C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Coolant Contains Oil
SMCS - 1348-035; 1395-035
Probable Causes
• Engine oil cooler
• Cylinder head
• Cylinder block
Recommended Actions
Cylinder Head
1. Check the cylinder head for flatness. Refer to SystemsOperation/Testing and Adjusting.
2. Check the mating face of the cylinder head for wear and signs of leakage. If excessive wear is found, replace the cylinder head. If signsof leakage are found, determine the cause of the leakage. Refer to Systems Operation/Testing and Adjusting.
3. Inspect the cylinder head gasket for damage and any signs of leakage. If necessary, install a newcylinder head gasket. Refer to Disassembly and Assembly.
Cylinder Block
1. Inspect the top face of the cylinder block for wear and signs of leakage. If excessive wear is found, replace the cylinder block. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation/Testing and Adjusting.
i05373720
2. Install the cylinder head. Refer to Disassembly and Assembly.
3. Fill the cooling system. Refer to the Operation and Maintenance Manual.
4. Check the quality of the engine oil. If necessary, drain the crankcase and refill the crankcase with clean engine oil. Install new engine oil filters. Refer to Operation and Maintenance Manual.
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Coolant Temperature Is High
SMCS - 1395-035
Use thisprocedure in order to troubleshoot high coolant temperature.
Probable Causes
• Lowcoolant level and/or coolant leakage
• Water temperature regulator and/or pressure relief valve
• Radiator
• Engine cooling fan
• Water pump Recommended Actions
Coolant
1. Inspect the coolant level. If necessary, add coolant.
2. Check the mixture of antifreeze and water. Refer to Operation and Maintenance Manual.
3. Check the cooling system for leaks. Repair any leaks immediately.
4. Check for air in the cooling system. Refer to Systems Operation/Testing and Adjusting for the correct procedure.
i04564726
Water Temperature Regulator and/or Pressure Relief Valve
1. Test the cooling system. Refer to Systems Operation/Testing and Adjusting for the correct procedure.
2. Check that the seating surfaces of the pressure relief valve and the radiator cap are clean and undamaged.
3. Check operation of the pressure relief valve and/or the water temperature regulator. If necessary, clean the components and/or replace the components.
Radiator
sample
1. Check the radiator fins for dirt, debris, and/or damage. Remove any dirt and/or debris and straighten any bent fins. Check for collapsed hosesand/or other restrictions.
2. Check the radiator for internal blockage. Refer to Systems Operation/Testing and Adjusting for more information.
Faulty Engine Cooling Fan
1. Check for loose drive belts. Aloose fan drive belt will cause a reduction in the air flowacross the radiator. Check the fan drive belt for proper belt tension. Adjust the tension of the fan drive belt, if necessary. Refer to Operation and Maintenance Manual.
Water Pump
1. Inspect the impeller of the coolant pump for damage and/or erosion.
2. Make sure that the drive gear is not loose on the drive shaft of the coolant pump.
3. If necessary, replace the coolant pump. Refer to Disassembly and Assembly for the correct procedure. Copyright 1993 - 2020 Caterpillar Inc.
Rights Reserved.
Network For SIS Licensees. Tue Jul 14 16:35:34 UTC+0530 2020
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Cylinder Is Noisy
SMCS - 1223-035
Probable Causes
• Lowquality fuel
• Not enough lubrication
• Too much valve lash
• Damage to valve train components
• Failure of connecting rod bearing
Recommended Actions
Low Quality Fuel
Updated -02/06/2016
Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel. Obtain a fuel analysis.
Not Enough Lubrication
Check the lubrication in the valve compartment. Check for sufficient lubrication between the injector tappet and the rocker arm buttons. Check for blocked oil passages. Oil passages must be clean. Ensure that the oil passages that send oil to the cylinder heads are clean.
ValveLash
i04564200
Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".
Damage to Valve Train Components
Remove the valve cover from the suspect cylinder. Check the following items for damage: camshaft, valve rotocoil, valve springs, lifters, pushrods and bridges. Check for valves that do not move freely. Remove the cylinder head. Inspect the valves. Replace any damaged parts.
Failure of Connecting Rod Bearing
Inspect the connecting rod bearings and the bearing surfaces(journals) on the crankshaft. Check the piston pin for excessive wear. Replace any damaged parts.
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Cranks but Does Not Start
SMCS - 1000-035; 1450-035
Probable Causes
• Air inlet and exhaust system
• Fuel supply
• Combustion
• Fuel shutoff solenoid
Recommended Actions
Air Inlet and Exhaust System
Updated -02/06/2016
1. Check the air filter restriction indicator for a plugged filter. If necessary, service the engine. Refer to the Operation and Maintenance Manual.
2. Check the air inlet and exhaust system for restrictionsand/or leaks. Refer to Systems Operation/Testing and Adjusting.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel. If the engine hasbeen run out of fuel, prime the fuel system. Refer to Operation and Maintenance Manual for the correct procedure.
i05360428
2. Ensure that there is good, clean fuel in the fuel tank. Refer to Testing and Adjusting, "Fuel Quality - Test". When possible, interviewthe operator in order to determine if fuel quality is in question. Try to determine if problem started soon after refueling. Replace the fuel in the fuel tank with good, clean fuel if necessary.
3. Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the linesand/or replace the lines.
4. Check the fuel tank for foreign objects which may block the fuel supply.
5. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during coldweather operation.
sample
6. Check fuel flow after the fuel filters. If the fuel flowislow, replace the fuel filters.
7. Ensure that the fuel shutoff solenoid operates correctly. Replace the fuel shutoff solenoid if found faulty.
Combustion
Check for mechanical problemsin the combustion system.
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Does Not Crank
SMCS - 1000-035; 1450-035
Probable Causes
• Battery cables and/or batteries
• Starting circuit
• Internal engine problem
Recommended Repairs
Battery Cables and/or Batteries
1. Inspect the main power switch, battery posts, and battery cables for loose connectionsand corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Clean the battery posts and then replace the cables. Tighten any loose connections.
2. Inspect the batteries.
a. Charge the batteries.
b. Load test the batteries. Refer to Systems Operation/Testing and Adjusting.
Starting Circuit
1. Inspect the starting motor and the flywheel ring gear for damage. Test the operation of the starting motor and associated circuit components. Refer to SystemsOperation/Testing and Adjusting.
i04564879
Internal Engine Problem
1. Remove the glow plugs. Refer to Disassembly and Assembly.
2. Attempt to rotate the crankshaft through 360 degrees in both direction. If the crankshaft rotates correctly but fluid is expelled from the hole for the glow plug, investigate the cause of the fluid in the cylinder. Refer to Systems Operation/Testing and Adjusting.
3. If the crankshaft rotates correctly and no fluid is expelled, install the glowplugs. Refer to Disassembly and Assembly.
4. If the engine does not rotate in Step 2, disassemble the engine. Refer to Disassembly and Assembly.
5. Inspect the internal componentsfor the following conditions: Seizure
Broken components Bent components
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Has Early Wear
SMCS - 1000-035; 1200-035
Premature Engine Wear
Probable Causes
• Incorrect engine oil
• Contaminated engine oil
• Contaminated inlet air
• Contaminated fuel
• Restriction in a passage for engine oil
Recommended Repairs
Engine Oil
Updated -02/06/2016
i01994326
Use engine oil that is recommended and change the engine oil at the interval that isrecommended by the engine's Operation and Maintenance Manual.
To determine whether the engine oil is contaminated, obtain an analysisof the engine oil.
Contaminated Inlet Air
Inspect the engine air cleaner for cleanliness and good condition. Inspect the connections and the gaskets for the air system.
Contaminated Fuel
Inspect the fuel filter. Replace the fuel filter, if necessary.
Contaminants in the fuel such as hydrogen sulfide, sulfur, and chlorofluorocarbons can lead to the formation of acidsin the crankcase. Obtain a fuel analysis.
Restriction in a Passage for Engine Oil
When some componentsof the engine showbearing wear in a short time, the cause can be a restriction in a passage for engine oil.
An indicator for the engine oil pressure may indicate sufficient pressure, but a component is worn due to a lack of lubrication. In such a case, look at the passage for the engine oil supply to the component.
sample
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Jul 14 16:38:28 UTC+0530 2020
This is the sample of the manual click on the download link for complete manual
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Has Mechanical Noise (Knock)
SMCS - 1000-035
Probable Causes
• Accessory equipment
• Valve train components
• Pistons
• Crankshaft
• Gear train
Recommended Actions
Accessory Equipment
Isolate the source of the noise. Remove the suspect engine accessory. Inspect the suspect engine accessory. Repair the engine accessory and/or replace the engine accessory, if necessary.
ValveTrain Components
Remove the valve mechanism cover. Check the following items for damage: camshaft, valve rotocoil, valve springs, camshaft followers, rocker shaft, bridges and injectors. Thoroughly clean the valve train components. If the camshaft isbeing replaced, also replace the valve lifters. Ensure that all of the valves move freely. Replace any damaged parts.
i02785818
Pistons
Inspect the pistons for damage and wear. Replace any damaged parts.
Crankshaft
Inspect the crankshaft and the related components. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position. Look for worn thrust platesand wear on the crankshaft. Check the counterweight bolts. Replace any damaged parts.
Gear Train
sample
Inspect the condition of the gear train. Replace any damaged parts.
Inspect the flywheel and the flywheel bolts.
Inspect the engine oil filters for nonferrousmaterial. Flaking of nonferrousmaterial could indicate worn gear train bearings.
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Misfires, Runs Rough or Is Unstable
SMCS - 1000-035
Probable Causes
• Poor fuel quality
• Air in fuel
• Lowfuel pressure
• Restriction in the fuel return line
• Fuel leakage from fuel injection line
• Incorrect fuel setting
• Incorrect fuel injection timing
• Incorrect valve setting
• Internal engine problem
Recommended Repairs
Poor Fuel Quality
Updated -02/06/2016
i05358944
Ensure that there is good, clean fuel in the tank. When possible, interview the operator in order to determine if fuel quality is in question. Replace the fuel in the fuel tank with good, clean fuel if necessary. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test".
Air in the Fuel
Check for air in the fuel system. Refer to Testing and Adjusting, "Air In Fuel".
Low Fuel Pressure
Replace the primary fuel filter and the secondary fuel filter. Check the fuel lines for blockage or damage.
Fuel Leakage From Fuel Injection Line
Check the fuel injection lines for leakage. If the fuel injection line nuts are loose, refer to the Disassembly and Assembly Manual tighten to the torque that is specified.
sample
Incorrect Fuel Setting
The fuel setting procedure can be performed with the governor and fuel injection pump on the engine.
Incorrect Fuel Injection Timing
Check Fuel Injection Timing. Refer to SystemsOperation, Testing and Adjusting, "Fuel Injection Timing - Check" for details.
Incorrect Valve Setting
Check valve adjustment.
Internal Engine Problem
Check for signs of damaged valves, damaged cylinder head gasket, etc.
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Speed - Test
SMCS - 1907-038; 1915-038
Specification
For the 303.5E, 304E, 305E, and 305.5E, refer to Testing and Adjusting, "Engine Performance - Test - Engine Speed" in the Hydraulic System manual for the low idle and high idle specifications.
For the 901C, 902C, and 903C, refer to Testing and Adjusting, "Hydrostatic System - Test and Adjust" in the Power Train manual for the low idle and high idle specifications.
Required Tools
Table 1
Required Tools
Engine Preparation
1. Ensure that the engine islevel.
2. Stop the engine.
3. Install a piece of reflective tape on the fan or a pulley on the engine.
i05320708
Test Procedure
1. Start the engine.
2. Increase the hydraulic oil temperature to 55°± 5°C (131° ± 9°F).
3. Read the engine speed display (rpm) on the photo-tachometer. Refer to "Specification"for the specificationsfor engine speed at the desired engine operation.
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Top Speed Is Not Obtained
SMCS - 1915-035
Probable Causes
• Air inlet and exhaust system
• Fuel supply
• Cylinder performance
• Accessory equipment
Recommended Actions
Air Inlet and Exhaust System
1. Check the air filter restriction indicator. Clean plugged air filters or replace plugged air filters Refer to the Operation and Maintenance Manual.
2. Check the air inlet and exhaust system for restrictionsand/or leaks. Refer to Systems Operation/Testing and Adjusting.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel. If the engine hasbeen run out of fuel, it will be necessary to purge the air from the fuel system. Refer to Operation and Maintenance Manual.
i05358949
2. Check the fuel lines for the following problems: restrictions, collapsed lines, pinched linesand loose connections. If problems are found with the fuel lines, repair the lines and/or replace the lines.
3. Check the fuel tank for foreign objects which may block the fuel supply.
4. Check the fuel filters.
5. Ensure that there is clean fuel in the fuel tank. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test". When possible interview the operator in order to determine if the fuel quality is questionable. Try to determine if this is started soon after refueling. Replace the fuel in the fuel tank with good, clean fuel if necessary.
sample
6. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during coldweather operation.
Cylinder Performance
1. Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation/Testing and Adjusting for the procedure.
2. Possible causes of low compression are shown in the following list:
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
3. Perform all necessary repairs. Ensure that the repairs have eliminated the problem.
Accessory Equipment
Check all accessory equipment for problems that may create excessive load on the engine. Repair any damaged components or replace any damaged components.
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jul 14 16:39:09 UTC+0530 2020
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Engine Vibration Is Excessive
SMCS - 1000-035
Probable Causes
• Vibration damper
• Engine supports
• Driven equipment
• Engine misfiring and/or running rough
Recommended Actions
Engine Supports
Inspect the mounts and the brackets while you run the engine through the speed range. Look for mounts and brackets that are loose and/or broken. Tighten all of the mounting bolts. Install new components, if necessary.
Driven Equipment
Check the alignment and the balance of any driven equipment.
Engine Misfiring or Running Rough
Refer to the symptom Troubleshooting, "Engine Misfires, Runs Rough or IsUnstable".
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Exhaust Has Excessive White Smoke
SMCS - 1088-035; 1250-035
Note: Some white smoke may be present during cold start-up conditions when the engine is operating normally. If the white smoke persists, there may be a problem.
Probable Causes
• Starting aids
• Fuel supply
• Cooling system
• Unit injectors
• Component wear Recommended Actions
Starting Aids (If Applicable)
1. If a jacket water heater is installed on your application, check for proper operation of the circuit. Repair the circuit for the jacket water heater, if necessary.
Fuel Supply
i04564264
Contact withhigh pressure fuel may cause fluid penetrationand burn hazards. High pressure fuel spray may cause a fire hazard. Failure to followthese inspection, maintenance and service instructions may cause personal injury or death.
Do not loosen any high pressure fuel lines when the engine is running. The high pressure in the fuel linescan cause personal injury or death. Wait 60 seconds after the engine has stopped to allow pressure to purge before any service or repair is performedon the engine fuel lines.
sample
1. Check the fuel pressure during engine cranking. Check the filtered fuel pressure. If the fuel pressure islow, replace the fuel filters. Refer to SystemsOperation/Testing and Adjusting, "Fuel System Pressure - Test".
2. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during coldweather operation.
Cooling System
Check for an internal coolant leak into a cylinder and/or the exhaust. Refer to Systems Operation/Testing and Adjusting for information on inspecting the cooling system.
Ensure that the temperature readings for the sensor are reasonable for the conditionsthat are present.
Component Wear
1. Check the valve lash and reset the valve lash, if necessary. Refer to Systems Operation/Testing and Adjusting.
2. Possible causes of low compression are shown in the following list:
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jul 14 16:39:39 UTC+0530 2020
C1.7, C1.8, and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -KENR6757-10
Exhaust System Contains Oil
SMCS - 1050-035; 1348-035
Probable Causes
• Worn valve guide seals or faulty valve guide seals
• Worn valve guides
• Worn piston rings
• Scored cylinder liners or worn cylinder liners
Recommended Actions
Worn Valve Guide Seals or Faulty ValveGuide Seals
Inspect the valve guide seals for wear and for damage. Replace the valve guide seals, if necessary.
Worn Valve Guides
Inspect the valve guides for wear. Refer to the Specification manual for the maximum permissible wear of the valve guides. If necessary, recondition the cylinder head.
Worn Piston Rings
Piston ringsthat have excessive wear can cause too much pressure in the crankcase. The additional pressure in the crankcase will cause more than the normal amount of crankcase blowby from the
i04695909
crankcase breather. Refer to Testing and Adjusting, "Compression - Test"for more information. Inspect piston ringsand install new parts, as required.
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
