3126 HEUI INDUSTRIAL ENGINES ENGINES EQUIPPED WIT Caterpillar

SECTION 3: Troubleshooting Without A Diagnostic Code

Usage:

How To Use The Functional Tests

This section is to be used for troubleshooting problems that have symptoms but does not have ACTIVE diagnostic codes. Some engine symptoms are caused by conditions or components other than the electronic control system, such as poor fuel quality or improperly adjusted valved.

Before using this section, be sure that you have gathered information about the complaint to adequately describe the symptoms, verified that the complaint is not due to normal engine operation and repaired all ACTIVE Diagnostic Codes. Refer To Section 4: Troubleshooting With A Diagnostic Code.

The basic philosophy of troubleshooting this engine is to follow the steps listed below first to diagnose a symptom.

* Check for ACTIVE/LOGGED Diagnostic Codes.

* Check the oil level, supply and/or condition.

* Check the fuel level, supply and/or condition.

If these steps reveal no problems, then identify probable causes using the procedure in this section which best describes the symptoms. Then narrow the probable causes by answering the following questions as a guide.

Operator Information

* What happened, and when?

* Under what conditions?

* Does the problem occur at specific engine speeds?

* Does the problem occur only when the engine is cold or warmed up, when the weather is cold or warm?

* Certain altitudes, loads, gears, etc.

* Does the problem occur when other vehicle systems are engaged, or are other vehicle systems also malfunctioning?

* What else occurred?

* When did the symptoms begin (and what else happened at that time)?

LOGGED Diagnostic Codes

* Do they correlate to probable causes? Did they occur at the same time as the symptoms?

* Are some logged repeatedly?

Other Symptoms

* Are they related to this symptom?

* Do they have common probable causes?

* Finally, test each probable cause using the tests suggested by the procedure. Be sure to check connectors, especially on intermittent problems!

NOTE: Do not exchange components to avoid troubleshooting a repeatable problem.

P-301: Engine Will Not Crank

Probable Root Causes:

* Batteries

* Starting circuit problem (in vehicle wiring)

* Starting Motor solenoid

* Starting Motor

* Engine accessory

* Hydraulic cylinder lock

* Internal Engine Problem

* Flywheel ring gear

* Transmission or Power Take-Off problem

NOTE: These are NOT electronic problems with the Engine Control System. For more details on the following tests, Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

Perform The Following Tests In Order:

1. Charge batteries (Refer To Special Instruction SEHS7633, For Battery Test Procedure). Load Test Batteries (Refer To Special Instruction SEHS9249, For Use Of 4C4911 Battery Load Tester).

2. Check vehicle wiring to starting motor solenoid (Refer To Vehicle OEM Instructions). Check engine start switch, switch power relay, etc.

3. Inspect starting motor cables for damage or loose connections. Remove and clean starting motor cables and connections if corroded.

4. Test starting motor solenoid operation. Refer to Systems Operation, Testing and Adjusting Manual, SENR1158. Test Starting Motor Operation.

5. Remove and inspect engine accessories that may lock up the engine (Air Compressor, Power Steering Pump, Oil Pump, etc).

6. Check for fluid in cylinders by removing individual injectors. Check for timing Pin left in flywheel housing after setting valve lash.

7. Attempt to manually turn the engine using the 9S9082 Turning Tool.

8. Disassemble engine to inspect for internal components that may be seized, broken, bent, etc. Refer To Disassembly & Assembly Manual, SENR1142.

9. Remove and inspect flywheel ring gear for damage. Ensure free movement of driveline.

P-302: Engine Cranks But Will Not Start

Probable Root Causes:

* Low Oil, Out of Fuel, Air in the High Pressure Oil System.

* ECM to Service Tool Communications check

* After market engine protection devices (those not installed by Caterpillar).

* Electrical power supply to ECM

* Unprogrammed Personality Module in a New ECM or ECM.

* Incorrect Engine Software

* Engine Speed/Timing Signal

* Injection Actuation Pressure System

* Fuel supply

* Low pressure/poor fuel quality

* Combustion problem

NOTE: A new ECM has an unprogrammed Personality Module, and will cause this symptom. Accessing "ECM Status" in the FLASH PC Program without following this request with programming the Personality Module may also cause the engine to not start or communicate. Cycling the keyswitch OFF, then ON will correct this problem.

Perform The Following Tests In Order:

1. Check the engine oil level. Engine oil feeds the high pressure hydraulic pump. Make sure the engine is not out of fuel.

2. If the engine has been recently worked on, check for air in the High Pressure Oil System. Only after opening/working on the High Pressure Oil System.

3. Crank the engine for up to five 30 second cycles to purge the air from the oil system. Connect an Electronic Service Tool. Ensure the keyswitch is in the ON position. Attempt to access "Truck Engine Functions". If the Electronic Service Tool indicates the ECM will not communicate, proceed to next item.

4. After market engine protection devices may interrupt power to the ECM and the ECM will not communicate with the Service Tool. Check for correct installation and operation of after market engine protection devices. You may have to override or bypass the device before you continue.

5. Verify the ECM is receiving battery voltage. Check the ECM Power and Ground connections. Verify that the ECM is receiving battery voltage when the keyswitch is turned ON. Wire a bypass as indicated in Section 5: P-503 Electrical Power Supply To The ECM.

6. If the ECM still will not communicate and the engine will not start, temporarily install a new ECM. Flash Program the same Personality Module into the new ECM. Test to verify that the ECM will communicate and the engine starts. If the engine starts, the old ECM is bad. If the engine does not start the problem is elsewhere.

7. Connect an Electronic Service Tool and verify there is not an active 252-11 Incorrect Engine Software (59) diagnostic code. If the diagnostic code is present, Refer To Section 5: P-513 ECM Personality Module.

8. Observe the engine rpm with an Electronic Service Tool Status Screen while cranking the engine. This may require the Electronic Service Tool to be powered by a separate 12VDC power source as shown below.

9. If the Service tools displays 0 rpm while cranking the engine, there is a problem in the Speed/Timing Sensor circuit. Refer To Section 5: P-514 Speed/Timing Sensor. If engine rpm is present, the electronics are OK. Proceed to the next item.

10. Crank engine while monitoring the Injection Actuation Pressure and Injection Actuation Control Valve Output. If the Injection Actuation Pressure is reaching at least (5 MPa) 725 psi the problem is not in the High Pressure Oil System.

Connect an Electronic Service Tool and check for a 164-11 Injection Actuation Pressure System Fault Diagnostic EVENT Code. If a 164-11 has been recently logged, Refer To Section 5: P-515: Injector Solenoids

11. Injection Actuation Pressure Sensor indicating a higher than actual pressure. Disconnect the Injection Actuation Pressure Sensor, and then crank the engine. If the engine starts. Monitor exhaust for smoke while cranking. If smoke is not present, there may be a fuel supply problem.

12. Check fuel quality.

13. Check Fuel Pressure. Check to ensure fuel system is primed. Check for restricted fuel supply lines and fuel filters. In temperatures below (0°C), 32°F check for congealed fuel (wax).

P-303: Engine Misfires, Runs Rough Or Is Unstable

Probable Root Causes:

* Individual cylinder malfunction

* Fuel supply

* Low pressure

* Combustion gas/air in fuel

* Poor fuel quality

* Throttle Position Sensor signal

* Low Injection Actuation Pressures

* Valve Lash Adjustment

NOTE: If the problem only occurs under certain conditions (high rpm, full load, engine operating temperature, etc), test the engine under those conditions. Troubleshooting the symptoms under other conditions can give misleading results.

Perform The Following Tests In Order:

Inspect ECM Connector J2/P2 for full connection and corrosion. Connect an Electronic Service Tool and cut out each cylinder to isolate the misfiring cylinder(s). If it can be isolated to a specific cylinder(s), Refer To Section 5: P-515: Injector Solenoids.

1. Check fuel quality.

2. Inspect fuel system and check fuel pressure or for air in fuel. Refer to Systems Operation, Testing and Adjusting Manual, SENR1158.

3. Check Engine Oil Level to ensure the engine is not low on oil.

4. Use the Cruise Control Switches to operate the engine in Idle mode. Vary the engine rpm with the Set/Resume switches.

5. If the engine is stable using Idle mode to control engine rpm, but unstable using the throttle sensor, connect an Electronic Service Tool and monitor the throttle position status. If it is unstable when it should not be, Refer To Section 5: P-504 Throttle Position Sensor.

P-304: Consistent Low Power or Poor Response To Accelerator

Probable Root Causes:

* Customer Specified Parameters

* Cold Mode Operation

Dedicated PTO Switch ON or Torque Limit Switch always ON.

* Electronic System problem

* Fuel supply

* Low pressure

* Combustion gas/air in fuel

* Poor fuel quality

* Air-To-Air Aftercooler Core Leak Test

* Air inlet or exhaust system restrictions, or air system leaks

* Individual cylinder malfunction

* Low Injection Actuation Pressures

Perform The Following Tests In Order:

1. Customer Specified Parameters (normal operation) Verify the complaint is not normal (programmed parameter) operation. Connect an Electronic Service Tool and check for the following.

- rating # (if rating # is 0, the engine is limited to [89.5 kW] 120 hp

Vehicle Speed Limit

Set each parameter to its maximum value one at a time and check if, after changing each parameter, the problem is corrected.

2. Monitor any of the Electronic Service Tool Status screens to verify the engine has shifted out of Cold Mode. An Active Cold Mode is indicated in the upper corner of any Status Screen. During Cold Mode engine power maybe limited.

3. Check the Customer Parameter setting for the Dedicated PTO Parameter Torque Limit. If it is programmed below (2712 N·m) 2000 lb ft, check the status screen for Multi-Function Input #1 and Multi-Function Input #2 to ensure the status indicates OFF. If the status is ON with a Torque Limit programmed, the system is operating correctly. If the switch connected to this input is not switching ON and OFF,.

4. Monitor "Fuel Pos", "Rated Fuel Pos", and "FRC Fuel Pos", on the Electronic Service Tool. These three parameters should be as follows while the vehicle is operating under full load.

"Fuel Pos" = "Rated Fuel Pos" AND "Fuel Pos" is less than "FRC Fuel Pos"

If the three parameters are as indicated above, the Electronics are operating correctly. If these three parameters are not as indicated check the following.

5. Monitor Turbocharger Compressor Outlet Pressure on the Electronic Service Tool status screen for normal operation. Turn the key ON, engine OFF, and check the Pressure on an Electronic Service Tool status screen - with the engine OFF it should indicate (0 kPa) 0 psi.

6. Monitor the Throttle Position status. Operate the engine to high idle with the vehicle in neutral. If the engine can not reach programmed Top Engine Limit, check the Throttle Duty Cycle to verify it is within calibration (75 to 90 percent at high idle). If throttle position is unstable when it should not be, check the Throttle Duty Cycle while slowly operating the accelerator pedal to verify it is within calibration (10 to 22 percent at low idle, 75 to 90 percent at high idle), and the duty cycle changes along with pedal position. If a problem with the Throttle Sensor is suspected, Refer To Section 5: P-504 Throttle Position Sensor.

7. Monitor the vehicle speed signal and verify accuracy compared to actual speed. If vehicle speed on an Electronic Service Tool indicates vehicle speed is greater than the programmed VSL, power is limited. If a problem is discovered, Refer To Section 5: P-593 Machine/Vehicle Speed Circuit.

8. Check fuel quality.

9. Inspect fuel system, check fuel pressure and for air in fuel, and fuel quality. Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

10. Air-To-Air Aftercooler Core Leak Test Refer to Systems Operation, Testing and Adjusting Manual, SENR1158.

11. Check air inlet and exhaust systems for restrictions and leaks. Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

12. Inspect ECM Connector J2/P2 for full connection and corrosion. Connect an Electronic Service Tool and cut out each cylinder to isolate the misfiring cylinder(s). If it can be isolated to a specific cylinder(s).

13. Perform a PAR (Performance Analysis Report) Test.

14. Check Engine Oil Level to ensure the engine is not low on oil.

15. Connect an Electronic Service Tool and check for a 164-11 Injection Actuation Pressure System Fault Diagnostic EVENT Code. If a 164-11 has been recently logged.

P-305: Intermittent Engine Shutdowns

* Probable Root Causes:

* Idle Shutdown Battery power or ground to ECM

* After market engine protection devices

* Fuel supply

* Low pressure

* Poor fuel quality

* Erratic, Low Injection Actuation Pressures

* ECM

NOTE: Induce the engine to shutdown before attempting to troubleshoot the problem.

Perform The Following Tests In Order:

1. Connect an Electronic Service Tool and read the Customer Parameters Engine Monitoring and Idle Shutdown Time. If Idle Shutdown Time is programmed above 0, use an Electronic Service Tool and look for the following Diagnostic Code. 71-01 Idle Shutdown Timer (47)

2. Check for correct installation of 40-Pin ECM Connectors J1/P1 and J2/P2, Engine Speed/Timing Sensor Connectors J9/P9 and J4/P4.

3. Check Electronic Service Tool for 168-02 Intermittent Battery (51) Diagnostic Code.

4. Follow battery wires from ECM back to the battery compartment. Inspect these wires and the power relay, usually mounted in or near the battery compartment. Check the ECM Power and Ground connections If a problem is suspected, wire a bypass as indicated in P-503 Electrical Power Supply To The ECM.

5. If the problem seems to occur only after the engine is warmed up and disappears after the truck has been allowed to cool, the circuit breakers may be tripping because of heat. Check to ensure that the circuit breakers on the truck are an automatically resetting type.

6. Check for correct installation and operation of after-market engine protection devices.

7. Inspect fuel system and check fuel pressure. Refer To Systems Operation, Testing And Adjusting Manual, SENR1158. Check fuel quality.

8. Check Engine Oil Level to ensure the engine is not low on oil.

Connect an Electronic Service Tool and check for a 164-11 Injection Actuation Pressure System Fault Diagnostic EVENT Code. If a 164-11 Diagnostic EVENT Code has been recently logged, Refer To Section 5: P-515 Injector Solenoids.

9. Refer to Section 5: P-513 ECM/Personality Module.

P-306: Intermittent Low Power Or Power Cutouts

Probable Root Causes:

* Poor electrical connections

* Battery power or ground to ECM (vehicle wiring)

* Air supply/low Turbocharger Compressor Outlet

* Throttle Position Sensor signal

* Fuel Supply

* Vehicle speed signal

* Caterpillar Engine Monitoring Derate

* Dedicated PTO Switch ON or Torque Limit Switch always ON.

* Erratic, Low Injection Actuation Pressures

Perform The Following Tests In Order:

1. Check Vehicle Harness and connectors (Refer To Section 5: P-501 Inspecting Electrical Connectors).

2. Check Electronic Service Tool for 168-02 Intermittent Battery (51) Diagnostic Code.

3. Check the ECM Power and Ground connections. If a problem is suspected, wire a bypass as indicated in P-503 Electrical Power Supply To The ECM.

4. Monitor "Fuel Pos", "Rated Fuel Pos", and "FRC Fuel Pos", on the Electronic Service Tool. These three parameters should be as follows while the vehicle is operating under full load.

"Fuel Pos" = "Rated Fuel Pos" AND "Fuel Pos" is less than "FRC Fuel Pos"

If the parameters are as indicated above, the Electronics are operating correctly. If these three parameters are not as indicated check the following.

5. Monitor Turbocharger Compressor Outlet Pressure on the Electronic Service Tool status screen for normal operation. Turn the keyswitch ON, engine OFF, and check the Turbocharger Compressor Outlet Pressure on an Electronic Service Tool status screen - with the engine OFF it should indicate 0 kPa (0 psi).

6. Establish the engine in PTO mode and vary the engine rpm with the Set/Resume switches. If the engine is stable using the switches, but unstable using the accelerator pedal, Refer To Section 5: P-504 Throttle Position Sensor.

7. If the engine is stable using PTO mode to control engine rpm, but not the throttle sensor, connect an Electronic Service Tool and monitor the Throttle Position status. Operate the engine to high idle with the vehicle in Neutral. If the engine can not reach programmed Top Engine Limit, check the Throttle Duty Cycle to verify it is within calibration (75 to 90 percent at high idle). If throttle position is unstable when it should not be, check the Throttle Duty Cycle while slowly operating the accelerator pedal to verify it is within calibration (10 to 22 percent at low idle, 75 to 90 percent at high idle), and the duty cycle changes along with pedal position. If a problem with the Throttle Sensor is found, Refer To Section 5: P-504 Throttle Position Sensor, in this manual.

8. Check fuel lines for restrictions, fuel/water separator, and fuel tanks for foreign objects which may block fuel supply.

9. Monitor the vehicle speed signal and verify accuracy compared to actual speed. If Electronic Service Tool vehicle speed is greater than VSL, power is limited. If a problem is discovered, Refer To Section 5: P-593 Machine/Vehicle Speed Circuit.

10. Check an Electronic Service Tool for Diagnostic Codes capable of derating when Engine Monitoring is programmed to Derate.

11. Connect an Electronic Service Tool and check the Customer Parameter setting for the Dedicated PTO Parameter Torque Limit. If it is programmed below 2712 N·m (2000 lb ft), check the status screen for Multi-Function Input #1 and Multi-Function Input #2 and ensure the status indicates OFF. If the status is ON with a Torque Limit programmed the system is operating correctly. If the switch connected to this input is not switching ON and OFF.

Check Engine Oil Level to ensure the engine is not low on oil. Connect an Electronic Service Tool and check for a 164-11 Injection Actuation Pressure System Fault Diagnostic EVENT Code. If a 164-11 Diagnostic EVENT Code has been recently logged, Refer To Section 5: P-515 Injector Solenoids.

P-307: Electronic Service Tool Will Not Communicate With ECM

Probable Root Causes For ECAP:

* ECAP connector is receiving battery voltage but the ECM is not

* Battery power or ground to ECM (machine wiring)

* ECAP cable problem

* Machine harness data link wiring problem

* ECM or Personality Module problem

Perform The Following Tests In Order:

1. Ensure the keyswitch is in the ON position and any override switches are not creating the problem, or start the engine and then connect an ECAP. If communication occurs when the engine is started, but not with the keyswitch in the ON position, some type of override switch or system is preventing power to the ECM.

2. Start engine, if it cranks, but will not start check the ECM power and ground connections, and the ECM 40-Pin Connectors. Wire a bypass as indicated in the last step of P-503: Electrical Power Supply To The ECM if necessary. For further information Refer To P-503: Electrical Power Supply To The ECM.

3. Start engine, if it starts, but will not communicate check the Electronic Service Tool connections and wiring. Connect another Electronic Service Tool to the system, and also try another Electronic Service Tool harness cable to determine if the problem is with the Electronic Service Tool or the harness. For further information Refer To P-532: ATA (SAE J1587) Data Link.

4. Start engine, if it starts, but will not communicate, connect a 40-Pin Breakout T into J1/P1 and access the power (pin-6), ground (ground stud), Data Link+ (pin-7), and Data Link- (pin-1). Make jumper wires and connect these directly to the Electronic Service Tool harness. For further information Refer To P-532: ATA (SAE J1587) Data Link.

5. Start engine, if it cranks, but will not start and the battery connections have been thoroughly inspected (with no problem found), connect another ECM (first transfer the Personality Module Data from the suspect ECM to the known good ECM). For further assistance Refer To P-513: ECM/Personality Module.

NOTE: A new ECM has an unprogrammed Personality Module, and will cause this symptom.

Probable Root Causes For ET:

* Connector or wiring problem in electronic system wiring harness

* Electronic Technician or Communication Adapter Service Tool cable problem

* Electrical power supply; faulty keyswitch or input to ECM

* Data Link problem

* ECM or Personality Module problem

Perform The Following Tests In Order:

1. Check the wiring harness including ECM Connectors J1/P1, J2/P2, Machine Interface connector J3/P3 and Service Tool Connector J8/P8 for opens/shorts.

Refer To P-501: Inspecting Electrical Connectors.

2. Verify correct operation of Electronic Service Tool and Communication Adapter Tool and connector cables on another engine if possible.

3. Refer To P-503: Electrical Power Supply to the ECM. If the keyswitch is not receiving battery voltage, the ECM will remain in a powered down (OFF) state. It can not communicate until 24 VDC is applied to the keyswitch input.

4. Refer To P-532: ATA (SAE J1587) Data Link

P-308: ECM Will Not Accept Factory Passwords

Probable Root Causes:

* Incorrect screen (Electronic Service Tool expects customer passwords)

* Incorrect information used to obtain password

* Error entering password

* Error entering Reason Code

Perform The Following Tests In Order:

1. Verify that the Electronic Service Tool is on factory password screen (and expects Factory Passwords rather than Customer Passwords).

2. Verify engine serial number used to calculate password was from Electronic Service Tool screen, not from the engine information plate. Verify all information on the Electronic Service Tool screens was provided to Caterpillar to get the password.

NOTE: A new ECM comes with the engine serial number programmed as 0XX00000. Be sure to use this number in getting passwords. Verify correct passwords were entered (upper case only). Also check each character in password for accuracy (for instance I vs. 1, Z vs. 2, O vs. 0, etc). Turn the keyswitch to the OFF position, then retry.

NOTE: Refer To Section 2: Programmable Parameters for more details. Verify correct Reason Code was entered (upper case only). Turn the keyswitch to the OFF position, then retry.

P-310: Excessive Black Smoke

Probable root causes:

* Air inlet restriction

* Incorrect valve adjustment

* Faulty unit injector

* Turbocharger Compressor Outlet Pressure Sensor signal

* Personality Module

1. Check air inlet and exhaust systems for restrictions, Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

2. Inspect ECM Connector J2/P2 for full connection and corrosion. Connect an Electronic Service Tool and cut out each cylinder to isolate the misfiring cylinder(s). If it can be isolated to a specific cylinder(s), Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

3. Monitor "Fuel Pos", "Rated Fuel Pos", and "FRC Fuel Pos", on the Electronic Service Tool. These three parameters should be as follows while the vehicle is operating under full load.

"Fuel Pos" equal to "Rated Fuel Pos" AND "Fuel Pos" is less than "FRC Fuel Pos"

4. Fuel Pos should be limited to FRC until Turbocharger Compressor Outlet Pressure is up to a predetermined level. If the parameters are as indicated above, the Electronics are operating correctly. If these parameters are not as indicated check the following,

6. Connect an Electronic Service Tool and check to ensure the correct Personality Module is installed compared to the engine configuration.

P-311: Excessive White Smoke

Probable Root Causes:

* Normal operation

* Fuel supply

* Low pressure

* Combustion gas/air in fuel

* Poor fuel quality

* Incorrect fuel blend

* Faulty unit injector

* Combustion problem

* Inlet Air Heater Malfunction

* Air inlet restriction

* Coolant Temperature or Inlet Manifold Air Temperature Sensor Circuit

Perform The Following Tests In Order:

1. The engine may smoke briefly under cold conditions if the brake or clutch have been depressed, because the ECM will exit Cold Mode briefly (to allow an Automatic Transmission to be put in gear). Cold Mode will gradually return if the Coolant Temperature is below 17°C (64°F).

2. Check fuel quality. Inspect fuel system and check fuel pressure. Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

3. Check for air in fuel. Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

4. Connect an Electronic Service Tool and check for Coolant Temperature or Inlet Manifold Air Temperature Sensor Diagnostic Codes. Monitor Coolant Temperature Sensor and inlet Manifold Air Temperature Status on an Electronic Service Tool. If an Active Open or Short Circuit Diagnostic Code is detected, Inspect ECM Connector J2/P2 for full connection and corrosion. Connect an Electronic Service Tool and cut-out each cylinder to isolate the misfiring cylinder(s). If it can be isolated to a specific cylinder(s), Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

5. If the Inlet Air Heater fails to come ON in cold weather white smoke could result. Check the Coolant and Inlet Air Temperature Sensors through an Electronic Service Tool, and Inlet Air Heater Grid, Inlet Air Heater Relay, and wiring.

6. Check air inlet and exhaust systems for restrictions, Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

P-312: Can Not Reach Top Engine RPM

Probable Root Causes:

* Customer Specified Parameters

* Cold Mode Operation

* Throttle Position Sensor signal

* Vehicle speed signal

* Fuel supply:

* Low pressure

* Poor fuel quality

* Vehicle Speed Limit

* Lower Gears Engine RPM Limit

* Intermediate Gears Engine RPM Limit

* Gear Down Protection Engine RPM Limit

* Dedicated PTO Switch ON or Torque Limit Switch always ON.

Perform The Following Tests In Order:

Verify the complaint is not normal (programmed parameter) operation. Connect an Electronic Service Tool and check for the following rating # (if rating # is 0, the engine is limited to 87.5 kW [120 hp])

7. Set each parameter to its maximum value one at a time and check if, after changing each parameter, the problem is corrected. For a description of these parameters, Refer To Section 2: Programming Parameters.

8. Monitor any of the Electronic Service Tool Status screens to verify the engine has shifted out of Cold Mode. An Active Cold Mode is indicated in the upper corner of any Status Screen.

9. Monitor the Throttle Position status. Operate the engine to high idle with the vehicle in neutral. If the engine can not reach Top Engine Limit check the Throttle Duty Cycle to verify it is within calibration (75 to 90 percent at high idle). If a problem with the Throttle Sensor is suspected, Refer To Section 5: P-504 Throttle Position Sensor.

10. Monitor the vehicle speed signal and verify accuracy compared to actual speed. If Electronic Service Tool vehicle speed is greater than the programmed Vehicle Speed Limit (VSL), engine rpm is limited, or if it equals VSL, engine rpm is limited to the programmed rpm for the VSL Protection parameter. If a problem is discovered, Refer To Section 5: P-593 Machine/Vehicle Speed Circuit Test.

11. Check fuel quality.

12. Inspect fuel system and check fuel pressure. Refer To Systems Operation, Testing And Adjusting Manual, Senr1158.

13. Check the Customer Parameter setting for the Dedicated PTO Parameter Torque Limit. If it is programmed below 2712 N·m (2000 lb ft), check the status screen for Multi-Function Input #1 and Multi-Function Input #2 to ensure the status indicates OFF. If the status is ON with a Torque Limit programmed, the system is operating correctly. If the switch connected to this input is not switching ON and OFF.

P-313: Poor Acceleration or Response

Probable Root Causes:

* Customer Specified Parameters (normal operation)

* Turbocharger Compressor Outlet Pressure Sensor signal

* Cold Mode Operation

* Individual cylinder malfunction

* Personality Module

* Dedicated PTO Switch ON or Torque Limit Switch always ON.

* Actual Injection Actuation Pressure Less Than Desired Injection Actuation Pressure.

* Mechanical Problems

* Individual cylinder malfunction

Perform The Following Tests In Order:

1. Verify the complaint is not normal (programmed parameter) operation. Connect an Electronic Service Tool and check for the following.

- rating # (if rating # is 0, the engine is limited to 87.5 kW [120 hp])

- Vehicle Speed Limit

2. Set each parameter to its maximum value one at a time and check if, after changing each parameter, the problem is corrected. For a description of these parameters, Refer To Section 2: Programming Parameters.

3. Monitor "Fuel Pos", "Rated Fuel Pos", and "FRC Fuel Pos", on the Electronic Service Tool. These three parameters should be as follows while the vehicle is operating under full load. "Fuel Pos" equal to "Rated Fuel Pos" AND "Fuel Pos" is less than "FRC Fuel Pos"

4. Fuel Pos should be limited to FRC until Turbocharger Compressor Outlet Pressure is up to a predetermined level. If the parameters are as indicated, the Electronics are operating correctly. If these parameters are not as indicated check the following;

6. Monitor any of the Electronic Service Tool Status screens to verify the engine has shifted out of Cold Mode. An Active Cold Mode is indicated in the upper corner of any Status Screen.

7. Inspect ECM Connector J2/P2 for full connection and corrosion. Connect an Electronic Service Tool and cut-out each cylinder to isolate the misfiring cylinder(s). If it can be isolated to a specific cylinder(s), Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

8. Connect an Electronic Service Tool and check to ensure the correct Personality Module is installed compared to the engine configuration.

9. Connect an Electronic Service Tool and check the Customer Parameter setting for the Dedicated PTO Parameter Torque Limit and/or PTO TEL Parameter. If it is programmed below 2712 N·m (2000 lb ft), check the status screen for Multi-Function Input #1 and Multi-Function Input #2 and verify the status indicates OFF. If the status is ON with a Torque Limit programmed the system is operating correctly. If the switch connected to this input is not switching ON and OFF.

10. Check the Injection Actuation Pressure from an Electronic Service Tool against the Desired Injection Actuation Pressure to verify that Desired Injection Actuation Pressure is being reached.

11. Refer To The Systems Operation, Testing And Adjusting Manual, SENR1158.

12. Perform a PAR (Performance Analysis Report) Test.

P-314: Poor Fuel Consumption

Probable Root Causes:

* Vehicle operation

* Vehicle Specifications

* Fuel supply

* Poor fuel quality

* Air inlet or exhaust system restrictions

Perform The Following Tests In Order:

1. Inspect the ECM Totals idle time for excessive idling. Check the Customer Parameter Vehicle Speed Limit for a high programmed Vehicle Speed Limit.

2. Consider environmental conditions such as wind, snow, road condition, etc.

3. Gearing or power train, vehicle aerodynamics, or unusually heavy loads.

4. Check fuel quality.

5. Check air inlet and exhaust systems for restrictions and leaks, Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

P-336: Cruise Control Or Idle/PTO Cannot Be Set

Probable root causes:

* High Cruise And Low Cruise Vehicle Speed Limits

* Idle/PTO Vehicle and Engine rpm limit

* Cruise Control On/Off switch,

* Dedicated PTO On/Off switch

* Cruise Control or PTO On/Off Switch, Set/Resume Switch, Service Brake, Clutch Switch Circuits, or vehicle speed circuit.

Perform The Following Tests In Order:

1. Connect an Electronic Service Tool and check the Status Screens for the Cruise Control On/Off, Set/Resume, Brake, Clutch switches, and vehicle speed. View the Electronic Service Tool while turning the switch ON/OFF, to Set/Resume, or depressing the clutch/service brake.

2. Also view the Electronic Service Tool and compare Electronic Service Tool vehicle speed to the speedometer. Possible vehicle speed circuit root causes would be incorrect Vehicle Speed.

3. "SET SW TIMEOUT" indicates either the operator depressed the Set switch for more than 15 seconds, or the circuit experienced a short circuit to Sensor Common. "RES SW TIMEOUT" is identical except it applies to the Resume switch and Resume switch circuit. If the operator depresses the switch in either position for more than 15 seconds, the Cruise Control On/Off Switch must be turned OFF and then back ON before Cruise Control can be set/or used again.

4. Make sure the programmed Transmission Style matches the switches installed in the vehicle.

P-337: Can Not Reach Vehicle Speed Limit

Probable Root Causes:

Customer Specified Parameters

* Normal operation

* Incorrect Programming of Vehicle Speed Calibration Pulses per Mile

* Cold Mode Operation

* Electronic System problem

* Fuel supply:

* Low pressure

* Poor fuel quality

NOTE: Soft Vehicle Speed Limit will not allow the vehicle to achieve programmed VSL under all engine load conditions. Programming Soft VSL to NO may be required to eliminate the complaint.

Perform The Following Tests In Order:

1. Verify the complaint is not normal (programmed parameter) operation. Connect an Electronic Service Tool and check for the following.

- rating # (if rating # is 0, the engine is limited to 87.5 kW [120 hp])

- Vehicle Speed Limit setting value

- Vehicle Speed Limit Protection

- Set each parameter to its maximum value one at a time and check if, after changing each parameter, the problem is corrected.

3. Monitor "Fuel Pos", "Rated Fuel Pos", and "FRC Fuel Pos", on the Electronic Service Tool. These three parameters should be as follows while the vehicle is operating under full load. "Fuel Pos" = "Rated Fuel Pos" AND "Fuel Pos" is less than "FRC Fuel Pos"

4. If the parameters are as indicated above, the Electronics are operating correctly. If these parameters are not as indicated check the following.

6. Monitor the Throttle Position status. Operate the engine to high idle with the vehicle in Neutral. If the engine can not reach Top Engine Limit, check the Throttle Duty Cycle to verify it is within calibration (75 to 90 percent at high idle). If throttle position is unstable when it should not be, check the Throttle Duty Cycle while slowly operating the accelerator pedal to verify it is within calibration (10 to 22 percent at low idle, 75 to 90 percent at high idle), and the duty cycle changes along with pedal position. If a problem with the Throttle Sensor is suspected, Refer To Section 5: P-504 Throttle Position Sensor.

7. Monitor the vehicle speed signal and verify accuracy compared to actual speed. If Electronic Service Tool vehicle speed is greater than VSL, power is limited. If a problem is discovered, Refer To Section 5: P-593Machine/Vehicle Speed.

8. Check fuel quality.

9. Inspect fuel system and check fuel pressure. Refer To Systems Operation, Testing And Adjusting Manual, SENR1158.

P-338: Intermittent Cruise Control Or PTO Drop-Out/Kickout

Probable root causes:

Incorrectly adjusted clutch switch, incorrectly adjusted service brake switch (or switches for vehicles with two service brake switches), malfunctioning Cruise Control On/Off switch, or a vehicle speed circuit problem.

* If Electronic Service Tool indicates "SW TURNED OFF",

* Cruise Control On/Off switch OFF

* Electronic Service Tool indicates "BRAKE" or "CLUTCH"

* Service brake or clutch pedals,

* If Electronic Service Tool indicates "BAD VEH SPD", OR... "BAD VEH SPD"

* If Electronic Service Tool indicates "VEH SPD < 5 MPH", OR.

* If Electronic Service Tool indicates "VEH SPD > LIMIT",

* If Electronic Service Tool indicates "SET SW TIMEOUT" or "RES SW TIMEOUT",

NOTE: The Electronic Service Tool will only provide access to the last cause of the Cruise Control dropout. If the ECM is powered down (keyswitch turned OFF), and then back ON, the Electronic Service Tool display will be blank. It may be necessary to take the vehicle for a drive to repeat the problem, and check the Electronic Service Tool before the keyswitch is switched OFF.

Perform The Following Tests In Order:

1. "SW TURNED OFF" indicates the ECM has detected an open circuit in the On/Off switch circuit. This applies to both the cruise control and PTO On/Off circuits.

2. Ensure the operator has not actually turned the Cruise Control On/Off switch OFF, and check the Electronic Service Tool status screen while using the switch. If a problem is not apparent, inspect the switch and wiring. "BRAKE" or "CLUTCH" indicates the ECM has detected an open circuit in the switch circuit for the service brake #1 or clutch circuit. If the Transmission Style Parameter is programmed to Auto w/2 Brake Sw there should be a second service brake switch. The second brake switch could be closed when it should be open (pedal released). This applies to both cruise control and PTO.

3. Ensure the operator has not actually depressed the service brake or clutch pedals, then check the Electronic Service Tool status screen while using the service brake or clutch. If a problem is not noticeable, inspect the switch (especially air system for service brakes to verify treadle is not hung up causing pressure spikes, or clutch switch adjustment/return spring).

4. "BAD VEH SPD" indicates the vehicle speed signal is erratic or intermittent. This applies to cruise control only.

5. "VEH SPD < 5 MPH" indicates the vehicle speed signal was at least temporarily lost. This applies to cruise control only.

"VEH SPD > LIMIT" indicates the vehicle speed signal exceeded the programmed Idle/PTO Vehicle Speed Limit or the vehicle speed is erratic or intermittent. This applies to Idle/PTO only.

6. "SET SW TIMEOUT" indicates either the operator depressed the Set switch for more than 15 seconds, or the circuit experienced a short circuit to Sensor Common. "RES SW TIMEOUT" is identical except it applies to the Resume switch and Resume switch circuit. If the operator depresses the switch in either of these positions for more than 15 seconds, the Cruise Control On/Off Switch must be turned OFF and then back ON before Cruise Control can be set/or used again.

7. Inspect the vehicle speed sensor for debris on the sensor and inspect the vehicle speed circuit. Check Electronic Service Tool status screen vehicle speed while idling (rev the engine up and down) and while driving to verify that the Electronic Service Tool indicated vehicle speed varies significantly from the speedometer. If a problem is not noticeable Refer To Section 5: P-593 Machine/Vehicle Speed. Inspect both ECM Connectors for moisture entry. Refer To Section 5: P-501 Inspecting Electrical Connectors. This cause will result in engine rpm cutouts or other more severe problems associated with it. If this is a suspected cause, Refer To Section 5: P-503 Electrical Power Supply To The ECM.