Caterpillar 3406E, C10, C12, C15, C16, C18 Diesel Engine Troubleshooting Manual

Covers: Cat 3406E, C10, C12, C15, C16, C18 on-highway diesel engines with serial prefixes

• WIA
• CPD
• 1MM
• CJP
• MDP
• MEP
• 2KS
• 2WS
• 3CS
• 6NZ
• 7CZ

Type: Troubleshooting Manual
Language: English
Pages: 420
Format: PDF
File size: 25mb
Features: Searchable, printable
Compatibility: Windows/Mac/Tablet/Mobile

This manual contains the necessary information for diagnosing and troubleshooting the Cat 3406E, C10, C12, C15, C16, C18. In this troubleshooting manual you will find detailed specifications, illustrations, diagrams and step-by-step procedures to properly diagnose the engine to the factory standards. Over 400 pages of detailed factory service information. View this manual on your computer or print off pages as needed to save time and money.

Contents:

• TROUBLESHOOTING
  • SYSTEM OVERVIEW
  • GLOSSARY
  • ELECTRONIC SERVICE TOOLS
  • REPLACING THE ECM
  • SENSORS AND ELECTRICAL CONNECTORS
  • ENGINE WIRING HARNESS DIAGRAM
  • VEHICLE WIRING HARNESS DIAGRAM
• PROGRAMMING PARAMETERS
  • TEST ECM MODE
  • CUSTOMER PASSWORDS
  • ECM DATE/TIME STAMPED INFORMATION
  • ECM SNAPSHOT
  • FACTORY PASSWORDS
  • FACTORY PASSWORDS WORKSHEET
  • FLASH PROGRAMMING
  • SERVICE INFORMATION REPORT
• CUSTOMER SPECIFIED PARAMETERS
• SYSTEM CONFIGURATION PARAMETERS
• TROUBLESHOOTING WITHOUT A DIAGNOSTIC CODE
  • CAN NOT REACH TOP ENGINE RPM
  • CAN NOT REACH VEHICLE SPEED LIMIT
  • CHECK ENGINE LAMP OR WARNING LAMP IS MALFUNCTIONING
  • COOLING FAN IS ALWAYS ON
  • CRUISE CONTROL, IDLE, OR PTO CAN NOT BE SET
  • DRIVER QUESTIONNAIRE
  • DRIVER QUESTIONNAIRE RESPONSE
  • ECM WILL NOT ACCEPT FACTORY PASSWORDS
  • ELECTRONIC SERVICE TOOL WILL NOT COMMUNICATE WITH ECM
  • ENGINE CRANKS BUT WILL NOT START
  • ENGINE MISFIRES, RUNS ROUGH OR IS UNSTABLE
  • ENGINE RETARDER (COMPRESSION BRAKE) WILL NOT TURN ON
  • ENGINE VIBRATION
  • ENGINE WILL NOT CRANK
  • EXCESSIVE BLACK SMOKE
  • EXCESSIVE FUEL CONSUMPTION
  • EXCESSIVE WHITE SMOKE
  • INTERMITTENT CRUISE CONTROL, IDLE, OR PTO KICK-OUT
  • INTERMITTENT ENGINE SHUTDOWN
  • INTERMITTENT LOW POWER OR POWER CUTOUT
  • LOW POWER/POOR OR NO RESPONSE TO THROTTLE
  • POOR ACCELERATION OR RESPONSE
• TROUBLESHOOTING WITH A DIAGNOSTIC CODE
  • DIAGNOSTIC CODE DETECTED -55
  • CYLINDER #1 INJECTOR CURRENT FAULT -72
  • CYLINDER #2 INJECTOR CURRENT FAULT -72
  • CYLINDER #3 INJECTOR CURRENT FAULT -73
  • CYLINDER #4 INJECTOR CURRENT FAULT -73
  • CYLINDER #5 INJECTOR CURRENT FAULT -74
  • CYLINDER #6 INJECTOR CURRENT FAULT -74
  • PRIMARY TO SECONDARY ENGINE SPEED SIGNAL CALIBRATION -42
  • ENGINE SPEED SIGNAL CALIBRATION NOT PERFORMED -42
  • PTO THROTTLE SIGNAL INVALID -29
  • PTO THROTTLE OUT OF CALIBRATION -29
  • 8 VOLT SUPPLY VOLTAGE HIGH -21
  • 8 VOLT SUPPLY VOLTAGE LOW -21
  • KEY SWITCH FAULT -71
  • AIR INLET SHUTOFF SHUTDOWN 0
  • AUXILIARY OUTPUT #06 CURRENT LOW -66
  • AUXILIARY OUTPUT #06 CURRENT HIGH -66
  • AUXILIARY OUTPUT #07 CURRENT LOW -67
  • AUXILIARY OUTPUT #07 CURRENT HIGH -67
  • SECONDARY ENGINE SPEED LOSS OF SIGNAL -34
  • IDLE SHUTDOWN OVERRIDE -1
  • IDLE SHUTDOWN -47
  • PTO SHUTDOWN -47
  • VEHICLE OVER-SPEED WARNING -41
  • VEHICLE SPEED LOSS OF SIGNAL -31
  • VEHICLE SPEED SIGNAL INVALID -36
  • VEHICLE SPEED SIGNAL OUT OF RANGE -36
  • VEHICLE SPEED SIGNAL RATE OF CHANGE -36
  • QUICK STOP OCCURRENCE
  • THROTTLE POSITION INVALID -32
  • THROTTLE POSITION OUT OF CALIBRATION -32
  • LOW OIL PRESSURE WARNING -46
  • OIL PRESSURE VOLTAGE HIGH -24
  • OIL PRESSURE VOLTAGE LOW -24
  • VERY LOW OIL PRESSURE -46
  • EXCESSIVE BOOST PRESSURE
  • BOOST PRESSURE VOLTAGE HIGH -25
  • BOOST PRESSURE VOLTAGE LOW -25
  • HIGH INTAKE MANIFOLD AIR TEMPERATURE WARNING -64
  • INTAKE MANIFOLD AIR TEMPERATURE VOLTAGE HIGH -38
  • INTAKE MANIFOLD AIR TEMPERATURE VOLTAGE LOW -38
  • VERY HIGH INTAKE MANIFOLD AIR TEMPERATURE -64
  • BAROMETRIC PRESSURE VOLTAGE HIGH -26
  • BAROMETRIC PRESSURE VOLTAGE LOW -26
  • HIGH COOLANT TEMPERATURE WARNING -61
  • COOLANT TEMPERATURE VOLTAGE HIGH -27
  • COOLANT TEMPERATURE VOLTAGE LOW -27
  • VERY HIGH COOLANT TEMPERATURE -61
  • LOW COOLANT LEVEL WARNING -62
  • COOLANT LEVEL SIGNAL INVALID -12
  • COOLANT LEVEL VOLTAGE HIGH -12
  • COOLANT LEVEL VOLTAGE LOW -12
  • VERY LOW COOLANT LEVEL -62
  • LOW/HIGH RETARDER CURRENT LOW -14
  • LOW/HIGH RETARDER CURRENT HIGH -14
  • MED/HIGH RETARDER CURRENT LOW -14
  • MED/HIGH RETARDER CURRENT HIGH -14
  • ECM BATTERY POWER INTERMITTENT -51
  • AMBIENT AIR TEMPERATURE VOLTAGE HIGH
  • AMBIENT AIR TEMPERATURE VOLTAGE LOW
  • AMBIENT AIR TEMPERATURE DATA LOST
  • HIGH FUEL TEMPERATURE WARNING -65
  • FUEL TEMPERATURE VOLTAGE HIGH -13
  • FUEL TEMPERATURE VOLTAGE LOW -13
  • ENGINE OVER-SPEED WARNING -35
  • PRIMARY ENGINE SPEED LOSS OF SIGNAL -34
  • TRANSMISSION NOT RESPONDING -68
  • THEFT DETERRENT ACTIVE 0
  • THEFT DETERRENT ACTIVE WITH ENGINE CRANKING 0
  • J1939 DATA INCORRECT -58
  • J1939 DATA LINK FAULT -58
  • J1939 DEVICE NOT RESPONDING
  • 5 VOLT SUPPLY VOLTAGE HIGH -21
  • 5 VOLT SUPPLY VOLTAGE LOW -21
  • BRAKE PEDAL SWITCH #1 FAULT
  • BRAKE PEDAL SWITCH #2 FAULT
  • J1922 DATA LINK FAULT -58
  • ENGINE SOFTWARE INCORRECT -59
  • CHECK CUSTOMER OR SYSTEM PARAMETERS -56
  • CHECK TRANSMISSION CUSTOMER PARAMETERS -56
• DIAGNOSTIC FUNCTIONAL TESTS
  • 5 VOLT ENGINE PRESSURE SENSOR SUPPLY CIRCUIT – TEST
  • ACCELERATOR PEDAL (THROTTLE) POSITION SENSOR CIRCUIT – TEST
  • AIR INLET SHUTOFF CIRCUIT – TEST
  • ATA (SAE J1587/J1708) DATA LINK CIRCUIT-TEST
  • AUXILIARY BRAKE CIRCUIT – TEST
  • CHECK ENGINE LAMP CIRCUIT – TEST
  • CLUTCH PEDAL POSITION SWITCH CIRCUIT – TEST
  • COOLANT LEVEL SENSOR CIRCUIT – TEST
  • COOLING FAN CIRCUIT AND A/C HIGH PRESSURE SWITCH CIRCUIT – TEST
  • CRUISE CONTROL SWITCH CIRCUIT – TEST
  • DIAGNOSTIC ENABLE SWITCH CIRCUIT – TEST
  • EATON TOP 2 TRANSMISSION CIRCUIT – TEST
  • ECM MEMORY – TEST
  • ELECTRICAL CONNECTORS – INSPECT
  • ENGINE PRESSURE SENSOR OPEN OR SHORT CIRCUIT -TEST
  • ENGINE RUNNING OUTPUT CIRCUIT – TEST
  • ENGINE SHUTDOWN OUTPUT CIRCUIT – TEST
  • ENGINE SPEED/TIMING SENSOR CIRCUIT – TEST
  • ENGINE TEMPERATURE SENSOR OPEN OR SHORT CIRCUIT- TEST
  • FAN OVERRIDE SWITCH CIRCUIT – TEST
  • IDLE SHUTDOWN TIMER – TEST
  • IGNITION KEY SWITCH CIRCUIT AND BATTERY SUPPLY CIRCUIT- TEST
  • IGNORE BRAKE/CLUTCH SWITCH CIRCUIT – TEST
  • INJECTOR SOLENOID CIRCUIT – TEST
  • MULTI-TORQUE – TEST
  • NEUTRAL SWITCH CIRCUIT – TEST
  • POWERTRAIN DATA LINK CIRCUIT – TEST
  • PTO ENGINE RPM SET SPEED (INPUT A AND INPUT B) CIRCUIT – TEST
  • PTO SHUTDOWN TIMER – TEST
  • PTO SWITCH CIRCUIT – TEST
  • PTO SWITCH ON LAMP CIRCUIT TEST
  • REMOTE PTO ACCELERATOR POSITION SENSOR CIRCUIT -TEST
  • RETARDER (COMPRESSION BRAKE) SOLENOID CIRCUIT-TEST
  • SERVICE BRAKE PEDAL POSITION (SWITCH 1) CIRCUIT-TEST
  • SERVICE BRAKE PEDAL POSITION (SWITCH 2) CIRCUIT-TEST
  • STARTING AID OUTPUT CIRCUIT – TEST
  • STARTING AID SWITCH CIRCUIT – TEST
  • TACHOMETER CIRCUIT – TEST
  • TORQUE LIMIT SWITCH CIRCUIT – TEST
  • TWO SPEED AXLE SWITCH CIRCUIT – TEST
  • VEHICLE SPEED AND SPEEDOMETER CIRCUIT – TEST
  • WARNING LAMP CIRCUIT – TEST
• CALIBRATION PROCEDURES
  • ENGINE SPEED/TIMING SENSOR – CALIBRATE
  • INJECTOR CODE – CALIBRATE
  • VEHICLE SPEED CIRCUIT – CALIBRATE
• ALPHABETICAL INDEX

Please note this manual is in downloadable PDF format only. If you have any questions about this product or would like to request sample pages, please contact us and reference the product name or SKU.