RENR9318 C11 C13 Troubleshooting

Electronic Troubleshooting 01/11/2005

• System Overview 01/11/2005

o System Operation 01/11/2005
Electronic Controls 01/11/2005
Cold Mode 01/11/2005
Fuel Injection 01/11/2005
o Programmable Parameters 01/11/2005
o Passwords 01/11/2005

• Electronic Service Tools 01/11/2005

o Required Service Tools 01/11/2005
o Optional Service Tools 01/11/2005
o Caterpillar Electronic Technician (ET) 01/11/2005
Connecting Cat ET 01/11/2005
Connecting with the Communication Adapter II 01/11/2005
Communicating with the Wireless Communication
Adapter 01/11/2005

• Electronic Display Module - If Equipped 01/11/2005

• Replacing the ECM 01/11/2005

• Self-Diagnostics 01/11/2005

• Sensors and Electrical Connectors 01/11/2005

o C11 and C13 Engines 01/11/2005

• Engine Wiring Information 01/11/2005

o Harness Wire Identification 01/11/2005
Conversion of AWG Numbers to Metric Measurements 01/11/2005
Welding on Applications that are Equipped with an Electronic Control
Module (ECM) 01/11/2005

Programming Parameters 01/11/2005

• Programming Parameters 01/11/2005

• Test ECM Mode 01/11/2005

• Factory Passwords 01/11/2005

• Factory Passwords Worksheet 01/11/2005

• Flash Programming 01/11/2005

o Programming a Flash File 01/11/2005
"WinFlash" Error Messages 01/11/2005

• Injector Trim File 01/11/2005

System Configuration Parameters 01/11/2005

• System Configuration Parameters 01/11/2005

o Parameter Descriptions 01/11/2005
"Product ID" 01/11/2005
"Equipment ID" 01/11/2005
"Engine Serial Number" 01/11/2005
"FLS" (Full Load Setting) 01/11/2005
"FTS" (Full Torque Setting) 01/11/2005
"Engine Fan Control" 01/11/2005
"Engine Fan Reversing Feature" 01/11/2005
"Ether Control" 01/11/2005
"System Battery Voltage Low Elevated Idle" 01/11/2005
o Parameter Table 01/11/2005
o Parameter Worksheet 01/11/2005

Troubleshooting without a Diagnostic Code 01/11/2005

• Alternator - Charging Problem 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Alternator Drive Belts 01/11/2005
Charging Circuit 01/11/2005
Alternator or Regulator 01/11/2005

• Can Not Reach Top Engine RPM 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Active Engine Derate 01/11/2005
Cold Mode 01/11/2005
Throttle Signal 01/11/2005
Intake Manifold Pressure Sensor or Atmospheric Pressure
Sensor 01/11/2005
Fuel Supply 01/11/2005
Air Inlet and Exhaust System 01/11/2005
Accessory Equipment 01/11/2005

• Coolant in Engine Oil 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Engine Oil Cooler Core 01/11/2005
Cylinder Head Gasket 01/11/2005
Cylinder Head 01/11/2005
Cylinder Liner 01/11/2005
Cylinder Block 01/11/2005

• Coolant Temperature Is Too High 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Faulty Temperature Regulator 01/11/2005
Radiator 01/11/2005
Low Coolant Level 01/11/2005
Faulty Jacket Water Coolant Pump 01/11/2005
Faulty Engine Cooling Fan (if equipped) 01/11/2005
 Faulty Pressure Relief Valve 01/11/2005

• ECM Will Not Accept Factory Passwords 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005

• ECM Will Not Communicate with Other Systems or Display Modules 01/11/2005
o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005

• Electronic Service Tool Will Not Communicate with ECM 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Configuration for the Communications Adapter 01/11/2005
Electrical Connectors 01/11/2005
Communication Adapter and/or Cables 01/11/2005
Electrical Power Supply to the Service Tool Connector 01/11/2005
Cat ET and Related Hardware 01/11/2005
Electrical Power Supply to the Electronic Control Module
(ECM) 01/11/2005
Flash File 01/11/2005
Cat Data Link 01/11/2005

• Elevated Idle 01/11/2005

o Probable Causes 01/11/2005
o Conditions 01/11/2005
Low Battery 01/11/2005
Cold Mode 01/11/2005

• Engine Cranks but Will Not Start 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Diagnostic Codes and Event Codes 01/11/2005
Electronic Control Module 01/11/2005
Starting Aids 01/11/2005
Engine Shutdown Switches 01/11/2005
Starting Motor, Solenoid, or Starting Circuit 01/11/2005
Engine Speed/Timing 01/11/2005
Unit Injector 01/11/2005
Fuel Supply 01/11/2005
Combustion 01/11/2005

• Engine Has Early Wear 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Incorrect Engine Oil 01/11/2005
Contaminated Engine Oil 01/11/2005
Contaminated Air 01/11/2005
Contaminated Fuel 01/11/2005
Low Oil Pressure 01/11/2005

• Engine Misfires, Runs Rough or Is Unstable 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
 Diagnostic Codes 01/11/2005
Electrical Connectors 01/11/2005
Cold Mode Operation and Cold Cylinder Cutout 01/11/2005
Throttle Signal 01/11/2005
Unit Injectors 01/11/2005
Fuel Supply 01/11/2005
Air Inlet and Exhaust System 01/11/2005

• Engine Oil in Cooling System 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Engine Oil Cooler Core 01/11/2005
Cylinder Head Gasket 01/11/2005
Water Pump 01/11/2005

• Engine Oil Temperature Is Too High 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Engine Oil Level 01/11/2005
Engine Oil Cooler Bypass Valve 01/11/2005
Engine Oil Cooler Core 01/11/2005
Engine Coolant Temperature 01/11/2005

• Engine Stalls at Low RPM 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Unit Injectors 01/11/2005
Fuel Supply 01/11/2005
Air Supply 01/11/2005
Engine Idle 01/11/2005
Accessory Equipment 01/11/2005

• Engine Vibration 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Vibration Damper 01/11/2005
Engine Supports 01/11/2005
Driven Equipment 01/11/2005
Engine Misfiring or Running Rough 01/11/2005

• Engine Will Not Crank 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Batteries and/or Battery Cables 01/11/2005
Starting Motor Solenoid or Starting Circuit 01/11/2005
Starting Motor or Flywheel Ring Gear 01/11/2005
Transmission or Engine Accessories 01/11/2005
Hydraulic Cylinder Lock 01/11/2005
Internal Engine Problem 01/11/2005

• Excessive Black Smoke 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Air Inlet or Exhaust System 01/11/2005
 Engine Speed/Timing 01/11/2005
Atmospheric Pressure Sensor 01/11/2005
Intake Manifold Pressure Sensor, "Fuel Position", and/or "FRC Fuel
Limit" 01/11/2005
Flash File 01/11/2005
Fuel Quality 01/11/2005
Valve Adjustment 01/11/2005

• Excessive Engine Oil Consumption 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Oil Leaks 01/11/2005
Oil Level 01/11/2005
Turbocharger 01/11/2005
Internal Engine Wear 01/11/2005

• Excessive Fuel Consumption 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Engine Operation 01/11/2005
Fuel Leaks 01/11/2005
Fuel Quality 01/11/2005
Engine Speed/Timing 01/11/2005
Unit Injectors 01/11/2005
Air Inlet and Exhaust System 01/11/2005
Accessory Equipment 01/11/2005

• Excessive Valve Lash 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Lubrication 01/11/2005
Valve Lash 01/11/2005
Valve Train Components 01/11/2005

• Excessive White Smoke 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Starting Aids 01/11/2005
Coolant Temperature Sensor 01/11/2005
Engine Speed/Timing 01/11/2005
Unit Injectors 01/11/2005
Flash File 01/11/2005
Fuel Supply 01/11/2005
Component Wear 01/11/2005
Cooling System 01/11/2005

• Exhaust Temperature Is Too High 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Diagnostic Codes 01/11/2005
Air Inlet and Exhaust System 01/11/2005

• Fuel in Cooling System 01/11/2005

o Probable Causes 01/11/2005
 o Recommended Actions 01/11/2005
Replace Any Damaged Seals 01/11/2005

• Fuel Dilution of Engine Oil 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Leaking Seals on the Case of the Unit Injector or on the Barrel of the Unit
Injector 01/11/2005
Leaking Seals on the Fuel Line Adapter for the Cylinder Head 01/11/2005
Excessive Leakage from the Unit Injector Tip or Breakage of the Unit
Injector Tip 01/11/2005
Cracked Fuel Supply Manifold 01/11/2005
Leaking Fuel Transfer Pump Seal 01/11/2005

• Intermittent Engine Shutdown 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Diagnostic Codes and/or Event Codes 01/11/2005
Electrical Connectors 01/11/2005
Circuit Breakers 01/11/2005
Fuel Supply 01/11/2005

• Intermittent Low Power or Power Cutout 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Diagnostic Codes and Event Codes 01/11/2005
Turbocharger 01/11/2005
Air Inlet and Exhaust Restrictions 01/11/2005
Throttle Signal 01/11/2005
ECM Power Supply 01/11/2005
Fuel Supply 01/11/2005

• Low Engine Oil Pressure 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Engine Oil Level 01/11/2005
Engine Oil Filters and Oil Filter Bypass Valve 01/11/2005
Engine Oil Pump 01/11/2005
Oil Cooler 01/11/2005
Fuel Dilution 01/11/2005
Engine Wear 01/11/2005

• Low Power/Poor or No Response to Throttle 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Diagnostic Codes and Event Codes 01/11/2005
Cold Mode 01/11/2005
Throttle Signal 01/11/2005
Electrical Connectors 01/11/2005
Unit Injectors 01/11/2005
Intake Manifold Pressure Sensor 01/11/2005
Air Inlet and Exhaust System 01/11/2005
Parameters 01/11/2005
Fuel Supply 01/11/2005
 • Mechanical Noise (Knock) in Engine 01/11/2005
o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Accessory Equipment 01/11/2005
Valve Train Components 01/11/2005
Connecting Rod and Main Bearings 01/11/2005

• Noise Coming from Cylinder 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Diagnostic Codes 01/11/2005
Fuel Quality 01/11/2005
Unit Injectors 01/11/2005
Valve Lash 01/11/2005
Cylinder Head and Related Components 01/11/2005

• Poor Acceleration or Response 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005
Engine Derate or Active Codes 01/11/2005
Cold Mode 01/11/2005
Flash File 01/11/2005
Throttle Signal 01/11/2005
Electrical Connectors 01/11/2005
Unit Injectors 01/11/2005
Intake Manifold Pressure Sensor 01/11/2005
Air Inlet and Exhaust System 01/11/2005
Fuel Supply 01/11/2005

• Valve Rotator or Spring Lock Is Free 01/11/2005

o Probable Causes 01/11/2005
o Recommended Actions 01/11/2005

Troubleshooting with a Diagnostic Code 01/11/2005

• Diagnostic Codes 01/11/2005

o Diagnostic Codes 01/11/2005
o Active Diagnostic Codes 01/11/2005
o Logged Diagnostic Codes 01/11/2005

• CID 0001 FMI 05 Cylinder #1 Injector open circuit 01/11/2005

• CID 0001 FMI 06 Cylinder #1 Injector short 01/11/2005

• CID 0002 FMI 05 Cylinder #2 Injector open circuit 01/11/2005

• CID 0002 FMI 06 Cylinder #2 Injector short 01/11/2005

• CID 0003 FMI 05 Cylinder #3 Injector open circuit 01/11/2005

• CID 0003 FMI 06 Cylinder #3 Injector short 01/11/2005

• CID 0004 FMI 05 Cylinder #4 Injector open circuit 01/11/2005

• CID 0004 FMI 06 Cylinder #4 Injector short 01/11/2005

• CID 0005 FMI 05 Cylinder #5 Injector open circuit 01/11/2005

• CID 0005 FMI 06 Cylinder #5 Injector short 01/11/2005

• CID 0006 FMI 05 Cylinder #6 Injector open circuit 01/11/2005

• CID 0006 FMI 06 Cylinder #6 Injector short 01/11/2005

• CID 0041 FMI 03 8 Volt DC Supply short to +batt 01/11/2005

• CID 0041 FMI 04 8 Volt DC Supply short to ground 01/11/2005

• CID 0091 FMI 08 Throttle Position signal abnormal 01/11/2005

• CID 0094 FMI 03 Fuel Pressure open/short to +batt 01/11/2005

• CID 0094 FMI 04 Fuel Pressure short to ground 01/11/2005

• CID 0100 FMI 03 Engine Oil Pressure open/short to +batt 01/11/2005

• CID 0100 FMI 04 Engine Oil Pressure short to ground 01/11/2005

• CID 0100 FMI 10 Engine Oil Pressure Sensor abnormal rate of change 01/11/2005

• CID 0110 FMI 03 Engine Coolant Temperature open/short to +batt 01/11/2005

• CID 0110 FMI 04 Engine Coolant Temperature short to ground 01/11/2005

• CID 0168 FMI 00 System Voltage High 01/11/2005

• CID 0168 FMI 01 System Voltage Low 01/11/2005

• CID 0168 FMI 02 System Voltage intermittent/erratic 01/11/2005

• CID 0172 FMI 03 Intake Manifold Air Temp open/short to +batt 01/11/2005

• CID 0172 FMI 04 Intake Manifold Air Temp short to ground 01/11/2005

• CID 0174 FMI 03 Fuel Temperature open/short to +batt 01/11/2005

• CID 0174 FMI 04 Fuel Temperature short to ground 01/11/2005

• CID 0190 FMI 08 Engine Speed abnormal 01/11/2005

• CID 0253 FMI 02 Personality Module mismatch 01/11/2005

• CID 0261 FMI 11 Engine Timing Calibration invalid 01/11/2005

• CID 0261 FMI 13 Engine Timing Calibration required 01/11/2005

• CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt 01/11/2005

• CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground 01/11/2005

• CID 0267 FMI 02 Incorrect Engine Shutdown Switch inputs 01/11/2005

• CID 0268 FMI 02 Check Programmable Parameters 01/11/2005

• CID 0274 FMI 03 Atmospheric Pressure open/short to +batt 01/11/2005

• CID 0274 FMI 04 Atmospheric Pressure short to ground 01/11/2005

• CID 0275 FMI 03 Right Turbo Inlet Pressure open/short to +batt 01/11/2005

• CID 0275 FMI 04 Right Turbo Inlet Pressure short to ground 01/11/2005

• CID 0283 FMI 05 Filter Restrict Lamp open/short to +batt 01/11/2005

• CID 0283 FMI 06 Filter Restrict Lamp short to ground 01/11/2005

• CID 0291 FMI 05 Engine Cooling Fan Solenoid open circuit 01/11/2005

• CID 0291 FMI 06 Engine Cooling Fan Solenoid short to ground 01/11/2005

• CID 0296 FMI 09 Unable to communicate with Transmission ECM 01/11/2005

• CID 0296 FMI 12 Transmission ECM failed 01/11/2005

• CID 0342 FMI 08 Secondary Engine Speed signal abnormal 01/11/2005

• CID 0596 FMI 09 Unable to communicate with Implement ECM 01/11/2005

• CID 0596 FMI 12 Wrong Response from Implement ECM 01/11/2005

• CID 1639 FMI 02 Machine Security System incorrect 01/11/2005

• CID 1639 FMI 09 Machine Security System Module not communicating on link 01/11/2005

• CID 1785 FMI 03 Intake Manifold Pressure Sensor voltage high 01/11/2005

• CID 1785 FMI 04 Intake Manifold Pressure Sensor voltage low 01/11/2005

• CID 1785 FMI 10 Intake Manifold Pressure Signal abnormal rate of change 01/11/2005

• CID 2417 FMI 05 Ether Injection Control Solenoid current low 01/11/2005

• CID 2417 FMI 06 Ether Injection Control Solenoid current high 01/11/2005
Troubleshooting with an Event Code 01/11/2005

• Event Codes 01/11/2005

o Active Event Codes 01/11/2005
o Logged Event Codes 01/11/2005
o Clearing Event Codes 01/11/2005
o Troubleshooting 01/11/2005
o Trip Points for the Monitoring System 01/11/2005

• E096 High Fuel Pressure 01/11/2005

• E172 High Air Filter Restriction 01/11/2005

• E194 High Exhaust Temperature 01/11/2005

• E265 User Defined Shutdown 01/11/2005

• E360 Low Engine Oil Pressure 01/11/2005

• E362 Engine Overspeed 01/11/2005

• E363 High Fuel Temperature 01/11/2005

• E390 Fuel Filter Restriction 01/11/2005

• E441 Idle Elevated to Increase Battery Voltage 01/11/2005

• E539 High Intake Manifold Air Temperature 01/11/2005

Diagnostic Functional Tests 01/11/2005

• 5 Volt Engine Pressure Sensor Supply Circuit - Test 01/11/2005

• Cat Data Link Circuit - Test 01/11/2005

• Electrical Connectors - Inspect 01/11/2005

• Electrical Power Supply Circuit - Test 01/11/2005

• Engine Fan Control Solenoid Circuit - Test 01/11/2005

• Engine Fan Reversing Solenoid Circuit - Test 01/11/2005

• Engine Pressure Sensor Open or Short Circuit - Test 01/11/2005

• Engine Speed/Timing Sensor Circuit - Test 01/11/2005

• Engine Temperature Sensor Open or Short Circuit - Test 01/11/2005

• Ether Injection System - Test 01/11/2005

 • Fuel Filter Differential Pressure Switch Circuit - Test 01/11/2005

• Indicator Lamp Circuit - Test 01/11/2005

• Injector Solenoid Circuit - Test 01/11/2005

• Throttle Position Sensor Circuit - Test 01/11/2005

• User Defined Shutdown Input Circuit - Test 01/11/2005

Calibration Procedures 01/11/2005

• Engine Speed/Timing Sensor - Calibrate 01/11/2005