Caterpillar C11 C13 C15 C18 Industrial Engine Troubleshooting Manual

C11, C13, C15 and C18 Industrial Engines

RENR5042-02 February 2005 Troubleshooting C11, C13, C15 and C18 Industrial Engines JRE1-Up (Engine) WJH1-Up (Engine) LGK1-Up (Engine) GLS1-Up (Engine)

Page 1

C11, C13, C15 and C18 Industrial Engines

i01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read 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 warnings are 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 pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on 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. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.

You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was 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 can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.

Page 2

C11, C13, C15 and C18 Industrial Engines

RENR5042-02 3 Table of Contents Table of Contents Troubleshooting with a Diagnostic Code Flash Codes .......................................................... 52 Diagnostic Codes .................................................. 52 Diagnostic Code Cross Reference ....................... 53 CID 0001 FMI 05 Injector Cylinder 1 open circuit .. 56 CID 0001 FMI 06 Injector Cylinder 1 short ........... 56 CID 0001 FMI 11 Injector Cylinder #1 fault ........... 57 CID 0002 FMI 05 Injector Cylinder 2 open circuit .. 57 CID 0002 FMI 06 Injector Cylinder 2 short ........... 57 CID 0002 FMI 11 Injector Cylinder #2 fault ........... 58 CID 0003 FMI 05 Injector Cylinder 3 open circuit ..

58 CID 0003 FMI 06 Injector Cylinder 3 short ........... 58 CID 0003 FMI 11 Injector Cylinder #3 fault ........... 59 CID 0004 FMI 05 Injector Cylinder 4 open circuit .. 59 CID 0004 FMI 06 Injector Cylinder 4 short ........... 59 CID 0004 FMI 11 Injector Cylinder #4 fault ........... 60 CID 0005 FMI 05 Injector Cylinder 5 open circuit .. 60 CID 0005 FMI 06 Injector Cylinder 5 short ........... 60 CID 0005 FMI 11 Injector Cylinder #5 fault ........... 61 CID 0006 FMI 05 Injector Cylinder 6 open circuit .. 61 CID 0006 FMI 06 Injector Cylinder 6 short ........... 61 CID 0006 FMI 11 Injector Cylinder #6 fault ........... 61 CID 0041 FMI 03 8 Volt DC Supply short to +batt ..

62 CID 0041 FMI 04 8 Volt DC Supply short to ground ................................................................. 62 CID 0091 FMI 08 Throttle Position signal abnormal ............................................................. 62 CID 0091 FMI 13 Throttle Position calibration required ............................................................... 63 CID 0094 FMI 03 Fuel Pressure open/short to +batt .................................................................... 63 CID 0094 FMI 04 Fuel Pressure short to ground .. 63 CID 0100 FMI 03 Engine Oil Pressure open/short to +batt ....................................................................

63 CID 0100 FMI 04 Engine Oil Pressure short to ground ................................................................. 64 CID 0100 FMI 10 Engine Oil Pressure Sensor abnormal rate of change ..................................... 64 CID 0102 FMI 03 Boost Pressure Sensor short to +batt .................................................................... 64 CID 0102 FMI 04 Boost Pressure Sensor short to ground ................................................................. 65 CID 0102 FMI 10 Boost Pressure Sensor abnormal rate of change .....................................................

65 CID 0110 FMI 03 Engine Coolant Temperature open/short to +batt .............................................. 65 CID 0110 FMI 04 Engine Coolant Temperature short to ground ............................................................. 66 CID 0111 FMI 02 Engine Coolant Level Sensor Loss of Signal .............................................................. 66 CID 0168 FMI 00 System Voltage High ................ 66 CID 0168 FMI 01 System Voltage Low ................. 67 CID 0168 FMI 02 System Voltage intermittent/ erratic ..................................................................

67 CID 0172 FMI 03 Intake Manifold Air Temp open/short to +batt ................................................................ 67 CID 0172 FMI 04 Intake Manifold Air Temp short to ground ................................................................. 68 CID 0174 FMI 03 Fuel Temperature open/short to +batt .................................................................... 68 CID 0174 FMI 04 Fuel Temperature short to ground ................................................................. 68 CID 0190 FMI 08 Engine Speed abnormal ........... 68 Troubleshooting Section Electronic Troubleshooting System Overview ....................................................

5 Electronic Service Tools .......................................... 6 Electronic Display Module (If Equipped) ................. 8 Replacing the ECM ................................................. 8 Self-Diagnostics ...................................................... 9 Sensors and Electrical Connectors ....................... 10 Engine Wiring Information .................................... 13 Programming Parameters Programming Parameters ..................................... 15 Customer Passwords ............................................ 15 Factory Passwords ............................................... 15 Factory Passwords Worksheet .............................

16 Flash Programming .............................................. 16 Injector Trim File ................................................... 17 Service Information Report ................................... 18 System Configuration Parameters System Configuration Parameters ........................ 20 Troubleshooting without a Diagnostic Code Alternator (Charging Problem) .............................. 28 Battery .................................................................. 28 Can Not Reach Top Engine RPM ......................... 28 Coolant in Engine Oil ............................................ 30 Coolant Temperature Is Too High .........................

30 ECM Will Not Accept Factory Passwords ............. 31 ECM Will Not Communicate with Other Systems or Display Modules .................................................. 31 Electronic Service Tool Will Not Communicate with ECM .................................................................... 31 Engine Cranks but Will Not Start .......................... 32 Engine Has Early Wear ........................................ 35 Engine Misfires, Runs Rough or Is Unstable ........ 35 Engine Oil in Cooling System ............................... 36 Engine Oil Temperature Is Too High ..................... 37 Engine Stalls at Low RPM ....................................

37 Engine Vibration ................................................... 38 Engine Will Not Crank ........................................... 38 Excessive Black Smoke ........................................ 39 Excessive Engine Oil Consumption ...................... 40 Excessive Fuel Consumption ............................... 41 Excessive Valve Lash ........................................... 42 Excessive White Smoke ....................................... 42 Exhaust Temperature Is Too High ......................... 43 Fuel in Cooling System ......................................... 44 Fuel Dilution of Engine Oil ....................................

44 Intermittent Engine Shutdown ............................... 44 Intermittent Low Power or Power Cutout .............. 45 Low Engine Oil Pressure ...................................... 46 Low Power/Poor or No Response to Throttle ....... 46 Mechanical Noise (Knock) in Engine .................... 48 Noise Coming from Cylinder ................................. 49 Poor Acceleration or Response ............................ 49 Valve Rotator or Spring Lock Is Free .................... 51

Page 3

C11, C13, C15 and C18 Industrial Engines

4 RENR5042-02 Table of Contents CID 0247 FMI 09 J1939 Data Link communications .................................................. 69 CID 0253 FMI 02 Personality Module mismatch .. 69 CID 0261 FMI 13 Engine Timing Calibration required ............................................................... 69 CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt ....................................................... 70 CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground .................................................... 70 CID 0268 FMI 02 Check Programmable Parameters .........................................................

70 CID 0273 FMI 00 Turbo Outlet Pressure above normal ................................................................. 71 CID 0274 FMI 03 Atmospheric Pressure open/short to +batt ................................................................ 71 CID 0274 FMI 04 Atmospheric Pressure short to ground ................................................................. 71 CID 0342 FMI 08 Secondary Engine Speed signal abnormal ............................................................. 72 CID 0545 FMI 05 Ether Start Relay open/short to +batt ....................................................................

72 CID 0545 FMI 06 Ether Start Relay short to ground ................................................................. 72 CID 1835 FMI 03 Auxiliary Pressure Sensor open/short to +batt .............................................. 72 CID 1835 FMI 04 Auxiliary Pressure Sensor short to ground ................................................................. 73 CID 1836 FMI 03 Auxiliary Temperature Sensor open/short to +batt .............................................. 73 CID 1836 FMI 04 Auxiliary Temperature Sensor short to ground .............................................................

73 CID 2417 FMI 05 Ether Injection Control Solenoid current low .......................................................... 74 CID 2417 FMI 06 Ether Injection Control Solenoid current high ......................................................... 74 Electrical Power Supply Circuit - Test ................. 125 Engine Pressure Sensor Open or Short Circuit - Test ................................................................... 129 Engine Speed/Timing Sensor Circuit - Test ........ 134 Engine Temperature Sensor Open or Short Circuit - Test ................................................................... 140 Ether Injection System - Test ..............................

146 Injector Solenoid Circuit - Test ............................ 152 Maintenance Due Lamp Circuit - Test ................. 160 PTO Switch Circuit - Test .................................... 163 Switch Circuits - Test .......................................... 168 Throttle Position Sensor Circuit - Test ................ 171 Warning Lamp Circuit - Test ................................ 176 Calibration Procedures Engine Speed/Timing Sensor - Calibrate ............ 180 Throttle Position Sensor - Calibrate .................... 182 Index Section Index ...................................................................

185 Troubleshooting with an Event Code Event Codes ........................................................ 75 E057 Low Engine Coolant Level Derate ............... 79 E058 Low Engine Coolant Level Shutdown .......... 79 E059 Low Engine Coolant Level Warning ............ 80 E096 High Fuel Pressure ...................................... 81 E360 Low Engine Oil Pressure ............................. 81 E361 High Engine Coolant Temperature .............. 82 E362 Engine Overspeed ....................................... 83 E363 High Fuel Temperature ................................ 83 E443 High Auxiliary Pressure ...............................

84 E445 High Auxiliary Temperature ......................... 84 E539 High Intake Manifold Air Temperature ......... 85 Diagnostic Functional Tests 5 Volt Engine Pressure Sensor Supply Circuit - Test ..................................................................... 87 Air Shutoff System - Test ...................................... 95 CAN Data Link Circuit - Test ............................... 100 Cat Data Link Circuit - Test ................................. 104 Coolant Level Sensor Circuit - Test .................... 106 Diagnostic Lamp Circuit - Test ............................. 110 Digital Sensor Supply Circuit - Test .....................

114 ECM/Personality Module - Test ........................... 118 Electrical Connectors - Inspect ........................... 120

Page 4