Can Not Reach Top Engine RPM

Note: If this problem occurs under load, refer to the diagnostic procedure Troubleshooting, "Low Power/Poor Or No Response To Throttle".
Probable Causes
• Derated engine
• Cold mode
• Flash file
• Throttle signal
• Fuel supply
• Air inlet restriction
• Exhaust restriction
• Leaks in air system
• Valve adjustment
• Injectors
• Faulty accessory equipment
Recommended Actions
Derate
Connect Caterpillar Electronic Technician (ET) and check for an active derate event. A derate status flag will appear on Cat ET if an active engine derate is occurring. In order to view active events, go to the "Events" menu under "Diagnostics". Refer to Troubleshooting, "Troubleshooting with an Event Code" for the specific events for this application.
Cold Mode
Use Cat ET to verify that the engine has exited cold mode. A status flag will appear if the engine is operating in cold mode. This may limit engine speed.
Flash File
Verify that the correct flash file has been installed.
Throttle Signal
Use Cat ET in order to monitor the status of the throttle. Observe the throttle position. Verify that the throttle position is smooth from low idle to high idle. The throttle position should reach 100 percent at high idle.
Fuel Supply
Check fuel lines for the following problems: restrictions, collapse and pinched line. Repair the lines and/or replace the lines.
1. Check the fuel tank for foreign objects which may block the fuel supply. Check for air leaks in the suction line of the fuel pump. Prime the fuel system after you perform the following procedures:
o Replacing the fuel filters
o Working on the low pressure fuel supply circuit
o Replacing fuel injectors
2. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold weather operation.
3. Check the fuel pressure during engine cranking. Check the fuel pressure after the fuel filter. Refer to the Systems Operation/Testing and Adjusting manual for the correct pressure values. If the fuel pressure is low, replace the fuel filters. If the fuel pressure is still low, check the following items: fuel transfer pump, fuel transfer pump coupling and fuel pressure regulating valve.

Replacing the ECM caterpillar c27 engine

The Electronic Control Module (ECM) contains no moving parts. Follow the troubleshooting procedures in this manual in order to be sure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem.
Note: Ensure that the ECM is receiving power and that the ECM is properly grounded before a replacement of the ECM is attempted. Refer to the diagnostic functional test Troubleshooting, "Electrical Power Supply".
A spare ECM can be used to determine if the ECM is faulty. Install a spare ECM in place of the suspect ECM. Transfer the personality module from the suspect ECM to the spare ECM. Program the parameters for normal operation. The parameters must match the parameters in the suspect ECM. Refer to the following test steps for details. If the spare ECM resolves the problem, reconnect the suspect ECM. Verify that the problem returns. If the problem returns, replace the ECM.
Note: The replacement or the spare ECM must have the same serial number suffix as the suspect ECM. Ensure that the replacement ECM and the Interlock code for the personality module match the suspect ECM. Be sure to record the parameters from the replacement ECM. Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on the Caterpillar Electronic Technician (ET).
Perform the following procedure in order to replace the ECM.
1. Start Cat ET.
2. Print the parameters from the "Configuration" screen on Cat ET. If a printer is unavailable, record all of the parameters. Record any logged diagnostic codes and logged event codes for your records.
3. Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on Cat ET. Select "Load from ECM" in order to copy the configuration from the suspect ECM.
Note: If the "Copy Configuration" process fails and the parameters were not obtained in Step 2, the parameters must be obtained elsewhere. Some parameters are stamped on the engine information plate, but most parameters must be obtained from the Service Center at the Caterpillar Large Engine Center.
4. Remove the ECM.
a. Turn the keyswitch to the OFF/RESET position.
b. Disconnect the ECM connectors J1/P1 and J2/P2.
c. Remove the fuel lines from the ECM.
d. Remove the mounting bolts from the ECM.
e. Disconnect the ECM ground strap from the engine.
f. If you are flash programming, go to Step 7. If you are physically replacing the personality module, proceed to Step 5.
Note: Flash programming is the preferred method for replacing the personality module. The personality module can be physically removed, if flash programming is unsuccessful.
5. Remove the personality module from the old ECM.
a. Remove the tag wire from the back cover of the ECM.
b. Remove the bolts from the back cover of the ECM.
c. Remove the O-ring seal from the cover.
d. Remove the personality module by squeezing the tabs on the ends of the blue plastic case. Pull the module straight out of the ECM.
6. Install the personality module into the replacement ECM.
a. Carefully seat the personality module in the EPROM carrier socket.
Note: Do not use excessive force to insert the module into the socket. The socket will accept the personality module in only one position. A click is audible when the personality module is inserted correctly.
b. Install the O-ring seal for the cover of the personality module.
c. Install the access cover for the personality module on the ECM. Tighten the cover bolts for the personality module to a torque of 1.36 N•m (12 lb in).
7. Install the replacement ECM.
a. Use the old mounting hardware to install the replacement ECM. Make sure that the mounting hardware is free of damage.
b. Reconnect the fuel lines.
c. Ensure that the ECM mounting hardware is installed correctly. The fuel lines should not be pulling the ECM. The rubber grommets are used to protect the ECM from excessive vibration. The ECM should be able to drift in the rubber grommets. If the ECM cannot be moved slightly in the grommets, check that the fuel lines are not pulling the ECM against one side of the grommets.
d. Install the ECM ground strap on the engine.
e. Reconnect ECM connectors J1/P1 and J2/P2. Tighten the allen head screws on the connectors to a torque of 2.25 N•m (20 lb in).
f. If the personality module has been physically replaced, go to Step 9. If you are flash programming, continue to Step 8.
8. Flash program the personality module into the ECM. Refer to the diagnostic procedure Troubleshooting, "Flash Programming" for the correct procedure.
9. Use Cat ET to match the engine application and the Interlock code for the personality module if the replacement ECM was used for a different application.
10. Configure the ECM.
a. If the "Copy Configuration" process from Step 3 was successful, return to the "Copy Configuration/ECM Replacement" screen on Cat ET and select "Program ECM". Go to Step 12.
b. If the "Copy Configuration" process was unsuccessful, program the ECM parameters. The parameters should match the parameters from Step 2.
Note: If the "Copy Configuration" process fails and the parameters were not obtained in Step 2, the parameters must be obtained elsewhere. Some parameters are stamped on the engine information plate, but most parameters must be obtained from the Service Center at the Caterpillar Large Engine Center.
c. If necessary, program the engine monitoring system.
11. Calibrate the injection timing. Refer to the calibration procedure Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".
12. Check for diagnostic codes and event codes.

caterpillar c27 engine specs

Cold Cylinder Cutout

During a cold start or extended periods at low idle, the engine ECM will automatically turn off one unit injector at a time in order to determine if the cylinder is firing. If the ECM determines that the cylinder is not firing, the ECM turns off the unit injector. If the ECM determines that the cylinder is firing, the ECM turns on the unit injector. This strategy improves engine starting. This strategy reduces the following: white smoke, the use of ether injection and warm-up time.

Cold Mode Operation

Cold mode controls fuel injection timing when the engine is cold. When the engine is cold, controlling the fuel injection timing reduces the possibility of engine damage. When the engine is cold, controlling the fuel injection timing helps minimize white smoke.

Cold mode is activated whenever the engine coolant temperature is below 70 °C (158 °F). Cold mode remains active until the engine coolant temperature is warmer than 73 °C (163 °F).

FRC Limit

The flash file inside the engine ECM sets certain limits on the amount of fuel that can be injected. The FRC limit is a limit that is based on the boost pressure. The boost pressure is calculated as the difference in pressure between atmospheric pressure and turbocharger outlet pressure. The FRC limit is used to control the air/fuel ratio for control of emissions. When the engine ECM senses a higher boost pressure, the engine ECM increases the FRC limit. A higher boost pressure indicates that there is more air in the cylinder. When the engine ECM increases the FRC limit, the engine ECM allows more fuel into the cylinder.

used c-9 caterpillar bus engine

Passwords

Passwords are part of a security system that helps to prevent unauthorized changing of certain parameters. Passwords prevent unauthorized erasing of logged events. Passwords allow the factory to control access to engine calibration parameters. Passwords allow the customer to control access to certain engine parameters.

Factory Passwords

Factory passwords are required to clear any event code. Factory passwords are required to change certain parameters such as "Full Load Setting". Factory passwords restrict changes to authorized personnel. When the correct factory passwords have been entered, the changes can then be made.

Note: Factory passwords are calculated on a computer system that is only available to Caterpillar dealers.

In order to obtain the proper factory passwords, certain information must be given to an authorized Caterpillar dealer. Since the factory passwords contain alphabetic characters, the Caterpillar Electronic Technician (ET) can be used to perform this function. In order to obtain the factory passwords, proceed as if you already have the factory passwords. At some point, if the factory passwords are actually needed, Cat ET will request the factory passwords and Cat ET will display the information that is required to obtain the factory passwords.

Note: The old interlock code and the new interlock code are required to change the interlock code on a used Electronic Control Module (ECM).

The Cat ET screen for factory passwords will display the following parameters:

• Serial number of the ECM
• Engine serial number
• Serial number for Cat ET
• Reason code
• Interlock code
• Total tattletale

Note: Factory passwords are only valid for the current Cat ET screen. A different set of factory passwords will be required if you exit the current Cat ET screen. A different set of passwords will be required to change information on another Cat ET screen.

Alternator diesel engine

The probable root causes are listed below:

• The alternator is not charging the battery.
• The battery charge is low.
• The battery charge is high.
• Noisy operation

Perform the following checks:

1. Loosen the drive belts on the alternator. Adjust the drive belt tension. Inspect all of the cables and the connections. Clean the connections and tighten the connections. Replace faulty parts. Inspect the rotor. Install a new rotor.

2. Inspect the rectifier diodes. Replace the diode.

3. Inspect the alternator for loose connections. Tighten all connections to the alternator. Inspect the regulator. If a replacement is required, the alternator must be disassembled.

4. Inspect the drive belts. Install new drive belts. Loosen the drive pulley. Tighten the pulley. Refer to the Specifications manual. If the belt and the pulley are misaligned, adjust the belt and the pulley. If the alternator bearings are worn, install new bearings.

5. If the problem is still present, refer to Special Instruction, REHS0354, "Charging System Troubleshooting".

How to test engine injector

Three tests can be used to determine which cylinder or injector is
malfunctioning:
Injector Solenoid Test
This test is performed while the engine is stopped. The injector solenoids
can be tested automatically with the ET Service Tool using the Injector
Solenoid Test. This function individually tests each solenoid in sequence
and indicates if a short or open circuit is present.
Cylinder Cut-out (Manual test)
This test is performed while the engine is running at any speed. The
105 Volt pulse can be individually cut out to aid in troubleshooting
misfire problems in the injector and cylinder.
Automatic Injector Test
This test is performed with the ET Service Tool while the engine is
running at any speed. The test makes a comparative evaluation of all
injectors and numerically shows the results. The test enables an
on-engine evaluation of the injectors. (This test cannot be performed
using the ECAP.)
A satisfactory test of all injector solenoids without any diagnostic
messages indicates that a mechanical problem in the cylinder probably
exists.

Electronic Control Module caterpillar 3116 engine

The engine is designed for electronic control of most engine operating functions. The electronic system consists of an Electronic Control Module (ECM), the wiring harness, switches, sensors, and fuel injectors. The engine ECM receives information from the sensors and the switches on the engine. The engine ECM processes the information that is collected in order to make decisions on control of the engine. By altering the fuel delivery with the fuel injectors, the engine ECM controls the speed and the power that is produced by the engine.

Electronic Controls

Electronic Control Module

The ECM consists of two main components, the control computer (hardware) and the personality module (flash file). The control computer consists of a microprocessor and electronic circuitry. The flash file contains the engine's operational characteristics. The operating maps influence the engine's performance.

Engine Governor

The engine ECM governs engine speed. The engine ECM and the personality module work together by controlling the amount of fuel that is delivered by the injectors. Desired engine rpm is determined by the throttle position sensor signal and certain sensor readings. Diagnostic codes may derate the engine. Actual engine rpm is measured by the engine speed/timing signal.

Fuel Injection

The engine ECM controls the timing, the duration, and the pressure of the fuel that is injected. The engine ECM varies the signals to the fuel injectors. Fuel is injected only while an injector solenoid is energized by a 105 volt signal from the engine ECM. The timing of the injection signal determines the engine timing. The length of the injection signal determines engine speed. By controlling the timing and duration of the 105 volt signal, the ECM controls the engine speed.

Injection timing depends on the following conditions: desired engine rpm and load. The ECM detects the top center of each cylinder. The ECM sends an injection signal at the desired time.