C4.4 and C6.6 Engines Caterpillar


Engine Top Speed Is Not Obtained

Usage:

C4.4 448
Note: If this fault occurs only under load, refer to Troubleshooting, "Acceleration Is Poor or Throttle Response Is Poor".

Probable Causes

  • Diagnostic codes

  • ECM parameters

  • Accessory and/or parasitic loads

  • Flash file

  • Throttle signal

  • Air intake and exhaust system

  • Turbocharger or turbochargers

  • Fuel supply

  • Transfer Pump Inlet Regulator (TPIR)

  • Electric Fuel Lift Pump (EFLP)

  • Return fuel lines

  • Low compression (cylinder pressure)

  • Electronic unit injectors

  • Individual malfunctioning cylinders

Table 1
Associated Diagnostic Trouble Codes 
J1939 Code  CDL Code 
157-18  E398 (2) 

Recommended Actions

Note: The procedures have been listed in order of probability. Complete the procedures in order.

Table 2
Troubleshooting Test Steps  Values  Results 

1. Diagnostic Codes

A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.

B. Download the Warranty Report and the Product Status Report with Histograms before performing any troubleshooting or clearing any diagnostic codes.

Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is needed.

C. Use the electronic service tool to check for active or logged codes.
 

Diagnostic codes
 

Result: There are active or logged codes.

Repair: Troubleshoot any codes before continuing with this procedure.

Result: There are no active or logged codes.

Proceed to Test Step 2.
 

2. ECM Parameters

A. Use the electronic service tool to verify that the correct engine parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.

B. If applicable, verify that all parameters for any parasitic loads are correct.
 

Parameters
 

Result: The parameters are not configured correctly.

Repair: Correctly configure the parameters.

Verify that the configuration change eliminated the fault.

Result: The parameters are configured correctly.

Proceed to Test Step 3.
 

3. Accessory and/or Parasitic Loads

A. Check all accessory equipment for problems that may create excessive load on the engine.

B. Check for any excess parasitic load on the engine.
 

Parasitic loads
 

Result: There is an excessive load on the engine.

Repair: Diagnose and repair the fault.

Verify that the repair eliminated the fault.

Result: There is not an excessive load on the engine.

Proceed to Test Step 4.
 

4. Flash File

A. Verify that the latest flash file is installed in the Electronic Control Module (ECM). Refer to Troubleshooting, "ECM Software - Install" for the correct procedure.
 

Flash file
 

Result: The latest flash file is not installed in the ECM.

Repair: Install the latest flash file. Verify that the repair eliminated the fault.

Result: The latest flash file is installed in the ECM.

Proceed to Test Step 5.
 

5. Throttle Signal

A. Use the electronic service tool and observe the throttle signal. Make sure that the throttle reaches the 100% raw position and the calibrated position.
 

CAN data link
 

Result: The throttle signal is erratic or does not reach the 100% raw position or the calibrated position.

Repair: Refer to the appropriate circuit test for the type of throttle that is installed.

Result: The throttle signal is OK.

Proceed to Test Step 6.
 

6. Air Intake and Exhaust System

A. Check the air filter restriction indicator, if equipped.

B. Check the air inlet and exhaust system for restrictions and/or leaks.
 

Restrictions
 

Result: The air filter is plugged.

Repair: Clean or replace the air filter. Refer to the Operation and Maintenance Manual for further information.

Result: There are restrictions in the air inlet or exhaust system.

Repair: Make the necessary repairs, Verify that the repair eliminated the fault.

Result: There are no restrictions in the air inlet or exhaust system.

Proceed to Test Step 5.
 

7. Turbocharger or Turbochargers

A. Check for the correct operation of the turbocharger or turbochargers.
 

Turbocharger
 

Result: A turbocharger is not operating correctly.

Repair: Repair or replace the faulty turbocharger. Verify that the repair eliminated the fault.

Result: The turbocharger is operating correctly.

Proceed to Test Step 8.
 

------ WARNING! ------

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.



NOTICE

Contact with high-pressure fuel may cause personal injury or death. Wait 10 minutes after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.


Table 3
Troubleshooting Test Steps  Values  Results 

8. Fuel Supply

A. Check for leaks from the high-pressure fuel lines.

B. Ensure that the vent in the fuel cap is not filled with debris.

C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).

E. Check the primary filter/water separator for water in the fuel.

F. Check for fuel supply lines that are restricted.

G. Replace the in-line fuel filter that is installed upstream of the Electric Fuel Lift Pump (EFLP).

H. Replace the primary and secondary fuel filters.

I. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".

J. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
 

Fuel system
 

Result: There is a leak from a high-pressure fuel line.

Repair: Replace the high-pressure fuel line. Refer to Disassembly and Assembly, "Fuel injection lines - Remove" and Disassembly and Assembly, "Fuel injection lines - Install".

Result: The vent in the fuel cap is blocked.

Repair: Install a replacement fuel cap.

Result: The fuel contains solidified wax.

Repair: Replace the fuel with fuel of the correct specification for the ambient conditions.

Result: There are fuel supply lines that are restricted.

Repair: Replace any damaged or restricted fuel lines.

Replace the primary fuel filter and the secondary fuel filters. Refer to the Operation and Maintenance Manual for further information.

Result: There is air in the fuel system.

Repair: Prime the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".

Result: The diesel fuel is contaminated.

Repair: Drain the fuel tank and the fuel system.

Replace the primary fuel filter and the secondary fuel filters. Refer to the Operation and Maintenance Manual for further information.

Fill and prime the fuel system with fuel of the correct specification. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".

Result: The fuel supply is OK.

Proceed to Test Step 9.
 


Illustration 1g03700009
Transfer Pump Inlet Regulator (TPIR) components on a C4.4 engine
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port


Illustration 2g06100802
Transfer Pump Inlet Regulator (TPIR) components on a C6.6 engine
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port


Illustration 3g02485896
Minimum TPIR flow rate in a 12 VDC systems on a C4.4 engine


Illustration 4g02485897
Minimum TPIR flow rate in a 24 VDC systems on a C4.4 engine


Illustration 5g02355128
Minimum TPIR flow rate in a 12 VDC systems on a C6.6 engine


Illustration 6g02355130
Minimum TPIR flow rate in a 24 VDC systems on a C6.6 engine

Table 4
Troubleshooting Test Steps  Values  Results 

9. Transfer Pump Inlet Regulator (TPIR) Flow Test

For a C4.4 engine, refer to Illustration 1. For a C6.6 engine, refer to Illustration 2.

A. Disconnect the TPIR return line from the drain port on the TPIR. Install a suitable blanking cap on the open port in the TPIR return line.

B. Connect a temporary drain line to the drain port on the TPIR.

C. Place the end of the temporary drain line into a suitable calibrated container.

D. With the isolator switch in the ON position but the engine not running, use a suitable multimeter to measure the input voltage to the EFLP. Record the reading.

E. With the isolator switch in the ON position but the engine not running, measure the fuel flow from the temporary drain line.

F. Refer to Illustration 3 through 6 for the minimum acceptable flow rate.

G. Remove the temporary drain line from the drain port on the TPIR. Connect the TPIR return line to the TPIR.
 

TPIR flow rate
 

Result: The fuel flow is greater than the minimum limit.

Proceed to Test Step 11.

Result: The fuel flow is less than the minimum limit.

Proceed to Test Step 10.
 


Illustration 7g02527498
Minimum EFLP flow rate in a 12 VDC system


Illustration 8g02527518
Minimum EFLP flow rate in a 24 VDC system

Table 5
Troubleshooting Test Steps  Values  Results 

10. EFLP Flow Test at the Primary Fuel Filter Inlet

A. Make sure the keyswitch is in the OFF position.

B. Disconnect the fuel inlet connection from the primary fuel filter head.

C. Install a suitable blank on the fuel inlet port on the primary fuel filter head.

D. Place the open end of the fuel inlet line in a suitable calibrated container.

E. With the keyswitch in the ON position, measure the input voltage at the EFLP. Record the result.

F. With the keyswitch in the ON position, measure the flow from the fuel inlet line. Record the result.

G. Check the recorded voltage and fuel flow on the graph in Illustration 7 or 8.
 

EFLP flow
 

Result: The fuel flow is below the minimum value for the recorded voltage.

Repair: Replace the EFLP. Refer to Disassembly and Assembly, "Fuel Priming Pump - Remove and Install".

Result: The fuel flow is above the minimum value for the recorded voltage.

Proceed to Test Step 8.
 

11. Check the Return Fuel Lines

A. Make sure that the TPIR return line is not blocked or kinked.

B. If the TPIR return line is clear, confirm that the Electric Fuel Lift Pump (EFLP) is operating. Make sure that fuel lines between the EFLP and the TPIR are not blocked or kinked.
 

Return lines
 

Result: The TPIR return line or the fuel lines between the EFLP and the TPIR are blocked or kinked.

Repair: Clear or replace the blocked line.

Result: The TPIR return line and the fuel lines between the EFLP and the TPIR are clear.

Repair: Replace the EFLP.

If the fault is still present, proceed to Test Step 12.
 

12. Low Compression (Cylinder Pressure)

A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test".
 

Cylinder compression
 

Result: The results of the compression test are outside the specifications.

Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in the following list:

· Loose glow plugs
· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 13.
 

13. Electronic Unit Injectors

A. Use the electronic service tool to perform the automatic "Cylinder Cut Out Test".

Note: If the compression test that was performed in Test Step 9 was satisfactory, the "Cylinder Cut Out Test" will identify any faulty injectors.
 

Electronic Unit Injectors
 

Result: A faulty injector is indicated.

Repair: Remove any faulty electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove".

Install new electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".

Repeat the automatic "Cylinder Cut Out Test". If the fault is still apparent, remove the replacement electronic unit injector and install the original electronic unit injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install".

Result: All injectors are OK.

Proceed to Test Step 14.
 

14. Individual Malfunctioning Cylinders

A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test".

As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of the engine.

Note: If a change in the sound of the engine is not noted, the isolated cylinder is not operating under normal conditions. If the isolation of a cylinder results in a change in the sound that is less noticeable, the cylinder may be operating below normal performance.
 

Cylinders
 

Result: The test indicates a faulty cylinder.

Repair: Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance.

Result: The test indicates that all cylinders are OK.

Contact the Dealer Solutions Network (DSN).
 

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