Caterpillar Cat C175-16 and C175-20 Engine Troubleshooting Manual

Caterpillar Cat C175-16 and C175-20

Caterpillar Cat C175-16 and C175-20 Engine Troubleshooting Manual

Manual Contents:

Introduction
General Information
Welding Precaution
Electronic Service Tools 5
Electronic System Overview
Component Location 9
Engine Monitoring System 14
Diagnostic Capabilities 14
Electrical Connectors 16
Wiring Information 18
Configuration Parameters
Configuration Parameters ……. 20
Diagnostic Trouble Codes
Diagnostic Trouble Codes ……. 22
Event Codes
Event Codes …30
Symptom Troubleshooting
Symptom Troubleshooting …39
Alternator Problem (Charging Problem and/or Noisy
Operation) 39
Coolant Contains Fuel ………0
Coolant Contains Oil ……0
Coolant Pressure Is Low ………1
Coolant Temperature Is High …..2
Coolant Temperature Is Low …………4
Crankcase Pressure Is High …………5
ECM Does Not Communicate with Other
Modules ………………..6
Engine Cranks but Does Not Start …6
Engine Does Not Crank ……………….9
Engine Has Mechanical Noise (Knock) 50
Engine Misfires, Runs Rough or Is Unstable 50
Engine Overspeeds …. 52
Engine Top Speed Is Not Obtained . 53
Engine Vibration Is Excessive 53
Exhaust Has Excessive Black Smoke ………54
Exhaust Has Excessive White Smoke ………55
Fuel Filter Is Restricted ……56
Fuel Pressure Is High 57
Fuel Pressure Is Low …57
Fuel Rail Pressure Is High 59
Fuel Rail Pressure Is Low ……. 60
Fuel Temperature Is High ……. 61
Fuel Transfer Pump Inlet Pressure Is Low …62
Inlet Air Is Restricted … 63
Intake Manifold Air Temperature Is High ……64
Oil Consumption Is Excessive 65
Oil Contains Coolant 65
Oil Contains Fuel 66
Oil Filter Differential Pressure Problem 66
Oil Pressure Is Low 67
Oil Temperature Is High ……. 68
Power Is Intermittently Low or Power Cutout Is
Intermittent ……. 69
Prelubrication Pump Problem ……. 70
Turbocharger Turbine Temperature Is High 71
Valve Lash Is Excessive ………72
Valve Rotator or Spring Lock Is Free …………73
Circuit Tests
Coolant Level – Test …74
Data Link – Test …81
Electrical Power Supply – Test …… 89
Ether Starting Aid – Test 96
Fuel Priming Pump – Test. 104
Fuel Rail Pressure – Test ……. 111
Injector Solenoid – Test …… 120
Oil Renewal – Test ….. 137
Prelubrication – Test 143
Sensor Signal (Analog, Active) – Test. 152
Sensor Signal (Analog, Passive) – Test ……164
Sensor Signal (PWM) – Test ……. 173
Sensor Supply – Test ……. 181
Shutdown – Test ….. 192
Speed/Timing – Test 197
Service
Factory Passwords …… 207
ECM Will Not Accept Factory Passwords …207
Electronic Service Tool Does Not Communicate .. 208
Test ECM Mode ….. 212
Injector Trim File – Install …. 213
ECM Software – Install 213
ECM – Configure 214
ECM – Replace …… 215
Electrical Connectors – Inspect …… 216
Index Section
Index 221

Disassembling and assembling truck engines like the Caterpillar C15, C16, and C18 require careful attention to detail, proper tools, and adherence to manufacturer guidelines.

It’s important to note that performing engine disassembly and assembly is a complex task that should be undertaken by experienced technicians. However, I can provide you with a general overview of the steps involved.

Please keep in mind that this overview is not exhaustive, and it is crucial to consult the official Caterpillar service manuals and guidelines for detailed instructions. Here are the basic steps:

1. Preparation: Gather all the necessary tools, safety equipment, and service manuals for the specific engine model you’re working on. Ensure the engine is in a secure position, and disconnect the battery before starting any work.

2. Drain Fluids: Remove engine oil, coolant, and fuel from the engine system according to the recommended procedures. Properly dispose of the fluids following local regulations.

3. Removal of External Components: Begin by removing any external components attached to the engine, such as the air intake system, exhaust system, alternator, starter motor, and any other ancillary components.

4. Disconnect Electrical Connections: Label and disconnect all electrical connections, including wiring harnesses, sensors, and connectors attached to the engine.

5. Remove Accessories: Remove additional components such as the fan, fan clutch, belts, pulleys, and other accessories connected to the engine.

6. Drivetrain Disconnect: If the engine is still connected to the drivetrain, disconnect the transmission, clutch, or other components as necessary.

7. Disassembly of Engine Components: Begin disassembling the engine by following the sequence outlined in the service manual. Remove components such as the cylinder head, pistons, connecting rods, crankshaft, camshaft, timing gears, oil pump, and other internal parts. Keep track of the disassembled parts, label and organize them for inspection, cleaning, and potential replacement.

8. Inspection and Cleaning: Thoroughly inspect each component for wear, damage, or signs of failure. Clean the parts using appropriate methods and solvents, ensuring all contaminants are removed.

9. Replacement of Components: If necessary, replace worn-out or damaged components with genuine Caterpillar parts, following the manufacturer’s specifications and torque values.

Caterpillar Cat C175-16 and C175-20 Engine Troubleshooting Manual
Caterpillar Cat C175-16 and C175-20 Engine Troubleshooting Manual
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Caterpillar Cat C175-16 and C175-20 Troubleshooting Manual

10. Assembly: Begin the assembly process by following the reverse order of disassembly. Pay close attention to proper torque values, clearances, and alignment of components. Lubricate moving parts as required.

11. Installation of External Components: Reinstall all external components that were previously removed, such as the fan, alternator, starter motor, air intake system, exhaust system, and other accessories.

12. Fluid Refill: Refill the engine with fresh oil, coolant, and fuel according to the recommended specifications. Perform any necessary priming or bleeding procedures.

13. Final Checks: Double-check all connections, components, and fluids. Verify that everything is properly installed, tightened, and aligned.

14. Testing and Verification: Start the engine and run it for a brief period to check for any abnormal noises, leaks, or other issues. Monitor vital engine parameters to ensure proper operation.

Again, it is crucial to consult the official Caterpillar service manuals and guidelines for specific instructions, torque values, and safety precautions when performing engine disassembly and assembly. These manuals provide detailed and accurate information tailored to each engine model, ensuring a successful and reliable process.

Caterpillar Cat C175-16 and C175-20 Engine Manual