3176C, 3196 and 3406E Engines for 725, 730, 735, 740, and 740 Ejector Articulated Trucks Troubleshooting Manual

3176C, 3196 and 3406E Engines for 725, 730, 735, 740, and 740 Ejector Articulated Trucks Troubleshooting Manual

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This Manual Include information, specifications, and illustrations For Troubleshooting Your 3176C, 3196 and 3406E Engines , The Troubleshooting Manual Cover All Errors that With Diagnostic Code Or Without  Diagnostic Code.

Covers: Caterpillar 3176C, 3196 and 3406E Engines With Serial Numbers:  

• AGF1-Up (Machine)
• AXM1-Up (Machine)
• AWR1-Up (Machine)
• AFX1-Up (Machine)
• AZZ1-Up (Machine)
• 3PD1-Up (Engine)
• 5ED1-Up (Engine)
• BET1-Up (Engine)

Format: PDF
Compatibility: Windows/Mac/Linux

Table of Contents

Troubleshooting Section
Electronic Troubleshooting
System Overview .................................................... 5
Electronic Service Tools .......................................... 6
Electronic Display Module (If Equipped) ................. 9
Replacing the ECM ................................................. 9
Self-Diagnostics ..................................................... 11
Sensors and Electrical Connectors ........................ 11
Engine Wiring Information .................................... 16
Programming Parameters
Programming Parameters ..................................... 18
Factory Passwords ............................................... 18
Flash Programming .............................................. 18
System Configuration Parameters
System Configuration Parameters ........................ 20
Troubleshooting without a Diagnostic Code
Alternator (Charging Problem) .............................. 23
Alternator (Noisy Operation) ................................. 23
Can Not Reach Top Engine RPM ......................... 23
Coolant in Engine Oil ............................................ 25
Coolant Temperature Is Too High ......................... 25
ECM Will Not Accept Factory Passwords ............. 25
ECM Will Not Communicate with Other Systems or
Display Modules .................................................. 26
Electronic Service Tool Will Not Communicate with
ECM .................................................................... 26
Engine Cranks but Will Not Start .......................... 27
Engine Has Early Wear ........................................ 30
Engine Misfires, Runs Rough or Is Unstable ........ 30
Engine Oil in Cooling System ............................... 31
Engine Oil Temperature Is Too High ..................... 32
Engine Overspeeds on Start-up ........................... 32
Engine Stalls at Low RPM .................................... 32
Engine Vibration ................................................... 33
Engine Will Not Crank ........................................... 34
Excessive Black Smoke ........................................ 34
Excessive Engine Oil Consumption ...................... 35
Excessive Fuel Consumption ............................... 36
Excessive Valve Lash ........................................... 37
Excessive White Smoke ....................................... 37
Exhaust Temperature Is Too High ......................... 38
Fuel in Cooling System ......................................... 39
Fuel Dilution of Engine Oil .................................... 39
Intermittent Engine Shutdown ............................... 40
Intermittent Low Power or Power Cutout .............. 41
Low Engine Oil Pressure ...................................... 41
Low Power/Poor or No Response to Throttle ....... 42
Mechanical Noise (Knock) in Engine .................... 43
Noise Coming from Cylinder ................................. 44
Poor Acceleration or Response ............................ 44
Valve Rotator or Spring Lock Is Free .................... 46
Troubleshooting with a Diagnostic Code
Diagnostic Codes .................................................. 47
CID 0001 FMI 11 Cylinder #1 Injector fault ........... 48
CID 0002 FMI 11 Cylinder #2 Injector fault ........... 48
CID 0003 FMI 11 Cylinder #3 Injector fault ........... 48
CID 0004 FMI 11 Cylinder #4 Injector fault ........... 49
CID 0005 FMI 11 Cylinder #5 Injector fault ........... 49
CID 0006 FMI 11 Cylinder #6 Injector fault ........... 49
CID 0041 FMI 03 8 Volt DC Supply short to +batt .. 50
CID 0041 FMI 04 8 Volt DC Supply short to
ground ................................................................. 50
CID 0091 FMI 08 Throttle Position signal
abnormal ............................................................. 50
CID 0094 FMI 03 Fuel Pressure open/short to
+batt .................................................................... 50
CID 0094 FMI 04 Fuel Pressure short to ground .. 51
CID 0100 FMI 03 Engine Oil Pressure open/short to
+batt .................................................................... 51
CID 0100 FMI 04 Engine Oil Pressure short to
ground ................................................................. 51
CID 0110 FMI 03 Engine Coolant Temperature
open/short to +batt .............................................. 51
CID 0110 FMI 04 Engine Coolant Temperature short
to ground ............................................................. 52
CID 0168 FMI 00 System Voltage High ................ 52
CID 0168 FMI 01 System Voltage Low ................. 52
CID 0168 FMI 02 System Voltage intermittent/
erratic .................................................................. 52
CID 0172 FMI 03 Intake Manifold Air Temp open/short
to +batt ................................................................ 53
CID 0172 FMI 04 Intake Manifold Air Temp short to
ground ................................................................. 53
CID 0174 FMI 03 Fuel Temperature open/short to
+batt .................................................................... 53
CID 0174 FMI 04 Fuel Temperature short to
ground ................................................................. 54
CID 0190 FMI 02 Loss of Engine Speed Signal ... 54
CID 0190 FMI 11 Engine Speed Sensor mechanical
failure .................................................................. 54
CID 0248 FMI 09 Cat Data Link not
communicating .................................................... 55
CID 0253 FMI 02 Personality Module mismatch .. 55
CID 0254 FMI 12 Electronic Control Module
Error .................................................................... 55
CID 0261 FMI 13 Engine Timing Calibration
required ............................................................... 56
CID 0262 FMI 03 5 Volt Sensor DC Power Supply
short to +batt ....................................................... 56
CID 0262 FMI 04 5 Volt Sensor DC Power Supply
short to ground .................................................... 56
CID 0267 FMI 02 Incorrect Engine Shutdown Switch
inputs .................................................................. 57
CID 0268 FMI 02 Check Programmable
Parameters ......................................................... 57
CID 0273 FMI 03 Turbo Outlet Pressure open/short
to +batt ................................................................ 57
CID 0273 FMI 04 Turbo Outlet Pressure short to
ground ................................................................. 58
CID 0274 FMI 03 Atmospheric Pressure open/short
to +batt ................................................................ 58
CID 0274 FMI 04 Atmospheric Pressure short to
ground ................................................................. 58
CID 0275 FMI 03 Right Turbo Inlet Pressure
open/short to +batt .............................................. 58
CID 0275 FMI 04 Right Turbo Inlet Pressure short to
ground ................................................................. 59
CID 0283 FMI 05 Filter Restrict Lamp open/short to
+batt .................................................................... 59
CID 0283 FMI 06 Filter Restrict Lamp short to
ground ................................................................. 59
CID 0291 FMI 05 Engine Cooling Fan Solenoid open
circuit ................................................................... 60
CID 0291 FMI 06 Engine Cooling Fan Solenoid short
to ground ............................................................. 60
CID 0296 FMI 09 Unable to communicate with
Transmission ECM .............................................. 60
CID 0342 FMI 02 Loss of Secondary Engine Speed
signal ................................................................... 61
CID 0342 FMI 11 Secondary Engine Speed Sensor
mechanical failure ............................................... 61
CID 0545 FMI 05 Ether Start Relay open/short to
+batt .................................................................... 61
CID 0545 FMI 06 Ether Start Relay short to
ground ................................................................. 62
CID 0788 FMI 02 Loss of Engine Retarder Selector
Switch Signal ...................................................... 62
CID 0791 FMI 05 Compression Brake Low/High
Solenoid current low ........................................... 62
CID 0791 FMI 06 Compression Brake Low/High
Solenoid current high .......................................... 63
CID 0792 FMI 05 Compression Brake Medium/High
Solenoid current low ........................................... 63
CID 0792 FMI 06 Compression Brake Medium/High
Solenoid current high .......................................... 63
CID 1076 FMI 05 Engine Cooling Fan Bypass
Solenoid open circuit ........................................... 63
CID 1076 FMI 06 Engine Cooling Fan Bypass
Solenoid short to ground ..................................... 64
CID 1586 FMI 05 Retarder Indicator Lamp open
circuit ................................................................... 64
CID 1586 FMI 06 Retarder Indicator Lamp short to
ground ................................................................. 64
Troubleshooting with an Event Code
Event Codes ........................................................ 65
E015 High Engine Coolant Temperature Derate .. 65
E017 High Engine Coolant Temperature
Warning ............................................................... 66
E025 High Inlet Air Temperature Derate ............... 67
E027 High Inlet Air Temperature Warning ............ 68
E039 Low Engine Oil Pressure Derate ................. 69
E056 High Fuel Temperature Warning .................. 71
E094 Axle Protection Derate ................................ 72
E100 Low Engine Oil Pressure Warning ............... 72
E190 Engine Overspeed Warning ........................ 74
E272 Inlet Air Restriction Warning ........................ 74
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit Test
..................................................................... 77
Air Filter Restriction Lamp - Test ........................... 83
Cat Data Link Circuit - Test ................................... 85
Compression Brake Lamp Circuit - Test ............... 92
Compression Brake Solenoid Circuit - Test .......... 95
Digital Sensor Supply Circuit - Test .................... 100
Electrical Connectors - Inspect ........................... 105
Electrical Power Supply Circuit - Test .................. 110
Engine Cooling Fan Bypass Solenoid Circuit Test
.................................................................... 115
Engine Fan Control Solenoid Circuit - Test .......... 118
Engine Pressure Sensor Open or Short Circuit Test
................................................................... 122
Engine Shutdown Switch Circuit - Test ............... 130
Engine Speed/Timing Sensor Circuit - Test ........ 133
Engine Temperature Sensor Open or Short Circuit Test
................................................................... 139
Ether Injection System - Test .............................. 145
Injector Solenoid Circuit - Test ............................ 151
Throttle Position Sensor Circuit - Test ................ 160
Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 165
Index Section
Index ................................................................... 171