run the engine through the Proceed to Test Step 3.
Results: Mounts and brackets are
damaged.
speed range. Look for mounts and
brackets that are loose and/or broken.
Tighten all of the mounting bolts.
Install new components, if
necessary.
Result: Driven equipment is OK.
STOP
3. Driven Equipment
Alignment and
balance of driven Result: Driven equipment is
Check the alignment and the balance of
equipment NOT OK.
the driven equipment.
Repair or replace the faulty
driven equipment.
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Troubleshooting

i05901433
Excessive Black Smoke

SMCS - 1088-035
Probable Causes
• Air inlet or exhaust system
• Engine speed/timing sensor
• Atmospheric pressure sensor
• Boost pressure sensor
• "Fuel Position" and/or "FRC Fuel Limit"
• Flash file
• Fuel quality
• Valve adjustment
Recommended Actions
Table 1
1. Air Inlet and Exhaust System Result: There are no restrictions or

leaks in the air inlet or exhaust
A. Check the air inlet system, air filter, air system.
inlet piping, and exhaust system for Restrictions
restrictions and/or leaks. Proceed to Test Step 2.
B. Ensure that the turbocharger is in working Result: There are restrictions and
order. leaks in the air inlet or exhaust
system.
Repair: Make the necessary repairs,
C. Repair any leaks that were found. Remove
and refer to Systems Operation,
any restrictions that were found and replace
Testing and Adjusting, "Engine
any damaged components that were found.
Valve Lash - Inspect/Adjust" for the
correct procedure.
Result: The timing sensor is

operating properly and the
crankshaft and camshaft drive gears
are aligned.
2. Engine Speed/Timing
A. Check the calibration of the engine
Result: The timing sensor is not
speed/timing sensor. Refer to
operating properly and the
Troubleshooting, "Engine Speed/Timing
Timing crankshaft and camshaft drive gears
Sensor - Calibrate".
Signal are not aligned.
B. Verify that the crankshaft and the camshaft
Repair: Repair the timing sensor
drive gears are set with the proper orientation.
and properly align the crankshaft
Refer to the Disassembly and Assembly
and camshaft drive gears. Refer to
manual.
Troubleshooting, "Engine
Speed/Timing Sensor - Calibrate"
for troubleshooting information.
Verify that the repair eliminated the
problem.
Result: The atmospheric pressure

sensor is properly working and
3. Atmospheric Pressure Sensor shows no signs of debris, moisture,
and ice.
A. Remove the atmospheric pressure sensor
and inspect the sensor. Proceed to Test Step 4.
B. Check the Caterpillar Electronic Pressure Result: The atmospheric pressure

Technician (ET) for active diagnostic codes Sensor sensor is not properly work and has
on the sensor. If no active diagnostic code either debris, moisture, and/or ice on
exists, the sensor may be used. The correct the sensor.
reading for the atmospheric pressure is
between 50 kPa (7.25 psi) and 100 kPa Repair: Remove the debris,
(14.5 psi). moisture, or ice from the sensor and
reuse. If sensor is not working
properly replace the sensor.
4. Boost Pressure Sensor, "Fuel Position", Result: The boost pressure sensor,
and/or "FRC Fuel Limit" Pressure "Fuel Position" and "FRC Fuel
Sensor Limit" are OK.
A. Monitor the status of "Fuel Position" and
"Rated Fuel Limit" while the engine is Proceed to Test Step 5.
operating under full load. If "Fuel Position"
equals "Rated Fuel Limit", and "Fuel
Position" is less than "FRC Fuel Limit" the
Electronic Control Module (ECM) is
providing the correct control.
B. Monitor the status of "Boost Pressure" and Result: The boost pressure sensor,
"Atmospheric Pressure" on Cat ET and verify "Fuel Position" and "FRC Fuel
that there are no active codes for the boost Limit" are not correct and properly
pressure sensor. When the engine is not working.
running, "Boost Pressure" should be 0 kPa
(0 psi). Repair: Perform the necessary
repairs and return to service.
Note: A problem with the "FRC Fuel Limit"
will only cause black smoke during
acceleration. A problem with the "FRC Fuel
Limit" will not cause black smoke during
steady state operation.
Result: The correct flash file is

installed.

5. Flash File
Flash File Result: The correct flash file is not
A. Verify that the correct flash file is
installed.
installed.
Repair: Install the correct flash file
and refer to Troubleshooting, "Flash
Programming" for information.
Result: The fuel quality is correct.

6. Fuel Quality
Result: The fuel quality is not
A. Verify that the fuel quality is correct. Fuel correct.
Quality
Note: Cold weather adversely affects the Repair: Refer to the Operation and
characteristics of the fuel. Maintenance Manual for
information on improving the
characteristics of the fuel during
cold-weather operation.
Result: The valve lash is set

7. Valve Adjustment correctly.
Valve Lash
A. Check the valve lash. STOP
Result: The valve lash is not set

correctly.
Repair: Set the valve lash correctly

and refer to Systems Operation and
Testing and Adjusting, "Engine
Valve Lash - Inspect/Adjust" for the
correct procedure.
Shutdown SIS
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Troubleshooting

i05902924
Excessive Fuel Consumption

SMCS - 1250-035
Probable Causes
• Engine operation
• Fuel leaks
• Fuel quality
• Engine speed/timing
• Unit injectors
• Accessory equipment
Recommended Actions
Table 1
Result: Cat ET shows no sign of

1. Engine Operation excessive idle time and/or high load
factor.
A. Use Caterpillar Electronic Technician
Engine Proceed to Test Step 2.
(ET) to check the "Current Totals" for
Operation
excessive idle time and/or for a high load
factor which would be indicative of poor Result: Cat ET shows signs of
operating habits. excessive idle time and/or high load
factor.
Repair: Make the necessary repairs

and return to service.
Result: The fuel pressure during

engine cranking and after the fuel
filter is within specifications.

2. Fuel Leaks
Result: The fuel pressure during
A. Check the fuel pressure during engine
engine cranking and after the fuel
cranking.
filter is not within specifications.
B. Check the fuel pressure after the fuel Fuel Leaks
Repair: If the fuel pressure is low,
filter.
replace the fuel filters. If the fuel
pressure is still low, check the
Refer to the Systems Operation and Testing
following items:
and Adjusting for the correct pressure
values.
- Fuel Transfer Pump
- Fuel Transfer Pump Coupling
- Fuel Pressure Regulating Valve
Result: The fuel quality is correct.

3. Fuel Quality
Result: The fuel quality is not
A. Verify that the fuel quality is correct. correct.
Fuel Quality
Note: Cold weather adversely affects the Repair: Refer to the Operation and
characteristics of the fuel. Maintenance Manual for information
on improving the characteristics of
the fuel during cold-weather
operation.
Result: The speed/timing sensor is

operating properly.
4. Engine Speed/Timing
A. Perform a speed/timing sensor
calibration. Timing Result: The speed/timing sensor is
Signal not operating properly.
Refer to Troubleshooting, "Engine
Speed/Timing Sensor - Calibrate" for Repair: Repair the speed/timing
troubleshooting information. sensor.
problem.
5. Unit Injectors
Result: The connectors were
correctly installed and the test were
A. Check for correct installation of the
successful.
J1/P1 and J2/P2 Electronic Control Module
(ECM) connectors and the unit injector
connectors.
Result: The connectors were not
B. Perform the "Injector Solenoid Test" on
installed correctly and the test were
Cat ET in order to determine if all of the Fuel
not successful.
injector solenoids are being energized by Injectors
the ECM.
Repair: Reinstall the connectors
correctly and remove the suspect
C. Perform the "Cylinder Cutout Test" in
injector, and install a new electronic
order to identify any injectors that might be
unit injector. Refer to Disassembly
misfiring.
and Assembly.
Ensure that the repairs have
Refer to Troubleshooting, "Injector
determined the problem.
Solenoid - Test".
Result: There are restrictions in the

6. Air Inlet and Exhaust System air inlet or exhaust system.
A. Check the air filter restriction indicator, Repair: Make the necessary repairs.
if equipped. Clean plugged air filter or Verify that the repair eliminated the
replace plugged air filters. Refer to the Restrictions problem.
Operation and Maintenance Manual.
Result: There are no restrictions in
B. Check the air inlet and exhaust system the air inlet or exhaust system.
for restrictions and/or leaks.
Result: There is no engine

accessories creating an excessive
load on the engine.
7. Accessory Equipment STOP

Engine
A. Check all accessory equipment for Result: An engine accessory is
Accessories
problems that may create excessive load on creating an excessive load.
the engine.
Repair: Repair the engine
accessory.
problem.
Shutdown SIS
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Troubleshooting

i02167024
Excessive White Smoke

SMCS - 1088-035
Note: Some white smoke may be present during cold start-up conditions when the engine is operating
normally. If the white smoke persists after warm-up, there may be a problem.
Probable Causes
• Starting aids
• Water temperature regulators
• Unit injectors
• Personality module (flash file)
• Fuel supply
• Cooling system
• Component wear
Recommended Actions
Diagnostic Codes
Check for active diagnostic codes on the Caterpillar Electronic Technician (ET). Troubleshoot any
active codes before continuing with this procedure.
Starting Aids
Ensure that the air inlet heater is functioning properly. For additional information, refer to
Troubleshooting, "Air Inlet Heater Circuit - Test".
Ensure that the ether injection system is programmed to "On". For additional information, refer to the
appropriate publication.
Ensure that the ether injection system is functioning properly. For additional information, refer to
Troubleshooting, "Ether Injection System - Test".
Oil Grade Plugs
Ensure that the correct oil grade plug is installed. The oil grade plug should match with the oil that is
installed in the engine. Do not program the "Engine Oil Weight" with Cat ET.
Water Temperature Regulators

Check the water temperature regulators for correct operation. Refer to Testing and Adjusting,
"Cooling System" for the proper procedure.
Unit Injectors
Use Cat ET to perform the cylinder cutout test. Try to simulate the conditions for the test that were
experienced during operation. Cut out each cylinder individually for approximately one minute in
order to isolate any misfiring cylinders. If the misfire can be isolated to a specific cylinder, proceed to
Troubleshooting, "Injector Solenoid Circuit - Test".
Personality Module (Flash File)

Verify that the correct personality module (flash file) is installed. The personality module that is
installed in the ECM will be displayed on the "Configuration" screen on Cat ET.
Fuel Supply
1. Monitor the exhaust for smoke while the engine is being cranked.
If no smoke is present, there may be a problem with the fuel quality or there may be a problem
with the fuel supply.
2. Check the fuel quality. Make sure that the fuel meets the requirements of Special Publication,
SEBU6250, "Caterpillar Machine Fluids Recommendations ".
3. Check the fuel pressure. Refer to Testing and Adjusting, "Fuel System Pressure - Test".
4. Ensure that the fuel system has been primed. Refer to Testing and Adjusting, "Fuel System -
Prime".
5. Check for fuel supply lines that are restricted.
6. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
7. Check for air in the fuel system. Refer to Testing and Adjusting, "Air in Fuel - Test".
Cooling System
Check for an internal coolant leak. Check for coolant in the engine oil, coolant in the cylinders, and
coolant in the exhaust system. Refer to Testing and Adjusting, "Cooling System".
Component Wear
Check the following components for excessive wear:
• Valves
• Pistons
• Rings
• Cylinder liners
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Troubleshooting

i01669174
Low Engine Oil Pressure

SMCS - 1348-035-LP
Note: This is NOT an electronic system problem. Refer to Testing and Adjusting, "Lubrication
System" for additional information on the following tests.
Probable Causes
• Oil Level
• Oil Filters
• Oil Cooler
• Diesel Fuel in Lubrication Oil
• Oil Pressure Gauge
• Oil Pressure Relief Valve
• Oil Pump
• Bearing Clearances
Recommended Actions
Oil Level
Add oil if the system is low.
Oil Filters
Check the operation of the bypass valve for the filter. If the operation indicates restricted filters,
install new oil filters.
Oil Cooler
Clean the oil cooler core or install a new oil cooler core. Remove the used oil from the engine. Put
new oil in the engine.
Diesel Fuel in Lubrication Oil

Check for presence of fuel in lubricating oil. Refer to Troubleshooting, "Fuel Dilution of Engine Oil".
Oil Pressure Sensor

Ensure that the sensor is operating properly. Refer to Troubleshooting, "Engine Pressure Sensor Open
or Short Circuit-Test".
Oil Pressure Relief Valve

Clean the bypass valve and the housing. Install any new required parts.
Oil Pump
Check the inlet screen on the oil pump for obstructions. Check for air leakage into the supply to the
oil pump. Examine the oil pump for excessive wear. Repair the oil pump or replace the oil pump.
Bearing Clearances
1. Install new camshaft bearings and new crankshaft bearings if the bearings are worn.
2. Inspect the main bearings. Replace the main bearings if the bearings are worn.
Shutdown SIS
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Troubleshooting

i01712218
Low Power/Poor or No Response to Throttle

SMCS - 1000-035
Probable Causes
• Event codes
• Injector trim codes
• Starting aids
• Throttle signal
• Unit injectors
• Fuel supply
• Turbocharger outlet pressure sensor
Recommended Actions
Note: If the problem only occurs under certain conditions, test the engine under those conditions.
Examples of certain conditions are high engine speed, full load and engine operating temperature.
Troubleshooting the symptoms under other conditions can give misleading results.
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may cause poor performance. Connect the Caterpillar
Electronic Technician (Cat ET) and check for active codes and/or logged codes. Troubleshoot any
codes that are present before continuing with this procedure.
Injector Trim Codes

If any of the injectors or the electronic control module have been replaced, ensure that the injector
trim codes have been reprogrammed to the correct values. Refer to Troubleshooting, "System
Configuration Parameters" for additional information.
Starting Aids
Cold Mode
Use Cat ET to verify that the engine has exited cold mode. If the engine is operating in cold mode, an
indicator will be displayed on the top of any of the status screens on Cat ET. Cold mode operation
may slow throttle response.
Ensure that the air inlet heater is programmed to "On". Ensure that the air inlet heater is functioning
properly. Refer to Troubleshooting, "Air Inlet Heater Circuit - Test" for additional information.
Oil Grade Plugs (If Equipped)
Ensure that the correct oil grade plug is installed. Refer to Operation and Maintenance Manual,
"Engine Oil and Filter - Change" for additional information.
Throttle Signal
Monitor the throttle signal on Cat ET. Verify that the throttle is operating correctly. Refer to
Troubleshooting, "Throttle Position Sensor Circuit - Test" for additional information.
Check the J1/P1 ECM connector, the J2/P2 ECM connector, the J300/P300 unit injector connector,
the connectors for the throttle position sensor, and the associated wiring for damage, abrasion,
corrosion, or incorrect attachment. Refer to Troubleshooting, "Electrical Connectors-Inspect" for
additional information.
Unit Injectors
2. Perform the Cylinder Cutout Test on Cat ET in order to identify any injectors that might be
misfiring. Refer to Troubleshooting, "Injector Solenoid Circuit - Test" for the proper procedure.
Injection Actuation Pressure

1. Check the engine oil level. Engine oil is used to activate the high pressure hydraulic pump.
2. Ensure that the engine oil meets the recommendations. Refer to Operation and Maintenance
Manual for additional information.
3. Crank the engine and monitor the injection actuation pressure and the output of the injection
actuation pressure control valve. The high pressure oil system is operating properly if the
pressure output is a minimum of 6 MPa (870 psi).
Fuel Supply
been performed:
Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer
to Testing and Adjusting for more information.
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.
4. Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance
Manual, "Fuel System - Prime" for the correct procedure.
Special Instruction, SEBD0717, "Diesel Fuels And Your Engine".
6. Check the fuel pressure after the fuel filter while the engine is being cranked. Refer to Testing
and Adjusting for the correct pressure values. If the fuel pressure is low, replace the fuel filters.
If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer
pump coupling and fuel pressure regulating valve. Refer to Testing and Adjusting for more
information.
Turbocharger Outlet Pressure Sensor

1. Monitor "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on the Cat ET status screen
while the engine is operating under full load. These parameters should reflect the information
below.
Table 1
"Fuel Position"="Rated Fuel Limit"
"AND"
"Fuel Position"<"FRC Fuel Limit"
If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit",
the electronics are operating properly. Otherwise, proceed with the next step.
2. Monitor the status of "Turbo Outlet Pressure", "Boost Pressure", and "Atmospheric Pressure"
while the engine is operating under full load.
3. Monitor the status of"Turbo Outlet Pressure", "Boost Pressure", and "Atmospheric Pressure"
while the engine is operating at low idle.
4. Turn the keyswitch to the OFF position. The engine should be off. Turn the keyswitch to the
ON position.
5. Monitor the status of "Turbo Outlet Pressure", "Boost Pressure", and "Atmospheric Pressure"
for normal operation on Cat ET. When the engine is not running, "Turbo Outlet Pressure"
should be equal to "Atmospheric Pressure". When the engine is not running, "Boost Pressure"
should be 0 kPa (0 psi).

1. Check for an air filter restriction. Clean plugged air filters or replace plugged air filters. Refer to
the Operation and Maintenance Manual for additional information.
Adjusting, "Air Inlet and Exhaust System" for additional information.
Shutdown SIS
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Troubleshooting

i01727041
Poor Acceleration or Response

SMCS - 1000-035
Probable Causes
• Diagnostic Codes
• Event Codes
• Starting Aids
• Active engine derate
• Throttle switch
• Decelerator pedal
• Unit injectors
• Fuel supply
Recommended Actions
Diagnostic Codes
Certain diagnostic codes may cause poor performance. Connect the Caterpillar Electronic Technician
(Cat ET) and check for active codes and/or event codes. Troubleshoot any codes that are present
before continuing with this procedure.
Event Codes
Certain event codes may cause poor performance. Connect the Caterpillar Electronic Technician (Cat
ET) and check for active codes and/or logged codes. Troubleshoot any codes that are present before
continuing with this procedure.
Starting Aids
Cold Mode
Use Cat ET to verify that the engine has exited Cold Mode. Cold Mode operation may slow throttle
response.
Make sure that the ether injection system is programmed to "ON". For additional information, refer to
Troubleshooting, "Ether Injection System-Test".
Active Engine Derate

Use Cat ET to check for logged engine derates and/or active engine derates. A derate status flag will
appear on Cat ET if an engine derate is active. The engine may be derated due to one of the following
conditions: high altitude, dirty air filters and other factors.

Verify that the correct personality module (flash file) is installed.
Throttle Switch
Monitor the throttle switch on Cat ET. Verify that the throttle switch is stable at the low idle position.
Verify that the signal is stable at the high idle position. Move the switch from the low idle position to
the high idle position in order to verify that the engine is able to reach the high idle position. Refer to
Troubleshooting, "Throttle Switch Circuit - Test" for the proper troubleshooting procedure.
Decelerator Pedal
Monitor the decelerator pedal on Cat ET. Verify that the decelerator pedal is operating properly. Refer
to Troubleshooting, "Throttle Position Sensor Circuit - Test" for the proper troubleshooting
procedure.
Unit Injectors
1. Use Cat ET to determine if there are any active diagnostic codes for the unit injectors.

1. Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on Cat ET
below.
Table 1
"Fuel Position" = "Rated Fuel Limit"
AND
"Fuel Position" < "FRC Fuel Limit"
the electronics are operating correctly. Otherwise, proceed with the next Step.
2. Monitor the status of "Boost Pressure" and "Atmospheric Pressure" for normal operation on Cat
ET. When the engine is not running, "Boost Pressure" should be 0 kPa (0 psi).

1. Observe the Check Engine Lamp. Check for an air filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.
Fuel Supply
been performed:

NOTICE
again.
information.
Shutdown SIS
Previous Screen
Troubleshooting

i01727041
Poor Acceleration or Response

SMCS - 1000-035
Probable Causes
• Diagnostic Codes
• Event Codes
• Starting Aids
• Active engine derate
• Throttle switch
• Decelerator pedal
• Unit injectors
• Fuel supply
Recommended Actions
Diagnostic Codes
Certain diagnostic codes may cause poor performance. Connect the Caterpillar Electronic Technician
(Cat ET) and check for active codes and/or event codes. Troubleshoot any codes that are present
before continuing with this procedure.
Event Codes
Certain event codes may cause poor performance. Connect the Caterpillar Electronic Technician (Cat
ET) and check for active codes and/or logged codes. Troubleshoot any codes that are present before
continuing with this procedure.
Starting Aids
Cold Mode
Use Cat ET to verify that the engine has exited Cold Mode. Cold Mode operation may slow throttle
response.
Make sure that the ether injection system is programmed to "ON". For additional information, refer to
Troubleshooting, "Ether Injection System-Test".
Active Engine Derate

Use Cat ET to check for logged engine derates and/or active engine derates. A derate status flag will
appear on Cat ET if an engine derate is active. The engine may be derated due to one of the following
conditions: high altitude, dirty air filters and other factors.

Verify that the correct personality module (flash file) is installed.
Throttle Switch
Monitor the throttle switch on Cat ET. Verify that the throttle switch is stable at the low idle position.
Verify that the signal is stable at the high idle position. Move the switch from the low idle position to
the high idle position in order to verify that the engine is able to reach the high idle position. Refer to
Troubleshooting, "Throttle Switch Circuit - Test" for the proper troubleshooting procedure.
Decelerator Pedal
Monitor the decelerator pedal on Cat ET. Verify that the decelerator pedal is operating properly. Refer
to Troubleshooting, "Throttle Position Sensor Circuit - Test" for the proper troubleshooting
procedure.
Unit Injectors
1. Use Cat ET to determine if there are any active diagnostic codes for the unit injectors.

1. Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on Cat ET
below.
Table 1
"Fuel Position" = "Rated Fuel Limit"
AND
"Fuel Position" < "FRC Fuel Limit"
the electronics are operating correctly. Otherwise, proceed with the next Step.
2. Monitor the status of "Boost Pressure" and "Atmospheric Pressure" for normal operation on Cat
ET. When the engine is not running, "Boost Pressure" should be 0 kPa (0 psi).

1. Observe the Check Engine Lamp. Check for an air filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.
Fuel Supply
been performed:

NOTICE
again.
information.
Shutdown SIS
Previous Screen
Troubleshooting

i02379465
E190 Engine Overspeed Warning

SMCS - 7427-038
Event E190
Conditions Which Generate This Code:
The engine speed has exceeded 2800 rpm.
System Response:
The Electronic Control Module (ECM) logs the event.
Troubleshooting:
Test Step 1. Question the Operator
Determine the events that caused the overspeed of the engine. The operator may be operating the
machine incorrectly.
Results:
• OK - STOP
Shutdown SIS
Previous Screen
Disassembly and Assembly

D6R Series II Track-Type Tractor C9 Engine Supplement
Media Number -RENR4253-01 Publication Date -01/10/2002 Date Updated -02/10/2002

i01665350
Engine and Torque Converter - Remove

SMCS - 1000-011; 1003-011; 3101-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8S-9906 Ratchet Puller 2
207-0755 Plate 1
B 142-6893 Adjustable Hook 1
207-0756 Chain 1
Start By:
A. Remove the radiator guard. Refer to Disassembly and Assembly, "Radiator Guard - Remove".
B. Remove the main drive shaft. Refer to Disassembly and Assembly, RENR4257, "Main Drive
Shaft - Remove and Install".
C. Remove the drive shaft (pump coupling). Refer to Disassembly and Assembly, RENR4257,
"Drive Shaft (Pump Coupling) - Remove and Install".
D. Remove the bottom guards. Refer to Disassembly and Assembly, RENR4261, "Bottom Guard -
Remove".
1. Remove the floorplates.

Illustration 1 g00861674
2. Use Tooling (A) to secure hydraulic pump (1) out of the way. Leave the lines connected to the
hydraulic pump.
3. Remove the guard from the auxiliary drive shaft.
4. Disconnect hose assembly (2) from the back of the cylinder head.
5. Disconnect hose assemblies (3) .
6. Disconnect hose assembly (4) from the right side of the torque converter.
7. Disconnect harness assembly (5) from priority valve (6) .

8. Remove bolt (7). Disconnect tube assembly (8) from the turbocharger.
9. Remove clips (9). Disconnect positive wire (10) from alternator (11) .
10. Remove bolt (12) .

11. Disconnect harness assembly (13) .
12. Disconnect harness assemblies (14) .
13. Disconnect positive wire (15) and ground wire (16) from the starter.
14. Remove bolt (17) and the spacer.
15. Remove bolt (18) from the oil filter tube. Remove bolt (19) from the positive battery cable
clamp.
16. Disconnect hose assembly (20) .
17. Remove bolts (21) on each side of bracket. Remove bracket (22) .
18. Attach Tooling (B) to the engine. Remove bolts (23) .

19. Remove mounting bolts (24) on both sides of the engine.
20. Remove engine (25). The weight of engine (25) is approximately 1588 kg (3500 lb).
Shutdown SIS
Previous Screen


i01665354
Engine and Torque Converter - Install

SMCS - 1000-012; 1003-012; 3101-012
Installation Procedure
Table 1
Required Tools
207-0755 Plate 1
207-0756 Chain 1
1. Attach Tooling (B) to the engine. Install engine (25). The weight of engine (25) is
approximately 1588 kg (3500 lb).
2. Install mounting bolts (24) on both sides of the engine.
3. Install bolts (23) .
4. Install bracket (22). Install bolts (21) on each side of bracket.
5. Connect hose assembly (20) .
6. Install bolt (19) on the positive battery cable clamp. Install bolt (18) on the oil filter tube.
7. Install the spacer and bolt (17) .
8. Connect positive wire (15) and ground wire (16) to the starter.
9. Connect harness assemblies (14) .

10. Connect harness assembly (13) .
11. Install bolt (12) .
12. Connect positive wire (10) on alternator (11). Install clips (9) .
13. Connect tube assembly (8) to the turbocharger. Install bolt (7) .
14. Connect harness assembly (5) to priority valve (6) .
15. Connect hose assembly (4) to the right side of the drive shaft.
16. Connect hose assemblies (3) .
17. Connect hose assembly (2) to the back of the cylinder head.
18. Install the guard on the auxiliary drive shaft.

19. Remove Tooling (A) from hydraulic pump (1) .
20. Install the floorplates.
,,,
End By:
a. Install the bottom guards. Refer to Disassembly and AssemblyRENR4261, "Bottom Guard -
Install".
b. Install the drive shaft (pump coupling). Refer to Disassembly and AssemblyRENR4257, "Drive
Shaft (Pump Coupling) - Remove and Install".
c. Install the main drive shaft. Refer to Disassembly and AssemblyRENR4257, "Main Drive Shaft
- Remove and Install".
d. Install the radiator guard. Refer to Disassembly and Assembly, "Radiator Guard - Install".
Shutdown SIS
Previous Screen
Specifications
C-9 Engines for Caterpillar Built Machines

i02841820
Engine Design
SMCS - 1201
Cylinder and valve location
(A) Exhaust valves
(B) Inlet valves
Bore ... 112.0 mm (4.41 inch)
Stroke ... 149.0 mm (5.87 inch)
Displacement ... 8.8 L (537 cu in)
Cylinder arrangement ... In-line six cylinder
Valves per cylinder ... 4
Type of combustion ... Direct injection

Valve lash with engine stopped (cold)
Inlet ... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust ... 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Note: The front of the engine is opposite of the flywheel end of the engine. The left side and the right
side of the engine are viewed from the flywheel end of the engine. The no. 1 cylinder is the front
cylinder.
Crankshaft rotation direction (view from the flywheel end) ... Counterclockwise
Firing order (injection sequence) ... 1, 5, 3, 6, 2, 4
Shutdown SIS
Previous Screen
Specifications
C9 Engines for Caterpillar Built Machines

i02136474
Engine Design
SMCS - 1201
S/N - 5111-UP
S/N - 5221-UP
S/N - 5321-UP
S/N - 5411-UP
S/N - 5511-UP
S/N - 5521-UP
S/N - A6M1-UP
S/N - AAX1-UP
S/N - AEP1-UP
S/N - B6H1-UP
S/N - B941-UP
S/N - B9D1-UP
S/N - B9E1-UP
S/N - B9G1-UP
S/N - B9L1-UP
S/N - B9M1-UP
S/N - B9T1-UP
S/N - BXG1-UP
S/N - BYN1-UP
S/N - BZR1-UP
S/N - C5K1-UP
S/N - C6Z1-UP
S/N - D3D1-UP
S/N - D6R1-UP
S/N - D9G1-UP
S/N - D9T1-UP
S/N - DBZ1-UP
S/N - DEX1-UP
S/N - DEY1-UP
S/N - DJG1-UP
S/N - DJR1-UP
S/N - DLM1-UP
S/N - DLN1-UP
S/N - DMK1-UP
S/N - DPS1-UP
S/N - DSH1-UP
S/N - EFT1-UP
S/N - EMM1-UP
S/N - ERN1-UP
S/N - EXL1-UP
S/N - EXW1-UP
S/N - F7B1-UP
S/N - F7C1-UP
S/N - F7G1-UP
S/N - FAR1-UP
S/N - GCT1-UP
S/N - GGE1-UP
S/N - GJB1-UP
S/N - GMT1-UP
S/N - H3K1-UP
S/N - HAS1-UP
S/N - HDC1-UP
S/N - HHK1-UP
S/N - HKE1-UP
S/N - HPB1-UP
S/N - J2F1-UP
S/N - J6D1-UP
S/N - JBF1-UP
S/N - JBT1-UP
S/N - JDL1-UP
S/N - JEK1-UP
S/N - JEN1-UP
S/N - JHB1-UP
S/N - JJM1-UP
S/N - JLP1-UP
S/N - JRX1-UP
S/N - JTN1-UP
S/N - JWD1-UP
S/N - KDJ1-UP
S/N - KJL1-UP
S/N - KKT1-UP
S/N - L5X1-UP
S/N - LAE1-UP
S/N - LAY1-UP
S/N - LBD1-UP
S/N - LCP1-UP
S/N - LDX1-UP
S/N - LEM1-UP
S/N - LFB1-UP
S/N - LFM1-UP
S/N - LKJ1-UP
S/N - M4T1-UP
S/N - MDS1-UP
S/N - MEY1-UP
S/N - MFA1-UP
S/N - MPL1-UP
S/N - MRT1-UP
S/N - MTJ1-UP
S/N - MWP1-UP
S/N - MYP1-UP
S/N - NAH1-UP
S/N - NBD1-UP
S/N - NBN1-UP
S/N - PEL1-UP
S/N - PEZ1-UP
S/N - PRF1-UP
S/N - R2D1-UP
S/N - R7B1-UP
S/N - R7C1-UP
S/N - R7H1-UP
S/N - RAS1-UP
S/N - RBR1-UP
S/N - RFC1-UP
S/N - RLW1-UP
S/N - S6T1-UP
S/N - S6X1-UP
S/N - S6Y1-UP
S/N - SER1-UP
S/N - SEW1-UP
S/N - SKL1-UP
S/N - SMC1-UP
S/N - T2Y1-UP
S/N - TBC1-UP
S/N - THJ1-UP
S/N - TLY1-UP
S/N - W3K1-UP
S/N - WCB1-UP
S/N - WCG1-UP
S/N - WDC1-UP
S/N - WET1-UP
S/N - WFH1-UP
S/N - WRG1-UP
S/N - WRK1-UP
S/N - WTN1-UP
S/N - XBH1-UP
S/N - YCF1-UP
S/N - ZCT1-UP
S/N - ZEB1-UP
S/N - ZML1-UP
(A) Exhaust valves
(B) Inlet valves
Bore ... 112.0 mm (4.41 inch)
Stroke ... 149.0 mm (5.87 inch)
Displacement ... 8.8 L (537 cu in)
Cylinder Arrangement ... In-line six cylinder
Valves per cylinder ... 4
In order to check the engine valve lash setting, the engine must be cold and the engine must be
stopped. Engine valve lash setting
Inlet ... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust ... 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Type of combustion ... Direct Injection
Firing order ... 1, 5, 3, 6, 2, 4

The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation ...
counterclockwise
Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed from the flywheel end of the engine. The No. 1
cylinder is the front cylinder.
Shutdown SIS
Previous Screen


i01665350
Engine and Torque Converter - Remove

SMCS - 1000-011; 1003-011; 3101-011
Removal Procedure
Table 1
Required Tools
207-0755 Plate 1
207-0756 Chain 1
Start By:
A. Remove the radiator guard. Refer to Disassembly and Assembly, "Radiator Guard - Remove".
B. Remove the main drive shaft. Refer to Disassembly and Assembly, RENR4257, "Main Drive
Shaft - Remove and Install".
C. Remove the drive shaft (pump coupling). Refer to Disassembly and Assembly, RENR4257,
"Drive Shaft (Pump Coupling) - Remove and Install".
D. Remove the bottom guards. Refer to Disassembly and Assembly, RENR4261, "Bottom Guard -
Remove".
1. Remove the floorplates.

2. Use Tooling (A) to secure hydraulic pump (1) out of the way. Leave the lines connected to the
hydraulic pump.
3. Remove the guard from the auxiliary drive shaft.
4. Disconnect hose assembly (2) from the back of the cylinder head.
5. Disconnect hose assemblies (3) .
6. Disconnect hose assembly (4) from the right side of the torque converter.
7. Disconnect harness assembly (5) from priority valve (6) .

8. Remove bolt (7). Disconnect tube assembly (8) from the turbocharger.
9. Remove clips (9). Disconnect positive wire (10) from alternator (11) .
10. Remove bolt (12) .

11. Disconnect harness assembly (13) .
12. Disconnect harness assemblies (14) .
13. Disconnect positive wire (15) and ground wire (16) from the starter.
14. Remove bolt (17) and the spacer.
15. Remove bolt (18) from the oil filter tube. Remove bolt (19) from the positive battery cable
clamp.
16. Disconnect hose assembly (20) .
17. Remove bolts (21) on each side of bracket. Remove bracket (22) .
18. Attach Tooling (B) to the engine. Remove bolts (23) .

19. Remove mounting bolts (24) on both sides of the engine.
20. Remove engine (25). The weight of engine (25) is approximately 1588 kg (3500 lb).
Shutdown SIS
Previous Screen


i01665354
Engine and Torque Converter - Install

SMCS - 1000-012; 1003-012; 3101-012
Table 1
Required Tools
207-0755 Plate 1
207-0756 Chain 1
1. Attach Tooling (B) to the engine. Install engine (25). The weight of engine (25) is
approximately 1588 kg (3500 lb).
2. Install mounting bolts (24) on both sides of the engine.
3. Install bolts (23) .
4. Install bracket (22). Install bolts (21) on each side of bracket.
5. Connect hose assembly (20) .
6. Install bolt (19) on the positive battery cable clamp. Install bolt (18) on the oil filter tube.
7. Install the spacer and bolt (17) .
8. Connect positive wire (15) and ground wire (16) to the starter.
9. Connect harness assemblies (14) .

10. Connect harness assembly (13) .
11. Install bolt (12) .
12. Connect positive wire (10) on alternator (11). Install clips (9) .
13. Connect tube assembly (8) to the turbocharger. Install bolt (7) .
14. Connect harness assembly (5) to priority valve (6) .
15. Connect hose assembly (4) to the right side of the drive shaft.
16. Connect hose assemblies (3) .
17. Connect hose assembly (2) to the back of the cylinder head.
18. Install the guard on the auxiliary drive shaft.

19. Remove Tooling (A) from hydraulic pump (1) .
20. Install the floorplates.
,,,
End By:
a. Install the bottom guards. Refer to Disassembly and AssemblyRENR4261, "Bottom Guard -
Install".
b. Install the drive shaft (pump coupling). Refer to Disassembly and AssemblyRENR4257, "Drive
Shaft (Pump Coupling) - Remove and Install".
c. Install the main drive shaft. Refer to Disassembly and AssemblyRENR4257, "Main Drive Shaft
- Remove and Install".
d. Install the radiator guard. Refer to Disassembly and Assembly, "Radiator Guard - Install".
Shutdown SIS
Previous Screen


i01657460
Engine Trunnion - Remove and Install

SMCS - 1153-010
Removal Procedure
Table 1
Required Tools
6V-3160 Double Acting Cylinder 1
A
3S-6224 Electric Hydraulic Pump Gp 1
Start By:
A. Remove the front bottom guard. Refer to Disassembly and Assembly, "Bottom Gurads -
Remove and Install".
B. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, "Crankshaft
Vibration Damper - Remove and Install".
1. Remove front mounting bolts (1) .
2. Remove bolts (2) and bracket (3) .
3. Install Tooling (A) and suitable blocking for support.

4. Lift engine mount (4) from mount (5) approximately 12.7 mm (0.50 inch) from mount (5) .
5. Place blocks (6) under the front of oil pan (7). Lower the engine on blocks (6) and remove
Tooling (A). Remove bolts (10). Remove the crankshaft pulley. Blocks (6) are setting in bottom
guard (8). Remove bolts (9). Remove engine mount (4) .
6. Remove bolts (11) and remove trunnion (12) from the engine.
1. Install trunnion (12) to the original location. Install bolts (11) .

2. Install engine mount (4) and bolts (9). Install the crankshaft pulley and bolts (10) .
3. Use Tooling (A) to lift the engine off blocks (6). Remove blocks (6) from oil pan (7) and
bottom guard (8) .
4. Lower Tooling (A) until engine mount (4) is seated on mount (5). Remove Tooling (A) .
5. Install bracket (3) and install bolts (2) .
6. Install front mounting bolts (1) .

End By:
a. Install the vibration damper and the pulley. Refer to Disassembly and Assembly, "Crankshaft
b. Install the front bottom guard. Refer to Disassembly and Assembly, "Bottom Gurads - Remove
and Install".
Shutdown SIS
Previous Screen


i01657460
Engine Trunnion - Remove and Install

SMCS - 1153-010
Removal Procedure
Table 1
Required Tools
6V-3160 Double Acting Cylinder 1
A
3S-6224 Electric Hydraulic Pump Gp 1
Start By:
A. Remove the front bottom guard. Refer to Disassembly and Assembly, "Bottom Gurads -
B. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, "Crankshaft
1. Remove front mounting bolts (1) .
2. Remove bolts (2) and bracket (3) .
3. Install Tooling (A) and suitable blocking for support.

4. Lift engine mount (4) from mount (5) approximately 12.7 mm (0.50 inch) from mount (5) .
5. Place blocks (6) under the front of oil pan (7). Lower the engine on blocks (6) and remove
Tooling (A). Remove bolts (10). Remove the crankshaft pulley. Blocks (6) are setting in bottom
guard (8). Remove bolts (9). Remove engine mount (4) .
6. Remove bolts (11) and remove trunnion (12) from the engine.
1. Install trunnion (12) to the original location. Install bolts (11) .

2. Install engine mount (4) and bolts (9). Install the crankshaft pulley and bolts (10) .
3. Use Tooling (A) to lift the engine off blocks (6). Remove blocks (6) from oil pan (7) and
bottom guard (8) .
4. Lower Tooling (A) until engine mount (4) is seated on mount (5). Remove Tooling (A) .
5. Install bracket (3) and install bolts (2) .
6. Install front mounting bolts (1) .

End By:
a. Install the vibration damper and the pulley. Refer to Disassembly and Assembly, "Crankshaft
b. Install the front bottom guard. Refer to Disassembly and Assembly, "Bottom Gurads - Remove
and Install".
Shutdown SIS
Previous Screen

D6R Series II Track-Type Tractor Machine Systems

i02526705
Bottom Guard - Install

SMCS - 7153-012-GD
Table 1
Required Tools
A 1U-7505 Hydraulic Jack 1
1. Use Tooling (A) and support the bottom guard that will be installed. The weight of the bottom
guard is approximately 45 kg (100 lb) to 84 kg (185 lb).
Bottom guard with pivot pin assembly
2. Install pin (6). Install nuts (4) that attach bottom guard (3) to both sides of tractor frame (5) .
3. Move Tooling (A) and support the next bottom guard, as needed. Repeat Step 1 to Step 2 and
install the bottom guards with pivot pin assembly.
4. Use Tooling (A) and a suitable block to install the front bottom guard.
5. Install bolts and washers (2). Install nuts (1) and the washers.
Raising Bottom Guards

Table 2
Required Tools
A 1U-9200 Lever Puller 1
1. Attach suitable slings to one side of the machine. Attach Tooling (A) to the other side of the
machine. Attach suitable lifting slings (1) to Tooling (A) and pull tightly under bottom guard
(2), as shown. The bottom weight of the bottom guard is approximately 45 kg (100 lb) to 84 kg
(185 lb).
2. Use Tooling (A) to raise the bottom guard from ground level. The bottom guard pivots on pin
(4) .
3. Install nuts (3) on both sides that secure bottom guard (2) to tractor frame (4).
Shutdown SIS
Previous Screen


i01652958
Hood and Dust Ejector - Remove and Install

SMCS - 1055; 7251-010
Removal Procedure
Table 1
Required Tools
A 138-7573 Link Bracket 3
Start By:
A. Remove the engine side guards. Refer to Disassembly and Assembly, "Engine Side Guards -
B. Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and
Install".
1. Remove hose assemblies (1) from primary fuel filter (2) and secondary fuel filter (4).
Disconnect electrical connector (3). Remove all the cable straps.
2. Remove exhaust ejector (4) and precleaner (5) from hood (6) .
3. Attach Tooling (A) to hood (6). Attach a suitable lifting device to hood (6). Remove hood (6).
The weight of hood (6) is approximately 91 kg (200 lb).
1. Attach Tooling (A) to hood (6). attach a suitable lifting device to hood (6). Install hood (6). The
weight of hood (6) is approximately 91 kg (200 lb).
2. Install precleaner (5) and exhaust ejector (4) on hood (6) .

3. Connect electrical connector (3). Install all the cable straps. Connect hose assemblies (1) on
primary fuel filter (2) and secondary fuel filter (4) .
End By:
a. Install the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
b. Install the engine side guards. Refer to Disassembly and Assembly, "Engine Side Guards -
Shutdown SIS
Previous Screen
Troubleshooting

i02210499
Engine Cranks but Will Not Start

SMCS - 1000-035
Probable Causes
• Event codes
• ECM power supply
• Oil level
• Starting aids
• Engine shutdown switches
• Engine speed/timing
• Unit injectors
• Fuel supply
• Combustion
Recommended Actions
Diagnostic Codes, Event Codes, and ECM Power Supply
Certain diagnostic codes and/or event codes may prevent the engine from starting. Connect the
Caterpillar Electronic Technician (ET) and check for active codes and/or logged codes. Troubleshoot
any codes that are present before continuing with this procedure.
Note: If Cat ET will not communicate with the ECM, the problem is most likely with the electrical
power supply to the ECM. Refer to Troubleshooting, "Electrical Power Supply Circuit - Test".

5 Engine Arrangement

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Shutdown SIS

Engine Misfires, Runs Rough or Is Unstable

• Injection actuation pressure

• Air inlet and exhaust system

Air Inlet Heater (If Equipped)

Ether Injection System (If Equipped)

Oil Grade Plugs

Injection Actuation Pressure

◦ Replacement of the fuel filters

◦ Replacement of unit injectors

Air Inlet and Exhaust System

Engine Stalls at Low RPM

1. Unit Injectors Result: The J1/P1 and

Result: The connectors

Repair the connectors.

Result: The fuel lines are

Result: The fuel lines are

Make the necessary

Result: The are no

3. Air Supply Proceed to Test Step 4.

Repair the restrictions in

4. Engine Idle Proceed to Test Step 5.

Repair the low engine

The procedure corrected the issue. Return the engine to service.

The procedure did not correct the issue.

• Engine misfiring or running rough

Result: The vibration damper has

2. Engine Supports Loose or broken Results: Mounts and brackets are

Result: Driven equipment is OK.

Excessive Black Smoke

• Engine speed/timing sensor

• Atmospheric pressure sensor

• Boost pressure sensor

• "Fuel Position" and/or "FRC Fuel Limit"

1. Air Inlet and Exhaust System Result: There are no restrictions or

Result: The timing sensor is

Result: The atmospheric pressure

B. Check the Caterpillar Electronic Pressure Result: The atmospheric pressure

Result: The correct flash file is

Proceed to Test Step 6.

Result: The fuel quality is correct.

Proceed to Test Step 7.

Result: The valve lash is set

Result: The valve lash is not set

Repair: Set the valve lash correctly

Excessive Fuel Consumption

• Air inlet and exhaust system

Result: Cat ET shows no sign of

Repair: Make the necessary repairs

Result: The fuel pressure during

Proceed to Test Step 3.

- Fuel Transfer Pump Coupling

- Fuel Pressure Regulating Valve

Result: The fuel quality is correct.

Proceed to Test Step 4.

Result: The speed/timing sensor is

Result: There are restrictions in the

Result: There is no engine

7. Accessory Equipment STOP

Excessive White Smoke

• Water temperature regulators

• Personality module (flash file)

Ether Injection System (If Equipped)