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    261 views196 pages

    C11 C13 C15 C18 Troubleshooting PDF

    Uploaded by

    Sergio Sebastian Ramirez Gamiño

    Copyright:

    © All Rights Reserved
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    of 196
    CATERPILLAR’ oes ee Troubleshooting ee C11, C13, C15 and C18 Industrial and Petroleum Engines Wuwi-tp engine) Important Safety Information ost accidents that involv prodkt operation, ritenance and repair are cased by fale to absewve bisne salty nies ox precautons An seedon can often be avoided by recognizing potently hazardous histone Eetore on acoder ooaue_A person must be ats poten hazards this person should alo Fave te nacesary raining, sis ar tools fo perform these functions propery Improper operation, lubrication, malntenance or repair of his product can be dangerous and ‘oul result Injury or death Do not operate or perform any lubrication, maintenance c repalr on this product, until you have Pid ane! undrctond the operation eatin maintenance and real information, Safety precautons and waenings are provised inhi manual an onthe product these hazard warnings ‘areal needed, body injury of deat cou ooturTo you ors other persons ‘The hacards ate ientiied by the Safety Ale Symbo" and lowed by a“Signal Word” such as DANGER” IARNING® of CAUTION" The Safty Abt WARNING” label's shown below “Toe meaning of tis safety set symbo sas flows: Aitention! Become Alert! Your Safety is Involved. “The message that appears under the warning explains he hezard and canbe ether writen or ptony resetes ‘Operations thet may cause produc damage are dente by NOTICE” Tabes on he product and in ‘hs pubeaton Caterplar cannot anticipate every possibie creumstancs that might involve a potential hazard Fae arninge In tis pubiction and on the produc aro, eretore, otal ncusve a tool, procedure work method or operating technique tate not specifically recommended by Catrpilar {2 voed, you must saisty yourself hat ls safe for you and for others, You should lao ansure that the product wil not be damaged ot be made unsafe by te operation, lubrication, maintenance or pair procedures that you choose, “The information, specications, and lutions i this pubieaton ae onthe bis of nfrmaton tht ‘wos evalgole 3 ste that he publcaton was wmen. Tre specications, rues, pressures, ressurements, agustente,Hustatens, and other tems cv change at ay te. These changes can {et the serves thats quent the pret Obtain the canolte and most curentinformaton before you Sit ony pb. Caterplar Seles have tho most curren mornatonavalable, ‘When replacement parts aro required for this product Cterilar recommoncs using Caterpl- Far 'replacement parts or parts with equivalent ‘specications including, but nt inmted to ys {eal dimensions, type, strongthand materia. Failuce to heed this warning can lead to prema- {ure failures, product damage, dersonal jury oF seth RENRS042.07 Table of Contents ‘Troubleshooting Section Electronic Troubleshooting om Overview| s oarone Serve es é ‘lecvonc Dapay Modi tiated : Replacing tne ee $ Setoiagnosies 0 Sensor on iectiai Cannas * Engine Wing Inraton ‘4 Programming Parameters Programming Parameters 18 Customer Passwords ie Factory Basaworss 8 Feary Password ioriahast i Fash Programming % Injector Tam Fe ie Serve Infomation Repo 8 System Contiguration Paramore System Contiguraton Params 20 ‘Troubleshooting without a Diagnostic Code ‘Momatar(harang Proie), » Bator 3 an nec Top Engine RP 38 Esoiotin Eras Ot 2 eel Temperature eT High 3s Eh Wa Not Accept Factory Passwords 28 ECM Wa Not Conmunsate win Ober Sais or Diply Mecsas ‘a Elegtonlc Seven Téa Wi Not Communi wit one 9 Engi Cron bt Wi Not Sat FA Engine Has Cay Wear 2 Engine tres, Runs Rough aris Ustbie 33 Engine Ob n Cooing Sysiem x Engine Os Temperate oo High au Ene Salsa tow RPM ss Engine Vixaton ss Eng Wi Not Crank x Excessive lack Se » Exeessve Engine 01 Conon 33 Excessive Fuel Conaunpion 3% Excessive Vale Las 2 Excessive White Soke 3% Eitavst Temperature Is Too High 2 Fuctn Cocing System a Fuel Ouaion at ain Oi 4 Intrniten Engine Shadow 2 Intrmitert Low Power 0 Power Cutt 3 Low Ere Oi Pear “ Icorarieal Nae (knoe th Engine & Noise Coming from Grinder a Poor hcsnraton or ess a Wave Rotator or Spring Lek Free % a ‘able of Contes Troubleshooting with a Diagnostic Code Fisen Coase 50 Dsgrote Codes 50 Diapreste Cave Clos Reteonce 5 {iD COOT Fie os Cyinder #7 Iyecor agen rest. st iD aa Fil 0 Gye injector short Sk {Gio coa2 Ful 5 Cyiinder #2 Injector ope rea. 55 Gv cbad io Gyn injector har BB {Go Goas Fil 05 Cytinser #3 Injector open ewe s lo cobs Fil 08 Gnd 3 injector show 88 {ib 0204 FM 08 Cyénder Injector open ‘eu s ib doo Fi 08 Gyinder injector shor 86 {io 0205 FM 05 Cyinar 8 Injector open ‘reat 56 ib a3 Fl 08 Gyn BS njecor Shon 87 {ib 0708 FM 05 Cyinder 8 Injecor open feu. st ib 036 Fi 06 Gyinder #6 injector short ST Gib os41 FAM|OSB voLDG Supply shoo ail 87 {iD toe} Fos 8 vet DC Supy shor to ground 59 Gi (094 Fi 68 Tote Postion signal ‘abner 58 ib 009" Fi 13 Thre Boston calibration requred ip 0304 Fil 03 Fe Pressure openishart to bat 58 ib Oni i Ga Eva Pressire shot ie ground 58 {ip 0100 Ft 63 Engine Oi Pressure openshot “tat Ey CID D100 i Od Engine Oi Pressure shot ‘ground ib 0100 Fi 1d Engin Of Pressure Sensor ‘boom rate of ange 6 CIO cae FMI 03 Boos! Pressure Sensor sheet fo “al 80 (iD ot Fi aes! Presse Sensor hod fo growed eo Gib 0102 Fi 16 csi Pressre Sensor abnormal rate of change 3 ib oit0 Fil 08 Engine Csoiant Temperate ‘apen'shor to seat ot (ib orto ra ca Engin Cacia’ Temperate short ib gound 3 (lo 0168 Fit co yom Vlage High 8 (ib 0-68 FI OF ystom Vtage Low 6 (iO 0168 Fin C2 System Votage intimin rat 6 ib 072 Fi 8 ik stir Tem openishor ‘oot 33 ib 077 Fi fink Hianod Air Yam shod to goure 6 Cibo Fi 63 FT opin Yo “tee 83 ib oii Fil 0 Fi Temperate sr fo ground 83 HD o180 Fil 08 Engine Speed signal normal” 6 (CD 0:58 FM G2 Personally Module mismatch 8 4 Table of Contents (10 0261 Fat 13 Engine Timing Caltration requred 05 ip 0262 Fi 035 von Sensor OC Pawar Suply hort to bat 5 ib tesa Pil Ga Vo Sensor OC Power py shore rouna 65 ip 128 Ft 02 Check Brogammabia Parameters 6s C10 GZ74 Fa G3 Aimosphene Passe cpio” ib 0274 Fla map Bessie shor to ‘gourd GD oe Fil 68 Una to communicate wits “Transmssion ECM 66 ‘cip 032 Ful 08 Secondary Engin Speed tana, ‘abnormal 7 tO 07a Fil 8 CampreSion Brake Lonihigh Solero ouvert aw (lO 076 FA 08 Camprcsicn Brake Lomiigh Selene eurent hgh or clo 6792 Fas 05 Compression Brake Weta Solenea carent wr clo 6792 Fat 08 Compression Brake itor “Solenoid current hgh 10 789 Eo nak and Prssie Sensor ‘votage ng 8 Clb 178s Fi nis Maris Pressure Sensor ‘otage ow 8 CD ‘T785 FUi 30 intake Hani Pressure Signal ‘abner ate of change, 0 ib 835 Fu 03 Antiay Prosire Sensor opeaishon to batt 60 iD TH Ful 0€ Auniiary Pressure Gansor shot ‘rund 50 ib 1836 Fi 3 Auiiany Temperature Sensor ‘penshor ta tat 70 Cb Ta Fu Of Auli Temperature Sensor shart ‘0 oround 0 ib 2417 Fil G8 ita injection Conta! Solas ‘curentiow 70 iD 2417 Fu 0 Ete injection Convo! Solancis ‘ent igh 70 ‘Troubleshooting with an Event Code Event Codes R E008 igh Fue Pressure % Efa¢ High Exhaust Tempore % £360 Low Engine Ol Pressure n E361 Nigh Engine Coolant Tena ” 362 Engr Overspeed 7% 363 High Fue! Supa Temperature Fa 443 Hgh Ausliay Pressure % 5 Han Aur) Temperate % £599 HghInfake Manas Ar Terpaciure 8D E2143 Low Engine Contant Lave! cy Diagnostic Functional Tests ENolt Engine Pressure Sensor Supply Creut- “est ® ‘Ar Shuto Sytem “Test % CAN Data Link Crt Test 93 RENRS042.07 (st Lats Link Grout Test. 102 (oont Level Seneor Crout- Tet 104 Compression Brake Solonod Grout Test. 108 Diagrst Lamp Creu Test nr Dig! Sensor Soply Creut- Tet m1 EGulPerconaly Modu Test, 5 Eoetical Connectors «Inspect wm Etectcal Power Suppy Grout Test 82 Engine Pressure Sensor Opan ot Shot Gicll iar 136 Engine Spcedining Sensor Gut Test. 142 Engine Temperature Sensor Open or Short cut Tost ar Etvrinjecion Sytem eat tsa Inyecor Scena Creu est 189 Mantnance Due Lam Creu Tot 187 PO Swen Grout Test, 70 Sires Create Test 18 “Thvote Poston Sensor Cit Test 19 lang Lamp Creu Tet 183 Ccalivation Procedures Engre Speea/Tming Sensor alba... 188 ‘Thvate Potion Santer Calibrate 1 Index Section Index 194 RENR5042.07 Troubleshooting Section Electronic Troubleshooting System Overview ‘SMCS Code: 1000 ‘System Operation ‘This engine i electronically conrad Each eyindor has an elecrone unt inecor The Eecrane Cona Module (ECM) sends a sgral lo each njecer foenoid order to conto the operabon ofthe fel injection system, Electronic Controls The etecronic system consists of the flowing components: the ECh), the Mechanicaty Actusted Etetronicaty Cenraled Unt injector (MEU!) the wining hamess the saiches, andthe eonsore: The EEcitis the computr The fash les the sofware forthe computer The fash fle conta the operating ‘maps Th apetaing maps define the flaw Characcnistes ofthe engine + Horsepower + Torque curves ‘The ECM determines the ting andthe amount of ‘ual hate deivored tote jinders, These decsions fe based on the acl conan anaie onthe Sesred conaitona at any given te, ‘The ECM compares the desied engine speed 1 the actual engine speed. Th act’ ange speed IS'eterminea trcugh a signal fom the engine Speeding sansar The desies engine speeds ‘determined wit te aloweg factors + Thottosignat + Otter input signs fom sensors + Censinciagnoste codes the desired enging speed greater han the actual engine speed, the ECM ects more fel order to Inafeace the actual engine speed 5 “Troubleshooting Secton Cold Mode ‘The EOM lms engine power dung cold mode perzion and tne ECM modes mecton tng Ahn etd mode operation Cold made operation Proves he folowing banat, + Inceased cold weather starting capabity + Reduced warmap time + Reduced white smoke Cold node is activated whenever the engine temperature fas below a pedsiemined valve. Cold mode remains active unt the engune temperature Foes above a predetermined value or url abe Tmt s exceeded Fuol injection “The ECM contol the amount of fuel tat is ijectad by vanyng te signals tothe nestor, The nestor wil Bump felony the injector olen is energized ‘The EOM sends ang votge signal fo the steno ‘This i vaage slgal energizes the slonad y canting the tring ana the duration of te gh ‘oage signal, the ECM ean contol njocion tng sande engine RPM ‘The sh lense the ECM ses eran nts on the aroun of fue that can be nested The FAC Foe! Limi i used to contol hea! rat for corel of emissions. The "FRC Fue int iat ‘Bate based onthe turboenarger out pressure ‘Aigher turbocharger outet pressure ndatos that ‘here's more atin he cyinder When the ECM Senses a higher tuibocnargor cute prossure, the ECM nareasostne“FRC Fuel mt “When the €OM ineeases the “FRE: Fuol mt’, the ECM allows ‘ore elmo the eying The “FRC Fost Lim ‘ogranmed into the ECN athe fociry The "FRC Fol Lin” cannol be changes ‘Tho "atos Ful Lit 9 Stthat is based on the ower rang ofthe engine and on engine rem. The ‘Rates Fool Lt ssi to the rack stop ano the logue sprng ona mechansaly govemedengine, ‘he "ated Ful Limit proviss the power curves and fe torque cures fora speci engine army and fora spetic engine rating The Rates Foal Lint Dyogremmod ine the ECM athe factory. The Rates Fuel Lit cannot be cnenged 6 Troubleshooting Section (Once te ECM determines the amount of fe that 's requed, the ECM must tere te rng Otte fel injecton. The ECM caleulates tne op ant poslton af each ojinder ram ihe engi Speediimng sensors egal The ECM cece when Fal njecton shou ocr relate tothe top ctor postion and the ECM provides the signal fo the Injector tthe Gesited bine The FCN adusts ining ‘Sopra engine pertmance fr pu a Programmable Parameters Ccentain parameters tat fect he engine operation ‘may be changed with CeterpaarElecrone ‘echncian (ET). The parameters ae sored in the ECM, and tome parameters ae protected from unauthoized changes by passworss These passwords ae cod for pacewords Passwords ‘Several eystam configuaton parameters and most legged events ae protacted by factory passworss Factory pasewords are avalae ony to Caterer dealers Refer to Teubeshooing “Facto, Pesswords for additonal infomation. Electronic Service Tools ‘SMS Code: 0795, CCoterilar electronic serie tools ara designed to help the service technician perfor te follwing tosxe + Infomation access + System dgnostes + System caitrations + systom configurations + Data ink communiatons Required Service Tools “Tho tal that are lated in Tabo 1 ae equred in ofder te enable a erie ectman operon Me {est procesures tht ar found ns mans! RENR5042.07 aT] )) ea, Description “WA | dm Alen Wench) a-2197_| ttn E1655 cates 148-4000 | Dg Hunt Gp) TEITO [Hine Pee "D.e070_| Adee Cable PR BREAKOUT) 204-0050 | Apter Cable As PIN BREAKOUT) 257-8710 | Ade Cate A 2-PN BREAKOUT) 167-8225_| Hames (SERVICE TOOL ADAPTER) 10-5804 _|crinp Tet (12rAWG TO 18-AWG) 175-3700_| ComestorRepa KI OEUTSCH GT) “wo short jumper wires ae needed to check he contruty of somo wring hamess ecu by shoring {wo adjacent terminals togeter na connector A long extension vie may also be needed i check the ‘contruty of some wring hamess eects, Optional Service Tools Table? ts the optonal service tol that may be weded during eebng repo Engine Prwere Gv imp To ea 1 AG Baty Lon eo 08 | Tapert Ade ORLTMETER) | [er e810 | comecrTos Gr [6176 | Acc Coren Pee 26-0010”| Mato Gp Sounome bravia pee “ov-n1908 RENR5042.07 Caterpillar Electronic Technician (ET) (Cat ET can dspay th folowing intrmaton: + Parameters + Event coves. + Dlagnoste codes + Engine coniguration (at ET can be used by the tachi to perorm the fotowng functions + Diagnose tsts + Caltratons + Fash programming + Configuration ofthe Electron Cont Module ew) “Table 3 ts he sofware tal sequen oor to use Gat ET Alay use te atest version of Cat £T that avalabe “fe Rann eT a a Number JERDRTZE | Sng user kane or Cat ET senoara | Dag aetna eres ad Note: For mara information regarding the use ot CCatET and the PC raqurements for Gal ET reer to ‘he documents tat sccompanies your Gat EF soit, Connecting Cat ET Connecting with the Communication Adaptor “abl sts the standard hardware hat required in oer to connect Cat ET, 7 ‘Troubleshooting Section "Star Hardware ra Une of Ga T Part Member | Oeseion Na Prenat Conger) Carmien Ager arse | SeUsrer eat ar. 7e [nr caine] Pleat ate zas-soosn | (Sue ATON sooreg” (3 Peace) (3) fe 00 npr ate {028 sos Priel a Cai COMMUMCATION ADAPTER) (G)aor-enas Atporcabe xe ‘Note: tems 3) (5) and) ae par ofthe 275-5120 Commumeaton Adeoet Sp Use th flowing procedure ode o connect Cat ETand he Communeaton Asap 1. Remove he electrical power fom the ECM. 2. Connect communicatons adape (5) toa ‘sonmunicatons port onthe PC by tng one of the folowing methods: 8 Troubleshooting Secon : Connect cable (4 between the “COMPUTER tna commences adap (ad te Baal port of PC (1) Be sure to contre [Sat Er fore paral por. This confgaration proves ine fstet connecton 'b. Gomect cable (3) Setucen the COMPUTER” ‘Sed of communication spta (5) ana the 5232 serial por of PC (1), &- Connect cables (2) and 3) between the COMPUTER’ end of eomuniaton adopter (6) and to USB por of PC (1), ‘Connect cable (6) communication adarer (5). 4. Connect cable (6) oa service tol connector ‘erty at the “POWER” incicator onthe ‘communication adapters turin, 6. Establish conenunication between Gat ET andthe Ech 7. Cet ET and tne communication adaptor Ge nat communate wrth the ECM, eer {eubleshoobng wihout a Sagrostic code ‘Treubleshcing “Eason Serves Teo Wl Not Communicate win CM ‘Communicating withthe Wireless Communication Adapts “Table 5 sts the optical hardware that ie needed in order to eannse: Cat ET by using wireless ‘omecton. Crs io re a oT Partnumber | overoton a Persona Compt) — RENR5042.07 {Pan moe (2) Rarer Cee ‘Not: ems (7) (8) and (9) ae prt ofthe 261-8363 ‘reise Communcaton Adopter Gp Use te folowing procedure in oder to connect he wires communicaton adapter for use wah Gat ET 4. Remove th eloctcal ower om the ECM, Ensure thatthe computer has been carecy oigured for the 201-4867 Card (PCM), Veit at te PC card is installed ine onputrs PO expansion sit Connect cable (8) between communication rato (Ghana the sence tol connector 4. Restore ne electrical power tothe ECM. Cat ET {Sethe cornmunicaton rao do ol commoneats lin the ECM oer Youbiesnootng wrhout ‘idagnostc code Trobieshovtng,“elacrone ‘Seviee Too Wi NOt Comments with ECM Electronic Display Module (If Equipped) cs code: 7480 [An slectrenic splay module may be sed to ‘pir CID-Fl information rom the settle {ont gystam Refer tothe sence mana for your loco play module tor more oration RENRS042.07 Replacing the ECM ‘SMCS Code: 1901-510, NOTICE Care mustbe taken to ensure hat lds re contained sdrng performance of nspecton,matenance, test tig adjusting undp tthe prose Se prepa TS ‘ic the fd wih eutabie containers belore ope ing any compartment or osassemtling any Sompo- ont canta fais Refer to Special Pubeaton, NENG2S00,“Cateplar Dealer Sehvce Tea! Cataiog Yor fois snd supplies Stable to calect and contain fide on Catepor products Dispose of a fuds according to local regulations and mandate, NOTICE Koop at parts clean fom contaminant, Contaminants may cause rapid wear and shortened component ‘ne Electronic Conrl Module (ECM) contains no moving pare. Repacement of te ECM can be {osty Roplacerent can also be atime consuming {ask Use tose procedures to entre that ne SM '5 the causo of te prodion ‘Note: Ensure thatthe ECM ie receiving power and that he ECM is propery wed the negative battery ‘eu before you step! to replace he ECM Refer, to he diagnose funcional text Troubleshooting, "Rrcetieal Powe Suppiy Creu Test Some eppticaon software supports the use ofa new CHI aba lst ECM A naw ECM can be temporary placed into a "Test ECM Mode” Tha ECM car {nen be used to replace 2 suspect ECM n order {O detormne fhe msspect ECM i faulty Rete fo ‘opramming parameters Teublesnoctng “Test, Ch Mode = NOTICE tetas tle and engine appeaton ae nt matched ingine damage nay ess Perform the following procedure In order to replace the EM ° ‘Troubleshooting Section 1. Prnt he parameters trom the ‘Canfgurtion' 2en on Catrall SoutroneTechnizan {Etta printer unavalabe record al of the Parameters. Record any logged slagneste codes lant nage event codes for jour rors Record ite injector sera numbers fom the ‘Catbratons" soon under the Servee" mend on Cat ET "Note: The injector serial numbers are necessary for ‘Sbtaning te coreat ject tim fies, The EER Uses fe njctr tm les order to compensa or tmanufacturng varatons betwoen ndviual jection, Ityourepiaoe any ofthe unt nectors you must Feproyram the joo im fies forthe now njectors ‘Abo, you replace the ECM, the jer tm fee mast 9g stale so the new ECM A soonest “Copy Goniguraton’ process wl ccompisn this task “or more Insbuston, ert programming Parameters Toublesocng “Injector Tim Fe" 2, Use the Copy ConfiguratonEC Replacement {etre tat found under the “Service” ren on Ga ET Select "Lond rom EM nord copy ‘he coniguraion from he suspect £oM "Not: the ‘Copy Configuration” process fas ena the patametere enero notobtamed n Sep tthe arametors mast be abled elsewhere, Some Parameters are stamped on te engine information Plate, eu most parameters mut be obtained fron bre vaso, 3. Remove the ECM rom the engine a. Remove the electical power fom the ECM. ‘i. Disconnect the JPY and J2IP2 ECM onnectors NOTICE Use a suitable contain fe eat any fel tat might i lean up any sped fel immediately NOTICE Do no: aiow cto entr te ful system. Thoroughly ‘lean he area around a fuel sytem component tat \illoe disconnected Fi a sutabie cover ver ascon- acted ul system component ©. Remove the felines (f equipped) rom the cM. 4, Remove the mounting bots fom the ECM, ©. Disconnect the ECM ground strap fam the rane 4, Intl th replacement ECM, 10 Troubleshooting Section 1 ne off mounting harswae isn good ropa, you-can use he ae mouringharoware 16 Insta the reptacoment CM, b. Reconnect ne felines equipped) ©. Ensure thatthe EOM meurtng narawar stalled comet The fal ines mut ot put \ibraton. The ECM most be able tah tha rubber grommets the ECM cannot be moved sagy nthe grommets oneck tht tne fal nes salped rot ung he ECM pamet eno se othe grommets 4. Connect the ECM ground sap, {6 Gonect ne J1P1 and J2/P2 ECM connectors. “Tighten tne allen head sere on ach othe GM connectors othe proper torque eter 0 {he dlagnoste funcbona test ovblesnoctng. "ocieal Gannetors Inspect fore cars torque value. 5. Program the fash fe into the ECM. Retr to programming parameters Traveshootg, Flash Programm) 6. Ifthe replacement ECM was used previously for 2 aferent appeston, use Gat ET fo match he engine spplation andthe fash fe 7. Contigue he ECM 1. Ithe “Load from ECM process rom Step 2 was successful rtun fe the "Copy Confgurationie Ch Replacement” seen on (Cat Et and soloct“Pregram ECM Altorusng the “Program ECM feat, be sure ‘Bele he power to the ECM, Wnt at est ‘s.geconds ate: turing the keyawe ote (OFF postion Note: Some contol modules have a power off day, ‘The 15 saconde willbe suicent fo cover tha delay, 2 tne "Program ECM" process was sucess, proceed to Step 8 1.1 the “Program ECM” process wae Unsvecessfu, manual program te ECM Pararmetar nto the replacement ECM. The Barameters must match the parameters from Bip RENR5042.07 Note: If the “Copy Coniguaion” press fais ang the pramoters were not ablased 9 Step he Parameters must bs ablaned sewers’ Some Parameters ae stamped on the engine information Plate but most pararsters must be obtaned from fre cory, 4. tf necessary program the enge monitoring sper 8. Program the injctor tim fles. Refer to praramming parameters Troubleshooting, inecor Tm Fl 8 Ceck for an ative dagnostic cade fr tng calbraten Ire agnostic code active, caltrate the inzion ting Rel arlen proces ‘Treulechoatna, “Engine Speed Ting Sensor Carat 10.ceck or lagnoste codes and for event codes, Self-Diagnostics SMCS Code: 1001 ‘The Electronic Contol Module (ECM) ha he aby {oldest priors wih ne eestone system and, unt engie operaban When a prosiem ts detected, 9 {ode s generated An alarm may alo be generated ‘Thereate two types of codes + Diagnose + Event Diagrostle Code — When a problem wih the ‘loctoni system is detcted, te ECM ganas 2 ‘Tagnoste ode This ineates te spac pobiem ‘wih be eeu Diagnostic codes can have two dierent states + Aetve + Logged Active Code An acive diagnostic code indates that an active Doblem has boon detected Ave codes require Irnmedate stanton Always tence ste cages bore senrer bggea ses. Logged Code RENRS0«2.07 Every generated codes stored inte permanent memoty ofthe ECM. Th codes are logged, Logged codes may ntinaicate hat a repair is ‘needed. The problem may nave een erporay The ‘roblem may have been resaved since th ogging the code If te sytor is powered, tis posable {o generate an actve clagnes cods whenever a Component is dlecomectea, When the sonnet is ‘cornu te cou fe no onger ace ‘odes may be Usk to help oublhoetieretent problems. Logged codes can ato be used 1 evn the perlomance of te engine and ofthe eacronie stor Event Code ‘An event code is generated bythe detacton ofan ‘borat eng aperatingconditon. For example, ‘an event cose willbe gonerstes ihe of pressure {Wo ow In ts case, the even cove mata the ‘symptom ofa preiem Sensors and Electrical Connectors ‘Ses Code: 1900-NS; 7553-¥¥) 4" “Troubleshooting Secton 2 RENRSO42.07 ‘Troubleshooting Section RENR5042.07 a ‘Troubieshoctng Seaton C11 and C13 Engines 7 LEFT SIDE VIEW 4 RENR50«2.07 ‘Troubleshooting Scion C15 and C18 Engines FRONT VIEW (9) Ena coe tempera sere geemaeecer. scene, jaa ieee. Engine Wiring Information ee ae Tuc car“ [Soreoa] oar [ae fm fea ‘The wiring schematics are revised periodically. aR Brown | BU Bue asing cise cae ieee, [9 —_Jemn fou oe ‘made to the machine hamess. For the most current oo Rea__Jeu_ —— Son fearoestieeaas nents [og — |g [are ‘schematic, Use the schematic with the latest revision ae Creve _|GY_1G__ number. aia eee Harness Wire Identieation ————— tng se ea oA ne cuwpon entertainer nazcoon ia gue dettn et A nt fecerintreteentdecasese, Seaereyaeuaeremee cs (sovacierasetiecieccnetetee Graig caret ee ‘eatin wie encaton on he schematic he re eer, We sl or gauges Yeferred to as AN (Gumetca Wo Gauge) AVNG iss desertion ofthe lamar ofthe wire RENRS042.07 For example a code of 150.0R-14 on he shame woul neal that he orange wee mn cre 160 8 8 SANG wie Ine gauge ofthe wie notte, the wires 16 AWG. Conversion of AWG Numbers to Met Measurements Table 7 shows the various ANG numbers that ara Used fr te wres.‘Ths mate equator or fhe ‘ameter ofeach AWG sumer ae iso shown, Welding on a Machine that is Equipped with an Electronic Control Module Proper welding procedures are necessary inorder to.avid damage fore engines sloarone cor! Module, sensor, and assouated components. The Component that roqures walang should be removed. ‘When welding ona machine hts equipped wth an ECM and removal of te empenent st posse, {he folowing proceduo rust oe alowed. The Brocedure poes the mnimum amount ok {he elecrontc components NOTICE 1p not ground the welder to electrical comgonents suchas the ECM or sensors. Improper grounding oat ‘ause damage to he sive tan beanngs, hyarule ‘Someones, secricl components. and ther con ponenss ‘Gamp the ground cable for he welder tothe com ponent that willbe welded. Pace the lamp 28 Soae ‘sos othe weld. Ths vl help rede the pos ‘Shey of damage, 1. Stop te engine. Tum the keyeitoh othe OFF potion. 2. Disconnect the negative atery cable fom tne Datery tra batory asconnect Sth is ete, 6 “Troublesrootng Seton ) Expoctod Resut: “The resistances beeen 57 ana 63 Ohms. Resuts: Proceed fo Test Step 6 + NotOK ~ Tho resistance I between 114 Ohms ‘and 128 Ohms. A terminaing estos mig RENR5042.07 Repair: Verity that two terminating elses exist ‘ne data ink One restr must be oeated on ‘ch end afte data ine. the optona’nemess ‘Stdored wi the engine, the angie m hipped vith ne terminating rear that nealed between ‘ie ECM and tha customer connector Foor othe sppropit electrical schema in ‘er fe detomine te missing resinr Repice the maseng reise Ven that te pobre resolves, stop. + Not OK ~The resistance is es than 57 Ohms Proceed a Test Step + Not OK — The resistance is greater than 126 ‘Ons, Precood to Tost Sep Test Step 4. Check for a Short Circuit [A Disconnect he J/P1 ECM connector 5. Remove he eminating rx tom he CAN uta 11038 depay i instal, esconnedt he ‘ieply . Measure the resistance between the pols hat af itoain Table 12. Be ure to wggl ne wires Inthe hamesses as you make each feetance Reltnce Mebsrn Trhe CAN Data ink Connector and Femina | Pi(em ens) | Aeon [Era pound I-34 (CR0 dank) | Aa ne terial on Expected Result Each check ofthe resistance indestes an open Resute: + OK ~ Each enact nf ha rastance indestes an ‘pen cru Proceed to Test Stap 8 + Not OK ~ At least one check ofthe esstance es not ideate an pen cut There ie short ‘rout in atharness. Tere may be protiem with 101 “Troubeshooting Secton Real: Repair he wing ander th connect Replace pt neces vant problem stor, Test Step 5. Check for an Open |. Verify that ofthe connections an aarnnnactn uit . Fabricate a umper wwe, Use te jumper wire in bere eats shor exeut betveen terminals G fant Fonte series tol connector, Measure the resistance betwoen terminals PY-50 (CAN Gatatines) and P38 (CAN data bk). 1. Remove the jumper ws rom the sence tol connector Expected Result: ‘The resistance i las han tan Ons Resute: + Ok ~The resistance sess than en Ons, There Isat an open ercut Procecd to Tet Stop 6 + NotOX ~ The resistances more than ten Obs ‘The san open creut or excessive resistance in thecreuit There may bea preemie connector Reflee pa ncaneay Vr ae bin ‘Steeoved stor Test Step 6. Check the J1939 Display A. Comet theJ1859 ely to nother eng Oporto the engine an montor the 11999. Expected Resut: The 1809 sly operates propeny Reus: + OK = The 11980 splay operates property on snoher engine Repair: Connect tho pay to he orignal engine Ith display operates crac, there may bs Trotbieshooting,Elocical Connectors Inspect: I the display does not eparatecorecty onthe ‘ignal engine thera may be a prolem wih he ean 02 ‘Troubleshocteg Secton Ie unikaly tat tho ECM has faed. Perform Mis entre procedure again Replace the ECM it Ie dpay doesnot operate corey. Refer to Troubleshooting, Repacing he ECM stor. + Not OK ~The 41939 spay doesnot operate propery on andthe eine Repair: Replace tho J1880 spay Verty thatthe problem resolves sop Cat Data Link Circuit - Test ‘SMCS Code: 1901-038 ‘system Operation Description: Note: This procedure checks fran open cet Orfor a short creat nth Cat Data Link Il you fare experencrg problms wih communications Between te Catrpar Heston Tachneian (ET) and the Electronic Contel Module (ECW, er {@ Troubleshooting, “Elesronc Seve Teo) Wl Not Commureate wih ECM" beore you Use this preceaure ‘The Cat Data Link's he standard data Ink nat |S used by ne ECM to conmuncat with Cat ET ‘The ECM communicates wih Cat ET'm cero share stat normeton and dagnoste fomation. {Cat ET can also be used fo contgure tha £OM paremters. This formation wil not be aval Eommunicaton fas between the ECM and Cat ET pe peBelgfen orate comune |] - RENRS0«2.07 ‘Test Step 4. Inspect the Electrical wectors and the Wiring Conn ror icaonne) (note1 eM eomaaee (2B enone cnc 1. Inraughiynapect connectors (1. (2, and (2) Refer to Troubleshooting ‘Beeea Connectors Inspec revmsozo7 ) ECM SIDE aoooss Roose lao 3333 moose 3e8880 2888 SRasenpemi mee 7) (pcan + (ers ee Saati? 103 ‘Troubleshooting Secton 4J61 TERMINAL SIDE ae t Ofoocooy soo088 Goo000 #00000 290004 P61 TERMINAL SIDE (Cota ink hee ae t= (©. Potorm a 45 N (101) pul tet on ‘estat are associated wth a Cat . Check the alen head screw on each ECN ‘omector forthe prope torque Also, check the ‘ten eas screw onthe customer ssonscor {ore proper oraue. Rete to Toubleshoctng, ‘Bictrel Connectors Inspect for he cores, toreve values Expected Result: ‘Allcomecos, pins, and seckes re completely inserted and coupled The harness Sd wing are {fee ofeaosion, of abrasion, and of pach ports ooutt: + OK = The hamoss and he connectors appear to be CK: Prooeod io Tost Step 2 + Not OK = The connoctarsanaor te wing are not OK 408 ‘Troubleshectng Section Repair: Repai the connectors andr tho wiring FRepace parts necessary Ensure Data fe seas are property in lace and ensure tal ne Eonnectrs are completly coupled Very thatthe ‘ginal problem sresoved stop ‘Test Step 2. Check for a Short Circuit [A Disconnect he Pt connector. 1. Disconnect at ET tom te serves oo connector {C Measure ine relstance between the pont hat ‘pe ined Tale fo. Be sure to wag the wires inne hamesses os you make each fealstance Resistance Measoromants forthe Cat Osta Link {Connector and “Terminal "rma P19 GxtOmmLnk | Aka e emia PI (GatOataUnk-) | tet he oer imal on ‘rou ts Expected Result Each check of tne raistancsincatas an open rot Results: + OK = Each check of the resetanceinostes on pen ceut Prose to Test Step 3 + Not OK ~ A eat one check ofthe reitance ees no neate an open ercutt There ea short ‘reat nthe hamess orn a connector Repair: Repair the connectors andr th wing Fepiace parts necessary Very tate orginal problem fe resolves stor, Tost Step 3. Check for an Open Circuit ‘A. Fabrica a jumper wie, Use the jumper wir in {58-0 (Cat ata Link») and J8S (Cat Data Link a RENRS042.07 B. Measure the esstance between P18 (Cat Data Ure and Pt (at Osta Link) Expected Result: Each check ofthe resistance i ss than ten Ohms, Results + Ok = Each cnack of th resistance is less than te Orme Repair: Pertorm the folowing procedure: 4. Connect the JP connectors. Connect Cat ET tothe seria tol connector ‘check the Cat Data Link fr proper operation. the Dal Link des not operate creed, thre nay bea robem wih Me ECM Temporary installa now ECM, Check the Cat Data ink again the new ECM solves the problem, ial ine original ECM and vert that fhe ocgral robo tus. the new ECM ‘operate correc andthe orignal ECM does Tot operate coecty repace te orginal ECM, ‘erty tat the probe is resolved sT0P + Nat OK ~ Atleast one check fhe esstance is (geste than tan Obs, Thee isan open eet or ‘Seesaverastanes in he hamass. There may be ‘Srobim wits comecter Repair: Reparthe winng andor he connectors. Replace parts, necossary. Vey thatthe ginal Probie osahe stor, Coolant Level Sensor Circuit - Test ‘SMCS Code: 5574.098-CUT ‘systom Operation Description: Use his procedure to troubleshoot any suspect ‘robe wih the engine coolant level sensor “The engine coolant eve sensor provides a means of ‘Te operator inte even athe soln evel sow. ‘Theengine colant evel sensor's usualy feated tne to tan of erase The sensor shousbe Immersed in colt at a ies RENRS042.07 When the sensor's messed in coolant, an internal sch ie closed When the mtral switch closes {he sana fr th engine colant vel is grounded {trough the sansr return The Eectone Con! Module (ECM) aetcts tne ground onthe np rhe engine cooint evel the slg snot present, sn ‘Sven code is generated Vent that the coolant eve hs been roorammed {o'Enabied” onthe configuration screen onthe Caterer Elecvone Tecioan (7) ithe cooiant level sna programmed. Cat ET wil dpley *Unavalani forthe parameter comaseuenn el « Sees ‘Test Stop 1. Check the Coolant Level Pressurized System: Hot coolant can cause ser- ‘us burns. To open the cooling system filer e=p, ‘Stop the engine and wai ntl the cooling systert ‘Components are cool Loosen the cooling system ‘ressure cap slowly in order to rllve the pres: | Stop he engine Aw the engine e600 B. Chock the coolant evel. Refer to the engine's Operator ane artosarc ar tbe roar Expected Result: ‘The coolant evel low Results: + OK ~The coolant vel ow 105 “Towiesosing Sector Repair: Ada coolant according tothe procedure in the Opetaton and Maintenance Manoa! oentiy the source ofthe cootnt akan x the problem Very thatthe ogra preter resolved Army be tapped inthe oooing sytem Purge any 8° tate trapped he cooing system, stor + NotOX — the coolant it at the proper evel Prose to Tet Step 2, Test Stop 2. Inspect the Electrical Connectors and the Wiring ‘A Tum the keyawich to he OFF postin, 108 routieshooting Section RENRS042.07 ECM SIDE 00000000@@000 00000 00000 bare 000% sooo 0002 (o) C0008 lwoa00 WOO000- > 000@0~ (0233929899300 | (06sec (meas Rew veo! pes wth eran coset ean 3. Torus spect connec (122) inspect ecto for Ue engitecostant evel senor fete TorToubosheoing,"Eecveal Connector Tere tal amas (Pr eon ta RENRS042.07 "foooo rpocce O 0000 Heooo} i \ 61 TERMINAL SIDE Goce oo]D[ooooel| BeeSeelgleacoch GooooolMsooocs Boo08) [oocoss P61 TERMINAL SIDE (1806 sesor gy es (38 Eoae ct . Performa 46 N (101) pullteston each ofthe wires Inthe ECM connector the eastomer connector ang tho sensor connect that fe sociated wih ‘te creuitor the engine coolant evel sensor. '. Check ho allen head serew on each ECM onmectr fo the proper torque. Refer fo “Troubleshooting, "Elecbcsl Connectors Inepec™ forthe covect eque vales . Check the aon head screw on the customer connector for the proper torque. Refer fo Troubleshootrg,‘Bletrcal Connectors = Inspec” forthe correct que value Expected Result A connects, pins, and sockets ae completely Coupled and’ eete. and the harness nd wing fr fee of coosin, of abrasion, and of pinch pon Results: + OK — The connectors and wing a OK Precged to Tes Step + Not OK — Thee ea proble wit the connectors ‘slo the wang 07 “Troubleshooting Secton Royale: Repar he wing anaor the connectors Replace pars, necessary Ensue that a of Teseae are propery contests. Very thatthe ‘otal problem rested, stor, ‘Test Step 3. Short the Harness and Monitor the Status of the "Coolant Level” |. Cennost Cat ET to the serie 001 connector Fete fo Troubleshooting, "Bcctrone Seviee ‘eae 'B. Dconnect the J800/P800 connectors forthe fngine Sola eve senser ©. tal a jumper wire between P&CO- (Dil Sersor feturn) and P8G0-c (Coolant Level Sensor, . Tum the keys to the ON poston . Mantor te status of Coolant Lovl'on Gat ET Uhl the jarper wie sistas F. Tus the keytch to the OFF postion 6. Renove the jumper wire H. Connect the J800!P500 connectors Expectod Result: “The shtus of tho “Coolant Lever ig “OKC when the Jumper wire iste Results: + OK ~ The status ofthe "Coolant Lever g“OK* wher te ump vires stall, Te ECM, the ‘Sora wire. ane the rtom wie are OK Proceed forest Step + NoLOK - The status of the ‘Coolant Love's ot “OKC when the jumger wis nstated Proceed to Tee Step Tost Step 4, Check the Supply Voltage at the Sengor Connector .”PY Voltage ‘A. Dssoneet he Ja/PE00 connate, B. Tun the keysteh one ON poston . teasure the votage beeen temials P6000 {Rei athe nares conn he engine Serint evel sensor . Tum the keys to the OFF poston, RENR5042.07 Trubleshooteg Section Expected Result: ‘The vottage between terminals (+8 digital #199) and B(eensor et) #8004 VOC, osu: + OK ~ The suply voltage is eaching he sensor Repair: Replace the engine coolant eve sensor ‘ich tat te orga probe a resoved stop + NotOK ~The supply votage snot reaching the Repair: Refer to Troubleshooting, “Dnt Sensor Supply Ctcut- Tet fre appropri troulesnootng procedure stor. Tost Stop 6. Croate a Short Circuit at the ECM P1 Connector | Remove terminals P13 and P1-49 Install 2 Jumpor wr no pen ierminalePI-3 and P48, B, Tum the keysitch oth ON poston and monitor the satus of Coolant Leveron Cat ET whe he Jumper wre stad. ©. Remove to jumpor wre, Monitor the sats of "Coolant ver on Cat ET . Ten the koyetch othe OFF positon Expected Result: ‘The satus of be such is “OK” when the jumper wre IGeonnected The stats of ie sachs -Low when the jumper wie Snot connect, Results: + OK ~The satus of the eusen “OK" when the [hmpe wre ts connected. The stats ofthe such '5 "Low when the jumper wie isnot connected ‘The ECA Is propel reading he sich np However the COM ald nt cette jumper wire at tha sensor connector Theresa protem win fhe wing. There may be a problem wah @ connector Repair: Rept the wing andor te connector. Replace pats, necessary Very thal to orignal etiam venalod stor. + Not OK ~The ECM is nt reading the etch input Repair: Replace the ECM. for to Trebleshectng, “Replacing the ECM” ‘ery that the orginal problem is esoved sToR Compression Brake Solenoid Circuit - Test SMCS Code: 5479.030.68K ‘stim Operation Description Use his procedure to voublestoot any suspect probleme with te compression brake solenoids Use is procedure forthe fotowing agnostic codes: + 791.05 Compression Brake Lowihigh Solenot Curent Setgw normal + 791-08 Compression Brake Lowihigh Slenot Curent stove normal + 792.05 Compression Brake MediumiHigh Solenokt rent Set normal + 792-08 Compression Brake MediumiMigh Solenokt rent ove normal Porfrm his procedure under consis that are ‘Genteao tne condone tat ox when the problem ‘ears. Typlaly probims wi the compression ‘rae solenone docu when he engine warmed Upandorwnen te engine funds taton (heavy tease. “Compression Brake Solenoid Test” ‘The ‘Compression Brake Solenot Tet Is 3 agrost teat that i avaiable on Cater Eleevone Teennisian (£7) Use the"Comeression Brake Solero Tet fo aust n voubieshootng ‘robens nthe creut fr the compression brake. ‘The etconie Contot Modula (€CN wil on tock hors inthe ercut forthe compression bak when 2 lest is activ. “Curent high” agnosis ee (Shor creas) wie logged nce ett has bon Gezcwated The ECM wil ery detect opens the cru or he compreseion brake when the test ‘Sno: actve, The teat must be actos and then ‘encnated before tre ECM wil dotoct an open {eat "Curent ion” ciagnoste codes (open ercuts) ‘Note: Th engine spood must be zero before the "Conprosslon Brave Solenoid Test wil nto RENR5062.07 109 ‘roubeshooting Secon RENRS042.07 ReNR50«2.07 (eSoo3 29) 00 90 oeoeoN Ween joes se ECM SIDE (02) Compan tie (P28) Gempenentne soa meat eta opesan Troubleshooting Seeton ECM SIDE [frames ({f co0c0000@d000 lsecoo0, 0000 (AN 33888 (6) 25 erento ake sks nigh eames ae og 42 ‘Traubleshooteg Secton (- ° | Sh |fpooco|L] oooedy H}e0000 [a] cosas 1 Hoo060 Ol ooodds | fpooee| looooge 5 janO J61 TERMINAL SIDE e000] 0focooa! 9 000/a]o00008, $60000}) 0 000% #20000 2003} P61 TERMINAL SIDE (ri Og nae {tame Sarena sole oh {temes 3} Earn au sca {20 Conensin wat ae nan, (i Ogee = how (©. Perform #45 N (10) pul last on each of he wires i the ECM connector hat ate aszocated ‘th njecer soled RENR50«2.07 . Check he allen head screw foreach ofthe EDM connectors ond the machine connectors {the proper tore, Refer to Troubleshooting “Biecreal Cnnectrsnepec for he cores, seque values. . Greck the hamess and wing fr abrasion and for ch pons fom he valve cover back tothe ECM, Expected Result: [All esonecors, pins, and sockets ae comply ‘ovple andor nse and the harness and wing ‘16 oe ofcomesion, oF abrasion rf pinch pons + OK

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