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詳細描述
Troubleshooting
2206D-E13TA Industrial Engine
Level 3 – Level 3 requires an immediate safe
shutdown of the engine to avoid damage to the
engine or injury to personnel around the engine. The
problem that caused the event must be corrected
before engine operation can resume.
Active Event Codes
An active event code represents a problem with
engine operation. Correct the problem as soon as
possible.
Active event codes are listed in ascending numerical
order. The code with the lowest number is listed first.
Illustration 21 is an example of the operating range of
a sensor.
Illustration 21
g01365757
Example of the typical operating range of a sensor
(1) This area represents the normal operating range of the engine
parameter.
(2) In these areas, the engine is operating in an unsafe operating
range of the monitored parameter. An event code will be
generated for the monitored parameter. The sensor circuit
does not have an electronic problem.
(3) In these areas, the signal from the sensor is outside of the
operating range of the sensor. The sensor circuit has an
electronic problem. A diagnostic code will be generated for the
sensor circuit. Refer to Troubleshooting, “Diagnostic Trouble
Codes” for additional information on diagnostic codes.
Logged Event Codes
When the Electronic Control Module (ECM)
generates an event code, the ECM logs the code in
permanent memory. The ECM has an internal
diagnostic clock. The ECM will record the following
information when an event code is generated:
• The hour of the first occurrence of the code
• The hour of the last occurrence of the code
• The number of occurrences of the code
Logged events are listed in chronological order. The
most recent event code is listed first.
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UENR4542
41
Event Codes
This information can be helpful for troubleshooting
intermittent problems. Logged codes can also be
used to review the performance of the engine.
Be sure to check the connectors. This step is
important for problems that are intermittent. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
Clearing Event Codes
If these steps do not resolve the problem, refer to
Table 10 or Table 9 for the procedure to troubleshoot
the event code.
A code is cleared from memory when one of the
following conditions occur:
• The code does not recur for 100 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
• The service technician manually clears the code.
Always clear logged event codes after investigating
and correcting the problem which generated the
code.
Troubleshooting
For the basic troubleshooting of the engine, perform
the following steps to diagnose a malfunction:
1. Obtain the following information about the
complaint:
• The event and the time of the event
• Determine the conditions for the event. The
conditions will include the engine rpm and the
load.
• Determine if there are any systems that were
installed by the dealer or by the customer that
could cause the event.
• Determine whether any additional events
occurred.
2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
due to error of the operator.
3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
history of the engine.
4. Perform a visual inspection. Inspect the following
items:
• Fuel supply
• Oil level
• Oil supply
• Wiring
• Connectors
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UENR4542
Symptom Troubleshooting
Symptom Troubleshooting
Follow the Procedures
If these inspections do not reveal any problems, use
the procedure that best describes the symptoms. The
procedures in this manual provide the most efficient
way to determine the root cause of the problem.
i05958963
Symptom Troubleshooting
i05958966
Acceleration Is Poor or
Throttle Response Is Poor
Use the following guidelines as you troubleshoot an
engine symptom:
Gather Information
Download the “Warranty Report” from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes.
Interview the operator about the problem before you
begin troubleshooting, when possible.
Probable Causes
• Codes
Verify the Problem
Attempt to duplicate the problem. Try to duplicate the
operating conditions, when possible. Verify that the
complaint is not due to normal engine operation.
• Parameters
• Throttle Signal
• Air Inlet and Exhaust System
• Fuel System
Diagnostic Codes
Check for any logged diagnostic codes.
• Determine if the logged diagnostic codes correlate
to probable causes.
• Engine Load
• Determine if the logged diagnostic codes occur at
the same time as the symptoms.
• Valve Lash
Recommended Actions
• Determine if the logged diagnostic codes are
logged repeatedly.
Note: The procedures have been listed in order of
Repair all active diagnostic codes. Refer to
Troubleshooting, “Diagnostic Trouble Codes” for the
correct troubleshooting procedure.
probability. Complete the procedures in order.
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load, and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Connectors and Wiring
Check the wiring and the connectors for the following
problems:
• Damage
• Abrasion
• Corrosion
• Incorrect attachment
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Symptom Troubleshooting
Table 11
Troubleshooting Test Steps
Values
Results
1. Check for Codes
Result: A diagnostic code is present.
Repair: Troubleshoot the code.
Diagnostic
Codes
A. Connect the electronic service tool to the service tool
connector.
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Incorrect Parameters
Result: The parameters are correct.
Proceed to Test Step 3.
Parameters
A. Use the electronic service tool to verify that the correct param-
eters are being used. Refer to Troubleshooting, “Configuration
Parameters” for additional information.
Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Trouble-
shooting, “Configuration Parameters” for additional
information.
3. Throttle Signal
Result: The throttle signal is stable.
Throttle Signal Proceed to Test Step 4.
A. Monitor the status for “Throttle Position” on the electronic serv-
ice tool. Verify that the status for “Throttle Position” is stable and
that the engine is able to reach high idle speed.
Result: The throttle signal is not stable.
Repair: Make the necessary repairs, Refer to the appro-
priate circuit test.
4. Restriction in the Air Inlet and Exhaust System
Result: There are no restrictions in the air inlet or exhaust
Restrictions
system.
A. Observe the check engine lamp. Check for an air filter restric-
tion indicator. Replace any plugged air filters. Refer to the Opera-
tion and Maintenance Manual.
Proceed to Test Step 5.
Result: There are restrictions in the air inlet or exhaust
B. Check the air inlet and exhaust system for restrictions and/or
system.
leaks.
Repair: Make the necessary repairs, Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and Exhaust
System - Inspect” for additional information.
(continued)
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UENR4542
Symptom Troubleshooting
(Table 11, contd)
5. Check the Fuel System
Result: The fuel pressure is OK.
Proceed to Test Step 6.
Fuel system
Refer to Systems Operation/Testing and Adjusting, “Fuel System”
for additional information.
Result: The fuel pressure is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the
fuel gauge only.
Repair: Replace the fuel filters. Clean the primary filter/
water separator of debris. Refer to the Operation and
Maintenance Manual for details.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position.
D. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information.
E. Cold weather adversely affects the characteristics of the fuel.
Refer to the engines Operation and Maintenance Manual for infor-
mation on improving the characteristics of the fuel during cold-
weather operation. Cold mode (if applicable) is activated when-
ever the engine coolant temperature falls below a predetermined
value. Monitor the status screen on the electronic service tool in
order to verify that the engine has exited cold mode. Observe the
reading for coolant temperature on the electronic service tool.
Refer to "Cold Mode Operation" within the Systems Operation,
“General Information”.
F. Check fuel quality. Refer to Systems Operation/Testing and Ad-
justing, “Fuel Quality - Test” for the proper procedure. Check the
fuel tank for debris or foreign objects which may block the fuel
supply.
G. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation/Testing and Adjusting, “Fuel System” for
test information.
6. Engine Load
Engine loads
Result: There is not a parasitic load.
Proceed to Test Step 7.
A. Check accessories and parasitic loads on the engine.
Result: There is a parasitic load.
Repair: Remove the parasitic load.
7. Valve Lash
Valve lash
Result: The valve lash is not set correctly.
A. Check the valve lash. The valve lash can affect the perform-
Repair: Set the valve lash. Refer to Testing and Adjusting,
ance of the engine.
“Engine Valve Lash - Inspect/Adjust” for the correct
procedure.
STOP
i06244264
• Charging Circuit
Alternator Problem
Recommended Actions
Probable Causes
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
• Alternator
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Symptom Troubleshooting
Table 12
Troubleshooting Test Steps
Values
Results
1. Condition of the Alternator Drive Belts
Drive belt
Result: The alternator drive belts are in good condition
and the belt tension is correct.
A. Inspect the condition of the alternator drive belts.
Proceed to Test Step 2.
B. Check the belt tension. If the engine is equipped with an
automatic belt tensioner, check the automatic belt tensioner.
Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
Repair: If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and Assembly for
the correct procedure.
If necessary, replace the automatic belt tensioner. Refer to
Disassembly and Assembly for the correct procedure.
2. Condition of the Alternator Drive Pulley
Alternator Drive
Pulley
Result: There is excessive wear on the alternator drive
pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt.
Check that the nut for the pulley has not become loose.
Repair: Replace the pulley.
Result: The alternator drive pulley nut was loose.
Repair: Tighten the nut.
Result: There is not excessive wear on the alternator drive
pulley.
Proceed to Test Step 3.
3. Wear of the Alternator Bearings
Alternator bearings Result: The alternator bearings are OK.
Proceed to Test Step 4.
A. Check the alternator bearings for signs of wear.
Result: The alternator bearings are not OK.
Repair: Repair the alternator or replace the alternator, as
needed. Refer to Disassembly and Assembly for the cor-
rect procedure.
4. Operation of the Alternator or Regulator
Regulator and
alternator
Result: The regulator and alternator are operating
properly.
A. Verify that the alternator or the regulator is operating cor-
rectly. Refer to Systems Operation, Testing and Adjusting,
“Charging System - Test” for the proper testing procedures.
Proceed to Test Step 5.
Result: The regulator and alternator are not operating
properly.
Repair: Repair the alternator and regulator or replace the
alternator and regulator, as needed. Refer to Disassembly
and Assembly for the correct procedure.
5. Inspection of the Charging Circuit
Charging circuit
Result: The charging circuit is not working properly.
A. Inspect the battery cables, wiring, and connections in the
Repair: Clean all connections and tighten all connections.
charging circuit.
Replace any faulty parts.
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UENR4542
Symptom Troubleshooting
If the procedure did not correct the issue, contact the
Dealer Solutions Network (DSN).
i05959017
Battery Problem
Probable Causes
• Battery
• Switched Battery Circuit
Recommended Actions
Download the Product Status Report from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Troubleshoot any
active codes before continuing with this procedure.
Table 13
Troubleshooting Test Steps
Values
Results
1.Check the Battery
Battery
Result: The battery is OK.
A. Verify that the battery is no longer able to hold a charge. Refer
Proceed to Test Step 2.
to Systems Operation/Testing and Adjusting, “Battery - Test”.
Result: The battery is not OK.
Repair: Replace the battery. Refer to Disassembly and As-
sembly for the correct procedure.
2. Check the Switched Battery Circuit
Switched
battery
circuit
Result: The switched battery circuit drained the battery by
being left in the ON position.
A. Verify that a switched battery circuit drained the battery by
being left in the ON position.
Repair: Charge the battery. Verify that the battery is able to
maintain a charge. Refer to Systems Operation/Testing and
Adjusting for the correct procedure.
i06245217
Coolant Contains Fuel
Probable Causes
• Leaking injector sleeve and/or damaged seal
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Symptom Troubleshooting
Recommended Actions
Table 14
Troubleshooting Test Steps
Values
Results
1. Leaking injector sleeve and/or damaged seal
A. Remove the valve mechanism covers.
Result: The injector sleeve is leaking.
Injector sleeve
Repair: Remove the injector sleeve that is leaking. Carefully
inspect the sleeve for damage. If there are visible signs of
damage to the injector sleeve, replace the sleeve. Replace the
O-ring seals for the injector sleeve and reinstall the sleeve. Re-
place any damaged components.
B. Remove the fuel injectors from the cylinder head.
Refer to the Disassembly and Assembly manual for details.
Do not allow the pressure on the cooling system to exceed
103 kPa (15 psi) during the test. Damage to the cooling
system may result from applying excessive pressure.
Coolant may also be contaminating the fuel system. After the
engine is shut down, the retention of pressure in the cooling
system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of
coolant in the fuel system may damage injectors and other fuel
system components. Ensure that all of the fuel system compo-
nents are in good repair prior to returning the engine to
service.
C. Pressurize the cooling system in order to identify the injector
sleeve that is leaking. Closely inspect the sealing joint around
the top of the injector sleeve. Small amounts of coolant will be
dripping from the injector sleeve that is leaking.
Coolant may also be contaminating the fuel system. After the
engine is shut down, the retention of pressure in the cooling
system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of
coolant in the fuel system may damage injectors and other fuel
system components. Ensure that all of the fuel system compo-
nents are in good repair prior to returning the engine to service.
Do not crank the engine if a cylinder is full of fluid. Cata-
strophic damage can occur to the engine.
Evacuate all cylinders of fluid before trying to start the engine.
Complete the procedure in the order in which the
steps are listed.
i06245230
Coolant Contains Oil
Probable Causes
• Engine Oil Cooler
• Power Train Oil Cooler (if equipped)
• Water-Cooled Turbocharger
• Cylinder Head Gasket
• Block
The procedures have been listed in order of
probability. Complete the procedures in order.
Verify the presence of oil in the coolant with a
scheduled oil sample. Verification must be made
before performing the procedure.
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Symptom Troubleshooting
Recommended Actions
Table 15
Troubleshooting Test Steps
Values
Results
1. Leak in the Engine Oil Cooler
Oil Cooler
Result: A leak is found in the engine oil cooler.
A. Check for leaks in the engine oil cooler. Refer to Testing
Repair: Install a new oil cooler core. Refer to the Disas-
and Adjusting for the proper procedure.
sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and
Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.
Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the crankcase with the proper oil after
the leak has been repaired. Refer to the Operation and
Maintenance Manual for the correct oil capacities and
viscosity.
Result: A leak was not found in the engine oil cooler.
Proceed to Test Step 2.
2. Leak in the Power Train Oil Cooler
Power train cooler Result: A leak is found in the power train oil cooler.
A. Check for leaks in the power train oil cooler. Refer to Test-
Repair: Install a new oil cooler core. Refer to the Disas-
ing and Adjusting for the proper procedure
sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and
Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.
Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the oil after the leak has been re-
paired. Refer to the Operation and Maintenance Manual
for the correct oil capacities and viscosity.
Result: A leak was not found in the power train oil cooler.
Proceed to Test Step 3.
(continued)
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Symptom Troubleshooting
(Table 15, contd)
Troubleshooting Test Steps
Values
Results
3. Water-Cooled Turbocharger (if equipped)
Turbocharger
Result: The turbocharger is cracked.
A. Inspect the turbocharger for cracks.
Repair: Replace the turbocharger. Refer to the engine
Disassembly and Assembly for the correct procedure.
B. Remove the oil drain line from the turbo and pressurize the
cooling system, Refer to Testing and Adjusting, “Cooling Sys-
tem - Test”.
Flush the cooling system, Refer to the Operation and
Maintenance Manual for the correct procedure.
C. Check the turbocharger for coolant leakage.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.
Check the oil for coolant. If coolant is found in the oil, drain
the oil. Refill the oil after the leak has been repaired. Refer
to the Operation and Maintenance Manual for the correct
oil capacities.
Result: The turbocharger is not cracked.
Proceed to Test Step 4.
4. Cylinder Head Gasket
Cylinder head
gasket
Result: New cylinder head gasket and water seals were
installed.
A. Remove the cylinder head. Refer to the Disassembly and
Assembly manual.
Proceed to Test Step 5.
B. Check the cylinder liner projection. Refer to the Systems
Operation/Testing and Adjusting manual.
C. Install a new cylinder head gasket and new water seals in
the spacer plate. Refer to the Disassembly and Assembly
manual.
5. Cylinder Head
Cylinder head
Result: A crack is found in the cylinder head.
A. Check for cracks in the cylinder head. Perform a leak test
on the cylinder head. Refer to System Operation, Testing and
Adjusting for the proper procedure for checking the cylinder
head.
Repair: Repair the cylinder head and/or replace the cylin-
der head. Refer to the Disassembly and Assembly
manual.
Result: A crack is not found in the cylinder head.
Proceed to Test Step 6.
Result: A crack is found in the cylinder block.
6. Cylinder Block
Cylinder block
Repair: Repair the cylinder block or replace the cylinder
block. Inspect the top deck. Refer to Systems Operation,
Testing and Adjusting, “Cylinder Block - Inspect” for the
proper inspection procedure.
A. Inspect the cylinder block for cracks.
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UENR4542
Symptom Troubleshooting
Complete the procedure in the order in which the
steps are listed.
i06300672
Coolant Level Is Low
Use this procedure in order to troubleshoot low
coolant level or use this procedure if one of the
following codes is active. Refer to Troubleshooting,
“Diagnostic Trouble Codes” for information about
diagnostic codes. Access the monitoring system on
the electronic service tool in order to view the current
trip points for these codes. For information on the
engine monitoring system, refer to Troubleshooting,
“Diagnostic Capabilities”.
Note: Some of the following codes may not be
applicable for certain applications.
Table 16
Diagnostic Trouble Codes
Code Description
J1939 Code
PDL Code
System Response
The engine has been running for 60 seconds. The engine cool-
Engine Coolant Level : Low - Most ant level has fallen below the coolant level sensor for the
111-1
E2143 (3)
Severe (3)
specified delay time.
Engine power is derated. The code is logged.
The engine has been running for 60 seconds. The engine cool-
ant level has fallen below the coolant level sensor for the
specified delay time.
Engine Coolant Level : Low - Least
Severe (1)
111-17
111-18
E2143 (1)
E2143 (2)
The code is logged.
The engine has been running for 60 seconds. The engine cool-
ant level has fallen below the coolant level sensor for the
specified delay time.
Engine Coolant Level : Low - Moder-
ately Severe (2)
Engine power is derated. The code is logged.
Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant level sensor
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
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Symptom Troubleshooting
Table 17
Troubleshooting Test Steps
Values
Results
1. Low Coolant Level and/or Coolant Leakage
Coolant level Result: The engine coolant level is OK.
Proceed to Test Step 2.
A. Inspect the coolant level.
Result: The engine coolant level is not OK.
Repair: Troubleshoot the cause of the incorrect coolant
level.
1. Check for the correct mixture of antifreeze and water. Re-
fer to Operation and Maintenance Manual.
2. Check the cooling system for leaks. Refer to Systems Op-
eration/Testing and Adjusting, “Cooling System - Test” for
the correct procedure. Repair any leaks immediately.
3. Check for air in the cooling system. Refer to Systems Op-
eration/Testing and Adjusting, “Testing the Cooling System”
for the correct procedure.
2. Faulty Sensor
Coolant level Result: The coolant level sensor is not operating properly.
sensor
A. If an electrical problem with the coolant level sensor is sus-
pected, refer to Troubleshooting, “Coolant Level - Test” for informa-
tion that is related to troubleshooting an electrical problem with the
coolant level sensor.
Repair: Replace the coolant level sensor.
Complete the procedure in the order in which the
steps are listed.
i06300696
Coolant Temperature Is High
Use this procedure in order to troubleshoot high
coolant temperature or use this procedure if one of
the following event codes is active. Access the
monitoring system on the electronic service tool in
order to view the current trip points for these codes.
Table 18
Diagnostic Trouble Codes
Code Description
J1939 Code
PDL Code
Comments
The engine coolant temperature has exceeded the
Engine Coolant Temperature High trip point and the delay time has expired.
110-0
E361 (3)
- Most Severe (3)
Engine power is derated.
The code is logged.
The engine coolant temperature has exceeded the
trip point and delay time has expired.
The code is logged.
Engine Coolant Temperature
High- Least Severe (1)
110-15
110-16
E361 (1)
E361 (2)
The engine coolant temperature has exceeded the
trip point and the delay time has expired.
The code is logged.
High Engine Coolant Temperature
High - Moderate Severity (2)
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UENR4542
Symptom Troubleshooting
Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant Temperature Sensor
• Water Temperature Regulator and/or Pressure
Relief Valve
• Radiator
• Heat Exchanger
• Engine Cooling Fan (if equipped)
• Coolant Pump
• Cylinder Head Gasket
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Table 19
Troubleshooting Test Steps
Values
Results
1. Coolant
Engine coolant Result: The engine coolant level is OK.
level
A. Inspect the coolant level.
Proceed to Test Step 2.
Result: The engine coolant level is not OK.
Repair: Check the cooling system for leaks. Refer to Trou-
bleshooting, “Coolant Level is Low” for additional informa-
tion. Repair any leaks immediately.
2. Coolant Temperature Sensor and/or the Circuit
Coolant tem-
perature
sensor
Result: The temperature sensor is working properly.
Proceed to Test Step 3.
A. Check the reading of the coolant temperature on the electronic
service tool. The temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable.
Result: The temperature sensor is not working properly.
Repair: Troubleshoot the circuit and the coolant tempera-
ture sensor. Refer to Troubleshooting, “Sensor Signal
(Analog, Passive) - Test”.
3. Water Temperature Regulator and/or Pressure Relief Valve
Temperature
regulator
Result: The pressure relief valve and/or the water temper-
ature regulator are operating properly.
A. Pressure-test the cooling system. Refer to Systems Operation/
Testing and Adjusting for the correct procedure.
Proceed to Test Step 4.
B. Check that the seating surfaces of the pressure relief valve and
Result: The pressure relief valve and/or the water temper-
the radiator cap are clean and undamaged.
ature regulator are not operating properly.
C. Check operation of the pressure relief valve and/or the water
Repair: Clean the components and/or replace the
temperature regulator.
components.
(continued)
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53
Symptom Troubleshooting
(Table 19, contd)
Troubleshooting Test Steps
Values
Results
4. Radiator
Radiator
Result : The radiator fins are not damaged and the radia-
tor does not have an internal blockage.
A. Check the radiator fins for dirt, debris, and/or damage.
B. Check for collapsed hoses and/or other restrictions.
C. Check the radiator for internal blockage.
Proceed to Test Step 5.
Result : The radiator fins are damaged.
Repair: Remove any dirt and/or debris and straighten any
Ensure that the radiator size is sufficient. An undersized radiator
does not have enough area for the effective release of heat. An un-
dersized radiator may cause the engine to run at a temperature
that is higher than normal. The normal temperature is dependent
on the ambient temperature.
bent fins.
Result : The radiator has internal blockage.
Remove the blockage.
5. Heat Exchanger
Heat
exchanger
Result : The flow of cooling water is sufficient.
Proceed to Test Step 6.
A. Check for sufficient flow and temperature of the cooling water
through the heat exchanger.
Result : The flow of cooling water is not sufficient.
Repair: Determine the location of the obstruction. If the
temperature of the cooling water is too high, determine the
cause. Ensure that the size of the heat exchanger is suffi-
cient. Make the necessary repairs.
6. Faulty Engine Cooling Fan (if equipped)
Fan belt or
clutch
Result : The fan belt is tensioned correctly.
Proceed to Test Step 7.
A. If the fan is belt driven, check for loose drive belts.
A loose fan drive belt will cause a reduction in the air flow across
the radiator.
Result : The fan belt is not tensioned correctly.
Repair: Adjust the tension of the fan drive belt, if neces-
B. Check the fan clutch, if equipped.
sary. Refer to Operation and Maintenance Manual.
A fan clutch or a hydraulic driven fan that is not turning at the cor-
rect speed can cause improper air speed across the radiator core.
The lack of proper air flow across the radiator core can cause the
coolant not to cool to the proper temperature differential.
Result : The fan clutch is operating correctly.
Proceed to Test Step 7.
Result : The fan clutch is not operating correctly.
Repair: Refer to Troubleshooting, “Cooling Fan Control -
Test” for troubleshooting information.
(continued)
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UENR4542
Symptom Troubleshooting
(Table 19, contd)
Troubleshooting Test Steps
Values
Results
7. Inspection of the Coolant Pump
Coolant pump Result : The coolant pump is operating correctly.
Proceed to Test Step 8.
A. Inspect the impeller of the coolant pump for damage and/or
erosion.
Result : The coolant pump is not operating correctly.
B. Make sure that the drive gear is not loose on the drive shaft of
the coolant pump.
Repair: If necessary, replace the coolant pump. Refer to
Disassembly and Assembly for the correct procedure.
9. Cylinder Head Gasket
Head gasket
Result : The cylinder head was checked for leaks and the
gasket was replaced.
A. Remove the cylinder head. Refer to the Disassembly and As-
sembly manual.
Verify that the problem was corrected.
B. Check the cylinder liner projection. Refer to the Systems Opera-
tion/Testing and Adjusting manual.
C. Pressure test the head for leaks.
D. Install a new cylinder head gasket and new water seals in the
spacer plate. Refer to the Disassembly and Assembly manual.
Complete the procedure in the order in which the
steps are listed.
i06245465
Cylinder Is Noisy
Probable Causes
• Active codes and logged codes
• Low quality fuel
• Injectors
• Lack of lubrication
• Valve train components
• Gear train and components of the lower end
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
55
Symptom Troubleshooting
Table 20
Troubleshooting Test Steps
Values
Results
1. Active Codes and Logged Codes
Codes
Result: A diagnostic trouble code is not active or logged.
Proceed to Test Step 2.
A. Establish communication between the electronic service tool
and the Electronic Control Module (ECM).
Result: A diagnostic trouble code is active or logged.
Repair: Troubleshoot the active or logged codes.
2. Low Quality Fuel
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 3.
A. Refer to Operation and Maintenance Manual for information on
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is
being used for the engine. Refer to Systems Operation/Testing and
Adjusting, “Fuel System Quality Test” for the proper procedure.
Result: The fuel quality is not OK.
Repair: Replace the fuel. Verify that the repair eliminated
the problem.
3. Injectors
Injector Sole- Result: The test was successful.
noid Test or
Cylinder Cut- Proceed to Test Step 4.
out Test
Result: The test was not successful.
A. Perform the “Injector Solenoid Test” on the electronic service
tool in order to determine if all of the injector solenoids are being
energized by the ECM.
Repair: Diagnose the problem and then repair the
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests”
under the “Diagnostics” menu.
problem.
Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.
C. Perform the “Automatic Cylinder Cutout Test” on the electronic
service tool.
4. Lack of Lubrication
Lubrication
Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker
arms.
Proceed to Test Step 5.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information.
not have proper lubrication.
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
56
UENR4542
Symptom Troubleshooting
(Table 20, contd)
Troubleshooting Test Steps
Values
Results
5. Valve Train Components
Valve train
Result: The valve train components are not damaged.
Proceed to Test Step 6.
A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the valve
cover from the suspect cylinders. Check the following items for
damage:
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
4. Camshaft followers
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
Refer to Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
6. Gear Train and Components of the Lower End
Gear train
Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.
Complete the procedure in the order in which the
steps are listed.
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in the order of
the listed test steps.
i05962229
ECM Does Not Communicate
with Other Modules
Probable Causes
• Wiring and/or electrical connectors
• Perkins Data Link
• CAN data link (if equipped)
• Electronic Control Module (ECM)
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
57
Symptom Troubleshooting
Table 21
Troubleshooting Test Steps
Values
Results
1. Check for correct installation of the con-
nectors for the ECM J1/P1, J2/P2, and J3/
P3.
ECM
Result: Connectors are installed incorrectly.
Repair: Correct the installation issue. Return
Refer to Troubleshooting, “Electrical Connec-
tors - Inspect”
to service.
Result: Connectors are installed correctly.
Proceed to Test Step 2
Result: The electronic service tool will not
communicate with the ECM.
Proceed to troubleshooting without a diagnos-
tic code Troubleshooting, “Electronic Service
Tool Does Not Communicate”.
2. Connect the Electronic Service Tool to
the Service Tool Connector.
The electronic service tool
Result: The electronic service tool communi-
cates with the ECM. Proceed to Test Step 3.
3. Troubleshoot the Perkins Data Link for
possible problems.
Perkins Data Link
Result: Perkins Data Link does not connect.
Refer to Troubleshooting, “Data Link Circuit -
Test”.
Result: Perkins Data Link connects. Proceed
to Test Step 4.
4. Troubleshoot the CAN Data Link (if
equipped) for possible problems.
CAN Data Link
Result: CAN Data Link does not connect. Re-
fer to Troubleshooting, “CAN Data Link Circuit
- Test”.
Result: CAN Data Link connects. Return to
service.
i06301360
Engine Cranks but Does Not
Start
Download the “Product Status Report” from the
engine Electronic Control Module (ECM) before
performing any troubleshooting or clearing diagnostic
trouble codes.
Note: If the engine will not start and the electronic
service tool will not communicate with the ECM, the
problem is most likely with the electrical power supply
to the ECM. Refer to Troubleshooting, “Electrical
Power Supply - Test”.
This document has been printed from SPI2. NOT FOR RESALE
58
UENR4542
Symptom Troubleshooting
Table 22
Troubleshooting Test Steps
Values
Results
1. Inspection of the Fuel Supply
Fuel Level
Result : The fuel level is OK.
A. Visually check the fuel level in the fuel tank. Do not rely
on the fuel gauge only.
Proceed to Test Step 2.
Result : The fuel level is NOT OK.
Repair : Fill the tank.
STOP
B. Ensure that the fuel supply valve (if equipped) is in the
full OPEN position.
2. Check the , Engine Shutdown Switches if Applicable
Engine Shutdown Result : The switches are in the OFF position.
Switches
A. The engine shutdown switches must be in the OFF
Proceed to Test Step 3.
position.
Result : The switches are not in the OFF position.
Repair : Turn the switches to the OFF position.
STOP
B. Use the electronic service tool to verify the status of the
engine shutdown switches. When a shutdown occurs, the
keyswitch must be turned to the OFF position for at least 15
seconds before restarting the engine.
3. Check the Engine Starting Aids if Applicable
Starting Aids
Result : The starting aid is operating correctly.
Proceed to Test Step 4.
A. If cold ambient conditions exist, check the operation of
the starting aids. Verify that the starting aid is operating
correctly.
Result : The starting aid is not operating correctly.
Repair : Refer to the appropriate circuit test in order to trou-
bleshoot the starting aid.
4. Restrictions in the Air Inlet and Exhaust System
Air and Exhaust
System
Restrictions
Result : There are no system restrictions.
Proceed to Test Step 5.
A. Check for an air filter restriction indicator.
B. Check the air inlet and exhaust system for restrictions
Result : There are system restrictions.
and/or leaks.
Refer to Testing and Adjusting, “Air Inlet and Exhaust System
- Inspect” for more information on air system restrictions.
Repair : Replace plugged air filters. Refer to the Operation
and Maintenance Manual for the correct procedure.
5. Check for Activation of the Theft Deterrent System if Theft Deterrent
Result : The theft deterrent system is not active.
Proceed to Test Step 6.
Applicable
System
A. Verify that the theft deterrent system is not active.
Result : The theft deterrent system is active.
Repair : Turn the theft deterrent system OFF.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
59
Symptom Troubleshooting
(Table 22, contd)
Troubleshooting Test Steps
Values
Results
6. Check the Coolant Temperature Sensor for Proper
Operation
Coolant Tempera- Result : The sensor is operating properly.
ture Sensor
Proceed to Test Step 7.
A. The coolant temperature sensor must provide a correct
signal in order for cold mode operation to operate correctly.
Refer to Cold Mode Operation within the Systems Opera-
tion, “General Information”.
Result : The sensor is not operating properly.
Repair : Refer to Troubleshooting, “Sensor Signal (Analog,
Passive) - Test” for troubleshooting information.
B. Verify that the coolant temperature on the electronic serv-
ice tool is reasonable for the conditions that are present.
7. Check the Engine Speed Signal for Proper Operation Timing Signal
Result : The timing sensor is operating properly.
Proceed to Test Step 8.
A. Crank the engine and observe the engine speed on the
electronic service tool status screen. Refer to Troubleshoot-
ing, “Speed/Timing - Test” for additional information.
Result : The timing sensor is not operating properly.
Upon initial cranking, the status for engine speed may indi-
cate that the engine speed signal is abnormal. This mes-
sage will be replaced with an engine speed once the ECM
is able to calculate a speed from the signal.
Repair : Refer to Troubleshooting, “Speed/Timing - Test” for
troubleshooting information.
8. Inspect the Low-Pressure Fuel System
Low-Pressure
Fuel System
Result : The low-pressure fuel system is not operating
properly.
A. Inspect the fuel system. Refer to Systems Operation/
Testing and Adjusting, “Fuel System” for additional
information.
Repair : Make the necessary repairs. Return the engine to
service.
B. Cold weather adversely affects the characteristics of the
fuel. Refer to the engines Operation and Maintenance Man-
ual for information on improving the characteristics of the
fuel during cold-weather operation.
C. Check fuel quality. Refer to Systems Operation/Testing
and Adjusting, “Fuel System” for the proper procedure.
Check the fuel tank for debris or foreign objects which may
block the fuel supply.
D. Check the filtered fuel pressure while the engine is being
cranked. Refer to Systems Operation/Testing and Adjusting,
“Fuel System” for the test procedure and for the correct
pressure values.
If the fuel pressure is low, replace the fuel filters. Clean the
primary filter/water separator of debris. Refer to the Opera-
tion and Maintenance Manual for details.
E. Check for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting, “Fuel
System” for test information.
i05963806
Engine Does Not Crank
Use this procedure to troubleshoot an engine that will
not crank.
This document has been printed from SPI2. NOT FOR RESALE
60
UENR4542
Symptom Troubleshooting
Table 23
Troubleshooting Test Steps
Values
Results
1. Inspection of the Batteries and Battery Cables
Batteries are OK Result The batteries and cables are OK.
Proceed to Test Step 2.
A. Inspect the main power switch, battery posts, and battery ca-
bles for loose connections and for corrosion. If the battery ca-
bles are corroded, remove the battery cables and clean the
battery cables. Tighten any loose connections.
Result The batteries and cables are not OK.
Make the necessary repairs. STOP.
B. Inspect the batteries.
C. Charge the batteries.
D. Test the batteries. Systems Operation, Testing and Adjusting,
“Battery - Test”.
2. Switches and/or Circuit Breakers (if applicable)
Switches and/or Result The switches and/or circuit breakers are OK.
circuit breakers
A. If equipped, check any switches and/or circuit breakers that are OK
may interfere with the engine cranking. Refer to the applications
electrical schematic for additional information.
Proceed to Test Step 3.
Result The switches and/or circuit breakers are not OK.
Make the necessary repairs. STOP.
3. Starting Motor Solenoid and Starting Circuit
Starting motor
solenoid and cir-
Result The starting motor solenoid and circuit are OK.
Proceed to Test Step 4.
Test the operation of the starting motor circuit. Refer to Systems cuit are OK.
Operation/Testing and Adjusting, “Electrical System” for addi-
tional information.
Result The starting motor solenoid and circuit are not OK.
Make the necessary repairs. STOP.
4. Inspect the Starter Pinion and Flywheel Ring Gear
Starter pinion
and flywheel ring
gear are OK
Result The starter pinion and flywheel ring gear are OK.
A. Test the operation of the starting motor.
Proceed to Test Step 5.
B. Check the pinion clearance. Inspect the pinion and the fly-
wheel ring gear for damage. Refer to Systems Operation/Test-
ing and Adjusting, “Electrical System” for additional information.
Result The starter pinion and flywheel ring gear are not
OK.
Make the necessary repairs. STOP.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
61
Symptom Troubleshooting
(Table 23, contd)
Troubleshooting Test Steps
Values
Results
5. Inspect Engine Accessories and the Transmission (if
applicable)
Engine accesso- Result The engine accessories and transmission are OK.
ries and trans-
mission are OK Proceed to Test Step 6.
A. Ensure free movement of the driveline.
Result The engine accessories and transmission are not
B. Remove any engine accessories that may lock up the engine
and inspect any engine accessories that may lock up the
engine.
OK.
Make the necessary repairs. STOP.
The following list illustrates examples of engine accessories that
may lock up the engine:
1. Hydraulic pump that is driven from the rear gear group
2. Air compressor
3. Engine oil pump
4. Other components that are driven by the engine
6. Hydraulic Cylinder Lock
Hydraulic cylin- Result The engine has hydraulic cylinder lock.
der lock
A. If an injector has been replaced, evacuate any fluids from the
cylinder and attempt to start the engine. Fuel will flow from the
cylinder head into the cylinders when a unit injector is removed.
Make the necessary repairs. STOP.
B. If the engine will not start, check for fluid in the cylinders (hy-
draulic cylinder lock) by removing the individual unit injectors.
Check for damaged seals. Determine the type of fluid that
locked up the cylinder.
C. If there was excessive fuel in the cylinder, replace the seals
and reinstall the injector. Drain any excess fuel from the cylinder
head.
D. If a mechanical problem is suspected, disassemble the en-
gine. Refer to the Disassembly and Assembly manual. Inspect
the internal components for the following conditions:
1. Seizure
2. Broken components
3. Bent components
i06251981
Recommended Actions
Engine Has Early Wear
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Probable Causes
• Incorrect maintenance intervals and/or incorrect
oil
• Contaminated engine oil
• Low oil pressure
• Leaks in the air system
• Inspect the fuel filters for contamination.
This document has been printed from SPI2. NOT FOR RESALE
62
UENR4542
Symptom Troubleshooting
Table 24
Troubleshooting Test Steps
Values
Results
1. Incorrect Maintenance Intervals and/or Incorrect Oil
Maintenance
intervals
Result: The engine oil was changed at the interval that is
recommended by the engines Operation and Mainte-
nance Manual.
A. Use engine oil that is recommended and change the engine oil
at the interval that is recommended by the engines Operation and
Maintenance Manual.
Proceed to Test Step 2.
Result: The engine oil was not changed at the interval
that is recommended by the engines Operation and Main-
tenance Manual.
Repair: Use at least the minimum recommended grade
of oil. refer to the Operation and Maintenance Manual.
Change the engine oil at the interval that is recom-
mended. Repair or replace any damaged parts.
2. Contaminated Engine Oil
Contamination
Result: The oil is contaminated.
A. Check the engine oil for contamination.
B. Check the oil filter bypass valve.
Repair: Determine the reason for any contamination of
the engine oil and make the necessary repairs. Drain the
crankcase and refill the crankcase with clean engine oil.
Install new engine oil filters. Refer to the engines Opera-
tion and Maintenance Manual.
If the oil filter bypass valve is open, the oil will not be filtered.
Check the oil filter bypass valve for a weak spring or for a broken
spring. If the spring is broken, replace the spring. Verify that the oil
bypass valve is operating correctly. Refer to the Disassembly and
Assembly manual.
Result: The oil is not contaminated.
Proceed to Test Step 3.
3. Low Oil Pressure
Restriction
Result: The inlet tube has a restriction.
Repair: Clear the obstruction. Verify the repair.
Result: The inlet tube does not have a restriction.
Proceed to Test Step 4.
A. Engine oil that is contaminated with another liquid can cause
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil.
B. The inlet screen of the suction tube for the engine oil pump can
have a restriction. This restriction will cause cavitation and a loss
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.
When some components of the engine show wear in a short time,
the cause can be a restriction in a passage for engine oil. An indi-
cator for the engine oil pressure may indicate sufficient pressure,
but a component is worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
63
Symptom Troubleshooting
(Table 24, contd)
Troubleshooting Test Steps
Values
Results
4. Leaks in Air System
Air leak
Result: There are no air leaks.
A. A leak in the air intake system may allow unfiltered air into the
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the
connections.
Proceed to Test Step 5.
Result: There are air leaks.
Repair: Repair any leaks.
5. Inspect the Fuel Filters for Contamination
Fuel filters
Result: The fuel has contamination.
A. Remove the fuel filters. Inspect the fuel filters for contamina-
tion. Contaminants in the fuel such as hydrogen sulfide and sulfur
can lead to the formation of acids in the crankcase. Obtain a fuel
analysis.
Repair: Determine the cause of any contamination and
make the necessary repairs.
Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.
Complete the procedure in the order in which the
steps are listed.
i06302640
Engine Has Mechanical Noise
(Knock)
Probable Causes
• Active codes and logged codes
• Electrical connections
• Fuel injection
• Fuel quality
• Proper lubrication
• Isolate the source of the noise.
• Valve train components
• Gear train and lower end components
• Crankshaft
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
64
UENR4542
Symptom Troubleshooting
Table 25
Troubleshooting Test Steps
Values
Results
1. Active Codes and Logged Codes
Codes
Result: There are active codes.
A. Establish communication between the electronic service tool
and the Electronic Control Module (ECM). Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary.
Repair: Troubleshoot any active codes before continuing
with this procedure.
Result: There are no active codes.
B. Check for active diagnostic codes.
Proceed to Test Step 2.
2. Electrical Connections
Connectors
Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the J2/
P2 connectors. Check for correct installation of the fuel injector
connectors.
Repair: Repair connectors that are suspect or replace con-
nectors that are suspect.
Perform the “Wiggle Test” on the electronic service tool.
Result: There are no suspect connectors.
Proceed to Test Step 3.
3. Fuel Injection
Diagnostic
Test
Result: The test was successful.
A. Perform the “Injector Solenoid Test” on the electronic service
tool in order to determine if all of the injector solenoids are being
energized by the ECM.
Proceed to Test Step 4.
Result: The test was not successful.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests”
under the “Diagnostics” menu.
Repair: Diagnose the problem and then repair the problem.
Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.
C. Perform the “Automatic Cylinder Cutout Test” on the electronic
service tool.
4. Fuel Quality
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 5.
A. Refer to Operation and Maintenance Manual for information on
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is
being used for the engine. Refer to Systems Operation/Testing
and Adjusting, “Fuel System Quality Test” for the proper
procedure.
Result: The fuel quality is not OK.
Repair: Replace the fuel. Verify that the repair eliminated
the problem.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
65
Symptom Troubleshooting
(Table 25, contd)
Troubleshooting Test Steps
Values
Results
5. Proper Lubrication
Lubrication
Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check
for sufficient lubrication between the injector tappets and the rock-
er arms.
Proceed to Test Step 6.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information.
not have proper lubrication.
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an oil analysis. The analysis will contribute to a better
understanding of oil contamination and the origin of the
contamination.
6. Isolate the Source of the Noise
Engine
Result An engine accessory is the source of the noise.
accessory
A. If the source of the noise is the engine accessory, remove the
Repair: Repair the engine accessory and/or replace the en-
suspect engine accessory. Inspect the suspect engine accessory.
gine accessory, if necessary.
Result An engine accessory is not the source of the noise.
Proceed to Test Step 7.
7. Valve Train Components
Valve train
Result: The valve train components are not damaged.
Proceed to Test Step 8.
A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items
for damage:
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
4. Camshaft followers
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
Refer to the Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
66
UENR4542
Symptom Troubleshooting
(Table 25, contd)
Troubleshooting Test Steps
Values
Results
8. Gear Train and Components of the Lower End
Gear train
Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.
Result: The gear train or lower end components are not
damaged.
Proceed to Test Step 9.
9. Crankshaft
Crankshaft
Result: The crankshaft or the related components are dam-
aged or worn.
A. Inspect the crankshaft and the related components. Look for
worn thrust plates and wear on the crankshaft.
Repair: Repair or replace any damaged parts. Verify that
the repair eliminated the problem.
B. Inspect the connecting rod bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in the correct
position.
C. Check the counterweight bolts.
Complete the procedure in the order in which the
steps are listed.
i06302645
Engine Misfires, Runs Rough
or Is Unstable
Note: Refer to Troubleshooting, “Service Tool
Features” for information about service features.
Probable Causes
• Active codes and logged codes
• Low quality fuel
• Fuel injectors
• Lack of lubrication
• Valve train components
• Gear train and components of the lower end
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
67
Symptom Troubleshooting
Table 26
Troubleshooting Test Steps
Values
Results
1. Active Codes and Logged Codes
Codes
Result: There are active codes.
A. Establish communication between the electronic service tool
and the Electronic Control Module (ECM). Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary.
Repair: Troubleshoot any active codes before continuing
with this procedure.
Result: There are no active codes.
B. Check for active diagnostic codes.
Proceed to Test Step 2.
Troubleshoot any active codes before continuing with this
procedure.
2. Fuel Quality
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 3.
A. Refer to Operation and Maintenance Manual for information on
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is
being used for the engine. Refer to Systems Operation/Testing
and Adjusting, “Fuel Quality - Test” for the proper procedure.
Result: The fuel quality is not OK.
Repair: Replace the fuel. Verify that the repair eliminated
the problem.
3. Fuel Injectors
Diagnostic
Test
Result: The test was successful.
If service has been performed on the engine fuel system recently,
verify that the injector trim files are correct. Use the electronic serv-
ice tool to check that the injector trim files are correct for the injec-
tors that are installed on the engine.
Proceed to Test Step 4.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem.
Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.
A. Perform the “Injector Solenoid Test” on the electronic service
tool in order to determine if all of the injector solenoids are being
energized by the ECM.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests”
under the “Diagnostics” menu.
C. Perform the “Automatic Cylinder Cutout Test” on the electronic
service tool.
4. Proper Lubrication
Lubrication
Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker
arms.
Proceed to Test Step 5.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information.
not have proper lubrication.
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an oil analysis. The analysis will contribute to a better
understanding of oil contamination and the origin of the
contamination.
(continued)
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UENR4542
Symptom Troubleshooting
(Table 26, contd)
Troubleshooting Test Steps
Values
Results
5. Valve Train Components
Valve train
Result: The valve train components are not damaged.
Proceed to Test Step 6.
A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items
for damage:
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
4. Camshaft followers
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
Refer to the Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
6. Gear Train and Components of the Lower End
Gear train
Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.
Complete the procedure in the order in which the
steps are listed.
i06302647
Engine Overspeeds
Use this procedure in order to troubleshoot an engine
overspeed or use this procedure if the following event
code is active.
Note: Some of the following codes may not be
applicable for certain applications.
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
69
Symptom Troubleshooting
Table 27
Diagnostic Trouble Codes
Code Description
PDL Code
(code descriptions may
vary)
J1939 Code
190-0
Comments
E362 (3)
E362 (1)
Engine Overspeed
Engine Overspeed
The code requires factory passwords to be cleared.
The code is logged.
190-15
Probable Causes
• Proceeding down steep grades (if applicable)
• Proper operation of the turbocharger
• Intake air
• Starting aids that are not operating properly
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Table 28
Troubleshooting Test Steps
Values
Results
1. Proceeding Down Steep Grades (If Applicable)
Steep grades
Result: Steep grades are the cause of the overspeed.
Repair: Control the engine speed during steep grades.
Result: Steep grades are not the cause of the overspeed.
Proceed to Test Step 2.
Engaging the engine brakes on a steep grade may be
necessary.
A. The operator needs to understand the proper operation of
the machine while using the engine brakes.
Not all applications have engine brakes.
2. Proper Operation of the Turbocharger
Turbocharger
Result: The turbocharger is leaking oil into the inlet.
Repair: Repair or replace the turbocharger.
Result: The turbocharger is not leaking oil into the inlet.
Proceed to Test Step 3.
A. Check for proper operation of the turbocharger.
B. Check for any oil that may be leaking into the air inlet.
3. Intake Air
Air quality
Result: The atmosphere has combustible gases.
A. Check for combustible gases in the surrounding
Repair: Do not operate the engine in an environment with
atmosphere.
combustible gases.
B. Check for proper operation of starting aids (if equipped).
This document has been printed from SPI2. NOT FOR RESALE
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UENR4542
Symptom Troubleshooting
Complete the procedure in the order in which the
steps are listed.
i06302649
Engine Shutdown Occurs
Intermittently
Note: Use this procedure only if the engine shuts
down completely during operation.
Probable Causes
• Air shutoff
• Active codes and logged codes
• Unstable fuel supply
• Electrical connections
• Switches
• Circuit protection
• Engine speed/timing
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Table 29
Troubleshooting Test Steps
Values
Results
1. Air Shutoff
Air shutoff
Result: The air shutoff system is operating properly.
Proceed to Test Step 2.
A. Check the operation of the air shutoff system.
Result: The air shutoff system is not operating properly.
Repair: Repair the air shutoff system. Refer to Troubleshoot-
ing, “Air Shutoff - Test” for troubleshooting information.
2. Active Codes and Logged Codes
Codes
Result: There are associated diagnostic trouble codes active
or logged.
A. Certain diagnostic codes and/or event codes may cause an
engine shutdown. Connect the electronic service tool and check
for active codes and for logged codes. Troubleshoot any codes
that are present prior to continuing with this procedure.
Repair: Troubleshoot any active or logged associated diag-
nostic trouble codes before continuing with this procedure.
Result: There are no associated diagnostic trouble codes ac-
tive or logged.
Proceed to Test Step 3.
(continued)
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
71
Symptom Troubleshooting
(Table 29, contd)
Troubleshooting Test Steps
Values
Results
3. Electrical Connections
Connectors
Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the
J2/P2 connectors. Check for correct installation of the fuel injec-
tor connectors.
Repair: Repair connectors that are suspect or replace con-
nectors that are suspect.
Perform the “Wiggle Test” on the electronic service tool.
Result: There are no suspect connectors.
Proceed to Test Step 4.
4. Unstable Fuel Supply
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 5.
If there is an immediate engine shutdown, troubleshoot the elec-
trical connectors before proceeding with this procedure.
Result: The fuel quality is not OK.
A. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information.
Repair: Replace the fuel. Verify that the repair eliminated the
problem.
Cold weather adversely affects the characteristics of the fuel.
Refer to the engine Operation and Maintenance Manual for in-
formation on improving the characteristics of the fuel during
cold-weather operation.
B. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
C. Check the filtered fuel pressure while the engine is being
cranked.
5. Electrical Connections
Electrical
connectors
Result: The electrical connections are OK.
Proceed to Test Step 6.
A. Check the power and ground connections to the ECM. Refer
to Troubleshooting, “Electrical Power Supply - Test”.
Result: The electrical connections are not OK.
Repair: Repair or replace the damaged connectors. Verify
that the repair eliminated the problem.
6. Switches
Switches
Result: The shutdown switches and wiring are OK.
Proceed to Test Step 7.
A. Check the keyswitch input to the ECM.
B. Check any engine shutdown switches and associated wiring.
Result: The shutdown switches and wiring are not OK.
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
(continued)
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UENR4542
Symptom Troubleshooting
(Table 29, contd)
Troubleshooting Test Steps
Values
Results
7. Circuit Protection
Circuit
Result The circuit protection device is tripped.
protection
A. Inspect the wires and connectors to all circuit protection for
the engine.
Repair: Reset the circuit breakers if the circuit breakers are
tripped. If necessary, replace fuses (if equipped). Prior to re-
turning the engine to service, determine the condition that
caused the circuit breaker to trip. Make the necessary repairs.
B. Check the device for circuit protection.
Result The circuit protection device is not tripped.
Proceed to Test Step 8.
8. Engine Speed/Timing
Speed/Timing Result: The Speed/Timing sensor circuit is not operating
properly.
A. Thoroughly inspect the connectors for the engine speed/tim-
ing sensors.
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem. Refer to Troubleshooting, “Speed/
Timing `- Test”
B. Crank the engine, if the engine starts and no speed timing co-
des are logged, the speed timing circuit is operating properly.
Complete the procedure in the order in which the
steps are listed.
i06255977
Engine Stalls at Low RPM
Note: Refer to Troubleshooting, “Service Tool
Features” for information about service features.
Probable Causes
• Active codes and logged codes
• Incorrect parameters
• Air shut-off system
• Low-pressure fuel system
• Fuel injectors
• Engine accessories
• Parasitic loads
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
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Symptom Troubleshooting
Table 30
Troubleshooting Test Steps
Values
Results
1. Active Codes and Logged Codes
Diagnostic
code
Result: A code is active or logged.
A. Establish communication between the electronic service tool and
the Electronic Control Module (ECM) . Refer to Troubleshooting,
“Electronic Service Tools”, if necessary.
Repair: Troubleshoot any active codes before continuing
with this procedure.
Result: A code is not active or logged.
B. Determine if a code is active or logged.
Proceed to Test Step 2.
2. Incorrect Parameters
Parameters
Result: The correct parameters are being used.
Proceed to Test Step 3.
A. Use the electronic service tool to verify that the correct parame-
ters are being used. Refer to Troubleshooting, “Configuration Pa-
rameters” for additional information.
Result: The correct parameters are not being used.
Repair: Configure the correct parameters.
3. Air Shutoff System (if equipped)
Air shutoff
Result: The air shutoff is operating correctly.
Proceed to Test Step 4.
A. Check for proper operation of the air shutoff system. Refer to
Troubleshooting, “Air Shutoff - Test”.
Result: The air shutoff is not operating correctly.
Repair: Make the necessary repairs. Verify the repair.
4. Low Pressure Fuel System
Fuel system
Result: The fuel system is operating properly.
Proceed to Test Step 5.
A. Visually check the fuel level in the fuel tank. Do not rely on the
fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position.
Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing and
Adjusting, “Fuel System - Inspect” for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer
to the engines Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather
operation.
D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being
cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.
(continued)
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UENR4542
Symptom Troubleshooting
(Table 30, contd)
Troubleshooting Test Steps
Values
Results
5. Fuel Injectors
Diagnostic Test Result: The test was successful.
Proceed to Test Step 6.
If service has been performed on the engine fuel system recently,
verify that the injector trim files are correct. Use the electronic serv-
ice tool to check that the injector trim files are correct for the injec-
tors that are installed on the engine.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the
A. Perform the “Injector Solenoid Test” on the electronic service tool
in order to determine if all of the injector solenoids are being ener-
gized by the ECM.
problem.
Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” under
the “Diagnostics” menu.
C. Perform the “Automatic Cylinder Cutout Test” on the electronic
service tool.
6. Engine Accessories
Engine
Result: An engine accessory is creating an excessive
accessories
load.
A. Inspect any engine accessories and the transmission (if
applicable).
Repair: Repair the engine accessory.
Complete the procedure in the order in which the
steps are listed.
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
i06302669
Engine Top Speed Is Not
Obtained
Note: If this fault occurs only under load, refer to
Troubleshooting, “Acceleration Is Poor or Throttle
Response Is Poor”.
Note: Refer to Troubleshooting, “Service Tool
Features” for information about service features.
Probable Causes
• Active codes and logged codes
• Incorrect parameters
• Accessory and/or parasitic loads
• Incorrect flash file
• Restriction in the air inlet and exhaust system
• Proper operation of the turbocharger
• Low-pressure fuel system
• Fuel injectors
This document has been printed from SPI2. NOT FOR RESALE
UENR4542
75
Symptom Troubleshooting
Table 31
Troubleshooting Test Steps
Values
Results
1. Active Codes and Logged Codes
Codes
Result: There are active codes.
A. Establish communication between the electronic service
tool and the Electronic Control Module (ECM). Refer to Trou-
bleshooting, “Electronic Service Tools”, if necessary.
Repair: Troubleshoot any active codes before continuing with
this procedure.
Result: There are no active codes.
B. Check for active diagnostic codes.
Proceed to Test Step 2.
2. Incorrect Parameters
Parameters
Result: The parameters are configured correctly.
Proceed to Test Step 3.
A. Use the electronic service tool to verify that the correct en-
gine parameters are being used. Refer to Troubleshooting,
“Configuration Parameters” for additional information.
Result: The parameters are not configured correctly.
Repair: Correctly configure the parameters.
Verify that the repair eliminated the problem.
B. Verify that all of the parameters for parasitic loads are
correct.
3. Accessory and/or Parasitic Loads
Parasitic loads Result: There is not an excessive load on the engine.
Proceed to Test Step 4.
A. Check all accessory equipment for problems that may cre-
ate excessive load on the engine.
Result: There is an excessive load on the engine.
Repair: Diagnose the problem and then repair the problem.
Verify that the repair eliminated the problem.
B. Check for any excess parasitic load on the engine.
4. Incorrect Flash File
Flash file
Result: The latest flash file is installed in the ECM.
Proceed to Test Step 5.
A. Verify that the latest flash file is installed in the Electronic
Control Module (ECM). Refer to Troubleshooting, “ECM Soft-
ware - Install” for the proper procedure.
Result: The latest flash file is not installed in the ECM.
Repair: Install the latest flash file. Verify that the repair elimi-
nated the problem.
5. Restriction in the Air Inlet and Exhaust System
Restrictions
Result: There are restrictions in the air inlet or exhaust
system.
A. Check the air filter restriction indicator, if equipped. Clean
plugged air filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual.
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
B. Check the air inlet and exhaust system for restrictions
Result: There are no restrictions in the air inlet or exhaust
and/or leaks.
system.
Proceed to Test Step 6.
(continued)
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UENR4542
Symptom Troubleshooting
(Table 31, contd)
Troubleshooting Test Steps
Values
Results
6. Proper Operation of the Turbocharger
Turbocharger
Result: The turbocharger is operating properly.
A. Check for proper operation of the turbocharger.
Proceed to Test Step 7.
Result: The turbocharger is not operating properly.
Repair: Repair or replace the turbocharger. Verify that the re-
pair eliminated the problem.
7. Low Pressure Fuel System
Fuel system
Result: The fuel system is operating properly.
Proceed to Test Step 8.
A. Visually check the fuel level in the fuel tank. Do not rely on
the fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position.
Repair: Make the necessary repairs. Verify that the repair
eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Test-
ing and Adjusting, “Fuel System - Inspect” for additional
information.
Cold weather adversely affects the characteristics of the fuel.
Refer to the engines Operation and Maintenance Manual for
information on improving the characteristics of the fuel during
cold-weather operation.
D. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being
cranked. Refer to Troubleshooting, “Fuel Pressure Is Low”
for the proper testing procedure.
8. Fuel Injectors
Injector Solenoid Result: The test was successful.
Test or Cylinder
If service has been performed on the engine fuel system re- Cutout Test
cently, verify that the injector trim files are correct. Use the
electronic service tool to check that the injector trim files are
correct for the injectors that are installed on the engine.
Return the unit to service.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem.
Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.
A. Perform the “Injector Solenoid Test” on the electronic serv-
ice tool in order to determine if all of the injector solenoids are
being energized by the ECM.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests”
under the “Diagnostics” menu.
C. Perform the “Automatic Cylinder Cutout Test” on the elec-
tronic service tool.
This document has been printed from SPI2. NOT FOR RESALE