operation and maintenance manualthis manual contains safety, operation instructions, lubrication and...

SEBU8606-01May 2011

Operation andMaintenanceManualC4.4 Industrial Engine4481-Up (Engine)

SAFETY.CAT.COM

i03991620

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labelson the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-placement parts or parts with equivalent speci-fications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

SEBU8606-01 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 6

General Hazard Information ................................... 8

Burn Prevention ..................................................... 11

Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 14

Mounting and Dismounting ................................... 15

High Pressure Fuel Lines ..................................... 15

Before Starting Engine .......................................... 16

Engine Starting ..................................................... 17

Engine Stopping ................................................... 17

Electrical System .................................................. 17

Engine Electronics ................................................ 18

Product Information Section

Model Views ......................................................... 20

Product Identification Information ........................ 29

Operation Section

Lifting and Storage ................................................ 31

Gauges and Indicators .......................................... 34

Features and Controls .......................................... 36

Engine Diagnostics ............................................... 46

Engine Starting ..................................................... 52

Engine Operation .................................................. 55

Engine Stopping ................................................... 57

Cold Weather Operation ....................................... 59

Maintenance Section

Refill Capacities .................................................... 64

Maintenance Recommendations .......................... 70

Maintenance Interval Schedule ............................ 72

Warranty Section

Warranty Information ........................................... 112

Reference Information Section

Engine Ratings .................................................... 113

Customer Service ................................................ 114

Reference Materials ............................................. 116

Index Section

Index .................................................................... 119

4 SEBU8606-01Foreword

ForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.

Use fuel consumption or service hours to determineintervals. Calendar intervals shown (daily, annually,etc.) may be used instead of service meter intervalsif they provide more convenient schedules andapproximate the indicated service meter reading.

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced anddisplayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine's permanent record.

See the section in the Operation and MaintenanceManual, “Maintenance Records” for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

SEBU8606-01 5Foreword

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

6 SEBU8606-01Safety SectionSafety Messages

Safety Sectioni04245489

Safety MessagesSMCS Code: 1000; 7405

There may be several specific warning signs on yourengine. The exact location and a description of thewarning signs are reviewed in this section. Pleasebecome familiar with all warning signs.

Ensure that all of the warning signs are legible. Cleanthe warning signs or replace the warning signs ifthe words cannot be read or if the illustrations arenot visible. Use a cloth, water, and soap to cleanthe warning signs. Do not use solvents, gasoline, orother harsh chemicals. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures thewarning signs. The warning signs that are loosenedcould drop off the engine.

Replace any warning sign that is damaged ormissing. If a warning sign is attached to a part of theengine that is replaced, install a new warning sign onthe replacement part. Your Caterpillar distributor canprovide new warning signs.

(1) Universal Warning

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.

g01154807Illustration 1

Typical example

The Universal Warning label (1) is located in twopositions. The warning labels are located on the rearright side of the valve mechanism cover and locatedon the crankcase breather body.

SEBU8606-01 7Safety Section

Safety Messages


(1) Universal Warning

(2) Hand (High Pressure)

Contact with high pressure fuel may cause fluidpenetration and burn hazards. High pressure fu-el spray may cause a fire hazard. Failure to fol-low these inspection, maintenance and service in-structions may cause personal injury or death.

g02382677Illustration 3Typical example

8 SEBU8606-01Safety SectionGeneral Hazard Information


(2) Hand (High Pressure)

The warning label for the Hand (High Pressure)(2) is a wrap around label that is installed on thehigh-pressure fuel line.

Ether WarningAn ether warning label will be installed on the aircleaner or close to the air cleaner. The location willdepend on the application.

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.


i04261691

General Hazard InformationSMCS Code: 1000; 7405


Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore the engine is serviced or before the engine isrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engine and toeach operator control station. When it is appropriate,disconnect the starting controls.

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

• Tampering with the engine installation or tamperingwith the OEM supplied wiring can be dangerous.Personal injury, death and/or engine damage couldresult.

• Vent the engine exhaust to the outside when theengine is operated in an enclosed area.


General Hazard Information

• If the engine is not running, do not release thesecondary brake or the parking brake systemsunless the vehicle is blocked or unless the vehicleis restrained.

• Wear a hard hat, protective glasses, and otherprotective equipment, as required.

• When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

• Ensure that all protective guards and all covers aresecured in place on the engine.

• Never put maintenance fluids into glass containers.Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform themaintenance under the following conditions:

• The engine is stopped. Ensure that the enginecannot be started.

• The protective locks or the controls are in theapplied position.

• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle beforemaintenance or repairs are performed.

• Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

• Disconnect the connectors for the unit injectors thatare located on the valve cover base. This will helpprevent personal injury from the high voltage to theunit injectors. Do not come in contact with the unitinjector terminals while the engine is operating.

• Do not attempt any repairs or any adjustments tothe engine while the engine is operating.

• Do not attempt any repairs that are not understood.Use the proper tools. Replace any equipment thatis damaged or repair the equipment.

• For initial start-up of a new engine or for starting anengine that has been serviced, make provisions tostop the engine if an overspeed occurs. This maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine. Ensure thatonly the fuel supply line is shut off. Ensure that thefuel return line is open.

• Start the engine from the operators station (cab).Never short across the starting motor terminals orthe batteries. This could bypass the engine neutralstart system and/or the electrical system could bedamaged.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.Gradually loosen, but do not remove the last twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in order torelieve any spring pressure or other pressure.


• Wear a hard hat, protective glasses, and otherprotective equipment, as required.

10 SEBU8606-01Safety SectionGeneral Hazard Information

• When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

• Ensure that all protective guards and all covers aresecured in place on the engine.

• Never put maintenance fluids into glass containers.Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, performthe maintenance under the following conditions:

• The engine is stopped. Ensure that the enginecannot be started.

• Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not understood.Use the proper tools. Replace any equipment thatis damaged or repair the equipment.

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the OEMinformation for any procedures that are required torelieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Cat DealerService Tool Catalog” or refer to Special Publication,PECJ0003, “Cat Shop Supplies and Tools Catalog” fortools and supplies suitable to collect and contain fluidson Cat products.

Dispose of all fluids according to local regulations andmandates.


Burn Prevention

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

• Stay away from areas that might have asbestosparticles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i04246490

Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating enginesystem. The engine, the exhaust, and the engineaftertreatment system can reach temperatures ashigh as 650° C (1202° F) under normal operatingconditions.

Allow the engine system to cool before anymaintenance is performed. Relieve all pressure in theair system, hydraulic system, lubrication system, fuelsystem, and the cooling system before the relateditems are disconnected.

12 SEBU8606-01Safety SectionFire Prevention and Explosion Prevention


After the engine has stopped, you must wait for 10minutes in order to allow the fuel pressure to bepurged from the high-pressure fuel lines before anyservice or repair is performed on the engine fuel lines.

Allow the pressure to be purged in the air system, inthe hydraulic system, in the lubrication system, orin the cooling system before any lines, fittings, orrelated items are disconnected.

Induction System

Sulfuric Acid Burn Hazard may cause serious per-sonal injury or death.

The exhaust gas cooler may contain a smallamount of sulfuric acid. The use of fuel with sul-fur levels greater than 15 ppm may increase theamount of sulfuric acid formed. The sulfuric acidmay spill from the cooler during service of theengine. The sulfuric acid will burn the eyes, skinand clothing on contact. Always wear the appro-priate personal protective equipment (PPE) thatis noted on a material safety data sheet (MSDS)for sulfuric acid. Always follow the directions forfirst aid that are noted on a material safety datasheet (MSDS) for sulfuric acid.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check that the coolant level after the engine hasstopped and the engine has been allowed to cool.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i04261710

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within 15 minutes after anemergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.


Fire Prevention and Explosion Prevention

If the application involves the presence of combustiblegases, consult your Caterpillar dealer for additionalinformation about suitable protection devices.

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in a case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.


After the engine has stopped, you must wait for 10minutes in order to allow the fuel pressure to bepurged from the high-pressure fuel lines before anyservice or repair is performed on the engine fuel lines.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


14 SEBU8606-01Safety SectionCrushing Prevention and Cutting Prevention

Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

EtherEther is flammable and poisonous.

Do not smoke while you are replacing an ethercylinder or while you are using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 °C(120 °F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Lines, Tubes, and HosesDo not bend high-pressure lines. Do not strikehigh-pressure lines. Do not install any lines that arebent or damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes, and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

• High-pressure fuel line or lines are removed.

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hose is kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.


Mounting and Dismounting

i04016709

Mounting and DismountingSMCS Code: 1000; 7405

Do not climb on the engine or the engineaftertreatment. The engine and aftertreatment havenot been designed with mounting or dismountinglocations.

Refer to the OEM for the location of foot and handholds for your specific application.

i03814031

High Pressure Fuel LinesSMCS Code: 1274



(1) High-pressure line(2) High-pressure line(3) High-pressure line

(4) High-pressure line(5) High-pressure fuel manifold (rail)(6) High-pressure line

(7) Fuel transfer line that is high pressure

16 SEBU8606-01Safety SectionBefore Starting Engine

The high-pressure fuel lines are the fuel lines thatare between the high-pressure fuel pump and thehigh-pressure fuel manifold and the fuel lines that arebetween the fuel manifold and cylinder head. Thesefuel lines are different from fuel lines on other fuelsystems.

These differences are because of the following items:

• The high-pressure fuel lines are constantly chargedwith high pressure.

• The internal pressures of the high-pressure fuellines are higher than other types of fuel system.

• The high-pressure fuel lines are formed to shapeand then strengthened by a special process.

Do not step on the high-pressure fuel lines. Do notdeflect the high-pressure fuel lines. Do not bend orstrike the high-pressure fuel lines. Deformation ordamage of the high-pressure fuel lines may cause apoint of weakness and potential failure.

Do not check the high-pressure fuel lines with theengine or the starting motor in operation. After theengine has stopped wait 10 minutes in order to allowthe fuel pressure to be purged from the high-pressurefuel lines. before any service or repair is performed.

Do not loosen the high-pressure fuel lines in orderto remove air from the fuel system. This procedureis not required.

Visually inspect the high-pressure fuel lines beforethe engine is started. This inspection should be eachday.

If you inspect the engine in operation, always usethe proper inspection procedure in order to avoida fluid penetration hazard. Refer to Operation andMaintenance Manual, “General hazard Information”.

• Inspect the high-pressure fuel lines for damage,deformation, a nick, a cut, a crease, or a dent.

• Do not operate the engine with a fuel leak. If thereis a leak, do not tighten the connection in orderto stop the leak. The connection must only betightened to the recommended torque. Refer toDisassembly and Assembly, “Fuel injection lines -Remove and Fuel injection lines - Install”.

• If the high-pressure fuel lines are torqued correctly,and the high-pressure fuel lines are leaking thehigh-pressure fuel lines must be replaced.

• Ensure that all clips on the high-pressure fuel linesare in place. Do not operate the engine with clipsthat are damaged, missing, or loose.

• Do not attach any other item to the high-pressurefuel lines.

• Loosened high-pressure fuel lines must bereplaced. Also removed high-pressure fuel linesmust be replaced. Refer to Disassembly andAssembly manual, “ Fuel Injection Lines - Install”.

i03560601

Before Starting EngineSMCS Code: 1000

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off theair and/or fuel supply to the engine.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controlsif there is a “DO NOT OPERATE” warning tag orsimilar warning tag attached to the start switch or tothe controls.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work properly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

SEBU8606-01 17Safety SectionEngine Starting

i03635086

Engine StartingSMCS Code: 1000

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

If a warning tag is attached to the engine start switchor to the controls DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator's compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingcorrectly, check the water temperature gaugeand/or the oil temperature gauge during the heateroperation.

Engine exhaust contains products of combustionwhich can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

These engines are equipped with a glow plug startingaid in each individual cylinder that heats the intake airin order to improve starting. Some Caterpillar enginesmay have a cold starting system that is controlled bythe ECM that allows a controlled flow of ether intothe engine. The ECM will disconnect the glow plugsbefore the ether is introduced. This system wouldbe installed at the factory.

i03648639

Engine StoppingSMCS Code: 1000

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to this Operation and Maintenance Manual,“Engine Stopping” topic (Operation Section).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. DO NOT use theEmergency Stop Button for normal engine stopping.After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stop theengine if an overspeed condition occurs.

i04231629

Electrical SystemSMCS Code: 1000; 1400

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “−” cable should be connected last fromthe external power source to the primary position forgrounding.

Check the electrical wires daily for wires thatare loose or frayed. Tighten all loose electricalconnections before the engine is started. Repair allfrayed electrical wires before the engine is started.See the Operation and Maintenance Manual forspecific starting instructions.

18 SEBU8606-01Safety SectionEngine Electronics

Grounding Practices


(1) Ground to the battery(2) Primary position for grounding(3) Ground to the starting motor(4) Ground to the engine block


(5) Ground to the battery(6) Ground to the cylinder block

Correct grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Incorrect grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to the crankshaft bearing journal surfacesand to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function correctly, an engine-to-frameground strap with a direct path to the battery must beused. This path may be provided by way of a directengine ground to the frame.

The connections for the grounds should be tight andfree of corrosion. The engine alternator must begrounded to the negative “-” battery terminal witha wire that is adequate to handle the full chargingcurrent of the alternator.

The power supply connections and the groundconnections for the engine electronics should alwaysbe from the isolator to the battery.

i03554965

Engine ElectronicsSMCS Code: 1000; 1400; 1900

Tampering with the electronic system installationor the OEM wiring installation can be dangerousand could result in personal injury or death and/orengine damage.

Electrical Shock Hazard. The electronic unit injec-tors use DC voltage. The ECM sends this voltageto the electronic unit injectors. Do not come incontact with the harness connector for the elec-tronic unit injectors while the engine is operating.Failure to follow this instruction could result inpersonal injury or death.

This engine has a comprehensive, programmableEngine Monitoring System. The Electronic ControlModule (ECM) has the ability to monitor the engineoperating conditions. If any of the engine parametersextend outside an allowable range, the ECM willinitiate an immediate action.

The following actions are available for enginemonitoring control:

• Warning


Engine Electronics

• Derate

• Shutdown

The following monitored engine operating conditionsand components have the ability to limit enginespeed and/or the engine power:

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Intake Manifold Air Temperature

• Engine Intake Throttle Valve Fault

• Wastegate Regulator

• Supply Voltage to Sensors

• Fuel Pressure in Manifold (Rail)

• NOx Reduction System

• Engine Aftertreatment System

The Engine Monitoring package can vary for differentengine models and different engine applications.However, the monitoring system and the enginemonitoring control will be similar for all engines.

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engineswill work in unison with the Engine MonitoringSystem. Together, the two controls will provide theengine monitoring function for the specific engineapplication. Refer to the Troubleshooting for moreinformation on the Engine Monitoring System.

20 SEBU8606-01Product Information SectionModel Views

Product InformationSection

Model Viewsi04246230

Model View IllustrationsSMCS Code: 1000

The following model views show typical featuresof the engine and the aftertreatment system.Due to individual applications, your engine, andyour aftertreatment may appear different from theillustrations.

Series Turbocharger Arrangement


(1) Front lifting eye(2) Crankcase breather(3) NOx Reduction system (NRS)(4) Primary fuel filter(5) Secondary fuel filter

(6) Electronic control module (ECM)(7) Fuel priming pump(8) Oil gauge (dipstick)(9) Fuel strainer(10) Oil filter

(11) Oil sampling valve(12) Oil filler(13) High-pressure fuel pump

SEBU8606-01 21Product Information Section

Model Views


(14) Rear lifting eye(15) High-pressure turbocharger(16) Low-pressure turbocharger(17) Back pressure valve

(18) Starting motor(19) Oil drain plug(20) Exhaust outlet(21) Flywheel housing

(22) Flywheel(23) NRS cooler



(24) Belt(25) Air intake(26) Coolant outlet connection

(27) Thermostat housing(28) Water pump(29) Coolant inlet connection

(30) Crankshaft pulley(31) Belt tensioner(32) Alternator


Model Views

Engine with a Single Turbocharger

g02407436Illustration 20(1) Front lifting eye(2) Crankcase breather(3) NOx reduction system (NRS)(4) Secondary fuel filter

(5) Primary fuel filter(6) Fuel priming pump(7) Fuel strainer(8) Electronic control module (ECM)

(9) Oil filter(10) Oil sampling valve(11) High-pressure fuel pump



(12) Rear lifting eye(13) Oil gauge (dipstick)(14) Turbocharger(15) Starting motor

(16) Oil drain valve(17) Oil drain plug(18) Back pressure valve(19) Flywheel housing

(20) Flywheel(21) Exhaust outlet(22) NRS cooler


Model Views


(23) Oil filler(24) Air intake(25) Coolant outlet connection(26) Thermostat housing

(27) Water pump(28) Coolant intake connector(29) Crankshaft pulley(30) Belt tensioner

(31) Alternator(32) Belt


Engine Aftertreatment System


(1) Flexible exhaust pipe(2) Inlet connection

(3) Clean emissions module(4) Mounting cradle

(5) Outlet connection

i04261751

Engine DescriptionSMCS Code: 1000

The Caterpillar C4.4 industrial engines have thefollowing characteristics.

• In-line 4 cylinder

• Four stroke cycle

• Single turbocharger

• Series turbochargers

Engines that have series turbochargers are equippedwith a low-pressure turbocharger and a high-pressureturbocharger.

Engine SpecificationsThe front end of the engine is opposite the flywheelend of the engine. The left and the right sides of theengine are determined from the flywheel end. Thenumber 1 cylinder is the front cylinder.

g01187485Illustration 24(A) Exhaust valves(B) Inlet valves


Model Views

Table 1

C4.4 Engine Specifications

Operating Range (rpm) 800 to 2200 (1)

Number of Cylinders 4 In-Line

Bore 105 mm (4.13 inch)

Stroke 127 mm (4.99 inch)

Single turbochargercharge cooled60 to 110 kW

(80.46 to 147.51 hp)

Power

Series turbochargerscharge cooled105 to 129.5 kW

(140.80 to 173.65 hp)

Aspiration Single Turbochargedcharge cooledSeries turbochargerscharge cooled

Compression Ratio 16.5:1

Displacement 4.4 L (268.504 cubic inch)

Firing Order 1-3-4-2

Rotation (flywheel end) Counterclockwise(1) The operating rpm is dependent on the engine rating, theapplication, and the configuration of the throttle.

Electronic Engine FeaturesThe engine operating conditions are monitored.The Electronic Control Module (ECM) controls theresponse of the engine to these conditions and tothe demands of the operator. These conditions andoperator demands determine the precise control offuel injection by the ECM. The electronic enginecontrol system provides the following features:

• Engine monitoring

• Engine speed governing

• Control of the injection pressure

• Cold start strategy

• Automatic air/fuel ratio control

• Torque rise shaping

• Injection timing control

• System diagnostics

• Low temperature regeneration

For more information on electronic engine features,refer to the Operation and Maintenance Manual,“Features and Controls” topic (Operation Section).

Engine DiagnosticsThe engine has built-in diagnostics in order to ensurethat the engine systems are functioning correctly. Theoperator will be alerted to the condition by a “Stop orWarning” lamp. Under certain conditions, the enginehorsepower and the vehicle speed may be limited.The electronic service tool may be used to displaythe diagnostic codes.

There are three types of diagnostic codes: active,logged, and event.

Most of the diagnostic codes are logged and storedin the ECM. For additional information, refer tothe Operation and Maintenance Manual, “EngineDiagnostics” topic (Operation Section).

The ECM provides an electronic governor thatcontrols the injector output in order to maintain thedesired engine rpm.

Engine Cooling and LubricationThe cooling system and lubrication system consistsof the following components:

• Gear-driven centrifugal water pump

• Water temperature regulator which regulates theengine coolant temperature

• Gear-driven rotor type oil pump

• Oil cooler

The engine lubricating oil is supplied by a rotor typeoil pump. The engine lubricating oil is cooled and theengine lubricating oil is filtered. The bypass valvecan provide unrestricted flow of lubrication oil tothe engine if the oil filter element should becomeplugged.

Engine efficiency, efficiency of emission controls, andengine performance depend on adherence to properoperation and maintenance recommendations.Engine performance and efficiency also depend onthe use of recommended fuels, lubrication oils, andcoolants. Refer to this Operation and MaintenanceManual, “Maintenance Interval Schedule” for moreinformation on maintenance items.

Aftertreatment SystemThe aftertreatment system is approved for use byCaterpillar. In order to be emission-compliant only theapproved Caterpillar aftertreatment system must beused on a Caterpillar engine.


Clean Emission Module (CEM)

The CEM comprises of two main components in asingle unit, the Diesel Oxidation Catalyst DOC andthe Diesel Particulate Filter DPF. The function of theCEM is to ensure that the engine exhaust meetsthe required emissions regulation for the country ofoperation.

The engine exhaust is connected by a flexible pipe tothe CEM. The exhaust gases pass through the DOCin order to remove contaminants, carbon monoxide,and hydrocarbons. The exhaust gases then enter theDPF where any particulate matter soot and ash willbe trapped.

The CEM uses a passive regeneration process toensure that normal operation of the engine removesthe soot. The soot is removed at an equal rate ofwhich the soot is captured. The ash remains in theDPF and must be removed at an engine overhaul.

Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants, andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is generally predicted by theaverage power that is demanded. The average powerthat is demanded is based on fuel consumption ofthe engine over a period of time. Reduced hours ofoperation at full throttle and/or operating at reducedthrottle settings result in a lower average powerdemand. Reduced hours of operation will increasethe length of operating time before an engineoverhaul is required.

Aftermarket Products andCaterpillar EnginesCaterpillar does not warrant the quality orperformance of non-Caterpillar fluids and filters.

When auxiliary devices, accessories, or consumables(filters, additives, catalysts, ) which are made by othermanufacturers are used on Caterpillar products, theCaterpillar warranty is not affected simply becauseof such use.

However, failures that result from the installationor use of other manufacturers devices,accessories, or consumables are NOT Caterpillardefects. Therefore, the defects are NOT coveredunder the Caterpillar warranty.


Product Identification Information

Product IdentificationInformation

i03895545

Plate Locations and FilmLocationsSMCS Code: 1000


Location of serial number plate

Serial Number Plate (1)The engine serial number plate is located on theleft side of the cylinder block to the rear of the frontengine mounting.

Caterpiller dealers need all of these numbers in orderto determine the components that were includedwith the engine. This information permits accurateidentification of replacement part numbers.


i03867276

Reference NumbersSMCS Code: 1000

Information for the following items may be needed toorder parts. Locate the information for your engine.Record the information in the appropriate space.Make a copy of this list for a record. Keep theinformation for future reference.

Record for ReferenceEngine Model _______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Drive Belt ____________________________________________________

Engine Aftertreatment System

Part Number ________________________________________________

30 SEBU8606-01Product Information SectionProduct Identification Information

Serial Number ______________________________________________

i04274710

Emissions Certification FilmSMCS Code: 1000; 7405

The label for the emission is installed on the frontgear cover.

Note: A second emission label will be supplied withthe engine. If necessary, the second emission labelwill be installed on the application by the originalequipment manufacturer.


SEBU8606-01 31Operation SectionLifting and Storage

Operation Section

Lifting and Storagei04195469

Product Lifting(Clean Emission Module)SMCS Code: 1000; 1404; 7002


Ensure that the correct clothing is worn, refer tothis Operation and Maintenance Manual, “GeneralHazard Information”.

The weight of the clean emission module (CEM)when laden is approximately 50 kg (110 lb). Twosuitable double looped slings are required in order tolift the CEM. Also a suitable hoist will be required inorder to remove and install the assembly.

The slings must be attached to the CEM in thepositions as shown in illustration 28.

Ensure that the slings only contact the body of theCEM. A test lift may be required in order to achievethe correct balance of the assembly.

Some applications may require a frame or jig in orderto lift the CEM. A frame or jig must only be connectedto the cradle of the CEM. Refer to the OEM for moreinformation.

i04332710

Product Lifting(Engine)SMCS Code: 1000; 1404; 7002


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting the fixtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for the specificengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult yourCaterpillar dealer for information regarding fixturesfor proper engine lifting.

32 SEBU8606-01Operation SectionLifting and Storage

Industrial Open Power Unit


(1) Location of front lifting eye(2) Location of rear lifting eye

SEBU8606-01 33Operation SectionLifting and Storage

i04342749

Product StorageSMCS Code: 1000; 1404; 7002

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderliner surface. Rust on the cylinder liner surface willcause increased engine wear and a reduction inengine service life.

To help prevent excessive engine wear, use thefollowing guidelines:

• Complete all of the lubrication recommendationsthat are listed in this Operation and MaintenanceManual, “Maintenance Interval Schedule”(Maintenance Section).

• If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. See this Operation and MaintenanceManual, “Refill Capacities and Recommendations”(Maintenance Section).

If an engine is out of operation and if use of the engineis not planned, special precautions should be made.If the engine will be stored for more than one month,a complete protection procedure is recommended.

For more detailed information on engine storage, seeSpecial Instruction, SEHS9031, “Storage ProcedureFor Caterpillar Products”.

Your Cat dealer can assist in preparing the engine forextended storage periods.

34 SEBU8606-01Operation SectionGauges and Indicators

Gauges and Indicatorsi04215941

Gauges and IndicatorsSMCS Code: 1900; 7450

Your engine may not have the same gauges or all ofthe gauges that are described. For more informationabout the gauge package, see the OEM information.

Gauges provide indications of engine performance.Ensure that the gauges are in good working order.Determine the normal operating range by observingthe gauges over a period of time.

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems mayalso be indicated by gauge readings that changeeven if the readings are within specifications.Determine and correct the cause of any significantchange in the readings. Consult your Caterpillardealer for assistance.

Some engine applications are equipped with IndicatorLamps. Indicator lamps can be used as a diagnosticaid. There are two lamps. One lamp has an orangelens and the other lamp has a red lens.

These indicator lamps can be used in two ways:

• The indicator lamps can be used to identify thecurrent operational status of the engine. Theindicator lamps can also indicate that the enginehas a fault. This system is automatically operatedvia the ignition switch.

• The indicator lamps can be used to identify activediagnostic codes. This system is activated bypressing the Flash Code button.

Refer to the Troubleshooting Guide, “IndicatorLamps” for further information.

NOTICEIf no oil pressure is indicated, STOP the engine. Ifmaximum coolant temperature is exceeded, STOPthe engine. Engine damage can result.

Engine Oil Pressure – The oil pressureshould be greatest after a cold engine isstarted. The typical engine oil pressure with

SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at ratedrpm.

A lower oil pressure is normal at low idle. If the loadis stable and the gauge reading changes, performthe following procedure:

1. Remove the load.

2. Stop the engine.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –Typical temperature range is 82° to 94°C(179.6° to 201.2°F). This temperature range

will vary according to engine load and the ambienttemperature.

A 100 kPa (14.5 psi) radiator cap must be installedon the cooling system. The maximum temperaturefor the cooling system is 108° C (226.4° F). Thistemperature is measured at the outlet for thewater temperature regulator. The engine coolanttemperature is regulated by the engine sensorsand the engine ECM. This programming cannot bealtered. An engine derate can occur if the maximumengine coolant temperature is exceeded.

If the engine is operating above the normal range,reduce the engine load. If high coolant temperaturesare a frequent event, perform the followingprocedures:

1. Reduce the load and the engine rpm.

2. Determine if the engine must be shut downimmediately or if the engine can be cooled byreducing the load.

3. Inspect the cooling system for leaks. If necessary,consult your Caterpillar dealer for assistance.

Tachometer – This gauge indicates enginespeed (rpm). When the throttle control leveris moved to the full throttle position without

load, the engine is running at high idle. The engine isrunning at the full load rpm when the throttle controllever is at the full throttle position with maximumrated load.

NOTICEOperation at speeds exceeding high idle rpm shouldbe kept to a minimum. Overspeeding can result in se-rious damage to the engine.

Ammeter – This gauge indicates theamount of charge or discharge in thebattery charging circuit. Operation of the

indicator should be to the “+” side of “0” (zero).

Fuel Level – This gauge indicates the fuellevel in the fuel tank. The fuel level gaugeoperates when the “START/STOP” switch

is in the “on” position.

SEBU8606-01 35Operation Section

Gauges and Indicators

Service Hour Meter – The gauge indicatestotal operating hours of the engine.

Indicator LampsThere are four indicator lamps that are available.

• Shutdown Lamp

• Warning Lamp

• Wait to Start Lamp

• Low Oil Pressure Lamp

For information, refer to this manual, “MonitoringSystem (Table for the Indicator Lamps)” for thesequence of operation of the shutdown lamp and thewarning lamp.

The function of the wait to start lamp is automaticallycontrolled at engine start-up.

The function of the low oil pressure lamp is controlledby the engine ECM. If low oil pressure is detected,the lamp will be illuminated. The reason for theillumination of the low-pressure lamp should beinvestigated immediately.

All lamps will illuminate for 2 seconds in order tocheck that the lamps are functioning when thekeyswitch is turned to the ON position. If any of thelamps stay illuminated, the reason for illuminationshould be investigated immediately.

Instrument panels and DisplaysIn order to monitor the engine a wide verity ofinstrument panels are available. These instrumentpanels can contain the indicator lamps and thegauges for the application.

Also available are mini power displays andperformance monitors. These displays and monitorscan show the operator the following engineinformation.

• The system configuration parameters

• The customer specified parameters

• Diagnostic codes

• Event codes

• Coolant temperature

• Oil temperature

• Oil pressure

• Intake temperature

• Intake pressure

• Atmospheric pressure

• Fuel temperature

36 SEBU8606-01Operation SectionFeatures and Controls

Features and Controlsi04340969

Monitoring SystemSMCS Code: 1900; 7400; 7402; 7450; 7451

If the Shutdown mode has been selected and thewarning indicator activates, engine shutdownmaytake as little as 20 seconds from the time the warn-ing indicator is activated. Depending on the ap-plication, special precautions should be taken toavoid personal injury. The engine can be restartedfollowing shutdown for emergency maneuvers, ifnecessary.

NOTICEThe Engine Monitoring System is not a guaranteeagainst catastrophic failures. Programmed delaysand derate schedules are designed to minimize falsealarms and provide time for the operator to stop theengine.

The following parameters are monitored:

• Coolant temperature

• Intake manifold air temperature

• Intake manifold air pressure

• Oil pressure

• Pressure in the fuel rail

• Engine speed/timing

• Fuel temperature

• Atmospheric pressure (Barometric pressure)

• The Inlet pressure and outlet pressure of the NOxreduction system

• Temperature of the NOx reduction system

• Water in fuel switch

• The amount of soot in the Diesel particulate filter

Programmable Options andSystems Operation

If the Warning/Derate/Shutdown mode has beenselected and the warning indicator activates,bring the engine to a stop whenever possible. De-pending on the application, special precautionsshould be taken to avoid personal injury.

The engine can be programmed to the followingmodes:

“Warning”

The orange warning lamp will turn “ON” and thewarning signal is activated continuously in order toalert the operator that one or more of the engineparameters is not within normal operating range.

“Derate”

The orange warning lamp will be flashing. After thewarning, the engine power will be derated.

The engine will be derated if the engine exceedspreset operational limits. The engine derate isachieved by restricting the amount of fuel that isavailable for each injection. The amount of thisreduction of fuel is dependent on the severity of thefault that has caused the engine derate, typically upto a limit of 50%. This reduction in fuel results in apredetermined reduction in engine power.

“Shutdown”

The orange warning will be flashing and the redshutdown lamp will be on solid. After the warning,the engine power will be derated. The engine willcontinue at the rpm of the set derate until a shutdownof the engine occurs. The engine can be restartedafter a shutdown for use in an emergency.

A shutdown of the engine may occur in as littleas 20 seconds. The engine can be restarted aftera shutdown for use in an emergency. However,the cause of the initial shutdown may still exist.The engine may shut down again in as little as 20seconds.

If there is a signal for high coolant temperature,there will be a 2 second delay in order to verify thecondition.

If there is a signal for low oil pressure, there will be a2 second delay in order to verify the condition.


Features and Controls

For information on the operation of the warning lampsand the shutdown lamp, refer to this Operation andMaintenance Manual, “ Monitoring System (Tablefor Indicator Lamps)”. For each of the programmedmodes, refer to Troubleshooting Guide, “IndicatorLamps” for more information on Indicator Lamps.

For more information or assistance for repairs,consult your Caterpillar dealer.


i04201172

Monitoring System(Table for the Indicator lamps)SMCS Code: 1900; 7400; 7402; 7450; 7451

Note: When in operation the amber warning lamphas three states, solid, flashing, and fast flashing.The sequence is to give a visual indication of theimportance of the warning. Some application canhave an audible warning installed.

Ensure that the engine maintenance is carried out atthe correct intervals. A lack of maintenance can resultin illumination of the warning lamp. For the correctintervals of maintenance, refer to the Operationand Maintenance Manual, “Maintenance IntervalSchedule”.

Table 2

WarningLamp

ShutdownLamp

Lamp State Description of the Indication Engine Status

On On Lamp Check When the keyswitch is moved to theON position, the lamps come on for 2seconds and the lamps will then gooff.

The keyswitch is in the ON position butthe engine has not yet been cranked.

Off Off No Faults With the engine in operation, thereare no active warnings, diagnosticcodes, or event codes.

The engine is operating with no detectedfaults.

On Solid Off Warning Level 1 warning The engine is operating normally butthere is one or more faults with theelectronic management system for theengine.

Flashing Off Warning Level 2 warning The engine continues to be operated,but the level of importance of thewarning has increased.Depending on the particular fault andthe severity the engine may be de-rated.The engine could be damaged ifcontinued to be operated.

Flashing On EngineShutdown

Level 3 warningIf both the warning lamp and theshutdown lamp are in operation, thisissue indicates one of the followingconditions.

1. One or more of the shutdownvalues for the engine protectionstrategy has been exceeded.

2. A serious active diagnostic codehas been detected.

After a short time period, the enginemay shut down.

The engine is either shutdown or anengine shutdown is imminent. One ormore monitored engine parametershave exceeded the limit for an engineshutdown. This pattern of lamps can becaused by the detection of a seriousactive diagnostic code.



i04215952

Sensors and ElectricalComponents(Aftertreatment)SMCS Code: 1439; 1900; 7400

The illustration within the section shows thetypical locations of the sensors and other electricalcomponents on the industrial engine. Specific engineaftertreatment systems may appear different due tothe application.

g02395776Illustration 31(1) Temperature Sensor(2) Connector for Temperature Sensor(3) Soot Sensor Connection(4) Aftertreatment Identification Module(5) Soot Sensor Connection(6) Soot Sensor

Note: The location of the soot sensor will dependon the application.

i04246269

Sensors and ElectricalComponentsSMCS Code: 1439; 1900; 7400

The illustration within the section shows thetypical locations of the sensors and other electricalcomponents on the Industrial engine. Specificengines may appear different due to the application.



(1) Coolant Temperature Sensor(2) Fuel Pressure Sensor (Fuel Rail

Pressure Sensor)(3) Intake Manifold Air Temperature Sensor(4) Intake Manifold Pressure Sensor(5) Electronic Control Module (ECM)(6) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

(7) Primary Speed/Timing sensor(Crankshaft Position Sensor)

(8) Diagnostic Connector(9) Oil Pressure Sensor(10) Fuel Temperature Sensor(11) Solenoid for the High Pressure Fuel

Pump(12) Wastegate Regulator

(13) Inlet Pressure Sensor for the NOxReduction System (NRS)

(14) Outlet Pressure Sensor for the NRS(15) Control Valve for the NRS(16) Temperature Sensor for the NRS



g02411837Illustration 33(17) Back Pressure Valve(18) Alternator

(19) Secondary Speed/Timing Sensor(Camshaft Position Sensor)

(20) Starting Motor

(21) Water in Fuel Switch(22) Oil Level Switch (if Equipped)(23) Electric Priming Pump


(1) Coolant Temperature Sensor(2) Fuel Pressure Sensor (Fuel Rail

Pressure Sensor)

(3) Intake Manifold Air Temperature Sensor(4) Intake Manifold Pressure Sensor(5) Electronic Control Module (ECM)


g02413839Illustration 35(6) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)(7) Primary Speed/Timing sensor

(Crankshaft Position Sensor)(8) Diagnostic Connector(9) Oil Pressure Sensor


(10) Fuel Temperature Sensor(11) Solenoid for the High Pressure Fuel

Pump

(12) Wastegate Regulator(13) Inlet Pressure Sensor for the NOx

Reduction System (NRS)

(14) Outlet Pressure Sensor for the NRS



g02414076Illustration 37(15) Control Valve for the NRS (16) Temperature Sensor for the NRS (17) Back Pressure Valve


(18) Alternator (19) Secondary Speed/Timing Sensor(Camshaft Position Sensor)

(20) Starting Motor


g02414506Illustration 39(21) Water in Fuel Switch(22) Oil Level Switch (if Equipped)(23) Electric Priming Pump

i04372673

Engine Shutoffs and EngineAlarmsSMCS Code: 1900; 7400; 7418

ShutoffsThe shutoffs are electrically operated or mechanicallyoperated. The electrically operated shutoffs arecontrolled by the ECM.

Shutoffs are set at critical levels for the followingitems:

• Operating temperature

• Operating pressure

• Operating level

• Operating rpm

The particular shutoff may need to be reset beforethe engine will start.

NOTICEAlways determine the cause of the engine shutdown.Make necessary repairs before attempting to restartthe engine.

Be familiar with the following items:

• Types and locations of the shutoff

• Conditions which cause each shutoff to function

• The resetting procedure that is required to restartthe engine

AlarmsThe alarms are electrically operated. The operationof the alarms is controlled by the ECM.

The alarm is operated by a sensor or by a switch.When the sensor or the switch is activated, a signalis sent to the ECM. An event code is created bythe ECM. The ECM will send a signal in order toilluminate the lamp.

Your engine may be equipped with the followingsensors or switches:

Coolant level – The low coolant level switchindicates when the coolant level is low.

Coolant temperature – The coolant temperaturesensor indicates high jacket water coolanttemperature.

Intake manifold air temperature – The intakemanifold air temperature sensor indicates high intakeair temperature.



Intake manifold pressure – The intake manifoldpressure sensor checks the rated pressure in theengine manifold.

Fuel rail pressure – The fuel rail pressure sensorchecks for high pressure or low pressure in the fuelrail.

Engine oil pressure – The engine oil pressuresensor indicates when oil pressure drops below ratedsystem pressure, at a set engine speed.

Engine overspeed – If the engine rpm exceeds theoverspeed setting, the alarm will be activated.

Air filter restriction – The switch checks the airfilter when the engine is operating.

User-Defined switch – This switch can shut downthe engine remotely.

Water in fuel switch – This switch checks for waterin the primary fuel filter when the engine is operating.

Fuel temperature – The fuel temperature sensormonitors the pressurized fuel in the high-pressurefuel pump.

Note: The sensing element of the coolanttemperature switch must be submerged in coolantin order to operate.

Engines may be equipped with alarms in orderto alert the operator when undesirable operatingconditions occur.

NOTICEWhen an alarm is activated, corrective measuresmustbe taken before the situation becomes an emergencyin order to avoid possible engine damage.

If corrective measures are not taken within areasonable time, engine damage could result. Thealarm will continue until the condition is corrected.The alarm may need to be reset.

TestingTurning the keyswitch to the ON position will checkthe indicator lights on the control panel. All theindicator lights will be illuminated for 2 seconds afterthe keyswitch is operated. Replace suspect bulbsimmediately.

Refer to Troubleshooting, KENR9111 for moreinformation.

i03554501

OverspeedSMCS Code: 1900; 1907; 1912; 7427

• ECM ______________________Electronic Control Module

• RPM ________________________ Revolutions Per Minute

An overspeed is detected by the speed/timingsensors.

The default setting for an overspeed is 3000 rpm.The ECM will cut the power to the electronic unitinjectors, until the rpm drops below 200 rpm of theoverspeed setting. A diagnostic fault code will belogged into the ECM memory and a warning lamp willindicate a diagnostic fault code.

An overspeed can be set from 2600 rpm to 3000 rpm.This setting depends on the application.

46 SEBU8606-01Operation SectionEngine Diagnostics

Engine Diagnosticsi01796959

Self-DiagnosticsSMCS Code: 1000; 1900; 1901; 1902

Caterpillar Electronic Engines have the capability toperform a self-diagnostics test. When the systemdetects an active problem, a diagnostic lampis activated. Diagnostic codes will be stored inpermanent memory in the Electronic Control Module(ECM). The diagnostic codes can be retrieved byusing Caterpillar electronic service tools.

Some installations have electronic displays thatprovide direct readouts of the engine diagnosticcodes. Refer to the manual that is provided by theOEM for more information on retrieving enginediagnostic codes.

Active codes represent problems that currently exist.These problems should be investigated first.

Logged codes represent the following items:

• Intermittent problems

• Recorded events

• Performance history

The problems may have been repaired since thelogging of the code. These codes do not indicate thata repair is needed. The codes are guides or signalswhen a situation exists. Codes may be helpful totroubleshoot problems.

When the problems have been corrected, thecorresponding logged fault codes should be cleared.

i03554520

Diagnostic LampSMCS Code: 1000; 1900; 1901; 1902; 7451

A diagnostic lamp is used to indicate the existenceof an active fault. A fault diagnostic code will remainactive until the problem is repaired. The diagnosticcode may be retrieved by using the electronic servicetool.

i04215570

Diagnostic Flash CodeRetrievalSMCS Code: 1000; 1900; 1901; 1902

Use the “DIAGNOSTIC” lamp or an electronic servicetool to determine the diagnostic flash code.

Use the following procedure to retrieve the flashcodes if the engine is equipped with a “DIAGNOSTIC”lamp:

1. Move the keyswitch from the on/off two timeswithin 3 seconds.

A flashing YELLOW lamp indicates a 3-digit code forthe engine. The sequence of flashes represents thesystem diagnostic message. Count the first sequenceof flashes in order to determine the first digit of theflash code. After a two second pause, the secondsequence of flashes will identify the second digit ofthe flash code. After the second pause, the thirdsequence of flashes will identify the flash code.

Table 3

Flash Code Table

Description Flash Code

Injector fault 111

Injector number 2 current out of range 112



Injector number 5 current out of range(6 cylinder only)

115

Injector number 6 current out of range(6 cylinder only)

116

Intake manifold air temperaturesensor out of range

133

Engine speed sensor out of range 141

Engine timing offset fault 143

Engine operation mode selectorswitch erratic, intermittent, orincorrect

144

High air filter restriction - Warning 151

Atmospheric pressure sensor out ofrange

152

Throttle position sensor out of range 154

Secondary throttle position sensorout of range

155

Oil pressure sensor out of range 157

(continued)

SEBU8606-01 47Operation SectionEngine Diagnostics

(Table 3, contd)

Fuel rail pressure sensor out of range 159

Fuel temperature sensor out of range 165

Engine coolant temperature sensorout of range

168

Low Engine Coolant Level -Shutdown

169

Turbo wastegate drive out of range 177

Intake manifold pressure sensor outof range

197

Glow plug start aid relay currentabove normal

199

Diesel Particulate Filter DPF Intaketemperature sensor out of range

224

DPF Soot sensors out of range 226

Exhaust gas recirculationtemperature/pressure out of range

227

Exhaust gas recirculation valvecontrol current out of range

228

Exhaust gas recirculation valvecontrol voltage out of range

229

Exhaust gas recirculation pressuresensor out of range

231

Air inlet temperature sensor voltageout of range

232

Ether injection control solenoid out ofrange

233

Idle validation switch #1 erratic,intermittent, or incorrect

245

Idle validation switch #2 erratic,intermittent, or incorrect

246

Exhaust Gas Recirculation OutletPressure Sensor out of range

247

Exhaust back pressure regulatorposition voltage out of range

249

Engine Fuel Supply Lift Pump Relayout of range

253

Personality module erratic,intermittent, or incorrect

415

Machine security system moduleabnormal update rate

426

Ignition key switch loss of signal 429

Electrical System Voltage fault 511

SAE J1939 Data Link abnormalupdate rate

514

5 Volt sensor DC power supplyvoltage out of range

516

(continued)

(Table 3, contd)

8 V DC Supply voltage out of range 517

Programmed parameter fault erratic,intermittent, or incorrect

527

5 Volt Sensor DC Power Supply #2out of range

528

No diagnostic code detected 551

Refer to Troubleshooting, “Diagnostic Flash CodeCross Reference” for more information.

i03554529

Fault LoggingSMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging.When the Electronic Control Module (ECM)generates an active diagnostic code, the code will belogged in the memory of the ECM. The codes thathave been logged in the memory of the ECM canbe retrieved with electronic service tools. The codesthat have been logged can be cleared with electronicservice tools. The codes that have been logged in thememory of the ECM will be automatically cleared fromthe memory after 100 hours. The following faults cannot be cleared from the memory of the ECM withoutusing a factory password: overspeed, low engine oilpressure, and high engine coolant temperature.

48 SEBU8606-01Operation SectionEngine Diagnostics

i03554534

Engine Operation with ActiveDiagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If a diagnostic lamp illuminates during normal engineoperation, the system has identified a situation thatis not within the specification. Use electronic servicetools to check the active diagnostic codes.

Note: If the customer has selected “DERATE” and ifthere is a low oil pressure condition, the ElectronicControl Module (ECM) will limit the engine poweruntil the problem is corrected. If the oil pressure iswithin the normal range, the engine may be operatedat the rated speed and load. However, maintenanceshould be performed as soon as possible.

The active diagnostic code should be investigated.The cause of the problem should be corrected assoon as possible. If the cause of the active diagnosticcode is repaired and there is only one activediagnostic code, the diagnostic lamp will turn off.

Operation of the engine and performance of theengine can be limited as a result of the activediagnostic code that is generated. Accelerationrates may be significantly slower. Refer to theTroubleshooting Guide for more information on therelationship between these active diagnostic codesand engine performance.

i01797063

Engine Operation withIntermittent Diagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If a diagnostic lamp illuminates during normal engineoperation and the diagnostic lamp shuts off, anintermittent fault may have occurred. If a fault hasoccurred, the fault will be logged into the memory ofthe Electronic Control Module (ECM).

In most cases, it is not necessary to stop the enginebecause of an intermittent code. However, theoperator should retrieve the logged fault codesand the operator should reference the appropriateinformation in order to identify the nature of the event.The operator should log any observation that couldhave caused the lamp to light.

• Low power

• Limits of the engine speed

• Excessive smoke, etc

This information can be useful to help troubleshootthe situation. The information can also be used forfuture reference. For more information on diagnosticcodes, refer to the Troubleshooting Guide for thisengine.

i04217251

Configuration ParametersSMCS Code: 1000; 1900; 1901; 1902

The engine electronic control module (ECM) hastwo types of configuration parameters. The systemconfiguration parameters and the customer specifiedparameters.

The electronic service tool is required in order to alterthe configuration parameters.

System Configuration ParametersSystem configuration parameters affect the emissionsof the engine or the power of the engine. Systemconfiguration parameters are programmed at thefactory. Normally, system configuration parameterswould never require changing through the lifeof the engine. System configuration parametersmust be reprogrammed if an ECM is replaced.System configuration parameters do not requirereprogrammed if the ECM software is changed.Factory passwords are required to change theseparameters.

SEBU8606-01 49Operation SectionEngine Diagnostics

Table 4

System Configuration Parameters

Configuration Parameters Record

Full Load Setting

Full Torque Setting

Rating

Engine Serial Number

Factory Installed Aftertreatment Identification Number

DPF Soot Loading Sensing System Configuration Code

Limp Home Engine Speed Ramp Rate

ECM Software Release Date

Customer Specified ParametersCustomer specified parameters allow the engine tobe configured to the exact needs of the application.

The electronic service tool is required in order to alterthe customer configu

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