Localización y Solución de Problemas

Localizacin y Solucin de Problemas
C175-16 and C175-20 Engines For 793F and 797F Off-Highway Trucks
Nmero de medio -KENR5398-
12
Fecha de publicacin -
01/11/2013
Fecha de actualizacin -
06/11/2013

i05123051
Turbocharger Turbine Temperature Is High
SMCS - 1052-035-TA

/sisweb/sisweb/f /sisweb/fulltext/fu

Use this procedure in order to troubleshoot a high turbocharger turbine inlet temperature
or if one of the following event codes is active.
Table 1
Event Code
Code and Description
Conditions which Generate this
Code
System Response
E245(1) High Right Turbo
Turbine Inlet
Temperature
The exhaust temperature is above
the trip point temperature.
The code is
logged.
Turbine Inlet
Temperature
The engine is
derated. The code is
logged.
Turbine Inlet
Temperature
The code is logged.
The engine is shut
down.
E246(1) High Left Turbo
Turbine Inlet
Temperature
The exhaust temperature is above
the trip point temperature.
The code is
logged.
Turbine Inlet
Temperature
The engine is
derated. The code is
logged.
Turbine Inlet
Temperature
The code is logged.
The engine is shut
down.
E278(2) High Exhaust
Differential
Temperature
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 turbocharger turbine inlet temperature, the
power to the engine Electronic Control 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.

E245
E246
E278

Result: An associated code is
present.

Repair: Troubleshoot any
associated codes before
continuing with this test.

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

Proceed to the next step.

Result: No active codes

STOP

2. Check for High Inlet Air
Temperature

A. Refer to Troubleshooting, "Intake
Manifold Air Temperature Is High".

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

Inlet air
temperature

Result: The inlet air
temperature is OK.


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.

3. Incorrect Valve Lash

A. Check the engine valve lash.

Valve lash

Result: The valve lash is OK.


Result: The valve lash is
NOT OK.

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


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

Result: The exhaust
temperature probes are not
reading correctly.

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

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.

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

Air inlet

Result: Compressor inlet
pressures are equal on each
turbocharger.

Repair: Check for boost side
or exhaust side air leaks.


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.

Result: The compressor
discharge back to engine is
OK.


Result: The compressor
discharge back to the engine
is NOT OK.

Repair: Remove restriction
or blockage

Result: The engine has No
Air Leaks.


Result: The engine has Air
Leaks..

Repair: Determine the cause
of the air leak and repair
damage or leaking
components.

proceed to the step 6.

6. Check the Exhaust System

A. Refer to Test and Adjust,
"Restriction of Air Inlet and
Exhaust".

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.

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.

Exhaust
system

Result: The air system lines
and connections are OK.


Result: The air system lines
and connections are NOT
OK.

Repair: If anything is loose
or cracked replace or repair
any issues.

proceed to the step 7.

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.

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

Aftercooler

Result: The aftercooler is
OK.


Result: The aftercooler is
NOT OK.

Repair: Clear restrictions and
replace aftercooler or any
damaged lines.


8. Check the Fuel Injectors

NOTE: Faulty injectors that deliver

Leak

Result: The injectors are OK.

too much fuel will increase exhaust
temperatures.

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

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 injectors are
NOT OK.

Repair: Repair or replace the
faulty injectors.

9. Inspect Turbochargers

A. Inspect turbine and compressor
wheels for visible signs of damage
or rubbing.

B. Inspect turbochargers and
turbocharger housings for leaks

Turbocharger

Result: The turbochargers are
OK.

Result: The turbochargers are
NOT OK.

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

Localizacin y Solucin de Problemas
C175-16 and C175-20 Engines For 793F and 797F Off-Highway Trucks
Nmero de medio -KENR5398-
12
Fecha de publicacin -
01/11/2013
Fecha de actualizacin -
06/11/2013

i05499331
Event Codes
SMCS - 1900

/sisweb/sisweb/f /sisweb/fulltext/fu

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 are 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
Mark
The engine oil level is below the specified level. Check the engine oil
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
Troubleshooting, "Oil Consumption Is Excessive" for details that are
related to troubleshooting this symptom.
E072(3) Oil Level Low
Mark
E096(1) High Fuel
Troubleshooting, "Fuel Pressure Is High"
Pressure
E098(1) Engine Pre-
lube 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
Warning
Troubleshooting, "Oil Filter Differential Pressure Problem"
E101(1) High
Crankcase Pressure
Warning
Troubleshooting, "Crankcase Pressure Is High"
E197(1) High Engine
Oil Temperature
Troubleshooting, "Oil Temperature Is High"
E197(2) High Engine
Oil Temperature
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
Separator Water
Level
The level of water that is in the fuel/water separator is excessive.
Remove the water from the fuel/water separator and return the
engine to service. Refer to the Operation and Maintenance Manual for
details. If an electrical problem with the sensor or the sensor circuit is
suspected, refer to Troubleshooting, "Water In Fuel - Test" for details
that are related to troubleshooting the problem.
E232(2) High
Fuel/Water
Separator Water
Level
E233(2) Low Engine
Pre-lube Pressure
Troubleshooting, "Prelubrication Pump Problem"
E245(2) High Right
Turbo Turbine Inlet
Temperature
Troubleshooting, "Turbocharger Turbine Temperature Is High"
E245(3) High Right
Turbo Turbine Inlet
Temperature
E246(2) High Left
Turbo Turbine Inlet
Temperature
E246(3) High Left
Turbo Turbine Inlet
Temperature
E265(2) User Defined
Shutdown
This event is used to record a requested shutdown from an
aftermarket shutdown device.
E278(2) High Exhaust
Differential
Temperature
Troubleshooting, "Exhaust Differential Temperature is High"
E360(1) Low Engine
Oil Pressure
Troubleshooting, "Oil Pressure Is Low"
E360(3) Low Engine
Oil Pressure
E361(1) High Engine
Coolant
Temperature
Troubleshooting, "Coolant Temperature Is High"
E361(2) High Engine
Coolant
Temperature
E361(3) High Engine
Coolant
Temperature
E362(1) Engine
Overspeed
Troubleshooting, "Engine Overspeeds"
E362(2) Engine
Overspeed
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
#1 Differential
Pressure
#2 Differential
Pressure
#2 Differential
Pressure
#3 Differential
Pressure
#3 Differential
Pressure
#4 Differential
Pressure
#4 Differential
Pressure
E678(2) Ground Level
Shutdown
The ground level shutdown switch has been activated. Reset the
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
Troubleshooting, "Fuel Temperature is High"
E1044(1) High Intake Troubleshooting, "Intake Manifold Air Pressure is High"
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
Operate
Troubleshooting, "Oil Renewal - Test"
E2112(1) Low Engine
Coolant Pressure
Troubleshooting, "Coolant Pressure Is Low"
E2143(2) Low Engine
Coolant Level
The coolant level is below the specified level. Check the level of the
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.
If an electrical problem is suspected with the cooling system, refer to
Troubleshooting, "Coolant Level - Test" for details that are related to
troubleshooting the coolant level switch.
E2143(3) Low Engine
Coolant Level
E2172(1) Low Fuel
Transfer Pump Inlet
Pressure
Troubleshooting, "Fuel Transfer Pump Inlet Pressure Is Low"
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
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 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 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 code 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 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 basic troubleshooting of the engine, perform the following steps in order to
diagnose a malfunction:
1. Obtain the following information about the complaint:
o The event and the time of the event
o Determine the conditions for the event. The conditions will include the engine
rpm and the load.
o Determine if there are any systems that were installed by the dealer or by the
customer that could cause the event.
o 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:
o Fuel supply
o Oil level
o Oil supply
o Wiring
o Connectors
Be sure to check the connectors. An important step for intermittent problems is to
confirm the connectors are in good repair. Refer to 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
Check Engine
Lamp
Action Lamp
Advisor message
Action Alarm
(1)
The lamp is
illuminated.
Off Off
(2)
The lamp is
illuminated.
The lamp will flash.
Advisor displays a warning
message.
Off
(3)
(1)

The lamp is
illuminated.
The lamp will flash.
Advisor displays a warning
message.
The alarm will
sound.
( 1 )
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 to 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
in
Seconds
Derate
(%)
E072 Oil Level Low
Mark
(2)
The circuit for the oil
level switch that is for
low oil level is open.
This event is enabled
when the keyswitch is
turned to the ON
position. The event is
disabled after the engine
has started.
3
N/A
(3)
(1)

The circuit for the oil
level switch that is for
low oil level is open.
This event is enabled 17
seconds after the engine
has been started.
20
E096 High Fuel
Pressure
(1) 900 kPa (131 psi) 8 N/A
E099 Engine Oil
Filter Restriction
Warning
( C175-16)
(2)

150 kPa (22 psi)
oil temperature has
exceeded
20 C (68 F).
10 N/A
E099 Engine Oil
Filter Restriction
Warning
( C175-20)
(2)

180 kPa (26 psi)
oil temperature has
exceeded
20 C (68 F).
10 N/A
E101 High
Crankcase Pressure
Warning
(1)

4 kPa (0.6 psi)
seconds after the coolant
temperature has
exceeded
15 C (59 F).
5 N/A
E197 High Engine
Oil Temperature
(1)

108 C (226 F)
15
N/A
(2)

110 C (230 F)
Map
Dependent
Values
(3)

115 C (239 F)
N/A
E198 Low Fuel
Pressure
(1)
Refer to the control map
for low fuel pressure in
Illustration 2 for
details.
10
N/A
(2)
Map
Dependent
Values
E199 Low Coolant
Temperature
(1)

70 C (158 F)
In order to enable this
event, the engine must
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
Fuel/Water
Separator Water
Level
(1)
The switch has opened.
40 N/A
(2) 3600 35
E233 Low Engine
Pre-lube
Pressure
(2)

48 kPa (7 psi)
45 N/A
E245 High Right
Turbo Turbine Inlet
Temperature
(2)

725 C (1340 F)
5
25
(3)

805 C (1480 F)
N/A
E246 High Left
Turbo Turbine Inlet
Temperature
(2)

725 C (1340 F)
5
25
(3)

805 C (1480 F)
N/A
E278 High Exhaust
Differential
Temperature
(2)

50 C (90 F)

(2)
N/A
E360 Low Engine
Oil Pressure
(1) Refer to the control map
for low oil pressure in
Illustration 3 for
details.
8 N/A
(3)
(1)
4 35
E361 High Engine
Coolant
Temperature
(1)

100 C (212 F)
10
N/A
(2)

101 C (214 F)
Map
Dependent
Values
(3)
(1)

N/A
110 C (230 F)
E362 Engine
Overspeed
(1) 2250 rpm
0.6
The ECM
disables
injection above
the trip point.
(2) 2325 rpm
(3) 2400 rpm
E390 Fuel Filter
Restriction
(1)

105 kPa (15 psi)
120 N/A
(2)

124 kPa (18 psi)
300 35
E396 High Fuel Rail
Pressure
(1)
(3)
N/A N/A
E398 Low Fuel Rail
Pressure
(2)
(3)
N/A 100
E539 High Intake
Manifold Air
Temperature
(1)

80 C (176 F)
8
N/A
(2)

90 C (194 F)
30
E583 High Air Inlet
#1 Differential
Pressure
(1)

7.5 kPa (1.1 psi)

(2)

Map
Dependent
Values
(2)
E584 High Air Inlet
#2 Differential
Pressure
(1)

7.5 kPa (1.1 psi)

(2)

Map
Dependent
Values
(2)
E585 High Air Inlet
#3 Differential
Pressure
(1)

7.5 kPa (1.1 psi)

(2)

Map
Dependent
Values
(2)
E586 High Air Inlet
#4 Differential
Pressure
(1)

7.5 kPa (1.1 psi)

(2)

Map
Dependent
Values
(2)
E678 Ground Level
Shutdown
(3)
The ground level switch is
on.
N/A
The engine ECM
disables fuel
injection to the
engine.
E770 High Fuel Rail
Temperature
(2)

100 C (212 F)
15
Map
Dependent
Values
E1044 High Intake
Manifold
Pressure
(1)
(3)

8 25
(2)
(3)

E1106 High Fuel
Rail Pump Flow
(2)
(3)
10 N/A
E2089 Oil Renewal
System Cannot
Operate
(1)
The ECM detects a fault
in the circuit for the oil
renewal solenoid.
or
in the circuit for the
coolant temperature
sensor.
or
in the circuit for the fuel
level sensor.
or
in the circuit for the oil
pressure sensor.
N/A N/A
E2112 Low Engine
Coolant Pressure
(1)
Refer to the control map
for low coolant pressure
in Illustration 4 for
details.
10 N/A
E2143 Low Engine
Coolant Level
(2)
The circuit for the engine
coolant level switch is
open.
This event is enabled
when the keyswitch is
turned to the ON
position.
3
N/A
(3)
(1)

The circuit for the engine
coolant level switch is
open.
has been started.
12
E2172 Low Fuel
Transfer Pump
Inlet Pressure
(1)

-50 kPa (-7 psi)
60 N/A
( 1 )
The VIMS will perform an engine shutdown when the vehicle speed is equal to zero mph and the
parking brake has been engaged.
( 2 )
The delay time for this event is dependent on the severity of the condition.
( 3 )
This code does not have a specific trip point. Several factors determine when the code is tripped.

Ver imagen

Control map for low fuel pressure

Ver imagen

Control map for low oil pressure

Ver imagen

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.

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