Cat C11 C13 & C15 On-highway Engines Systems Troubleshooting Manual – PDF DOWNLOAD
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DESCRIPTION:
Cat C11 C13 & C15 On-highway Engines Systems Troubleshooting Manual – PDF DOWNLOAD
KCA1-Up (Engine)
KCB1-Up (Engine)
JAM1-Up (Engine)
BXS1-Up (Engine)
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.
Troubleshooting Section
Electronic Troubleshooting
System Operation
These truck engines were designed for electronic control. A solenoid on each injector controls the amount of fuel that is delivered by the injector. An Engine Control Module (ECM) sends a signal to each injector solenoid in order to provide complete control of the fuel injection.
Electronic Controls
The electronic system consists of the ECM, the engine sensors and the vehicle interface. The ECM is the computer. The personality module is the software for the computer. The personality module contains the operating maps. The operating maps define the following characteristics of the engine:
• Horsepower
• Torque curves
• RPM
• Other characteristics
TABLE OF CONTENTS:
Cat C11 C13 & C15 On-highway Engines Systems Troubleshooting Manual – PDF DOWNLOAD
Troubleshooting Section
Electronic Troubleshooting
System Overview 6
Electronic Service Tools 13
Replacing the ECM 15
Sensors and Electrical Connectors 17
Programming Parameters
Programming Parameters 23
Dyno Mode 23
Test ECM Mode 23
Customer Passwords 24
ECM Date/Time Stamped Information 24
ECM Snapshot 25
Factory Passwords 26
Factory Passwords Worksheet 27
Flash Programming 27
Service Information Report 28
Customer Specified Parameters
Customer Specified Parameters 30
Customer Specified Parameters Table 31
Customer Specified Parameters Worksheet 37
Cruise Control Parameters 40
Data Link Parameters 44
Dedicated PTO Parameters 44
Driver Reward 47
ECM Identification Parameters 47
Engine/Gear Parameters 48
Engine Monitoring Parameters 51
Idle Parameters 51
Input Selections 52
Maintenance Parameters 56
Output Selections 57
Security Access Parameters 58
Selected Engine Rating 58
Smart Idle Parameters 59
Timer Parameters 59
Trip Parameters 61
Vehicle Activity Report Parameters 63
Vehicle Speed Parameters 63
System Configuration Parameters
System Configuration Parameters 66
Troubleshooting without a Diagnostic Code
Can Not Reach Top Engine RPM 67
Can Not Reach Vehicle Speed Limit 68
Check Engine Lamp or Warning Lamp Is
Malfunctioning 70
Cooling Fan Is Always ON 70
Cruise Control, Idle, or PTO Can Not Be Set 72
Driver Questionnaire 74
Driver Questionnaire Response 75
ECM Will Not Accept Factory Passwords 76
Electronic Service Tool Will Not Communicate with
ECM 76
Engine Cranks but Will Not Start 77
Engine Misfires, Runs Rough or Is Unstable 79
Engine Retarder (Compression Brake) Will Not Turn
ON 80
Engine Vibration 81
Engine Will Not Crank 82
Excessive Black Smoke 83
Excessive Fuel Consumption 84
Excessive White Smoke 85
Intermittent Cruise Control, Idle, or PTO Kickout 86
Intermittent Low Power or Power Cutout 87
Low Power/Poor or No Response to Throttle 89
Poor Acceleration or Response 91
Troubleshooting with a Diagnostic Code
Diagnostic Codes 93
No Diagnostic Code Detected (55) 96
0001-05 Cylinder #1 Injector current low (72) 96
0001-06 Cylinder #1 Injector current high (72) 97
0002-05 Cylinder #2 Injector current low (72) 97
0002-06 Cylinder #2 Injector current high (72) 97
0003-05 Cylinder #3 Injector current low (73) 98
0003-06 Cylinder #3 Injector current high (73) 98
0004-05 Cylinder #4 Injector current low (73) 99
0004-06 Cylinder #4 Injector current high (73) 99
0005-05 Cylinder #5 Injector current low (74) 99
0005-06 Cylinder #5 Injector current high (74) 100
0006-05 Cylinder #6 Injector current low (74) 100
0006-06 Cylinder #6 Injector current high (74) 100
0022-11 Primary to Secondary Engine Speed Signal
Calibration (42) 101
0022-13 Engine Speed Signal Calibration Not
Performed (42) 102
0030-08 PTO Throttle signal invalid (29) 103
0030-13 PTO Throttle out of calibration (29) 103
0041-03 8 Volt Supply voltage high (21) 103
0041-04 8 Volt Supply voltage low (21) 104
0043-02 Key Switch Fault (71) 104
0052-11 Air Inlet Shutoff Shutdown (00) 104
0054-05 Auxiliary Output #06 current low (66) 105
0054-06 Auxiliary Output #06 current high (66) 105
0055-05 Auxiliary Output #07 current low (67) 106
0055-06 Auxiliary Output #07 current high (67) 106
0064-08 Secondary Engine Speed loss of signal
(34) 106
0071-00 Idle Shutdown Override (01) 107
0071-01 Idle Shutdown (47) 107
0071-14 PTO Shutdown (47) 107
0084-00 Vehicle Overspeed Warning (41) 108
0084-01 Vehicle Speed loss of signal (31) 108
0084-02 Vehicle Speed signal invalid (36) 109
0084-08 Vehicle Speed signal out of range (36) 109
0084-10 Vehicle Speed signal rate of change
(36) 110
0084-14 Quick Stop Occurrence 110
0091-08 Throttle Position Invalid (32) 110
0091-13 Throttle Position out of calibration (28) 111
0100-01 Low Oil Pressure Warning (46) 111
0100-03 Oil Pressure voltage high (24) 114
0100-04 Oil Pressure voltage low (24) 115
0100-11 Very Low Oil Pressure (46) 115
0102-03 Boost Pressure voltage high (25) 119
0102-04 Boost Pressure voltage low (25) 119
4 SENR9698-09
Table of Contents
0105-00 High Intake Manifold Air Temperature
Warning (64) 120
0105-03 Intake Manifold Air Temperature voltage
high (38) 121
0105-04 Intake Manifold Air Temperature voltage low
(38) 121
0105-11 Very High Intake Manifold Air Temperature
(64) 122
0108-03 Barometric Pressure voltage high (26) 122
0108-04 Barometric Pressure voltage low (26) 123
0110-00 High Coolant Temperature Warning
(61) 123
0110-03 Coolant Temperature voltage high
(27) 124
0110-04 Coolant Temperature voltage low (27) 124
0110-11 Very High Coolant Temperature (61) 124
0111-01 Low Coolant Level Warning (62) 125
0111-02 Coolant Level signal invalid (12) 126
0111-03 Coolant Level voltage high (12) 126
0111-04 Coolant Level voltage low (12) 126
0111-11 Very Low Coolant Level (62) 127
0111-14 Low Coolant Level Warning 128
0121-05 Low/High Retarder current low (14) 129
0121-06 Low/High Retarder current high (14) 129
0122-05 Med/High Retarder current low (14) 129
0122-06 Med/High Retarder current high (14) 130
0166-14 Rated Engine Power Special
Instructions 130
0168-01 Low ECM Battery Power (17) 130
0171-03 Ambient Air Temperature voltage high 131
0171-04 Ambient Air Temperature voltage low 131
0171-11 Ambient Air Temperature Data Lost 131
0174-00 High Fuel Temperature Warning (65) 132
0174-03 Fuel Temperature voltage high (13) 132
0174-04 Fuel Temperature voltage low (13) 132
0190-00 Engine Overspeed Warning (35) 133
0190-08 Primary Engine Speed Loss of Signal
(34) 133
0191-07 Transmission Not Responding (68) 133
0212-03 5 Volt Sensor Supply #1 voltage high 134
0212-04 5 Volt Sensor Supply #1 voltage low 134
0224-11 Theft Deterrent Active (00) 135
0224-14 Theft Deterrent Active with Engine Cranking
(00) 135
0231-02 J1939 Data Incorrect (58) 135
0231-12 J1939 Device Not Responding 136
0246-11 Brake Pedal Switch #1 Fault 136
0247-11 Brake Pedal Switch #2 Fault 136
0252-11 Engine Software Incorrect (59) 137
0253-02 Check Customer or System Parameters
(56) 137
0253-11 Check Transmission Customer Parameters
(56) 138
0283-05 Intake Valve Actuation System Oil Pressure
Solenoid current low (97) 138
0283-06 Intake Valve Actuation System Oil Pressure
Solenoid current high (97) 138
0283-07 Intake Valve Actuation Oil Pressure not
responding (91) 139
0284-05 Engine Coolant Diverter current low
(98) 139
0284-06 Engine Coolant Diverter current high
(98) 139
0285-05 Intake Valve Actuator #1 current low
(92) 140
0285-06 Intake Valve Actuator #1 current high
(92) 140
0285-07 Intake Valve Actuator #1 not responding
(92) 140
0286-05 Intake Valve Actuator #2 current low
(92) 141
0286-06 Intake Valve Actuator #2 current high
(92) 141
0286-07 Intake Valve Actuator #2 not responding
(92) 141
0287-05 Intake Valve Actuator #3 current low
(93) 142
0287-06 Intake Valve Actuator #3 current high
(93) 142
0287-07 Intake Valve Actuator #3 not responding
(93) 143
0288-05 Intake Valve Actuator #4 current low
(93) 143
0288-06 Intake Valve Actuator #4 current high
(93) 143
0288-07 Intake Valve Actuator #4 not responding
(93) 144
0289-05 Intake Valve Actuator #5 current low
(94) 144
0289-06 Intake Valve Actuator #5 current high
(94) 145
0289-07 Intake Valve Actuator #5 not responding
(94) 145
0290-05 Intake Valve Actuator #6 current low
(94) 145
0290-06 Intake Valve Actuator #6 current high
(94) 146
0290-07 Intake Valve Actuator #6 not responding
(94) 146
0385-01 Low Intake Valve Actuation System Oil
Pressure 146
0385-03 Intake Valve Actuation System Oil Pressure
voltage high (95) 147
0385-04 Intake Valve Actuation System Oil Pressure
voltage low (95) 147
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit –
Test 148
Accelerator Pedal (Throttle) Position Sensor Circuit –
Test 152
Air Inlet Shutoff Circuit – Test 161
ATA (SAE J1587 / J1708) Data Link Circuit –
Test 167
Auxiliary Brake Circuit – Test 175
Check Engine Lamp Circuit – Test 180
Clutch Pedal Position Switch Circuit – Test 183
Coolant Level Sensor Circuit – Test 188
Cooling Fan Circuit and A/C High Pressure Switch
Circuit – Test 197
Cruise Control Switch Circuit – Test 210
Diagnostic Enable Switch Circuit – Test 217
SENR9698-09 5
Table of Contents
Eaton Top 2 Transmission Circuit – Test 221
ECM Memory – Test 228
Electrical Connectors – Inspect 232
Engine Coolant Diverter Circuit – Test 237
Engine Pressure Sensor Open or Short Circuit –
Test 242
Engine Running Output Circuit – Test 247
Engine Shutdown Output Circuit – Test 251
Engine Speed/Timing Sensor Circuit – Test 255
Engine Temperature Sensor Open or Short Circuit –
Test 261
Fan Override Switch Circuit – Test 265
Idle Shutdown Timer – Test 269
Ignition Keyswitch Circuit and Battery Supply Circuit –
Test 272
Ignore Brake/Clutch Switch Circuit – Test 279
Injector Solenoid Circuit – Test 282
Intake Valve Actuation System Oil Pressure Circuit –
Test 291
Intake Valve Actuator Circuit – Test 296
Intake Valve Actuator Response – Test 304
Multi-Torque – Test 314
Neutral Switch Circuit – Test 316
Powertrain Data Link Circuit – Test 322
PTO Engine RPM Set Speed (Input A and Input B)
Circuit – Test 327
PTO Shutdown Timer – Test 332
PTO Switch Circuit – Test 334
PTO Switch ON Lamp Circuit – Test 343
Remote PTO Accelerator Position Sensor Circuit –
Test 347
Retarder (Compression Brake) Solenoid Circuit –
Test 354
Service Brake Pedal Position (Switch 1) Circuit –
Test 364
Service Brake Pedal Position (Switch 2) Circuit –
Test 369
Starting Aid Output Circuit – Test 374
Starting Aid Switch Circuit – Test 378
Tachometer Circuit – Test 381
Torque Limit Switch Circuit – Test 386
Two Speed Axle Switch Circuit – Test 389
Vehicle Speed and Speedometer Circuit – Test 393
Warning Lamp Circuit – Test 402
Calibration Procedures
Engine Speed/Timing Sensor – Calibrate 406
Injector Code – Calibrate 408
Vehicle Speed Circuit – Calibrate 410
Index Section
Index 413
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