Localización y Solución de Problemas

Localización y Solución de Problemas C175-16 and C175-20 Engines For 793F and 797F Off-Highway Trucks Número de medio -KENR539812

Fecha de publicación 01/11/2013

Fecha de actualización 06/11/2013

i05123051

Turbocharger Turbo charger Turbine Temperature Is High SMCS - 1052-035-TA /sisw /sisw eb/si eb/sisw sw eb/ eb/

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Use this procedure in order to troubleshoot a high turbo turbocharger charger turbine inlet temperature or if one of the following event codes is active. acti ve. Table 1 Event Code Code and Description

Conditions which Generate Generate this Code

E245(1) High Right Turbo Turbine Inlet Temperature E245(2) High Right Turbo Turbine Inlet Temperature

System Response

The code is logged. The exhaust temperature is above the trip point temperature.

The engine is derated. The code is logged.

E245(3) High Right Turbo Turbine Inlet Temperature

The code is logged. The engine is shut down.

E246(1) High Left Turbo Turbine Inlet Temperature

The code is logged.

E246(2) High Left Turbo Turbine Inlet Temperature

The exhaust temperature is above the trip point temperature.

E246(3) High Left Turbo Turbine Inlet Temperature E278(2) High Exhaust Differential Temperature

The engine is derated. The code is logged. The code is logged. The engine is shut down.

The differential temperature for the exhaust is above the trip point temperature.

The code is logged.

If the engine is shut down due to a high turbo turbocharger charger turbine inlet temperature, the  power to the engine Electronic Control Module Module (ECM) must be cycled in order to restart the engine.

Probable Causes        

Diagnostic codes and event codes Inlet air temperature is high Incorrect valve lash Exhaust temperature is high Air Inlet or Exhaust System Leak Air Inlet or Exhaust System Restriction Aftercooler Fuel injectors

Recommended Actions Note: The procedures have been listed in order of probability. Complete the procedures in the order of the listed test steps.

Table 2 Troubleshooting Test Steps

Values

Results

1. Check for Codes A. Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary. B. Download the "Product Status Report" from the engine ECM  before performing any troubleshooting or clearing diagnostic trouble codes. C. Determine if the diagnostic trouble code that directed to this  procedure is present. D. Look for active diagnostic codes that are associated with the system for the event code that directed to this procedure.

Result: An associated code is  present. Repair: Troubleshoot any associated codes before continuing with this test.

E245 E246 E278

Result: An E245, E246, or E278 code is present.

Proceed to the next step. Result: No active codes

STOP

Result: The inlet air temperature is OK . 2. Check for High Inlet Air Temperature A. Refer to Troubleshooting, "Intake Manifold Air Temperature Is High".

Proceed to the next step.

Inlet air temperature

NOTE: A one degree increase in the inlet manifold temperature will increase the exhaust temperature by approximately three degrees.

Result: The inlet air temperature is NOT OK . Repair: Determine the cause of the high inlet air temperature and correct the  problem.

If the problem is not resolved,  proceed to the next step.

Result: The valve lash is OK .

Proceed to the next step. Result: The valve lash is NOT OK . 3. Incorrect Valve Lash

Valve lash A. Check the engine valve lash.

Repair: If necessary, adjust the engine valve lash. Refer to Systems Operation/Testing and Adjusting for information on adjusting the engine valve lash.

If the problem is not resolved,  proceed to the next step.

Result: The exhaust temperature probes are not reading correctly.

4. Check for High Exhaust Temperature A. Inspect the turbine inlet temperature probes and thermowells on each side of the engine. Ensure that the temperature probes are reading correctly B. Refer to Test and Adjust, "Measuring Exhaust Temperature".

Exhaust temperature

Repair: Clean, Repair, Replace temperature probes and Thermowells. Repair: All cylinders have comparable temperatures then  proceed to step 4

C. Install thermocouples or check individual cylinders with an infrared gun. Maintain a steady load and speed during the measurement to ensure an accurate comparison of each cylinder.

Repair: One or more of the cylinders deviate significantly from the average temperature on that bank, proceed to step 8

Result: Compressor inlet  pressures are equal on each turbocharger. Repair: Check for boost side or exhaust side air leaks.

Proceed to the next step. Result: Compressor inlet  pressures are not equal on each turbocharger. Repair: Check for plugged air filters or restriction  between the filter and the turbocharger compressor.

5. Check the Air Inlet System A. Check the compressor inlet  pressure for each turbocharger. B. Check for restriction or blockage from the compressor discharge back to the engine.

Air inlet

Result: The compressor discharge back to engine is OK .

Proceed to the next step. C. Check for air leaks. Inspect all hoses, tubes, bellows, and clamps from air inlet to the inlet manifold.

Result: The compressor discharge back to the engine is NOT OK . Repair: Remove restriction or blockage Result: The engine has No Air Leaks.

Proceed to the next step. Result: The engine has Air Leaks.. Repair: Determine the cause of the air leak and repair

damage or leaking components. If the problem is not resolved,  proceed to the step 6.

6. Check the Exhaust System A. Refer to Test and Adjust, "Restriction of Air Inlet and Exhaust".

Result: The air system lines and connections are OK .

Proceed to the next step. B. Inspect the exhaust system lines and all hoses, tubes, bellows connections from the exhaust manifold to the muffler. Also, inspect the bellows for cracks or loose clamps. Spray the joints with soapy water and inspect for leaks.

Exhaust system

Result: The air system lines and connections are NOT OK . Repair: If anything is loose or cracked replace or repair any issues.

C. Verify that all the bellows have the correct orientation. Ensure that the arrow on the bellows is pointing in the correct direction of exhaust flow.

If the problem is not resolved,  proceed to the step 7.

Result: The aftercooler is OK . 7. Check the Aftercooler A. Normal intake manifold pressure with high exhaust temperature can  be caused by blockage of the fins of the aftercooler core.

Proceed to the next step.

Aftercooler

Result: The aftercooler is NOT OK . Repair: Clear restrictions and replace aftercooler or any damaged lines.

B. Check for leaks and/or damage to the aftercooler.

If the problem is not resolved,  proceed to the next step.

8. Check the Fuel Injectors NOTE: Faulty injectors that deliver

Leak

Result: The injectors are OK .

Proceed to the next step.

too much fuel will increase exhaust temperatures.

Result: The injectors are NOT OK .

A. Connect Cat ET in order to determine if any diagnostic codes for the injector solenoids are  present.

Repair: Repair or replace the faulty injectors.

B. Perform the "Injector Solenoid Test". Check that the injector solenoids are "OK" on Cat ET. C. Perform the "Cylinder Cutout Test". Locate the misfiring cylinder and correct the problem. D. Perform the "Fuel System Verification Test". Identify any  problem injectors and perform the necessary repairs.

Refer to Troubleshooting, "Injector Solenoid - Test".

Result: The turbochargers are OK . 9. Inspect Turbochargers A. Inspect turbine and compressor wheels for visible signs of damage or rubbing. B. Inspect turbochargers and turbocharger housings for leaks

Result: The turbochargers are NOT OK .

Turbocharger

Repair: Repair the turbochargers or replace, if necessary. Refer to the engine Disassembly and Assembly manual for details.

Localización y Solución de Problemas C175-16 and C175-20 Engines For 793F and 797F Off-Highway Trucks Número de medio -KENR539812

Fecha de publicación 01/11/2013

Fecha de actualización 06/11/2013

i05499331

Event Codes SMCS - 1900

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Engine Monitoring The Electronic Control Module (ECM) monitors the operating parameters of the engine. The ECM will generate an event code if a specific engine parameter exceeds an acceptable range that is defined by the engine monitoring system. For information on the engine monitoring system, refer to Troubleshooting, "Engine Monitoring System".

Cross-Reference Information for Event Codes Event codes are generated when abnormal operating conditions exist. Table 1 is a list of the event codes for the engine. The event codes a re cross-referenced with the appropriate procedure that can be used to troubleshoot the code. Table 1

Cross-Reference from Event Code to the Appropriate Test Procedure

Event Code

Procedure

E072(2) Oil Level Low

The engine oil level is below the specified level. Check the engine oil

Mark

level. If necessary, add oil to the engine and return the engine to service. Refer to the Operation and Maintenance Manual for details. If a problem is suspected with the engine lubrication system, refer to

E072(3) Oil Level Low Mark

E096(1) High Fuel

Troubleshooting, "Oil Consumption Is Excessive" for details that are related to troubleshooting this symptom.

Troubleshooting, "Fuel Pressure Is High"

Pressure

E098(1) Engine Prelube Override

The keyswitch has been cycled from the START position, to the OFF position, and back to the START position in six seconds or less. The prelube cycle has been overridden by the operator.

E099(2) Engine Oil Filter Restriction

Troubleshooting, "Oil Filter Differential P ressure Problem"

Warning

E101(1) High Crankcase Pressure

Troubleshooting, "Crankcase Pressure Is High"

Warning

E197(1) High Engine Oil Temperature

E197(2) High Engine Oil Temperature

Troubleshooting, "Oil Temperature Is High"

E197(3) High Engine Oil Temperature

E198(1) Low Fuel Pressure Troubleshooting, "Fuel Pressure Is Low" E198(2) Low Fuel Pressure

E199(1) Low Coolant Temperature

Troubleshooting, "Coolant Temperature Is Low"

E232(1) High Fuel/Water

The level of water that is in the fuel/water separator is excessive.

Separator Water

Remove the water from the fuel/water separator and return the

Level

engine to service. Refer to the Operation and Maintenance Manual for details. If an electrical problem with the sensor or the sensor circuit is

E232(2) High Fuel/Water Separator Water

suspected, refer to Troubleshooting, "Water In Fuel - Test" for details that are related to troubleshooting the problem.

Level

E233(2) Low Engine Pre-lube Pressure

Troubleshooting, "Prelubrication Pump Problem"

E245(2) High Right Turbo Turbine Inlet Temperature

E245(3) High Right Turbo Turbine Inlet Temperature Troubleshooting, "Turbocharger Turbine Temperature Is High" E246(2) High Left Turbo Turbine Inlet Temperature

E246(3) High Left Turbo Turbine Inlet Temperature

E265(2) User Defined

This event is used to record a requested shutdown from an

Shutdown

aftermarket shutdown device.

E278(2) High Exhaust Differential

Troubleshooting, "Exhaust Differential Temperature is High"

Temperature

E360(1) Low Engine Oil Pressure Troubleshooting, "Oil Pressure Is Low" E360(3) Low Engine Oil Pressure

E361(1) High Engine Coolant Temperature

E361(2) High Engine Coolant

Troubleshooting, "Coolant Temperature Is High"

Temperature

E361(3) High Engine Coolant Temperature

E362(1) Engine Overspeed

E362(2) Engine Overspeed

Troubleshooting, "Engine Overspeeds"

E362(3) Engine Overspeed

E390(1) Fuel Filter Restriction Troubleshooting, "Fuel Filter Is Restricted" E390(2) Fuel Filter Restriction

E396(1) High Fuel Rail Pressure

Troubleshooting, "Fuel Rail Pressure Is High"

E398(1) Low Fuel Rail Pressure Troubleshooting, "Fuel Rail Pressure Is Low" E398(2) Low Fuel Rail Pressure

E539(1) High Intake Manifold Air Temperature Troubleshooting, "Intake Manifold Air Temperature Is High" E539(2) High Intake Manifold Air Temperature

E583(1) High Air Inlet #1 Differential

Troubleshooting, "Inlet Air Is Restricted"

Pressure

E583(2) High Air Inlet #1 Differential Pressure

E584(1) High Air Inlet #2 Differential Pressure Troubleshooting, "Inlet Air Is Restricted" E584(2) High Air Inlet #2 Differential Pressure

E585(1) High Air Inlet #3 Differential Pressure Troubleshooting, "Inlet Air Is Restricted" E585(2) High Air Inlet #3 Differential Pressure

E586(1) High Air Inlet #4 Differential Pressure Troubleshooting, "Inlet Air Is Restricted" E586(2) High Air Inlet #4 Differential Pressure

The ground level shutdown switch has been activated. Reset the E678(2) Ground Level Shutdown

switch to the RUN position. If an electrical problem with the switch or with the switch circuit is suspected, refer to Troubleshooting, "Shutdown - Test" for details that are related to troubleshooting the ground level shutdown switch.

E770(2) High Fuel Rail Temperature

E1044(1) High Intake

Troubleshooting, "Fuel Temperature is High"

Troubleshooting, "Intake Manifold Air Pressure is H igh"

Manifold Pressure

E1044(2) High Intake Manifold Pressure

E1106(2) High Fuel Rail Pump Flow

Troubleshooting, "Fuel Flow is High"

E2089(1) Oil Renewal System Cannot

Troubleshooting, "Oil Renewal - Test"

Operate

E2112(1) Low Engine Coolant Pressure

Troubleshooting, "Coolant Pressure Is Low"

E2143(2) Low Engine

The coolant level is below the specified level. Check the level of the

Coolant Level

engine coolant. If necessary, add coolant to the cooling system and return the engine to service. Refer to the Operation and Maintenance Manual for details.

E2143(3) Low Engine

If an electrical problem is suspected with the cooling system, refer to

Coolant Level

Troubleshooting, "Coolant Level - Test" for details that are related to troubleshooting the coolant level switch.

E2172(1) Low Fuel Transfer Pump Inlet

Troubleshooting, "Fuel Transfer Pump Inlet Pressure Is Low"

Pressure

Parts of the Event Code Event Code - The "E" identifies the code as an event code. The "XXX(X)" represents a numeric identifier for the event code. The fourth "(X)" assigns one of three levels to the active event code according to the severity of the abnormal system condition. A description of the code follows. Refer to the following example:   

E360(1) Low Oil Pressure E360(2) Low Oil Pressure E360(3) Low Oil Pressure

The definition for the levels of severity for an event are defined below: Table 2

Indicators (1), (2), and (3)

Warning Category Indicator

Severity

(1)

Least Severe

(2)

Moderate Severity

(3)

Most Severe

 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 1 is an example of the operating range of a sensor.

Ver imagen

Illustration 1

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 o f 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 ECM generates an event code, the ECM may log the event 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 c ode is listed first. This information can be helpful for troubleshooting intermittent problems. Logged codes can also be used to review the performance of the engine. Clearing Event Codes

A code is cleared from memory when one of the foll owing 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 c ode.

Always clear logged event codes after investigating and correcting the problem which generated the code.

Troubleshooting For basic troubleshooting of the engine, perform the following steps in order to diagnose a malfunction: 1. Obtain the following information about the complaint: The event and the time of the event o Determine the conditions for the event. The conditions will include the engine o rpm and the load. Determine if there are any systems that were installed by the dealer or by the o customer that could cause the event. Determine whether any additional events occurred. o 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 o Oil level o Oil supply o Wiring o Connectors o

Be sure to check the connectors. An important step for inter mittent problems is to confirm the connectors are in good repair. Refer t o Troubleshooting, "Electrical Connectors - Inspect". If these steps do not resolve the problem, refer to Table 1 for the procedure to troubleshoot the event code.

Machine Response to Active Event Codes The Advisor panel is used to notify the operator of an immediate problem or of an impending problem. An abnormal condition that is detected by the engine ECM is communicated over the Cat Data Link to the monitoring system. The following warning indicators are used by the monitoring system in order to communicate the levels of severity that are reported by the engine ECM:   

Check engine lamp Action lamp and Advisor message Action alarm

The following table summarizes the relationship between the levels of severity reported  by the ECM and the actions that are taken by the monitoring system. Table 3

VIMS Service Warning for the Engine System

Warning Category Indicator

(1)

(2)

(3)

(1)

(1)

Check Engine Lamp

The lamp is illuminated.

The lamp is illuminated.

The lamp is illuminated.

Action Lamp Advisor message

Off

Action Alarm

Off

The lamp will flash. Advisor displays a warning

Off

message.

The lamp will flash. Advisor displays a warning message.

The alarm will sound.

The VIMS may also perform an engine shutdown for some level 3 warnings that are reported by the engine ECM. This shutdown will only be performed if the vehicle speed is equal to zero mph and the parking brake has been engaged.

Parameter Settings of the Engine Monitoring System The default settings for the parameters are programmed at the factory. The parameter settings for the engine monitoring system can be viewed on Caterpillar Electronic Technician (ET). For information that is related t o the engine monitoring system, refer to Troubleshooting, "Engine Monitoring System". Table 4

Trip Points for the Monitoring System

Event Code

Level of Severity

Trip Point and Enabling Conditions

Delay Time

Derate

in

(%)

Seconds

The circuit for the oil level switch that is for low oil level is open. This event is enabled when the keyswitch is

(2)

3

turned to the ON position. The event is E072 Oil Level Low

disabled after the engine

Mark

has started.

N/A

The circuit for the oil level switch that is for (3)

(1)

low oil level is open. This event is enabled 17

20

seconds after the engine has been started.

E096 High Fuel Pressure

(1)

Warning ( C175-16)

8

N/A

10

N/A

150 kPa (22 psi)

E099 Engine Oil Filter Restriction

900 kPa (131 psi)

This event is enabled 15 (2)

seconds after the engine oil temperature has exceeded 20 °C (68 °F).

180 kPa (26 psi)

E099 Engine Oil Filter Restriction Warning

This event is enabled 15 (2)

seconds after the engine

10

N/A

5

N/A

oil temperature has

( C175-20)

exceeded 20 °C (68 °F).

4 kPa (0.6 psi) E101 High Crankcase Pressure

This event is enabled 15 (1)

seconds after the coolant temperature has

Warning

exceeded 15 °C (59 °F).

(1)

E197 High Engine Oil Temperature

N/A

108 °C (226 °F)

Map (2)

(3)

(1)

110 °C (230 °F)

N/A

N/A

Refer to the control map for low fuel pressure in

Pressure

Illustration 2 for

Dependent Values

115 °C (239 °F)

E198 Low Fuel (2)

15

10

Map Dependent

details.

Values

70 °C (158 °F) In order to enable this event, the engine must E199 Low Coolant Temperature

(1)

be running for ten minutes and the coolant temperature must exceed 75° C (167° F) before the temperature returns to

120

N/A

the trip point.

E232 High

(1)

Fuel/Water

N/A

3600

35

45

N/A

The switch has opened.

Separator Water Level

40

(2)

E233 Low Engine Pre-lube

(2)

48 kPa (7 psi)

Pressure

E245 High Right

(2)

25

725 °C (1340 °F)

Turbo Turbine Inlet

5

Temperature (3)

N/A

805° C (1480° F)

(2)

25

725 °C (1340 °F)

E246 High Left Turbo Turbine Inlet

5

Temperature (3)

N/A

805° C (1480° F)

E278 High Exhaust Differential

(2)

(2)

 

50° C (90° F)

Temperature

Refer to the control map

(1) E360 Low Engine

8

N/A

4

35

for low oil pressure in

Oil Pressure (3)

(1)

Illustration 3 for details.

(1)

N/A

100 °C (212 °F)

E361 High Engine Coolant Temperature

N/A

10

(2)

101 °C (214 °F)

(1)

(3)  

Map Dependent Values

N/A

110 °C (230 °F)

(1)

2250 rpm The ECM

E362 Engine Overspeed

(2)

2325 rpm

0.6

disables injection above the trip point.

(3)

(1)

2400 rpm

105 kPa (15 psi)

120

N/A

300

35

E390 Fuel Filter Restriction (2)

E396 High Fuel Rail Pressure

E398 Low Fuel Rail Pressure

124 kPa (18 psi)

(1)

(3)

N/A

N/A

(2)

(3)

N/A

100

(1) E539 High Intake

N/A

80 °C (176 °F)

Manifold Air

8

Temperature (2)

E583 High Air Inlet

30

90 °C (194 °F)

(1)

Map (2)

#1 Differential

7.5 kPa (1.1 psi)

Dependent

Pressure

(2)

Values

E584 High Air Inlet

(1)

Map (2)

#2 Differential

7.5 kPa (1.1 psi)

Pressure

(2)

E585 High Air Inlet

(1)

Pressure

Values

Map (2)

#3 Differential

7.5 kPa (1.1 psi) (2)

Dependent

Dependent Values

E586 High Air Inlet

(1) (2)

#4 Differential Pressure

Map 7.5 kPa (1.1 psi)

Dependent Values

(2)

The engine ECM E678 Ground Level Shutdown

(3)

The ground level switch is on.

N/A

disables fuel injection to the engine.

E770 High Fuel Rail Temperature

E1044 High Intake

Map (2)

(1)

100 °C (212 °F)

E1106 High Fuel Rail Pump Flow

Dependent Values

(3)

Manifold Pressure

15

(2)

(3)

(2)

(3)

8

25

10

N/A

N/A

N/A

10

N/A

The ECM detects a fault in the circuit for the oil renewal solenoid. or The ECM detects a fault in the circuit for the coolant temperature

E2089 Oil Renewal System Cannot

(1)

Operate

sensor. or The ECM detects a fault in the circuit for the fuel level sensor. or The ECM detects a fault in the circuit for the oil pressure sensor.

Refer to the control map E2112 Low Engine Coolant Pressure

(1)

for low coolant pressure in Illustration 4 for details.

The circuit for the engine coolant level switch is open. (2)

This event is enabled

3

when the keyswitch is turned to the ON position.

E2143 Low Engine

N/A

Coolant Level The circuit for the engine coolant level switch is (3)

(1)

open. This event is enabled 17

12

seconds after the engine has been started.

E2172 Low Fuel Transfer Pump

(1)

Inlet Pressure (1)

-50 kPa (-7 psi)

60

N/A

The VIMS will perform an engine shutdown when t he vehicle speed is equal to zero mph and the parking brake has been engaged.

2

(3)

The delay time for this event is dependent on the severity of the condition. This code does not have a specific trip point. Several factors determine when the code is tripped.

Ver imagen

Illustration 2

g02173843

Control map for low fuel pressure

Ver imagen

Illustration 3

g01594813

Control map for low oil pressure

Ver imagen

Illustration 4

g01594957

Control map for the low coolant pressure

Separate timers are used in the ECM for each response that is associated with a  parameter. If a trip point is reached, the timer for that event is started.