Challenger 35, Challenger 45 and Challenger 55 Agricultural Tractors Caterpillar

Troubleshooting - Engine

Usage:

45 1DR

The Engine Starts Hard or the Engine Does Not Start

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Table 1
The Engine Starts Hard or the Engine Does Not Start.
Cause	Solution
You are starting the engine incorrectly.	See Operation and Maintenance Manual, "Engine Starting".
The fuel level is low or the fuel tank is empty.	Check the fuel level, the fuel lines, and the fuel filters.
The temperature is too cold.	Use the air inlet heater. Make sure that you are using the correct type of fuel.
The incorrect viscosity oil was used in the engine.	Check the engine for the correct oil viscosity.
The fuel system is contaminated.	Clean the fuel system.
The fuel pressure is low.	When the engine is at cranking speed, the fuel transfer pump should supply fuel to the engine at 20 kPa (3 psi). Check the fuel pressure. If you find low fuel pressure, replace the fuel filters. Make sure that the fuel does not contain water, air, or dust. If the fuel pressure is still low, replace the fuel transfer pump.
The fuel filter is clogged.	Replace the fuel filter element.
The fuel injectors are malfunctioning.	Consult any Caterpillar dealer. ⁽¹⁾
The engine is not tuned correctly.	Consult any Caterpillar dealer. ⁽¹⁾

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Caterpillar dealers have the tools and the trained personnel for this service.

The Engine Misfires or The Engine Runs Rough

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Table 2
The Engine Misfires or The Engine Runs Rough.
Cause	Solution
The fuel injectors are damaged.	Consult any Caterpillar dealer. ⁽¹⁾
The valve clearance is not correct.	Set the valve clearance to the correct value.
The fuel injection timing is not correct.	Consult any Caterpillar dealer. ⁽¹⁾
The fuel pressure is low.	Check the fuel pressure. Check for leaks in the low pressure fuel system. Check for air in the fuel system. Check for wear or for damage in the fuel transfer pump. Check the fuel system for too much fuel return. Too much fuel return may be caused by a malfunctioning return fuel pressure regulating valve. Replace the fuel filters.
There is air in the fuel system.	Find the air leak. Correct the problem. Purge the air from the fuel system.
The fuel filter is clogged.	Replace the fuel filter element.

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Caterpillar dealers have the tools and the trained personnel for this service.

The Engine Has Low Power

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Table 3
The Engine Has Low Power.
Cause	Solution
The fuel pressure is low.	Check the fuel pressure. Check for leaks in the low pressure fuel system. Check for air in the fuel system. Check for wear or for damage in the fuel transfer pump. Check for too much fuel return to the tank. Too much fuel return may be caused by a malfunctioning return fuel pressure regulating valve. Replace the fuel filters.
The quality of the fuel is poor.	Remove the bad fuel from the fuel tank. Fill the fuel tank with quality diesel fuel. Replace the fuel filters.
There is a restriction in the air cleaner.	Check the air cleaner for a restriction.
The valve clearance is not correct.	Set the valve clearance to the correct value.
The fuel injection timing is not correct.	Consult any Caterpillar dealer. ⁽¹⁾
The engine is overloaded.	Shift to a lower gear or reduce the load.
The diesel engine operating temperature is too low.	Check the thermostats.

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Caterpillar dealers have the tools and the trained personnel for this service.

The Engine Stalls at Low RPM

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Table 4
The Engine Stalls at Low RPM.
Cause	Solution
The idle speed is too low.	Consult any Caterpillar dealer. ⁽¹⁾
The fuel pressure is low.	Check the fuel pressure. Check for leaks in the low pressure fuel system. Check for air in the fuel system. Check for wear or for damage in the fuel transfer pump. Check for too much fuel return to the tank. Too much fuel return may be caused by a malfunctioning return fuel pressure regulating valve. Replace the fuel filters.
The engine is overloaded.	Shift to a lower gear or reduce the load.

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Caterpillar dealers have the tools and the trained personnel for this service.

The Engine Uses Too Much Oil

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Table 5
The Engine Uses Too Much Oil.
Cause	Solution
Oil is leaking from the engine.	Replace gaskets or seals. Tighten all connections.
The engine oil level is too high.	Avoid overfilling the engine. Determine the cause. Drain excess oil.
The oil operating temperature is too high.	Check the oil cooler bypass valve. Replace the oil cooler bypass valve if the oil cooler bypass valve is damaged. Clean the oil cooler core.
The piston rings are worn.	As required, replace components. Consult any Caterpillar dealer. ⁽¹⁾
There is too much wear on the valve guides.	Recondition the cylinder head assembly.
The engine is overloaded.	The engine may be operating with increased power. Check the power output. As required, adjust the engine.

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Caterpillar dealers have the tools and the trained personnel for this service.

The Engine Uses Too Much Fuel

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Table 6
The Engine Uses Too Much Fuel.
Cause	Solution
Fuel is leaking from the fuel system.	Internal leaks may cause large changes in fuel consumption. Low oil pressure and high oil level in the engine oil pump may accompany internal leaks. Replace components that leak.
Engine knock results from poor combustion.	Small increases in fuel consumption may be caused by a damaged fuel injection nozzle or the result of misfiring. Also, small increases in fuel consumption may be caused by the causes of low engine power. See "The Engine Has Low Power".
The fuel setting is not correct.	Consult any Caterpillar dealer. ⁽¹⁾
The fuel injection timing is not correct.	Consult any Caterpillar dealer. ⁽¹⁾
The air/fuel ratio adjustment is not correct.	Check the air/fuel ratio adjustment. As required, rebuild the air/fuel ratio control system. ⁽¹⁾

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Caterpillar dealers have the tools and the trained personnel for this service.

The Engine Oil Pressure is Too Low

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Table 7
The Engine Oil Pressure is Too Low.
Cause	Solution
The engine oil is diluted with diesel fuel.	Check the lip type seals on the drive shaft for the fuel transfer pump. Drain the crankcase. Refill the crankcase with clean engine oil.
The suction bell is damaged.	Replace the suction bell.
The crankshaft bearings have excessive clearance.	Replace the crankshaft bearings and/or replace the crankshaft. Check the operation of the oil filter.
The bearings for the timing gear have excessive clearance.	Inspect the bearings. As required, replace components.
The bore of the rocker arm is too large or the rocker arm has too much wear.	Check the lubrication. As required, replace components.
The oil pump is damaged.	Repair the oil pump or replace the oil pump. Consult any Caterpillar dealer. ⁽¹⁾
The oil pressure gauge and/or the oil pressure sender are malfunctioning.	Install a new oil pressure gauge and/or install a new oil pressure sender.
The oil pump relief valve is stuck.	Clean the oil pump relief valve and clean the housing. As required, replace the components.
The oil filter is plugged.	Install a new oil filter.
The oil level is too low.	Check the oil level. As required, add engine oil.
There is air in the oil.	Check for foaming.

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Caterpillar dealers have the tools and the trained personnel for this service.

There is Coolant in The Engine Oil

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Table 8
There is Coolant in The Engine Oil.
Cause	Solution
The cylinder head gasket has failed.	Replace the cylinder head gasket. Maintain the proper torque on the bolts for the cylinder head.
The cylinder head is cracked or the cylinder head is damaged.	Replace the cylinder head. Consult any Caterpillar dealer. ⁽¹⁾
The cylinder block is cracked or the cylinder block has a defect.	Replace the cylinder head. Consult any Caterpillar dealer. ⁽¹⁾
The oil cooler is leaking.	Install a new core for the oil cooler. Drain the crankcase. Fill the crankcase with clean engine oil. Install a new oil filter element.

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Caterpillar dealers have the tools and the trained personnel for this service.

There is Engine Oil in the Coolant

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Table 9
There is Engine Oil in the Coolant.
Cause	Solution
The water pump cavity drain is plugged.	Unplug the water pump cavity drain.
The oil cooler core has failed.	Replace the oil cooler core.
The head gasket has failed.	Replace the head gasket.

The Coolant is Too Hot

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Table 10
The Coolant is Too Hot.
Cause	Solution
The engine speed is too low.	Low power can cause fan speed that is too slow.
Air flow through the radiator screen is restricted.	Clean the radiator screen.
The coolant level is too low.	Determine the cause of the low coolant level. Replace gaskets that leak and replace hoses that leak. Tighten all connections. Add coolant.
The thermostat is damaged or the temperature gauge is damaged.	Check the thermostat for correct opening temperature. Also, make sure that the thermostat is correctly installed. Check the temperature gauge for proper operation. As required, replace components.
Air flow through the radiator is restricted.	Remove debris from the outer surface of the radiator.
There is combustion gases in the coolant.	Find the combustion gas leakage. As required, repair the components or replace the components.
The water pump is damaged.	Check the water pump impeller. As required, repair the water pump.

The Engine Emits Too Much White Smoke

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Table 11
The Engine Emits Too Much White Smoke.
Cause	Solution
The weather is too cold.	White smoke is normal when you start the engine in cold weather.
There is air in the fuel system.	Purge the air from the fuel system. Check for air leaks on the inlet side of the engine oil suction tube.

The Engine Emits Too Much Blue Smoke

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Table 12
The Engine Emits Too Much Blue Smoke.
Cause	Solution
There is too much wear on the valve guides.	Recondition the cylinder head assembly. ⁽¹⁾
The piston rings are stuck or the piston rings are broken. Also, the piston rings may be worn.	Replace the piston rings. Consult any Caterpillar dealer. ⁽¹⁾
The engine oil level is too high.	Avoid overfilling the engine. Determine the cause. Drain excess oil.
The fuel injection timing is not correct.	Consult any Caterpillar dealer. ⁽¹⁾

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Caterpillar dealers have the tools and the trained personnel for this service.

The Engine Emits Too Much Gray Smoke or the Engine Emits Too Much Black Smoke

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Table 13
The Engine Emits Too Much Gray Smoke or the Engine Emits Too Much Black Smoke.
Cause	Solution
There is not enough air for combustion.	Check the air cleaner for a restriction.
A fuel injector is plugged or a fuel injector is leaking.	Replace the fuel injector.
The fuel setting is incorrect or the injection timing is incorrect.	Consult any Caterpillar dealer. ⁽¹⁾
The turbocharger has failed.	Consult any Caterpillar dealer. ⁽¹⁾
The air/fuel ratio is not correct.	Consult any Caterpillar dealer. ⁽¹⁾