C27 and C32 Generator Set Engines Troubleshooting Manual

C27 and C32 Generator Set Engines Troubleshooting Manual

 High resolution, searchable, printable PDF format  

Covers: C27 and C32 Generator Set Engines With Serial Numbers:

• DWB1-Up (Generator Set)
• SXC1-Up (Generator Set)
• MED1-Up (Power Module)
• MEG1-Up (Power Module)
• WDR1-Up (Generator Set)

Format: PDF
Compatibility: Windows/Mac/Linux

This Manual Include information, specifications, and illustrations For Troubleshooting Your C27 and C32 Generator Set Engines , The Troubleshooting Manual Cover All Errors that With Diagnostic Code Or Without  Diagnostic Code.

Table of Contents

Troubleshooting Section
Electronic Troubleshooting
System Overview ……………………………………………. 5
Electronic Service Tools …………………………………… 6
Replacing the ECM …………………………………………. 9
Self-Diagnostics ……………………………………………. 10
Sensors and Electrical Connectors ………………….. 12
Engine Wiring Information ……………………………… 15
Programming Parameters
Programming Parameters ………………………………. 17
Test ECM Mode ……………………………………………. 17
Factory Passwords ……………………………………….. 18
Factory Passwords Worksheet ……………………….. 18
Flash Programming ………………………………………. 18
Injector Trim File …………………………………………… 19
System Configuration Parameters
System Configuration Parameters …………………… 21
Troubleshooting without a Diagnostic Code
Alternator (Charging Problem) ………………………… 27
Can Not Reach Top Engine RPM ……………………. 27
Coolant in Engine Oil …………………………………….. 28
ECM Will Not Accept Factory Passwords …………. 29
ECM Will Not Communicate with Other Systems or
Display Modules ………………………………………….. 29
Electronic Service Tool Will Not Communicate with
ECM ………………………………………………………….. 29
Engine Cranks but Will Not Start …………………….. 31
Engine Has Early Wear …………………………………. 32
Engine Misfires, Runs Rough or Is Unstable …….. 33
Engine Oil in Cooling System …………………………. 34
Engine Stalls at Low RPM ……………………………… 34
Engine Vibration …………………………………………… 35
Engine Will Not Crank ……………………………………. 35
Excessive Black Smoke …………………………………. 36
Excessive Engine Oil Consumption …………………. 37
Excessive Fuel Consumption …………………………. 38
Excessive Valve Lash ……………………………………. 39
Excessive White Smoke ………………………………… 39
Fuel in Cooling System ………………………………….. 40
Fuel Dilution of Engine Oil ……………………………… 40
Intermittent Engine Shutdown …………………………. 41
Intermittent Low Power or Power Cutout ………….. 42
Low Engine Oil Pressure ……………………………….. 43
Low Power/Poor or No Response to Throttle ……. 43
Mechanical Noise (Knock) in Engine ……………….. 45
Noise Coming from Cylinder …………………………… 45
Poor Acceleration or Response ………………………. 46
Valve Rotator or Spring Lock Is Free ……………….. 47
Troubleshooting with a Diagnostic Code
Diagnostic Codes ………………………………………….. 49
Diagnostic Code Cross Reference ………………….. 50
CID 0001 FMI 05 Cylinder #1 Injector open
circuit …………………………………………………………. 54
CID 0001 FMI 06 Cylinder #1 Injector short ……… 54
CID 0002 FMI 05 Cylinder #2 Injector open
circuit …………………………………………………………. 54
CID 0002 FMI 06 Cylinder #2 Injector short ……… 54
CID 0003 FMI 05 Cylinder #3 Injector open
circuit …………………………………………………………. 55
CID 0003 FMI 06 Cylinder #3 Injector short ……… 55
CID 0004 FMI 05 Cylinder #4 Injector open
circuit …………………………………………………………. 55
CID 0004 FMI 06 Cylinder #4 Injector short ……… 56
CID 0005 FMI 05 Cylinder #5 Injector open
circuit …………………………………………………………. 56
CID 0005 FMI 06 Cylinder #5 Injector short ……… 56
CID 0006 FMI 05 Cylinder #6 Injector open
circuit …………………………………………………………. 57
CID 0006 FMI 06 Cylinder #6 Injector short ……… 57
CID 0007 FMI 05 Cylinder #7 Injector open
circuit …………………………………………………………. 57
CID 0007 FMI 06 Cylinder #7 Injector short ……… 57
CID 0008 FMI 05 Cylinder #8 Injector open
circuit …………………………………………………………. 58
CID 0008 FMI 06 Cylinder #8 Injector short ……… 58
CID 0009 FMI 05 Cylinder #9 Injector open
circuit …………………………………………………………. 58
CID 0009 FMI 06 Cylinder #9 Injector short ……… 59
CID 0010 FMI 05 Cylinder #10 Injector open
circuit …………………………………………………………. 59
CID 0010 FMI 06 Cylinder #10 Injector short ……. 59
CID 0011 FMI 05 Cylinder #11 Injector open
circuit …………………………………………………………. 59
CID 0011 FMI 06 Cylinder #11 Injector short …….. 60
CID 0012 FMI 05 Cylinder #12 Injector open
circuit …………………………………………………………. 60
CID 0012 FMI 06 Cylinder #12 Injector short ……. 60
CID 0091 FMI 08 Throttle Position signal
abnormal ……………………………………………………. 61
CID 0094 FMI 03 Fuel Pressure open/short to
+batt ………………………………………………………….. 61
CID 0094 FMI 04 Fuel Pressure short to ground .. 61
CID 0100 FMI 03 Engine Oil Pressure open/short to
+batt ………………………………………………………….. 61
CID 0100 FMI 04 Engine Oil Pressure short to
ground ……………………………………………………….. 62
CID 0100 FMI 10 Engine Oil Pressure Sensor
abnormal rate of change ………………………………. 62
CID 0110 FMI 03 Engine Coolant Temperature
open/short to +batt ………………………………………. 63
CID 0110 FMI 04 Engine Coolant Temperature short
to ground ……………………………………………………. 63
CID 0168 FMI 00 System Voltage High ……………. 63
CID 0168 FMI 01 System Voltage Low …………….. 64
CID 0168 FMI 02 System Voltage intermittent/
erratic ………………………………………………………… 64
CID 0172 FMI 03 Intake Manifold Air Temp open/short
to +batt ………………………………………………………. 64
CID 0172 FMI 04 Intake Manifold Air Temp short to
ground ……………………………………………………….. 65
CID 0174 FMI 03 Fuel Temperature open/short to
+batt ………………………………………………………….. 65
CID 0174 FMI 04 Fuel Temperature short to
ground ……………………………………………………….. 65
CID 0175 FMI 03 Engine Oil Temperature open/short
to +batt ………………………………………………………. 65
CID 0175 FMI 04 Engine Oil Temperature short to
ground ……………………………………………………….. 66
CID 0190 FMI 08 Engine Speed signal abnormal .. 66
CID 0247 FMI 09 J1939 Data Link
communications ………………………………………….. 66
CID 0253 FMI 02 Personality Module mismatch .. 67
CID 0261 FMI 11 Engine Timing Offset fault …….. 67
CID 0261 FMI 13 Engine Timing Calibration
required ……………………………………………………… 68
CID 0262 FMI 03 5 Volt Sensor DC Power Supply
short to +batt ………………………………………………. 69
CID 0262 FMI 04 5 Volt Sensor DC Power Supply
short to ground ……………………………………………. 69
CID 0268 FMI 02 Check Programmable
Parameters ………………………………………………… 69
CID 0274 FMI 03 Atmospheric Pressure open/short
to +batt ………………………………………………………. 70
CID 0274 FMI 04 Atmospheric Pressure short to
ground ……………………………………………………….. 70
CID 0342 FMI 08 Secondary Engine Speed signal
abnormal ……………………………………………………. 70
CID 0444 FMI 05 Start Relay open circuit ………… 70
CID 0444 FMI 06 Start Relay short to ground …… 71
CID 0446 FMI 05 Air Shutoff Relay open …………. 71
CID 0446 FMI 06 Air Shutoff Relay short …………. 71
CID 1785 FMI 03 Intake Manifold Pressure Sensor
voltage high ………………………………………………… 71
CID 1785 FMI 04 Intake Manifold Pressure Sensor
voltage low …………………………………………………. 72
CID 1785 FMI 10 Intake Manifold Pressure Signal
abnormal rate of change ………………………………. 72
Troubleshooting with an Event Code
Event Codes ……………………………………………….. 73
E057 Low Engine Coolant Level Derate …………… 77
E059 Low Engine Coolant Level Warning ………… 78
E096 High Fuel Pressure ……………………………….. 78
E194 High Exhaust Temperature …………………….. 79
E197 High Engine Oil Temperature …………………. 80
E198 Low Fuel Pressure ……………………………….. 82
E264 Emergency Stop Activated …………………….. 83
E360 Low Engine Oil Pressure ……………………….. 83
E361 High Engine Coolant Temperature ………….. 84
E362 Engine Overspeed ………………………………… 85
E363 High Fuel Supply Temperature ……………….. 86
E390 Fuel Filter Restriction ……………………………. 86
E539 High Intake Manifold Air Temperature ……… 87
E2087 Air Intake Shutoff Closed ……………………… 88
E2088 Air Intake Shutoff Detection Circuit Detected
but Not Installed ………………………………………….. 88
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit –
Test …………………………………………………………… 90
Air Shutoff System – Test ……………………………….. 94
CAN Data Link Circuit – Test …………………………. 102
Cat Data Link Circuit – Test …………………………… 106
Coolant Level Sensor Circuit – Test ……………….. 109
Electrical Connectors – Inspect ………………………. 115
Electrical Power Supply Circuit – Test …………….. 120
Emergency Stop Switch Circuit – Test …………….. 127
Engine Pressure Sensor Open or Short Circuit –
Test …………………………………………………………. 131
Engine Speed/Timing Sensor Circuit – Test …….. 137
Engine Temperature Sensor Open or Short Circuit –
Test …………………………………………………………. 142
Ether Injection System – Test ………………………… 147
Fuel Filter Differential Pressure Switch Circuit –
Test …………………………………………………………. 152
Injector Solenoid Circuit – Test ………………………. 155
Speed Control – Test ……………………………………. 163
Start Relay Circuit – Test ………………………………. 167
Calibration Procedures
Engine Speed/Timing Sensor – Calibrate ………… 174
Index Section
Index …………………………………………………………. 176