Troubleshooting Cat PDF

CJlTERPILLAR® KENR5404-03
October 2009
,/i:l3
roubleshooting
3500C Marine Propulsion Engines
TTA1-Up (Engine)
TTB1-Up (Engine)
MSC1-Up (Engine)
TTC1-Up (Engine)
MB01-Up (Engine)
TTD1-Up (Engine)
TTE1-Up (Engine)
TTF1-Up (Engine)
TTG1-Up (Engine)
TTH1-Up (Engine)
TTJ1-Up (Engine)
E3W1-Up (Engine)
E3X1-Up (Engine)
E3Z1-Up (Engine)
i03684547
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
-
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION", The Safety Alert "WARNING" label is shown below,
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
.~
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The speCifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
.
KENR5404-03 3
Table of Contents
Table of Contents Oil Filter Differential Pressure Problem ................

Oil Pressure Is Low ...............................................
61
62
Power Is Intermittently Low or Power Cutout Is
Intermittent .......................................................... 64
Troubleshooting Section Secondary ECM Assumes Control ....................... 65
Secondary ECM Indicator Lamp Problem ............ 65
Introduction
Synchronization Problem ...................................... 66
General Information ................................................ 4
Valve Lash Is Excessive ....................................... 74
Welding Precaution ................................................. 4
Valve Rotator or Spring Lock Is Free .................... 75
Electronic Service Tools .......................................... 5
Circuit Tests
Electronic System Overview
Air Shutoff - Test ................................................... 76
System Overview .................................................... 8
CAN Data Link - Test ............................................ 85
Component Location ............................................... 9
Cat Data Link - Test .............................................. 89
Electronic Display Module .................................... 12
Electrical Power Supply - Test .............................. 93
Diagnostic Capabilities ......................................... 14
Emergency Stop - Test ..... ............................. ..... 100
Programmable Parameters ................................... 15
Emergency Stop (Remote) - Test ....................... 108
Electrical Connectors............................................ 16
Engine Control Switch - Test ................................ 118
Injector Solenoid - Test ....................................... 129
Configuration Parameters
Prelubrication - Test ............................................ 140
Configuration Parameters ..................................... 19
Sensor Signal (Analog, Active) - Test ................. 151
Sensor Signal (Analog, Passive) - Test .............. 160
Diagnostic Trouble Codes
Sensor Signal (PWM) - Test ............................... 165
Diagnostic Trouble Codes ..................................... 24
Sensor Supply - Test ........................................... 170
Speed Control (Switch) - Test ............................. 177
Event Codes
Speedmming - Test ............................................ 184
Event Codes ........................................................ 29
Starting - Test ............ ........................... .... ........ ... 189
Symptom Troubleshooting
Symptom Troubleshooting .................................... 35

Service
Factory Passwords ............................................. 201
Acceleration Is Poor or Throttle Response Is
ECM Will Not Accept Factory Passwords ........... 201
Poor .................................................................... 35
Electronic Service Tool Does Not Communicate .. 201
Air Starting Motor Problem ................................... 37
Alternator Problem (Charging Problem and/or Noisy

ECM Software - Install ........................................ 203
Operation) ........................................................... 37
ECM - Replace ................................................... 204
Coolant Contains Fuel .......................................... 37

Electrical Connectors - Inspect ........................... 206
Coolant Contains Oil ............................................. 38

Pressure Sensor - Calibrate ............................... 209
Coolant Temperature Is High ................................ 39

Throttle Position Sensor - Calibrate .................... 210
Coolant Temperature Is Low ................................. 40

Timing - Calibrate ................................................. 211
Crankcase Pressure Is High ................................. 41
Cylinder Is Noisy ................................................... 42

Index Section
ECM Does Not Communicate with Other
Modules .............................................................. 43
Index ................................................................... 213
Engine Cranks but Does Not Start ........................ 43
Engine Does Not Crank ........................................ 44
Engine Has Early Wear ........................................ 45
Engine Has Mechanical Noise (Knock) ................ 46
Engine Misfires, Runs Rough or Is Unstable ........ 46
Engine Overspeeds .............................................. 48
Engine Shutdown Is Intermittent ........................... 49
Engine Stalls at Low RPM .................................... 50
Engine Top Speed Is Not Obtained ...................... 51
Engine Vibration Is Excessive .............................. 52
Exhaust Has Excessive Black Smoke .................. 53
Exhaust Has Excessive White Smoke .................. 54
Exhaust Temperature Is High ............................... 55
Fuel Consumption Is Excessive ............................ 56
Fuel Filter Is Restricted. ................................ 57
High Altitude Derate Occurrence .., ....................... 58
Inlet Air Is Restricted ............................................. 59
Oil Consumption Is Excessive ............................. 59
Oil Contains Coolant ................................., ........... 60
Oil Contains Fuel ................................................. 60
4 KENR5404-03
Section
Troubleshooting Section i02651478
Welding Precaution
Introduction SMCS Code: 1000 --
Proper welding procedures are necessary in order
i02612687 to avoid damage to the engine's electronic control
module, to sensors, and to associated components.
General Information Remove the component that requires welding.
When welding on a engine that is equipped with
SMCS Code: 1000 an Electronic Control Module (ECM) and removal
of the component is not possible, the following
Electronic Control System procedure must be followed. This procedure provides
the minimum amount of risk to the electronic
The electronic system consists of an Electronic components.
Control Module (ECM), the wiring harness, switches,
sensors, and fuel injectors. The ECM consists of two NOTICE
main components, the control computer (hardware) Do not ground the welder to electrical components
and the flash file (software). The control computer such as the ECM or sensors. Improper grounding can
consists of a microprocessor and electronic circuitry. cause damage to the drive train bearings, hydraulic
The flash file contains the engine's operational components, electrical components, and other com
characteristics. The operating maps define the ponents.
following characteristics of the engine:
Clamp the ground cable from the welder to the com
• Horsepower ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos
• Torque curves sibility of damage.
• Engine speed (rpm)
Refer to Troubleshooting, "System Overview" for

additional information on the electronic control
system.
1. Stop the engine. Remove the electrical power
from the ECM.
2. Disconnect the negative battery cable from the

-
battery. If a battery disconnect switch is installed,
open the switch.
Interface
The ECM interfaces with the engine via software - BATTERY CABLE BATTERY DISCONNECT
and electrical connectors on the ECM. The DISCONNECTED ~ SWITCH OPENED
engine provides inputs to the electrical connector
on the ECM in order to indicate the status of KEYSWITCH OFF II ~
switches and sensors. The ECM must be correctly
configured in order to interpret the inputs. The
ECM provides outputs for the engine systems via WELDING
the electrical connectors on the ECM in order to ROD
control lamps, solenoids, and other devices. Refer to

WELDER ENGINE ELECTRICAL OR
Troubleshooting, "Configuration Parameters". GROUND ELECTRONIC
CLAMP COMPONENT
/ COMPONENT \
BEING
WELDED
WELDING CURRENT
I
-------'
MAXIMIZE THE DISTANCE BETWEEN THE COMPONENT
THAT IS BEING WELDED AND ANY
ELECTRICAL OR ELECTRONIC COMPONENT
g01143634
--
Illustration 1
Service welding guide (typical diagram)
KEN R5404-03 5
Troubleshooting Section
3. Connect the welding ground cable as close Two short jumper wires are needed to check the
as possible to the area that will be welded. continuity of some wiring harness circuits by shorting
Components which may be damaged by welding two adjacent terminals together in a connector. A
include bearings, hydraulic components, and long extension wire may also be needed to check the
electrical/electronic components. continuity of some wiring harness circuits.
4. Protect the wiring harness from welding debris

and from spatter.
Optional Service Tools
Table 2 lists the optional service tools that may be
5. Weld the materials by using standard welding needed during testing or repair.
methods.
Table 2
i02772051 Optional Service Tools
•
Electronic Service Tools • Part Number Description

198-4240 Digital Pressure Indicator
SMCS Code: 0785 or
l
1U-5470 Engine Pressure Group
Caterpillar electronic service tools are designed to -"~--"~~
help the service technician perform the following 4C-4075 Crimp Tool (4-AWG TO 10-AWG)
.
tasks: 4C-4911(1) Battery Load Tester
5P-7277 Voltage Tester
• Information access
6V -9130(2) Temperature Adapter (MULTIMETER)
.. System diagnostics
8T·5319 Connector Tool Group
.. System calibrations 155-5176 AC/DC Current Probe
• System configurations 285-0910 Multi-Tool Gp

(1) Refer to Special Instructions, SEHS9249, "Use of 4C-4911
.. Data link communications Battery Load Tester for 6,8, and 12 Volt Lead Acid Batteries"
and Special Instructions, SEHS7633, "Battery Test Procedure".
(2) Refer to Special Instructions, SEHS8382, "Use of the 6V-9130
Required Service Tools Temperature Adapter Group".
The tools that are listed in Table 1 are required in Caterpillar Electronic Technician
order to enable a service technician to perform the
test procedures that are found in this manual. (ET)
Table 1 Cat ET can display the following information:
Required Service Tools
.. Parameters
Part Description
Number .. Event codes
N/A 4 Allen Wrench
.. Diagnostic codes
6V-2197 Transducer
7X-1171 Transducer Adapter .. Engine configuration
7X-1695 I Cable As Cat ET can be used by the technician to perform the

146 4080 Digital l\t1ultimeter Gp (RS232) following functions:
7X-1710 • Multimeter Probes .. Diagnostic tests

7X 6370 Adapter Cable As (3-PIN BREAKOUT)
.. Calibrations
208-0059 Adapter Cable As (70-PIN BREAKOUT)
• 257-8718 Adapter Cable As (120-PIN BREAKOUT) .. Flash programming
-~
167-9225 Harness (SERVICE TOOL ADAPTER) • Configuration of the Electronic Control Module
1U 5804 Crimp Tool (12-AWG TO 18-AWG) (ECM)
175-3700 Connector Repair Kit (DEUTSCH DT)

o
Table 3 lists the software that is required in order to

use Cat ET. Always use the latest version of Cat ET
that is available.
Table 3
Requirements for Cat ET
i Description
i Number
I JERD~2-1-2-4-\I-s-i-n-gl-e-U-s-er license for Cat ET
Data subscription for all engines and
[ JERD2129
machines
Note: For more information regarding the use of

Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
software.
Connecting Cat ET
g01255306
Illustration 2
Connecting with the Communication Adapter II
Connecting the Communication Adapter II
Table 4 lists the standard hardware that is required in (1) Personal Computer (PC)
(2) 237 - 7 54 7 Adapter Cable As
order to connect Cat ET. (3) 196 - 0055 Adapter Cable As
(4) 225 - 5985 Parallel Port Cable (COMMUNICATION ADAPTER)
Table 4 (5) 275 -5121 Communication Adapter As
Standard Hardware for the Use of Cat ET (6) 207 - 6845 Adapter Cable As
Part Number Description Note: Items (3), (5), and (6) are part of the 275 - 5120
Communication Adapter Gp.
N/A Personal Computer (PC)
ICommunication Adapter Use the following procedure in order to connect Cat

ET and the Communication Adapter II.
Gp (CAT ET TO ECM
INTERFACE)
1. Remove the electrical power from the ECM.
Cable As
Parallel Port Cable 2. Connect communications adapter (5) to a
225-5985(3) (COMMUNICATION communications port on the PC by using one of
ADAPTER) the following methods:
(2) The 237 - 7547 Adapter Cable As is required to connect to the
Universal Serial Bus (USB) on computers that are not equipped a. Connect cable (4) between the "COMPUTER"
with a RS232 serial port. end of communications adapter (5) and the
(3) The 225 5985 Parallel Port Cable is required to connect to parallel port of PC (1). Be sure to configure
the parallel port. Cat ET for the parallel port. This configuration
provides the fastest connection.
b. Connect cable (3) between the "COMPUTER"

end of communication adapter (5) and the
RS232 serial port of PC (1).
c. Connect cables (2) and (3) between the

"COMPUTER" end of communication adapter
(5) and the USB port of PC (1).
3. Connect cable (6) to communication adapter (5).
4. Connect cable (6) to a service tool connector.
5. Verify that the "POWER" indicator on the

communication adapter is illuminated.
KENR5404-03 7
6. Establish communication between Cat ET and the 2. Ensure that the computer has been correctly
ECM. configured for the 261-4867 Card (PCMCIA).
Verify that the PC card is installed in the
7. If Cat ET and the communication adapter computer's PCI expansion slot.
do not communicate with the ECIVI, refer to
Troubleshooting, "Electronic Service Tool Does 3. Connect cable (9) between communication radio
Not Communicate". (8) and the service tool connector.
Communicating with the Wireless Communication 4. Restore the electrical power to the ECM. If Cat ET
Adapter and the communication radio do not communicate
with the ECM, refer to Troubleshooting, "Electronic
Table 5 lists the optional hardware that is needed Service Tool Does Not Communicate".
in order to connect Cat ET by using a wireless
connection.
Table 5
Optional Hardware for the Use of Cat ET

Part Number Description
N/A Personal Computer (PC)
261 - 3363(1)
Wireless Communication
Adapter Gp
(1) Refer to Tool Operating Manual, "Using the 261 -3363
Wireless Communication Adapter Gp" for information that is
related to the installation and the configuration.
I~
9
g01297379
Illustration 3
(1) Personal computer (PC)
(7) 261 -4867 Card (PCMCIA)
(8) 239 - 9955 Communication Radio Gp
(9) 259 - 3183 Data Link Cable As
Note: Items (7), (8), and (9) are part of the 261 - 3363
Wireless Communication Adapter Gp.
Use the following procedure in order to connect the

wireless communication adapter for use with Cat ET.
1. Remove the electrical power from the ECM.

Electronic System Cold Mode Operation
Overview Cold mode operation automatically stops fuel

injection to cylinders that are not firing. Cold mode ~
operation has the following benefits: increased

i02627154 startability, reduced warm up period, and reduced
white smoke. Cold mode is activated whenever
System Overview the engine coolant temperature falls below a
predetermined value.
SMCS Code: 1000; 1900
The engine is designed for electronic control of most FRC Limit

engine operating functions. The electronic system
consists of an Electronic Control Module (ECM), the The flash file inside the engine ECM sets certain
wiring harness, switches, sensors, and fuel injectors. limits on the amount of fuel that can be injected.
The engine ECM receives information from the The FRC limit is a limit that is based on the boost
sensors and the switches on the engine. The engine pressure. The boost pressure is calculated as the
ECM processes the information that is collected difference in pressure between atmospheric pressure
in order to control the engine. By altering the fuel and turbocharger outlet pressure. The FRC limit
delivery with the fuel injectors, the engine ECM is used to control the air/fuel ratio for control of
controls the speed and the power that is produced emissions. When the engine ECM senses a higher
by the engine. 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
Electronic Controls increases the FRC limit, the engine ECM allows more
fuel into the cylinder.
Electronic Control Module
Rated Fuel Position
The ECM consists of two main components, the
control computer (hardware) and the flash file The rated fuel position is a limit that is based on the

(software). The control computer consists of a power rating of the engine. The rated fuel position
microprocessor and electronic circuitry. The flash file is similar to the rack stops and the torque spring
contains the engine's operational characteristics. The on a mechanically governed engine. The rated fuel
operating maps influence the engine's performance. position determines maximum power and torque
values for a specific engine family and a specific
Engine Governor rating. The rated fuel position is programmed into
the flash file at the factory.
The engine ECM governs engine speed. The engine
ECM and the flash file work together by controlling
the amount of fuel that is delivered by the injectors. i02627159
Desired engine rpm is determined by the throttle
position sensor signal and certain sensor readings.
Component Location
Actual engine rpm is monitored by the engine
SMCS Code: 1000; 1900
speed/timing sensor.
Fuel Injection
The engine ECM controls the timing and the duration
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.
Injection timing depends on the desired engine rpm

and load. The ECIVI detects the top center of each
cylinder. The ECM sends an injection signal at the
desired time.
~
KENR5404-03 9
hl""c::hnntinn Section
Engine's Electrical Components
ELECTRONIC UNIT
PRIMARY ELECTRONIC SECONDARY ELECTRONIC
INJECTORS (EUI)
CONTROL MODULE (ECM) CONTROL MODULE (ECM)
(8, 12 or 16)
SERVICE TOOL J1939 TERMINATING

AFTERCOOLER TEMPERATURE SENSOR CONNECTOR RESISTOR
CRANK OVERRIDE
COOLANT TEMPERATURE SENSOR
J-l.'l.J1'- PRELUBE OVERRIDE
FILTERED FUEL PRESSURE SENSOR ENGINE PROTECTION OVERRIDE
TORQUE LIMIT
UNFILTERED FUEL PRESSURE SENSOR ENGINE
LOCAL/REMOTE
INSTRUMENT THROTTLE
PANEL (MPD)
SECONDARY THROTTLE
FILTERED OIL PRESURE SENSOR POSITION SENSOR
UNFILTERED OIL PRESSURE SENSOR ~POWERDIST

.. PANEL
TO BATTERY
PRIMARY SPEEDfTlMING SENSOR
RIGHT EXHAUST TEMPERATURE SENSOR
SECONDARY SPEEDfTlMII\lG SENSOR
LEFT EXHAUST TEMPERATURE SENSOR
TIMING CALIBRATION SENSOR

COOLANT LEVEL
(BLOCK, SCAC)
LEFT TURBO INLET PRESSURE SENSOR
CUSTOMER
RIGHT TURBO INLET PRESSURE SENSOR CONNECTOR
r--------+-~~]J] J19139 TERMINATING mQ) PpR6~~~6J~~~~6~E

TURBO OUTLET PRESSURE SENSOR RESISTOR (CUSTOMER)
ATMOSPHERIC PRESSURE SENSOR
TRANSMISSION PRESS.
CRANKCASE PRESSURE SENSOR
TRANSMISSION TEMP
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
~ THROTTLE
=C[f r-----t::'=IlJ'U SYNC SWITCH
ENGINE OIL TEMPERATURE SENSOR REMOTE

'---------"=
....... E-STOP
Illustration 4 g01316909
Typical example
Location of the Engine

Components
2 3 4 5 6
"
10 11
g01019029
Illustration 5
Left side view
(1) Unfiltered fuel pressure sensor (5) Secondary ECM connector J2 (8) Secondary engine speed/timing sensor
(2) Filtered fuel pressure sensor (6) Left exhaust temperature sensor (9) Primary engine speed/timing sensor
(3) Aftercooler temperature sensor (7) Left turbocharger compressor inlet (10) Secondary ECM connector J1
(4) Coolant temperature sensor pressure sensor (11) Secondary ECM
'
KENR5404-03 11
Section
location of the Engine

Components
12 13 14
Illustration 6
901019032
Right side view
(12) Right turbocharger compressor inlet (13) Right exhaust temperature sensor
pressure sensor (14) Crankcase pressure sensor
I":: I'\.C 1'41"\;;J<tU<t-UJ
Section
Location of the Engine

Components
4 15 16 3 17 7 6 13 12
-
18
19 20 21
Illustration 7
Front and rear view
(4) Coolant temperature sensor (7) Left turbocharger compressor inlet (18) Atmospheric pressure sensor
g01019034

(15) Filtered engine oil pressure sensor pressure sensor (19) Primary ECM connector J1
(16) Unfiltered engine oil pressure sensor (6) Left exhaust temperature sensor (20) Primary ECM
(3) AftercooJer temperature sensor (13) Right exhaust temperature sensor (21) Primary ECM connector J2
(17) Turbocharger compressor outlet (12) Right turbocharger compressor inlet
pressure sensor pressure sensor
i03158926
Electronic Display Module

SMCS Code: 7490
The control panel is the control station for the

engine. The control panel has the following controls
on the front of the panel: Marine Power Display
(MPD), Engine Control Switch (ECS), emergency
stop switch, and indicator lamps. The control panel
contains the following controls on the inside of
the panel: override switches, local/remote switch
(throttle), control relays, and diodes.
-
KENR5404-03 13
nubleshootino Section
Control Panel
2 3 4 5 6 7 8 9
16 17 18 19 20 21 22 23 24 25 26 27 28
g01316970
Illustration 8
Control panel
(1) Marine Power Display (11) "Reset 1" relay (21) Overspeed indicator
(2) "ECM Ready" lamp (12) "Stop 1" relay (22) Emergency stop lamp
(3) Pyrometer (13) "Reset 2" relay (23) "STE" relay
(4) Override switch (crank) (14) "Stop 2" relay (24) "Run 1" relay
(5) Prelube override switch (15) Horn relay (25) "STPE" relay
(6) Marine override switch (16) Engine control switch (ECS) (26) "Run 2" relay
(7) Torque limit switch (17) Speed Control (27) "ECSIR" relay
(8) Local/remote switch (throttle) (18) Emergency stop switch (28) "SN" relay
(9) Diodes 01 to D10 (19) "ECM Active" lamp
(10) "RSR" relay (20) Alarm (horn)
Power Distribution Panel

The power distribution panel distributes power to
the various systems on the engine. The power
distribution panel has two external connections for
the battery. The power distribution panel has multiple
breakers that are mounted externally. The power
distribution panel contains the following controls
on the inside of the panel: control relays, circuit
breakers, diodes, control switches, and timer.
14 KEN R5404-03
Section
29 30 31 32 33 34 35 36 37 38 33 32 31 30 42
43 TOP 44 BOTTOM
LEVEL LEVEL
OF BOX OF BOX
g01621243
Illustration 9
Power distribution panel
(29) Circuit breaker for the primary ECM (20 (34) "PPR2" relay (44) "SO Notify" relay
Amp) (35) "Relay 4A" (45) Starting motor magnetic switch 2
(30) Circuit breaker for the secondary ECM (36) "Relay 4" (46) Starting motor magnetic switch 1
(20 Amp) (37) "Relay 3A" (47) "PPR1" switch
(31) Circuit breaker for the prelube and air (38) "Relay 3" (48) Air shutoff switch (ASOS)
shutoff circuits (40 Amp) (39) "Relay 2A"
(32) "Marine Power Display (MPD)" circuit (40) "Relay 2"
breaker (20 Amp) (41) "Relay 1"
(33) Starter and alternator circuit breaker (42) Air shutoff timer
(70 Amp) (43) General alarm relay
i03139943 Event Code - An event code is generated by the

detection of an abnormal engine operating condition.
Diagnostic Capabilities For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
SMCS Code: 1900 indicates the symptom of a problem. Event codes
indicate mechanical problems rather than electrical
Diagnostic Codes problems.
The engine's Electronic Control Module (ECM) has Codes can have two different states:
the ability to monitor the circuitry between the ECM
and the engine's components. The ECM also has the • Active
ability to monitor the engine's operating conditions. If
the ECM detects a problem, a code is generated. • Logged
There are two categories of codes: Active Codes

• Diagnostic code An active code indicates that a problem is present.
Service the active code first. For the appropriate
• Eventcode troubleshooting procedure for a particular code, refer
to the following troubleshooting procedure:
Diagnostic Code - A diagnostic code indicates an
electrical problem such as a short or an open in the • Troubleshooting, "Diagnostic Trouble Codes"
engine's wiring or in an electrical component.
KENR5404-03 15
Section
• Troubleshooting, "Event Codes"
Logged Codes
The codes are logged and stored in the ECM
memory. The problem may have been repaired
and/or the problem may no longer exist. If the
system is powered, it is possible to generate an
active diagnostic code whenever a component is
disconnected, If the component is reconnected, the
code is no longer active but the code may become
logged.
Logged codes may not indicate that a repair is

needed. The problem may have been temporary.
Logged codes may be useful to help troubleshoot
intermittent problems. Logged codes can also be
used to review the performance of the engine and
of the electronic system.
i03496620
Programmable Parameters
SMCS Code: 1900
The Caterpillar Electronic Technician (ET) can be

used to view certain parameters that can affect
the operation of the engine. Cat ET can also be
used to change certain parameters. There are
some parameters that cannot be changed and
there are some applications that do not allow any
changes to the programmable monitoring system.
The parameters are stored in the Electronic Control
Module (ECM). Some of the parameters are
protected from unauthorized changes by passwords.
Parameters that can be changed have a tattletale
number. The tattletale number shows if a parameter
has been changed.
I\t:.N K04U4-U,j
i02627789
Electrical Connectors
~
SMCS Code: 7S53-WW
Engine Electronic Control Module

(ECM)
J1 J2
HARNESS CONNECTOR P1 HARNESS CONNECTOR P2
~
~OOOOOOOOOOOOO~
o 0 0 0 0

0 0 0 0 ()14 230 0 0 0 0 0 0 0 0 0 0 14
310000 [~J 000()24 310000 l~J 000()24
gO 000 000032 ,©l 390000 i @
470 0 0 0 ' .
000()32
0 0 0 OlD
70 000 ' 0 0 0010
, 5700000 0 OOOOOls !S700000 0 0000048
0000000000000058 ~0000000000000()3)
~ ~
'
m
ECM SIDE ECM SIDE
/--...,
1 2 J 4 5 6 C 8 9 1011 1213 " I- 1 2 3 4 5 6 0 8 9 10 11 12 13 ~
1~
24i
X
@ >PEI<
)31
3 li 14
24 @
\;EI< mO
~1
o 0 36 0 o 0 6 0
,~
140{ ~ ~ "'~
7 [[: ~~O
58 5960 61 6263 C 65 66 67 6S 69 7D l-'" 58 5960 61 62 63 0 6566 67 686970 )
1..,- II !I ~
HARNESS SIDE HARNESS SIDE
Connectors for the ECM

70 pin connectors
~.
KENR5404-03 17
Section
Customer Connector Service Tool Connector for Cat ET
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KENR5404-03 19
i02627804
SMCS Code: 1900
Use this procedure if anyone of the diagnostic codes

in Table 6 is active.
Table 6
Diagnostic Codes Table
~
Description Conditions which Generate this Code System Response

268-2 Programmed Parameter Fault The engine's Electronic Control Module The ECM may use a default torque
erratic, intermittent, or incorrect (ECM) detects that one or more of the map or the ECM may limit the engine
programmable parameters have not to low idle.
been programmed. The code is active only.
1495-2 Injector Trim Codes Not The engine's ECM detects that one or The ECM may use a default torque
Programmed more of the injector trim codes have not map or the ECM may limit the engine
been programmed. to low idle.
The code is active only.
Some system configuration parameters are If a programmable parameter has not been
configurable by the customer in order to suit the programmed, the ECM will generate a 268-2
customer's particular application. The configuration diagnostic code. The unprogrammed parameters
file contains all of the adjustable settings for the will be set to default. Certain aspects of the engine's
monitoring system. The engine is shipped from the performance and engine monitoring may be affected.
factory with default values for these parameters. Program the miSSing parameter.
In most cases, the parameters do not need to be
changed. The system configuration parameters must If an injector code has not been programmed, the
be reprogrammed if an ECM is replaced and/or the ECM will generate a 1495-2 diagnostic code. The
engine rating is reprogrammed. System configuration injector code is a number that is found on each of
parameters do not need to be reprogrammed if the unit injectors. The ECM uses this number to
the flash file is replaced. Proper values for these compensate for manufacturing variations between
parameters are available on Caterpillar Electronic individual injectors. If you replace any of the unit
Technician (ET). Certain configuration parameters injectors, you must reprogram the code for the new
are also stamped on the engine information plate. injectors. Also, if you replace the ECM, you must
reprogram all of the injector codes.
If the default settings for the parameters have been
modified, there will be no record at the factory of the Note: The injector codes are not part of the
changes. These settings can be downloaded into a "Configuration" screen on the electronic service tool.
laptop computer and saved to a file. The customer "Injector Codes Calibration" can be found under
can then use the file in order to ease the future "Calibrations" in the "Service" menu on Cat ET.
replacement of the ECM.
No password is required for programming a new ECM

Parameter Descriptions
during the first 100 hours of service life. This 100 hour
"free configuration" feature enables the customer "Fuel Ratio Control"
to tailor some of the programmable setpoints to the
requirements of the installation. The "Fuel Ratio Control" limit controls the amount
of fuel to air ratio by limiting the raci< as a function
Note: If the parameters that are protected with of boost pressure, engine speed and altitude. The
the factory passwords are changed, the Caterpillar "Fuel Ratio Control" function permits an offset to be
warranty may be voided. applied to the calculation for the altitude. The offset
changes the fuel to the air ratio to a richer mixture
or a leaner mixture.
LU
hl",chl"\n+inl"l Section
"Rated Fuel Position"

This parameter is used to limit the engine power. A
factory password is required to change this setting.
"Engine Cooling System Configuration"

This parameter is used as a switch to toggle between
the SCAC cooling system or the JWAC cooling
system.
"Cold Cylinder Cutout"

The cold cylinder cutout automatically stops fuel
injection to cylinders that are not firing. The fuel
injection is stopped to the cylinders until the engine
reaches operating temperature.
"Cooldown Engine Speed"

This parameter defines the engine rpm level when
the Engine Control Switch (ECS) is placed in the
STOP position.
"Engine Cooldown Duration"

This parameter defines engine operation at the
cooldown speed. Programming this parameter to 0
will disable this function.
"Engine Prelube Duration"

This parameter sets the engine prelubrication timeout
period. Programming this parameter to 0 will disable
this function.
"Crank Duration n
The crank duration determines when the starting
motors will be energized. The crank duration
determines when the starting motors will be
disengaged. Programming this parameter to 0 will
prevent the ECM from engaging the starting motors.
"Maximum Number of Crank Cycles"

This parameter is the total number of crank cycles
that can be performed.
"Crank Terminate Speed"

This parameter determines when the starting motor
will disengage.
"Total Tattletale"
The parameter counts the number of changes to
system parameters.
KEN R5404-03 21
'oubleshootinCl Section
Parameter Table
Table 7
SY::>L<:t1ll Configuration
Parameter ECM Default Range Password
"Fuel Ratio Control Primary 0 -25 to +25 No
Offset"
"Rated Fuel Positon Primary Software Dependent Software Dependent Yes
(mm)"
"Engine Cooling Primary SCAC SCAC or JWAC • Yes
System Configuration"
Cold Cylinder Cutout Primary Enabled Enabled No
Disabled
"Cooldown Engine Primary 600 300 to 1600 No
Speed (rpm"
"Engine Cooldown Primary 5 o to 30 • No
Duration (min)"
"Engine Prelube Primary 0 o to 210 No
Duration (sec)"
"Crank Duration (sec)" Primary 0 o to 60 No
....... _
"Maximum Number of Primary 0 o to 10 No
Crank Cycles"
"Crank Terminate Primary 400 100 to 500 No
Speed (rpm)"
"Total Tattletale" Primary 0 o to 255 I N/A
Secondary
Customer Parameters "Personality Module Part Number"
"Equipment 10" "Personality Module Part Number" is programmed
into the software.
"Equipment 10" allows the customer to enter a

description into the ECM in order to identify the "Personality Module Release Date"
engine. A maximum of 17 characters may be entered

in the field. This parameter is only for reference by "Personality Module Release Date" is programmed
the customer. This parameter is not required. into the software.
"Engine Serial Number" "Engine Rotation"
"Engine Serial Number" must be programmed to The "Engine Rotation" can be viewed only.
match the engine serial number that is stamped on

the engine information plate. If the ECM is replaced, "Engine location"
the engine serial number must be programmed into

the new ECM. If multiple engines are installed, the parameter for the
engine location identifies the locations of the engines.
Note: When you are requesting factory passwords,
always use the engine serial number that is resident
in the ECM. "Full Load Setting (FlS)"
"FLS" is a number that represents the adjustment to
"ECM Serial Number" the fuel system that was made at the factory in order
to fine tune the fuel system. The correct value for
The "ECM Serial Number" is stored in the memory of this parameter is stamped on the engine information
the ECM. The "ECM Serial Number" can be accessed plate. Factory passwords are required.
by the use of the service tool.
L.L.
Section
"Full Torque Setting (FTS)"

"FTS" is similar to "FLS". Factory passwords are
required.
"High Idle Speed"

-
The "High Idle Speed" is programmed into the
software.
"Low Idle Speed"

"Low Idle Speed" is the minimum allowable operating
speed for the engine.
"Fuel Correction Factor"

The "Fuel Correction Factor" is a parameter that
adjusts the calculation of fuel consumption. The
fuel correction factor is used to correct the fuel
consumption that is calculated by the ECM.
"Coolant Level Sensor"

The "Coolant Level Sensor" parameter can be set to
the following status: "Not Installed", "Data Link", and
"Sensor". If the sensor is available via the EMS panel
in the engine control panel, set the status to the "Data
Link". If the sensor is mounted on the engine, set the
status to the "Sensor".
'
"Torque Limit Enable Status"

The "Torque Limit Enable Status" enables the torque
limit.
"Maximum Engine Torque Limit"

The "Maximum Engine Torque Limit" and the
range for the "Maximum Engine Torque Limit" is
programmed into the software.
"Minimum Engine Torque Limit"

The "Minimum Engine Torque Limit" and the range for
the "Minimum Engine Torque Limit" is programmed
into the software.
"Coolant Warning Engine Load Enable

Threshold"
The "Coolant Warning Engine Load Enable
Threshold" is programmed in order to set the setpoint
for low coolant.
"Air Shutoff Status"

This "Air Shutoff Status" enables the strategy for the
air shutoff.
-
KENR5404-03 23
Parameter Table
Table 8
Customer Parameters
Parameter ECM Default Range Password
"Equipment 10" Primary N/A 17 alphanumeric No
Secondary characters
"Engine Serial Number" Primary 8 alphanumeric No
Secondary characters
#AA#f:I###
"ECM Serial Number" Primary ECM Serial Number ECM Serial Number N/A
Secondary
"Personality Module Primary N/A
Part Number" Secondary
"Personality Module Primary Month N/A
Release Date" Secondary Year
"Engine Rotation" Primary Forward Forward/Reverse N/A
Secondary
"Engine Location" Primary Center Port No
Center
Starboard
"Full Load Setting Primary Not Programmed -128 to +127 Yes
(FLS)" Secondary
"Full Torque Setting Primary 0 -128 to +127 Yes
(FTS)" Secondary
"Rated Engine Speed" Primary Programmed at the Factory N/A
Factory
"High Idle Speed (rpm)" Primary Programmed at the Factory N/A
Factory
"Low Idle Speed (rpm)" Primary 600 300 to 900 No
Secondary
"Fuel Correction Factor" Primary 0 -64 to +63.5 No
"Coolant Level Sensor" Primary Installed "Not Installed" No
Data Link
Sensor
"Torque Limit Enable Primary "Not installed" Installed No
Status" Secondary "Not Installed"
"Maximum Engine Primary Programmed at the Factory No
Torque Limit" Secondary Factory
"Minimum Engine Primary Programmed at the Factory No
Torque Limit" Secondary Factory
"Coolant Warning Primary 40% 5 to 95% No
Engine Load Enable"
Threshold
"Air Shutoff Status" I Secondary Enabled Enabled No
Disabled
~4
i03140444

SMCS Code: 1900
Cross-Reference Information for

Diagnostic Codes
Table 9 is a list of the diagnostic codes for the
engine. The diagnostic codes are cross-referenced
with the appropriate procedure that can be used to
troubleshoot the code.
Further explanations of diagnostic codes are

explained after Table 9.
Table 9
Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure

Code and Description Procedure
1-5 Cylinder #1 Injector current below normal

Troubleshooting. "Injector Solenoid - Test"
1-6 Cylinder #1 Injector current above normal


Troubleshooting. "Injector Solenoid Test"




I 4-6 Cylinder #4 Injector current above normal Troubleshooting. "Injector Solenoid - Test"
• 5-5 Cylinder #5 Injector current below normal Troubleshooting, "Injector Solenoid Test" I
• 5-6 Cylinder #5 Injector current above normal Troubleshooting. "Injector Solenoid Test"
6-5 Cylinder #6 Injector current below normal i Troubleshooting. "Injector Solenoid - Test"
i 6-6 Cylinder #6 Injector current above normal Troubleshooting. "Injector Solenoid - Test"




Troubleshooting, "Injector Solenoid Test"


Troubleshooting, "Injector Solenoid - Test"

Troubleshooting, "Injector Solenoid Test"
10-6 Cylinder #10 Injector current above normal Troubleshooting. "Injector Solenoid Test"

11-6 Cylinder #11 Injector current above normal i Troubleshooting. "Injector Solenoid - Test"


. 13-5 Cylinder #13 Injector current below normal Troubleshooting. "Injector Solenoid - Test"
(continued)
KENR5404-03 25
i",ch""tinrt Section
(Table 9, contd)
Cross-Reference from CID-FMI Code on C at Data Link to Troubleshooting Procedure

13-6 Cylinder #13 Injector current above normal Troubleshooting, "Injector Solenoid Test"
14-5 Cylinder #14 Injector current below normal Troubleshooting, "Injector Solenoid - Test"
14-6 Cylinder #14 Injector current above normal Troubleshooting, "Injector Solenoid - Test"
15-5 Cylinder #15 Injector current below normal Troubleshooting, "Injector Solenoid Test"
15-6 Cylinder #15 Injector current above normal Troubleshooting, "Injector Solenoid - Test"
16-5 Cylinder #16 Injector current below normal Troubleshooting, "Injector Solenoid Test"
16-6 Cylinder #16 Injector current above normal Troubleshooting. "Injector Solenoid - Test"
91-8 Throttle Position Sensor abnormal frequency, pulse Troubleshooting, "Speed Control- Test"
width. or period
91-13 Throttle Position Sensor calibration required Troubleshooting, "Throttle Position Sensor - Calibrate"
94-3 Fuel Delivery Pressure Sensor voltage above normal Troubleshooting, "Sensor Signal (Analog, Active) Test"
94-4 Fuel Delivery Pressure Sensor voltage below normal Troubleshooting, "Sensor Signal (Analog, Active) Test"
100-3 Engine Oil Pressure Sensor voltage above normal Troubleshooting. "Sensor Signal (Analog, Active) - Test"
100-4 Engine Oil Pressure Sensor voltage below normal Troubleshooting, "Sensor Signal (Analog, Active) - Tesf'
101-3 Crankcase Air Pressure Sensor voltage above normal Troubleshooting, "Sensor Signal (Analog. Active) Test"
101-4 Crankcase Air Pressure Sensor voltage below normal Troubleshooting, "Sensor Signal (Analog, Active) - Test"
105-4 Inlet Manifold Temperature Sensor voltage below • Troubleshooting, "Sensor Signal (Analog, Passive) - Test"
normal
110-3 Engine Coolant Temperature Sensor voltage above I Troubleshooting, "Sensor Signal (Analog, Active) Test"
normal :
110-4 Engine Coolant Temperature Sensor voltage below I Troubleshooting, "Sensor Signal (Analog, Active) Tesf'
normal
168-0 Electrical System Voltage high most severe (3) ! Troubleshooting, "Electrical Power Supply - Test"
168-1 Electrical System Voltage low most severe (3) Troubleshooting, "Electrical Power Supply - Test"
168-2 Electrical System Voltage erratic, intermittent, or Troubleshooting, "Electrical Power Supply - Test"
incorrect
175-3 Engine Oil Temperature Sensor voltage above normal Troubleshooting, "Sensor Signal (Analog, Passive) - Test"
175-4 Engine Oil Temperature Sensor voltage below normal Troubleshooting, "Sensor Signal (Analog, Passive) - Test"
190-2 Engine Speed Sensor erratic, intermittent, or incorrect Troubleshooting, "SpeedlTiming - Test"
190-3 Engine Speed Sensor voltage above normal Troubleshooting, "SpeedlTiming - Test"
190-7 Engine Speed Sensor not responding properly Troubleshooting, "SpeedlTiming - Test"
190-8 Engine Speed Sensor abnormal frequency, pulse Troubleshooting, "SpeedlTiming - Test"
width, or period
248-9 @CatOatalinkLong@ not communicating Troubleshooting, "Cat Data Link - Test"
253-2 Personality Module erratic, intermittent, or incorrect Troubleshooting, "ECM Software - Install"
254-12 Electronic Control Module Error The Electronic Control Module (ECM) has detected a fatal
internal error. Replace the ECM. Refer to Troubleshooting,
"ECM - Replace".
261-13 Engine Timing Calibration calibration required Troubleshooting, 'Timing - Calibrate"
262-3 5 Volt Sensor DC Power Supply voltage above normal I Troubleshooting, "Sensor Supply - Test"
(continued)
Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure

262-4 5 Volt Sensor DC Power Supply voltage below normal Troubleshooting, "Sensor Supply - Test"
263-3 Digital Sensor Power Supply (8V Or 12V) voltage Troubleshooting, "Sensor Supply Test"
above normal
263-4 Digital Sensor Power Supply (8V Or 12V) voltage Troubleshooting, "Sensor Supply - Test"
below normal
268-2 Programmed Parameter Fault erratic, intermittent, or Troubleshooting, "Configuration Parameters"
incorrect
273-0 Turbocharger Outlet Pressure Sensor high - most Troubleshooting, "Sensor Signal (Analog, Active) - Test"
severe (3)
I 273-3 Turbocharger Outlet Pressure Sensor voltage above Troubleshooting, "Sensor Signal (Analog, Active) Test"
normal
273-4 Turbocharger Outlet Pressure Sensor voltage below Troubleshooting, "Sensor Signal (Analog, Active) - Test"
normal
274-3 Atmospheric Pressure Sensor voltage above normal Troubleshooting, "Sensor Signal (Analog, Active) Test"
274-4 Atmospheric Pressure Sensor voltage below normal Troubleshooting, "Sensor Signal (Analog, Active) Test"
275-3 Right Turbocharger Inlet Pressure Sensor voltage Troubleshooting, "Sensor Signal (Analog. Active) - Test"
above normal
275-4 Right Turbocharger Inlet Pressure Sensor voltage Troubleshooting, "Sensor Signal (Analog. Active) - Test"
below normal
276-3 Left Turbocharger Inlet Pressure Sensor voltage above Troubleshooting. "Sensor Signal (Analog. Active) - Test"
normal
276-4 Left Turbocharger Inlet Pressure Sensor voltage below Troubleshooting, "Sensor Signal (Analog, Active) Test"
normal
277-8 Timing Calibration Sensor abnormal frequency, pulse Troubleshooting, "Timing Calibrate"
width. or period
279-3 Aftercooler Coolant Temperature Sensor (Front) Troubleshooting, "Sensor Signal (Analog, Active) - Test"
voltage above normal
--_.. _-
279-4 Aftercooler Coolant Temperature Sensor (Front) Troubleshooting, "Sensor Signal (Analog. Active) - Test"
voltage below normal
289-3 Fuel Pressure Sensor - Before Fuel Filter voltage Troubleshooting. "Sensor Signal (Analog, Active) - Test"
above normal
289-4 Fuel Pressure Sensor - Before Fuel Filter voltage Troubleshooting. "Sensor Signal (Analog, Active) - Test"
below normal
336-2 Engine Control Switch erratic, intermittent, or incorrect Troubleshooting. "Engine Control Switch - Test"
337 -2 Remote Emergency Stop Switch erratic, intermittent. Troubleshooting. "Emergency Stop (Remote) - Test"
or incorrect
338-5 Engine Pre-Lube Pump Relay current below normal Troubleshooting, "Prelubrication - Test"
338-6 Engine Pre-Lube Pump Relay current above normal Troubleshooting, "Prelubrication - Test"
342-2 Secondary Engine Speed Sensor erratic. intermittent, Troubleshooting. "Speedffiming - Test"
or incorrect
342-3 Secondary Engine Speed Sensor voltage above Troubleshooting. "Speedffiming - Test"
normal
342-7 Secondary Engine Speed Sensor not responding Troubleshooting. "Speedffiming - Test"
I properly
342-8 Secondary Engine Speed Sensor abnormal frequency. Troubleshooting, "Speedffiming - Test"
pulse width, or period
(continued)
KENR5404-03 27
Section
C Refl fl CID-FMI Cod Cat Data Link to Troubleshootina P d

444-5 Starter Motor Relay current below normal Troubleshooting, "Starting - Test"
444-6 Starter Motor Relay current above normal Troubleshooting, "Starting - Test
446-5 Air Shutdown Relay current below normal Troubleshooting, "Air Shutoff - Test"
! 446-6 Air Shutoff Relay short Troubleshooting, "Air Shutoff - Test"
542-3 Engine Oil Pressure Sensor Before Oil Filter voltage

Troubleshooting, "Sensor Signal (Analog, Active) - Test"
above normal
542-4 Engine Oil Pressure Sensor - Before Oil Filter voltage

Troubleshooting, "Sensor Signal (Analog, Active) - Test"
i below normal
! 827-8 Left Exhaust Temperature Sensor abnormal frequency, Troubleshooting, "Sensor Signal (PWM) Test"
pulse width, or period
828-8 Right Exhaust Temperature Sensor abnormal

Troubleshooting, "Sensor Signal (PWM) - Test"
freq lCY, pulse I, pel
1249-8 Secondary Throttle Position signal abnormal Troubleshooting, "Speed Control- Test"
.......
1249-13 Secondary Throttle Position calibration required Troubleshooting, "Throttle Position Sensor - Calibrate"
11495-2 Injector Trim Codes Not Programmed Troubleshooting, "Configuration Parameters"
Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes are also used by the service technician 4.8 VDC
to identify the nature of the problem. Caterpillar
Electronic Technician (ET) is a software program
that is designed to run on a personal computer. The
software can be used by the service technician in
order to view the diagnostic code information for
4.2 VDC
an ECM. Diagnostic codes consist of the module
identifier (MID), the component identifier (CID), and
the failure mode identifier (FMI).
Component Identifier (MID) - The MID is a three

digit code that identifies the ECM that generated the
diagnostic code. For example, the MID 036 identifies
the primary engine ECM and the MID 047 identifies
the secondary ECM.
Normal
Engine
Component Identifier (CID) - The CID indicates the Operating
component that generated the code. For example, Range
the CID number 1 identifies the fuel injector for the

number one cylinder.
Failure Mode Identifier (FMI) - The FMI indicates

the type of failure.
Refer to Table 9 for a complete list of the diagnostic

codes and the appropriate troubleshooting procedure.
0.2 VDC
Note: Do not confuse diagnostic codes with DiagnostiC Code
event codes. Event codes alert the operator that an (Electronic Problem)
abnormal operating condition such as low oil pressure
or high coolant temperature has been detected. If an Illustration 14 g01117578
event code is active, refer to Troubleshooting, "Event
Codes". Output voltage from a typical analog temperature sensor
Illustration 14 indicates the signal range for a typical Note: Always clear logged diagnostic codes after
analog sensor. Diagnostic codes will be generated if investigating and correcting the problem which
the sensor's output signal is below 0.2 VDC or above
4.8 VDC.
Note: This graphic is an example. The signal ranges

generated the code.
-
in this graphic are used only as examples.
Active Diagnostic Codes

An active diagnostic code represents a problem with
the electronic control system. Correct the problem
as soon as possible.
When the engine's ECM generates an active

diagnostic code, the "Active Alarm" indicator ("Engine
Control Alarm Status" on Cat ET) is activated in order
to alert the operator. If the condition that generated
the code is momentary, the message disappears from
the list of active diagnostic codes. The diagnostic
code becomes logged.
Logged Diagnostic Codes

When the ECM generates a diagnostic code, the
ECM logs the code in permanent memory. The
ECM has an internal diagnostic clock. Each ECM
will record the following information when a code is
generated:
• The hour of the first occurrence of the code
• The hour of the last occurrence of the code

-
• The number of occurrences of the code
This information is a valuable indicator for

troubleshooting intermittent problems.
A code is cleared from memory when one of the

following conditions occur:
• The service technician manually clears the code.
• The code does not recur for 100 hours.
• A new code is logged and there are already ten

codes in memory. In this case, the oldest code is
cleared.
Some diagnostic codes may be easily triggered.

Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the failure
of an electronic module. Diagnostic codes that are
logged repeatedly may indicate a problem that needs
special investigation. -
KENR54D4-03 29
Section
Event Codes
i03140402
Event Codes
SMCS Code: 1900
CrossmReference Information for

Event Codes
Table 10 is a list of the event codes for the
engine. The event codes are cross-referenced with
the appropriate procedure that can be used to
troubleshoot the code.
Event codes are generated when abnormal operating

conditions exist. A further explanation of event codes
and the engine's monitoring system are described
after Table 10.
Table 10
Cross-Reference from Event Codes on Cat Data Link to Troubleshooting Procedure
i E007(2) High Aftercooler Tempera ure Dera e TroubleshootIng, "Coolant Tempera ure Is High"
I E008(3) High Aftercooler Temperature Shutdown Troubleshooting, "Coolant Temperature Is High"
E009(2) High Altitude Derate Troubleshooting, "High Altitude Derate Occurrance"
• E012(2) High Crankcase Pressure Derate Troubleshooting, "Crankcase Pressure Is High"
I E013(3) High Crankcase Pressure Shutdown Troubleshooting, "Crankcase Pressure Is High"
I E015(2) High Engine Coolant Temperature Derate Troubleshooting, "Coolant Temperature Is High"
E016(3) High Engine Coolant Temperature Shutdown Troubleshooting, "Coolant Temperature Is High"
I E017(1) High Engine Coolant Temperature Warning Troubleshooting, "Coolant Temperature Is High"
(2) Hlg p g, p g
E031 (2) Air Filter Restriction Derate Troubleshooting, "Inlet Air Is Restricted"
I E038(1) Low Engine Coolant Temperature Warning Troubleshooting, "Coolant Temperature Is Low"
E040(3) Low Engine Oil Pressure Shutdown Troubleshooting, "Oil Pressure Is Low" I
E043(1) Low System Voltage Warning Troubleshooting, "Electrical Power Supply - Test"
E095(1) Fuel Filter Restriction Warning Troubleshooting, "Fuel Filter Is Restricted"
E099(1) Engine Oil Filter Restriction Warning Troubleshooting, "Oil Filter Differential Pressure Problem"
E100(1) Low Engine Oil Pressure Warning Troubleshooting, "Oil Pressure Is Low"
I E101(1) High Crankcase Pressure Warning Troubleshooting, "Crankcase Pressure Is High"
i
E173(1) High Exhaust Temperature Warning i Troubleshooting, "Exhaust Temperature Is High"
E190(1) Engine Overs peed Warning Troubleshooting, "Engine Overspeeds"
E272(1) Inlet Air Restriction Warning Troubleshooting, "Inlet Air Is Restricted"
E279(1) High Aftercooler Temperature Warning I Troubleshooting, "Coolant Temperature Is High"
~u -11J:
Section
Parts of the Event Code

Event Code - The "E" identifies the code as an
event code. The "XXX (X)" represents a numeric
identifier for the event code. The fourth U(X)" assigns
one of three levels to the active event code according
4.8 VDC
Diagnostic Code
(Electronic Problem) 3
-
The temperature is too
to the severity of the abnormal system condition. This high but there
is followed by a description of the code. Refer to the is not an

Event Code 2
electronic
following example: problem
4.2VDC
• E360(1) Low Oil Pressure 107°C (225 OF)
• E360(2) Low Oil Pressure
• E360(3) Low Oil Pressure
The definition for the levels of severity for an event

are defined below:
Normal
Level 1 - Level 1 alerts the operator that an engine Engine
system requires attention. The operator should check Operating
the involved system condition or the operator should Range
perform maintenance on the involved system at the

earliest possible time.
Level 2 - Level 2 requires a change in the operation

of the engine or the performance of a maintenance
procedure. Failure to correct the problem that caused
this warning may result in damage to the engine
components.
Level 3 - Level 3 requires an immediate safe

shutdown of the engine in order to avoid damage to
the engine or injury to personnel around the engine.
0.2 VDC ~--------------------------------------.
Diagnostic Code
(Electronic Problem) 3 -
The problem that caused the event must be corrected Illustration 15
g01136660
before engine operation can resume.
Example of the typical operating range of a temperature sensor
(1) This area represents the normal operating range of the
Active Event Codes parameter. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC.
An active event code represents a problem with (2) In this area, the temperature above 107°C (225 OF) is higher
than normal. The output voltage of the sensor will generate an
engine operation. Correct the problem as soon as event code. The sensor does not have an electronic problem.
possible. (3) In these areas, the output voltage of the sensor is too high
or too low. The voltage is outside of the normal range. The
Active event codes are listed in ascending numerical electronic problem will generate a diagnostic code. Refer to
order. The code with the lowest number is listed first. Troubleshooting, "Diagnostic Trouble Codes" for additional
information on diagnostic codes.
Illustration 15 is an example of the operating range of

a temperature sensor. Do not use the Illustration to Logged Event Codes
troubleshoot temperature sensors.
When the Electronic Control Module (ECM)
generates an event code, the ECM logs the code
in permanent memory. The ECM has an internal
diagnostic clock. The ECM will record the following
information when an event code is generated:
• The hour of the first occurrence of the code
• The hour of the last occurrence of the code
• The number of occurrences of the code

.
Logged events are listed in chronological order. The
most recent event code is listed first.
KENR5404-03 31
Section
This information can be helpful for troubleshooting Be sure to check the connectors. This is very
intermittent problems. Logged codes can also be important for problems that are intermittent. Refer to
used to review the performance of the engine. Troubleshooting, "Inspecting Electrical Con nectars".
If these steps do not resolve the problem, refer to

Clearing Event Codes Table 10 for the procedure to troubleshoot the event
code.
A code is cleared from memory when one of the
Trip Points for the "Caterpillar
• The code does not recur for 100 hours. Monitoring System"
" A new code is logged and there are already ten
The monitoring system determines the level of action
codes in memory. In this case, the oldest code is
that is taken by the ECM in response to a condition
cleared.
that can damage the engine. When any of these
conditions occur, the appropriate event code will be
.. The service technician manually clears the code.
generated.
Always clear logged event codes after investigating
Table 11 contains the parameters that are monitored
and correcting the problem which generated the
and the appropriate event code(s) that can be
code.
generated for that parameter. Table 11 also contains
the minimum and maximum ranges for the parameter
Troubleshooting and the default trip points for each parameter. The
actual settings for each parameter can be viewed
For basic troubleshooting of the engine, perform the with Caterpillar Electronic Technician (ET). The trip
following steps in order to diagnose a malfunction: points for some of the parameters may be adjustable
with Cat ET
1. Obtain the following information about the
complaint:
.. The event and the time of the event
.. Determine the conditions for the event. The

conditions will include the engine rpm and the
load.
" Determine if there are any systems that were

installed by the dealer or by the customer that
could cause the event.
.. Determine whether any additional events

occurred.
2. Verify that the complaint is not due to normal

engine operation. Verify that the complaint is not
due to error of the operator.
3. Narrow the probable cause. Consider the operator

information, the conditions of operation, and the
history of the engine.
4. Perform a visual inspection. Inspect the following

iiems:
• Fuel supply
• Oil level
.. Oil supply
.. Wiring
" Connectors
j;l KENR5404-03
Table 11
Monitoring System Parameters
Parameter
I
i
Action
I
Delay Time in Seconds
Min Max i Default Min
Trip Point
Max Default
I Default
State I
-'
E007(2) High Aftercooler
Temperature Derate Warning i 1 60 I 5
40°C
(104 OF)
10rC
(225 OF)
10rC
(225 OF) On
i E008(3) High Aftercooler 40 ·C 10rC 10rC

Shutdown! 1 60 I 5 On
Temperature Shutdown (104 OF) (225 OF) I (225 OF)
I
E009(2) High Altitude
Derate
Derate(1) NfA ! NfA I 0
250 m
(820 ft)
4562 m I
(14967 ft) .
762 m
(2500 ft)
On
I
E012(2) High Crankcase Derate(2) i
60 I 0.5 kPa 6 kPa i 6 kPa i
1 10 On
Pressure Derate I (0.1 psi) (0.9 psi) ! (0.9 psi)
I I
E013(3) High Crankcase
Pressure Shutdown I Shutdown 1 60
i
3 I 0.5 kPa I• (0.9
6 kPa 3.5 kPa
(0.5 psi)
I On
I I (0.1 psi) psi) I
E015(2) High Engine
i Coolant Temperature
Derate
1 60
i
30 90°C I 107°C 107 °c
On
(3) (194 OF) • (225 OF) (225 OF)
Derate
E016(3) High Engine
Coolant Temperature Shutdown 1 60 5
90°C I 107 DC 107°C
On
i (194 OF) . (225 OF) (225 OF)
Shutdown
E017(1) High Engine
90°C 102°C 102 °c
Coolant Temperature Warning 1 60 5 On
(194 OF) (216 OF) (216 OF)
Warning
E021 (2) High Exhaust
Temperature Derate
Derate(4) 1
I 60 I 5
500°C I 800°C
i
750 °c
(1382 OF) On
-
(932 OF) (1472 OF)
I I
E031 (2) Air Filter I
Derate 1 60 5 1 kPa I 7 kPa
7 kPa (1 psi) On
Restriction Derate (0.14 psi) i (1 psi)
E038(1) Low Engine
Coolant Temperature Warning 1 60 5
! 63°C I 85 ·C 80°C
On
Warning
(145 OF) (185 OF) J (176 OF)
i
: ED40(3) Low Engine Oil
Pressure Shutdown Shutdown I 1 15 ! 9 NfA NfA I (5)
On
!
E043(1) Low System I Warning I
1 30 10 20VDC 22VDC 20VDC On
Voltage Warning ! 1
I E095(1) Fuel Filter 70 kPa 105 kPa 105 kPa
. Restriction Warning
Warning 1 60 5
(10 psi) (15 psi) 1 (15 psi) ! On
E099(1) Engine Oil Filter 70 kPa 105 kPa i 105 kPa

Warning 1 60 5 On
Restriction Warning (10 psi) (15 psi) 1 (15 psi) I
E100(1) Low Engine Oil (5)
Warning 1 15 4 NfA NfA i On
Pressure Waming
I
E101(1) High Crankcase
Warning 1 60 3 I 0.5 kPa I 6 kPa 2 kPa
On
Pressure Warning i (0.1 psi) • (0.9 psi) (0.3 psi)
i
E173(1) High Exhaust Warning I I 600°C 500 °c 800 ·C
1 60 5 i
On
Temperature Warning ! I (1112 OF) (932 OF) (1472 OF)
I
E190(1) Engine
Warning I 1 60 5 11200 rpm 2400 rpm
Application I On
Overspeed Warning I I
Dependent .
i E272(1) Inlet Air
. Restriction Warning
Warning I 1 I 60 5 I 3 kPa
I (0.4 psi) psi) .1 7 kPa (1 pSI).
7 kPa
(1 I
i On
~9(1) High Aftercooler

Temperature Warning
--.~-- ..
Warning 1 60 I 5 I
i
40°C
(104 OF)
102°C
(216 OF) I
102 °c
(216 OF)
I
i
on]
(continued)
-
KENR5404-03 33
(Table 11, contd)
Monitoring System Parameters

Delay Time in Seconds Trip Point
Parameter Action
Default
Min Max Default
Min Max Default State
400 kPa 400 kPa 400 kPa
High Boost Pressure Derate
N/A N/A 0
(58 psi) (58 psi) (58 psi)

On
High Transmission Oil 20°C 120°C 99°C

Warning
1 120 5
On
Tem perature(6) (68 OF) (248 OF) (210 OF)
Low Transmission Oil 900 kPa 2900 kPa 1500 kPa
Warning
1 60 5
On
Pressure(6) (131 psi) (421 psi) (218 psi)
Low Engine Coolant
Levei(6) Warning
1 120 10
N/A N/A ON On
(1) The ECM will derate the engine in 3 percent increments for every 305 m (1000 ft) increase in elevation up to a maximum derate of 35 percent.
(2) The ECM limits the fuel above the default crankcase pressure of 6 kPa (24 inches of H2 0). The ECM derates the engine from 0 percent to a
maximum derate of 15 percent over a period of 480 seconds when the crankcase pressure is above 6 kPa (24 inches of H 2 0).
(3) If the trip point for the derate is exceeded the derate will reduce power linearly from 0 percent to a maximum of 25 percent over a
period of 480 seconds.
(4) If the trip point is exceeded, engine power will be derated 2 percent for each 15 second time period. The maximum derate is 20 percent.
(5) Refer to the oil pressure map in Illustration 16.
(6) Optional equipment
Note: The engine monitoring system is enabled after

the engine is started. The ECM delays monitoring
some parameters at start-up. The delay is designed
to eliminate false warnings. The following parameters
have a delay at start-up.
• The delay for low engine oil pressure is 10 seconds.
• The delay for high transmission oil temperature is

30 seconds.
• The delay for low transmission oil pressure is 30

seconds.
• The delay for low engine coolant temperature is

600 seconds.
o The delay for low engine coolant level is 60

seconds.
J4
Oil Pressure Map
Hysteresis = 20kPa
240 \
220 1\
,,'
200
I \ " '"
~/'" /
1,.'"
~
180 , V
[, ...... /'
160
Oil 140 .i"

""",
V
Pressure 1",,"" . /
V
(kPa) 120
,,'"
---------1---
100 .
" V
89
./
80
60 -
40
20 -
00 I
I I
350 450 550 650 750 850 950 1050 1150 1250
Engine Speed (RPM)
Illustration 16 901027393
Oil pressure map

KENR5404-03 35
.. Determine if the logged diagnostic codes occur
at the same time as the symptoms.
i02581026 • Determine if the logged diagnostic codes are

logged repeatedly.
If these inspections do not reveal any problems, use
SMCS Code: 7569 the procedure that best describes the symptoms.
Some engine symptoms can be unrelated to the

electronic control system. Gather information about i02627888
the complaint that describes the symptoms. Verify
that the complaint is not due to normal engine
Acceleration Is Poor or Throttle
operation. Response Is Poor
Perform the following steps in order to determine the SMCS Code: 1000-035
problem.
1. Repair all active diagnostic codes.

Probable Causes
2. Gather operator information. • Fuel supply
3. Verify that the complaint is not due to normal • Engine derate or active codes
engine operation.
• Cold mode
4. Perform a visual inspection of the engine. Inspect
the following items: • Flash file
• Throttle signal
• Wiring
.. Connectors
• Electrical connectors
.. Fuel level
• Unit injectors
• Air inlet and exhaust system

• Fuel supply
.. Engine oil level

Recommended Actions
.. Engine oil supply
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
.. Coolant level
Examples of certain conditions are high engine
speed, full load and engine operating temperature .
.. Intake air system
Troubleshooting the symptoms under other
conditions can give misleading results .
.. Air exhaust system
Fuel Supply
5. Check the wiring and the connectors for the
following problems: 1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel
.. Damage to the fuel tank. If the engine has been run out of
fuel, it will be necessary to purge the air from the
.. Abrasion
fuel system. Refer to Operation and Maintenance
Manual for the correct procedure.
e Corrosion
2. Check the fuel lines for the following problems:

• Incorrect attachment restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
6. Check for any logged diagnostic codes. lines and/or replace the lines.
• Determine if the logged diagnostic codes 3. Check the fuel tank for debris or foreign objects
correlate to probable causes. which may block the fuel supply.
,;)0
Cold Mode
NOTICE
Do not crank the engine continuously for more than The Electronic Control Module (ECM) limits engine
30 seconds. Allow the starting motor to cool for two power during cold mode operation. The ECM may
minutes before cranking the engine again. modify the injection timing and the ECM may cut out
certain engine cylinders. This will increase startability
and this will reduce warm up time. Cold mode is
4. Prime the fuel system if any of the following activated whenever the engine coolant temperature
procedures have been performed: falls below a predetermined value. Cold mode
remains active until the engine has warmed or a time
• Replacement of the fuel filters limit is exceeded.
• Service on the low pressure fuel supply circuit

Flash File
• Replacement of unit injectors Verify that the latest flash file is installed in the ECM.
Note: Check the fuel system for air. Refer to Systems
Operation/Testing and Adjusting for information that Throttle Signal
is related to checking the fuel system for air.
Monitor the status for "Throttle Position" on Cat ET.
5. Check fuel quality. Cold weather adversely Verify that the status for "Throttle Position" is stable
affects the characteristics of the fuel. Refer to the and that the engine is able to reach high idle speed.
engine's Operation and Maintenance Manual for If a problem is suspected with the throttle, refer
information on improving the characteristics of the to the appropriate troubleshooting procedure for
fuel during cold weather operation. troubleshooting the throttle signal.
6. Check the filtered fuel pressure while the Electrical Connectors

engine is being cranked. Refer to Systems
OperationlTesting and Adjusting for the test Check for correct installation of the J1/P1 and
procedure and for the correct pressure values. J2/P2 ECM connectors and the connectors for the
unit injectors. Refer to Troubleshooting, "Electrical
If the fuel pressure is low, replace the fuel filters. Connectors - Inspect".
Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual Unit Injectors
for details.
1. Perform the "Injector Solenoid Test" on Cat ET in
If the fuel pressure is still low, check the operation order to determine if all of the injector solenoids
of the fuel pressure regulating valve. Also, check are being energized by the ECM.
for the proper operation of the fuel transfer pump.
Refer to Systems OperationlTesting and Adjusting 2. Perform the "Cylinder Cutout Test" on Cat ET
for test information. in order to determine the performance of each
cylinder. Refer to Troubleshooting, "Injector
Engine Derate or Active Codes Solenoid Test" for the proper procedure.
Some engine monitoring parameters that are capable Air Inlet and Exhaust System
of triggering an engine derate do not produce an
event code. Connect Caterpillar Electronic Technician 1. Observe the check engine lamp. Check for an
(ET) in order to check for a derate of the engine. air filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the
Certain diagnostic codes and/or event codes may Operation and Maintenance Manual.
cause poor performance. Use Cat ET to check for
active codes and for logged codes. Troubleshoot any 2. Check the air inlet and exhaust system for
codes that are present before continUing with this restrictions and/or leaks. Refer to Systems
procedure. Operation/Testing and Adjusting for information on
inspecting the air inlet and exhaust system.
Note: Although a sensor's Signal may be in the
operational range of the sensor, the signal may
not represent the actual reading. Use Cat ET to
check that the pressures and the temperatures are
fluctuating. Also check that the values are reasonable
for the conditions that are present.
KENR5404-03 37
h,........Hnn Section
i02627904 Recommended Actions

Air Starting Motor Problem Condition of the Alternator Drive Belts
SMCS Code: 1451-035
1. Inspect the condition of the alternator drive belts.
If the alternator drive belts are worn or damaged,
Probable Causes replace the belts.
• Diagnostic codes 2. Check the belt tension. If the engine is equipped

with an automatic belt tensioner, check the
• Low air pressure automatic belt tensioner. If necessary, replace the
automatic belt tensioner.
• Air starting motor
Note: Excessive belt tension can result in damage to
Recommended Actions the alternator.
Diagnostic Codes Condition of the Alternator Drive Pulley
Verify that there are no diagnostic codes for the Check the condition of the alternator drive pulley.
starting motor relays. If there are diagnostic codes Look for deep grooves that have been worn into the
for the starting motor relays, perform the appropriate pulley by the belt. If there is excessive wear, replace
troubleshooting procedure. the pulley. Check that the nut for the pulley has not
become loose. If necessary, tighten the nut.
Low Air Pressure Note: Make sure that the alignment is correct.
Ensure that the air pressure is adequate for the
starting system. If necessary, charge the system. Wear of the Alternator Bearings
Check the alternator bearings for signs of wear.
Air Starting Motor Repair the alternator or replace the alternator, as
needed.
Refer to the Systems OperationfTesting and Adjusting
manual for information on the air starting motor.
Operation of the Alternator or Regulator
i03372684 Verify that the alternator or the regulator is operating
correctly. Refer to Special Instruction, REHS0354,
Alternator Problem "Charging System Troubleshooting" for the proper
(Charging Problem and/or testing procedures. Repair the alternator or replace
the alternator, as needed.
Noisy Operation)
SMCS Code: 1405-035
Inspection of the Charging Circuit
Inspect the battery cables, wiring, and connections in
Probable Causes the charging circuit. Clean all connections and tighten
ali connections. Replace any faulty parts.
Alternator
i02726474
• Condition of the alternator drive belts
Coolant Contains Fuel
• Condition of the alternator drive pulley
SMCS Code: 1250-035; 1395-035
• Condition of the alternator bearings
• Operation of the regulator Probable Causes

.. Injector sleeve or injector sleeve seal
Charging Circuit
• Inspection of the charging circuit
",.."hf"'lf"'ltinl"l Section
Recommended Actions i02669797
Injector Sleeve or Injector Sleeve Seals

1. Remove the valve mechanism covers.
Coolant Contains Oil
SMCS Code: 1348-035; 1395-035 -
2. Remove the fuel injectors from the cylinder head. Probable Causes
Refer to the Disassembly and Assembly manual • Engine oil cooler core
for details.
• Cylinder head gasket
ii,W4R[\JII\i(; . • Cylinder head
Personal injury can result from hot coolant, steam
• Cylinder liner
and alkali.
• Cylinder block
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or Recommended Actions
steam. Any contact can cause severe burns.
Engine Oil Cooler Core
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool 1. Check for leaks in the oil cooler core. If a leak is
enough to touch with your bare hand. found, install a new oil cooler core. Refer to the
Disassembly and Assembly manual.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes. 2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters.
3. Pressurize the cooling system in order to identify Refer to the Operation and Maintenance Manual.
the injector sleeve that is leaking. Closely inspect ~
the sealing joint around the top of the injector Cylinder Head Gasket
sleeve. Small amounts of coolant will be dripping
from the injector sleeve that is leaking. 1. Remove the cylinder head. Refer to the
Disassembly and Assembly manual.
Note: Do not allow the pressure on the cooling
system to exceed 103 kPa (15 psi) during the test. 2. Check the cylinder liner projection. Refer to the
Damage to the cooling system may result from Systems OperationfTesting and Adjusting manual.
applying excessive pressure.
3. Install a new cylinder head gasket and new water
Refer to the Systems OperationfTesting and seals in the spacer plate. Refer to the Disassembly
Adjusting manual for details. and Assembly manual.
4. Remove the injector sleeve that is leaking. Cylinder Head

Carefully inspect the sleeve for damage. If there
are visible signs of damage to the injector sleeve, Check for cracks in the cylinder head. If a crack
replace the sleeve. Replace the O-ring seals is found, repair the cylinder head and/or replace
for the injector sleeve and reinstall the sleeve. the cylinder head. Refer to the Disassembly and
Replace any damaged components. Assembly manual.
Note: Coolant may also be contaminating the fuel
system. After the engine is shutdown, the retention
Cylinder Liner
of pressure in the cooling system may cause the
Check for cracked cylinder liners. Replace any
transfer of coolant into the fuel system. Visually
cracked cylinder liners. Refer to the Disassembly and
inspect the fuel tank for coolant. The contamination
Assembly manual.
of coolant in the fuel system may cause damage to
injectors and other fuel system components. Ensure
that all of the fuel system components are in good Cylinder Block
repair prior to returning the engine to service. ~
Inspect the cylinder block for cracks. If a crack is
found, repair the cylinder block or replace the cylinder
block.
KENR5404-03 39
Section
i03140025
Coolant Temperature Is High

SMCS Code: 1395-035
Use this procedure in order to troubleshoot a high

coolant temperature or use this procedure if one
of the following event codes is active. Refer to
Troubleshooting, "Event Codes" for information about
event codes and the default trip pOints for these
codes. You must access the monitoring system on
Caterpillar Electronic Technician (ET) in order to view
the current trip points for these codes.
Table 12
Code and Description Conditions which Generate this Code System Response
• E007(2) High Aftercooler Temperature The aftercooler temperature is above The engine will be derated.
the trip point temperature. The code is logged.
) High Aftercooler Temperature The aftercooler temperature is above I The engine will shut down. The code
the trip point temperature. is logged.
) High Engine Coolant The engine coolant temperature is I The engine will be derated.
ature Derate above the trip point temperature. The code is logged,
E016(3) High Engine Coolant The engine coolant temperature is The engine will shut down. The code
Temperature Shutdown above the trip point temperature. is logged.
E017(1) High Engine Coolant The engine coolant temperature is The code is logged.
Temperature warning
above the trip point temperature.
E279(1) High Aftercooler Temperature The aftercooler temperature is above The code is logged.
Warning
the trip point temperature.
Probable Causes Recommended Actions

• Low coolant level Low Coolant Level
.. Quality of coolant Inspect the coolant level. If necessary, add coolant.
• Air in cooling system
Quality of Coolant
.. Radiator
Check the quality of the coolant. The coolant should
.. Coolant leak have the following properties:
.. Faulty radiator cooling fan (if applicable) • Color that is similar to new coolant
.. Odor that is similar to new coolant

• Damaged hoses
.. Faulty temperature regulator .. Free from contamination
.. Properties that are recommended by the engine's

• Faulty jacket water coolant pump
Operation and Maintenance Manual
.. Aftercooler
If the coolant does not have these properties, drain
e Load on the system the system and flush the system. Refill the cooling
system according to the engine's Operation and
Maintenance Manual.
4U
Section
Air in Cooling System Faulty Jacket Water Coolant Pump

Check for air in the cooling system. Air can enter Inspect the impeller vanes at the jacket water pump
the cooling system in different ways. The following for damage and/or for erosion. Repair impeller vanes
conditions cause air in the cooling system: and/or replace the impeller vanes.
• Filling the cooling system incorrectly Aftercooler

• Combustion gas leakage into the cooling system A restriction of water flow through the aftercooler
can cause overheating. Check for debris or deposits
Combustion gas can get into the system through which restrict the free flow of water through the
the following conditions: internal cracks, damaged aftercooler.
cylinder head, and damaged cylinder head gasket.
Load on the system
Radiator
Check that the engine is not loaded beyond design.
Check the COOling fins on the radiator for dirt and/or
for debris. Remove the dirt and/or debris.
i03140031
1. Check the cooling fins on the radiator for damage.
Refer to the Systems Operationffesting and Coolant Temperature Is Low
Adjusting manual for instructions for testing and
inspecting the COOling system. SMCS Code: 1395-035
2. Check the radiator for internal blockage. Check Use this procedure in order to troubleshoot a
the temperature difference between the inlet and low coolant temperature or use this procedure
the outlet of the radiator. if the following event code is active. Refer to
event codes and the default trip points for these
Coolant Leak codes. You must access the monitoring system on
Check the cooling system for leaks. the current trip points for these codes.
1. Inspect the coolant for presence of bubbles.
Faulty Engine Cooling Fan (if applicable)

Check for proper operation of the cooling fan.
Damaged Hoses
Damaged hoses with leaks can normally be seen.
Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
kinked or crushed during operation. These areas of
the hose restrict the coolant flow. Hoses can crack
after a period of time. The inside of a hose can
deteriorate and the loose particles of the hose can
restrict the coolant flow.
Faulty Temperature Regulator

A water temperature regulator that does not open or
a water temperature regulator that only opens part of
the way can cause overheating.
A water temperature regulator that does not close

enables overcooling.
KENR5404-03 41
Section
Table 13
Event Code
Code and Description Conditions which Generate this Code i System Response
E038(1) Low Engine Coolant The coolant temperature is below the ! The code is logged.
Temperature Warning trip point temperature.
Probable Causes
.. Faulty water temperature regulator
• Very light loads
Recommended Actions
Water Temperature Regulator
A regulator that is stuck open can cause overcooling.
Overcooling also occurs when the water temperature
regulator is stuck between the following positions:
open position and closed position. Coolant leaks
that are around the water temperature regulator can
cause overcooling. An example would be a leak in
the vent line.
Very light Loads

Very light loads or a very slow engine speed can
cause overcooling. This overcooling is caused by the
low heat input of the engine.
i03140041
Crankcase Pressure Is High

SMCS Code: 1201-035-PX

crankcase pressure or use this procedure if one
Table 14
Event Code
.......................................................
E012(2) High Crankcase Pressure Engine crankcase pressure is above the The code is logged. The engine will be
Derate trip point pressure for the delay time. derated.
E013(3) High Crankcase Pressure The code is logged. The engine will
Shutdown shut down.
E101(1) High Crankcase Pressure The code is logged.
Warning
.... '"
Section

• Worn engine components
• Plugged crankcase breather

Low Quality Fuel
Refer to Operation and Maintenance Manual for
information on the proper characteristics of the fuel.
-
Recommended Actions Obtain a fuel analysis.
Engine Components Electrical Connectors
Damaged pistons or rings can cause too much Check for the correct installation of the connector(s)
pressure in the crankcase. This condition will cause for the Electronic Control Module (ECM) J1/P1 and/or
the engine to run rough. There will be more than the J2/P2. Check for correct installation of the applicable
normal amount of fumes (blowby) rising from the fuel injector connectors. Repair the connector and/or
crankcase breather. The breather can then become replace the connector. Refer toTroubleshooting,
restricted in a very short time, causing oil leakage "Electrical Connectors - Inspect".
at gaskets and seals that would not normally have
leakage. Blowby can also be caused by worn valve Injector
guides or by a failed turbocharger seal.
Use Caterpillar Electronic Technician (ET) to
Crankcase Breather determine if any diagnostic codes for the injector
solenoids are present. Perform the "Injector Solenoid
A plugged crankcase breather will cause excessive Test". Observe that the injector solenoids are being
crankcase pressure. Leakage of the crankshaft seal energized on Cat ET. Perform the "Cylinder Cutout
can occur. Sealing of the piston rings can be lost. Test". Locate the misfiring cylinder. Refer to the
This will enable crankcase blowby to further increase diagnostic functional test Troubleshooting, "Injector
the crankcase pressure. Solenoid - Tese
-
The 8T -2700 Blowby/Air Flow Indicator is used Not Enough Lubrication
to check the amount of blowby. Refer to Special
Instruction, SEHS8712, "Using the 8T - 2700 Check the lubrication in the valve compartment.
Blowby/Air Flow Indicator" for the test procedure for Check for sufficient lubrication between the injector
checking the blowby. tappet and the rocker arm buttons. Check for blocked
oil passages. Oil passages must be clean. Ensure
that the oil passages that send oil to the cylinder
i02610496
heads are clean.
Cylinder Is Noisy
Valve Lash
SMCS Code: 1223-035
Check the valve lash. Refer to the diagnostic
procedure Troubleshooting, "Valve Lash Is
Probable Causes Excessive" .
• Low quality fuel
Damage to Valve Train Components
Remove the valve cover from the suspect cylinder(s).
• Injector Check the following items for damage: camshaft,
valve rotocoil, valve springs, lifters, pushrods, and
• Not enough lubrication bridges. Check for valves that do not move freely.
Remove the cylinder head. Inspect the valves.
• Too much valve lash Replace any damaged parts.
• Damage to valve train components Failure of Connecting Rod Bearing

• Failure of connecting rod bearing Inspect the connecting rod bearings and the bearing
-
surfaces Uournals) on the crankshaft. Check the
piston pin for excessive wear. Replace any damaged
parts.
KENR5404-03 43
Section
i03648660 i02610526
ECM Does Not Communicate Engine Cranks but Does Not

with Other Modules Start
SMCS Code: 1901-038 SMCS Code: 1000-035; 1450-035
Probable Causes Probable Causes

Electronic Control Module (ECM) • Diagnostic codes
• Power to the ECM • Event codes
• Fuel supply
Data Link
• Electrical power supply to the Electronic Control
.. Problem in the circuit for the Cat Data Link or the Module (ECM)
CAN data link
• Starting aids (if applicable)
Electrical connectors
• Engine shutdown switches (if applicable)
• Installation of electrical connectors
• Engine speed/timing
Recommended Actions
• Unit injectors
Power to the ECM • Combustion
Check for power to the ECM. Refer to
Troubleshooting, "Electrical Power Supply - Test". Recommended Actions
Connect Caterpillar Electronic Technician (ET) Diagnostic Codes, Event Codes, and
to the service tool connector. If the ECM does
Electrical Power Supply to the ECM
not communicate with Cat ET, refer to service
Troubleshooting, "Electronic Service Tool Does Not
Certain diagnostic codes and/or event codes may
Communicate" .
prevent the engine from starting. Connect Caterpillar
Electronic Technician (ET) and check for active codes
Problem in the Circuit for the Cat Data and/or for logged codes. Troubleshoot any codes that
Link or the CAN Data link are present before continuing with this procedure.
Verify that the data link does not have an open or Note: If Cat ET will not communicate with the
short circuit. Refer to the circuit tests Troubleshooting, ECM, the problem is most likely with the electrical
"Cat Data Link - Test" or refer to the circuit tests power supply to the ECM. Refer to Troubleshooting,
Troubleshooting, "CAN Data Link - Test". "Electrical Power Supply - Test".
Installation of Electrical Connectors Fuel Supply

Check for correct installation of the J1/P1 and J2/P2 1. Visually check the fuel level. Do not rely on the fuel
ECM connectors. Check for correct installation of gauge only. If necessary, add fuel. If the engine
all other applicable connectors. Refer to service has been run out of fuel, it will be necessary to
Troubleshooting, "Electrical Connectors - Inspect". prime the fuel system. Refer to Operation and
Maintenance Manual for the correct procedure.

restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
3. Check the fuel tank for foreign objects which may

block the fuel supply.
44
Note: Upon initial cranking. the status for engine

NOTICE speed may indicate that the engine speed signal is
Do not crank the engine continuously for more than abnormal. This message will be replaced with an
30 seconds. Allow the starting motor to cool for two engine speed once the ECM is able to calculate a
minutes before cranking the engine again. speed from the signal.
2. Ensure that the timing reference gear is installed

4. Prime the fuel supply system if any of the following correctly. The engine will not start if the gear was
procedures have been performed: installed backward. Check for proper orientation
between the crankshaft and camshaft drive gears.
• Replacement of the fuel filters Correct the orientation and/or replace the drive
gear, if necessary. Refer to the Disassembly and
• Service on the low pressure fuel supply circuit Assembly manual.
• Replacement of unit injectors

Unit Injectors
Note: A sight glass in the supply line is helpful in
Perform the "Injector Solenoid Test" on Cat
diagnosing air in the fuel. Refer to the Systems
ET in order to determine if all of the injector
Operation/Testing and Adjusting manual for more
solenoids are being energized by the ECM. Refer
information.
to Troubleshooting. "Injector Solenoid - Test" for
additional information.
5. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving Combustion
the characteristics of the fuel during cold weather
operation. Check for mechanical problems in the combustion
system.
6. Check fuel flow after the fuel filters. If the fuel flow
is low, replace the fuel filters. If the fuel flow is still ;03123741
low, check the following items: fuel transfer pump.
fuel transfer pump coupling, and fuel pressure Engine Does Not Crank
regulating valve.
SMCS Code: 1000-035; 1450-035
Starting Aids (if applicable)
Probable Causes
1. If cold ambient conditions exist, check operation
of starting aids. Verify that the ether system is • Batteries
operating correctly. Refer to Troubleshooting.
"Starting Aid - Test". • Battery cables
2. Ensure the proper operation of the jacket water • Starting circuit
heater. Repair the jacket water heater and/or
replace the jacket water heater, if necessary. • Starting motor solenoid
3. Check for presence of solidified fuel (wax). • Starting motor
Engine Shutdown Switches (if applicable) • Flywheel ring gear
The engine shutdown switches should be in the • Transmission (if applicable)

OFF position. Use Cat ET to verify the status of the
shutdown switches. When a shutdown occurs. the • Engine accessories
keyswitch must be turned to the OFF position for at
least 15 seconds before restarting the engine. • Hydraulic cylinder lock
Engine SpeedlTiming • Internal engine problem
1. Crank the engine and observe the engine speed

on the Cat ET status screen. If Cat ET indicates
zero rpm, refer to Troubleshooting, "SpeedlTiming
Test".
KENR5404-03 45
Section
Recommended Actions Note: Drain the fuel from the cylinder head. Fuel will
flow from the cylinder head into the cylinders when
Batteries and/or Battery Cables the unit injector is removed.
1. Inspect the main power switch, battery posts, Internal Engine Problem
and battery cables for loose connections and
for corrosion. If the battery cables are corroded, Disassemble the engine. Refer to the Disassembly
remove the battery cables and clean the battery and Assembly manual. Inspect the internal
cables. Tighten any loose connections. components for the following conditions:
2. Inspect the batteries. .. Seizure
a. Charge the batteries. Refer to Special

.. Broken components
Instruction, SEHS7633, "Battery Test
Procedure".
• Bent components
b. Load test the batteries. Refer to Special

i03506600
Instruction, SEHS9249, "Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries".
Engine Has Early Wear
SMCS Code: 1000-035; 1200-035
Starting Motor Solenoid or Starting
Circuit Probable Causes
1. Test the operation of the starting motor solenoid.
Engine Oil
2. Check the wiring to the starting motor solenoid.
• Incorrect maintenance intervals
Starting Motor or Flywheel Ring Gear .. Contaminated engine oil
1. Test the operation of the starting motor. • Low oil pressure

2. Inspect the pinion for the starting motor and the
flywheel ring gear for damage. Contaminated Air
.. Leaks in air intake system
Transmission (if applicable) or Engine
Accessories Contaminated Fuel
1. Ensure free movement of the driveline. .. Inspect the fuel filters for contamination.
2. Remove any engine accessories that may lock up

the engine and inspect any engine accessories Recommended Actions
that may lock up the engine.
Incorrect Maintenance Intervals
The following list illustrates examples of engine
accessories that may lock up the engine: Use engine oil that is recommended and change the
engine oil at the interval that is recommended by the
• Hydraulic pump that is driven from the rear gear engine's Operation and Maintenance Manual.
group
Contaminated Engine Oil
• Air compressor
Drain the crankcase and refill the crankcase with
• Engine oil pump clean engine oil. Install new engine oil filters. Refer to
the engine's Operation and Maintenance Manual.
.. Other components that are driven by the engine
If the oil filter bypass valve is open, the oil will not be
Hydraulic Cylinder Lock filtered. Check the oil filter bypass valve for a weak
spring or for a broken spring. If the spring is broken,
Check for fluid in the cylinders (hydraulic cylinder replace the spring. Refer to the engine's Disassembly
lock) by removing the individual unit injectors. and Assembly manual. Make sure that the oil bypass
valve is operating correctly.
40
Low Oil Pressure Recornmended Actions

When some components of the engine show bearing
wear in a short time, the cause can be a restriction in
a passage for engine oil.
Isolate the Source of the Noise
Isolate the source of the noise. Remove the suspect
engine accessory. Inspect the suspect engine
-
An indicator for the engine oil pressure may indicate accessory. Repair the engine accessory and/or
sufficient pressure, but a component is worn due replace the engine accessory, if necessary.
to a lack of lubrication. In such a case, look at the
passage for the engine oil supply to the component.
Valve Train Components
Leaks in Air Intake System Remove the valve mechanism cover and the
camshaft covers. Check the following items for
A leak in the air intake system may allow unfiltered damage: camshaft, valve springs, lifters, pushrods,
air into the engine. Inspect the air intake system for and bridges. Thoroughly clean the valve train
streaks which may indicate a leakage of unfiltered air. components. Ensure that all of the valves move
Inspect all of the gaskets and the connections. Repair freely. Replace any damaged parts.
any leaks. Refer to Systems Operation, Testing and
Adjusting for more information. During engine operation at rated speed, the valve
rotation can be observed and measured.
Inspect the air filter. Replace the air filter, if necessary.
Pistons
Inspect the Fuel Filters for Contamination
Inspect the pistons for damage and wear. Replace
1. Remove the fuel filters. Inspect the fuel filters for any damaged parts.
contamination. Instali new fuel filters. Refer to the
Operation and Maintenance Manual. Determine
the cause of the contamination.
Crankshaft
2. Contaminants in the fuel such as hydrogen sulfide Inspect the crankshaft and the related components.
and sulfur can lead to the formation of acids in the Inspect the connecting rod bearings and the bearing
~
crankcase. Obtain a fuel analysis. surfaces on the crankshaft. Make sure that the
bearings are in the correct position. Look for worn
thrust plates and wear on the crankshaft. Check the
i03385119 counterweight bolts. Replace any damaged parts.
Engine Has Mechanical Noise Gear Train

(Knock)
Inspect the condition of the gear train. Inspect the
SMCS Code: 1000-035 engine oil filters for nonferrous material. Replace any
damaged parts.
Probable Causes
i02628186
Accessory Equipment
Engine Misfires, Runs Rough
• Isolate the source of the noise. or Is Unstable
Internal Engine Components SMCS Code: 1000-035
• Valve train components The probable root causes are listed in order below:
• Pistons Note: If the problem is intermittent and the problem

cannot be duplicated, refer to Troubleshooting,
• Crankshaft "Power Is Intermittently Low or Power Cutout Is
Intermittent".
• Gear train
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full load
and engine operating temperature. Troubleshooting
the symptoms under other conditions can give

misleading results.
KENR5404-03 47
Section
Probable Causes 7. Check the diesel fuel for contamination. Refer to

Systems OperationlTesting and Adjusting .
• Diagnostic codes
.. Fuel supply of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
• Cold mode operation and cold cylinder cutout the characteristics of the fuel during cold weather
operation.
• Throttle
Cold Mode Operation and Cold Cylinder
• Air intake and exhaust system
Cutout
" Cylinder performance
Use Cat ET in order to verify that the engine has
exited cold mode. During cold mode, fuel injection
.. Electrical connectors
timing is modified. When the engine is in cold mode,
the cold cylinder cutout strategy may be active.
.. Electronic unit injectors
Cold mode cylinder cutouts may cause variations
in vibration and available power. This is normal
.. Governor
operation.
Recommended Actions Throttle

Diagnostic Codes There may be a problem with the throttle. Refer to
Troubleshooting, USpeed Control - Test".
Check for active diagnostic codes on Caterpillar
Electronic Technician (ET). Troubleshoot any active Air Intake and Exhaust System
codes before continuing with this procedure.
1. Check the air filter restriction indicator, if equipped.
Fuel Supply Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance
1. Visually check the fuel level. Do not rely on Manual.
the fuel gauge only. If necessary, add fuel. If
the engine has been run out of fuel, it will be 2. Check the air inlet and exhaust system for
necessary to purge the air from the fuel system. restrictions and/or leaks. Refer to Systems
Refer to Operation and Maintenance Manual for OperationlTesting and Adjusting.
more information.
Cylinder Performance
2. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position. 1. Check the valve lash and reset the valve lash, if
necessary. Refer to Systems OperationlTesting
3. Check the fuel lines for the following problems: and Adjusting.
restrictions, collapsed lines, pinched lines, and
loose connections. If problems are found with the 2. Check for correct installation of the unit injector
fuel lines, repair the lines and/or replace the lines. connectors. Check for correct installation
of all other applicable connectors. Refer to
4. Prime the fuel system if any of the following Troubleshooting, uElectrical Connectors -Inspect".
procedures have been performed:
3. Perform the "Cylinder Cutout Test" on Cat ET
.. Replacement of the fuel filters in order to identify any injectors that might be
misfiring.
.. Service on the low pressure fuel su pply circuit
4. If Cat ET indicates a problem, remove the
" Replacement of unit injectors electronic unit injector from the suspect cylinder.
Refer to Disassembly and Assembly.
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems 5. Possible causes of low compression are shown
OperationlTesting and Adjusting. in the following list:
5. Check the fuel tank for foreign objects which may
• Faulty piston
• Faulty piston rings
6. Check the fuel filters.
'
4ts
• Worn cylinder bores
• Worn valves
• Faulty cylinder head gasket
• Damaged cylinder head
6. Perform all necessary repairs. Ensure that the

repairs have eliminated the problem.
7. If the repair does not eliminate the problem,

reinstall the electronic unit injectors that were
removed and continue with this test procedure.
Electronic Unit Injectors

order to determine if all of the injector solenoids
are being energized by the ECM.

in order to identify any injectors that might be
misfiring.

electronic unit injector from the suspect cylinder
and install a new electronic unit injector. Refer to
Disassembly and Assembly.
4. Ensure that the repairs have eliminated the

problem. If there is still a problem, refer to
Troubleshooting, "Injector Solenoid - Test".
Governor
Adjust the parameters for the governor in order to
maintain stability.
i03140049
Engine Overspeeds
SMCS Code: 1915-035
Use this procedure in order to troubleshoot an

engine overspeed or use this procedure if one
KENR5404-03 49
Table 15
Event Code
E190(1) Engine Overspeed Warning The engine rpm has exceeded the trip The air shutoff will be activated. The
point for engine overs peed for the delay engine will shut down.
time. Power must be cycled to the engine's
Electronic Control Module (ECM) in
order to reset the code.
The code is logged.

• Intake air is combustible. Diagnostic Codes and/or Event Codes
• Sudden drop of load Certain diagnostic codes and/or event codes may
cause an engine shutdown. Connect Caterpillar
Recommended Actions Electronic Technician (ET) and check for active codes
and for logged codes. Troubleshoot any codes that
are present prior to continuing with this procedure.
Intake Air is Combustible
Check for hydrocarbons in the surrounding Electrical Connectors
atmosphere. Do not operate the engine in an
environment with hydrocarbons in the surrounding 1. Check for correct installation of the J 1/P 1 and
atmosphere. J2/P2 connectors for the Electronic Control
Module (ECM). Also, thoroughly inspect the
connectors for the engine speed/timing sensors.
Sudden Drop of Load
Refer to Troubleshooting, "Electrical Connectors
- Inspect".
Decrease the load on the engine gradually.
2. Inspect the battery wires from the ECM to the
i02672327 battery compartment. Refer to the Schematic for
specific wiring information. Check the keyswitch
Engine Shutdown Is input to the ECM. Check the unit injector
Intermittent connectors and associated wiring for damage, or
for intermittent problems. Inspect the wires and
SMCS Code: 1900-035 connectors to all circuit protection for the engine.
Check the power and ground connections to
Note: Use this procedure only if the engine shuts the ECM. Check any engine shutdown switches
down completely during operation. and associated wiring. Refer to Troubleshooting,
"Electrical Power Supply - Test".
Probable Causes Circuit Breakers

• Diagnostic codes
Check the state of each of the circuit breakers. Reset
the circuit breakers if the circuit breakers are tripped.
• Event codes
Prior to returning the engine to service, determine
the condition that caused the circuit breaker to trip.
Make the necessary repairs.
• Circuit breakers
Fuel Supply
• Fuel supply
1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel
to the fuel tank. If the engine has been run out of
fuel, it will be necessary to prime the fuel system.
Refer to the Operation and Maintenance Manual.
'
bU
Section
2. Check the fuel lines for the following problems: Recommended Actions
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the Diagnostic Codes
Check for active diagnostic codes on Caterpillar
3. Check the fuel tank for debris or foreign objects Electronic Technician (ET). Troubleshoot any active
which may block the fuel supply. codes before continuing with this procedure.
NOTICE Fuel Supply

Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two 1. Visually check the fuel level. Do not rely on the fuel
minutes before cranking the engine again. gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary to
purge the air from the fuel system. Refer to the
4. Prime the fuel system if any of the following
Operation and Maintenance Manual.
2. Ensure that the fuel supply valve (if equipped) is
• Replacement of the fuel filters
in the full OPEN position.
• Service on the low pressure fuel supply circuit
loose connections. If problems are found with the
fuel lines, repair the lines and/or replace the lines.
Note: Check the fuel system for air. Refer to the
Systems OperationlTesting and Adjusting manual.
4. Prime the fuel system if any of the following
5. Check fuel quality. Cold weather adversely
affects the characteristics of the fuel. Refer to the
Operation and Maintenance Manual. • Replacement of the fuel filters
6. Check the filtered fuel pressure while the • Service on the low pressure fuel supply circuit
engine is being cranked. Refer to Systems
OperationlTesting and Adjusting. • Replacement of unit injectors
If the fuel pressure is low, replace the fuel filters. Note: A sight glass in the low pressure supply line is
Clean the primary filterlwater separator of debris. helpful in diagnosing air in the fuel. Refer to Systems
Refer to the Operation and Maintenance Manual. OperationlTesting and Adjusting.
If the fuel pressure is still low, check the operation 5. Check the fuel tank for foreign objects which may
of the fuel pressure regulating valve. Also, check block the fuel supply.
for the proper operation of the fuel transfer pump.
Refer to Systems OperationlTesting and Adjusting. 6. Check the fuel filters.
7. Check the diesel fuel for contamination. Refer to

i02958578 Systems OperationlTesting and Adjusting.
Engine Stalls at Low RPM 8. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
SMCS Code: 1000-035; 1900-035 Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Probable Causes operation.
• Diagnostic codes Air Supply

• Fuel supply Check for a restriction in the air inlet system. If
equipped, verify that the air shutoff valves are
• Air supply completely open.
• Engine idle Engine Idle

• Accessory equipment Check the parameter for the low engine idle (if
applicable). Refer to Troubleshooting, "Configuration
• Electronic unit injectors Parameters" .
KENR5404-03 51
Accessory Eq uipment Recommended Actions

Check all accessory equipment for problems that Diagnostic Codes, Event Codes and
may create excessive load on the engine. Repair
any damaged components or replace any damaged Derates
components.
Certain diagnostic codes, event codes and/or derates
may cause poor performance. Connect Caterpillar
Electronic Unit Injectors Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
1. Perform the "Injector Solenoid Test" on Cat ET in are present before continuing with this procedure.
are being energized by the ECM. If this application supports engine derates, use
Cat ET to check for logged derates. Refer to
2. Perform the "Cylinder Cutout Test" on Cat ET Troubleshooting, "Event Codes" for the specific
in order to identify any injectors that might be events that are applicable to this application. A status
misfiring. screen on Cat ET will display a derate if a derate is
active.
electronic unit injector from the suspect cylinder
and install a new electronic unit injector. Refer to Engine Parameters
Disassembly and Assembly.
Verify that the correct engine parameters are being
4. Ensure that the repairs have eliminated the used.
problem. If there is still a problem, refer to the
circuit test Troubleshooting, "Injector Solenoid Throttle Signal
Test".
Monitor the status for 'Throttle Position" on Cat ET.
Verify that the status for "Throttle Position" is stable
i03140061 and that the engine is able to reach high idle speed.
Engine Top Speed Is Not
Air Inlet and Exhaust System
Obtained
1. Check the air filter restriction indicator, if equipped.
SMCS Code: 1915-035 Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance
Note: If this fault occurs only under load, refer to Manual.
Troubleshooting, "Acceleration Is Poor or Throttle
Response Is Poor". 2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Probable Causes OperationlTesting and Adjusting.
.. Diagnostic codes Fuel Supply

e Event codes 1. Visually check the fuelleve\. Do not rely on the fuel
gauge only. If necessary, add fuel. If the engine
• Derates has been run out of fuel, it will be necessary
to purge the air from the fuel system. Refer to
e Engine parameters Operation and Maintenance Manual.
• Throttle signal 2. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position .
.. Air inlet and exhaust system
• Fuel supply restrictions, collapsed lines, pinched lines, and
loose connections. If problems are found with the
.. Cylinder performance fuel lines, repair the lines and/or replace the lines.
• Electrical connectors 4. Prime the fuel system if any of the following

.. Replacement of the fuel filters
'--
;:JL.
• Service on the low pressure fuel supply circuit 8. If the repair does not eliminate the problem,
reinstall the electronic unit injectors that were
Note: A sight glass in the low pressure supply line is

removed and continue with this test procedure.
i03368844
-
helpful in diagnosing air in the fuel. Refer to Systems
OperationlTesting and Adjusting. Engine Vibration Is Excessive
5. Check the fuel tank for foreign objects which may SMCS Code: 1000-035; 1152-035; 3252-035
6. Check the fuel filters. Probable Causes

7. Check the diesel fuel for contamination. Refer to Vibration Damper
Systems OperationlTesting and Adjusting.
• Inspect the vibration damper.
of the fuel. Refer to the Operation and Engine Mounts and Brackets
the characteristics of the fuel during cold weather • Engine supports
operation.
• Driven equipment
Cylinder Performance
Engine Misfiring or Running Rough
1. Check the valve lash and reset the valve lash, if
necessary. Refer to Systems OperationlTesting • Engine misfiring
and Adjusting for the procedure.
• Running rough
2. Check for correct instal/ation of the unit injector
connectors. Check for correct installation
of all other applicable connectors. Refer to
Troubleshooting, "Electrical Connectors - Inspect".

Recommended Actions
Inspect the Vibration Damper
-
order to determine if all of the injector solenoids Check the vibration damper for damage. Install a
are being energized by the ECM. new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace
4. Perform the "Cylinder Cutout Test" on Cat ET any damaged bolts. Refer to the Disassembly and
in order to identify any injectors that might be Assembly manual.
misfiring.
Engine Supports
electronic unit injector from the suspect cylinder. Inspect the mounts and the brackets while you run
Refer to Disassembly and Assembly. the engine through the speed range. Look for mounts
and brackets that are loose and/or broken. Tighten
6. Possible causes of low compression are shown all of the mounting bolts. If necessary, replace any
in the following list: damaged components. Check the alignment of the
following before operating the engine under load for
• Faulty piston any length of time:
• Mounts
• Coupling
• Worn valves • Crankshaft deflection
Driven Equipment

Inspect the mounting bolts for the driven equipment.
Inspect the alignment and the balance of the driven
-
repairs have eliminated the problem. equipment. Inspect the coupling. If necessary,
disconnect the driven equipment and test the engine.
KENR5404-03 53
'hloc>hnntinn Section
Engine Misfiring or Running Rough Atmospheric Pressure Sensor

Refer to Troubleshooting, "Engine Misfires, Runs Check the atmospheric pressure sensor for dirt
Rough or Is Unstable". and/or for debris. Remove any dirt and/or debris that
is present. The correct reading for the atmospheric
pressure is between 50 kPa (7.25 psi) and 100 kPa
i02720249 (14.5 psi).
Exhaust Has Excessive Black
Intake Manifold Pressure Sensor, "Fuel
Smoke Position", and/or "FRC Fuel Limit"
SMCS Code: 1088-035; 1250-035
1. Monitor the status of "Fuel Position" and "Rated
Fuel Limit" while the engine is operating under full
Probable Causes load. If "Fuel Position" equals "Rated Fuel Limit"
and "Fuel Position" is less than "FRC Fuel Limit",
" Air inlet or exhaust system the Electronic Control Module (ECM) is providing
the correct control. Otherwise, proceed to the next
., Engine speed/timing sensors Step.
" Atmospheric pressure sensor 2. Verify that there are no active diagnostic codes for
the intake manifold pressure sensor.
., Intake manifold pressure sensor
3. Monitor the status of "Intake Manifold Pressure"
.. "Fuel Position" and/or "FRC Fuel Limit" and "Atmospheric Pressure" on Caterpillar
Electronic Technician (ET). When the engine is
o Flash file not running, "Intake Manifold Pressure" should be
o kPa (0 psi).
G Fuel quality
Note: A problem with the "FRC Fuel Limit" will only
" Valve adjustment cause black smoke during acceleration. A problem
with the "FRC Fuel Limit" will not cause black smoke
Recommended Actions during steady state operation.
Air Inlet or Exhaust System Flash File
1. Check the air inlet system for restrictions and for Verify that the correct flash file is installed in the
leaks. ECM. Refer to Troubleshooting, "ECM Software
Install" for information.
a. Check for an air filter restriction.
Fuel Quality
b. Perform a visual inspection of the air inlet
piping for restrictions and for leaks. Cold weather adversely affects the characteristics of
the fuel. Refer to Operation and Maintenance Manual
2. Ensure that the turbocharger is in good repair. for information on improving the characteristics of the
fuel during cold weather operation.
3. Check the exhaust system for restrictions.
Valve Adjustment
4. Repair any leaks that were found. Remove
any restrictions that were found. Replace any Check for the correct valve adjustment. Refer
damaged components. to Systems Operation/Testing and Adjusting for
information on adjustment of the valves.
Engine Speed/Timing Sensors
1. Check the calibration of the engine speed/timing
sensors. Refer to Troubleshooting, "Timing
Calibrate".
2. Verify that the crankshaft and the camshaft drive

gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
'
54 4··~-
hl",,,hnntinn Section
i03392680 Recommended Actions

Exhaust Has Excessive White Cold Mode Operation
Smoke
Excessive white smoke emissions may occur during
SMCS Code: 1088-035; 1250-035 cold mode operation of the engine. During cold mode
operation of the engine, the ECM may modify the
Note: Some white smoke may be present during injection timing and the ECM may cut out certain
cold start-up conditions when the engine is operating engine cylinders. This will increase startability and
normally. If the white smoke persists, there may be this will reduce warm up time. Cold mode is activated
a problem. whenever the engine coolant temperature falls
below a predetermined value. Cold mode remains
active until the engine has warmed or a time limit is
Probable Causes exceeded.
Cold mode
Jacket Water Heater
• Cold mode operation
If the application has a jacket water heater that is
installed, check for proper operation of the circuit.
Starting Aids Repair the circuit for the jacket water heater, if
necessary.
• Jacket water heater
• Air inlet heater

Air Inlet Heater
If the application has an air inlet heater that is
" Ether injection
installed, ensure that the heater is operating correctly.
Refer to the particular test procedure for your
Coolant application.
• Coolant temperature
Ether Injection
• Coolant leak
If the application has an ether injection system,
ensure that the ether canister is not empty or low.
Engine SpeedlTiming Replace the ether canister if the ether canister is
empty or low. If an electrical problem with the ether
• Engine speed/timing sensor injection system is suspected, refer to the particular
test procedure for your application.
Electronic Control Module (ECM)
Coolant Temperature
• Flash file
Compare the coolant temperature from Caterpillar
Injector Electronic Technician (ET) to the coolant temperature
that is obtained from the 6V - 9130 Temperature
• Injector Adapter (MULTIMETER). Ensure that the temperature
readings are reasonable for the conditions that are
Fuel present.
• Fuel supply Coolant Leak
Low Compression Check for an internal coolant leak into the cylinder
and/or the exhaust
• Component wear
Engine SpeedlTiming Sensor
1. Check the calibration of the engine speed/timing
sensor(s). Refer to Troubleshooting, "Timing
Calibrate".
'-
KENR5404-03 55
2. Verify that the timing of the crankshaft and i03140085

camshaft drive gears are set with the proper
orientation. Refer to Disassembly and Assembly Exhaust Temperature Is High
for information that is related to the correct gear
installation. SMCS Code: 1088-035-TA; 7498-035

Flash File exhaust temperature or use this procedure if one
Verify that the correct flash file is installed in the ECM.
Refer to Troubleshooting, "ECM Software - Install". event codes and the default trip pOints for these
Injector Caterpillar Electronic Technician (ET) in order to view
1. Perform the "Cylinder Cutout Test" on Cat ET in
order to try to isolate any cylinders that may be
misfiring. A misfiring cylinder could be related to
an injector that is worn or in poor repair. Refer to
2. Cut out each individual cylinder for 30 to 60

seconds. Verify that the smoke decreases.

electronic unit injector from the suspect cylinder.
Refer to Disassembly and Assembly.
Fuel Supply
Check the fuel quality. Low cetane fuel can create
white smoke. If necessary, replace the fuel with a
higher cetane fuel.
Component Wear
1. Check the valve lash and reset the valve lash, if
necessary. Refer to Systems Operationrresting
and Adjusting.
2. Possible causes of low compression are shown

in the following list:
o Faulty piston
• Worn valves

repairs have eliminated the problem.
'-
ot)
Table 16
Event Code
E173(1} High Exhaust Temperature The exhaust temperature is above the The code is logged.
Warning trip point temperature.
E021 (2) High Exhaust Temperature The engine is derated. The code is
Derate logged.
Probable Causes i03392822
• Diagnostic codes Fuel Consumption Is

Excessive
• Air inlet and exhaust system
SMCS Code: 1250-035
• Fuel injectors
• Aftercooler (if applicable) Probable Causes
Recommended Actions Engine Operation

• Look for excessive idle or high load
Diagnostic Codes
Connect Cat ET and check for active and/or logged
Fuel Supply
diagnostic codes. Troubleshoot any active diagnostic
codes before continuing with this procedure. • Unstable fuel supply
Air Inlet and Exhaust System Engine Speed/Timing

• Calibration procedure of the engine speed/timing
Check for air inlet restrictions and/or leaks. A one
degree increase in the inlet manifold temperature will
increase the exhaust temperature by approximately Fuel Injection System
three degrees. Check for leaks between the exhaust
manifold and the turbocharger. Check for exhaust • Unstable injection system
restrictions. Refer to the Systems OperationlTesting
and Adjusting manual for more information on Air Inlet and Exhaust System
inspecting the air inlet and exhaust system.
• Restriction in the air inlet and exhaust
Fuel Injectors
Accessory Equipment
Faulty injectors that deliver too much fuel will
increase exhaust temperatures. Connect Cat ET in • Check for damaged accessory equipment
order to determine if any diagnostic codes for the
injector solenoids are present. Perform the "Injector
Solenoid Test". Observe that the injector solenoids Recommended Actions
are being energized on Cat ET. Perform the "Cylinder
Cutout Test". Locate the misfiring cylinder. Refer to Look for Excessive Idle or High Load
Use Caterpillar Electronic Technician (ET) to check
Aftercooler (if applicable) the "Current Totals" for excessive idle time and/or for
a high load factor which would be indicative of poor
operating habits.
Normal intake manifold pressure with high exhaust
temperature can be caused by blockage of the fins of
the aftercooler core. Unstable Fuel Supply
If the application has an aftercooler, check the Visually check the fuel level. Do not rely on the fuel
aftercooler for correct operation. Check for blockage gauge only. If necessary, add fuel. If the engine has
in the cores of the aftercooler. been run out of fuel, it will be necessary to purge the
air from the fuel system. Refer to the Operation and
Maintenance Manual.
KENR5404-03 57
Section
Ensure that the fuel supply valve (if equipped) is in 2. Check the air inlet and exhaust system for
the full OPEN position. restrictions and/or for leaks. Refer to Systems
OperationlTesting and Adjusting.
Check fuel lines for the following problems:
restrictions, collapse, and pinched line. Repair the Check for Damaged Accessory
Equipment
1. Check the fuel tank for foreign objects which
Check all accessory equipment for problems that
may block the fuel supply. Check for air leaks in
may create excessive load on the engine. Repair
the suction line of the fuel pump. Purge the fuel
any damaged components or replace any damaged
system after you perform the following procedures:
components.
• Replacing the fuel filters
i03140114
• Working on the low pressure fuel supply circuit
Fuel FUter Is Restricted
• Replacing fuel injectors
SMCS Code: 1261-035
of the fuel. Refer to the Operation and Use this procedure if the following event code is
Maintenance Manual for information on improving active. Refer to Troubleshooting, "Event Codes" for
the characteristics of the fuel during cold weather information about event codes and the default trip
operation. pOints for this code. You must access the monitoring
system on Caterpillar Electronic Technician (ET) in
3. Check the fuel pressure during engine operation. order to view the current trip point for this code.
Check the fuel pressure after the fuei 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 pump, pump coupling, and fuel pressure
reg[.llating valve.
Calibration Procedure of the Engine

SpeedlTiming
Perform a speed/timing sensor calibration. Refer to
the calibration procedure Troubleshooting, "Timing
- Calibrate".
Unstable Injection Actuation System

1. Check for correct installation of the J 1/P 1
and J2/P2 Electronic Control Module (ECM)
connectors and the injector connectors. Refer to
Troubleshooting, "Electrical Connectors -Inspect".

are being energized by the ECM.

in order to identify any injectors that might be
misfiring. Refer to Troubleshooting, "Injector
Solenoid - Test".
Restriction in the Air Inlet and Exhaust

1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter
or replace the air filter.
btj
Table 17
Event Code
Code and Description I Conditions which Generate this Code i System Response
E095(1) Fuel Filter Restriction Warning The difference between the filtered fuel • The code is logged. I
pressure and the unfiltered fuel pressure I
. is greater than the trip point pressure. i
Probable Causes
• Fuel filter element
Recommended Actions
Fuel Filter Element
Replace the fuel filter element.
i03140151
High Altitude Derate

Occurrence
SMCS Code: 1900-035

altitude derate or use this procedure if the following
event code is active. Refer to Troubleshooting,
"Event Codes" for information about event codes and
the default trip point for this code. You must access
the monitoring system on Caterpillar Electronic
Technician (ET) in order to view the current trip point
for this code.
Table 18
Event Code
E009(2) High Altitude Derate . The Electronic Control Module (ECM) The engine is derated. The code is
• detects atmospheric pressure that is
jless than normal.
j logged.
Probable Causes Atmospheric Sensor

• High altitude operation Check for any active diagnostic codes or logged
diagnostic codes for the atmospheric sensor.
• Atmospheric sensor If an active diagnostic code is present, refer to
Troubleshooting, "Sensor Signal (Analog, Active)
Recommended Actions Test".
High Altitude Operation

The engine is being operated at an altitude that is
too high.
',-
KEN R5404-03 59
i03140181
Inlet Air Is Restricted

SMCS Code: 1087-035
Use this procedure if the following event code is

active. Refer to Troubleshooting, "Event Codes"
for information about event codes and the default
trip points for these codes. You must access
the monitoring system on Caterpillar Electronic
Technician (ET) in order to view the current trip pOints
for these codes.
Table 19
Event Code
E272(1) Inlet Air Restriction Warning The inlet air restriction is above the trip The code is logged.
point pressure for the delay time.
E031 (2) Air Filter Restriction Derate The engine is derated. The code is
logged.
Probable Causes Turbocharger

" Air filter element • Turbocharger seal
Recommended Actions Recommended Actions

Air Filter Element Excessive Oil in the Crankcase
Check the air intake system for plugged air filters or Check the engine oil level. Too much oil in the engine
for damaged air filters. If the engine is equipped with crankcase can cause the engine to consume oil.
an air intake precieaner, verify the proper operation Remove excessive engine oil from the crankcase.
of the air intake precieaner.
Ensure that the dipstick is properly calibrated
and/or that the dipstick is correct for the application.
i03361543
Calibrate the dipstick and/or replace the dipstick.
Oil Consumption Is Excessive
Oil Leaks on the Outside of the Engine
SMCS Code: 1348-035
Check for leakage at the seals at each end of the
crankshaft. Look for leakage at the gasket for the
Probable Causes engine oil pan and all lubrication system connections.
Look for any engine oil that may be leaking from
Oil Level the crankcase breather. This can be caused by
combustion gas leakage around the pistons. A dirty
• Excessive oil in the crankcase crankcase breather will cause high pressure in the
crankcase. A dirty crankcase breather will cause the
Oil leaks gaskets and the seals to leak.
" Oil leaks on the outside of the engine Oil Leaks in the Combustion Area of the
Cylinder
" Oil leaks in the combustion area of the cylinders
Engine oil that is leaking into the combustion area of
Oil Viscosity the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into
" Incorrect oil viscosity the combustion area of the cylinders:
" Leaks between worn valve guides and valve stems
'-
tiU
Section
• Worn components or damaged components Cylinder Liner

(pistons, piston rings, or dirty return holes for the
engine oil) • Cracks in a cylinder liner
• Incorrect installation of the compression ring and/or Cylinder Block

the intermediate ring
• Cracks in the cylinder block
• Leaks past the seal rings in the turbocharger shaft
• Overfilling of the crankcase Recommended Actions

• Wrong oil level gauge or guide tube Leaks in the Cooling System
• Sustained operation at light loads Pressurize the cooling system. Refer to Systems
OperationlTesting and Adjusting, "Cooling System
Oil Viscosity - Test". If the test indicates a drop in pressure and
no outside leaks are detected in the cooling system,
Excessive consumption of engine oil can also there may be an internal leak. Make any repairs, as
result if engine oil with the wrong viscosity is used. required.
Engine oil with a thin viscosity can be caused by fuel
leakage into the crankcase or by increased engine Leaks in Core of Oil Cooler
temperature.
Check for leaks in the oil cooler core.
Turbocharger Seal
Leaks in the Cylinder Head Gasket
Check for turbocharger shaft seal leakage. Remove
the air inlet piping and the exhaust outlet piping from Inspect the cylinder head gasket for leaks.
the turbocharger. Check the compressor wheel and
the turbine for evidence of an oil leak. If necessary, Damaged Water Seals
repair the turbocharger or replace the turbocharger.
Refer to Systems Operation/Testing and Adjusting, Inspect the water seal for damage.
"Turbocharger Inspect".
Cracks in the Cylinder Head
i03362442
Check for cracks in the cylinder head. If a crack is
Oil Contains Coolant found, repair the cylinder head and/or replace the
cylinder head.
SMCS Code: 1348-035; 1395-035
Cracks in a Cylinder Liner
Probable Causes
Check for cracked cylinder liners. Replace any
Cooling System cracked cylinder liners.
• Leaks in the cooling system Cracks in the Cylinder Block
Engine Oil Cooler Inspect the cylinder block for cracks. If a crack is
found, repair the cylinder block or replace the cylinder
• Leaks in the core of oil cooler block.
Cylinder Head Gasket i02581426
• Leaks in the cylinder head gasket Oil Contains Fuel

• Damaged water seals SMCS Code: 1250-035; 1348-035
Cylinder Head Probable Causes

• Cracks in the cylinder head • Leaking seals on the case of the unit injector or on
the barrel of the unit injector
KENR5404-03 61
• Leaking seals on the fuel line adapter for the Leaking Fuel Transfer Pump Seal
cylinder head
Ensure that the weep hole is not plugged. If
• Excessive leakage from the unit injector tip or necessary, repair the fuel transfer pump or replace
breakage of the unit injector tip the fuel transfer pump.
" Cracked fuel supply manifold

i03140203
• Leaking seal on the fuel transfer pump Oil Filter Di'fferential Pressure
Note: For additional information, refer to, REHS3007, Problem
"Determining the Cause of Fuel Dilution of Engine
Oil". SMCS Code: 1308-035-PX
Use this procedure if the following event code is

Recommended Actions active. Refer to Troubleshooting, "Event Codes" for
the default conditions for this code. .
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu
el spray may cause a fire hazard. Failure to fol
low these inspection, maintenance and service in
structions may cause personal injury or death.
Do not loosen any high pressure fuel lines when

the engine is running. The high pressure in the
fuel lines can cause personal injury or death. Wait
60 seconds after the engine has stopped to allow
pressure to purge before any service or repair is
performed on the engine fuel lines.
Leaking Seals on the Case of the Unit

Injector or on the Barrel of the Unit
Injector
Look for signs of damage to the seals for the unit
injectors. Replace any seals that are leaking.
leaking Seals on the Fuel line Adapter

for the Cylinder Head
Look for signs of damage to the seals on the fuel line
adapter for the cylinder head. Repair any leaking fuel
lines or components and/or replace any leaking fuel
lines or components.
Excessive Leakage from the Unit Injector

Tip or Breakage of the Unit Injector Tip
Look for signs of damage to the unit injectors. If
necessary, repair the unit injectors or replace the unit
injectors.
Cracked Fuel Supply Manifold

Look for signs of damage to the fuel supply manifold.
'-
OL I\t:NK::>4U4-U6
Table 20
Description
E099(1) Engine Oil Filter Restriction

Event Code
Default Conditions which Generate
this Code
System Response
The difference between the filtered on-I The code is logged.

-
Warning pressure and the unfiltered oil pressure
is greater than the trip point pressure.
Probable Causes i03242605
• Plugged oil filter or faulty oil filter Oil Pressure Is Low

• Faulty oil pressure sensor and/or circuit SMCS Code: 1348-035-PX
• Malfunctioning of the oil filter bypass valve Use this procedure in order to troubleshoot low
engine oil pressure. Use this procedure if one
Recommended Repairs Troubleshooting, "Event Codes" for information about
event codes and the default trip pOints for these
Check the Oil Filters codes. You must access the monitoring system on
Check the oil filter differential pressure. If the oil filter the current trip points for these codes.
differential pressure is too high, change the oil filter
elements.
Inspect the oil filters for good condition. Replace any

suspect oil filter.
Check the Oil Pressure Sensors and/or

Circuits '
Use Caterpillar Electronic Technician (ET) to compare
the readings of the filtered oil pressure and the
unfiltered oil pressure while the engine is OFF. If the
readings are not approximately zero for both of the
sensors, troubleshoot the sensor circuit(s). Refer to
Troubleshooting, "Sensor Signal (Analog, Active)
Test". Make sure that the sensors are correctly wired.
Check the Oil Filter Bypass Valve

An oil filter bypass valve that is stuck in the closed
position can cause a high reading for differential
pressure when the oil is COld. An oil filter bypass
valve that is stuck in the open position can cause a
low reading for differential pressure when the oil is
hot. Check the operation of the oil filter bypass valve.
If the oil filter bypass valve is faulty, repair the valve,

when possible. Replace the valve, if necessary.
KENR5404-03 63
Section
Table 21
Event Code
Code and Description Conditions which Activate the Code System Response
E100(1) Low Engine Oil Pressure The engine oil pressure is less than the The code is logged.
Warning trip point and the delay time has expired.
E039(2) Low Engine Oil Pressure The engine will be derated. The code
Derate is logged.
E040(3) Low Engine Oil Pressure Fuel injection is disabled. The code is
Shutdown logged. The engine is shut down.
Probable Causes Improper Circulation of the Engine Oil

• Low engine oil level Several factors could cause improper circulation of
the engine oil:
.. Contaminated engine oil
.. The engine oil filter is clogged. Replace the engine
• Incorrect viscosity oil filter.
• Faulty oil pressure sensors • An engine oil line or a passage for engine oil is
disconnected or broken.
• Improper circulation of the engine oil
.. The engine oil cooler is clogged. Thoroughly clean
• Worn components the engine oil cooler.
.. There is a problem with a piston cooling jet.

Recommended Repairs Breakage, a restriction, or incorrect installation of a
piston cooling jet will cause seizure of the piston.
Low Engine Oil Level
.. The inlet screen of the suction tube for the engine
Check the oil level. Add oil, as needed. oil pump can have a restriction. This restriction will
cause cavitation and a loss of engine oil pressure.
Contaminated Engine Oil Check the inlet screen on the suction tube and
remove any material that may be restricting engine
Engine oil that is contaminated with another liquid oil flow.
will cause low engine oil pressure. High engine oil
level can be an indication of contamination. Obtain .. The suction tube is drawing in air. Check the joints
an analysis of the engine oil. Determine the reason of the tube for cracks or for a damaged O-ring seal.
for contamination of the engine oil and make the
necessary repairs. Change the engine oil and the .. There is a problem with the engine oil pump. Check
engine oil filter. For the correct engine oil to use, refer the gears of the engine oil pump for excessive
to the Operation and Maintenance Manual. wear. Engine oil pressure is reduced by gears that
have too much wear.
Incorrect Viscosity
.. The engine oil pump's pressure regulating valve or
Make sure that the engine is supplied with the correct a bypass valve is stuck in the open position. Clean
engine oil. For the correct engine oil to use, refer to the valve. Replace parts, if necessary.
the Operation and Maintenance Manual.
Worn Components
Faulty Engine Oil Pressure Sensors
Excessive clearance at the crankshaft or camshaft
Use Caterpiller Electronic Technician (ET) to compare bearings will cause low engine oil pressure. Also,
the readings of the filtered engine oil pressure and inspect the clearance between the rocker arm shafts
the unfiltered engine oil pressure while the engine is and the rocker arms. Check the engine components
OFF. Both readings should be close to zero pressure. for excessive clearance.
If a reading is significantly different from zero, refer Obtain an analysis of the engine oil. Check the
to Troubleshooting, "Sensor Signal (Analog, Active) analysis for the level of wear metals in the engine oil.
Test".
'-
04
i02672319 Throttle Signal

Power Is Intermittently Low or Monitor the status for "Throttle Position" on Cat ET
Power Cutout Is Intermittent Verify that the status for 'Throttle Position" is stable
and that the engine is able to reach high idle speed.
SMCS Code: 1000-035-PWR Refer to Troubleshooting, "Speed Control - Test".
Note: Use this procedure only if the engine does not ECM Power Supply
shut down completely.
1. Inspect the circuit between the ECM and
the batteries. Refer to the Electrical System
Probable Causes Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to
• Diagnostic codes Troubleshooting, "Electrical Power Supply - Test"
for more information.
• Eventcodes
2. Inspect the circuit between the ECM and
• Air inlet and exhaust restrictions
the keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors,
• Throttle signal
and the components in the circuit. Refer to
Troubleshooting, "Electrical Power Supply - Test"
• Power supply for the Electronic Control Module
for more information.
(ECM)
• Fuel supply Fuel Supply

1. Visually check the fuel level. Do not rely on the fuel
Recommended Actions gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary to
Note: If the problem only occurs under certain purge the air from the fuel system. Refer to the
conditions, test the engine under those conditions. Operation and Maintenance Manual for more
Examples of certain conditions are high engine information.
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other 2. Ensure that the fuel supply valve (if equipped) is
conditions can give misleading results. in the full OPEN position.
Diagnostic Codes and Event Codes 3. Check the fuel lines for the following problems:
Certain diagnostic codes and/or event codes may loose connections. If problems are found with the
cause poor performance. Connect Caterpillar fuel lines, repair the lines and/or replace the lines.
Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that 4. Prime the fuel system if any of the following
are present before continuing with this procedure. procedures have been performed:
Air Inlet and Exhaust Restrictions • Replacement of the fuel filters
Ensure that the turbocharger is operating correctly. • Service on the low pressure fuel supply circuit
Periodic inspection and cleaning is recommended for
the turbocharger compressor housing (inlet side). • Replacement of unit injectors
Check the air filter restriction indicator, if equipped. Note: A sight glass in the low pressure supply line is
Clean plugged air filters or replace plugged air filters. helpful in diagnosing air in the fuel. Refer to Systems
Refer to the Operation and Maintenance Manual. OperationlTesting and Adjusting.
Check the air inlet and exhaust system for restrictions 5. Check the fuel tank for foreign objects which may
and/or leaks. Refer to Systems OperationlTesting block the fuel supply.
and Adjusting.
6. Check the fuel filters.
7. Check the fuel quality. Make sure that the fuel

meets the requirements of Special Publication,
SEBU6250, "Caterpillar Machine Fluids
Recommendations ".
KENR5404-03 65
Section
8. Cold weather adversely affects the characteristics Multiple Diagnostic Codes for the Injector
of the fuel. Refer to the Operation and Solenoids
the characteristics of the fuel during cold weather If two diagnostic codes for the injector solenoids are
operation. active for a 12 cylinder engine at the same time,
then the primary ECM will terminate the primary
i02628640
ECM heartbeat signal to the secondary ECM. If
four diagnostic codes for the injector solenoids
Secondary ECM Assumes are active for a 16 cylinder engine at the same
time, then the primary ECM will terminate the
Control primary ECM heartbeat signal to the secondary
ECM. The secondary ECM will assume control of
SMCS Code: 1901-035 governing if the primary ECM heartbeat signal to
the secondary ECM is interrupted. Check for active
Use this procedure in order to troubleshoot the diagnostic codes or for logged diagnostic codes
reason that the secondary Electronic Control Module for the injector solenoids. If diagnostic codes are
(ECM) has assumed control of the engine. present or if diagnostic codes were logged, refer to
Troubleshooting, "Injector Solenoid - Test",
Probable Causes
Engine Overspeed Condition
.. Battery voltage to the primary ECM
If an engine overspeed occurs, the secondary ECM
.. Loss of primary ECM heartbeat signal will assume control of governing. The secondary
ECM will stop fuel injection to the engine. The
• Diagnostic codes for the injector solenoids secondary ECM will remain in control of governing
until keyswitch power to the primary ECM has
• Engine overspeed condition been cycled. Determine the cause for the engine
overspeed. Refer to Troubleshooting, "Engine
Recommended Actions Overspeeds" .
Battery Voltage to the Primary ECM i02629050
Connect Caterpillar Electronic Technician (ET). Secondary ECM Indicator

Establish communication with the primary ECM.
If communication with the primary ECM cannot
lamp Problem
be established, verify that voltage is present at SMCS Code: 1901-035; 7431-035
the primary ECM. If voltage is not present at the
keyswitch input on the primary ECM, refer to Use this procedure in order to troubleshoot the
Troubleshooting, "Engine Control Switch - Test". If circuit for the secondary ECM ready lamp and the
battery voltage is not present at the inputs on the secondary ECM active lamp on the "Marine Power
primary ECM, refer to Troubleshooting, "Electrical Display (MPDr panel.
Power Supply - Test".
Loss of Primary ECM Heartbeat Signal Probable Causes

The secondary ECM will assume control of governing " Battery voltage to the secondary ECM
the engine if the primary ECM heartbeat signal to the
secondary ECM is interrupted. Verify that the wire • Open circuit condition
that carries the primary ECM heartbeat signal to the
secondary ECM does not have an open or that the
wire is not shorted. The secondary ECM will remain
in control of governing until keyswitch power to the
primary ECM has been cycled.
00
Recommended Actions Table 22
Number of Valid Engine Secondary

Battery Voltage to the Secondary ECM
Connect Caterpillar Electronic Technician (ET).
I
I
Synchronized
Engines
none
Locations
Port
Throttle
Enabled
-"
Establish communication with the secondary ECM. I

Starboard Disabled
If communication with the secondary ECM cannot Center
be established, verify that voltage is present at the Engine #n
secondary ECM. If voltage is not present at the I
keyswitch input on the secondary ECM, refer to 2 Port unavailable
Starboard
Troubleshooting, "Engine Control Switch - Test". If
battery voltage is not present at the inputs on the 3 Port unavailable
secondary ECM, refer to Troubleshooting, "Electrical Starboard
Power Supply - Test". Center j
4 or more Engine #n unavailable
Open Circuit Condition
The secondary ECM ready lamp and the secondary In a single engine installation, there could be up to
ECM active lamp are activated by sinking drivers on two throttle inputs. One of the inputs is the primary
the secondary ECM. The secondary ECM ready lamp throttle signal. Another one of the inputs is the
and the secondary ECM active lamp are powered by secondary throttle signal. The secondary throttle is
the "MPD Breaker" in the MPD panel. An open circuit activated with a single switch. Illustration 17 shows
in either wire to the secondary ECM ready lamp or to the wiring for a single engine installation.
the secondary ECM active lamp will cause the lamps
to not illuminate. Refer to the electrical schematic
in order to identify the wires to the secondary ECM
ready lamp and to the secondary ECM active lamp.
Check the wires for an open circuit. If the wires to the ECM
secondary ECM ready lamp or to the secondary ECM PRIMARY THROTTLE PRIMARY
active lamp are OK, check for voltage to the one side INPUT
THROTTLE.
of the lamps from the "MPD Breaker". If voltage is
present, replace the lamp.
SECONDARY THROTTLE SECONDARY
-
INPUT THROTTLE
i02629167
SYNC INPUT 1 0
Synchronization Problem
SYNC INPUT 2 01 a ·BATTERY
SMCS Code: 1900-035 SECONDARY
THROTTLE
ENABLE
In order to synchronize the throttle control on multiple

engines, the Electronic Control Module (ECM)
receives four input signals to the ECM. One of the
inputs is the primary throttle signal. Another one of the
inputs is the secondary throttle signal. The other two g01331941
inputs are from the engine synchronization switch. Illustration 17
These four inputs can be used to synchronize the Wiring for the throttle in a single engine installation
throttle signals from multiple engines. The response
from the ECM to the four input values depends on the Table 23 shows the logic for a single engine
values in the following programmable parameters. installation. If the primary throttle will be used, disable
the secondary throttle by setting the parameter for
• Number of synchronized engines the secondary throttle to the disabled position.
• Engine location
• Secondary throttle
The logic and wiring for synchronization is dependent

upon the number of engines that are being
synchronized. The ECM response is dependent on
the programmed engine location. Refer to Table 22
for the engine locations that are valid for a given
number of engines.
'.~
KENR5404-03 67
Section
Table 23
Engine Synchronization Input Active Throttle Sy nchronization

Status
1 2
Open Open Primary unavailable
Open Low Secondary unavailable
Low Open Primary unavailable
Primary unavailable
In a twin engine installation, the ECM will assume

that one engine is on the port side of the vessel and
that the other engine is on the starboard side of the
vessel. The ECM will label the engines as the port
engine and as the starboard engine on the service PORT
tool and on the display. The operator can synchronize ENGINE
both engines in order to be controlled with either the

ECM
port throttle or the starboard throttle. The operator
could choose to not synchronize the engine throttles PRIMARY THROTTLE PORT
at all. Illustration 18 shows the wiring for twin engine INPUT THROTTLE
installations.
SECONDARY THROTTLE
INPUT I
MIDDLE
SYNC INPUT 1 a r-
(NO SYNC)
l' 0
ii1
0
SYNC INPUT2 .,!.. 0
I -BATTERY
STARBOARD
ENGINE
ECM
PRIMARY THROTTLE STARBOARD I

INPUT THROTTLE
SECONDARY THROTTLE
INPUT
SYNC INPUT 1 0 !
SYNC INPUT 2 0 -
Wiring for the throttle in a twin engine installation
The logic for Illustration 18 is shown in Table 24.
'-
00
hf'\f'\tinn Section
Table 24
~--""~"-""-~ ..
Synchronization No Synchronization Synchronization Synchronization
Port
Status
Engine
Synchronization
Open
Port Side
Low
Starboard Side
Open -
Input
1
Engine Open Open Low
Synchronization
Input
2
--..--.-
Active Throttle Primary Primary Secondary
Starboard Engine Open Open Low
Synchronization
Input
1
Engine Open Low Open
Synchronization
Input
2
._-
Active Throttle Primary Secondary Primary
Table 25 shows the logic for the Port side control in a

twin engine installation.
Table 25
Engine Synchronization Input Active Throttle Port ECM
Open
1 2
Open Primary
Synchronization
Status
No
Synchronization
-
Open Low Secondary Synchronization

on the Starboard
side
Low Open Primary Synchronization
on the Port side
Low Low Primary Invalid
•
Table 26 shows the logic for the Starboard side

control in a twin engine installation.
Table 26
Engine Synchronization Input ! Active Throttle Starboard ECM
Sy nchronization
1 2 Status
Open Open Primary No
Synchronization
Open Low Secondary Synchronization
on the Port side
on the Starboard
side
Low Low
'---
Prjmary Invalid
-
KENR5404-03 69
When there are three engines in an installation,

the engines will be arranged in a master-slave
configuration. The user must designate the master
throttle control. The user must synchronize throttle
control to the master throttle control only. The user
can add a fourth throttle control. The fourth throttle
control can be used as the master throttle control.
Illustration 19 shows the wiring for an installation of

three engines. Illustration 19 shows the center engine
as the master throttle control.
PORT STARBOARD CENTER

THROTTLE THROTTLE THROTTLE
ECM ECM ECM
PRIMARY THROTTLE
INPUT
ot PRIMARY THROTTLE 0+
INPUT
PRIMARY THROTTLE ot-l
INPUT
(
-BATTERY
SECONDARY THROTTLE 0+- SECONDARY THROTTLE 0+- SECONDARY THROTTLE 0+

INPUT INPUT INPUT
SYNC INPUT 1 0 SYNC INPUT 1 0 SYNC INPUT 1 0+-
SYNC INPUT 2 0+-1- - - ' SYNC INPUT 2 0-\01----' SYNC INPUT 2 0
ENGINE ENGINE ENGINE
g01331943
Illustration 19
Wiring for the throttle in a triple engine installation (center as master throttle)
'-
IU 4
Table 27
Engine Synchronization Input No Synchronization Sy nchronization

Port
I
Engine Synchronization
Input
1
Open Open i
I
'
Engine Synchronization Open Low
Input I I
2 I
Active Throttle Primary Secondary
I
Starboard !
Engine Synchronization Open Open
Input
1 I
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Low
Input
1 I
Input
2
Active Throttle Primary i Secondary

three engines. Illustration 20 shows the port engine
-
ECM
PRIMARY THROTTLE
ECM
PRIMARY THROTTLE
lJ ECM
PRIMARY THROTTLE 0+ (

INPUT
INPUT i INPUT
-BATTERY
SECONDARY THROTTLE 0+

SECONDARY THROTTLE SECONDARY THROTTLE at--
INPUT
INPUT INPUT
SYNC INPUT 1 0 SYNC INPUT 1 0 SYNC INPUT 1 0+-1- - - '
SYNC INPUT2 0+--- SYNCINPUT2o~I----~ SYNC INPUT 2 0
'
Wiring for the throttle in a triple engine installation (Port as master throttle)

KENR5404-03 71
Table 28
Synchronization No Synchronization Synchronization

Status
Port Engine Synchronization Open Low
Input
1
Input
2
Starboard Engine Synchronization Open Open

Input
1
Input
2
Center Engine Synchronization Open Open
Input
1
Input
2

three engines. Illustration 21 shows the starboard
engine as the master throttle control.

ECM ECM ECM 1

PRIMARY THROTTLE 0+
INPUT
PRIMARY THROTILE o{---i
INPUT
PRIMARY THROTILE of
INPUT
(
-BATTERY
SECONDARY THROTTLE 0+- SECONDARY THROTTLE 0+ SECONDARY THROTTLE 01-

INPUT INPUT INPUT
SYNC INPUT 1 0 SYNC INPUT 1 0+- SYNC INPUT 1 0
SYNC INPUT 2 0101----" SYNC INPUT 2 0 SYNC INPUT 2 0+1- - - '
Illustration 21
901331946
Wiring for the throttle in a triple engine installation (starboard as master throttle)
'--
Table 29
Synchronization
Status
No Synchronization Synchronization --
Port Engine Synchronization Open Open
Input
1
Input
2
Starboard Engine Synchronization Open Low
Input
1
Input
2
Input
1
Input
2
~
three engines. Illustration 22 shows the fourth throttle
'
KENR5404-03 73
Section
PORT STARBOARD I CENTER MASTER

THROTTLE THROTTLE I THROTTLE THROTTLE
~
I
I
-1
ECM
PRIMARY THROTTLE
JJ I
ECM
PRIMARY THROTTLE 0+

ECM
PRIMARY THROTTLE (
INPUT INPUT iNPUT
-BATTERY
SECONDARY THROTTLE SECONDARY THROTTLE 0 1 SECONDARY THROTTLE 0-1

INPUT INPUT INPUT
SYNC INPUT 1 0 SYNC INPUT 1 0 SYNC INPUT 1 0
SYNC INPUT 2 0+-1- - - " SYNC INPUT 2 o>!-I-----" SYNCINPUT2o~I----~
g01331950
Illustration 22
Wiring for the throttle in a triple engine installation (fourth throttle as master throttle)
Table 30
Synchronization No Synchronization Synchronization

Status
Port Engine Synchronization Open Open
Input
1
Input
2
Active Throttle ~ry Secondary
Starboard Engine Synchronization Open Open
Input
1
Input
2
Input
1
Input
2
14 Kt:NK!:>4U4-U,j
1.::u:,hl"\l"\ti"" Section
Table 31 shows the logic for the ECM in a triple

engine installation. Use the logic in Table 31 in order
to synchronize multiple engines to a single throttle
control.
Table 31
Engine Synchronization Input Active Throttle Port

Starboard
1 2 Center
I Synch",nization
Status
I
(same for all)
Open Open Primary No
Synchronization
I Open Low Secondary Synchronization

I
Low Low I Primary Invalid
If you are experiencing problems with the i03372246

synchronization of the throttle controls, verify that
the wiring matches the configurations for your Valve Lash Is Excessive
application. Verify that the following parameters are
programmed in order to match the configurations for SMCS Code: 1105-035
your application.
Probable Causes
• Number of synchronized engines
Lubrication
• Engine location
• Inadequate lubrication
• Secondary throttle
The probable root causes are listed below: Valve Train Components
• Vessel wiring • Worn valve train components
• Faulty synchronizing switch Valve Lash

Check the wiring for the following problems: • Incorrect valve lash
damage, abrasion, corrosion, and incorrect
attachments.
Recornmended Actions
1. Check the wiring for continuity or shorts between
the synchronizing switch and the ECM. Inadequate Lubrication
2. Check the wiring for continuity or shorts between Remove the valve mechanism covers. Refer to
the throttle position sensor and the ECM. Disassembly and Assembly for removing the valve
mechanism cover. Check the lubrication in the valve
3. Check the wiring for continuity or shorts between compartment. Ensure that there is adequate engine
the ECM connectors. oil flow in the valve compartment. The passages for
the engine oil must be clean.
Check the synchronizing switch for proper
operation. Worn Valve Train Components
1. Disconnect the wiring from the synchronizing 1. Inspect the following components of the valve
switch. train:
2. Check continuity across the contacts of the • Rocker arms

synchronizing switch as the synchronizing switch
is turned to different pOSitions. • Pushrods
• Valve lifters
KENR5404-03 75
Section
.. Camshaft
• Valve stems
• Rocker shafts
2. Check the components for the following conditions:

abnormal wear, excessive wear. straightness. and
cleanliness. Replace parts, if necessary.
Note: If you replace the camshaft, you must also

replace the valve lifters.
Incorrect Valve Lash

Check the engine valve lash. If necessary,
adjust the engine valve lash. Refer to Systems
Operation/Testing and Adjusting for information on
adjusting the engine valve lash.
i02643299
Valve Rotator or Spring lock

Is Free
SMCS Code: 1109-035
Use this procedure in order to troubleshoot a problem

with the valve rotators or spring locks.
Probable Cause
• Valve Components
Recommended Actions
Valve components
1. A valve rotator that is cracked or a valve rotator
that is broken is an indication of an engine
overspeed. Determine the cause of the engine
overspeed. Repair the condition.
2. Inspect the following components for damage:
.. Valve rotators
.. Spring locks
• Valve springs
• Valves
Note: Ensure that the valve has not contacted the

piston. If the valve has contacted the piston, check
the exhaust system for debris.
3. Replace any damaged components.

Trou Section
Circuit Tests
i02634043
Air Shutoff - Test

SMCS Code: 1078-038
System Operation Description:
Use this procedure in order to troubleshoot the air

shutoff system or use this procedure if anyone of
the diagnostic codes in Table 32 is active or easily
repeated.
Table 32
446-5 Air Shutdown Relay current below The Electronic Control Module (ECM) The code is logged.
normal detects low current in the circuit. The
ECM can only detect this condition when
the output driver is not activated.
446-6 Air Shutoff Relay short The ECM detects excessive current flow
in the circuit. The ECM can only detect
this condition when the output driver is
activated.
The secondary ECM has the ability to stop the engine Relay "R3A" and relay "R3" are energized through
by shutting off the inlet air supply in an emergency terminal 3 of the diode assembly. Terminal 3 of the
situation. The secondary ECM activates the output diode assembly will energize relay "R3A" and relay
driver for the emergency shutdown system. The "Air "R3" for one second. The contacts of relay "R3" keep
Shutoff Switch (ASOS)" energizes the two air shutoff relay "R3A" and relay "R3" energized until power is
solenoids. The solenoids trip the air shutoff valves. cycled. The contacts of relay "R3A" keep the coils of
relay IlR2" and relay "R2A" energized. When relays
There are two conditions which cause the engine IlR2" and "R2A" are energized, power is removed
control to activate the output driver for the air shutoff from the primary ECM and the secondary ECM. The
relay. The first condition occurs when the operator primary ECM and the secondary ECM will power
activates the customer's emergency stop. When the down. The injection signals to the injector solenoids
customer's emergency stop button is activated, the will stop.
emergency stop inputs U and T to the primary ECM
and the secondary ECM from the customer connector The contact of relay "R3A" also supplies power to
go high. The secondary ECNI will recognize this terminal 3 of the connector for a timer. When power
change. The secondary ECM will energize the output is applied to terminal 3 of the connector for the timer,
drive for the emergency shutdown system for one the timer will activate. The timer outputs 24 VDC
second through the diode assembly. from terminal 6 of the connector for the timer for
2.5 seconds. The 24 VDC from the timer is applied
The second condition occurs for an engine to the coil of the "ASOS" and to terminal 2 of the
overspeed. If an engine overspeed occurs, the ECM diode assembly. The "ASOS" energizes the two air
will activate the output driver for the emergency shutoff solenoids. The solenoids trip the air shutoff
shutdown system through the diode assembly. An valves. The 2.5 second time limit for activation of the
overspeed can be simulated by using Caterpillar <lASOS" prevents damage to the air shutoff solenoids.
Electronic Technician (ET). In order to verify that the A normally open switch at the air shutoff valves will
overspeed function is operable, the operator must close when the air shutoff solenoid activates the
access the screen for overriding parameters on Cat air shutoff valve. The switch inputs a signal to the
ET. When the override for the engine overspeed is primary ECM and to the secondary ECM. The signal
set to the ON position, the setpoint for the engine notifies the primary ECM and the secondary ECM
overspeed is at 75% of the original setpoint. When that the air shutoff valves are closed. The primary
the engine reaches the modified setpoint, the normal ECM and the secondary ECM will not send injection
strategy for an engine overspeed is initiated. signals to the injector solenoids until the switch inputs
from the air shutoff valves indicate that the valves
are open.
KENR5404-03 77
The "ASOS" can also be activated without the aid

of the secondary ECIVI. When the local emergency
stop switch on the instrument panel is depressed
or the customer's remote emergency stop switch is
activated, the coils of relay "R4" and relay "R4A"
are energized. The contacts of relay "R4A" supplies
power to terminal 3 of the connector for the timer and
to the coils of relay "R2" and relay "R2A". When relays
"R2" and "R2A" are energized, power is removed
from the primary ECM and the secondary ECM. The
circuit with the timer will operate in the same manner
that was described above except that the emergency
stop lamp on the instrument panel will illuminate and
the relays "R3A" and "R3" will de-energize after 2.5
seconds. When relays "R3A" and "R3" de-energize,
the overspeed indicator turns off.
Regardless of the reason for activation, the Engine

Control Switch (ECS) must be turned to the
OFF/RESET position for three seconds. This resets
the ECM and the relays in the circuit. In addition
to turning the ECS to the OFF/RESET position,
the operator must determine the cause for the
emergency shutdown before resetting the circuit. The
operator must manually open the air shutoff valves
before restarting the engine.
'--
/0 I\.t:NK04U4-U':)
Section
Prim. ECM+ Prim. ECM- Sec. ECM+ Sec. ECM·
Air S/O
" H708 i>
'-6 K708,-----,
220
Air S/O
Sol. LH
Air S/O
Switch LH
Bl03
Al50
A103(103)~
R3 C150(150) R2
...-------iD229(229)------'
A120 I I E I Overspeed ~F708 .----------A287(B287)

P·Cl1
A·CSO P1 J1 Primary ECM
P·C21 I B el50 53 +Battery
A·C91
A·Cl1 150 52 +Battery
F·C21G·C6 120 D9 E·C2 D229 65 -Battery
E·ClI 229 63 -Battery
C-C1
354 113 70 Keyswitch
/\J, D998 5 Digital Ref.
Secondary H401A 55 Air Shutoff Tripped
ECM Ready H401 56 Air Shutoff Tripped
F715
r~"1~·C21112
23 E-Stop 1
~6?6 F719 F719 28 E-Stop 2
/ "
Secondary 700 4 8V Digital Power
ECMActive 997 2 5V Analog Power Left
G·C6
START' 1'+
STOP 1.5 6
II 354
A99?
993
A99S
18 5V Analog Power Right
3 Analog Ref. Left
0 E-Stop 35 Analog Ref. Right
F72l 68 ECS in Remte/Auto
~ I 1 1 1 1354
Local E-Stop
8V Digital Power
F998--t:1661 Digital Ref.
Switch P2J2
Customer E-Stop 1 'iT P1 J1 Secondary ECM

113---dl' v 1/'''' 1 I~ Customer E-Stop 2 T
.BA
I
Ai, Sh"'off Tripped m
Cust. Rem. E-Stop AS
+Battery
-Battery
-Battery
\wJ 11"'.1\ 1 4 Sec. ECM Active u E-Stop 2
A120--CJY 0
STOP Sec. ECM Ready ~ E-Stop 1
0 5
TB·Cl/C-C18 Keyswitch
0 Cust
Conn. Air Shutoff Drive
Sec. ECM Ready
Sec. ECM Active
113
P2 J2
Typical example
"
KEN R5404-03 79
RIGHT SIDE VIEW
o/~~n I
1 2 3 4 5
ZO
aO
@GO OE
0 0
dO
eO
fO
0
®
8 @
43
OA
OB
OC
bO OF
cO 000
.G
0 ~ 0 ) ~
~
LEFT SIDE VIEW
@ ®
EO
oG@ Oa
Illustration 25
g01320528
C0 G0
AO
80
Co
a
®
8 ®
(:) Od
Oe
Of
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2IJ-C2 RH rigid harness connectors
(3) P-C 1/A-C90 Connectors for the power distribution panel
FO Ob
(4) P-C2/A-C91 Connectors for the power distribution panel
(0r;\@ (5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
V Oc (6) C-C22 Primary ECM connector P2
®CD (7) C-C15 Primary ECM connector P1

(8) C-C28 Secondary ECM connector P2
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C 1 Customer connectors
(12) C-C2/J-C 1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01322302
Illustration 24
Terminal locations for the following connectors P-C1/A-C90 Test Step 1. Inspect the Electrical
Connector for the power distribution panel, A-C2/J-C2 RH rigid Connectors and the Wiring
harness connector, and C-C2/J-C1 LH rigid harness connectors
(Terminal G) Drive for the air shutoff switch F708-BK A. Turn the circuit breaker for the battery to the OFF
(Terminal H) Return for the air shutoff solenoid H708-BK position.
(Terminal I) Drive for the air shutoff solenoid G708-BK
B. Turn the ECS to the OFF/RESET position.
C. Thoroughly inspect the ECM connectors J1/P1

and J2/P2. Inspect all of the other connectors
that are associated with the circuit. Check the
allen head screw on each of the ECM connectors
for the proper torque. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for the correct
torque values.
D. Perform a 45 N (10 Ib) pull test on each of the

wires in the ECM connectors that are associated
with the circuit.
'-
tlU KENR5404-03
E. Check the harness and the wiring for abrasion C. Reconnect the P-C1/A-C90 connector.
and for pinch points.
Expected Result:
All connectors, pins, and sockets are completely

D. Activate the customer's emergency stop switch.
E. Monitor the voltage on the wire jumper in terminal

I at connector A-C90 of the rigid harness. Refer to
--
coupled and/or inserted, and the harness and wiring Illustration 24 for terminal locations.
are free of corrosion, of abrasion or of pinch points.
F. Deactivate the customer's emergency stop switch.
Results:
G. Return all wiring to the original configuration.
• OK - The harness and wiring appear to be OK.

Proceed to Test Step 2. Expected Result:
• Not OK - There is a problem in the connectors The voltage measures 24 ± 3 VDC for approximately
and/or wiring. 2.5 seconds.
Repair: Repair the connectors or wiring and/or Results:
replace the connectors or wiring. Ensure that all of

the seals are properly in place and ensure that the • OK - The voltage measures 24 ± 3 VDC for
connectors are completely coupled. approximately 2.5 seconds. The circuit is operating
correctly to this point. Proceed to Test Step 7.
STOP.
• Not OK - The voltage did not measure 24 ± 3
Test Step 2. Test the Air Shutoff System VDC for approximately 2.5 seconds. Proceed to
Test Step 4.
A. Turn the circuit breaker for the battery to the ON
position. Test Step 4. Test for Voltage to the Coil of
the "ASOS" at the Connector A-C90 for
B. Turn the ECS to the STOP position. the Power Distribution Panel
C. Activate the customer's emergency stop switch. A. Remove wire F708-BK from terminal "G" of
connector A-C90.

D. Monitor the air shutoff solenoids.
B. Turn the ECS to the STOP position.
E. Deactivate the customer's emergency stop switch.
C. Activate the customer's emergency stop switch.

Expected Result:
D. Monitor the voltage on wire F708-BK.

The air shutoff solenoids activated.

Results:
F. Return all wiring to the original configuration.
• OK - The air shutoff solenoids activated correctly.
Expected Result:
Repair: The problem may be intermittent. If the

problem is intermittent, refer to Troubleshooting, The voltage measures 24 ± 3 VDC for approximately
"Electrical Connectors -Inspect". one second.
STOP. Results:
• Not OK - The air shutoff solenoids failed to • OK - The voltage measures 24 ± 3 VDC for
activate. Proceed to Test Step 3. approximately one second. The circuit is operating
Test Step 3. Check for the Voltage from
the "ASOS" at the Connector P-C1/A-C90 • Not OK - No voltage was measured. Proceed to
for the Power Distribution Panel Test Step 14.
A. Turn the ECS to the STOP position. Test Step 5. Test for Voltage to the Coil '-'
of the "ASOS"
B. Remove wire G708-BK from terminal "I" of
connector A-C90. Install a wire jumper into the A. Turn the ECS to the OFF/RESET position.
connector for wire G708-BK.
KENR5404-03 81
,hlo",hl"\l"\tinl'l Section
B. The input to the coil of the "ASOS" is wire T708-BK Results:

from the diode assembly. Remove wire T708
from the coil of the "ASOS". Connect a voltmeter • OK - The voltage measures 24 ± 3 VDC for
between wire T708-BK and the engine ground. approximately 2.5 seconds. The circuit is operating
correctly to this point.
Note: The "ASOS" is turned on for one second by
the ECM. The timer keeps the "ASOS" energized for Repair: Repair the wire G708-BK between the
approximately 2.5 seconds. "ASOS" and terminal I at connector P-C1 of the
power distribution panel.
C. Turn the ECS to the STOP position.
STOP.
D. Activate the customer's emergency stop switch.
• Not OK - The voltage did not measure 24 ± 3 VDC
E. Monitor the voltage on the voltmeter. for approximately 2.5 seconds.
F. Deactivate the customer's emergency stop switch. Repair: Verify that 24 ± 3 VDC is present on wire
K708-BK at the normally open contacts of the
"ASOS". If voltage is not present on wire K708-BK,
check the wiring and the circuit breaker for the air
Expected Result:
shutoff for problems.
The voltage measures 24 ± 3 VDC for approximately

Check wire 220-BK on the coil of the "AS OS" for
2.5 seconds.
continuity to the -Battery. If necessary, repair the
wire or replace the wire.
Results:
If wire 220-BK is OK and voltage is present on wire

• OK - The voltage measures 24 ± 3 VDC for K708-BK, replace the "ASOS".
approximately 2.5 seconds. The circuit is operating
correctly to this point. Proceed to Test Step 6. STOP.
• Not OK No voltage was measured. Proceed to Test Step 7. Check the Voltage at the
Test Step 10. Connector for the Air Shutoff Solenoids
" Not OK - The voltage did not measure 24 ± 3 VDC A. Turn the ECS to the OFF/RESET position.
for 2.5 seconds. Proceed to Test Step 8.
B. Disconnect the connector for the air shutoff
Test Step 6. Check for Voltage from the solenoids. Disconnect the connector for the right
"ASOS" to the Air Shutoff Solenoids and left sides of the engine.
A. Turn the ECS to the OFF/RESET position. C. Connect a voltmeter between wire G708-BK on
the connector for the air shutoff solenoid and the
B. Disconnect wire G708-BK from the !lASOS". engine ground.
C. Connect a voltmeter to the empty terminal on the D. Turn the ECS to the STOP position.
"ASOS". Connect the other lead of the voltmeter
to engine ground. E. Activate the customer's emergency stop switch.
D. Turn the ECS to the STOP position. F. Monitor the voltage on the voltmeter.
E. Activate the customer's emergency stop switch. G. Deactivate the customer's emergency stop switch.
F. Monitor the voltage on the voltmeter. H. Reconnect the connectors for the air shutoff
solenoids.
G. Deactivate the customer's emergency stop switch.
Expected Result:
H. Reconnect wire G708-BK to the "ASOS".
Expected Result:
2.5 seconds.
2.5 seconds.
u.£. o
Results: B. Remove wire n08 from terminal 6 of the

connector for the timer.
• OK - The voltage measures 24 ± 3 VDC for
approximately 2.5 seconds. The circuit is operating C. Connect a voltmeter between terminal 6 of the '
correctly to this point. connector for the timer and engine ground.
Repair: Check the wire H708-BK from terminal D. Turn the ECS to the STOP position.
A of the connector for the air shutoff solenoid
for continuity to the -Battery terminal. If the wire E. Activate the customer's emergency stop switch.
H708-BK to the -Battery terminal is OK, replace
the air shutoff solenoid. F. Monitor the voltage on the voltmeter.
STOP. G. Deactivate the customer's emergency stop switch.
• Not OK The voltage did not measure 24 ± 3 VDC H. Return all wiring to the original configuration.
for approximately 2.5 seconds. System voltage
was not available at the solenoid connector. Expected Result:
Repair: Repair the wire G708-BK between the The voltage measures 24 ± 3 VDC for approximately
connector for the air shutoff solenoids and terminal 2.5 seconds.
Illustration 23 for a schematic of the circuit. Results:
STOP. • OK - The voltage measures 24 ± 3 VDC for

approximately 2.5 seconds. Proceed to Test Step
Test Step 8. Check the Voltage at the 12.
Contact of Relay "R3A"
A. Turn the ECS to the OFF/RESET position. for approximately 2.5 seconds.
B. Disconnect wire T120-BK from terminal 87 of Repair: Check for 24 ± 3 VDC on terminal 3 of the ~
relay "R3A". connector for the timer. If voltage is not present
on terminal 3, repair the wire T120-BK between
C. Connect a voltmeter between terminal 87 of relay terminal 87 of relay "R3A" and terminal 3 of the
"R3A" and the engine ground. connector for the timer.
D. Turn the ECS to the STOP position. If voltage is present on terminal 3 of the connector
for the timer, verify that wire 220-BK on terminal 2
E. Activate the customer's emergency stop switch. of the connector for the timer has continuity to the
-Battery. If wire 220-BK does not have continuity
F. Monitor the voltage on the voltmeter. to the -Battery, repair the wire.
G. Deactivate the customer's emergency stop switch. Verify that 24 ± 3 VDC is present on terminal 1
of the connector for the timer. If 24 ± 3 VDC is
H. Reconnect wire T120-BK.

not present on terminal 1 of the connector for the
timer, verify that the engine control switch is not in
Expected Result:
the "OFF/RESET" position. Verify that the "MPD"
breaker is not tripped. Check the normally closed
The voltage measures 24 ± 3 VDC.

contact of relay "R1" for proper operation. Check
the wire 120 between terminal 1 of the connector
Results:
for the timer and relay "R 1" for damage. Check
the wire A120 between relay "R1" and the "MPD"
• OK - The voltage measures 24 ± 3 VDC. Proceed breaker for damage. If necessary, repair the wires.
to Test Step 9.
If the voltage is present on terminal 1 and terminal
• Not OK - The voltage did not measure 24 ± 3 3 of the timer and wire 220-BK is OK, replace the
VDC. Proceed to Test Step 11. timer.
Test Step 9. Check the Voltage at Terminal

6 of the Connector for the Timer
A. Turn the ECS to the OFF/RESET position.
STOP.
-
KENR5404-03 83
Section
Test Step 10. Check the Voltage at If the voltage does not measure 24 ± 3 VDC for
Terminal 4 of the Connector for the approximately one second, repair the wire F708-BK
Diodes between the connector for the diodes and wire
F708-BK on pin G at connector A-C90 of the right
A. Turn the ECS to the OFF/RESET position. rail. Return all wiring to the original configuration.
B. Remove wire T708 from terminal 4 of the STOP.

connector for the diodes.
Test Step 11. Check the Voltage at the
C. Connect a voltmeter between terminal 4 of the Coil of Relay "R3A"
connector for the diodes and the engine ground.
D. Turn the ECS to the STOP position.
B. Remove wire 918-BK from terminal 86 of relay
E. Activate the customer's emergency stop switch. "R3A".
F. Monitor the voltage on the voltmeter. C. Connect a voltmeter between wire 918-BK and
the engine ground.
G. Deactivate the customers emergency stop switch.
H. Return all wiring to the original configuration.
E. Activate the customer's emergency stop switch.

Expected Result:
F. Monitor the voltage on the voltmeter.

one second.
Results:
• OK - The voltage measures 24 ± 3 VDC for Expected Result:

approximately one second.
Repair: Repair the wire n08 between the
connector for the diodes and the "ASOS". Return Results:
all wiring to the original configuration.
• OK - The voltage measures 24 ± 3 VDC.
STOP.
Repair: Check wire 220-BK on the coil of the "R3A"
• Not OK - The voltage did not measure 24 ± 3 VDC relay for continuity to the -Battery. If necessary,
for approximately one second. repair the wire or replace the wire.
Repair: Check for 24 ± 3 VDC on wire 120-BK on terminal

30 of relay "R3A". If 24 ± 3 VDC is not present on
1. Turn the ECS to the OFF/RESET position. wire 120-BK, verify that the engine control switch
is not in the "OFF/RESET' position. Verify that the
2. Connect a voltmeter between terminal 1 of the "MPD" breaker is not tripped. Check the normally
connector for the diodes and the engine ground. closed contact of relay "R1" for proper operation.
Check the wire 120-BK between terminal 30 of the
3. Turn the ECS to the STOP position. relay "R3A" and relay "R1" for damage. Check the
wire 120-BK between relay "R1" and the "MPD"
4. Activate the customer's emergency stop switch. breaker for damage. If necessary, repair the wires.
5. Monitor the voltage on the voltmeter. If wire 220-BK is OK and voltage is present on wire
120-BK on terminal 30, replace relay "R3A".
S. Deactivate the customer's emergency stop
switch. STOP.
If the voltage measures 24 ± 3 VDC for • Not OK The voltage did not measure 24 ± 3
approximately one second, replace the diodes. VDC. Proceed to Test Step 13.
84 KENR5404-03
Test Step 12. Check the Voltage to Expected Result:
Terminal 2 of the Connector for the

Diodes from the Timer The voltage measures 24 ± 3 VDC.
'
A. Turn the ECS to the OFF/RESET position. Results:
B. Remove wire T708 from terminal 2 of the • OK - The voltage measures 24 ± 3 VDC.
connector for the diodes.
Repair: Repair the wire 918-BK between the
C. Connect a voltmeter between wire T70S and the diodes and relay "R3A".
engine ground.
STOP.

E. Activate the customer's emergency stop switch. VDC.
F. Monitor the voltage on the voltmeter. Repair: Replace the diodes.
G. Deactivate the customer's emergency stop switch. STOP.
H. Return a/l wiring to the original configuration.

Test Step 14. Check the Output Driver for
the Air Shutoff System at the ECM
Expected Result:

B. Disconnect the secondary ECM connector P2.

Results:
C. Remove wire F708-BK from ECM connector

• OK - The voltage measures 24 ± 3 VDC. Proceed P2-13. Install a wire jumper into P2-13.
-
to Test Step 13.
D. Reconnect ECM connector P2.
VDC. E. Connect a voltmeter between the wire jumper in
P2-13 and engine ground.
Repair: Repair the wire T70S-BK between the
diodes and the timer. F. Turn the ECS to the STOP position.
STOP. G. Activate the customer's emergency stop switch.
Test Step 13. Check the Voltage from H. Monitor the voltage on the voltmeter.
Terminal 3 of the Connector for the Diode
Assembly I. Deactivate the customer's emergency stop switch.
A. Turn the ECS to the OFF/RESET position. J. Return all wiring to the original configuration.
B. Remove wire 918 from terminal 3 of the connector Expected Result:
for the diodes.

The voltage measures 24 ± 3 VDC for one second.
C. Connect a voltmeter between terminal 3 of the

connector for the diode assembly and the engine Results:
ground.
• OK - The voltage measures 24 ± 3 VDC for one
D. Turn the ECS to the STOP position. second.
E. Activate the customer's emergency stop switch. Repair: Repair the wire F70S-BK between the
ECM connector and terminal G at connector A-C90
F. Monitor the voltage on the voltmeter. of the rigid harness. Refer to Illustration 23 for a

schematic of the circuit. Check for voltage at the
following connectors C-C2/J-C1 LH rigid harness
connectors and A-C2/J-C2 RH rigid harness
connectors.

STOP.
KENR5404-03 85
Section

VDC.
Repair: Monitor the status screen for the

emergency stop in order to verify that the ECM is
receiving the emergency stop signal. If the ECM
is receiving the emergency stop signal from the
customer connector, replace the ECM. If the ECM
is not receiving the emergency stop signal from the
customer connector, repair the wiring between the
ECM and the customer connector.
STOP.
i02635725
CAN Data link - Test

SMCS Code: 1900-038
The CAN data link is used for communication

between the following modules: engine's Electronic
Control Module (ECM), customer devices, and
various display modules. Two 120 Ohm terminating
resistors must be installed in the wiring harness in
order for the CAN data link to function properly.
86 KENR5404-03
Section
r--- r-- r- (\ r-- r:-:I

5 A A A I '
l ) 1.:..:-:I
6 B B B
I~-
Y C 1200HM
7 C ~ '-
~
• MPDPANEL ~
r-
T N
C-C17(LH) A"
A-C93(RH) - I- B '" ~
PRIMARY ECM ' -C- " ' -

J1 P1 MARINE POWER
~[893
DISPLAY PORT
CAT DATA LINK +
892 .Q=~1939G-< 7 ....;:
D~
J19 19G
I J1939Y-( 8 ....;:
I
J19 19Y- ~ J1939SH 9 <'
J19 19SH
CUSTOMER
CONNECTOR
C-C18
CAT DATA LINK + ! 8 [893

893- h <f
CAT DATA LINK - . 9 892
i
892- 9 <f
CAN DATA LINK + 50 J19 19G C\

J1939G- BV "-:-:L
CAN DATA LlNK- 34 J19 19Y J1939Y-

1.:..:-:I I
BU
CAN (SHIELD) 42 J19 19SH Y J1939SH- BT < 120 OHM TER~
RESI
9 PIN SERVICE TOOL

CONNECTOR
893- D
892-- E
C\
J1939Y F
I ) -J1939G G
~
Y J1939SH C
Typical example
"--.
KENR5404-03 87
Section
WIRE SIDE
o~~o
€~:~
488~88000g3§~57
000088®
00000006
00000000@
0000000000
ECM SIDE 0000000@8
8®@®®®®®88
®@@@®®8®®
230 0 0 0 0
"0000
390 0
470 0
570 0
0
0
0
0
0
0
0 0
m
130 0 0 0 0 0 0 0 00 0 00 1 •
0 0 0 0 014:
0
0
0
0 0
0000"
•
•
•
0
0
0
032
040
048
@@@@®®®®
@®®§8®®
®eee
,700 0 0 0 0 0 0 0 0 0 0 0 058
g01321419 901321422
Illustration 27 Illustration 29
Pi ECM connector Customer connector
(P1-34) J1939 data link (Terminal Bn J1939 shield
(P1-42) J1939 shield (Terminal BU) Ji939 data link
(Pi-50) J1939 data link + (Terminal BV) J1939 data link +
Test Step 1. Inspect Electrical Connectors

and Wirmg
A. Remove power from the ECM.
o ®@0)®
o
B. Thoroughly inspect the J1/P1 ECM connector
@ ®® CD
and the J2/P2 ECM connector. Inspect all of the
® ® ® 0 connectors that are associated with the circuit.
@ ®® ®
® ®®®250 Refer to Troubleshooting, "Electrical Connectors
, t;6'I Q ® q. Inspect" for details.
~@@®@@)~
@ ® @@ ® 0 C. Perform a 45 N (10 Ib) pull test on each of the
@ @fi\@ CD wires in the ECM connectors that are associated
® V:::J ® with the circuit.
O~~ o
D. Check the allen head screw on each ECM
connector for the proper torque. Refer to
Troubleshooting, "Electrical Connectors Inspect"
for the correct torque values.
E. Check the harness and wiring for abrasion and
Connector for the control panel
for pinch points.
(Terminal 5) Ji939 data link +
(Terminal 6) Ji939 data link
(Terminal 7) Ji939 shield
Expected Result:
All connectors, pins and sockets are completely

coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion or of pinch points.
tltl
Results: • P1-34 (CAN data link-)
• OK - The harness and wiring appear to be OK. Expected Result:

Proceed to Test Step 2. '
Each resistance measurement indicates an open
• Not OK - There is a problem in the wiring harness. circuit.
Repair: Perform the following repair: Results:
Repair the connectors or wiring and/or replace • OK - There are no shorts. Proceed to Test Step 4.
the connectors or wiring. Ensure that all of the
seals are properly in place and ensure that the • Not OK - A short exists in the wiring harness.
connectors are completely coupled. Refer to
Troubleshooting, "Electrical Connectors - Inspect". Repair: Make the necessary repairs.
Verify that the repair eliminates the problem. Verify that the repair eliminates the problem.
STOP. STOP.
Test Step 2. Verify the Proper Installation Test Step 4. Check for an Open Circuit
of the Data Link Circuit
A. Make sure that all connections remain
A. Disconnect any module that is connected to the disconnected.
CAN data link.
B. Fabricate a jumper wire. Use the jumper wire in
B. Disconnect J1/P1 ECM connector and measure order to short pin F to pin G on the service tool
the resistance between P1-50 (CAN data link +) connector.
and P1-34 (CAN data link -).
C. Measure the resistance between P1-S0 (CAN
Expected Result:
The resistance is between 57 and 63 Ohms.
Results:
data link +) and P1-34 (CAN data link -) at the

ECM connector.
D. Remove the wire short.
-
Expected Result:
• OK - The resistance is within the range. Proceed

to Test Step 5. The resistance measurement indicates a short circuit.
• Not OK - The range of the resistance is 114 Ohms Results:
to 126 Ohms. A terminating resistor is missing.

• OK - There is not an open circuit. Proceed to Test
Repair: Verify that two terminating resistors exist Step S.
on the data link. One resistor must be located on
each end of the data link. • Not OK - An open circuit exists in the wiring
harness.
STOP.
Repair: Make the necessary repairs.
• I\lot OK - Resistance is less than 57 Ohms.
Proceed to Test Step 3. Verify that the repair eliminates the problem.
• Not OK - Resistance is greater than 126 Ohms. STOP.

Proceed to Test Step 4.
Test Step 5. Check the Module on the
Test Step 3. Check for a Short Circuit CAN Data Link
A. Remove the terminating resistors from the CAN A. Connect the module to another engine.
data link.
B. If the module operates properly on a different
B. Measure the resistance from the following pins
to every pin on ECM connector P1 and to engine
ground.
engine, there may be a problem with the ECM.
C. If the module does not function properly on the

'
different engine, replace the module.
• P1-S0 (CAN data link +)
'"
KENR5404-03 89
Section
Expected Result:
The module operates properly.
Results:
.. OK - The module operates properly on another
engine.
problem is intermittent, refer to Troubleshooting,
"Electrical Connectors - Inspect".
STOP.
.. Not OK - The module does not operate properly

on another engine.
Repair: Replace the module. Verify that the repair
corrects the problem.
STOP.
i02635835
Cat Data Link .. Test

SMCS Code: 1900-038
Use this procedure to troubleshoot the electrical

system if a problem is suspected with the Cat Data
Link or if the diagnostic code in Table 33 is active or
easily repeated.
Table 33

Code and Description Conditions which Generate this Code • System Response
248-9 @CatDatalinkLong@ not Communication on the Cat Data Link The ECM will log the diagnostic code.
communicating was lost for the last two seconds.
The Cat Data Link is used for communication

between electronic modules. The Cat Data Link is
used to communicate information from the engine's
Electronic Control Module (ECM) to other electronic
systems. The Cat Data Link is used for programming
and for troubleshooting the ECM.
The engine's ECM communicates with Caterpillar

Electronic Technician (ET) in order to share
information on engine status and on engine
diagnostics. Cat ET can also be used to configure
the engine's parameters. This information will not be
available if communication fails between the engine's
ECM and Cat ET.
90 5404-03
w
MPD PANEL
C-C17(LH)
A-C93(RH)
~ ~ffi3 ~j V~ "
PRIMARY ECM
! II
J1 P1 MARINE POWER
DISPLAY PORT
CAT DATA LINK + 8 fB93

CAT DATA LINK 9 892
D~
CAN DATA LINK + 50 J1939G I I
CAN DATA LI NK 34 -J1939Y
CAN (SHIELD) 42 J1939SH I.
SECONDARY ECM
J1 P1
CAT DATA LINK + 8 t893 893
CAT DATA LINK 9 892 892
CAN DATA LINK + 50 J1939G (/\) J1939G
CAN DATA LINK 34 J1939Y J1939Y
CAN (SHIELD) 42 J1939SH Y J1939SH-:
LL--J
9 PIN SERVICE TOOL

CONNECTOR
'------893--1 0
F
G
C
-
Typical example
-
KENR5404-03 91
130 0 0 0 • • 0 0 0 0 0 0 01
30 0 0 0 0
310000 ~@~
390 0 0 0
0
~
0 00 0 014
000024
0 0 0 032
o 0000
~0®0®8®
0
470 0 0 0 0 0 0 040
570 0 0 0 0 0 0 0 0 0 048 00000000
\700 0 0 0 0 0 0 0 0 0 0 0 058.
000808008
8880888888
ECM SIDE
888808088
1 2 3 4 5 60 8 9 10111213 §®®®8@®®88
0000000••0000
1400000 0000023 ®®@®8®8®®
1240000@@000031
o0000 0 0000 0
®®®®®@®®
§®®S@)®@)
400000
4800000
000047
0000057
0000000000000
58596061 6263 0 656667686970
o @®®® 0
i i ii
HARNESS SIDE
P1 ECM connector Customer connector

(Pi-8) Cat Data Link + (Terminal g) Cat Data Link +
(P1-9) Cat Data Link (Terminal h) Cat Data Link
901161999
Illustration 33
Service tool connector
(Terminal D) Cat Data Link +
(Terminal E) Cat Data Link

and Wirmg
B. Thoroughly inspect the J1/P1 ECM connector

connectors that are associated with the circuit.

Inspect" for details.
"
tiL
C. Perform a 45 N (10 Ib) pull test on each of the Expected Result:

with the circuit. Each check of the resistance indicates an open
circuit. ~
D. Check the allen head screw on each ECM

connector for the proper torque. Refer to Results:
Troubleshooting, "Electrical Connectors -Inspect"
for the correct torque values. • OK - Each check of the resistance indicates an
open circuit. Proceed to Test Step 3.
E. Check the harness and wiring for abrasion and
for pinch points. • Not OK - At least one check of the resistance
does not indicate an open circuit. There is a short
Expected Result: circuit in the harness or in a connector.
All connectors, pins, and sockets are completely Repair: Repair the connectors and/or the wiring.
inserted and coupled. The harness and wiring are Replace parts, if necessary. Verify that the original
free of corrosion, of abrasion, and of pinch points. problem is resolved.
Results: STOP.
• OK - The harness and the connectors appear to Test Step 3. Check for an Open Circuit
be OK. Proceed to Test Step 2.
A. Fabricate a jumper wire. Use the jumper wire in
• I\lot OK - The connectors and/or the wiring are order to create a short circuit between terminals
not OK. D (Cat Data Link +) and terminal E (Cat Data Link
-) on the service tool connector.
Repair: Repair the connectors and/or the wiring.
Replace parts, if necessary. Ensure that all of the B. Measure the resistance between P1-8 (Cat Data
seals are properly in place and ensure that the Link +) and P1-9 (Cat Data Link -).
connectors are completely coupled. Verify that the
original problem is resolved.
STOP.
C. Measure the resistance between the terminals
at the connector for each control module that
was connected to the Cat Data Link. Refer to
--.
Illustration 30.
Test Step 2. Check for a Short Circuit
D. Remove the jumper wire from the service tool
A. Disconnect the P1 ECM connector. connector.
B. Disconnect Cat ET from the service tool connector. Expected Result:
C. Disconnect any other control modules from the Each check of the resistance indicates a short circuit
Cat Data Link. Refer to the electrical schematic in
order to identify other control modules on the Cat Results:
Data Link.
• OK - Each check of the resistance indicates a
D. Measure the resistance between the paints that short circuit.
are listed in Table 34. Be sure to wiggle the wires
in the harnesses as you make each resistance Repair: Perform the following procedure:
measurement.
1. Connect the J1/P1 connectors. Connect Cat ET
Table 34 to the service tool connector.
Resistance Measurements for the Cat Data Link

2. Check the Cat Data Link for proper operation. If
Connector and Terminal the Data Link does not operate correctly, there
Terminal may be a problem with the ECM.
P1-8 (Cat Data Link +) All of the other terminals on

the Pi connector
Pi-9 (Cat Data Link-)

I
Ground stud
of the other terminals on
Pi connector
Ground stud
--
KENR5404-03 93
Section
Temporarily install a new ECM. Check the Cat

Data Link again, If the new ECM solves the
problem, install the original ECM and verify that
the original problem returns, If the new ECM
operates correctly and the original ECM does
not operate correctly, replace the original ECM.
Refer to Troubleshooting, "ECM - Replace".
STOP.
• Not OK - At least one check of the resistance

does not indicate a short circuit. There is an open
circuit or excessive resistance in the harness.
There may be a problem with a connector.
Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Verify that the original
problem is resolved.
STOP.
i03140238
Electrical Power Supply ~ Test

SMCS Code: 1401-038

system if a problem is suspected with the power to
the engine's Electronic Control Module (ECM) or if
anyone of the diagnostic codes or the event code
in Table 35 is active or easily repeated. Refer to
Table 35

E043(1) Low System Voltage Warning The battery supply voltage is less than I The code is logged.
20 VDC for ten seconds.
!
168-0 Electrical System Voltage high The battery supply voltage is greater
most severe (3) than 32 VDC for 0.5 seconds.
The engine is not being cranked.
168-1 Electrical System Voltage low The battery supply voltage is less than
most severe (3) 18 VDC for 0.5 seconds.
The engine is not being cranked.
168-2 Electrical System Voltage erratic, The engine is running but not cranking.
intermittent. or incorrect The battery supply voltage is less than
18 VDC for at least .06 seconds. Three
times in the last seven seconds, the
battery supply voltage was less than 18
VDC.
Section
The engine has a Primary ECM and a Secondary

ECM. The electrical power to the primary ECM
comes through the breaker for the primary ECM and
the contact of relay "R2A". The electrical power to the
secondary ECM comes through the breaker for the
secondary ECM and the contact of relay "R2". Power
goes to pin P1-53 and pin P1-52 of the ECM(s).
The -Battery comes through the breakers for the
primary ECM and the secondary ECM. The -Battery
connects to pin P1-63 and pin P1-65 of the ECM(s).
The Engine Control Switch (ECS) sends a signal to

pin P1-70 on the primary ECM and to pin P1-70 on
the secondary ECM when the ECS is in the following
positions: REMOTE, STOP, and START. When the
primary ECM senses battery voltage on pin P1-70 of
the primary ECM, the primary ECM will power up.
When the secondary ECM senses battery voltage on
pin P1-70 of the secondary ECM, the secondary ECM
will power up. When the ECS is in the OFF/RESET
position, voltage is not present on these inputs and
the ECM(s) will power down.
If an emergency shutdown occurs, circuitry will

energize relay "R2" and relay "R2A". When these two
relays are energized the contacts of the relays will
open. When the contacts of the relays open, battery
power is removed from the ECM(s).
In order to restart the engine, the operator must

correct the cause of the emergency shutdown. The
Engine Control Switch (ECS) must be turned to
the OFF/RESET position. This resets the electrical
circuits in the circuit. In addition to turning the ECS to
the OFF/RESET position, the operator must manually
open the air shutoff valves before starting the engine.
The presence of two +Battery connections and two

-Battery connections to the ECM reduce harness
resistance. All of these connections must be complete
in order to ensure proper engine operation.
KENR5404-03 95
Section
Battery Prim. ECM+ Prim. ECM- Sec. ECM+ Sec. ECM POP RHRAIL
P-C2fA-C91 A-C2fJ·C2
L-----+------0229--i(1 M M
4----k1 N
,------T120
MPD
220
MPD+
R3 229---....J
.----0229'---....J
A1201 I Overspeed I ~~:~

x1~d
918
/ , Primary ECM
I r-t--1< 16 53 +Battery
ECS
M150 Cd",
/ '
E-Stop
354
L--4-r+~-1~J--~52
0229 65
'---t-1r-229--j:: 63
+Battery
-Batte ry
-Battery
Keyswitch
22 09 LHCONTROL
OFF
P1 J1
PANEL
0
REMOTE 23 I
M150
/ , G·C6JF·C2
START 24 Secondary
25 ECM Ready
o STOP
12 ",' /,,, 676
0
OFF / ,
REMOTE 13 Secondary
START 14
STOP 15
ECMActive II ~~~3
A287
+ Battery
+ Battery
-Battery
0
OFF 7 --8287 -Battery
0
REMOTE 8 • 113 Keyswitch
START 9 ~354
10 II Local E-Stop
P1 J1
U I~
Cust. E-Stop 1
113---ctY V 11"'\f'\ I
STOP 20
. I T
Cust. E-stop 2 T ~,
BA
0
0
OFF 2 IAir Shutoff Tripped m
REMOTE 3 Cust. Rem, E-Stop ASI~I I I I 354
Sec, ECM Active u
START 4 Sec. ECM Ready v
o STOP 5
Keyswitch c 040
ILHCONTROL LHCONTROL i
TB-C1/C-C18 PANEL PANEL
Cust. Conn, G·C6JF·C2 F·C11C·C17
113
Typical example
~o
WIRE SIDE
-
fD
aO
0(00 OE
dO ~ (0 OA
eO 0 (0 @OB
ECM SIDE
fO ® 0 OC
bO OF
®G)0
It; ~
' 0 0 0 oooooooooo~ •
230 0 0 0 0 0 0 000 014 ae
"0000 [~J 0000"
390 0 0 0 @ 0 0 0 032
470 0 0 0 0 0 0 0 40
570 0 0 0 • 0 • 0 0 0 048
70. 0 0 0 0 • 0 • 0 0 0 0 058
e
EO
08@ Oa
Illustration 35
g01321565
AO (0 e Od
P1 connections for the electrical power supply circuit
(0
(P1-52)
(P1-53)
(P1-63)
(P1-65)
+Battery
+Battery
-Battery
-Battery
BO@
Co
FO
49 @
0
Ob
0e
Of

(P1-70) Keyswitch 080
em
Tenninal locations for the following connectors P-C2/A-C91

Connector for the power distribution panel, A-C2/J-C2 RH rigid
harness connectors, and C-C2/J-C1 LH rigid harness connectors.
(Terminal K) +Battery to primary ECM 150-BK
(Terminal L) +Battery to primary ECM C150-BK
(Terminal M) -Battery to primary ECM D229-BK
(Terminal N) -Battery to primary ECM 229-BK
(Terminal S) -Battery to secondary ECM A287-BK
(Terminal T) -Battery to secondary ECM B287-BK
(Terminal U) +Battery to secondary ECM A 103-BK
(Terminal V) +Battery to secondary ECM 103-BK
'
KENR5404-03 97
hl",<::hr\r\tinn Section
o ~
~@(1)®
CD
o 1 2 3
RIGHT SIDE VIEW
4 5
@®@@® 0
@@ ®® @ ®
®@@ @ ® @0
®@@ @ @®0
® ® @@ °0
9 @)@®0
o @~O
LEFT SIDE VIEW
g01320528
Illustration 38
Connector locations
(1) A-C1JE-C2 RH rigid harness connectors
(2) A-C2JJ-C2 RH rigid harness connectors
(3) P-C1JA-C90 Connectors forthe power distribution panel
(4) P-C2JA-C91 Connectors for the power distribution panel
(5) G-C6JF-C2JF-C1JA-C92 Connectors for a RH Control panel
g01323336 (6) C-C22 Primary ECM connector P2
Illustration 37
(7) C-C15 Primary ECM connector P1
Terminal locations for the C-C17JF-C1 LH rigid harness connectors (8) C-C28 Secondary ECM connector P2
and the connectors G-C6JF-C2 for a LH Control panel (9) C-C29 Secondary ECM connector P1
(Terminal 14) Keyswitch 113-BK (10) G-C6JF-C2JF-C1/C-C17 Connectors for a LH Control panel
(Terminal 15) Remote keyswitch 040-BK (11) C-C18/TB-C1 Customer connectors
(Terminal 16) +BaUery to ECS M 150-BK (12) C-C2/J-C1 LH rigid harness connectors
Note: If a remote start switch is installed, the remote

start switch must be in the LOCAL position for this
test.

and Wirmg
B. Turn the circuit breaker for the battery to the OFF

position.
C. Thoroughly inspect the ECM connectors J1/P1

and J2/P2. Refer to Troubleshooting, "Electrical
Connectors - Inspect" for details.

wires in the ECM connector that are associated
with the circuit.
E. Check the ECM connector (allen head screw) • Not OK - The voltage is incorrect at all of
for the proper torque. Refer to Troubleshooting, the connections to the ECM(s). The wiring or
"Electrical Connectors - Inspect" for details. components between the battery and the ECM are
preventing the voltage from reaching the ECM. '
F. Check the harness and the wiring for abrasion Proceed to Test Step 3.
• Not OK - P1-70 - The voltage is not 24 ± 3 VDC
Expected Result: on the input for the keyswitch to the ECM. Proceed
to Test Step 5.
coupled and/or inserted, and the harness and wiring Test Step 3. Check the Battery Voltage
Results:
B. Turn the circuit breaker for the battery to the OFF
• OK - The connectors and wiring are OK. Proceed position.
to Test Step 2.
c. Measure no-load battery voltage at the battery
• Not OK - The connectors and/or wiring need terminals. Refer to Testing and Adjusting, "Test
repair. Tools for the Electrical System" for the proper
procedures to check the batteries.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of D. Load test the batteries. Use the 4C - 4911
the seals are properly in place and ensure that the Battery Load Tester. Refer to the Operating
connectors are completely coupled. Manual, SEHS9249. Refer to Special Instruction,
SEHS7533.
STOP.
Expected Result:
Test Step 2. Check the Voltage to the ECM
The no-load voltage at the batteries is at least 23.5
A. Disconnect the primary ECM connector J1/P1 and VDC and the batteries pass the load test.
the secondary ECM connector J 1/P1. '
Results:
B. Turn the circuit breaker for the battery to the ON
position. • OK - The no-load voltage at the batteries is at
least 23.5 VDC, and the batteries pass the load
c. Turn the ECS to the STOP position. test. Proceed to Test Step 4.
D. Measure the voltage between the following pins • Not OK - The no-load voltage at the batteries is
on the primary ECM and on the secondary ECM. less than 23.5 VDC, and/or the batteries fail the
load test.
• P1-52 and P1-53
Repair: The batteries or the alternator are causing
• P1-53 and P1-55 the problem. Recharge the batteries or replace
the batteries. Refer to Systems Operation/Testing
• P1-70 and P1-65 and Adjusting.
Expected Result: STOP.
The voltage measures 24 ± 3 VDC. The difference Test Step 4. Check the Voltage from the
between the three voltage measurements is less Power Distribution Panel
than 0.5 VDC.
A. Disconnect the P-C2/A-C91 connector on the RH
Results: rigid rail.
• OK - The ECM is receiving the correct battery B. Measure the voltage between the following
voltage. terminals on the P-C2 connector.
Repair: The problem may be intermittent. If the • Terminal S and Terminal L

'
"Electrical Connectors - Inspect". • Terminal T and Terminal K
STOP. • Terminal M and Terminal U

KENR5404-03 99
Section
.. Terminal N and Terminal V " Not OK - The voltage is not 24 ± 3 VDC on

terminal 30 of relay "R2" and/or relay "R2A".
C. Turn the ECS to the OFF/RESET position.
Repair: Verify that voltage is present on wire A 150
D. TUrn the circuit breaker for the battery to the OFF at the breaker for the primary ECM. If voltage is
position. present at the breaker, repair the wiring between
the breaker for the primary ECM and relay "R2A".
Expected Result:
Verify that voltage is present on wire B 103 at
The voltage measures 24 ± 3 VDC. the breaker for the secondary ECM. If voltage is
present at the breaker, repair the wiring between
Results: the breaker for the secondary ECM and relay "R2".
.. OK The voltage measures 24 ± 3 VDC. STOP.
Repair: Check continuity of the wiring between " Not OK - The voltage is not 24 ± 3 VDC on
connector A-C91 and the ECM connectors. Check terminal 87A of relay "R2" and/or relay "R2A".
for opens in the wiring and for shorts in the wiring.
Refer to Illustration 34 for the connectors and Repair: Verify that voltage is not present on wire
terminals that interconnect the two connectors. T120 at the coil of relay "R2A". If voltage is present
Repair the wiring andfor connectors. on wire T120, check all emergency stop switches
for proper operation. Check for diagnostic codes
STOP. for an engine overspeed. If voltage is not present
on wire T120, replace relay "R2A".
• Not OK - The voltage does not measure 24 ± 3
VDC. Verify that the wiring to the -Battery does not Verify that voltage is not present on wire T120
have an open circuit. Proceed to Test Step 5. at the coil of relay "R2". If voltage is present on
wire T120, check all emergency stop switches for
Test Step 5. Check the Voltage at Relay proper operation. Check for a diagnostic code for
"R2u and/or Relay "R2A" an engine overspeed. If voltage is not present on
wire T120, replace relay "R2".
A. Turn the circuit breaker for the battery to the OFF
position. STOP.
B. Remove the wire 103-BK and the wire A103-BK Test Step 6. Check the Voltage at the ECS
from terminal 87A of relay "R2".
C. Remove the wire 150-BK and the wire C150-BK
from terminal 87A of relay "R2A". B. Remove wire 113-BK from terminal 16 of the ECS.
D. Turn the circuit breaker for the battery to the ON C. Turn the ECS to the STOP position.
position.
D. Measure the voltage between terminal 16 and
E. Measure the voltage between the following engine ground. Measure the voltage between
terminals on relay "R2" and relay "R2A". terminal 20 and engine ground.
" Terminal 30 and the -Battery terminal Expected Result:
" Terminal 87 A and the -Battery terminal The voltage measures 24 ± 3 VDC on both terminals.
Expected Result: Results:
The voltage measures 24 ± 3 VDC on all terminals. • OK - The voltage is 24 ± 3 VDC on both terminals.
Results: Repair: The wire 113-BK between the ECS and

the prirnary ECM and/or the secondary ECM needs
., OK - The voltage is 24 ± 3 VDC. repair. Repair the connectors or wiring and/or
replace the connectors or wiring.
Repair: Repair the wiring between relay "R2"
and/or relay "R2A" and the P-C2 connector on the STOP.
RH rigid rail.
" Not OK - Terminal 16 - The correct voltage is not
STOP. present on terminal 16 of the ECS.
IUU
hl",,,,hl"ll"ltinn Section
Repair: If 24 ± 3 VDC is present on terminal 20 of Relay "R3A" and relay "R3" are energized at the
the ECS, replace the ECS. same time as the "ASOS" through terminal 3 of the
STOP.
• Not OK - Terminal 20 - The correct voltage is not

present on terminal 20 of the ECS.
diode assembly. Terminal 3 of the diode assembly will
energize relay "R3A" and relay "R3" for 2.5 seconds.
The relays "R3A" and "R3" will de-energize after 2.5
seconds. The overspeed indicator on the control
panel will illuminate for 2.5 seconds.
-
Repair: Repair wire M150-BK between terminal In order to start the engine after an emergency
20 of the ECS and the ECM. Check for voltage stop condition, the ECS must be turned to the
at the connectors for the control panel. Check for OFF/RESET position. This resets the ECM and the
voltage at diode D9. Refer to Illustration 34 for the air shutoff timer. In addition to turning the ECS to the
connectors and terminals between the ECM and OFF/RESET position, the operator must manually
terminal 20 on the ECS. open the air shutoff valves before starting the engine.
STOP.
;02637229
Ernergency Stop - Test

SMCS Code: 7332-038-SQ
When the local emergency stop switch on the control

panel is depressed, the coils of relay "R4" and relay
"R4A" are energized. The contacts of relay "R4" keep
the coils of relay "R4" and relay "R4A" energized
-
until the Engine Control Switch (ECS) is cycled to
the OFF/RESET position. The contacts of relay
"R4A" energize the coils of relays "R2" and "R2A".
When relays "R2" and "R2A" are energized, power is
removed from the engine's primary Electronic Control
Module (ECM) and the engine's secondary ECM.
The primary ECM and the secondary ECM will power
down. The injection signals to the injector solenoids
will stop. The emergency stop lamp on the control
panel will illuminate.
The contact of relay "R4A" also supplies power

to terminal 3 of the connector for the timer. When
power is applied to terminal 3 of the connector for
the timer, the timer will activate. The timer outputs
24 VDC to terminal 6 of the connector for the timer
for 2.5 seconds. The 24 VDC from terminal 6 of
the connector for the timer is applied to the coil of
the "Air Shutoff Switch {ASOS)". The contact of the
"ASOS" energizes the air shutoff solenoids. The
timer will output voltage to the coil of the "AS OS"
for approximately 2.5 seconds. The "ASOS" will
then deactivate and power is removed from the air
shutoff solenoids. This prevents damage to the air
shutoff solenoids. A normally open switch at the air
shutoff valves will close when the air shutoff solenoid
activates the air shutoff valve. The switch input to the
ECM notifies the ECM that the air shutoff valves are
closed. The ECM will not send injection signals to the
injector solenoids until the switch inputs from the air
shutoff valves indicate that the valves are open. -
KENR5404-03 101
Prim. ECM+ Prim. ECM- Sec. ECM+ Sec. ECM

.'--J, A287(82S7)-------_
[I
rI • I 1 I I- 8103
0229(229)---------+__---,
Air S/O
'--J, H708 ---------------~b
'-I> K7081-----, H 7 0 8 W Air SID

~--_+--G708 B Sol. RH
Air SID
220 ~--f__-H401 ~ Switch RH
F401
Air SID
Sol. LH
918----\------' Air SID

Switch LH
-.- I • I I I I T120
R1 R3A R3 R4
120 .. I 120 ,-------D229(229)-------'
Overspeed ~F708 A287(8287)
918 X1~ P·C11 Primary ECM

/ ' A-C90
P-C2I C150 +Battery
A-C91 18
A-Ci1 150 +Battery
120 D9 E-C2 0229 -Battery
M150 I IftIl E-C11 229 -Battery
" " C-C1 113 Keyswitch
B.r\X2 354
/....1, , 0998 Digital Ref.
i
Secondary H401A Air Shutoff Tripped
ECM Ready H401 H401 Air Shutoff Tripped
F715 F715
~676
E-Stop 1
/ , F719 F719 E-Stop 2
Secondary 700 8V Digital Power
ECM Active !;-C2I 112 997 5V Analog Power Left
X2' /X1 G-C6 A997 5V Analog Power Right
/ , 354
993 Analog Ref. Left
E-Stop A993 Analog Ref. Right
F721 ECS in RemtelAuto
~ II III 354 A70a 8V Digital Power
F998 Digital Ref.
Local E-Stop
Switch P2 J2
Customer E-Stop 1
_ =....!..!...!!...!.."---jIL.. - I ~ Customer
E-Stop 2 T
IT P1 J1
3-1<153~ +Battery
Secondary ECM
~ BA
103--kiS2J +Battery
Air Shutoff Tripped ~ -Battery
Cust. Rem. E-Stop AS -Battery
Sec. ECM Active u E-Stop 2
Sec. ECM Ready v E-Stop 1
TB-C1IC-C1S 113--l<170~1 Keyswitch
Cust.
-675--+<1311 Sec. ECM Ready
L - - - - - - - - - - - r - - 6 7 6 - k 29«1 Sec. ECM Active
L-------------113--------------------~
Typical example
'-....
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RIGHT SIDE VIEW
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Illustration 40
Connector locations
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(2) A-C2/J-C2 RH rigid harness connectors
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2 g01322359
Illustration 41
(7) C-C 15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2 Terminal locations for the C-C17/F-C 1 LH rigid hamess connectors
(9) C-C29 Secondary ECM connector P1 and the connectors G-C6/F-C2 for a LH Control panel
(10) G-C6/F-C2/F-ClIC-C17 Connectors for a LH Control panel (Terminal 11) 24 VDC 120-BK
(11) C-C18/TB-C1 Customer connectors (Terminal 12) Emergency stop signal 354-BK
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1!E-C1 LH rigid harness connectors
'
KEN RS404-03 103
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Terminal locations for the P-C2fA-C91 connectors for the power

distribution panel
(Terminal B) Emergency stop signal 354-BK
®®®®
(Terminal E) 24 VDC 120-BK
g01322442
Illustration 43
Terminal locations for the C-C1fE-C1 LH rigid harness connectors
and the A-C1fE-C2 RH rigid harness connectors
(Terminal f) 24 VDC 120-BK
(Terminal m) Emergency stop signal 354-BK
Test Step 1. Inspect the Electrical

Connectors and the Wiring
position.

C. Thoroughly inspect the ECM connectors J1/P1 • Not OK - The air shutoff solenoids failed to
and J2/P2. Inspect all of the other connectors. activate. Proceed to Test Step 3.
Check the allen head screw on each of the
ECM connectors for the proper torque. Refer to Test Step 3. Check for Voltage from the
Troubleshooting, "Electrical Connectors - Inspect" "ASOS" at the Connector P-C1 for the
for the correct torque values. Power Distribution Panel
D. Perform a 45 N (10 Ib) pull test on each of the A. Turn the ECS to the OFF/RESET position.
with the circuit. B. Remove wire G708-BK from terminal "I" of
connector A-C90. Install a wire jumper into the
E. Check the harness and the wiring for abrasion connector for wire G708-BK.
Expected Result:
D. Activate the local emergency stop switch.
coupled and/or inserted, and the harness and wiring E. Monitor the voltage on the wire jumper in terminal
are free of corrosion, of abrasion or of pinch points. I at connector A-C90 of the rigid harness. Refer to
Illustration 39 for a schematic of the circuit.
Results:
F. Activate the local emergency stop switch.
• OK - The harness and wiring appear to be OK.
Proceed to Test Step 2. G. Return all wiring to the original configuration.
• Not OK - There is a problem in the connectors Expected Result:

and/or wiring.
Repair: Repair the connectors or wiring and/or 2.5 seconds.
the seals are properly in place and ensure that the
connectors are completely coupled.
STOP.
Results:

-
Test Step 2. Test the Circuit for the Local
Emergency Stop Switch • Not OK - The voltage did not measure 24 ± 3
VDC for approximately 2.5 seconds. Proceed to
A. Turn the circuit breaker for the battery to the ON Test Step 4.
position.
Test Step 4. Test for Voltage to the Coil of
B. Turn the ECS to the STOP position. Relay "R4A" at the Connector P-C2 for
the Power Distribution Panel
C. Activate the local emergency stop switch on the
control panel. A. Turn the ECS to the OFF/RESET position.
D. Monitor the air shutoff solenoids. B. Remove wire 354-BK from terminal "B" of
connector A-C91.
E. Deactivate the local emergency stop switch.
Expected Result:
D. Activate the local emergency stop switch.
The air shutoff solenoids activated.
E. Monitor the voltage on wire 354 at connector
Results: A-C91 of the rigid harness.
• OK - The air shutoff solenoids activated correctly. F. Deactivate the local emergency stop switch.

Expected Result:
-
STOP. The voltage measures 24 ± 3 VDC.
KENR5404-03 105
Section
Results: H. Reconnect wire G708-BK to the "ASOS".
• OK The voltage measures 24 ± 3 VDC. The Expected Result:
circuit is operating correctly to this point Proceed

to Test Step 5. The voltage measures 24 ± 3 VDC for approximately
2.5 seconds.
• Not OK No voltage was measured. Proceed to

Test Step 11. Results:
Test Step 5. Test for Voltage at the Coil • OK - The voltage measures 24 ± 3 VDC for
of the "ASOS" approximately 2.5 seconds. The circuit is operating
Repair: Repair the wire G708-BK between the
B. The input to the coil of the "AS aS" is wire T708-BK "AS OS" and wire G708-BK on pin I at connector
from terminal 6 of the timer. Remove wire T708-BK P-C 1 of the rigid harness.
from the "ASOS".
STOP.
C. Connect a voltmeter between wire T708-BK from
the "AS aS" and the engine ground. • Not OK - The voltage did not measure 24 ± 3 VDC
for approximately 2.5 seconds.
Repair: Verify that 24 ± 3 VDC is present on wire
E. Activate the local emergency stop switch. K708-BK at the normally open contacts of the
F. Monitor the voltage on the voitmeter. check the wire K708-BK and the circuit breaker for
the air shutoff for problems.
G. Deactivate the local emergency stop switch.
If voltage is present on the wire K708-BK, check
wire 220-BK on the coil of the "ASOS" for continuity
to the -Battery. If necessary, repair the wire or
Expected Resu It:
replace the wire. If wire 220-BK is OK and voltage
is present on wire K708-BK, replace the /oASOS".
2.5 seconds.
STOP.
Results:
Connector for the Air Shutoff Solenoids
o OK - The voltage measures 24 ± 3 VDC for
approximately 2.5 seconds. The circuit is operating A. Turn the to the OFF/RESET position.
• Not OK - The voltage did not measure 24 ± 3 solenoids. Disconnect the connector for the right
VDC. Proceed to Test Step S. and left sides of the engine.
Test Step 6. Check for Voltage from the C. Connect a voltmeter between wire G708-BK on
"ASOS" to the Air Shutoff Solenoids the connector for the air shutoff solenoid and the
engine ground.
B. Disconnect wire G70S-BK from the "ASOS".
E. Activate the local emergency stop switch.
C. Connect a voltmeter to the empty terminal on
the "ASOS". Connect the other lead from the F. Monitor the voltage on the voltmeter.
voltmeter to engine ground.
H. Reconnect the connectors for the air shutoff
E. Activate the local emergency stop switch. solenoids.

IVO
Trou bleshooting Section
Expected Result: Expected Result:

2.5 seconds.
Results:
Results: -
• OK - The voltage measures 24 ± 3 VDC. Proceed
• OK - The voltage measures 24 ± 3 VDC for to Test Step 9.
correctly to this point. • Not OK - The voltage did not measure 24 ± 3
VDC. Proceed to Test Step 10.
Repair: Check the wire H708-BK from terminal A
of the connector for continuity to the -Battery. If Test Step 9. Check the Voltage at Terminal
the wire H708-BK to the -Battery terminal is OK, 6 of the Connector for the Timer
replace the air shutoff solenoid. Verify that the
circuit operates correctly. A. Turn the ECS to the OFF/RESET position.
If the wire H708-BK does not have continuity to the B. Disconnect wire T708-BK from terminal 6 of the
-Battery from terminal A of the connector, check for connector for the timer.
continuity on wire H708-BK on pin H at connector
P-C1/A-C90 of the rigid harness to -Battery. If C. Connect a voltmeter between terminal 6 of the
the wire H708-BK does not have continuity to the connector for the timer and engine ground.
-Battery from pin H at connector P-C1 of the rigid
harness, verify that the breaker for the air shutoff D. Turn the ECS to the STOP position.
is not tripped.
STOP.
• Not OK The voltage did not measure 24 ± 3 VDC
for approximately 2.5 seconds. System voltage G. Deactivate the local emergency stop switch.
was not available at the solenoid connector.
~
Repair: There is a problem in the wiring between
the connector for the air shutoff solenoids and wire Expected Result:
G708-BK on pin I at connector P-C1/A-C90 of

the rigid harness. Repair the connectors or wiring The voltage measures 24 ± 3 VDC for approximately
and/or replace the connectors or wiring. 2.5 seconds.
STOP. Results:
Test Step 8. Check the Voltage at the • OK - The voltage measures 24 ± 3 VDC for
Contact of Relay "R4A" approximately 2.5 seconds.
A. Turn the ECS to the OFF/RESET position. Repair: Repair the wire T708-BK between the
"AS OS" and terminal 6 of the timer.
B. Disconnect wire T120-BK from terminal 87 of
relay "R4A". STOP.
C. Connect a voltmeter between terminal 87 of relay • Not OK - The voltage did not measure 24 ± 3 VDC
"R4A" and the engine ground. for approximately 2.5 seconds.
D. Turn the ECS to the STOP position. Repair: Check for 24 ± 3 VDC on terminal 3 of the
connector for the timer.

If voltage is not present on terminal 3, repair the
F. Monitor the voltage on the voltmeter. wire T120-BK between terminal 87 of relay "R4A"
and terminal 3 of the connector for the timer.

If voltage is present on terminal 3 of the connector ~
H. Turn the ECS to the OFF/RESET position. for the timer, verify that wire 220-BK on terminal 2
of the connector for the timer has continuity to the
I. Reconnect wire T120-BK. -Battery. If wire 220-BK does not have continuity
to the -Battery, repair the wire.
KENR5404-03 107
Section
Verify that 24 ± 3 VDC is present on terminal 1 of Repair: Repair the wire 354-BK between the coil
the connector for the timer. If 24 ± 3 VDC is not of the "AS OS" and the connector P-C2/A-C91 on
present on terminal 1 of the connector for the timer, the power distribution panel.
verify that the ECS is not in the "OFF/RESET"
position. Verify that the "MPD" breaker is not STOP.
tripped. Check the normally closed contact of
relay "R 1" for proper operation. Check the wire Test Step 11. Check the Voltage from the
120-BK between terminal 1 of the connector for Local Emergency Stop Switch to Relay
the timer and relay "R 1" for damage. Check the "R4A"
wire A120-BK between relay "R1" and the "MPD"
breaker for damage. If necessary, repair the wires. A. Turn the ECS to the OFF/RESET position.
If the voltage is present on terminal 1 and 3 of the B. Disconnect wire 354-BK from the local emergency
timer and wire 220-BK is OK, replace the timer. stop switch.
STOP. C. Connect a voltmeter to the empty terminal on the

local emergency stop switch. Connect the other
Test Step 10. Check the Voltage at the lead from the voltmeter to engine ground.
Coil of Relay "R4A"
B. Connect a voltmeter between wire 354-BK on
terminal 86 of relay "R4A" and the engine ground. F. Monitor the voltage on the voltmeter.
C. Turn the ECS to the STOP position. G. Deactivate the local emergency stop switch.
D. Activate the local emergency stop switch. H. Reconnect wire 354-BK.
E. Monitor the voltage on the voltmeter. Expected Result:
F. Deactivate the local emergency stop switch. The voltage measures 24 ± 3 VDC.
The voltage measures 24 ± 3 VDC. • OK - The voltage measures 24 ± 3 VDC.

Results: Repair: Repair the wire 354-BK between the local
emergency stop switch and the wire 354-BK on pin
• OK - The voltage measures 24 ± 3 VDC. B at connector P-C2/A-C91 of the rigid harness.
Refer to Illustration 39 for a schematic of the circuit
Repair: Check wire 220-BK on the coil of the "R4A" and the interconnecting connectors of the circuit.
relay for continuity to the -Battery. If necessary,
repair the wire or replace the wire. STOP.
Check for 24 ± 3 VDC on wire 120-BK on terminal .. Not OK - The voltage did not measure 24 ± 3
30 of relay "R4A". If 24 ± 3 VDC is not present VDC. Proceed to Test Step 12.
on wire 120-BK, verify that the ECS is not in the
"OFF/RESET' position. Verify that the "MPD" Test Step 12. Check the Voltage to the
breaker is not tripped. Check the normally closed Local Emergency Stop Switch
contact of relay "R 1" for proper operation. Check
the wire 120-BK between terminal 30 of the relay A. Turn the ECS to the OFF/RESET position.
"R4A" and relay "R1" for damage. Check the
wire A120-BK between relay "R1" and the "MPD" B. Connect a voltmeter between wire 120-BK on the
breaker for damage. If necessary, repair the wires. local emergency stop switch and engine ground.
If wire 220-BK is OK and voltage is present on wire C. Turn the ECS to the STOP position.
120-BK on terminal 30, replace relay "R4A".
D. Monitor the voltage on the voltmeter.
STOP.
Expected Result:
.. Not OK - The voltage did not measure 24 ± 3

VDC. The voltage measures 24 ± 3 VDC.
.vv
Section
Results:

~
Repair: Replace the local emergency stop switch.
STOP.

VDC.
Repair: Check the wire 120-BK on pin Eat

connector P-C2/A-C91 of the rigid harness
between the connector and the local emergency
stop switch for damage. Refer to Illustration 39 for
a schematic of the circuit and the interconnecting
connectors of the circuit.
Verify that the ECS is not in the "OFF/RESET'

position. Verify that the "MPD" breaker is not
tripped. Check the normally closed contact of relay
"R1" for proper operation. Check the wire A120-BK
between relay "R1" and the "MPD" breaker for
damage. If necessary, repair the wires.
STOP.
i02639558
Emergency Stop (Remote)

Test
SMCS Code: 7332-038-S0
Use this procedure in order to troubleshoot the

customer's emergency stop system or use this
procedure if the diagnostic code in Table 36 is active
or easily repeated.
Table 36
System Response
Switch The two inputs from the customer The code is logged.
erratic, intermittent, or incorrect shutdown switch are in the opposite
state.
When the customer's emergency stop button is Relay "R3A" and relay "R3" are energized through
activated, the emergency stop inputs U and T to terminal 3 of the diode assembly. Terminal 3 of the
the primary ECM and the secondary ECM from the diode assembly will energize relay "R3A" and relay
customer connector go high. The secondary ECM will "R3" for one second. The contacts of relay "R3" keep
recognize this change. The secondary ECM activates relay "R3A" and relay "R3" energized until the Engine
the output driver for the emergency shutdown Control Switch (ECS) is cycled to the OFF/RESET
system. The "Air Shutoff Switch (ASOS)" energizes position. The contacts of relay "R3A" keep the coils
the two air shutoff solenoids. The solenoids trip the of relay "R2" and relay "R2A" energized. When relays
air shutoff valves. "R2" and "R2A" are energized, power is removed
from the primary ECM and the secondary ECM. The
primary ECM and the secondary ECM will power
down. The injection signals to the injector solenoids
will stop.
KE NR5404-03 109
The contact of relay "R3A" also supplies power to

terminal 3 of the connector for a timer. When power
is applied to terminal 3 of the connector for the timer,
the timer will activate. The timer outputs 24 VDC
from terminal 6 of the connector for the timer for
2.5 seconds. The 24 VDC from the timer is applied
to the coil of the "AS OS" and to terminal 2 of the
diode assembly. The "ASOS" energizes the two air
shutoff solenoids. The solenoids trip the air shutoff
valves. The 2.5 second time limit for activation of the
"ASOS" prevents damage to the air shutoff solenoids.
A normally open switch at the air shutoff valves will
close when the air shutoff solenoid activates the
air shutoff valve. The switch inputs a signal to the
primary ECM and to the secondary ECM. The signal
notifies the primary ECM and the secondary ECM
that the air shutoff valves are closed. The primary
ECM and the secondary ECM will not send injection
signals to the injector solenoids until the switch inputs
from the air shutoff valves indicate that the valves
are open.
In order to start the engine after an emergency

stop condition, the ECS must be turned to the
OFF/RESET position. This resets the ECM and the
air shutoff timer. In addition to turning the ECS to the
OFF/RESET position, the operator must manually
open the air shutoff valves before starting the engine.
-I-IU
Prim. ECM+ Sec. ECM+ Sec. ECM
Air 5/0
'-...p H70B i>
b K70B-------,
,----t--~;~m8
~ ~:I.S~~
Air SIO
'-----4-"~n. '-1>-220
H401 ~ Switch RH
F401
Air SIO
Sol. LH
·-~918--'------' Air SIO

Switch LH
I + I I I i T120 A1 SO
A103(103)~
R3A R3 C150(1S01~-'-----'
- - - - + - - - -....-+1-120 '" I ,------D229(229)------"

r---------~A287(B287)
A120 Overspeed F70a
P·C11
A-C90 P1 J1 Primary ECM
B C150 +BaUery
150 +Batte ry
C·C17fF-C1 F-C2JG-C6
"I D9 D229 -Battery
120
229 -Battery
M150
I 1l1li
Keyswitch
~X2 ,.-354
Digital Ref.
o OFF 22 / "
Secondary Air Shutoff Tripped
REMOTE 23
ECM Ready Air Shutoff Tripped
START 24
1 I " I F71 E-stop 1
o STOP 25 ~676 E-Stop 2
/ "
o OFF 12 Secondary 8V Digital Power
ECMActive 997 5V Analog Power Left
oREMOTE~13
A2~ A997 5V Analog Power Right
o START b14 993 Analog Ref. Left
/ "
o STOP ~15 E-stop A993 Analog Ref. Right
o OFF 7
F721 ECS in Remte/Auto
oREMOTE 8
A70a 8V Digital Power
o START 16 9
~354 F998 Digital Ref.
o STOP •• 10
Local E-Stop
Switch P2J2
o OFF iP17
oREMOTE!618 Customer E-stop 1 U
Secondary ECM
113 START .~ Customer E-Stop 2 T
+Battery
o STOP .20 B +Battery
~
Air Shutoff Tripped m -Battery
o OFF Cust. Rem, E-Stop AS -Battery
/ " REMOTE 3
o START 4 Sec. E CM Active u E-stop 2
A120 Sec. ECM Ready v E-stop 1
o STOP 5
TB-C1/C·C18 113 Keyswitch
o Cust.
Sec. ECM Ready
Sec. ECM Active
L------------~113--------------------~
P2 J2
Typical example
KENR5404-03 111
WIRE SIDE
148888goOO88~23
6 D 8 9
o 0000 o
000008(~)
€~ @ g§83R 00008006
4800000 0 0 0 0 0 57 /000888080
0000000000000
! (~)880G80888
( 88800088@
ECM SIDE
\13®®®®8®®88
i/;~ ~ .8B@®®B8®@)
Co 0 0 0 0 00 0 0 0 0 0 0 )14 ®®®@§®®®
23.0000000000
"000" [~J 0000>< @®®§®®@
390 0 0 0
470 0 0 0
570 0 0 0 0
@ 0 0 0 032
0
0 0 0 0 40
0 0 0 0 048
,~"
§®®®
o
',,-----,,'
~O 0 0 00 000 000 O~
~ ~
Illustration 45
g01323905
0000
P1 ECM connector
//8800000
(P1-23) "E-Stop 1"
(P1-28) "E-Stop 2"
'/00000000
:~00888000
:~(~)808G0CD88
WIRE SIDE
:388000888
(08®®B®®®®®
4
000000000000.
14 0 0 0 0 0 0000023 ®®8B®®@®®
08888 ~® 8888 0
3
8®@®@@@@
=j400ooo~ 0 0 0 0 47 ®®®8®®®
IJ488888800088888 57 ®®®®
ECM SIDE
g01323796
Illustration 47
1:::
1380000000000 0 ~j
~~ Terminal locations for the TB-C1/C-C18 customer connector
(Terminal U) HE-Stop 1"
230 0 0 0 0 0 0 0 0 0 014 (Terminal T) "E-Stop 2"
,,0000
39000 0
(I@J
@ 0000"000032
47000 0 0000 40
5700000 0 0000048
~O 0 0 0 0 0 0 0 0 0 0 0 0)
~ :e
P2 ECM connector
(P2-13) Drive for the air shutoff
ll~
RIGHT SIDE VIEW
o/~~n I
2 3 4 5
ZO
aO
®Ge
OE
G0 (0
8
dO OA
eO 0 @ OB
fO ® @ OC
bO OF I / I 6 7 8 9 10
080
® @
LEFT SIDE VIEW

@
EO
eG@ Oa g01320528
CD ()) I"ustration 49
AO
BO
Co
4E)
®
8 @
0
Od
Oe
or
Connector locations
FO Ob
CDG)0 (5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
® (8) C-C28 Secondary ECM connector P2
(11) TB-C1/C-C18 Customer connectors
g01322302
Illustration 48
Terminal locations for the following connectors P-C1/A-C90 Test Step 1. Inspect the Electrical
Connector for the power distribution panel, A-C2/J-C2 RH rigid Connectors and the Wiring for the
harness connector, and C-C2/J-C1 LH rigid harness connectors Customer's Emergency Stop
(Terminal G) Drive for the air shutoff switch F708·BK
(Terminal H) Return for the air shutoff solenoid H708-BK Note: The 337-2 diagnostic code is generated
(Terminal I) Drive for the air shutoff solenoid G708-BK
because of a problem with the emergency stop
inputs to the ECM from the customer connector. The
two signals should be at a low potential or the two
signals should be at a high potential. When the two
signals are at a different potential from each other
the diagnostic code is generated.

position.

C. Disconnect the following connectors.
• C-C18 customer connector

KENR5404-03 113
'oubleshootinq Section
• P1 primary ECM connector • Not OK - There is a problem in the connectors

and/or wiring.
• P1 secondary ECM connector
.. P2 primary ECM connector

.. P2 secondary ECM connector

STOP.
D. Check for an open circuit in the wiring. Test Step 2. Test the Air Shutoff System
a. Install a wire jumper between terminal U and A. Turn the circuit breaker for the battery to the ON
terminal T at the customer connector. position.
b. Measure the resistance between P1-23 and B. Turn the ECS to the STOP position. The engine
P1-28 on the primary P1 ECM connector and should be off.
on the secondary P1 ECM connector. Wiggle
the harness while performing the resistance C. Activate the customer's emergency stop switch.
checks.
D. Monitor the air shutoff solenoids.
c. Remove the wire jumper.
E. Check for a short circuit in the wiring.

Expected Result:
s. Measure the resistance between wire F715-BK

and every wire on the following connectors . The air shutoff solenoids activated.
.. C-C18 customer connector Results:
.. P1 primary ECM connector • OK The air shutoff solenoids activated correctly.
e P1 secondary ECM connector Repair: The problem may be intermittent. If the

"Electrical Connectors -Inspect".
" P2 secondary ECM connector

STOP.
b. Measure the resistance between wire F719-BK • Not OK - The air shutoff solenoids failed to
and every wire on the following connectors. activate. Proceed to Test Step 3.
• C-C18 customer connector

Test Step 3. Check for the Voltage from
the "ASOS" at the Connector P-C1fA-C90
" P1 primary ECM connector
for the Power Distribution Panel
A. Turn the ECS to the STOP position. The engine
should be off.
B. Remove wire G708-BK from terminal "I" of

connector for wire G708-BK
Expected Result:
C. Activate the customer's emergency stop switch.

The resistance checks indicate a short circuit when
the wire jumper is installed. The resistance checks

D. Monitor the voltage on the wire jumper in terminal
indicate an open circuit when the wire jumper is
removed.
Illustration 44 for terminal locations.
Results:
" OK - The harness and wiring appear to be OK.

Verify that the two input signals on terminal U and
terminal T from the customer connector TB-C 1 are
at the same potential before proceeding. Proceed
to Test Step 2.
11"1
Expected Result: C. Turn the ECS to the STOP position.
The voltage measures 24 ± 3 VDC for approximately D. Activate the customer's emergency stop switch.
2.5 seconds. ~
E. Monitor the voltage on the voltmeter.

Results:
F. Deactivate the customer's emergency stop switch .
• OK The voltage measures 24 ± 3 VDC for
approximately 2.5 seconds. The circuit is operating G. Return all wiring to the original configuration.

Expected Result:
.. Not OK - The voltage did not measure 24 ± 3

VDC for approximately 2.5 seconds. Proceed to The voltage measures 24 ± 3 VDC for approximately
Test Step 4. 2.5 seconds.
Test Step 4. Test for Voltage to the Coil of Results:
the "ASOS" at the Connector A-C90 for

the Power Distribution Panel • OK - The voltage measures 24 ± 3 VDC for
A. Remove wire F708-BK from terminal "G" of correctly to this point. Proceed to Test Step 6.
connector for wire F708-BK. • Not OK - No voltage was measured. Proceed to
Test Step 10.
C. Activate the customer's emergency stop switch. for 2.5 seconds. Proceed to Test Step 8.
D. Monitor the voltage on the wire jumper in terminal Test Step 6. Check for Voltage from the
G at connector A-C90 of the rigid harness. Refer "ASOS" to the Air Shutoff Solenoids
to Illustration 44 for terminal locations.

B. Disconnect wire G708-BK from the "ASOS".

-
C. Connect a voltmeter to the empty terminal on the
Expected Result: "ASOS". Connect the other lead of the voltmeter
to engine ground.
one second. D. Turn the ECS to the STOP position. The engine
should be off.
Results:
approximately one second. The circuit is operating F. Monitor the voltage on the voltmeter.
• Not OK - No voltage was measured. Proceed to
Test Step 14. H. Reconnect wire G708-BK to the "ASOS",
Test Step 5. Test for Voltage to the Coil Expected Result:
of the "ASOS"
A. Turn the ECS to the OFF/RESET position. 2.5 seconds.
B. The input to the coil of the "ASOS" is wire T708-BK Results:
from the diode assembly. Disconnect wire

T708-BK from the "ASOS". Connect a voltmeter • OK - The voltage measures 24 ± 3 VDC for
between wire T708-BK and the engine ground.
Note: The "AS OS" is turned on for one second by

the ECM. The timer keeps the "ASOS" energized for
approximately 2.5 seconds.
-
KENR5404-03 115
Repair: Repair the wire G708-BK between the Repair: Check the wire H708-BK from terminal
"AS OS" and terminal I at connector P-C1 of the A of the connector for the air shutoff solenoid
power distribution panel. for continuity to the -Battery terminal. If the wire
H708-BK to the -Battery terminal is OK, replace
STOP. the air shutoff solenoid.
G Not OK - The voltage did not measure 24 ± 3 VDC STOP.

Repair: Verify that 24 ± 3 VDC is present on wire for approximately 2.5 seconds. System voltage
K708-BK at the normally open contacts of the was not available at the solenoid connector.
check the wiring and the circuit breaker for the air Repair: Repair the wire G708-BK between the
shutoff for problems. connector for the air shutoff solenoids and terminal
Check wire 220-BK on the coil of the "AS OS" for Illustration 44 for a schematic of the circuit.
continuity to the -Battery. If necessary, repair the
wire or replace the wire. STOP.
If wire 220-BK is OK and voltage is present on wire Test Step 8. Check the Voltage at the
K708-BK, replace the "ASOS". Contact of Relay "R3A"
STOP. A. TUrn the ECS to the OFF/RESET position.
Test Step 7. Check the Voltage at the B. Disconnect wire T120-BK from terminal 87 of
Connector for the Air Shutoff Solenoids relay "R3A".
A. Turn the ECS to the OFF/RESET position. C. Connect a voltmeter between terminal 87 of relay
"R3A" and the engine ground.
solenoids. Disconnect the connector for the right D. Turn the ECS to the STOP position.
and left sides of the engine.
C. Connect a voltmeter between wire G708-BK on
the connector for the air shutoff solenoid and the F. Monitor the voltage on the voltmeter.
engine ground.
D. Turn the ECS to the STOP position. The engine
should be off. H. Reconnect wire T120-BK.
E. Activate the customer's emergency stop switch. Expected Result:
F. Monitor the voltage on the voltmeter. The voltage measures 24 ± 3 VDC.
G. Deactivate the customer's emergency stop switch. Results:
H. Reconnect the connectors for the air shutoff " OK - The voltage measures 24 ± 3 VDC. Proceed
solenoids. to Test Step 9.
Expected Result: .. Not OK - The voltage did not measure 24 ± 3

2.5 seconds. Test Step 9. Check the Voltage at Terminal
6 of the Connector for the Timer
Results:
approximately 2.5 seconds. The circuit is operating B. Connect a voltmeter between terminal 6 of the
correctly to this point. connector for the timer and engine ground.
D. Activate the customer's emergency stop switch .
.
~
110
E. Monitor the voltage on the voltmeter.

F. Deactivate the customers emergency stop switch.

Expected Result:
Expected Result:

2.5 seconds.
2.5 seconds.
Results:
Results:
• OK - The voltage measures 24 ± 3 VDC for • OK - The voltage measures 24 ± 3 VDC for
approximately 2.5 seconds. Proceed to Test Step approximately 2.5 seconds.
12.
Repair: Repair the wire T708 between the
• Not OK - The voltage did not measure 24 ± 3 VDC connector for the diodes and the "ASOS".

STOP.
Repair: Check for 24 ± 3 VDC on terminal 3 of the
connector for the timer. If voltage is not present • Not OK - The voltage did not measure 24 ± 3 VDC
on terminal 3, repair the wire T120-BK between for approximately 2.5 seconds.
terminal 87 of relay "R3A" and terminal 3 of the
con nector for the timer. Repair:
If voltage is present on terminal 3 of the connector 1. Turn the ECS to the OFF/RESET position.
for the timer, verify that wire 220-BK on terminal 2
of the connector for the timer has continuity to the 2. Disconnect wire F708-SK from terminal 1 of the
-Battery. If wire 220-BK does not have continuity connector for the diodes.
to the -Battery, repair the wire.
3. Connect a voltmeter between wire F708-SK and
Verify that 24 ± 3 VDC is present on terminal 1 the engine ground.
of the connector for the timer. If 24 ± 3 VDC is
not present on terminal 1 of the connector for the 4. Turn the ECS to the STOP position.
timer, verify that the engine control switch is not in
the "OFF/RESET" position. Verify that the "MPD" 5. Activate the customer's emergency stop switch.
breaker is not tripped. Check the normally closed
contact of relay "R 1" for proper operation. Check 6. Monitor the voltage on the voltmeter.
the wire 120 between terminal 1 of the connector
for the timer and relay "R1" for damage. Check 7. Deactivate the customer's emergency stop
the wire A120 between relay "R1" and the "MPD" switch.
breaker for damage. If necessary, repair the wires.

If the voltage measures 24 ± 3 VDC for
If the voltage is present on terminal 1 and terminal approximately one second, replace the diodes.
3 of the timer and wire 220-BK is OK, replace the
timer. If the voltage does not measure 24 ± 3 VDC
for approximately one second, repair the wire
STOP. F708-SK between the connector for the diodes
and wire F708-BK on pin G at connector A-C90
Test Step 10. Check the Voltage at of the rig ht rail.
Terminal 4 of the Connector for the
Diodes STOP.
A. Turn the ECS to the OFF/RESET position. Test Step 11. Check the Voltage at the
Coil of Relay "R3A"
8. D isconnect wire T708-BK from terminal 4 of the
connector for the diodes. A. Turn the ECS to the OFF/RESET position.
C. Connect a voltmeter between terminal 4 of the 8. Disconnect wire 918-SK from terminal 86 of relay
connector for the diodes and the engine ground. "R3A".
D. Turn the ECS to the STOP position. C. Connect a voltmeter between wire 918-SK and
the engine ground.
'-
KENR5404-03 117
Section
D. Turn the ECS to the STOP position. Results:
E. Activate the customer's emergency stop switch. .. OK The voltage measures 24 ± 3 VDC. Proceed
to Test Step 13.
.. Not OK The voltage did not measure 24 ± 3
G. Deactivate the customer's emergency stop switch. VDC.

Repair: Repair the wire T708-BK between the
diodes and the timer.
Expected Result:
STOP.
Test Ster 13. Check the Voltage from

Results:
Termina 3 of the Connector for the Diode
Assembly

Repair: Check wire 220-BK on the coil of the "R3A"
relay for continuity to the -Battery. If necessary, B. Connect a voltmeter between terminal 3 of the
repair the wire or replace the wire. connector for the diode assembly and the engine
ground.
Check for 24 ± 3 VDC on wire 120-BK on terminal
30 of relay "R3A". If 24 ± 3 VDC is not present on C. Turn the ECS to the STOP position. The engine
wire 120-BK, verify that the engine control switch should be off.
is not in the "OFF/RESET" position. Verify that the
"MPD" breaker is not tripped. Check the normally D. Activate the customer's emergency stop switch.
closed contact of relay "R1" for proper operation.
Check the wire 120-BK between terminal 30 of the E. Monitor the voltage on the voltmeter.
relay "R3A" and relay "R1" for damage. Check the
wire 120-BK between relay "R1" and the "MPD" F. Deactivate the customer's emergency stop switch.
breaker for damage. If necessary, repair the wires.

Expected Result:
If wire 220-BK is OK and voltage is present on wire

120-BK on terminal 30, replace relay "R3A". The voltage measures 24 ± 3 VDC.
STOP. Results:
.. Not OK - The voltage did not measure 24 ±3 • OK - The voltage measures 24 ± 3 VDC.
Repair: Repair the wire 918-BK between the
Test Ster 12. Check the Voltage to diodes and relay "R3A".
Termina 2 of the Connector for the

Diodes from the Timer STOP.
A. Turn the ECS to the OFF/RESET position. .. Not OK - The voltage did not measure 24 ± 3
VDC.
B. Connect a voltmeter between the terminal 2 of the
connector for the diodes and the engine ground. Repair: Replace the diodes.
C. Turn the ECS to the STOP position. The engine STOP.

should be off.
Test Step 14. Check the Output Driver for
D. Activate the customer's emergency stop switch. the Air Shutoff System at the ECM
E. Monitor the voltage on the voltmeter. A. Turn the ECS to the OFF/RESET position.
F. Deactivate the customer's emergency stop switch.

B. Disconnect the secondary ECM connector P2.
Expected Result:
C. Remove wire F708-BK from ECM connector
P2-13. Install a wire jumper into P2-13.
D. Reconnect ECM connector P2.
~
110
Section
E. Connect a voltmeter between the wire jumper in

P2-13 and engine ground.
F. Turn the ECS to the STOP position.
G. Activate the customer's emergency stop switch.
H. Monitor the voltage on the voltmeter.
I. Deactivate the customer's emergency stop switch.
J. Return all wiring to the original configuration.
Expected Result:
The voltage measures 24 ± 3 VDC for one second.
Results:
• OK - The voltage measures 24 ± 3 VDC for one

second.
Repair: Repair the wire F708-BK between the

ECM connector and terminal G at connector A-C90
of the rigid harness. Refer to Illustration 44 for a
schematic of the circuit. Check for voltage at the
following connectors C-C2/J-C1 LH rigid harness
connectors and A-C2/J-C2 RH rigid harness
connectors.
STOP.

VDC.
Repair: Monitor the status screen for the

emergency stop in order to verify that the ECM is
receiving the emergency stop signal. If the ECM
is receiving the emergency stop signal from the
customer connector, replace the ECM. If the ECM
is not receiving the emergency stop signal from the
customer connector, repair the wiring between the
ECM and the customer connector.
STOP.
i02640069
Engine Control Switch - Test

SMCS Code: 1416-038
Use this procedure in order to troubleshoot the

engine control switch (ECS) or use this procedure
if the diagnostic code in Table 37 is active or easily
repeated.
~
KENR5404-03 119
Section
Table 37

336-2 Engine Control Switch erratic, The two inputs from the engine control The code is logged.
intermittent, or incorrect switch are in the opposite state.
The ECS can operate in four modes: OFF/RESET, When the ECS is in the STOP position, the following
START, STOP, and REMOTE. relays energize: "Stop 1" relay and "Stop 2" relay. The
start/run/stop inputs P1-21 and P1-22 will be high.
The primary electronic control module (ECM)
receives three signals that allow the ECM to When the ECS is in the OFF/RESET position, none
determine the mode of operation. The input signals of the relays are energized.
on P1-21 and P1-22 tell the ECM the position of the
ECS. The input signals on P1-21 and P1-22 must
be at the same potential or a diagnostic code will be
generated. The third input signal on P1-68 tells the
ECM if the ECS is in the REMOTE position. If the
input signal on P1-68 is low, the ECM knows that the
ECS is in the REMOTE position. If the input signal on
P1-68 is not low, the ECM knows that the ECS is not
in the REMOTE position.
When the ECS is in the REMOTE position, inputs

from the customer control the operation of the engine.
The following list contains some of the inputs from
the customer connector and the inputs function.
• C remote start 2
• 0 remote start 1
• E remote stop 1
e F remote stop 2
• S "ECS (remote/auto)"
" c keyswitch
When the ECS is in the REMOTE position, the

"Remote Start" relay and the "Remote Stop" relay are
energized. When the remote start inputs C and D go
low, the following relays energize: "Run 1" relay, "Run
2" relay, "Reset 1" relay, and "Reset 2" relay. The
start/run/stop inputs P1-21 and P1-22 will be pulled
low. The engine will begin the start cycle. When the
customer's remote stop inputs F and E are low, the
following relays energize: "Stop 1" relay and "Stop
2" relay. The start/run/stop inputs P1-21 and P1-22
will be high. The engine will begin the stop function.
When the ECS is in the REMOTE position, the "ECS
in Remote" relay energizes. The "ECS in Remote"
relay sends a signal to the customer connector that
allows the customer to determine the position of the
When the ECS is in the START position, the following

relays energize: "Run 1" relay, "Run 2" relay, "Reset
1" relay, and "Reset 2" relay. The start/run/stop inputs
P1-21 and P1-22 will be pulled low. The engine will
begin the start cycle.
l:.cU - •• j
F71S~~----------Ir::~~:::::::::::::::::::2~::::::~~~~~~~~~~~===::====
r--F717 F716 TB-3 [!}------{!J TB-2
F717~
rrf'~~t~~=~F=~~~f;==[=
I L -- M150--i--------..---
M150
DM775
M150
DM775
I
_
fDM776jl
I TB-6 TB-S
Al /\2. LHCONTROL
PANEL
F716
~ 20
G-CS
IF-C2
20
F-C1
IC-C17
II
22 11
Stop1 Stop2 Run1 Run2 RH CONTROL RH TO LH
~
PANEL HARNESS
19 19 i i
20 20 j j
'TH775 BM775 DM77S BM77S-i- G-C6 F-C1 A-C1 E-C1
IF-C2 IA-C92 IE-C2 !C-C1
,II I , B998---~
i--M150 L.DM775 I .-

,--SM775 SM775
M775 1775-,
r-MM776~
Al A2 Al A2
24
111 0-........... 14 111 14 22
12 12 14
Reset1 12
Reset2
Remote Remote
Start Stop
I), ~ I T~ PR77:~776 D1 02
~ T~~'I~
L--SM775 1
_ 03
PMno i
MM775 MM 776 D5
PR776 D4
B9SS D6
4
040--
G721
R909
B998
11;'
r F721 III III IIII

ECM
Customer o-:.:=:-::::-!,:;:;-G721
Conn.
Primary r-;;.x -Battery
SR910
~
:;11;:
ECM Start/Run/Slop 1
/'IN SR909
IB~r
D9 R2A
~C150,"*A150·-"b~
J>!,J SR909 "':":;:;;;;"';'-i'-:-:--T791 JMa:: Start/Run/Slop
Keyswitch
~~2311111111 I
SA
X ~=-:":;-'--p-::;,-- LH775 Fn1 Digital Return
I ECS Remote/Auto
Engine Speed
Y L702--!1
Control
040·········-
'-----M1S0!] G721-(Remole}
R776-(start 2 )
Qi R775-(S1art 1 )
3 +BeD~'''''''' ............. H77S-(Slop 2) r-C998
2 DeD
1 SeD 389
5-($1op 1 ) -
5 III , rB998
;;:;-;;;-t---
-BeD CA998
LHCONTROL
H-A150 PANEL
,1M I
Rl '--------' ECS
Local/Remote
Throttle Sw.
5
4
I • I I In
II "'Wi =.
R907-------'
IF-C2 IC-Cll
RSR
CA99€
·-------;'-'11i11 D9981-------
P715
G-CS F-Cl A·Cl E-Cl
IF-C2 IA-C92 /E-C2 IC-Cl
Typical example
KENR5404-03 121
WIRE SIDE WIRE SIDE
4 5 6 D 8 9 10 11 12 13
0000000000000
14 0000000000000
00000 00••0 23 14 00000 00000 23
08888 ~® 8888 0 08888 ~t@ 8888
4 3 4 3
0
400000 ~ 0000 47 400000 ~ 0000 47
48
888880008888857 4888888000~~8857
ECM SIDE ECM SIDE
390 00 0
470 0 0 0
570 0 0 0 0 0
m
130000000000000 1
230 • • 0 0 0 0 0 0 0 0 1 4
"0000
~
0000"
0 0 0 032
0 0 0 0 40
0 0 0 0 048
130 0 0 00 0 0 0 0 0 0 0 0 1
230 0 0 0 0
"0000
390 0 0 0
470 0 0 0
570 0 • • 0
0
0
ooJ
0 0 0 0 014
0000"
0 0 0 032
0 0 0 0 40
00 0 0 048
.700 00 0 0 00 0 0 0 0 0 058 .700 0 0 0 0 0 0 0 0 0 0 0 058
Illustration 51 901324452 901324924

Illustration 52
P1 Primary ECM connector P2 Primary ECM connector
(P1-21) "Start/Run/Stop 1" (P2-54) "Digital return"
(P1-22) "Start/Run/Stop 2" (P2-55) "Digital return"
'
I.!..!.
RIGHT SIDE VIEW
1 2 3 4 5 0000
(~)0®0088
00000006
000808080
8880880808
8880808e®
@®®®BGeeS8
®@8®®®88®
@@@@®@®®
@®®®®®®
LEFT SIDE VIEW

o @®®® 0
901320528 0000
(~)O®0000
Illustration 53
Connector locations
80000000

080808000

8080880888
(7) C-C15 Primary ECM connector Pi @@0000888

(9) C-C29 Secondary ECM connector Pi 8SeeG8®®®®
(11) C-C18ITB-C1 Customer connectors e88®®®@@®
(12) C-C21J-C1 LH rigid harness connectors

(13) C-C1/E-C1 LH rigid harness connectors 8®@®®@@@
®®®®®®®
®®®®
g01324537
Illustration 54
Terminal locations for the A-C1/E-C2 RH rigid harness connectors
and the C-C1/E-C1 LH rigid harness connectors
(Terminal i) "Start/Run/Stop 1"
(Terminal j) "Start/Run/Stop 2"
(Terminal AL) "Digital return"
(Terminal AK) "Digital return"
KENR5404-03 123
Section
,r
o €,O)@80 o
o 0000 0
®@®@e®
t;;;\ 35 23 (;\
ee000C0®
~ ~
@ e® @
@@ @) @ ® ®0 ®®08000®
@@@@@®0 000888080
@@@@®0 (~()CD0080808
0) @f29\@ CD
@ ~ 0 : 88800008@
O~O
(08@(0888888
688®88888
@®@@®®®®
®®®®®®®
@~O
&000
880008
1100008000
//000088000
Illustration 55
g01324917 ( / 8080880088
Terminal locations for the following connectors G-C6/F l\ @80000888

C2/F-C1/A-C92 Connectors for a RH Control panel and
G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel \ \ 8888886@88
(Terminal 19) "Start/Run/Stop 1" \\ 8888®®§8®

(Terminal
(Terminal
20)
23)
"Start/Run/Stop 2"
Digital return 8®®®®®®®
(Terminal 45) Digital return

®®®®®®®
®®®®
g01324914
Illustration 56
Terminallocalions for the TB-C1/C-C18 customer connector
(Terminal C) "Remote start 2"
(Terminal D) "Remote start 1"
(Terminal E) "Remote stop 1"
(Terminal F) "Remote stop 2"
(Terminal S) "ECS in remote"
(Terminal c) "Keyswitch"

position.

lL4
Section
C. Thoroughly inspect the primary ECM connectors Test Step 3. Check the Status of the ECS
J1/P1 and J2/P2. Inspect all ofthe other in the START Position
connectors. Check the allen head screw on each
of the ECM con nectors for the proper torque. A. Turn the ECS on the control panel to the START
Refer to Troubleshooting, "Electrical Connectors position.
Inspect" for the correct torque values.
B. Observe the status for the ECS on Cat ET.

wires in the ECM connectors that are associated Expected Result:
with the circuit.

The status for the ECS is "RUN".
E. Check the harness and the wiring for abrasion

and for pinch points. Results:
Expected Result: • OK - The ECS is functioning correctly. Proceed

to Test Step 4.
coupled and/or inserted. The harness and wiring are • Not OK - The status of the ECS is not "RUN".
free of corrosion, of abrasion or of pinch points. Proceed to Test Step 5.
Results: Test Step 4. Check the Status of the ECS

in the REMOTE Position
• OK - The connectors and wiring are OK. Proceed
to Test Step 2. A. Turn the ECS on the control panel to the REMOTE
position.
• Not OK - The connectors and/or wiring need
repair. B. Observe the status for the ECS on Cat ET.
Repair: Repair the connectors or wiring and/or Expected Result:

The status for the ECS is "AUTO".
STOP.
Results:
Test Step 2. Check the Status of the ECS

in the STOP Position • OK - The ECS is working correctly.
A. Turn the circuit breaker for the battery to the ON Repair: The problem may be intermittent. If the
position. problem is intermittent, refer to Troubleshooting,
"Electrical Connectors Inspect".
B. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. STOP.
C. Turn the ECS on the control panel to the STOP • ECS Not OK - The status for the ECS is not
position. "AUTO". Proceed to Test Step 6.
D. Observe the status for the ECS on Cat ET. Test Step 5. Install a Wire Jumper at the
ECM in order to Simulate a START/STOP
Expected Result: Function
The status for the ECS is "STOP". A. Turn the ECS to the OFF/RESET position.
Results: B. Disconnect the primary ECM connector P1.
• OK - The ECS is functioning correctly. Proceed C. Remove wire F716 from P1-21. Install a wire
to Test Step 3. jumper into the socket P1-21.
• Not OK - The status for the ECS is not "STOP". D. Remove wire F717 from P1-22. Install a wire
Proceed to Test Step 5. jumper into the socket P1-22.
E. Reconnect the primary ECM connector P1.
F. Fabricate a wire jumper.
"
KENR5404-03 125
Section
G. Install the wire jumper between the wire jumpers J. Observe the status for the ECS on Cat ET.
in P1-21 and P1-22 and engine ground.
K. Turn the ECS to the OFF/RESET position.
H. Turn the ECS to the STOP position. Remove the wire jumpers and replace all wires.
Reconnect the primary ECM connector P1.
I. Observe the status for the ECS on Cat ET.
Expected Result:
J. Remove the wire jumper between the wire jumpers
in P1-21 and P1-22 and engine ground. The status for the ECS displays "AUTO" while the
wire jumper is installed. The status for the ECS
K. Observe the status for the ECS on Cat ET. displays "OFF" when the wire jumper is removed.
L. Turn the ECS to the OFF/RESET position. Results:

Remove the wire jumpers and replace all wires.
Reconnect the primary ECM connector P1. • OK - The status for the ECS displays the proper
states. The problem is not with the ECM.
Expected Result:
Repair: Perform the following steps.
The status for the ECS displays "RUN" while the wire
jumper is installed. The status for the ECS displays 1. Check continuity of wire F721 between the ECS
"STOP" when the wire jumper is removed. and the P1-68 primary ECM connector.
Results: 2. Check continuity of wire G721 between the ECS

and terminal S of the customer connector.
• OK The status for the ECS displays the
proper states. The problem is not with the ECM. 3. Verify that terminal S on the customer connector
Troubleshoot the wire F716 and the wire F717. In has continuity to ground.
order to troubleshoot the wire F716, proceed to
Test Step 7. Repair any opens in the wiring. Repair any shorts
in the wiring.
• Not OK - The status for the ECS does not display
the correct state. STOP.
Repair: Replace the ECM. Refer to

• Not OK - The status for the ECS does not display
Troubleshooting, "ECM - Replace".
the correct state.
STOP. Repair: Replace the ECM. Refer to
Test Step 6. Install a Wire Jumper at

the ECM in order to Simulate an AUTO STOP.
Condition
Test Step 7. Check for Voltage on Wire
A. Turn the ECS on the control panel to the F716 at the Normally Closed Contacts of
OFF/RESET position. the "Stop 1" Relay
B. Disconnect the primary ECM connector P1. A. Turn the ECS on the control panel to the
OFF/RESET position.
C. Remove wire F721 from P1-68. Install a wire
jumper into the socket P1-68. B. Remove wire F716 from terminal 22 of the "Stop
1" relay.
D. Reconnect the primary ECM connector P1.
C. Turn the ECS on the control panel to the STOP
E. Fabricate a wire jumper. position.
F. Install the wire jumper between the wire jumper in D. Measure the voltage between wire F716 and
P1-68 and engine ground. engine ground.
G. Turn the ECS to the STOP position. Turn the ECS that is on the control panel to the
OFF/RESET position.
H. Observe the status for the ECS on Cat ET.
F. Replace all wiring to the original configuration.
I. Remove the wire jumper between the wire jumper
in P1-68 and engine ground.
'-
-ILO
Section
Expected Result: Test Step 9. Check for Voltage on Wire

DM775
The voltage is 6.5 ± 0.5 VDC.
A. Remove wire DM775 from terminal 21 of the "Run '
Results: 1" relay.
• OK - The voltage is 6.5 ± 0.5 VDC. Proceed to B. Remove wire PR775 from terminal 11 of the
Test Step 8. "Remote Start" relay.
• Not OK - The voltage is not 6.5 ± 0.5 VDC. C. Turn the ECS on the control panel to the START
position.
Repair: Repair the wire F716 between the normally
closed contacts on the "Stop 1" relay and the O. Measure the voltage between wire DM775 and
ECM. Refer to Illustration 50 for a schematic of the engine ground at the "Run 1" relay.
connections between the control panel and the
ECM. E. Measure the voltage between wire PR775 and
engine ground at the "Remote Start" relay.
STOP.
F. Turn the ECS that is on the control panel to the
Test Step 8. Check for Voltage at the OFF/RESET position.
Normally Closed Contacts of the "Stop
1" Relay G. Leave wire DM775 disconnected from terminal
21 of the "Run 1" relay. Reconnect wire PR775 to
A. Remove wire DM775 from terminal 21 of the "Stop terminal 11 of the "Remote Start" relay.
1" relay.
Expected Result:
B. Turn the ECS on the control panel to the START
position. The voltage is 6.5 ± 0.5 VDC.
-
C. Measure the voltage between terminal 21 of the Results:
"Stop 1" relay and engine ground.
• OK The voltage is 6.5 ± 0.5 VDC. Proceed to
O. Turn the ECS that is on the control panel to the Test Step 10.
OFF/RESET position.
• Not OK - The voltage is not 6.5 ± 0.5 VDC.
E. Replace all wiring to the original configuration.
Repair: There is a problem with the wire DM775
Expected Result: between the "Stop 1" relay and the "Run 1" relay.
Repair the wire DM775.

There is a problem with the wire DM775 between
Results: the "Stop 1" relay and the "Remote Start" relay.
Check for voltage on wire DM775 at diode D2. If
• OK - The voltage is 6.5 ± 0.5 VDC. Proceed to voltage is present at diode D2, the problem is in
Test Step 9. wire PR775. If voltage is not present at diode D2,
the problem is in wire DM775.
• Not OK - The voltage is not 6.5 ± 0.5 VDC. The

"Stop 1" relay's normally closed contacts are faulty STOP.
or the "Stop 1" relay is energized.
Test Step 10. Check for Voltage at
Repair: Check the voltage across the coil of the the Normally Closed Contacts of the
"Stop 1" relay. If voltage is present across the coil "Remote Start" Relay
of the "Stop 1" relay, ensure that the ECS is not in
the STOP position. A. Remove wire LR775 from terminal 12 of the
"Remote Start" relay.
If no voltage is measured across the coil of
the "Stop 1" relay, the normally closed contacts B. Turn the ECS on the control panel to the START
between wire F716 and wire DM775 are faulty.
Replace the "Stop 1" relay and check for diagnostic
codes.
STOP.
position.
C. Measure the voltage between terminal 12 of the

"Remote Start" relay and engine ground.
-
KENR5404-03 127
Section
D. Turn the ECS that is on the control panel to the Repair: There is a problem with the wire LR775
OFF/RESET position. between terminal 9 of the ECS and the "Remote
Start" relay. Repair the wire LR775.
E. Reconnect wire LR775 to terminal 12 of the
"Remote Start" relay. STOP.
Expected Result: Test Step 12. Check for Voltage on Wire

F717 at the Normally Closed Contacts of
The voltage is 6.5 ± 0.5 VDC. the "Stop 2" Relay
Results: A. Turn the ECS on the control panel to the
OFF/RESET position .
.. OK - The voltage is 6.5 ± 0.5 VDC. Proceed to
Test Step 11. B. Remove wire F717 from terminal 22 of the "Stop
2" relay.
It Not OK The voltage is not 6.5 ± 0.5 VDC. The
"Remote Start" relay is energized or there is a C. Turn the ECS on the control panel to the STOP
problem with the normally closed contacts of the position.
"Remote Start" relay between wire LR775 and wire
PR775. D. Measure the voltage between wire F717 and
engine ground.
Repair: Check the voltage across the coil of the
"Remote Start" relay. Voltage should not be present E. Turn the ECS that is on the control panel to the
across the coil. If voltage is present, verify that the OFF/RESET position.
ECS is not in the REMOTE position. Check for a
short in wire R791. F. Replace all wiring to the original configuration.
If voltage is not present across the coil of the Expected Result:
"Remote Start" relay, replace the "Remote Start"

relay. The voltage is 6.5 ± 0.5 VDC.
STOP. Results:
Test Step 11. Check for Voltage on Wire G OK - The voltage is 6.5 ± 0.5 VDC. Proceed to
LR775 at Terminal 9 of the ECS Test Step 13.
A. Remove wire LR775 from terminal 9 of the ECS. • Not OK - The voltage is not 6.5 ± 0.5 VDC.
B. Turn the ECS on the control panel to the START Repair: Repair the wire F717 between the normally
position. closed contacts on the "Stop 2" relay and the
ECM. Refer to Illustration 50 for a schematic of the
C. Measure the voltage between wire LR775 and connections between the control panel and the
engine ground. ECM.
D. Turn the ECS that is on the control panel to the STOP.

OFF/RESET position.
Test Step 13. Check for Voltage at the
E. Reconnect wire LR775 to terminal 9 of the ECS. Normally Closed Contacts of "Stop 2"
Reconnect wire DM775 to terminal A2 of the "Run Relay
1" relay.
A. Remove wire DM776 from terminal 21 of the "Stop
Expected Result:
2" relay.

position.
Results:

• OK The voltage is 6.5 ± 0.5 VDC. Wire F716 "Stop 2" relay and engine ground.
is OK. Proceed to Test Step 12 in order to check
wire F717. D. TUrn the ECS that is on the control panel to the
OFF/RESET position.
.. Not OK - The voltage is not 6.5 ± 0.5 VDC.
E. Replace all wiring to the original configuration.
-I~I:S
Expected Result: Repair: There is a problem with the wire DM776
between the "Stop 2" relay and the "Run 2" relay.
The voltage is 6.5 ± 0.5 VDC. Repair the wire DM776.
'
Results: There is a problem with the wire DM776 between
the "Stop 1" relay and the "Remote Start" relay.
• OK - The voltage is 6.5 ± 0.5 VDC. Proceed to Check for voltage on wire DM776 at diode D5. If
Test Step 14. voltage is present at diode D5, the problem is in
wire PR776. If voltage is not present at diode D5,
• Not OK - The voltage is not 6.5 ± 0.5 VDC. There the problem is in wire DM776.
is a problem with the normally closed contacts of
the "Stop 2" relay or the "Stop 2" relay is energized. STOP.
Repair: Check the voltage across the coil of the Test Step 15. Check for Voltage at
"Stop 2" relay. If voltage is present across the coil the Normally Closed Contacts of the
of the "Stop 2" relay, ensure that the ECS is not in "Remote Start" Relay
the STOP position.
A. Remove wire LR775 from terminal 22 of the
If no voltage is measured across the coil of the "Remote Start" relay.
"Stop 2" relay, there is a problem with the normally
closed contacts between wire F717 and wire B. Turn the ECS on the control panel to the START
DM776. Replace the "Stop 2" relay and check for position.
diagnostic codes.
STOP. "Remote Start" relay and engine ground.
Test Step 14. Check for Voltage on Wire D. Turn the ECS on the control panel to the
DM776 OFF/RESET position.
A. Remove wire DM776 from terminal 21 of the "Run E. Reconnect wire LR775 to terminal 22 of the
2" relay.
B. Remove wire PR776 from terminal 21 of the

Expected Result:
-
C. Turn the ECS on the control panel to the START
position. Results:
D. Measure the voltage between wire DM776 and • OK - The voltage is 6.5 ± 0.5 VDC. Wire F717 is
engine ground at the Run 2 relay. OK.
E. Measure the voltage between wire PR776 and Repair: Check wire C99S for continuity between
engine ground at the Remote Start relay. the ECS and the ECM connector P2-54.
F. Turn the ECS on the control panel to the Check the ECS for proper operation. Check
OFF/RESET position. continuity between terminal 6 and terminal 9 of the
ECS. Check continuity with the ECS in the START
G. Leave wire DM776 disconnected from terminal and STOP positions.
21 of the "Run 2" relay. Reconnect wire PR776 to

terminal 21 of the "Remote Start" relay. Refer to Illustration 50 for a schematic of the
Expected Result: ECM.
The voltage is 6.5 ± 0.5 VDC. STOP.
Results: • Not OK - The voltage is not 6.5 ± 0.5 VDC. The

"Remote Start" relay is energized or there is a
• OK - The voltage is 6.5 ± 0.5 VDC. Proceed to problem with the normally closed contacts of the
Test Step 15.

"Remote Start" relay between wire LR775 and wire
PR776.
KENR5404-03 129
Repair: Check the voltage across the coil of the i02641427

"Remote Start" relay. Voltage should not be present
across the coil. If voltage is present, verify that the Injector Solenoid .. Test
ECS is not in the REMOTE position. Check for a
short in wire R791. SMCS Code: 1290-038-JV
If voltage is not present across the coil of the System Operation Description:
"Remote Start" relay, replace the "Remote Start"
relay. Use this procedure to troubleshoot the electrical
system if a problem is suspected with the injectors
STOP. or if anyone of the diagnostic codes in Table 38 is
active or easily repeated.
Test Step 16. Check for Voltage on Wire
lR775 at Terminal 9 of the ECS
A. Remove wire LR775 from terminal 9 of the ECS.

position.
C. Measure the voltage between wire LR775 and

engine ground.
D. Turn the ECS that is on the control panel to the

OFF/RESET position.
E. Reconnect wire LR775 to terminal 9 of the ECS.

Reconnect wire DM776 to terminal A2 of the "Run
1" relay.
Expected Result:
Results:
• OK - The voltage is 6.5 ± 0.5 VDC. Wire F717 is

OK.
Repair: Check wire C998 for continuity between

the ECS and the primary ECM connector P2-54.
Refer to Illustration 50 for a schematic of the
ECM.
STOP.
Repair: There is a problem with the wire LR775

between terminal 9 of the ECS and the "Remote
Start" relay. Repair the wire LR775.
STOP.
'
I,)U
Table 38
! Code and Description

11-5 Cylinder #1 Injector current below
i normal
!
Conditions which Generate this Code
The engine's Electronic Control Module ! The code is logged.
(ECM) detects an open circuit. The ECM continues to fire the injector
System Response
-
solenoid.
1-6 Cylinder #1 Injector current above The ECM detects a short circuit. The code is logged.
normal
The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
2-5 Cylinder #2 Injector current below The ECM detects an open circuit. i The code is logged.
normal
The ECM continues to fire the injector
solenoid. I
2-6 Cylinder #2 Injector current above The ECM detects a short circuit. i The code is logged.
normal
· The ECM will disable the solenoid
i circuit. The ECM will periodically try
remains, this sequence of events will be I
5 Cylinder #3 Injector current below The ECM detects an open circuit. · The code is logged.
)rmal
i The ECM continues to fire the injector i
solenoid.
13-6 Cylinder #3 Injector current above i The ECM detects a short circuit. I The code is logged.
normal · The ECM will disable the solenoid
4-5 Cylinder #4 Injector current below The ECM detects an open circuit.
remains, tniS sequence OT events Will De
The code is logged.
-
normal The ECM continues to fire the injector
solenoid.
normal · The ECM will disable the solenoid
5-5 Cylinder #5 Injector current below The ECM detects an open circuit. The code is logged.
solenoid.
normal The ECM will disable the solenoid
i 6-5 Cylinder #6 Injector current below The ECM detects an open circuit. The code is logged.
normal · The ECM continues to fire the injector
i solenoid.
/:!: ~ I"' •• t:_....! ___ ~ l ..... : ___ J:. _ _ _ _ •• __ .... _ ... _L._ .......
.1..._ ,-"'11.., -1_ ... _ _ ,1, _ __ '-_....I. _! __ . . ~L I ""T"'L _ _ _ -1_ !_ 1 _ _ _ _ ..1
normal i The ECM will disable the solenoid

(continued)
-
KENR5404-03 131
(Table 38, contd)

solenoid.
solenoid.
solenoid.
10-5 Cylinder #1 0 Injector current below The ECM detects an open circuit. The code is logged.
solenoid.
10-6 Cylinder #1 0 Injector current above The ECM detects a short circuit. The code is logged.
normal The ECfVI will disable the solenoid
solenoid.
solenoid.
(continued)
I,;)"::
(Table 38, contd)

Code and Description Conditions which Generate this Code System Response ~
solenoid.
solenoid.
I repeated until the problem is corrected.

solenoid.
15-6 Cylinder #15 Injector current above I The ECM detects a short circuit. The code is logged.
remains, this sequence of events will be I
~
16-5 Cylinder #16 Injector current below I The ECM detects an open circuit. The code is logged.
solenoid.
16-6 Cylinder#16 Injector current above I The ECM detects a short circuit. The code is logged.
Perform this procedure under conditions that are If an open is detected in the solenoid circuit, a
identical to the conditions that exist when the problem diagnostic code is generated. The ECM continues
occurs. Typically, problems with the injector solenoid to try to fire the injector. If a short is detected, a
occur when the engine is warmed up and/or when diagnostic code is generated. The ECM will disable
the engine is under vibration (heavy loads). the solenoid circuit. The ECM will periodically try
to fire the injector. If the short circuit remains, this
These engines have Electronic Unit Injectors (EUI) sequence of events will be repeated until the problem
that are mechanically actuated and electronically is corrected.
controlled. The ECM sends a 105 volt pulse to each
injector solenoid. The pulse is sent at the proper time When an injector is replaced, program the new
and at the correct duration for a given engine load injector code into the ECM. If the ECM is replaced, all
and speed. The solenoid is mounted on top of the sixteen injector codes must be programmed into the
fuel injector body. new ECM. The injector codes are a four digit number.
Refer to Troubleshooting, "Configuration Parameters"
-
for information on injector codes.
Caterpillar Electronic Technician (ET) includes the

following tests that aid in troubleshooting the injector
solenoids:
KENR5404-03 133
"Cylinder Cutout Test"
All active diagnostic codes must be repaired before

running the "Cylinder Cutout Test". Use the "Cylinder
Cutout Test" to diagnose a malfunctioning injector
while the engine is running. When a good injector is
cut out, the "Delivered Fuel Volume" of the remaining
injectors should change. The change in "Delivered
Fuel Volume" is due to the extra load on each of the
remaining cylinders. If a malfunctioning injector is cut
out, the "Delivered Fuel Volume" will not change for
the remaining injectors. The "Cylinder Cutout Test" is
used to isolate the malfunctioning injector in order to
avoid replacement of good injectors.
"Injector Solenoid Test"
Use the "Injector Solenoid Test" to aid in diagnosing

an open circuit or a short circuit while the engine
is not running. The "Injector Solenoid Test" briefly
activates each solenoid. A good solenoid will create
an audible click when the solenoid is activated. Cat
ET will indicate the status of the solenoid as "OK",
"Open", or "Short".
'~
Iv'" f'>C I,. r. '-l<tU'" -U.J
PRIMARY ECM J2 P2 P2 J2 SECONDARY ECM

~
~,13 I-A702
!--A701f~J~~~~======================~~=
1 Injector 1 Drive
Injector 2 Drive A701 3 Injector 2 Drive
Injector 31 Drive
Injector Drive I-A703
40 ' A702 40 Injector 3 Drive
Injector 4 Drive '" 42 I-A704 A703 42 Injector 4 Drive
Injector S Drive '" 14 I-A705 A704 14
Injector 6 Drive '" 16 ~Al06 AlOS
Injector 5 Drive
~48
16 Injector 6 Drive
Injector 7 Drive !-A707 A706
~ 50
48 Injector7 Drive
Injector 8 Drive !-A708 A7D?
~ 24
50 Injector S Drive
Injector 9 Drive I-A709 A708 24
~ 34
Injector 9 Drive
Injector 10 Drive r-A710 A709 34
~ 58
Injector 10 Drive
Injector 11 Drive -A711 A7l0 58
~-; 52
Injector 11 Drive
Injector 12 Drive -A712 A711 52 Injector 12 Drive
Injector 13 Drive 32 !-A713 A712 32 Injector 13 Drive
Injector 14 Drive 60 I-A714 A713 60 Injector 14 Drive
Injector 15 5 -A715 A714
~
5 Injector 15 Drive
Injector 16 26 -A71S A71S
~
26 Injector 16 Drive
Injector 1 Return 2 -A717 A716 2
~
Injector 1 Return
Injector 2 Return 4 -A718 A717
~41
4 Injector 2 Return
Injector 3 Return !-A719 A71S 41 Injector 3 Return
Injector 4 Return 1"743 !-A720 A719
~ 15
43 Injector 4 Return
Injector 5 Return !-A721 A720 15 Injector 5 Return
Injector 6 Return -:;"'17 -A722 An1 17
~
Injector 6 Return
Injector 7 Return 49 -A723 A722
~
49 Injector 7 Return
Injector 8 Return 51 -A724 A723 51 Injector 8 Return
Injector 9 Return ..;.. 25 -A725 A724 25 Injector 9 Return
Injector 10 Return ..;.. 35 -A726 A725 Injector 10 Return
Injector 11 Return ..;.. 59 -A727 A726
-~Z~~.
Injector 11 Return
Injector 12 Return -? 62 A727
~"
Injector 12 Return
Injector 13 Return '"733 A728 Injector 13 Return
Injector 14 Return -:;"'61 -A730 A729 61~ Injector 14 Return
Injector 15 Return ";"18 !-A731 A730
27 -A732'-IITT-t--t--i'-rt-++-t-+-I-~f-~f++-t+l+:p=l=r+O:l==A731 27 <E-'
I 18~ Injector 15 Return
Injector 16 Return ..". A732 Injector 16 Return
~_~;I lBCSMlsDlsNlsElsplsF SRlsHlss BJ 8T 8K 8U SL sVi
~~~~ iSCBM/sblsNlsElsplBF BRISHISSi8J 8TIsKIsu sJB'VI
I I
Solenoid
~
1 '
Solenoid
Cylinder 1
Solenoid
Cylinder 3
Solenoid
Ti
2
1
,
~
'rf
r:u.:.J
Ci£.J 'rf
Cylinder 2
Solenoid
Cylinder 4
Solenoid

-
Cylinder 5
~
"'T" r1 Cylinder 6
Solenoid
2JF======~J L===~~
1 Solenoid
Cylinder 7 CylinderS
Solenoid
Cylinder 9 rC~~11===========~
j 2 1
Solenoid
Cylinder 10
Solenoid
Solenoid
Cylinder 11 2 1
Cylinder 12
Solenoid
2!t=============~ L.::======~2
1
Solenoid
Cylinder 13 Cylinder 14
Solenoid
Cvlinder 15
rC~~11=================~~ L:::========:iiI~
:[
Solenoid
Cylinder 16
Typical schematic
--
KENR5404-03 135
'130 0 0 0 0 0 0 0 • • • I) 81
300000 0
[I@J
eee4l2.
• • • • • 14 o 0000 o
.0000
90000 ~ • • • • 4'32 0000080
70000
570 0 0 0 0 0
• • • e40
• • • • •48 00000000)
JOO 0 0 0 0 0 0 0 • • • • 858. 000888080
8000888888
ECM SIDE
88880088@
@®@®88®®88
®®®®888®®
@@@(@e(i)4i)i)
eeeeeee
.0
~
eeee 0
/
HARNESS SIDE
g01152207
0000
Illustration 58
P2 terminals that are associated with the injector solenoids @800000
(P2-1) Injector cytinder #1 power 60000000
(P2-2) Injector cylinder #1 return

(P2-3) Injector cylinder #2 power
080888000
(P2-40) Injector cylinder #3 power 8080880008
(P2-41) injector cylinder #3 return

(P2-42) Injector cylinder #4 power 880000888

(P2-14) Injector cylinder #5 power 88®®88®@8®

(P2-16) Injector cylinder #6 power ®®888®®@®

ei)®@®
_sese
eee
(P2-59) Injector cylinder #11 return Illustration 59 g01325367
(P2-62) Injector cylinder #12 return Terminal locations for the C-C1/E-C1 LH rigid harness connectors
(P2-32) Injector cylinder #13 power and the A-C1/E-C2 RH rigid harness connectors
1':>0
(Terminal BC) Injector cylinder #1 power B. Thoroughly inspect the ECM connector J2!P2.
(Terminal BM) Injector cylinder #1 return Inspect the connectors for the injectors. Refer to
(Terminal BD) Injector cylinder #3 power the diagnostic functional test Troubleshooting,
(Terminal BN) Injector cylinder #3 return
(Terminal BE) Injector cylinder #5 power "Electrical Connectors - Inspect" for details.
(Terminal BP) Injector cylinder #5 return
(Terminal BF) Injector cylinder #7 power C. Perform a 45 N (10 Ib) pull test on each of the
(Terminal BR) Injector cylinder #7 return wires in the ECM connector that are associated
(Terminal BH) Injector cylinder #9 power
(Terminal BS) Injector cylinder #9 return
with the circuit.
(Terminal BJ) Injector cylinder #11 power
(Terminal BT) Injector cylinder #11 return D. Check the allen head screw on each ECM
(Terminal BK) Injector cylinder #13 power connector for the proper torque. Refer to
(Terminal BU) Injector cylinder #13 return Troubleshooting, "Electrical Connectors - Inspect"
(Terminal BL) Injector cylinder #15 power
(Terminal BV) Injector cylinder #15 return for the correct torque values.

Expected Result:
RIGHT SIDE VIEW
2 3 4 5 All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
Results:

to Test Step 2.
• l\Iot OK - There is a problem in the connectors

and/or wiring.

Verify that the repair eliminates the problem.

LEFT SIDE VIEW
STOP.
Test Step 2. Check for Logged Diagnostic

Illustration 60 901320528 Codes
Connector locations
A. Connect Cat ET to the service tool connector.
(1) A-Cl/E-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel B. Restore power to the ECM.
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel C. Check for logged diagnostic codes for the injector
(6) C-C22 Primary ECM connector P2 solenoids on Cat ET.
(7) C-C 15 Primary ECM connector Pi
(9) C-C29 Secondary ECM connector Pi Expected Result:
(10) G-C6/F-C2/F-Cl/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-Cl Customer connectors No 1-05 to 16-05 or 1-06 to 16-06 codes are logged.
(12) C-C2/J-Cl LH rigid harness connectors
Results:
and Wirmg • OK - No 1-05 to 16-05 or 1-06 to 16-06 codes are
logged. Proceed to Test Step 3.
• Not OK - A 1-05 to 16-05 code is logged. Proceed
to Test Step 4.
'
KENR5404-03 137
Section
• Not OK - A 1-06 to 16-06 code is logged. Proceed Test Step 4. Check the Harness between
to Test Step 5. the ECM and the Injector Connectors for
an Open Circuit
Test Step 3. Perform the "Cylinder Cutout
Test"
NOTICE This engine uses high voltage to control the fuel

Engine power is reduced when a properly functioning injectors.
cylinder is cut out. Make sure that you will not damage
auxiliary or driven equipment if the engine power is Disconnect electronic fuel injector enable circuit
suddenly reduced. connector to prevent personal injury.
A. Remove power from the ECM. Do not come in contact with the fuel injector ter·
minals while the engine is running.
B. Verify that the ECM connector J2/P2 and the
injector connectors are properly connected. A. Remove power from the ECM.
C. Restore power to the ECM. B. Disconnect the connectors for the suspect
injector(s).
D, Start the engine.
C. Fabricate a jumper wire 100 mm (4 inch) long with
E. Apply a load to the engine. Deutsch pins on both ends of the wire.
F. Perform the following steps on all suspect D. Insert one end of the jumper wire into the socket
cylinders (solenoids). for the suspect injector's power wire. Insert the
other end of the jumper wire into the socket for the
G. Use the diagnostic tests on Cat ET to initiate the suspect injector's return wire. This will replace the
"Cylinder Cutout Test". injector solenoid with a short circuit.
H. Perform the "Cylinder Cutout Test". Disable the E. Restore power to the ECM.
suspect cylinder(s) during the test.
Note: This test will help the service technician verify
Expected Result: that the ECM can fire the solenoids. Do not try to
manually crank the engine during this test. The ECM
The results indicated that the remaining injectors will terminate the "Injector Solenoid Test".
used more fuel when the "Cylinder Cutout Test"
disabled the suspect injector(s). F. Perform the "Injector Solenoid Test" at least two
times.
Results:
G. Repeat this test for each suspect injector. Stop
.. OK - There was a noticeable change in fuel usage. the "Injector Solenoid Test" before handling the
jumper wire.
Repair: The injectors are firing in all cylinders.
Reset the system and check for diagnostic codes. Expected Result:
STOP. Cat ET displays "Short" for the cylinder with the
jumper wire.
" Not OK - There was no noticeable change in fuel
usage. Results:
Repair: Verify that the engine valve lash for that • OK - Cat ET displays "Short" for the cylinder with
injector is set correctly. Rerun the "Cylinder Cutout the jumper wire. The harness between the ECM
Test". If the problem is still present, replace the and the injector connector does not have an open
injector. If the new injector has a trim code that is circuit. Proceed to Test Step 9.
different from the old injector, change the trim code
in the ECM.
• Not OK Cat ET displays "Open" for a right side
cylinder with a jumper wire. There is a problem
STOP. in the wiring between the ECM and the injector
connector. Proceed to Test Step 7.
"'';0
Section
• Not OK - Cat ET displays "Open" for a left side Test Step 6. Check the Harness between
cylinder with a jumper wire. There is a problem the ECM and the Rigid Harness for a
in the wiring between the ECM and the injector Short Circuit
connector. Proceed to Test Step 8.
Test Step 5. Check the Harness between AWARNINe; "

.<:'';'', .. :.. .....,.,.; .'-'-'-:.'.';.,---. ,,";::j
the ECM and the Connectors for the This engine uses high voltage to control the fuel
Injector for a Short Circuit injectors.
Disconnect electronic fuel injector enable circuit

connector to prevent personal injury.
This engine uses high voltage to control the fuel
injectors. Do not come in contact with the fuel injector ter
connector to prevent personal injury. A. Remove power from the ECM. A strong electrical
shock hazard is present if power is not removed
Do not come in contact with the fuel injector ter from the ECM.
B. Disconnect the wires for the suspect injectors from
A. Remove power from the ECM. A strong electrical the rigid harness. Refer to Illustration 59 for the
shock hazard is present if power is not removed terminal locations for the rigid harness.
from the ECM.
C. Restore power to the ECM.
B. Disconnect the connectors for the suspect
injector(s). Note: This test will help the service technician verify
that the ECM can fire the solenoids. Do not try to
C. Restore power to the ECM. manually crank the engine during this test. The ECM
will terminate the "Injector Solenoid Test".
that the ECM can fire the solenoids. Do not try to D. Perform the "Injector Solenoid Test" at least two
manually crank the engine during this test. The ECM times.
will terminate the "Injector Solenoid Test".
Expected Result:
D. Perform the "Injector Solenoid Test" at least two
times. All of the suspect cylinders indicate "Open" on Cat ET.
All of the suspect cylinders indicate "Open" on Cat ET. • OK All cylinders indicate "Open" on Cat ET.
The injector wires between the ECM and the rigid
Results: harness do not have a short circuit.
• OK All cylinders indicate "Open" on Cat ET. Repair: The short circuit is in the harness between
The harness between the ECM and the injector the rigid harness and the connector for the suspect
connector does not have a short circuit. Proceed injector. Repair the harness or the connector.
to Test Step 9.
STOP.
• Not OK - Cat ET displays "Short" for a right side
cylinder. Note the cylinders that indicate "Short". • Not OK One or more cylinders indicate "Short"
Proceed to Test Step 6. on Cat ET. Note the cylinders that indicate "Short".
• Not OK - Cat ET displays "Short" for a left side
cylinder. Note the cylinders that indicate "Short".
'
KENR5404-03 139
Section
Test Step 7. Check the Harness between .. Not OK - Cat ET displays "Open" for the cylinder
ECM and the Rigid Harness for an Open with the jumper wire. There is a problem in the
Circuit harness between the ECM and the rigid harness.
Test Step 8. Check the ECM for Proper

This engine uses high voltage to control the fuel
Operation
injectors.
A. Remove power from the ECM. A strong electrical
shock hazard is present if power is not removed
from the ECM.
connector to prevent personal injury.
B. Check the operation of the ECM by creating an
Do not come in contact with the fuel injector ter
open at the ECM.
a. Disconnect the appropriate suspect injector
A. Remove power from the ECM. wire from the P2 ECM connector. Remove the
power wire for the suspect injector(s) from the
B. Disconnect the wires for the suspect injector from ECM connector.
the rigid harness.
b. Install a jumper wire with Deutsch sockets on
C. Fabricate a jumper wire with clips on both ends each end into the socket for the power wire of
of the wire. the suspect injector(s).
D. Install the wire jumper between the suspect c. Reconnect the ECM connector.
injector's power wire and the suspect injector's
return wire. This will replace the injector solenoid d. Restore power to the ECM.
with a short circuit. Refer to Illustration 59 for the
terminal locations for the rigid harness. Note: This test will help the service technician verify
that the ECM can fire the solenoids. Do not try to
E. Restore power to the ECM. manually crank the engine during this test. The ECM
will terminate the "Injector Solenoid Tes1".
that the ECM can fire the solenoids. Do not try to e. Perform the "Injector Solenoid Test".
will terminate the "Injector Solenoid Test". f. All of the suspect cylinders indicate "Open" on
CatET.
F. Perform the "Injector Solenoid Test" at least two
times. g. Remove power from the ECM.
G. Repeat this test for each suspect injector. Stop C. Check the operation of the ECM by creating a
the "Injector Solenoid Test" before handling the short at the ECM.
jumper wire.
a. Create a short between the wire jumper for the
Expected Resu It: suspect power wire and engine ground.
Cat ET displays "Short" for the cylinder with the b. Restore power to the ECM.
jumper wire.
Results: that the ECM can fire the solenoids. Do not try to
• OK - Cat ET displays "Short" for the cylinder with will terminate the "Injector Solenoid Test".
the jumper wire. The harness between the rigid
harness and the ECM does not have an open c. Perform the "Injector Solenoid Tesr.
circuit.
d. Cat ET displays "Short" for the cylinder with the
Repair: The open circuit is in the harness between jumper wire.
the rigid harness and the connector for the suspect
injector. Repair the harness or the connector. e. Remove power from the ECM.
STOP. f. Remove the wire jumper. Reconnect a" wires

and connectors.
h ........ tinl"f Section
Expected Result: Repair: The problem may be intermittent. If the

problem is intermittent, refer to the diagnostic
Cat ET displays "Short" when the wire jumper is
shorted to engine ground. Cat ET displays "Open"
when the power wire for the injector is removed from
functional test Troubleshooting, "Electrical
Connectors - Inspect". Verify that the repair
eliminates the problem.
'_.
the ECM connector.
STOP.
Results:
• Not OK - The resistance is not 1.06 ± 0.5 Ohms.
• OK - The ECM is operating properly. The problem
is between the ECM and the rigid harness for a Repair: Replace the injector. If the new injector has
right side cylinder or between the ECM and the a trim code that is different from the old injector,
connector for the injector for a left side cylinder. change the trim code in the ECM.
Repair: Repair the harness or the connector. Refer STOP.

to the diagnostic functional test Troubleshooting,
"Electrical Connectors - Inspect". Verify that the
i02641643
repair eliminates the problem.
STOP.
Prelubrication - Test
SMCS Code: 1319-038
• Not OK The ECM did not detect the open or the
short. System Operation Description:
Troubleshooting, "ECM - Replace". Verify
system if a problem is suspected with a prelubrication
that the problem is resolved.
system or if one of the diagnostic codes in Table 39
is active or easily repeated.
STOP.
Test Step 9. Measure the Resistance of

the Injector Solenoid ---
Personal injury can result from high voltage.
The Electronic Control Module produces high

voltage.
Make sure the Electronic Control Module is not

powered and the fuel injector solenoids are dis
connected before proceeding.
A. Measure the solenoid resistance between pin 1

and pin 2 at the injector connector.
B. Record the measured resistance for each suspect

solenoid.
Expected Result:
The resistance is 1.06 ± 0.05 Ohms.
Results:
• OK - The resistance is 1.06 ± 0.05 Ohms.

~
',,
KENR5404-03 141
Table 39

338-5 Engine Pre-Lube Pump Relay The engine's Electronic Control Module The code is logged.
current below normal (ECM) detects an open circuit at the
prelube relay.
The ECM detects a short to battery
voltage at the prelube relay.
338-6 Engine Pre-Lube Pump Relay The engine's ECM detects a short
current above normal circuit at the prelube relay.
-
The ECM has the ability to automatically prelube When the ECM is in the START position, the ECM
the engine before cranking. This prelubrication may will activate the output driver for the "PPR 1" relay.
increase the life of certain engine parts. The ECM will When the "PPR1" relay energizes, the normally
prelube the engine, when the Engine Control Switch open contacts of the "PPR 1" relay close. This allows
(ECS) is placed in the START position. The ECM will current to flow to the prelube motor. The prelube
prelube the engine, when the ECS is placed in the motor activates the prelube pump. The prelube pump
AUTO position and the remote starUrun/stop switch builds pressure in the engine's lubrication system.
is closed. The length of time for the prelube cycle When the "prelube pressure switch" closes as a
can be programmed by the customer. The prelube result of the increased pressure, the ECM input for
cycle will end when the "prelube pressure switch" the "prelube pressure switch" is taken low. The ECM
closes or when the customer programmed time ends. then knows that the pressure in the prelube system is
The engine speed must equal zero rpm before the adequate. The ECM will begin the starting sequence.
prelube will begin.
The prelube cycle has the following status codes:

"OFF", "ON", "COMPLETED", and "DISABLED".
The "OFF" status is entered when the engine control

is first powered up with the ECS in the STOP position.
The "ON" status is entered when the ECM is on with

the ECS in the START position.
The "COMPLETED" status is entered when the

engine prelube duration is reached or when the
engine prelube's pressure switch is activated.
The "DISABLED" status is entered when the engine

prelube duration is programmed to O.
The prelube function will be aborted when one of the

• The "prelube pressure switch" is activated.
• The user defined engine prelube duration has been

reached.
e The operator activates the prelube override switch.
'~
RH CONTROL
G-C6! F-C1! A-C1!
F-C2 A-C92 E-C2
V
PRE LUBE
OVERRIDE LHCONTROL
SWITCH PRIMARY ECM
G-C6! F-C1!
F-C2 C-C17 P1 J1
Prelube Override
Digital Reference
Prelube
AirS/O F767---------~
BATTERY Breaker F7~,---------+_ Prelube Drive +
F900,----------+-- Digital Reference
+I <j-.!
24VDC P2 J2
I I I 0229
Prim. ECM 3 4
Breaker
PPR1 F 7 6 7 = f Prelube Override

F768 y Prelube Motor Contacts
G768 z Prelube Motor Contacts
P-C2J
A-C91 C-C18!
TB-C1
CUSTOMER
CONNECTOR
PRELUBE PRE LUBE

MOTOR PRESSURE
SWITCH
g01325464
Illustration 61
Typical schematic
'-
KENR5404-03 143
WIRE SIDE WIRE SIDE
0000.00000000 00000000000.0
14
00000 00000 23 14
00000 00000 23
08888 ~t@ 8888 08888 ~® 8888 0
4 3 4 3
0
400000 \@ 000047 400000 '@ 0000 47
4888888000~88857 4888888000~88857
ECM SIDE ECM SIDE
1//
Co 0 0 0 0 0 0 0
• 0 0 0 0 1
~
Co . 0 00 0 0 0 00 0 0 0')~
i(/
230 0 0 0 0
"0000
390 0 0 0
470 0 0 0
0
~
W
000 0 014
0000"
00 0 032
0 0 0 0 40
2300000
310000
390 0 0 0
470 0 0 0
~
0
[f@lJ
000024
0000014
0 0 0 032
0 000 40
570 0 0 0 0 0 00 0 0 048 570 0 0 00 0 0 0 00 048
~O oooe 000 0000 0 , ~O 0 00.00000000-,
~ !i
~ !i
Illustration 62 901325606 901325604

Illustration 63
P1 Primary ECM connector P2 Primary ECM connector
(P1-5) "Digital return" (P2-12) "Prelube drive"
(P1-66) "Prelube override switch" (P2-66) "Digital return"
144 I'\t:N~O.qU.q-U.j
~n)
@ ®
00 zo
@OCD
OE ®G)CD OE
aO
GD (0 d. aO
G0 (0 OA
dO
eo(!)
fO ®
8
®
@OB
OA
oc
ee (!)
fO ®
8 ®
@ OB
oc
bO OF bO OF
@8CD OG cO
@G)CD
® 0
r\
"'"
@ @®
Dr\
V
EO
CD 8@ Oa EO
CDG@
Oa
AO 0 (0 Od AO 0 (0 ad
0) (:) 0) (:) ae
80
co
®
FO
®
080
®
Ob
Oe
Of
80
CO
®
fO
®
080
®
Ob
Of -
GO
®0 ®0
g01325611 g01325633
Terminal locations for the P-C1/A-C90 Connector for the power Terminal locations for the P-C2/A-C91 Connector for the power
distribution panel distribution panel
(Terminal c) "Prelube drive +" (Terminal d) Contacts for the prelube motor
(Terminal 0) Drive for the prelube motor (Terminal e) Contacts for the prelube motor
(Terminal R) Return for the prelube motor
KENR5404-03 145
Section
o
@®
® ®
t:;";;\tW
0
® 0)
I?\
o 0000
0000080
~ ~ ~
e ®® @
®@® @ @
00000088
@®@ @ @
000888080
@ @ @@ ®
8800888808
@ @) f29\ ®
@ 88808008@
O~
IV
®®@®8G®®ee
B®®®®®8@@
@@@@®@®®
0 CD @@
_ C0®®®@®®
/;
/0
. 0
4 @
®
@@
®
® ® ®@
®
18
o @@@® 0
~
®@)@@®@)@
0®@@@®@
\0®@@®@
CD ® f29\ @) @,
0000
f9\ 'C'/ f13\ (~)000000

\V@®@~
~ 000000
080888080
Illustration 66 g01325642 8088888080
Terminal locations for the following connectors G-CB/F 880080888
C2/F-C1/A-C92 Connectors for a RH Control panel and

G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel ee®e®e®@@@
(Terminal 2) Prelube override switch \O®8®®@@@®
(Terminal 34) Digital return

e®®®@®®®
®®®®®®®
®®®®
Terminal locations for the A-C1/E-C2/E-C1/C-C1 rigid harness

(Terminal V) Prelube override switch
(Terminal AY) Digital return
'140
Section
o /00~ 0
2 3
RIGHT SIDE VIEW
4 5
--
00000(08
06000000
000888080
0808088808
88808888®
@@@®8G®®S8
6 7 8 9 10
®®®®®®8®®
@®®@@®®®
@®®8®®®
o . @®®® 0
LEFT SIDE VIEW
0000
Illustration 69
901320528
(~)(00000C0
--
Connector locations
80000060
(i) A-Ci/E-C2 RH rigid harness connectors
(2) A-C2fJ-C2 RH rigid harness connectors
080808080
(3) P-CifA-C90 Connectors for the power distribution panel
(4) P-C2fA-C9i Connectors for the power distribution panel
8088808080 (5) G-C6/F-C2/F-C1fA-C92 Connectors for a RH Control panel
I @88880880
(7) C-C15 Primary ECM connector Pi
88®®G8®®@@ (8) C-C28 Secondary ECM connector P2

(9) C-C29 Secondary ECM connector Pi
®®8®®®®®®
(10) G-C6fF-C2fF-C1fC-C17 Connectors for a LH Control panel
(11) C-C 18fTB-C 1 Customer connectors
8®®®®®®®
(12) C-C2fJ-C1 LH rigid harness connectors
(13) C-C1 fE-Ci LH rigid harness connectors
®®®§®®® Test Step 1. Inspect the Electrical

®®®®
901325637 B. Turn the breaker for the ECM to the OFF position.
Illustration 68
Terminal locations for the TB-Ci/C-C18 customer connector C. Thoroughly inspect the ECM connectors J1/P1
(Terminal i) Prelube override and J2/P2. Inspect all of the other connectors in
(Terminal y) Contacts for the prelube motor
the circuit. Refer to Troubleshooting, "Electrical
(Terminal z) Contacts for the prelube motor
Connectors - Inspect" for the proper procedure for
inspecting system wiring.

with the circuit.
E. Check the allen head screw for each of the

ECM connectors for the proper torque. Refer to
Troubleshooting, "Electrical Connectors - Inspect"
-
for details.
KENR5404-03 147
F. Check the harness and the wiring for abrasion " Not OK - A 6 diagnostic code is active at this time.
and for pinch points. Proceed to Test Step 3.
Expected Result: " Not OK - A 5 diagnostic code is active at this time.

coupled and/or inserted, and the harness and wiring Test Step 3. Create an Open at the
are free of corrosion, of abrasion, and of pinch pOints. Connector P-C1/A-C90 for the Power
Distribution Panel
Results:
to Test Step 2. B. Disconnect wire F705-BK from terminal c of the
connector P-C1/A-C90 for the power distribution
.. Not OK - The connectors and/or wiring are not panel.
OK.
replace the connectors or wiring. D. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active
STOP. diagnostic code.
Test Step 2. Check for Active Diagnostic Note: Wait at least 30 seconds in order for the
Codes diagnostic code to become active.
A. Connect Cat ET to the service tool connector. E. Select diagnostic tests from Cat ET.
B. Turn the breaker for the ECM to the ON position. F. Select the "Override Parameters" screen on Cat
ET.
G. Activate the prelube override.
D. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active H. Monitor the active diagnostic code screen on
diagnostic code. Cat ET. Check the prelube system for an active
diagnostic code.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. Note: Wait at least 30 seconds in order for the
diagnostic code to become active.
E. Select diagnostic tests from Cat ET.
I. Turn the ECS to the OFF/RESET position.
F. Select the "Override Parameters" screen on Cat
ET. J. Return all wiring to the original configuration.
G. Activate the prelube override. Expected Result:
H. Monitor the active diagnostic code screen on A 6 diagnostic code was active for the prelube relay.
Cat ET. Check the prelube system for an active After creating an open at the connector P-C1/A-C90
diagnostic code. for the power distribution panel, a 5 diagnostic code
is now active for the prelube relay.
diagnostic code to become active. Results:
I. Disable the prelube override.

• OK - A 6 diagnostic code was active before
disconnecting the wire. A 5 diagnostic code
Expected Result:
became active after disconnecting the wire. The
harness and the ECM are OK. The problem is in
No diagnostic codes are active.
the power distribution panel. Proceed to Test Step
6.
Results:
• Not OK - A 6 diagnostic code remains active. The

• OK - No diagnostic codes are active, but a short is between the connector P-C1/A-C90 for the
problem is suspected in the prelube system. power distribution panel and the ECM. Proceed
Proceed to Test Step 8. to Test Step 5.
140
Test Step 4. Create a Short at the Test Step 5. Test the Operation of the
Connector P-C1/A-C90 for the Power ECM
Distribution Panel
.~
A. Fabricate a jumper wire that is long enough to
A. Turn the ECS to the OFF/RESET position. create a test circuit at the ECM connector. Crimp
a connector socket to one end of the jumper wire.
B. Disconnect wire F705-BK from terminal c of the
connector P-C1/A-C90 for the power distribution B. Disconnect the J2/P2 ECM connector.
panel.
C. Remove the wire for the prelube relay from
C. Install a jumper wire between wire F705-BK and terminal P2-12 of ECM connector P2.
engine ground.
D. Install the jumper wire into the terminal location for
D. Turn the ECS to the STOP position. the prelube relay at the ECM connector.
E. Monitor the active diagnostic code screen on E. Connect the ECM connector.
diagnostic code. F. Check the operation of the ECM by creating an
open at the ECM connector:
diagnostic code to become active. a. Hold the loose end of the jumper wire away
from any components in order to create an
F. Select diagnostic tests from Cat ET. open circuit condition.
G. Select the "Override Parameters" screen on Cat b. Turn the ECS to the STOP position.
ET.
c. Monitor the active diagnostic code screen on
H. Activate the prelube override. Cat ET. Check the prelube system for an active
diagnostic code.
I. Monitor the active diagnostic code screen on

Cat ET. Check the prelube system for an active Note: Wait at least 30 seconds in order for the
~
diagnostic code. diagnostic code to become active.
Note: Wait at least 30 seconds in order for the d. Select diagnostic tests from Cat ET.
e. Select the "Override Parameters" screen on
J. Disable the prelube override. CatET.
K. Turn the ECS to the OFF/RESET position. f. Activate the prelube override.
L. Return all wiring to the original configuration.

g. Monitor the active diagnostic code screen on
Expected Result:
diagnostic code.
A 6 diagnostic code is active when the jumper wire

is installed. A 5 diagnostic code is active when the
jumper wire is removed.
h. Disable the prelube override.

Results:
G. Check the operation of the ECM by creating a

• OK - A 6 diagnostic code is active when the short circuit at the ECM connector:
jumper wire is installed. A 5 diagnostic code is
active when the jumper wire is removed. The a. Short the jumper wire in the socket for the
engine harness and the ECM are OK. The open prelube relay to engine ground.
circuit is in the power distribution panel. Proceed

to Test Step 7. b. Monitor the active diagnostic code screen on
• Not OK The 5 diagnostic code remains active

with the jumper in place. The open circuit is
between the connector P-C1/A-C90 for the power
distribution panel and the ECM. Proceed to Test
Step 5.
diagnostic code.


c. Select diagnostic tests from Cat ET.
KENR5404-03 149
I",,~hl"ll"ltinn Section
d. Select the "Override Parameters" screen on Note: Wait at least 30 seconds in order for the
CatET diagnostic code to become active.
e. Activate the prelube override. E. Select diagnostic tests from Cat ET
f. Monitor the active diagnostic code screen on F. Select the "Override Parameters" screen on Cat
Cat ET Check the prelube system for an active ET.
diagnostic code.
G. Activate the prelube override.
diagnostic code to become active. H. Monitor the active diagnostic code screen on
g. Disable the prelube override. diagnostic code.
H. Turn the ECS to the OFF/RESET position. Note: Wait at least 30 seconds in order for the
I. Return all wiring to the original configuration.
I. Disable the prelube override.
Expected Result:
J. Turn the ECS to the OFF/RESET position.
A 5 diagnostic code is active when the wire for the
prelube relay is open at the ECM connector. A 6 K. Leave wire F705-BK disconnected from the
diagnostic code is active jf the wire for the prelube "PPR2" relay.
relay is shorted at the ECM connector.
Expected Result:
Results:
A 6 diagnostic code was active for the prelube relay.
• OK - The ECM is operating properly. The problem After creating an open at the "PPR2" relay, the 6
is in the wiring between the ECM and the connector diagnostic code is no longer active.
P-C1/A-C90 for the power distribution panel.

Results:
replace the connectors or wiring. .. OK - A 6 diagnostic code is no longer active.
STOP. Repair: The short circuit is in the coil of the "PPR2"

relay. Replace the relay. Return all wiring to the
.. Not OK - One of the following conditions exists: original configuration.
The 5 diagnostic code is not active when the

wire for the prelube relay is disconnected. The 6 STOP.
diagnostic code is not active when the wire jumper

is connected to engine ground. • Not OK - A 6 diagnostic code remains active. The
short circuit is in the wiring between the connector
P-C1/A-C90 for the power distribution panel and
the "PPR 1" relay or the short circuit is in the
"PPR1" relay.
STOP. Repair: Perform the following test steps.
Test Step 6. Create an Open at the "PPR2" 1. Remove wire F705-BK from terminal 4 of the
Relay in the Power Distribution Panel "PPR1" relay. Activate the prelube override.
A. Turn the ECS to the OFF/RESET position. If the 6 diagnostic code changes to a 5
diagnostic code, the short is in the "PPR1" relay.
B. Disconnect wire F705-BK from terminal 86 of the Replace the "PPR1" relay.
"PPR2" relay in the power distribution panel.
If the 6 diagnostic code does not change, the
C. Turn the ECS to the STOP position. short is in the wiring between the relays and
terminal c on the connector P-C1/A-C90 for the
D. Monitor the active diagnostic code screen on power distribution panel. Repair the wire.
Cat ET Check the prelube system for an active
diagnostic code. STOP.
IOU
'oubleshootina Section
Test Step 7. Create a Short at the "PPR1" Verify that wire D229-BK has continuity to the
Relay and at the "PPR2" Relay in the "Primary ECM" breaker from the "PPR1" relay
Power Distribution Panel and from the "PPR2". If wire D229-BK is OK, the
open is in either the "PPR1" relay or in the "PPR2".
A. Turn the ECS to the OFF/RESET position. Check the coils of the relays for an open circuit.
B. Disconnect wire F705-BK from terminal 4 of the STOP.

"PPR1" relay in the power distribution panel.
• Not OK - A 5 diagnostic code remains active.
C. Disconnect wire F705-BK from terminal 86 of the
"PPR2" relay in the power distribution panel. Repair: The open circuit is in wire F705-BK
between the relays and the connector P-C1/A-C90
D. Create a short between wire F705-BK and engine for the power distribution panel. Repair the wire
ground. F705-BK.
E. Turn the ECS to the STOP position. STOP.
F. Monitor the active diagnostic code screen on Test Step 8. Check the Voltage at the
Cat ET. Check the prelube system for an active Prelube Motor
diagnostic code.
diagnostic code to become active. B. Disconnect connector A-C60 for the prelube
motor.
G. Select diagnostic tests from Cat ET.
C. Connect a voltmeter between terminal 4 and
H. Select the "Override Parameters" screen on Cat engine ground.
ET.
I. Activate the prelube override.
E. Select diagnostic tests from Cat ET.
J. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active F. Select the "Override Parameters" screen on Cat
diagnostic code. ET.
Note: Wait at least 30 seconds in order for the G. Activate the prelube override.
H. Measure the voltage between terminal 4 and
K. Turn the ECS to the OFF/RESET position. engine ground.
L. Return ali wiring to the original configuration. I. Disable the prelube override.
Expected Result: J. Turn the ECS to the OFF/RESET pOSition.

A 5 diagnostic code was active for the prelube relay. K. Retum all wiring to the original configuration.
After creating a short at the "PPR 1" relay and at the

"PPR2" relay, the 5 diagnostic code changed to a 6 Expected Result:
diagnostic code.
The voltage is 24 ± 3 VDC.
Results:
Results:
• OK - A 6 diagnostic code is active for the prelube

relay. The wiring between the relays and the ECM • OK - The voltage is 24 ± 3 VDC. Proceed to Test
is OK. Step 9.
Repair: The open circuit is in one of the following • Not OK - The voltage is not 24 ± 3 VDC.
components.
Repair: Perform the following steps.
• "PPR1" relay
• "PPR2" relay
• Wire D229-BK
KENR5404-03 151
Section
1. Remove the wire G705-BK from terminal 2 of i02644129

the "PPR1" relay. Activate the prelube override
and measure the voltage between terminal 2 Sensor Signal (Analog, Active)
and engine ground. If voltage is present on
terminal 2, repair the wire G705-BK between
- Test
the "PPR1" relay and the prelube motor. SMCS Code: 1439-038
2. If voltage is not present on terminal 2, verify that System Operation Description:
24 VDC is present on terminal 1 of the "PPR1"
relay. If voltage is not present on terminal 1 Use this procedure to troubleshoot the electrical
of the "PPR1" relay, repair the wire K708-BK system if a problem is suspected with the sensors
between the "Prelube Air S/O" breaker and the or if anyone of the diagnostic codes in Table 40 is
"PPR1" relay. active or easily repeated.
3. Verify that the wire 229-BK on terminal 4 of the

"PPR1" relay has continuity to the -Battery.
4. Verify that the coil of the "PPR 1" relay does not
have an open circuit
STOP.
Test Step 9. Check the Operation of the

Prelube Motor
A. Fabricate a wire jumper out of a piece of 10 AWG
wire and a 30A in-line fuse. Ensure that the wire
jumper is long enough to reach between the
+Battery terminal of the prelube motor and the
battery.
B. Connect one side of the wire jumper to the

+Battery.
C. For one second, connect the other end of the wire

to the positive terminal of the prelube motor.
Expected Result:
The prelube motor starts while the wire is connected

to the positive terminal of the prelube motor.
Results:
• OK - The prelube motor starts. There is a problem

in the wiring harness at the prelube motor.

STOP.
" Not OK - The prelube motor did not start.
Repair: Verify that the wire to the -Battery at the

prelube motor has continuity to the -Battery. If the
wire to the -Battery is OK, the problem is in the
prelube motor. Install a new prelube motor. Verify
that the problem is no longer present.
STOP.
I;:JL.
Section
Table 40
-
94-3 Fuel Delivery Pressure Sensor The Electronic Control Module (ECM) The code is logged.
voltage above normal detects signal voltage that is above The value of the parameter is set to
normal for one second. 500 kPa (75 psi).
The ECM has been powered for at least
three seconds.
94-4 Fuel Delivery Pressure Sensor ! The ECM detects signal voltage that is
voltage below normal below normal for one second.
The ECM has been powered for three
seconds. I
100-3 Engine Oil Pressure Sensor The ECM detects signal voltage that is The code is logged.
voltage above normal above nonnal for one second. i The value of the parameter Is set to
The ECM has been powered for at least 500 kPa (75 psi).
three seconds.
100-4 Engine Oil Pressure Sensor The ECM detects signal voltage that is
voltage below normal below normal for one second.
seconds.
I 101-3 Crankcase Air Pressure Sensor The ECM detects signal voltage that is • The code is logged .
voltage above normal above normal for one second. . The value of the parameter is set to
The ECM has been powered for at least zero.
three seconds.
i
101-4 Crankcase Air Pressure Sensor The ECM detects signal voltage that is
voltage below normal below normal for one second. :
three seconds.
'
I
• 110-3 Engine Coolant Temperature The ECM detects signal voltage that is The code is logged.
Sensor voltage above normal above normal for eight seconds. The value of the parameter is set to
The ECM has been powered for at least -40 QC (-40 OF).
two seconds.
110-4 Engine Coolant Temperature The ECM detects signal voltage that is
Sensor voltage below normal below normal for eight seconds.
The ECM has been powered for two
seconds.
273-0 Turbocharger Outlet Pressure The ECM reads turbocharger outlet The code is logged.
Sensor high - most severe (3) : pressure above 200 kPa (29 psi). The The value of the parameter is set to
engine speed is within 50 rpm of low idle zero.
for 5 seconds.
273-3 Turbocharger Outlet Pressure ::ts signal voltage that is
Sensor voltage above normal or one second.
)een powered for at least I
• three seconds.
273-4 Turbocharger Outlet Pressure The ECM detects signal voltage that is
Sensor voltage below normal below normal for one second.
seconds.
274-3 Atmospheric Pressure Sensor . The ECM detects signal voltage that is The code is logged.
voltage above normal above normal for one second. The value of the parameter is set to
The ECM has been powered for at least 45 kPa (6.5 psi).
three seconds.
274-4 Atmospheric Pressure Sensor The ECM detects signal voltage that is
voltage below normal
!
below normal for one second.
seconds.
(continued)
-
KENR5404-03 153
(Table 40, contd)
Diagnostic Codes Table I

275-3 Right Turbocharger Inlet Pressure The ECM detects signal voltage that is The code is logged.
Sensor voltage above normal above normal for one second. The value of the parameter is set to
three seconds.
275-4 Right Turbocharger Inlet Pressure The ECM detects signal voltage that is
seconds.
276-3 Left Turbocharger Inlet Pressure The ECM detects signal voltage that is The code is logged.
Sensor voltage above normal above normal for one second. The value of the parameter is set to
three seconds.
276-4 Left Turbocharger Inlet Pressure The ECM detects signal voltage that is
seconds.
279-3 Aftercooler Coolant Temperature The ECM detects signal voltage that is The code is logged.
Sensor (Front) voltage above normal above normal for one second. The ECM flags aftercooler temperature
The ECM has been powered for at least as invalid data.
three seconds.
279-4 Aftercooler Coolant Temperature The ECM detects signal voltage that is
Sensor (Front) voltage below normal below normal for one second.
seconds.
289-3 Fuel Pressure Sensor - Before The ECM detects signal voltage that is The code is logged.
Fuel Filter voltage above normal above normal for one second. The value of the parameter is set to
three seconds.
289-4 Fuel Pressure Sensor - Before The ECM detects signal voltage that is
Fuel Filter voltage below normal below normal for one second.
seconds.
542-3 Engine Oil Pressure Sensor The ECM detects signal voltage that is The code is logged.
Before Oil Filter voltage above normal above normal for one second. The value of the parameter is set to
three seconds.
542-4 Engine Oil Pressure Sensor The ECM detects signal voltage that is
Before Oil Filter voltage below normal below normal for one second.
seconds.
System Operation • Filtered fuel pressure sensor
Use this procedure to troubleshoot any suspect .. Turbocharger outlet pressure sensor
problems with the following sensors:
• Left turbocharger inlet pressure sensor
• Aftercooler temperature sensor
o Right turbocharger inlet pressure sensor
o Atmospheric pressure sensor
e Unfiltered engine oil pressure sensor
o Coolant temperature sensor
o Unfiltered fuel pressure sensor
• Crankcase pressure sensor
" Filtered engine oil pressure sensor

hl'\l'"\t,nn Section
The supply voltage is routed to terminal A of each

sensor connector. The sensor return is routed to
terminal B of each sensor connector. The sensor
signal is routed to terminal C of each sensor '
connector. The EC M provides short circuit protection
for the internal power supply. A short circuit to the
battery will not damage the internal power supply.
The ECM performs an automatic calibration of these

sensors whenever the ECM is powered and the
engine is off for at least five seconds. During an
automatic calibration, the ECM calibrates pressure
sensors to the value of the atmospheric pressure
sensor and against an acceptable offset pressure
range.
The ECM continuously outputs a pull-up voltage on

the input terminal from an analog sensor. The ECM
uses this pull-up voltage in order to detect an open or
a short in the signal circuit. When the ECM detects
the presence of a voltage that is above the normal
range of the sensor on the signal circuit, the ECM
will generate an open circuit diagnostic code 3 for
that sensor. When the ECM detects the absence of
the pull-up voltage on the signal circuit, the ECM will
generate a short circuit diagnostic code 4 for that
sensor. The presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
ground.
'
'
KENR5404-03 155
Section
FILTERED OIL PRESSURE

ANALOG SENSOR RETURN
ANALOG SENSOR POWER +5V
UNFILTERED FUEL PRESSURE

FILTERED FUEL PRESSURE

UNFILTERED OIL PRESSUREFtIW

. C
B
•
[ 993
P1/J1
PRIMARYECM

ANALOG RETURN (LH)
'-+--997 ANALOG POWER +5V (LH)
ANALOG SENSOR POWER +5V A
'-+-I---F737 UNRLTEREDFUELPRESSURE
'---I-l---F725 - FILTERED FUEL PRESSURE
'------l---; ---~-E796 UNFILTERED OIL PRESSURE
AFTERCOOLER TEMPERATURE R751 06 ~ AFTERCOOLER TEMPERATURE
ANALOG SENSOR RETURN ~C941 07" COOLANT TEMPERATURE
ANALOG SENSOR POWER +5V ,A993 35 ANALOG RETURN (RH)
. I -A997- 18 ANALOG POWER +5V (RH)
COOLANT TEMPERATURE·
ANALOG SENSOR RETURN TURBO OUTLET PRESSURE
ANALOG SENSOR POWER +5V LEFT TURBO INLET PRESS
ATMOSPHERIC PRESSURE
.111
CRANKCASE PRESSURE
RIGHT TURBO INLET PRESS
TURBO OUTLET PRESSUREFHB
ANALOG SENSOR RETURN • B
ANALOG SENSOR POWER +5V ; A
r
•
LEFTTLJRBO INLET PRESSURE
C-C1!
E-C1
ATMOSPHERIC PRESSURE
ANALOG SENSOR RETURN E-C21
ANALOG SENSOR POWER +5V A-C1
CRANKCASE PRESSURE
It1
RIGHT TURBO INLET PRESSURE

Typical schematic
130 0 0 0 0 0 • • 0 0 • • 01 130 0 0 0 0 0 0 0 0 0 0 0 01
230 0 0 0 0 0 • • • 0 014 2300000 0 0000014
310000 ~@~ 008824 310000 ~@~ 000024
3!X) 0 0 0 36 ~ 35. 0 0 032 3~ • • • 36 ~ 350 0 0 032
470 0 0 0 0 0 0 040 470 • 0 0 0 0 0 040
570 0 0 0 0 0 0 0 0 0 048 570 0 0 0 0 0 0 0 0 0 048
.700 0 0 0 0 0 0 0 0 0 0 0 05
,700 0 0 0 0 0 0 0 0 0 0 0 05
ECM SIDE ECM SIDE
1 2 3 4 5 6 0 8 9 10111213 1 2 3 4 5 6 0 8 9 101112 13
®
0 • •0 0• •000000 0000000000000
1400...
24• •0 0
o 000.35 0
0000()23
000031
360000 0
1400000
240000
o000035 0
(@)
0000()231
000031
36 • • • • 0
400000 00007 400000 0 0 .07 1
4800000 000007 4800000 000007
0000000000000 0000000000000
585960 61 62630656667686970
i i i I
HARNESS SIDE ENGINE SIDE
Illustration 71 901326575 901217213

Illustration 72
P1 ECM connector P2 ECM connector
(Pl-2) "5 V sensor supply (LH)" (P2-36) Turbocharger outlet pressure sensor
(Pl-3) "Sensor return (LH)" (P2-37) Atmospheric sensor
(Pl-6) Aftercooler temperature sensor (P2-38) Left turbocharger inlet pressure sensor
(Pl-7) Coolant temperature sensor (P2-39) Right turbocharger inlet pressure sensor
(Pl-16) Filtered engine oil pressure sensor (P2-46) Crankcase pressure sensor
(Pl-17) Unfiltered engine oil pressure sensor
(Pl-18) "5 V sensor supply (RH)"
(Pl-24) Filtered fuel pressure
(Pl-25) Unfiltered fuel pressure
(Pl-35) "Sensor return (RH)"
_/
KENR5404-03 157
JACK PLUG
o 00®088®
8800 0
00000086
000808880
8000880808
88808008@
§@@®8@®®88
Illustration 74
g01094844
®®@®®®8®®
Sensor connector
(Pin A) Sensor supply
@@®®®®®®
(Pin B) Sensor return
(Pin C) Signal
®®®®®®®
o @®®® 0
RIGHT SIDE VIEW
2 3 4 5
008e
®880®0®
00000000
088888000
8080880000
@80088888
88®@88®@@@
8®88®@@@®
8®®@@®@@
®®®®®®®
®®®®
LEFT SIDE VIEW
Illustration 73
g01326578 g01320528
Illustration 75
Connector locations

(Terminal A) "Sensor return (RH)"
(Terminal B) "5 V sensor supply (RH)"
(Terminal K) Right turbocharger inlet pressure sensor
(Terminal d) Crankcase pressure sensor
(11) C-C18/TB-C1 Customer connectors
_/
-10tj
Results:
• OK - A diagnostic code is not active.

STOP.
• Not OK - A diagnostic code is active. Proceed to

Test Step 2.
Test Step 2. Check the 5 Volt Supply

o
Voltage at the Sensor Connector
A. Do not disconnect the suspect connector.
B. Connect a voltmeter between pin A and pin B on

the sensor side of the connector for the suspect
sensor.
901234146
Illustration 76
C. Measure the voltage between pin A and pin B for
Location of ECM connectors
the suspect sensor(s).
Note: For the locations of the sensors on the engine,
D. Wiggle the harness while you monitor the voltage
refer to Troubleshooting, "Component Location".
on the voltmeter. Perform the 45 N (10 Ib) pull
test on each wire in the circuit. Each terminal
Test Step 1. Check for "Active" or
and each connector should easily withstand 45 N
"Logged" Diagnostic Codes
(10 Ib) of tension and each wire should remain
in the connector body. This test checks whether
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector. the wire was properly crimped in the terminal and
whether the terminal was properly inserted into
B. Restore electrical power to the ECM. the connector.
C. Monitor the diagnostic codes on Cat ET. Check Expected Result:

and record any diagnostic codes.
The supply voltage is 5.0 ± 0.5 VDC.
diagnostic codes to become active. Results:
D. Determine if a diagnostic code has occurred • OK - The supply voltage is 5.0 ± 0.5 VDC. An
several times. active 3 diagnostic code is present. Proceed to
Test Step 3.
Note: A diagnostic code that is logged several
times is an indication of an intermittent problem. • OK - The supply voltage is 5.0 ± 0.5 VDC. An
Most intermittent problems are the result of a bad active 4 diagnostic code is present. Proceed to
connection between a socket and a pin in a connector Test Step 5.
or a bad connection between a wire and a terminal.
The problem may be caused by moisture, corrosion, • Not OK - The supply voltage is not 5.0 ± 0.5 VDC.
or wear.
Repair: There is an open in the wiring or
E. Determine if the problem is active and related to connectors between the suspect sensor and the
one of the following diagnostic codes: ECM. Inspect the wiring and connectors. Refer to
• 3 STOP.
• 4
Expected Result:
A diagnostic code is not active.

KEN R5404-03 159
Section
Test Step 3. Check for Battery Voltage on Repair: Temporarily connect a new sensor to the
the Signal Wire harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic
A. Measure the voltage on the harness side of the codes for the sensor. If there are no active
sensor connector between pin B and pin C for the diagnostic codes for the sensor, permanently
suspect sensor(s). install the new sensor. Clear any logged diagnostic
codes.
Expected Result:
STOP.
The signal voltage is less than Battery voltage.
.. Not OK - A 3 diagnostic code is still active for the

Results:
suspect sensor(s). The problem may be in the
harness or with the ECM. Proceed to Test Step 6.
.. OK The signal voltage is less than Battery
voltage. Proceed to Test Step 4. Test Step 5. Create an Open at the

Suspect Sensor Connector
.. Not OK The signal voltage is equal to Battery
voltage. A. Remove electrical power from the ECM.
Repair: There is a short in the harness to the B. Disconnect the sensor connector of the suspect
+Battery. Repair the wiring.
sensor(s) with the active 4 diagnostic code.
STOP.
C. Restore electrical power to the ECM.
Test Step 4. Create a Short at the Sensor D. Monitor the diagnostic codes on Cat ET. Check for
Connector an active 3 diagnostic code for the suspect sensor.
A. Remove electrical power from the ECM. Note: Wait at least 30 seconds in order for the
B. Disconnect the suspect sensor.
E. Remove electrical power from the ECM.
C. Use a wire jumper in order to create a short
between terminal C (signal) and terminal B Expected Result:
(sensor return) at the sensor connector.
A 3 diagnostic code is now active for the suspect
D. Restore electrical power to the ECM. sensor(s).
E. Monitor the diagnostic codes on Cat ET. Check for Results:

an active 4 diagnostic code for the suspect sensor.
.. OK A 4 diagnostic code was active before
Note: Wait at least 30 seconds in order for the disconnecting the sensor. A 3 diagnostic code
diagnostic code to become active. became active after disconnecting the sensor. The
harness and the ECM are OK. There may be a
F. Remove electrical power from the ECM.
problem with the sensor.
Expected Result:
Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the
sensor(s).
codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently
Results:
install the new sensor. Clear any logged diagnostic
codes.
creating the short at the sensor connector. A 4 STOP.
diagnostic code became active after creating the
short at the sensor connector. The harness and .. Not OK A 4 diagnostic code is still active for the
the ECM are OK. There may be a problem with suspect sensor. Leave the sensor disconnected.
the sensor. The problem may be in the harness or with the
ECM. Proceed to Test Step 6.
b
Section
Test Step 6. Test the Operation of the Results:

ECM
A. Fabricate jumper wires that can be used to replace is in the wiring between the ECIVI and the connector
the signal wire in the ECM connector for the for the sensor.
suspect sensor. Crimp a connector socket to one
end of the jumper wire. Repair: If the code is active for more than one
sensor, the problem is most likely in the return wire
B. Disconnect the appropriate ECM connector for the for the sensor. Repair the return wire for the sensor
suspect sensor. or replace the harness.
C. Remove the signal wire for the suspect sensor If the code is only active for one sensor, the
from the ECM connector. problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor. Refer
D. Install the jumper wire into the terminal location for to Illustration 70 for a schematic of the circuit.
the suspect sensor at the ECM connector.
STOP.
E. Connect the ECM connector.
• Not OK - One of the following conditions exists:
F. Check the operation of the ECM by creating The 3 diagnostic code is not active when the sensor
an open at the ECM: signal wire is disconnected. The 4 diagnostic code
is not active when the wire jumper is shorted to
a. Hold the loose end of the jumper wire away ground.
from any components in order to create an
open circuit condition. Repair: Replace the ECM. Refer to
b. Turn the ECS to the STOP position. that the problem is resolved.
c. Monitor the active diagnostic code screen on STOP.

Cat ET. Check for a 3 diagnostic code for the
suspect sensor.
i02702818

Sensor Signal (Analog,
Passive) .. Test
G. Check the operation of the ECM by creating a
short circuit at the ECM: SMCS Code; 1439-038
a. Short the jumper wire for the suspect sensor to System Operation Description:
engine ground in order to create a short circuit
condition. Use this procedure to troubleshoot the electrical
system if a problem is suspected with the sensors
b. Turn the ECS to the STOP position. or if anyone of the diagnostic codes in Table 41 is
active or easily repeated.
c. Monitor the active diagnostic code screen on
Cat ET. Check for a 4 diagnostic code for the
suspect sensor.

H. Remove all jumper wires. Return the wiring to the

original configuration.
Expected Result:
A 3 diagnostic code is active when the sensor

signal wire is removed from the ECM connector. A
4 diagnostic code is active when the signal wire is
connected to engine ground.
KENR5404-03 161
Section
Table 41

105-3 Inlet Manifold Temperature The engine's Electronic Control Module The code is logged.
Sensor voltage above normal (ECM) detects signal voltage that is The value of the parameter is set to
more than 4.8 VDC for one second. zero.
three seconds.
105-4 Inlet Manifold Temperature The ECM detects signal voltage that is
Sensor voltage below normal less than 0.2 VDC for one second.
three seconds.
175-3 Engine Oil Temperature Sensor The ECM detects signal voltage that is The code is logged.
voltage above normal more than 4.8 VDC for one second. The value of the parameter is set to
The ECM has been powered for at least zero.
three seconds.
175-4 Engine Oil Temperature Sensor The ECM detects signal voltage that is
voltage below normal less than 0.2 VDC for one second.
three seconds.
System Operation
Use this procedure to troubleshoot any suspect

• Inlet manifold temperature sensor
• Engine oil temperature sensor
The sensor signal for the passive sensors is routed

to terminal C of each sensor connector. The sensor
return for the passive sensors is routed to terminal B
of each sensor connector.
X-C11
PRIMARYECM
C-C11 P1/J1
INLET MANIFOLD TEMP

SENSOR RETURN
INLET MANIFOLD AIR
RETURN (LEFT RAIL)
T~~;J
ENGINE OIL TEMP
B-<-'---, RETURN (RIGHT RAIL)
ENGINE OIL TEMP
SENSOR RETURN
EE-C11
CONN.
A-C49
Typical schematic
10
230 0 0 0 0
310000
0
~@~ 0.002,
0 0 0 0
0 36 ~ 35. 0 0 032
.14
o 0800 0
3R)
470
0
0
0
0 0 0 0 0 040 008008®
570 0 0 0 0 0 0 0 0 0 04a 00000000
,700 0 0 0 0 0 0 0 0 0 0 0 05
000888000
8008888808
ECM SIDE
8880008e®
1 2 3 4 5 6 0 8 9 10 1112 13 @®®®8®®®S8
00.0000000000 ®®@®®®88®
14.0000
240080
j~28~35©36
®
0000023
88001
08&;
@@@C§(§@®§
@®®8@®®
0,4800000
00000000
8><8807
0 0
o @@@@ 0
HARNESS SIDE
Illustration 78 g01242612 0080

P1 ECM connector (0000800
(P1-3) Sensor return (left rail)
(P1-14) "Inlet manifold temperature sensor"
00000000
(P1-26) Engine oil temperature sensor
(P1-35) Sensor return (right rail)
000808080
8088888000
8@0000888
8S®®C08®®®@
®®8®®®@®®
8®®®C§®@@
®®®®®®®
®®@@
Terminal locations for the A-C1/E-C2/E-C1/C-C1 rigid harness

(Terminal 8) Sensor return
(Terminal H) Engine oil temperature
KENR5404-03 163
Test Step 1. Check for "Active" or

"Logged" Diagnostic Codes
,
f- A. Connect Caterpillar Electronic Technician (ET) to
r- = the service tool connector.
B. Restore power to the ECM.
c. Monitor the diagnostic codes on Cat ET. Check

and record any diagnostic codes.
f
~

diagnostic codes to become active.
g01341865 D. Determine if the problem is active and related to

Illustration 80 one of the following diagnostic codes:
Sensor connector
(Terminal C) Sensor signal .. 3
(Terminal B) Sensor return

.. 4
Expected Result:
RIGHT SIDE VIEW No diagnostic codes are active at this time.
2 3 4 5
Results:
• OK - No diagnostic codes are active at this time.

problem is intermittent refer to Troubleshooting.
STOP.
• Not OK - An active 3 diagnostic code is present.

• Not OK - An active 4 diagnostic code is present.

Test Step 2. Check for Battery Voltage on

LEFT SIDE VIEW the Signal Wire
A. Measure the voltage on the harness side of the
sensor connector between terminal C (signal) and
engine ground for the suspect sensor(s).
g01320528
Illustration 81
Connector locations Expected Result:

(2) A-C2/J-C2 RH rigid harness connectors The Signal voltage is less than Battery voltage.

Results:

(7) C-C15 Primary ECM connector P1 .. OK - The signal voltage is less than battery
(8) C-C28 Secondary ECM connector P2 voltage. Proceed to Test Step 3.

(11) C-C18/TB-C1 Customer connectors • Not OK - The signal voltage is equal to battery
(12) C-C2/J-C1 LH rigid harness connectors voltage.
10"t
Repair: There is a short in the harness to the Expected Result:

+Battery. Repair the wiring.
STOP. sensor(s}.
Test Step 3. Create a Short at the Sensor Results:

Connector
A. Disconnect the suspect sensor. disconnecting the sensor. A 3 diagnostic code
became active after disconnecting the sensor.
B. Use a wire jumper in order to create a short
between terminal C (signal) and terminal B Repair: Temporarily connect a new sensor to the
(sensor return) at the sensor connector. harness, but do not install the new sensor in the
C. Restore power to the ECM. codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently
D. Access the "Active Diagnostic Code" screen on install the new sensor. Clear any logged diagnostic
Cat ET. Check for an active 4 diagnostic code for codes.
the suspect sensor.
STOP.
diagnostic codes to become active. • Not OK - A 4 diagnostic code is still active for the
suspect sensor. There is a short circuit between
Expected Result: the sensor connector and the ECM. Leave the
sensor disconnected. Proceed to Test Step 5.
sensor(s). Test Step 5. Check the Operation of the
ECM
Results:
creating the short at the sensor connector. A 4 B. Check the operation of the ECM by creating an
diagnostic code became active after creating the open at the ECM.
short at the sensor connector.
a. Remove the signal wire for the suspect
Repair: Temporarily connect a new sensor to the sensor from the Pi ECM connector. Refer to
harness, but do not install the new sensor in the Illustration 77 for terminal locations.
codes for the sensor. If there are no active b. Install a jumper wire with Deutsch sockets on
diagnostic codes for the sensor, permanently each end into the socket for the signal wire of
install the new sensor. Clear any logged diagnostic the suspect sensor.
codes.
c. Reconnect the ECM connectors.
STOP.
d. Restore power to the ECM. Monitor the "Active
• Not OK - A 3 diagnostic code is still active for the Diagnostic Code" screen on Cat ET. An open
suspect sensor(s}. Proceed to Test Step 5. circuit diagnostic code 3 should be active for
the suspect sensor.
Test Step 4. Create an Open at the
Suspect Sensor Connector Wait at least 30 seconds in order for the
A. Remove power from the EeM.
C. Check the operation of the ECM by creating a
B. Disconnect the sensor connector of the suspect short at the ECM.
sensor(s) with the active 4 diagnostic code.
a. Install a wire jumper between the wire jumper
C. Restore power to the ECM. for the signal wire for the suspect sensor and
engine ground.
D. Access the "Active Diagnostic Code" screen on
Cat ET. Check for an active 3 diagnostic code. b. Monitor the "Active Diagnostic Code" screen on
Cat ET. A 4 diagnostic code should be active
Wait at least 30 seconds in order for the diagnostic when the wire jumper is installed.
codes to become active.
KE NR5404-03 165
Wait at least 30 seconds in order for the

c. Remove the wire jumper. Reconnect all wires

and connectors.
Expected Result:
A 3 diagnostic code is active when the sensor

signal wire is removed from the ECM connector. A
4 diagnostic code is active when the signal wire is
connected to engine ground.
Results:

is in the wiring between the ECM and the connector
for the rail.
Repair: If the code is active for the engine oil

temperature sensor, make sure that you inspect
the connectors that are between the right hand
side of the engine and the left hand side of the
engine. Repair the wiring and connectors between
the ECM and the sensor. Refer to Illustration 77 for
terminal locations.
STOP.
• Not OK - One of the following conditions exists:

The 3 diagnostic code is not active when the sensor
signal wire is disconnected. The 4 diagnostic code
is not active when the wire jumper is installed.
STOP.
i02646178
Sensor Signal (PWM) - Test

SMCS Code: 1439-038

system if a problem is suspected with the exhaust
temperature sensors or if anyone of the diagnostic
codes in Table 42 is active or easily repeated.
IUU
Section
Table 42
-
Code and Description I Conditions which Generate this Code I System Response
827-8 Left Exhaust Temperature Sensor The Electronic Control Module (ECM) The value of the parameter is set to
abnormal frequency, pulse width, or detects a sensor frequency that is zero.
period greater than 1000 Hz or less than 150 The code is logged.
Hz.
The ECM detects a duty cycle that is
greater than 90 percent or a duty cycle
that is less than 10 percent.
828-8 Right Exhaust Temperature The ECM detects a sensor frequency
Sensor abnormal frequency, pulse that is greater than 1000 Hz or less than •
width, or period 150 Hz.
The ECM detects a duty cycle that is
greater than 90 percent or a duty cycle
that is less than 10 percent.
System Operation
Use this procedure to troubleshoot any suspect

• Left exhaust temperature sensor
~ Right exhaust temperature sensor
The "Pulse Width Modulated (PWM)" sensors provide

a signal to the engine's ECM for certain engine
-
operating conditions. The sensors receive a 8.0 ± 0.4
VDC regulated voltage from the ECM.
The sensor's wires are routed from the ECM to

the sensor connectors. The following list gives the
terminal locations for the sensor connector.
• Terminal A 8 V supply
• Terminal B sensor return
• Terminal C sensor signal
The ECM performs an automatic calibration of these

engine has been off for at least five seconds.
The ECM provides short circuit protection for the

internal power supply. A short circuit to the battery
will not damage the internal power supply.
-
KENR5404-03 167
DIGITAL SENSOR POWER +8V

DIGITAL SENSOR RETURN
LEFT EXHAUST TEMPERATURE
A I~
B
C l
700
D998
R803
R804
!ill 5
11
12
PRIMARY ECM
DIGITAL POWER +8V (LH)

DIGITAL RETURN (LH)
LEFT EXHAUST TEMPERATURE
RIGHT EXHAUST TEMPERATURE
1 DIGITAL POWER +8V (RH)
~I~ ~
DIGITAL SENSOR POWER +8V A700
DIGITAL SENSOR RETURN ~+-+---F998 DIGITAL RETURN (RH)
! I I
RIGHT EXHAUST TEMPERATURE
g01327527
Illustration 82
Typical schematic
130 • • 0 0 0 0 0 • • 0 0 01 130 0 0 0 0 0 0 0 0 0 0 0 01
230000000000014 230 0 0 0 0 0 0 0 0 0 014
310000 ~@~ 000024 310 00 0 ~@~ 0 0 0024
390 0 0 036 «Q> 35 0 0 0 032 390 0 0 036 «Q>
35 0 0 0 032
470 0 0 0 0 0 0 040 470 0 0 0 0 0 0 040
570 0 0 0 0 0 0 0 0 0 048 570800000000048
700 0 0 0 0 0 0 0 0 0 0 0 05 .700 0 0 0 • 0 0 0 0 0 0 0 05
ECM SIDE ECM SIDE
1 2 3 4 5 6 0 8 9 10111213 1 2 3 4 5 6 0 8 9 10 1112 13
0 0 0• •0 0 0 0 0• •0 I 0000000000000
1400000
240 0 0 0
0000035
@
0000023
000()31
0 360000DA
1400000
240 0 0 0
o000035 @
0000023
000()31 @
360000 0
400000 000047· I 400000 000047
4800000 0 0 0 0 07 1
4800000 000807
0000000000000 0000000080000
58 59 60 61 62 63 065 6667 68 6970
I I II
Illustration 83 g01213937 g01327661

Illustration 84
(P1-4) "8 V digital sensor supply (LH)" (P2-56) "8 V digital sensor supply (RH)"
(P1-5) "Digital sensor return (LH)" (P2-66) "Digital sensor return (RH)"
(P1-11) Left exhaust temperature
(P1-12) Right exhaust temperature
IUO
o 00eO 0 1 2 3
RIGHT SIDE VIEW
4 5
-'
0000080
0080000®
000808080
8880880808
808080088
§®@®8®®®®8
®@®®888@®
@@@@®@®®
®®®8®®®
o @®®® 0
LEFT SIDE VIEW
8e00 Illustration 86
g01320528
8800000
Connector locations
00000800
~
080808000
8080880088
(5) G-C6/F-C2IF-C1/A-C92 Connectors for a RH Control panel
@@0080808
(7) C-C15 Primary ECM connector Pi
8S®®88®@®@
®88®8@@@®
(10) G-C6/F-C2/F-Ci/C-C17 Connectors for a LH Control panel
(11) C-C18ITB-C1 Customer connectors
8®®®®®®@
®®®8®®®
@®®®

(Terminal C) "8 V digital sensor supply (RH)"
(Terminal D) "Digital sensor return (RH)"
(Terminal R) "Right exhaust temperature"
-'
KENR5404-03 169
Note: A diagnostic code that is logged several

times is an indication of an intermittent problem.
Most intermittent problems are the result of a bad
connection between a socket and a pin in a connector
or a bad connection between a wire and a terminal.
\'------{l~
F. Determine if a 8 diagnostic code is active for one

of the exhaust temperature sensors:
Expected Result:
No diagnostic code is active for the exhaust

temperature sensors.
Results:
• OK - No diagnostic codes are active.
Repair: If the problem is intermittent, refer to

for the correct procedures for inspecting electrical
Illustration 87
g01234146 connectors.
STOP.
• Not OK - A 8 diagnostic code is active or the

diagnostic code is logged several times. Proceed
JACK PLUG
to Test Step 2.
Test Step 2. Check the Digital Supply

Voltage at the Sensor Connector
A. Disconnect the suspect sensor(s) at the sensor
connector:
B. Measure the voltage on the ECM side of the

sensor connector between pin A and pin B for the
suspect sensor(s).
g01094844
Illustration 88
Sensor connector Expected Result:
(Pin B) Sensor return The supply voltage is 8.0 ± 0.4 VDC.
(Pin C) Signal
Results:
Test Step 1. Check for an "Active"

Diagnostic Code G OK - The supply voltage is 8.0 ± 0.4 VDC.

• Not OK - The supply voltage is not 8.0 ± 0.4 VDC.
B. Connect Caterpillar Electronic Technician (ET) to
the service tool connector. Repair: Refer to Troubleshooting, "Sensor Supply
- Test".
c. Turn the ECS to the STOP position.
STOP.
D. Monitor the diagnostic codes on Cat ET. Check
and record any diagnostic codes. Test Step 3. Check the Digital Sensor's
Signal Frequency and the Duty Cycle at
Note: Wait at least 30 seconds in order for the the Sensor Connector
E. Determine if a diagnostic code has occurred
several times. B. Remove the sensor's signal wire from pin C of the
sensor connector.
I IV
Section
C. Turn the ECS to the STOP position. • Not OK - The duty cycle is not correct.
D. Measure the frequency and the duty cycle Repair: There is a problem in the wiring between
between the sensor's signal wire and pin B of the the ECM and the connector for the sensor. Repair
suspect digital sensor at the sensor connector. the connectors and/or wiring between the ECM
and the connector for the sensor.
E. Turn the ECS to the OFF/RESET position.
STOP.
F. Replace the sensor's signal wire and reconnect
the sensor.
i02646020
Expected Result: Sensor Supply - Test

The duty cycle is between 10 to 90 percent. The SMCS Code: 1439-038
frequency reading is approximately 500 Hz.
Results:
• OK - The frequency and the duty cycle are correct. system if a problem is suspected with a sensor
Proceed to Test Step 4. supply or if anyone of the diagnostic codes in Table
43 is active or easily repeated.
• Not OK - The frequency or the duty cycle is not
correct.
Repair: Replace the sensor. Verify that no

diagnostic codes are active for the suspect sensor
before permanently installing the sensor.
STOP.
Test Step 4. Check the Sensor's Duty

Cycle at the ECM
B. Remove the suspect signal wire for the sensor

from ECM connector P1. Refer to Illustration 82
for the terminal locations for the ECM connector.
D. Measure the duty cycle between the sensor's

signal wire and the sensors return wire.
Note: Set the multimeter to "VDC". Press the "Hz"

button twice so that the % symbol is displayed.

Reconnect all wires.
Expected Result:
The duty cycle is between 10 to 90 percent.
Results:
• OK - The duty cycle is correct.
Repair: Replace the ECM. Refer to the diagnostic

procedure Troubleshooting, "ECM - Replace".
STOP.
KENR5404-03 171
Table 43

262-3 5 Volt Sensor DC Power Supply The analog sensor supply voltage is The code is logged.
voltage above normal above normal for two seconds. All sensors are set to default values.
262-4 5 Volt Sensor DC Power Supply The analog sensor supply voltage is
voltage below normal below normal for two seconds.
263-3 Digital Sensor Power Supply (8V The digital sensor supply voltage is
Or 12V) voltage above normal above normal for two seconds.
263-4 Digital Sensor Power Supply (8V The digital sensor supply voltage is
Or 12V) voltage below normal below normal for two seconds.
System Operation Note: The sensors are not protected from

overvoltage. A short from the supply line to the
The Electronic Control Module (ECM) supplies a +Battery may damage the sensors. If the diagnostic
regulated voltage of 5.0 ± 0.2 VDC to the following code 262-3 or the diagnostic code 263-3 is logged,
sensors: it is possible that all of the sensors have been
damaged. Repair the sensor supply and check
• Aftercooler temperature sensor for any active sensor diagnostic codes in order to
determine if a sensor has failed.
• Atmospheric pressure sensor
• Coolant temperature sensor
e Crankcase pressure sensor
• Filtered engine oil pressure sensor
• Filtered fuel pressure sensor
• Turbocharger outlet pressure sensor
e Left turbocharger inlet pressure sensor
.. Right turbocharger inlet pressure sensor
.. Unfiltered engine oil pressure sensor
• Unfiltered fuel pressure sensor
The ECM supplies a regulated voltage of 8.0 ± 0.4

VDC to the following sensors:
• Left exhaust temperature sensor
• Right exhaust temperature sensor
The supply voltage for the sensors is routed from the

ECM to terminal A of each sensor connector. The
sensor return for the sensors is routed from the ECM
to terminal B of each sensor connector. The ECM
provides short circuit protection for the internal power
supply. A short circuit to the battery will not damage
the internal power supply.
I f "
C·C20
FILTERED OIL PRESSURE r-~~ A
ANALOG SENSOR RETURN r-17 B 8
ANALOG SENSOR POWER +5V r-I7A 1/ C
'---~
D !
r-~ E~i=jl
-(~~
UNFILTERED FUEL PRESSURE ~-::
ANALOG SENSOR RETURN B i?-
:-
ANALOG SENSOR POWER +5V A 1)--<
-
FILTERED FUEL PRESSURE r-f;C~
Lw~
ANALOG SENSOR RETURN ~i7B j)- ~
ANALOG SENSOR POWER +5V-i7A 1)- PRIMARY ECM

'----
P1/J1
UNFILTERED OIL PRESSURE ~c:::::
ANALOG SENSOR RETURN r-{7B
ANALOG SENSOR POWER +5V:---i?A
>--
1)-
-993-
97
ANALOG RETURN (LH)
ANALOG POWER +5V (LH)
I '----'- F73j UNFILTERED FUEL PRESSURE
F72~ FILTERED FUEL PRESSURE
;----..,.-
E79( UNFILTERED OIL PRESSURE
AFTERCOOLER TEMPERATURE r-r;;>C R75 AFTERCOOLER TEMPERATURE
ANALOG SENSOR RETURN r-I7B .- -C9<1 COOLANT TEMPERATURE
ANALOG RETURN (RH)
I ANALOG SENSORPOWER +5V r-r;;>A
~- I I 'I - -I ANALOG POWER +5V (RH)
COOLANT TEMPERATURE - f ; C :
I
I ANALOG SENSOR RETURN c-->B ?-:- " TURBO OUTLET PRESSURE
ANALOG SENSOR POWER +5V r-I7A ) - F71: LEFT TURBO INLET PRESS
~-
A74 ATMOSPHERIC PRESSURE
E79 CRANKCASE PRESSURE
Fn RIGHT TURBO INLET PRESS
I TURBO OUTLET PRESSURE - f ; C :

ANALOG SENSOR RETURN -7B ) - :-
P2IJ2
I ANALOG SENSOR POWER +5V ->A ) -

--
i
I LEFT TURBO INLET PRESSURE ~-:: I

ANALOG SENSOR RETURN B )1- :-
ANALOG SENSOR POWER +5V A )1-
-
Id KIA B
C·C11
E·C1
--:-
ATMOSPHERIC PRESSURE i=7C
7B ?r-:-
ANALOG SENSOR POWER +5V 1 ~":::r-
I d K I A BI E-C2I
A-C1
CRANKCASE PRESSURE
RIGHT TURBO INLET PRESSURE
Typical schematic 5 V supply

KENR5404-03 173
PRIMARY ECM
DIGITAL SENSOR POWER +8V~A I~I 700 DIGITAL POWER +8V (LH)
DIGITAL SENSOR RETURN B 0998 DIGITAL RETURN (LH)
LEFT EXHAUST TEMPERATURE C R803 LEFT EXHAUST TEMPERATURE
R804- RIGHT EXHAUST TEMPERATURE
DIGITAL SENSOR POWER +8V~AI~1

DIGITAL SENSOR RETURN B
H=J
D D
A?OO
F998
DIGITAL POWER +8V(RH)
DIGITAL RETURN (RH)
RIGHT EXHAUST TEMPERATURE C R R P2IJ2
g01327527
Illustration 90
Typical schematic 8 V supply
130 0 0 0 0 0 0 0 • " • • 01 130 0 0 0 0 0 0 0 0 0 0 0 01

230 0 0 0 0 0 • 0 0 0 014 230 0 0 0 0 0 0 0 0 0 014
310000
3g() 0 0
~@~
0 36 ~ 35 • 0 0
000 ()24
032
310000
3g() 0 0
~@~
0 36 ~ 35 0 0 0
000 ()24
032
470 0 0 0 0 0 0 040 470 0 0 0 0 0 0 040
570 0 0 0 0 0 0 0 0 0 048 5?0 • 0 0 0 0 0 0 0 0 048
,700 0 0 0 0 0 0 0 0 0 0 0 05 ,700 0 0 0 • 0 0 0 0 0 0 0 058,
ECM SIDE
ECM SIDE
1 2 3 4 5 6 0 8 9 10111213
1 2 3 4 5 6 0 8 9 10 1112 13
0 ••••00000000 0000000000000
1400008
240000
0000()23
OOO()1
o000835 0 360000 0
@ 1400000
4
2 0000
0000()23
OOO() 1
o000035 @ 360000 0
(@)
400000 OOOO? 400000 OOOO?
4800000 OOOOO? 4800000 OOO.O?
0000000000000 00000000.0000
585960 61 62630656667686970 58 59 60 61 62 63 065 6667 68 69 70 ~/'
i i i I
- II II·
Illustration 91 g01327649 g01327661

Illustration 92
(P1-2) "5 V analog sensor supply (LH)" (P2-56) "8 V digital sensor supply (RH)"
(P1-3) "Analog sensor return (LH)" (P2-66) "Digital sensor return (RH)"
(P1-4) "8 V digital sensor supply (LH)"
(P1-5) "Digital sensor return (LH)"
(P1-18) "5 V analog sensor supply (RH)"
(P1-35) "Analog sensor return (RH)"
Section
o 0000086
eeee 0
2 3
RIGHT SIDE VIEW
4 5
00000000
000888080
8008880888
088080888
e®®®8®®®e8
7 8 9 10
®®8®®B8®®
@@@@®®®8
®®®®®®®
o @@®@2 0
LEFT SIDE VIEW
GaGe
g01320528
8800000 Illustration 94
Connector locations
80000000
080888080
--
8880880000 (5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
888080888 (7) C-C15 Primary ECM connector P1
8e®®®8®@@@ (S) C-C2S Secondary ECM connector P2

e®8B®®e®® (10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel

(11) C-C1S/TB-C1 Customer connectors
8®®®@@@@
@®®®@@§
®®®®
Terminal locations for the A-C1/E-C2 RH rigid hamess connectors

(Terminal A) "Analog sensor return (RH)"
(Terminal 8) "5 V analog sensor supply (RH)"
(Terminal C) "S V digital sensor supply (RH)"
(Terminal D) "Digital sensor return (RH)"
~
KENR5404-03 175
E. Check the harness and wiring for abrasion and for

pinch points from the sensors back to the ECM.
Expected Result:
All connectors, pins and sockets are completely

coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
Results:
Q OK - The harness and connectors appear to be

OK. Proceed to Test Step 2.
• Not OK - There is a problem with the connectors

and/or wiring.

g01234146
Illustration 95
STOP.
Test Step 2. Check for Active Diagnostic

JACK PLUG
Codes
the service tool connector.
B. Restore electrical power to the ECM.
C. Monitor the active diagnostic code screen on Cat

ET Check and record any active diagnostic codes.
Look for the following diagnostic codes:
g01094844 .. 262-3
Illustration 96
Sensor connector
.. 262-4

(Pin 8) Sensor return
(Pin C) Signal .. 263-3
Test Step 1. Inspect the Electrical .. 263-4

A. Remove electrical power from the ECM. diagnostic codes to become active.
B. Thoroughly inspect the J1/P1 ECM connector Expected Result:

connectors that are associated with the circuit. No diagnostic codes are active.
Refer to Troubleshooting, "Electrical Connectors Results:
Inspect" for details.

• OK - No diagnostic code is active.
C. Perform a 45 N (10 Ib) pull test on each of the

wires in the ECM connectors that are associated Repair: The problem is no longer present. If the
with the circuit. problem is intermittent, refer to Troubleshooting,
"Electrical Connectors Inspect".
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to Troubleshooting, STOP.
"Electrical Connectors -Inspect" for details.
II U
Section
• Not OK Either the 262-3 or 262-4 diagnostic • Not OK - The 262-3 or 262-4 diagnostic code
code is active at this time. Proceed to Test Step 3. remains active after all of the sensors are
disconnected. Leave the sensors disconnected.
• Not OK - Either the 263-3 or 263-4 diagnostic The sensors are not the cause of the diagnostic
code is active at this time. Proceed to Test Step 5. code. Proceed to Test Step 4.
Test Step 3. Disconnect the 5 Volt Test Step 4. Check the 5 Volt Supply
Sensors while you Monitor the Active Voltages at the ECM
Diagnostic Codes
A. Remove electrical power from the ECM.
A. Monitor the active diagnostic code screen on Cat
ET while you disconnect each 5 Volt sensor at the B. Remove the supply wire from P1-2. Install a wire
sensor connector. Check for an active 262-3 code jumper into the socket P1-2.
or an active 262-4 code.
C. Remove the supply wire from P1-18.
diagnostic codes to become active. D. Restore electrical power to the ECM.
a. Disconnect the following sensors one at a time: E. Measure the voltage between the wire jumper in
terminal P1-2 and engine ground.
• Aftercooler temperature sensor
F. Remove electrical power from the ECM.
• Atmospheric pressure sensor
G. Remove the wire jumper and replace all wires.
• Coolant temperature sensor

Expected Result:
• Crankcase pressure sensor

Each voltage measurement is 5.0 ± 0.2 VDC.
• Filtered engine oil pressure sensor

Results:
• Filtered fuel pressure sensor

• OK - The voltage measurement is 5.0 ± 0.2 VDC.
.. Turbocharger outlet pressure sensor The ECM is operating correctly.
• Left turbocharger inlet pressure sensor Repair: The supply wire is shorted to another wire
in the harness or the supply wire is shorted to
• Right turbocharger inlet pressure sensor engine ground. Repair the supply wire.
• Unfiltered engine oil pressure sensor STOP.
• Unfiltered fuel pressure sensor • Not OK The voltage measurement is not 5.0 ±
0.2 VDC.
B. Remove electrical power from the ECM.
Expected Result:
The diagnostic code deactivates when a particular

STOP.
sensor is disconnected.
Test Step 5. Disconnect the 8 Volt

Results:
Sensors while you Monitor the Active
Diagnostic Codes
• OK - The 262-3 or 262-4 diagnostic code
deactivates when a particular sensor is A. Monitor the active diagnostic code screen on Cat
disconnected. ET while you disconnect each 8 Volt sensor at the
sensor connector. Check for an active 263-3 code
Repair: Connect the suspect sensor. If the code or an active 263-4 code.
returns, replace the sensor. Connect all of the
connectors. Verify that the problem is resolved. Note: Wait at least 30 seconds in order for the
STOP.
a. Disconnect the following sensors one at a time:
• Exhaust temperature sensor (LH)

KENR5404-03 177
.. Exhaust temperature sensor (RH) Repair: The supply wire is shorted to another wire
in the harness or the supply wire is shorted to
B. Remove electrical power from the ECM.
engine ground. Repair the supply wire.
Expected Result:
STOP.
The diagnostic code deactivates when a particular

• Not OK - The voltage measurement is not 8.0 ±
sensor is disconnected.
0.4 VDC.
Results:
Troubleshooting, "ECM - Replace" .
.. OK - The 263-3 or 263-4 diagnostic code
deactivates when a particular sensor is STOP.
disconnected.
i02646517
Repair: Connect the suspect sensor. If the code
returns, replace the sensor. Connect all of the
connectors. Verify that the problem is resolved.
Speed Control (Switch) - Test

SMCS Code: 1915-038; 7332-038-VF
STOP.
• Not OK - The 263-3 or 263-4 diagnostic code
remains active after the sensors are disconnected. Use this procedure to troubleshoot the electrical
Leave the sensors disconnected. The sensors are system if a problem is suspected with the throttle
not the cause of the diagnostic code. Proceed to position sensor or if the diagnostic code in Table 44
Test Step 6. is active or easily repeated.
Test Step 6. Check the 8 Volt Supply
Voltage at the ECM
A. Disconnect the J2/P2 ECM connector.
B. Fabricate a wire jumper that is long enough to be

used to measure the supply voltage at the ECM
connector. Crimp a connector socket to one end
of the wire.
C. Remove the wire from terminal location P2-56 (8

V sensor supply). Install a wire jumper into the
socket P2-56.
D. Connect the J2/P2 ECM connector.
E. Remove the supply wire from P1-4.
F. Restore electrical power to the engine ECM.
G. Measure the voltage between the wire jumper in

P2-56 (8 V sensor supply) and engine ground.
H. Remove electrical power from the ECM.
I. Remove the wire jumper and replace all wires.
Expected Result:
The voltage measurement is 8.0 ± 0.4 VDC.
Results:
• OK - The voltage measurement is 8.0 ± 0.4 VDC.

The ECM is operating correctly.
Table 44

91-8 Throttle Position Sensor abnormal The Electronic Control Module (ECM) The code is logged. The ECM flags the
frequency, pulse width, or period detects an incorrect frequency on the throttle position as invalid data and a
throttle signal or an incorrect duty cycle default value of zero percent is used.
1249-8 Secondary Throttle Position on the throttle signal. The frequency is The engine speed is limited to low idle.
signal abnormal below 150 Hz or the frequency in above
1000 Hz. The duty cycle is less than 5
percent or the duty cycle is greater than
95 percent.
Terminal BN on the customer connector provides

the primary throttle signal to the engine's ECM.
Terminal BM on the customer connector provides the
secondary throttle signal to the engine's ECM. The
throttle signal should be a 500 Hz constant frequency
signal with a pulse width that varies with the throttle
signal. This output signal is referred to as a Pulse
Width Modulated signal (PWM).
The throttle signal's duty cycle should be between

5 percent to 10 percent at low idle and 90 percent
to 95 percent at high idle. The percent duty cycle is
translated in the ECM into the throttle position of 0
percent to 100 percent.
Primary ~
ECM TB-6 TB·5
II II TB-3 TB-2
OFF 22
~:;::
P1 J1 Primary ECM
8M G721-.J
BN 53 +Battery
AX SR91 0 65 -Battery
WI SR909 21 Start/Run/Stop 1
M150=:l AV SR909 T791 22 Start/Run/Stop 2
r---------------~ SA D998 113 70 Keyswitch
:Optional Equip. :I X F720--j LH775 D998 5 Digital Return
F767-l F721 68 ECS Remote/Auto
: :I y L702---l
REMOTE
F722 64 Sync B
: Local Speed : I c 040 START
R791
LR775 N715 62 Sync A
: Control: I S G 721-( Remote) STOP 10
F702 10 Primary Throttle
I Ii C R776 (start)
: Q ii D R775 [start 2)
I I: F H776 (stop 1)
I 3 +B ID I
I E H775 (stop 2)
I 2 DID I
Z P715
I
1 SID '389
I F722
I Secondary ECM
I -BID
I 1 "'Battery
I 1
I .Battery
1______ - - - - - - - - -
113 Keyswitch
Local/Remote
220 F70::! Primary Throttle
Throttle Sw.
E.Stop 1
M150 A150 SID Notify Drive +
5~ 676
F722 SyncB
6 RSR .. C N715 Sync A
CA998
3 P715- ~D998
N715
P2 J2
Typical example
KEN R5404-03 179
Throttle Position vs. PWIA Input
100%
(Programmed
High Idle)
all ZO
® ®
lhrot\le Position
%
aO
@GCD OE
G0 CD
8
dO OA
0%
(Programmed
La... Idle)
eO 8 @ OB
10
PVfIl lnpul 10 [ell fO ~ ~ OC
(r; Duly Cycle)
bO OF
~ 5% "D.odl>ond [n,ures ongine .iII roach LOB and High Idlo cO ®G)4D
• Engine drops 10 Low Idle ond a loull i. logged
0"" "' 0 @
g00725481
Illustration 98
Throttle Position Versus PWM Input
@®
OZ
C0G)@ Oa
CD G
BO ®
®
8 ®
CD
Oe
Od
Of
FO Ob
08@ Oc
® CD
g01328305
Illustration 99
Terminal locations for the following connectors P-C2/A-C91
Connector for the power distribution panel, A-C2/J-C2 RH rigid
harness connectors, and C-C2/J-C1 LH rigid harness connectors.
(Terminal L) +Battery to local speed control
180 KENR5404-03
Section
o @®8G) o
o~~o
Q ®@@@@0
~
35
® @®
23
@ \V
(;\
000008®
@@® @ @(0)
00000006
®@@@@®6 000808000
@ @ @@ ® 0 8800808808
@ ®@® 0)
@ 0
88808088@
O~O
®®@®®@®®8®
®®@®8B8@®
®@@@@@®®
@®®ee®§
o @@@@ 0
0000
0800000
00000000
000888080
g01328307 8088080080
Illustration 100
Terminal locations for the C-C17/F-C1 LH rigid harness connectors 880080888
and the connectors G-C6/F-C2 for a LH Control panel

88®®@®®@@@
(Terminal 16) +Battery to local speed control

®@8B®®@®®
8®@®®®@@
®®ee®®®
®@@®
g01328312
Illustration 101
Terminal locations for the TB-C lIC-C18 customer connector
(Terminal BM) Local speed control
(Terminal BN) Customer's speed control
KENR5404-03 181
Section
E. Check the harness and wiring for abrasion and for

pinch points from the sensors back to the ECM.
Expected Result:
RIGHT SIDE VIEW
2 3 4 5
Results:

to Test Step 2.
" Not OK - The connectors and/or wiring need

repair.

STOP.
Test Step 2. Check the Throttle Position

LEFT SIDE VIEW on Caterpillar Electronic Technician (ET)
A. Connect Cat ET to the service tool connector.
g01320528
Illustration 102
Connector locations C. Observe the position of the throttle on Cat ET.
(2) A-C2/J-C2 RH rigid harness connectors D. Adjust the speed control to the lowest setting.
E. Start at the lowest position. Slowly adjust the
(6) C-C22 Primary ECM connector P2 speed control to the highest setting. Monitor the
(7) C-C1S Primary ECM connector P1 position of the throttle on Cat ET.
(9) C-C29 Secondary ECM connector P1 Expected Result:
(11) C-C181TS-C1 Customer connectors
(12) C-C21J-C1 LH rigid harness connectors The throttle position on Cat ET is 0 percent at the
(13) C-C1/E-C1 LH rigid harness connectors lowest setting and 0 to 100 percent as tile speed
control is adjusted to the highest setting.
Connectors and the Wiring Results:
A. Turn the Engine Control Switch (ECS) to the • OK - The speed control is operating correctly.
OFF/RESET position.
Repair: There may be an intermittent problem. If
B. Thoroughly inspect the ECM connectors J1/P1 the problem is intermittent, refer to Troubleshooting,
and J2/P2. Inspect the wiring and the connectors "Electrical Connectors - Inspect" for details on
that are associated with the circuit. Refer to inspecting wiring and connectors.
for details. STOP.
C. Perform a 45 N (10 Ib) pull test on each of the • Not OK The throttle position on Cat ET does not
wires in the ECM connectors that are associated change correctly. 11' you are troubleshooting either
with the circuit. the primary speed control or the secondary speed
control from the customer, proceed to Test Step 3.
D. Check the ECM connector (allen head screw) If you are troublesllooting the local speed control
for the proper torque. Refer to Troubleshooting, on the instrument panel, proceed to Test Step 5.
"Electrical Connectors Inspect" for details.
182 KENR5404-03
Section
Test Step 3. Check the Signal Frequency E. Set the multimeter to "VDC". Press the "Hz" button
and the Duty Cycle at the Customer twice so that the % symbol is displayed.
Connector
F. Place the red probe of the multimeter on wire that
A. Turn the ECS to the OFF/RESET position. was removed from the ECM connector. Place
the black probe of the multimeter on the -Battery
B. Remove the wire for the throttle signal from the terminal.
customer's connector. Refer to Illustration 97 for
the schematic of the circuit. G. Turn the ECS to the STOP position.
C. Turn the ECS to the STOP position. H. Measure the percent duty cycle of the throttle
signal. Move the speed control from the lowest
D. Measure the frequency and the duty cycle of the setting to the highest setting.
throttle signal. Adjust the speed control from the
lowest position to the highest position. I. Turn the ECS to the OFF/RESET position.
E. Turn the ECS to the OFF/RESET position. J. Replace all connectors and wires.
F. Replace all connectors and wires. Expected Result:
Expected Result: The duty cycle is 5 to 10 percent at the lowest setting.
The duty cycle is 90 to 95 percent at the highest
The duty cycle is between 5 to 95 percent. The setting.
frequency reading is approximately 500 Hz.

Results:
Results:
• OK - The duty cycle and the throttle signal are
• OK - The duty cycle and the frequency are correct. correct.
Repair: Temporarily replace the ECM and perform
• Not OK - The duty cycle reading is not correct or the test again. If the problem is resolved, the ECM
the frequency is not correct. The throttle position is faulty. Permanently replace the EeM. Refer to
signal is not reaching the ECM. Troubleshooting, "ECM - Replace".
Repair: Check the signal from the customer's STOP.

connector to the customer's speed control.
• Not OK - The duty cycle reading is not correct.
STOP. The throttle signal is not reaching the ECM.
Test Step 4. Check the Duty Cycle at the Repair: Repair the wire between the ECM
ECM Connector connector and the customer connector.
Note: If you are troubleshooting the primary throttle STOP.

signal, the primary throttle signal goes to the
P 1 connector of both the primary ECM and the Test Step 5. Check the Supply Voltage to
secondary ECIVI. If you are troubleshooting the the Local Speed Control
secondary throttle signal, the secondary throttle
signal goes to the P2 connector of both the primary A. Turn the ECS to the STOP position.
ECM and the secondary ECM.
B. Connect the red probe of the digital multimeter to
A. Turn the ECS to the OFF/RESET position. the +B terminal of the local speed control. Connect
the black probe of the digital multimeter to the-8
B. Remove the appropriate ECM connector. from the terminal of the local speed control.
primary ECM. Remove the throttle signal wire
from the ECM connector. Refer to Illustration 97 C. Measure the voltage across the terminals of the
for the schematic of the circuit. local speed control.
C. Remove the appropriate ECM connector from the Expected Result:
secondary ECM. Remove the throttle signal wire

from the ECM connector. Refer to Illustration 97 The voltage is 24 ± 3 VDC.
for the schematic of the circuit.
D. Reconnect the ECM connectors.

KENR5404-03 183
Section
Results: Right hand control panel
.. OK - The voltage is 24 ± 3 VDC. The local speed • P-C2/A-C91 Terminal L Connectors for the
control is receiving the correct voltage. Proceed power distribution panel
to Test Step 7.
.. G-C6/F-C2/F-C1/A-C92 Terminal 16 Connectors
.. Not OK The voltage is not 24 ± 3 VDC. Verify for a RH Control panel
that the wire CA998 has continuity to a digital
reference. The local speed control is not receiving Refer to Illustration 102 in order to locate the
the correct voltage. Proceed to Test Step 6. various connectors on the rigid harness.
Test Step 6. Check the Voltage to the STOP.

Local Spe~d Control at the Rigid Harness
• Not OK - The voltage does not measure 24 ±3
A. Turn the ECS to the OFF/RESET position. VDC.
B. Remove wire C150 from terminal L of connector Repair: Verify that the breaker for the primary ECM
P-C2 of the rigid harness. is not tripped. Check for 24 ± 3 VOC on terminal
87A at the normally closed contact of relay "R2A".
C. Connect the red probe of the digital multimeter to Relay R2A is located in the power distribution
wire C150. Connect the black probe of the digital panel. Verify that the normally closed contact of
multimeter to the -Battery. Refer to Illustration relay "R2A" is operating correctly.
102 in order to locate the various connectors on
the rigid harness. If voltage is present on terminal8? A at the normally
closed contact of relay "R2A", repair the wire C150
D. Turn the ECS to the STOP position. between the contacts of relay "R2A" and terminal L
of connector P-C2 of the rigid harness.
E. Monitor the voltage on the digital muttimeter.
If 24 ± 3 VOC is present on wire C150 at diode 09,
F. Turn the ECS to the OFF/RESET position. verify that voltage is present on wire M150 at diode
09. If 24 ± 3 VOC is not present on wire M150 at
Expected Result: diode D9, replace the diode 09.
The voltage measures 24 ± 3 VOC. If 24 ± 3 VOC is present at the diode 09 on wire

M150, repair the wire M150 between the diode 09
Results: and the local speed control.
.. OK - The voltage measures 24 ± 3 VDC. STOP.
Repair: Check for 24 ± 3 VDC on wire C 150 at Test Step 7. Check the Signal Frequency
diode D9 in the control panel. If voltage is not and the Duty Cycle Of the local Speed
present on wire C150 at diode D9, repair the Control
wire C150 between diode 09 and terminal L of
connector P-C2 of the rigid harness. The following A. Turn the ECS to the OFF/RESET position.
connectors are between connector P-C2 and
connector G-C6 of the marine power display panel. B. Remove the wire 389 from the S terminal at the
The terminal locations for wire C150 are listed with local speed control.
the connectors.
Left hand control panel
D. Measure the frequency and the duty cycle
o P-C2/A-C91 Terminal L Connectors for the
between terminal S of the local speed control and
power distribution panel
engine ground. Adjust the local speed control from
the lowest setting to the highest setting.
• A-C2/J-C2 Terminal L RH rigid harness
connectors
• J-J1/C-C2 Terminal L LH rigid harness

F. Reconnect the wire 389 to the S terminal at the
connectors
local speed control .
.. G-C6/F-C2/F-C1/C-C17 Terminal 16 Connectors

for a LH Control panel
184 KENR5404-03
Expected Result: Repair: Temporarily replace the ECM and perform

the test again. If the problem is resolved, the ECM
The duty cycle is between 10 to 90 percent. The is faulty. Permanently replace the ECM. Refer to
frequency reading is approximately 500 Hz. Troubleshooting, "ECM - Replace".
Results: STOP.
• OK - The local speed control is supplying the • Not OK - The duty cycle reading is not correct.
correct signal. Proceed to Test Step 8. The throttle position signal is not reaching the
ECM.
• Not OK - The duty cycle or the frequency is not
correct on the multi meter. Repair: The signal is lost between the S terminal
of the local speed control and the ECM. Repair the
Repair: Temporarily install another speed control. wire 389 between the local speed control and the
Verify that the problem is no longer present. ECM.
Reinstall the old speed control. If the problem
returns, replace the local speed control. STOP.
STOP.
i02648157
Test Step 8. Check the Duty Cycle at the Speed/Timing - Test

ECM Connector
SMCS Code: 1912-038
Note: If you are troubleshooting the local speed
control, the local speed control goes to the P2 System Operation Description:
connector of both the primary ECM and the
secondary ECM. Use this procedure to troubleshoot the electrical
system if a problem is suspected with the engine
A. Turn the ECS to the OFF/RESET position. speed/timing sensor or if one of the diagnostic codes
in Table 45 is active.
B. Remove the ECM connector P2 from the primary
ECM. Remove the wire 389 from ECM connector
P2-68.
C. Remove the ECM connector P2 from the

secondary ECM. Remove the wire 389 from ECM
connector P2-68.
D. Reconnect the ECM connectors.
E. Turn the ECS to the STOP position.
F. Measure the percent duty cycle of the throttle

signal on wire 389. Move the throttle from LOW
idle position to HIGH idle position.
G. Turn the ECS to the OFF/RESET position.
H. Replace all connectors and wires.
Expected Result:
The duty cycle is 5 to 10 percent at the low idle stop.

The duty cycle is 90 to 95 percent at the high idle
stop.
Results:
• OK - The duty cycle and throttle position readings

are correct.
KENR5404-03 185
Section
Table 45

190-2 Engine Speed Sensor erratic, The engine speed signal cannot be The secondary engine speed/timing
, intermittent. or incorrect detected. The timing gear pattern signal will be used if the primary engine
retums within one second before being speed/timing signal is lost. The code is
lost and the battery voltage is greater logged.
than 9 VDC for the last two seconds.
The code will be active and logged if
the Electronic Control Module (ECM)
detects an incorrect signal for one
second. The battery voltage is greater
, 190-3 Engine Speed Sensor voltage A wire on the engine speedltiming The secondary engine speed/timing
above normal sensor is disconnected and/or broken. signal will be used if the primary engine
There is a short circuit to the +Battery speed/timing signal is lost. The code is
terminal. logged.
190-7 Engine Speed Sensor not The primary engine speedltiming sensor The code is active.
responding properly is connected to the harness for the
secondary engine speed/timing sensor.
190-8 Engine Speed Sensor abnormal The engine speed is greater than zero The secondary engine speed/timing
frequency, pulse width, or period rpm and the pattern from the timing ring signal will be used if the primary engine
is incorrect for five seconds. speed/timing signal is lost.
The code is logged if the pattern from
the timing ring returns for five seconds.
342-2 Secondary Engine Speed Sensor The engine speed signal cannot be The primary engine speed/timing signal
erratic, intermittent, or incorrect detected. The timing gear pattern will be used if the secondary engine
returns within one second before being speed/timing signal is lost. The code is
lost and the battery voltage is greater logged.
The code will be active and logged if the
ECM detects an incorrect signal for one
second. The battery voltage is greater
342-3 Secondary Engine Speed Sensor A wire on the engine speed/timing The primary engine speed/timing signal
voltage above normal sensor is disconnected and/or broken. will be used if the secondary engine
There is a short circuit to the +Battery speed/timing signal is lost. The code is
terminal. logged .
..
342-7 Secondary Engine Speed Sensor The secondary engine speed/timing The code is active.
not responding properly sensor is connected to the harness for
the primary engine speed/timing sensor.
342-8 Secondary Engine Speed Sensor The engine speed is greater than zero The primary engine speed/timing signal
abnormal frequency, pulse width, or rpm and the pattern from the timing ring will be used if the secondary engine
period is incorrect for five seconds. speed/timing signal is lost.
The code is logged if the pattern from
the timing ring returns for five seconds.
The ECM provides the engine speed/timing sensors

with a regulated voltage of 12.5 ± 1 VDC. The
engine speed/timing sensors provide a pulse signal
to the ECM. The signal is created as the timing
reference gear rotates past the pickup of the engine
speed/timing sensors. The timing reference gear is
mounted on the rear of the left camshaft. A unique
tooth pattern on the timing reference gear allows the
ECM to determine the crankshaft position, rotation,
and rpm.
186 KENRS404-03
The engine speed/timing sensors generate a pulse

signal to the ECM as each tooth passes the sensors.
The ECM counts the pulses in order to determine
the engine rpm. The ECM memorizes the pattern
of the pulses. The ECM compares that pattern to a
standard pattern in order to determine the crankshaft
position. The ECM uses this information to determine
the position of the No.1 cylinder. The ECM then
triggers each unit injector to fire in the correct firing
order and at the correct time. The actual timing
and duration of each injection is determined by the
ECM. The ECM uses engine rpm and engine load to
determine the timing and duration of injection. The
loss of a signal from an engine speed/timing sensor
generates a diagnostic on Caterpillar Electronic
Technician (ET). If the signals from both the primary
engine speed/timing sensor and the secondary
engine speed/timing sensor are lost, the ECM will
terminate fuel injection.
SECONDARY
SECONDARY ECM
SPEEDfTlMING SENSOR
P1 J1
SIGNALB C <E-<+I---_---- F732 13 SECONDARY SIGNAL
DIGITAL RETURN B (' I G791 51 DIGITAL RETURN
+V SPEEDfTlMING A ('I G790 43 +12V SPEEDrnMING
999 1 33 PRIMARY SIGNAL
PRIMARY ECM
PRIMARY
P1 J1
SPEEDfTlMING SENSOR
F732 13~ SECONDARY SIGNAL

SIGNALB 999 33 PRIMARY SIGNAL
DIGITAL RETURN A998 51 DIGITAL RETURf\1
+V SPEED/TIMING 996 43 +12V SPEEDrnMING
T723 41 TIMING CAL +
T724 40 TIMING CAL
TIMING CALIBRATION SENSOR
Typical schematic
KENR5404-03 187

and Wirmg
138 0 0 0 0 0 0 0 0 0 0 0 01
230 0 0 0 0 0 0 0 0 0 014 B. Thoroughly inspect the ECM connector J1/P1.
310 000 ~@~
~
000 024 Inspect all of the other connectors for the circuit.
3g() 0 0 0 0 0 • 032 Refer to Troubleshooting, "Electrical Connectors
470 0 0 0 • 0 • 840 Inspect" for details.
570 0 0 0 0 0 0 • 0 0 048
lOO 0 0 0 0 0 0 0 0 0 0 0 058. c. Perform a 45 N (10 Ib) pull test on each of the
with the circuit.
ECM SIDE
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to Troubleshooting,
"Electrical Connectors - Inspect" for details.

Expected Result:

coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion or of pinch points.
HARNESS SIDE
Results:
g01328997
Illustration 104
P1 ECM connector • OK - The harness and connectors appear to be
(P1-13) Secondary engine speed/timing signal OK. Proceed to Test Step 2.
(P1-33) Primary engine speed/timing signal
(P1-40) Engine timing calibration • Not OK - There is a problem with the connectors
(P1-41) Engine timing calibration +
and/or wiring.
(P1-43) +12.5 V supply
(P1-51) Digital retum
Note: The timing calibration sensor is only on the replace the connectors or wiring. Ensure that all of
J1/P1 connector for the primary ECM. the seals are properly in place and ensure that the
STOP.
Test Step 2. Check for an "ACTIVE" or

"lOGGED"Diagnostic Code
IIDII9DOOO::OOII the service tool connector.
n~r 0 gig:
:ggg:ooo:gg!!
c. Check the diagnostic codes on Cat ET.

Expected Result:
No diagnostic codes are active or logged repeatedly.
Results:
g01234146
Illustration 105 • OK - A diagnostic code for the engine speed/timing
Location of ECM connectors sensor is not active or logged repeatedly.
188 KENR5404-03
Repair: The problem is no longer present. If the Results:

"Electrical Connectors - Inspect". • OK - The engine speed/timing sensor is producing '-'
the correct output signal. Proceed to Test Step 5.
STOP.
• Not OK - The engine speed/timing sensor is not
• Not OK - A diagnostic code for the engine producing the correct output signal.
speed/timing sensor is active or logged repeatedly.
Proceed to Test Step 3. Repair: Replace the engine speed/timing sensor.
Calibrate the sensor. Perform the calibration
Test Step 3. Check the Supply Voltage to procedure Troubleshooting, "Timing - Calibrate".
the Sensor
STOP.
A. Disconnect the connector for the engine
speed/timing sensor. Test Step 5. Check the Signal Voltage at
the ECM
C. Measure the voltage between terminal A and
terminal B at the sensor connector. B. Check the signal voltage for the primary
engine speed/timing sensor.
Expected Result:
a. Remove the signal wire 999 from the primary
The supply voltage is 12.5 ± 1 VDC. ECM connector P 1-33 and from the secondary
ECM connector P 1-33.
Results:
b. Reconnect ECM connector J1/P1.
• OK - The supply voltage is 12.5 ± 1 VDC. Proceed
c. Restore electrical power to the ECM.
-
to Test Step 4.
• Not OK - The supply voltage is not 12.5 ± 1 VDC. d. Measure the voltage between the sensor's
Proceed to Test Step 6. signal wire and the digital return on P1-51.
Crank the engine and measure the voltage
Test Step 4. Check the Signal Voltage at between the sensor signal wire and P1-51.
the Sensor Perform this step on the primary ECM and on
the secondary ECM.

C. Check the signal voltage for the secondary
B. Remove the wire from terminal C of the sensor engine speed/timing sensor.
connector.
a. Remove the signal wire F732 from the primary
C. Restore electrical power to the ECM. ECM connector P 1-13 and from the secondary
ECM connector P1-13.
D. Measure the voltage between the sensor's signal

wire and terminal B of the sensor connector. Crank b. Reconnect ECM connector J1/P1.
the engine and measure the voltage between the
sensor signal wire and terminal B. c. Restore electrical power to the ECM.
E. Remove electrical power from the ECM. d. Measure the voltage between the sensor's
signal wire and the digital return on P1-51.
F. Reconnect the signal wire. Crank the engine and measure the voltage
between the sensor signal wire and P1-51.
Expected Result: Perform this step on the primary ECM and on
the secondary ECM.
The voltage measures less than 3 VDC or more than

9 VDC when the ECM is powered and the engine D. Remove electrical power from the ECM.
is not cranking. While the engine is cranking, the
voltage is between 2 VDC and 7 VDC.
Note: The voltage output is determined by the

E. Replace all wires. Reconnect ECM connector
J1/P1.
presence or the absence of a tooth on the timing gear.
KENR5404-03 189
Expected Result: c. Restore electrical power to the ECM.
The voltage measures less than 3 VDC or more than d. Measure the supply voltage between wire
9 VDC when the ECM is powered and the engine G791 in ECM connector P1-51 and the wire
is not cranking. While the engine is cranking, the jumper in P1-43.
voltage is between 2 VDC and 7 VDC.
E. Remove electrical power from the ECM.
Note: The voltage signal is generated by the
presence or the absence of a tooth on the timing F. Remove the wire jumper and replace all wires.
gear. Reconnect ECM connector J1/P1.
Results: Expected Result:
• OK - The correct voltage appears at ECM The supply voltage is 12.5 ± 1 VDC.
connector P1 but the ECM is not reading the signal.
Results:
Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, "ECM - Replace". • OK - The supply voltage is 12.5 ± 1 VDC. There is
an open circuit or a short circuit between the ECM
STOP. and the connector for the engine speed/timing
sensor.
• Not OK - There is a problem in the engine
speed/timing circuit. Repair: Repair the connectors and/or wiring or
replace the connectors and/or wiring.
Repair: The problem is between the ECM and the
engine speed/timing sensor. Repair the connectors STOP.
and/or wiring or replace the connectors and/or
wiring. • Not OK - The supply voltage is not 12.5 ± 1 VDC.
The supply voltage is incorrect.
STOP.
Test Step 6. Check the Supply Voltage Troubleshooting, "ECM - Replace".
for the Engine SpeedlTiming Sensor at

the ECM STOP.

i02647026
B. Disconnect ECM connector J1/P 1. Starting - Test

C. Check the supply voltage for the primary SMCS Code: 1451-038; 1453-038
a. Remove the supply wire 996 from ECM
connector P1-43. Install a wire jumper into the Use this procedure to troubleshoot the electrical
socket P 1-43. system if a problem is suspected with the starting
system or if one of the diagnostic codes in Table 46
b. Reconnect ECM connector J 1/P1. is active.
c. Restore electrical power to the ECM.
d. Measure the supply voltage between wire A998

in ECM connector P1-51 and the wire jumper
in P1-43.
D. Check the supply voltage for the secondary

a. Remove the supply wire G790 from ECM

connector P1-43. Install a wire jumper into the
socket P1-43.
b. Reconnect ECM connector J1/P1.

190 KENR5404-03
Table 46

444-5 Starter Motor Relay current below The Electronic Control Module (ECM) The code is logged.
normal detects an open circuit and/or a short to
the +Battery in the start relay. The ECM
can only detect this condition when the
start relay is not energized.
l
444-6 Starter Motor Relay current above The ECM detects a short circuit to
normal ground in the start relay. The ECM can
only detect this condition when the start
relay is energized.
The ECM has the ability to crank the engine when the
Engine Control Switch (ECS) is placed in the START
position. After the ECS is placed in the START
position, the ECM will begin the prelube cycle. The
ECM will send an engine start signal to terminal BH
of the customer connector after the prelube cycle
is complete. The customer's engine start signal will
return on terminal BJ of the customer connector. The
signal is then sent to terminal f of the A-C90/P-C1
connector on the power distribution panel.
The crank cycle will continue for the cycle crank time
that has been programmed or the crank cycle will
continue until the engine speed reaches the crank
terminate speed.
This process will repeat for a programmed amount of

times "Total Number of Crank Cycles". If the engine
does not start, Caterpillar Electronic Technician (ET)
will display "OVERCRANK". The engine control will
be in an idle state. The process can be restarted by
turning the ECS to the OFF/RESET position. Next,
turn the ECS to the STOP position. Then turn the
ECS to the START position.
The engine can be manually started by using the

"crank override switch" which is located on the inside
of the instrument panel.
KENR5404-03 191
I RH CONTROL PANEL -]
I I
I I
i [ib2 ~
PRIMARY ECM
E16
--L.J 1
P2J2 , I- - - - - - - - - - - - - - ,
G-C6/1 START SOL. DRIVER +

START SOL. DRIVER
_ _ JI
OVERRIDE_ _ _ _ _F-C2
G701t H ,. START SOL. DRIVE

FROM ECM
I PRIMARY F701 BJ
START SOL. DRIVE
I ECM BREAKER TO PO PANEL
1 CUST. CONN.
C-C18/TB-C1
C150--:
R2A I
STARTER I
ALTERNATOR L ____ _
BREAKER
I
I
I
1 * POWER
I DISTRIBUTION
: PANEL
1_ _ _ _ _ _ - - - -
A-C65 I
1
I
I AIR START
I SOLENOID
AIR START
I LH
SOLENOID
-IG229
RH I"
1
I
I
I
I
I
I
I BATTERY
_-.1
24VDC
Typical example
192 KEN RS404-03
WIRE SIDE
-\
o 0000 o
0000080
00000080
000888080
8800808800
888880888
ECM SIDE
8®@®88®®S8
8®®®®®8@®
130 0 0 0 0 0 • • 0 0 0 0 0 1
2300000 0 00000 14 @@@@@@®e
,,0000 ~J 0000"
©> e@@8®®®
390 0 0 0
470000
5700000 0
0 0 0 032
0000 40
0000048
.700 0 0 0 0 0 0 0 0 0 0 0 058.
o @®®®
o
Illustration 107
g01242365 0000
P2 ECM connector (~800000
(P2-6) Starter drive (+)
(P2-7) Return (-) 08000000
000888080
8088080080
@80080888
8S®®8@®®®@
®@8(80)®®8
e®@@@@@@
@®®®®@e
®®®®
Illustration 108
g01328549
Customer connector
(Terminal BH) Start Signal from ECM
(Terminal BJ) Start signal from customer
'~.'
KENR5404-03 193
Section
® @ ® @
00 ZO 00
@GCD OE aO
@OCD
OE
(]) CD 0 CD
®
8 @
@OB
OA
OC
dO
eO
fO
0
®
8 @
@
OA
OB
OC
OF bO OF
0(00 OG cO @8&
OG
CD (0 G) __~/O
0 0
® ® @ ®
DO
EO
G@ OZ
Oa
DO
EO
CDG@ Oa
(0 0 ed (0 0
AO
® 8 0)
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Od
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Co
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® @ Ob
0')
Oe BO
Co
FO
® ®
Ob
Oe
Of
GO CD 0 OC ~_OA0
® ® // ~~ ® ®
901328550 901328551
Terminal locations for the P-C1/A-C90 connector for the power Terminal locations for the following connectors P-C2/A-C91
distribution panel connector for the power distribution panel, A-C2/J-C2 RH rigid
harness connectors, and C-C2/J-C1 LH rigid harness connectors
(Terminal d) Override to starting motor switches
(Terminal f) Customer's start signal to starting motor switches (Terminal L) +8attery to the control panel
(Terminal 0) Power to starting motor #1
(Terminal R) Power to starting motor #2
194 KENR5404-03
o @@ CD 0
O!
® @
® f3s\ @@ f23\ CD(;\ ZO
® ~ ~ ~
18
@ ®® @
® @VVV@)
143\ f45\ f38\ CD
aO
@GCD OE
de G0 CD OA
®®@@@)@0
@@@@®0
e·8 0) ® 08
@ @)t;9\@) CD
fO @) 0 OC
J1'3l. 'eJ fg\ bO OF
~@®®V
o o
cO
0~C0
V
00
@
oz
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08@ Oa
CD 0
AO
60
Co
®
®
8 ®
0
ed
ee
Of -
FO Ob
C0 r;"l
V
0)
Oc
Terminal locations for the A-C92/F-C 1 RH rigid harness connectors

and the connectors G-C6/F-C2 for a RH control panel
®0
(Terminal 13) Override to starting motor switches
(Terminal 16) +Battery to crank override switch
g01328594
Illustration 112
Terminal locations for the A-C2/J-C2 RH rigid harness connectors
and the C-C2/J-C1 LH rigid harness connectors
(Terminal d) Override to right hand air start solenoid
(Terminal e) Return for the right hand air start solenoid
~
KENR5404-03 195
o 8008080
0
0000 2 3
RIGHT SIDE VIEW
4 5
0000000B
080808080
8808880808
888000888
§®@®888®88
®®§®®®8®®
@@@§®®®®
@®®§®®§
o @®§® 0
LEFT SIDE VIEW
0000
901320528
(~)808®00 Illustration 114
Connector locations
00000000
088888000
8880880080
888000888
8®®888®@®§
8®8®®®(~)(~® (10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel

(11) C-C 18/TB-C 1 Customer connectors
®®®®§@@@
®®®®®®®
®§®®
Terminal locations for the A-C 1/E-C2 RH rigid harness connectors

and the E-C1/C-C1 LH rigid harness connectors
(Terminal E) Start signal from customer
196 KENR5404-03

STOP.
Test Step 2. Attempt to Start the Engine

A. Turn the ECS to the STOP position.
B. Connect Cat ET to the service tool connector.
C. Observe the "startup mode" parameter on the Cat

ET status screen.
D. Turn the ECS to the START position. Continue

monitoring the "startup mode" parameter on the
Cat ET status screen as the engine cranks.
The crank cycle will continue for the time that

is equal to the cycle crank time that has been
programmed or the crank cycle will continue until
illustration 115
g01234146 the engine speed reaches the crank terminate
speed.
Expected Result:
and Wirmg
The status screen for the "startup mode" parameter
displays "CRANK". The engine cranks.
B. Turn the circuit breaker for the battery to the OFF Results:
position.
• OK - The "startup mode" parameter on the status
C. Thoroughly inspect the ECM connectors J1/P1 screen on Cat ET displays "CRANK". The engine
and J2/P2. Inspect all of the other connectors. cranks.
Inspect" for details. Repair: The problem may be intermittent. If the
D. Perform a 45 N (10 Ib) pull test on each of the "Electrical Connectors - Inspect".
with the circuit. STOP.
E. Check the allen head screw on each ECM • Not OK - Engine Doesn't Crank - The "startup
connector for the proper torque. Refer to mode" parameter on the status screen on Cat
Troubleshooting, "Electrical Connectors -Inspect" ET displays "CRANK". The engine will not crank.
for the correct torque values. Proceed to Test Step 3.
F. Check the harness and the wiring for abrasion • Not OK - Status Screen - The "startup mode"
and for pinch points. parameter on the status screen on Cat ET does
not display "CRANK".
Expected Result:
Repair: Refer to Troubleshooting, "Engine Control
All connectors, pins, and sockets are completely Switch - Test".
are free of corrosion, of abrasion, and of pinch points. STOP.
Results: Test Step 3. Check the Start Signal at the

Customer Connector
to Test Step 2. A. Remove wire F701 from terminal BJ on the
customer connector. Connect one end of a
• Not OK - The connectors and/or wiring need voltmeter to the -Battery terminal. Connect the
repair. other end of the voltmeter to terminal BJ.
KENR5404-03 197
Section
B. Turn the ECS to the START position. Verify that the engine prelube is operating correctly.
Refer to Troubleshooting, "Prelubrication Test".
C. Monitor the voltage on the voltmeter.
If the above systems are operating correctly,
D. TUrn the ECS to the OFF/RESET position. the problem may be in the ECM. Refer to
Troubleshooting, "ECM - Relace".
E. Reconnect all wires.
STOP
Expected Result:
Test Step 5. Check the Start Signal to the

Power Distribution Panel
Results:
A. Remove wire F701 from terminal f of connector
"A-C90" on the right hand rail. Connect one end of
• OK - The voltage is 24 ± 3 VDC. Proceed to Test a voltmeter to the -Battery terminal. Connect the
Step 5. other end of the voltmeter to wire F701.
.. Not OK - The voltage is not 24 ± 3 VDC. Proceed B. Turn the ECS to the START position.
to Test Step 4.
C. Monitor the voltage on the voltmeter.
Test Step 4. Check the Start Signal at the
ECM D. Turn the ECS to the OFF/RESET position.
A. Disconnect the ECM connector J2/P2. E. Reconnect all wires.
B. Remove wire G701 from the ECM connector P2-6. Expected Result:
Install a wire jumper into P2-6.

C. Reconnect the ECM connector J2IP2.

Results:
D. Connect one end of a voltmeter to the -Battery

terminal. Connect the other end of the voltmeter • OK - The voltage is 24 ± 3 VDC. If electric starting
to the wire jumper in P2-6. motors are installed on the engine, proceed to Test
Step 6.
E. Turn the ECS to the START position.
• OK - The voltage is 24 ± 3 VDC. If air start
F. Monitor the voltage on the voltmeter. solenoids are installed on the engine, proceed to
Test Step 10.
G. Turn the ECS to the OFF/RESET position.
• Not OK - The voltage is not 24 ± 3 VDC.
H. Remove the wire jumper and replace all wires.
Repair: Repair the wire F701 between terminal

Expected Result:
f of connector "A-C90" on the rig ht hand rail and
terminal BJ on the customer connector. Check
the voltage at the A-C1/E-C2 RH rigid harness
connectors and at the C-C1/E-C1 LH rigid harness
Results:
connectors. Refer to Illustration 106 for a schematic
of the circuit.
• OK The voltage is 24 ± 3 VDC.
STOP
Repair: Check wire G701 for continuity between
ECM connector P2-6 and terminal BH of the Test Step 6. Check the Voltage from
customer connector. If necessary, repair the wire. "SMMS1" and "SMMS2" to the Starting
If wire G701 is OK, repair the wiring or devices on Motors
the customer's side of the customer connector.
A. Remove wire 304 from terminal 0 of connector
STOP. "A-C91" on the right hand rail. Install a wire jumper
into terminal 0 of connector "A-C91", Connect
• Not OK - The voltage is not 24 ± 3 VDC. one end of a voltmeter to the -Battery terminal.
Connect the other end of the voltmeter to the wire
Repair: Check the electrical power to the ECM. jumper in terminal 0 of connector "A-C91".
Refer to Troubleshooting, "Electrical Power Supply
- Test" B. Turn the ECS to the START position.
198 KENR5404-03
Section
C. Monitor the voltage on the voltmeter. Results:
D. Turn the ECS to the OFF/RESET position. • OK - The voltage is 24 ± 3 VDC. The problem ~
appears to be in the starting motor.
E. Remove wire 314 from terminal R of connector
"A-C91" on the right hand rail. Install a wire jumper Repair: Install a new starting motor. Verify that the
into terminal R of connector "A-C91". Connect problem is no longer present.
one end of a voltmeter to the -Battery terminal.

Connect the other end of the voltmeter to the wire STOP.
jumper in terminal R of connector "A-C91".
F. Turn the ECS to the START position.
Repair: The problem is in the wire 314 between the
G. Monitor the voltage on the voltmeter. starting motor and terminal R of connector "P-C2"
or in the wire 304 between the starting motor and
H. Turn the ECS to the OFF/RESET position. terminal 0 of connector "P-C2". Check the voltage
at the A-C1/J-C2 RH rigid harness connectors and
I. Reconnect all wires.

at the C-C2/J-C1 LH rigid harness connectors.
Expected Result:
circuit.

STOP,
Results:
Test Step 8. Check the Voltage at the Coil
of "SMMS1 11 and the Coil of "SMMS2"
• OK - The voltage is 24 ± 3 VDC. Proceed to Test
Step 7. A. Turn the ECS to the OFF/RESET position.
• Not OK - The voltage is not 24 ± 3 VDC. Proceed B. Remove wire G701 from terminal 3 of "SMMS1"
to Test Step 8.

Starting Motor
and from terminal 3 of "SMMS2",
C. Connect a voltmeter between wire G701 and

engine ground.
--
A. Turn the ECS to the OFF/RESET position. D. Turn the ECS to the START position.
B. Remove wire 314 from terminal S of the starting E. Monitor the voltage on the voltmeter.
motor. Connect one end of a voltmeter to the
-Battery terminal. Connect the other end of the F. Turn the ECS to the STOP position.
voltmeter to wire 314.
G. Reconnect all wires.
C. Turn the ECS to the START position.

Expected Result:

E. Turn the ECS to the STOP position.

Results:
F. Remove wire 304 from terminal S of the starting

motor. Connect one end of a voltmeter to the • OK - The voltage is 24 ± 3 VDC, Proceed to Test
-Battery terminal. Connect the other end of the Step 9.
voltmeter to wire 304.
G. Turn the ECS to the START position.
Repair: Repair the wire G701 between the "SMMS"
H. Monitor the voltage on the voltmeter. switches and the diodes in the power distribution
panel. Repair the wire F701 between the diodes
I. Turn the ECS to the STOP position.

in the power distribution panel and terminal f of
Expected Result:
connector "P-C1" on the power distribution panel.
circuit.
--
STOP.
KENR5404-03 199
Section
Test Step 9. Check the Voltage from the If 24 ± 3 VDC is present on terminal 1 of "SMMS1"
Starting Motor Magnetic Switch(s) or on terminal 1 of "SMMS2" and wire G229 and
wire A287 are OK, replace either "SMMS1" or
A. Remove wire 314 from terminal 2 of the "SMMS2" "SMMS2".
switch. Connect one end of a voltmeter to the
-Battery terminal. Connect the other end of the STOP.
voltmeter to terminal 2 of "SMMS2".
Test Step 10. Check the Start Signal from
B. Turn the ECS to the START position. the Power Distribution Panel
C. Monitor the voltage on the voltmeter. A. Remove wire G701 from terminal d of connector
"A-C90" on the right hand rail. Install a wire jumper
D. Turn the ECS to the STOP position. into terminal d of connector "A-C90". Connect
one end of a voltmeter to the -Battery terminal.
E. Remove wire 304 from terminal 2 of the "SMMS1" Connect the other end of the voltmeter to the wire
switch. Connect one end of a voltmeter to the jumper in terminal d of connector "A-C90".
-Battery terminal. Connect the other end of the
voltmeter to terminal 2 of "SMMS1". B. Turn the ECS to the START position.
F. Turn the ECS to the START position. C. Monitor the voltage on the voltmeter.
G. Monitor the voltage on the voltmeter. D. Turn the ECS to the OFF/RESET position.
H. Turn the ECS to the STOP position. E. Reconnect all wires.
I. Reconnect all wires.

Expected Result:
Expected Result:

Results:
Results:
• OK - The voltage is 24 ± 3 VDC. Proceed to Test
Step 11.
• OK - The voltage is 24 ± 3 VDC.
Repair: Repair the wire 314 between terminal 2 of
"SMMS2" and terminal R of connector "P-C2" or Repair: Repair the wire G701 between terminal
repair the wire 304 between terminal 2 of "SMMS 1" d of connector "P-C1" on the right hand rail and
and terminal 0 of connector "P-C2". Repair the the diodes in the power distribution panel. Repair
wires or replace the wires. the wire F701 between the diodes in the power
distribution panel and terminal f of connector
STOP. "P-C1" on the power distribution panel. Refer to
$ Not OK - The voltage is not 24 ± 3 VDC.
STOP.
Repair: Verify that 24 ± 3 VDC is present on
terminal 1 of "SMMS1" or on terminal 1 of Test Step 11. Check the Voltage at the
"SMMS2". If voltage is not present on terminal 1 Connectors for the Air Start Solenoids
of "SMMS1" or on terminal 1 of "SMMS2", check
the wire A291 between terminal 1 of the starter A. TUrn the ECS to the OFF/RESET position.
magnetic switches and the "Starter and Alternator"
breaker. Verify that the "Starter and Alternator" B. Disconnect either the connector A-C65 for the
breaker is functioning properly. right hand air start solenoid or the connector
C-C27 for the left hand air start solenoid. Connect
Verify that wire G229 has continuity between a voltmeter across the terminals for the air start
terminal 4 of "SMMS1" or "SMMS2" and the diodes solenoid. Refer to Illustration 106 for a schematic
in the power distribution panel. Verify that wire of the circuit.
A287 has continuity between the diodes in the
power distribution panel and the breaker for the C. Turn the ECS to the START position.
secondary ECM.
200 KENR5404-03
E. Repeat the above steps for both of the air start

solenoids.
'-"
F. Turn the ECS to the STOP position.
Expected Result:
Results:
• OK - The voltage is 24 ± 3 VDC.
Repair: Replace the air start solenoid.
STOP.
• Not OK The voltage is not 24 ± 3 VDC.
Repair: The problem is in the wire G229 between
the connectors for the air start solenoids and the
ECM or in wire G701 between the connectors for
the air start solenoids and terminal d of connector
"P-C1".
STOP.
KENR5404-03 201
Section
Service i02826488
ECM Will Not Accept Factory

i02584369
Passwords
Factory Passwords SMCS Code: 0785; 1901
SMCS Code: 0785; 1900
Probable Causes
NOTICE
Operating the engine with a flash file not designed for One of the following items may not be recorded
that engine will damage the engine. Be sure the flash correctly on the Caterpillar Electronic Technician
file is correct for your engine. (ET):
• Passwords
Note: Factory passwords are provided only to
Caterpillar dealers. • Serial numbers
Factory passwords are required to perform each of • Total tattletale

the following functions:
• Reason code
• Program a new Electronic Control Module (ECM).
When an ECM is replaced, the system configuration Recommended Actions

parameters must be programmed into the new
1. Verify that the correct passwords were entered.
ECIVI. A new ECM will allow these parameters to
Check every character in each password. Remove
be programmed once without factory passwords.
the electrical power from the engine for 30
After the initial programming, some parameters are
protected by factory passwords. seconds and then retry.
.. Rerate the engine. 2. Verify that Cat ET is displaying the "Enter Factory
Passwords" dialog box.
This may require changing the interlock code,
which is protected by factory passwords.

3. Use Cat ET to verify that the following information
has been entered correctly:
• Unlock parameters.
.. Engine serial number
Factory passwords are required in order to unlock
certain system configuration parameters. Refer to • Serial number for the electronic control module
Troubleshooting, "Configuration Parameters".
• Serial number for Cat ET
• Clear engine events and certain diagnostic codes.

.. Total tattletale
Most engine events require factory passwords in

order to clear the code from ECM memory. Clear • Reason code
these codes only when you are certain that the
problem has been corrected. For example, the For additional information, refer to Troubleshooting,
Engine Overs peed code requires the use of factory "Factory Passwords".
passwords in order to clear the code from ECM
memory. i02909404
Since factory passwords contain alphabetic Electronic Service Tool Does

characters, the Caterpillar Electronic Technician (ET)
must be used to perform these functions. In order to
Not Communicate
obtain factory passwords, proceed as if you already
SMCS Code: 0785; 1900
have the password. If factory passwords are needed,
Cat ET will request the factory passwords and Cat
ET will display the information that is required to
obtain the passwords. For the worksheet that is used
Use this procedure to solve communication problems
for acquiring factory passwords, refer to Service
between Caterpillar Electronic Technician (ET) and
Troubleshooting, "Factory Passwords Worksheet".
the Electronic Control Module (ECM). Cat ET must
communicate with the ECM in order to fully service
the engine.
202 KEN R5404-03
There is a "POWER" indicator on the communication Results:

adapter that indicates that the communication
adapter is receiving power. An indicator on the • OK - The correct communication adapter and
communication adapter indicates that communication cables are being used. Attempt to establish
is occurring on the data link. Cat ET displays a communication. Continue with this procedure if the
message if Cat ET can not communicate with the communication adapter does not communicate on
data link. the data link.
The following conditions can cause a communication • Not OK - An incorrect communication adapter or
problem: cable was being used.
• Cat ET Repair: Connect the correct communication
adapter or cable. Refer to Troubleshooting,
• Communication adapter and/or cables "Electronic Service Tools", if necessary.
• Configuration for the communications adapter Attempt to establish communication. Continue with
this procedure if the communication adapter does
• Electrical power supply to the service tool not communicate on the data link.
connector
Test Step 3. Verify that Cat ET is
• Cat Data Link Configured Correctly
This procedure determines the root cause of failure Cat ET must be configured correctly in order to
to communicate on the data link. communicate. Perform the following procedure:
Test Step 1. Verify that the Newest A. Click on the "Utilities" menu.
Version of Cat ET is Being Used
B. Click on the "Preferences" menu.
Check the version of Cat ET. Cat ET must be the
newest version. C. Select the "Communications" tab.
Expected Result: D. Verify that "Caterpillar Communications Adapter II

(SeriaIIP)" is selected.
Cat ET is the most current version.
If "Caterpillar Communications Adapter II (Serial
Results: IP)" is not an option for selection, the firmware for
the communications adapter must be updated.
• OK - Cat ET is the most current version. Attempt Perform the following procedure:
to establish communication. Continue with this
procedure if the communication adapter does not Update the communication adapter's firmware by
communicate. using the "Comm Adapter II Toolkit". Then, select
the "Caterpillar Communications Adapter II (Serial
• Not OK - Cat ET is an old version. IP)" option.
Repair: Download the newest version of Cat ET. Continue with this procedure.
Attempt to establish communication. Continue with E. Check for any hardware that is utilizing the
this procedure if the communication adapter does same port as the communications adapter. If any
not communicate. devices are configured to use the same port, exit
or close the software programs for that device.
Test Step 2. Verify that the Correct
Communication Adapter and Cables are Note: The most commonly used port is "COM 1".
Being Used
F. Click "OK".
Refer to Troubleshooting, "Electronic Service Tools"
in order to determine the correct communication Note: Cat ET must reconnect in order for any
adapter and cables. changes to be used. Electronically disconnect Cat
ET if changes were made to any of the settings
Expected Result: for communications. Electronically connect Cat ET.
Attempt to establish communication. Observe the
The correct communication adapter and cables are indicator on the communications adapter.
used.
KENR5404-03 203
,hloch,.,,.,tinl"'l Section
Expected Result:
Repair: Verify that the cable between the service
tool connector and the communication adapter is
Cat ET communicates.
OK. Replace the cable, if necessary.
Results:
Replace the communication adapter if the following
conditions are true:
• OK - Cat ET communicates. STOP.
• There is power at the cable's "DATA LINK"
• Not OK - Cat ET does not communicate. The connector.
"POWER" indicator is not illuminated. Proceed to

Test Step 4. • The communication adapter's "POWER"
indicator is not illuminated .
.. Not OK - Cat ET does not communicate. The

"POWER" indicator is illuminated. Proceed to Test STOP.
Step 5.
Test Step 5. Check the Service Tool
Test Step 4. Check the Electrical Power Connector
to the Communications Adapter
A. Perform a visual inspection of the wiring to the
service tool connector. Look for these problems:
• Harness damage that is caused by chafing
• Harness damage that is caused by excessive

heat
A8
B. Inspect the service tool connector. Pull on each
GO OJ wire that is associated with the data link. This
OH verifies that each wire is properly attached to the
terminal and that the terminal is properly inserted
into the connector.
Repair any wiring problems. Attempt to establish

g01350067
Illustration 116 communication after the wiring has been repaired.
Power terminals on the service tool connectors. Continue with this procedure if the service tool
(A) +Battery does not communicate.
(B) -Battery
Expected Result:
A. Refer to Illustration 116. Check for battery voltage
at the service tool connector. The harness for the service tool is OK.
Battery voltage is not present at the service tool • OK The harness for the data link is OK.
connector.
Repair: Refer to Troubleshooting, "Cat Data Link
Results: Test" or refer to Troubleshooting, "CAN Data Link
Test".
• OK - Battery voltage is not present at the service
tool connector. STOP.
Repair: Inspect the wiring and fuses. Determine

i02959187
the cause of the missing voltage. Make the
necessary repairs. ECM Software - Install
Attempt to establish communication after the SMCS Code: 1901-591; 7620-012
electrical power is at the service tool connector.
Proceed to Test Step 5 if the service tool does not Use this procedure to troubleshoot the electrical
communicate. system if the diagnostic code in Table 47 is active .
.. Not OK Battery voltage is present at the service
tool connector.
204 KENR5404-03
'oe>hr".., tinn Section
Table 47

Code Conditions which Generate I System Response Procedure
• this Code
253-2 Personality Module The flash file is for a different I The engine will not start . Program the correct flash file .
: Erratic, Intermittent, or engine family or for a different ' Clearing this diagnostic code
Incorrect engine application. • requires factory passwords.
I The personality module code
must be reset to zero.
-
Flash Programming - This is a method of 4. Start the engine and check for proper operation.
programming or updating the flash file in an engine's Repair any active diagnostic or event codes.
Electronic Control Module (ECM).
"WinFlash" Error Messages
Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engine's ECM. If you receive any error messages during flash
programming, click on the "Cancel" button in order
If you do not have the flash file, use the "Flash File to stop the process. Access the information about
Search" tool on the Service Technician Workbench the "ECM Summary" under the "Information" menu.
(STW) to obtain the flash file for your engine. Make sure that you are flashing the correct file for
Alternatively, use the "Service Software Files" feature your engine.
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to
search for the flash file. After locating the correct i02629894
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference. ECM - Replace
SMCS Code: 1901-510
Programming a Flash File
NOTICE
1. Establish communication between Cat ET and the
Care must be taken to ensure that fluids are contained
engine's ECM.
during performance of inspection, maintenance, test
ing, adjusting and repair of the product. Be prepared to
2. Select "Win Flash" from the "Utilities" menu on Cat
collect the fluid with suitable containers before open
ET. ing any compartment or disassembling any compo
nent containing fluids.
Note: If "Win Flash" will not communicate with the
ECM, refer to troubleshooting without a diagnostic
Refer to Special Publication, NENG2500, "Caterpillar
code Troubleshooting, "Electronic Service Tool Does
Dealer Service Tool Catalog" for tools and supplies
Not Communicate".
suitable to collect and contain fluids on Caterpillar
products.
3. Program the flash file into the ECM.
Dispose of all fluids according to local regulations and
a. Select the engine ECM under the "Detected
mandates.
ECMs".
b. Press the "Browse" button in order to select the NOTICE

name of the flash file that will be programmed Keep all parts clean from contaminants.
into the ECM.
Contaminants may cause rapid wear and shortened
c. When the correct flash file is selected, press component life.
the "Open" button.
d. Verify that the "File Values" match the The Electronic Control Module (ECM) contains no
application. If the "File Values" do not match moving parts. Replacement of the ECM can be
the application,obtain the correct flash file. costly. Replacement can also be a time consuming
task. Follow the troubleshooting procedures in this
e. When the correct flash file is selected, press manual in order to ensure that replacing the ECM will
the "Begin Flash" button. correct the problem and that the ECM is the cause
of the problem.
f. Cat ET will indicate when flash programming
has been successfully completed.
KENR5404-03 205
Note: Ensure that the ECM is receiving power and d. Remove the mounting bolts from the ECM.
that the ECM is properly wired to the negative battery
circuit before you attempt to replace the ECM. Refer e. Disconnect the ECM ground strap from the
to Troubleshooting, "Electrical Power Supply - Test". engine.
4. Install the replacement ECM.

NOTICE
If the flash file and engine application are not matched,
a. If the old mounting hardware is in good repair,
engine damage may result.
you can use the old mounting hardware to
install the replacement ECM.
Perform the following procedure in order to replace
the ECM: b. Reconnect the fuel lines (if equipped).
1. Print the parameters from the "Configuration" c. Ensure that the ECM mounting hardware
screen on Caterpillar Electronic Technician is installed correctly. The rubber grommets
(ET). If a printer is unavailable, record all of the are used to protect the ECM from excessive
parameters. Record any logged diagnostic codes vibration. The ECM must be able to drift in the
and logged event codes for your records. Record rubber grommets. If the installation is equipped
the injector trim codes from the "Calibrations" with fuel lines, the fuel lines must not put
screen under the "Service" menu on Cat ET. tension on the ECM. If the ECM cannot be
moved slightly in the grommets, check that the
Note: The injector trim code is a number that is found fuel lines are not pulling the ECM against one
on each of the unit injectors. The ECM uses this side of the grommets.
number to compensate for manufacturing variations
between individual injectors. If you replace any of d. Connect the ECM ground strap.
the unit injectors, you must reprogram the injector
trim code for the new injector. Also, if you replace e. Connect the J1/P1 and J2/P2 ECM connectors.
the ECM, you must reprogram all of the injector trim Tighten the allen head screw on each of the
codes. ECfIII connectors to the proper torque. Refer
to Troubleshooting, "Electrical Connectors
2. Use the "Copy Configuration/ECM Replacement" Inspect" for the correct torque value.
feature that is found under the "Service" menu on
Cat ET. Select "Load from ECM" in order to copy 5. Install the ECM software. Refer to Troubleshooting,
the configuration from the suspect ECM. "ECM Software - Install".
Note: If the "Copy Configuration" process fails and 6. If the replacement ECfIII was used previously for a
the parameters were not obtained in Step 1, the different application, obtain factory passwords in
parameters must be obtained elsewhere. Some order to reset the interlock codes.
parameters are stamped on the engine information
plate, but most parameters must be obtained from 7. Configure the ECM.
the factory.
a. If the "Load from ECM" process from Step
3. Remove the ECM from the engine. 2 was successful, return to the "Copy
Configuration/ECM Replacement" screen on
a. Remove the electrical power from the ECM. Cat ET and select "Program ECM".
b. Disconnect the J1/P1 and J2/P2 ECM

After using the "Program ECM" feature, be sure
connectors.
to cycle the power to the ECM. Wait at least
30 seconds after turning the keyswitch to the
NOTICE OFF position.
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately. Note: Some control modules have a power off delay.
The 30 seconds will be sufficient to cover this delay.
NOTICE b. If the "Program ECM" process was successful,

Do not allow dirt to enter the fuel system. Thoroughly proceed to Step 7.d.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon c. If the "Program ECM" process was
nected fuel system component. unsuccessful, manually program the ECM
parameters into the replacement ECM. The
parameters must match the parameters from
c. Remove the fuel lines (if equipped) from the Step 1.
ECM.
206 KENR5404-03
,",,,,,tinn Section
Note: If the "Copy Configuration" process fails and • If a wire is cut, always install a new terminal for
the parameters were not obtained in Step 1, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the repair.
-
the factory.
The connection of any electrical equipment and
d. If necessary, program the engine monitoring the disconnection ofany electrical equipment may
system. cause an explosion hazard which may result in in
jury or death. Do not connect any electrical equip
8. Program the injector trim codes. ment or disconnect any electrical equipment in an
explosive atmosphere.
9. Check for an active diagnostic code for timing
calibration. 1. Determine If The Problem Is Intermittent.
If the diagnostic code is active, calibrate the If the problem is intermittent, attempt to test
injection timing. Refer to calibration procedures the circuit before you disconnect any electrical
Troubleshooting, "Timing - Calibrate". connectors. This helps identify the root cause of
intermittent problems.
10. Check for diagnostic codes and for event codes.
The "Wiggle Test" on the Caterpillar Electronic
Technician (ET) may be able to test the circuit.
i02614068
Refer to the documentation that accompanies Cat
Electrical Connectors - Inspect ET
SMCS Code: 7553-040-WW Perform the wiggle test on the circuit, when
possible. Otherwise, continue with this procedure.
Most electrical problems are caused by poor

connections. The following procedure will assist in 2. Check the Connectors for Moisture and For
detecting problems with connectors and with wiring.
If a problem is found correct the condition and verify
Corrosion.
-
~1
Intermittent electrical problems are sometimes

resolved by disconnecting and reconnecting
connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly crimped
terminals, mOisture, corrosion, and inadequate
mating of a connection.
Follow these guidelines:
• Always use a 1U- 5804 Crimp Tool to service

Deutsch HD and DT connectors. Never solder the
terminals onto the wires. Refer to "SEHS9615,
Servicing Deutsch HD and DT Style Connectors".
g01131211
Illustration 117
• Always use a 147 - 6456 Wedge Removal Tool Leaky seal allhe connector (typical example)
in order to remove wedges from DT connectors.
Never use a screwdriver to pry a wedge from a a. Inspect all wiring harnesses. Ensure that
connector. the routing of the wiring harness allows the
wires to enter the face of each connector at
• Always use a breakout harness for a voltmeter a perpendicular angle. Otherwise, the wire
~
probe or a test light. Never break the insulation will deform the seal bore. Refer to Illustration
of a wire in order to access to a circuit for 117. This will create a path for the entrance of
measurements. moisture. Verify that the seals for the wires are
sealing correctly.
KENR5404-03 207
0000000000000
OOOOO®]OOOOO
0000 0000
2 0000 0000
000 0 0000
0
000 00 0000
0000000000000
901131276 g01131165
Diagram for the installation of a connector plug (typical example) Seal for ECM connector (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug c. Disconnect the suspect connector and inspect
(3) Incorrectly inserted plug the connector seal. Ensure that the seals are
in good condition. If necessary, replace the
b. Ensure that the sealing plugs are in place. If connector.
any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into d. Thoroughly inspect the connectors for evidence
the connector. Refer to Illustration 118. of moisture entry.
Note: It is normal to see some minor seal abrasion

on connector seals. Minor seal abrasion will not allow
the entry of moisture.
If moisture or corrosion is evident in the

connector, the source of the moisture entry
must be found and the source of the moisture
entry must be repaired. If the source of the
moisture entry is not repaired, the problem will
recur. Simply drying the connector will not fix
the problem. Check the following items for the
possible moisture entry path:
901131019 • Missing seals

Illustration 119
Seal for a three-pin connector (typical example)

• Improperly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through

the inside of a wire. If moisture is found in a
connector, thoroughly check the connector's
harness for damage. Also check other
connectors that share the harness for moisture.
Note: The ECM is a sealed unit. If moisture is found

in an ECM connector, the ECM is not the source of
the moisture. Do not replace the ECM.
208 KENR5404-03
3. Check the Wires for Damage to the Insulation. b. Perform the 45 N (10 Ib) pull test on each
wire. Each terminal and each connector should
a. Carefully inspect each wire for signs of
easily withstand 45 N (10 Ib) of tension and
abrasion, of nicks, and of cuts.
each wire should remain in the connector
body. This test checks whether the wire was
Inspect the wires for the following conditions: properly crimped in the terminal and whether
the terminal was properly inserted into the
• Exposed insulation connector.
• Rubbing of a wire against the engine 6. Check Individual Pin Retention into the Socket.
• Rubbing of a wire against a sharp point
b. Check all of the wiring harness fasteners in

order to verify that the harness is properly
secured. Also check all of the fasteners in order
to verify that the harness is not compressed.
Pull back the harness sleeves in order to check
for a flattened portion of wire. A fastener that
has been overtightened flattens the harness.
This damages the wires that are inside the
harness.
4. Inspect the Connector Terminals.

g01131604
Visually inspect each terminal in the connector. Illustration 122
Verify that the terminals are not damaged. Diagram for testing pin retention (typical example)
Verify that the terminals are properly aligned in
the connector and verify that the terminals are a. Verify that the sockets provide good retention
properly located in the connector. for the pins. Insert a new pin into each socket
one at a time in order to check for a good grip
5. Perform a Pull Test on Each Wire Terminal on the pin by the socket.
Connection.
7. Check the Locking Mechanism of the
Connectors.
a. Ensure that the connectors lock properly. After

locking the connectors, ensure that the two
halves cannot be pulled apart.
b. Verify that the latch tab of the connector is

properly latched. Also verify that the latch tab
of the connector returns to the locked position.
8. Check the Allen Head Screws on the

Connectors.
Visually inspect the alien head screws for the

ECM connectors. Ensure that the threads on each
Receptacle lock wedge (typical example) allen head screw are not damaged.
a. Ensure that the locking wedge for the connector a. Connect the ECM connectors.
is installed properly. Terminals cannot be
retained inside the connector if the locking
wedge is not installed properly.
KENR5404-03 209
Section
0000000 .<'~ooooo
0000000 1'200000
o ooooo;,;#iiooooooo
oooooo~ooooooo
0000000 0000000
g01132827 g01133047
Illustration 123
Illustration 126
Allen head screw for the 120 pin ECM connector (typical example)
Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)
b. Torque the allen head bolt for the 120 pin ECM
connector to 7.0 ± 0.5 N'm (60 ± 4 Ib in). f. Torque the allen head screw for the 40 pin
customer connector and the 70 pin customer
connector to 2.25 ± 0.25 N'm (20 ± 2 Ib in).
i02629921
Pressure Sensor - Calibrate

SMCS Code: 1439-524-PXS; 1900-524-PXS
The Electronic Control Module (ECM) attempts to

perform an automatic calibration of all pressure
engine has been off for at least ten seconds. Cranking
the engine during the first ten seconds causes the
g01132849
ECM to abort the calibration attempt.
Illustration 124
Allen head screw for the 70 pin ECM connector (typical example) During an automatic pressure sensor calibration,
the ECM checks all pressure sensors against an
c. Torque the allen head screw for the 70 acceptable range. If any pressure sensor reading is
pin ECM connector to 6.0 + 1.5 - 1.0 N'm outside the acceptable range, the previous calibration
(55 + 13 - 9 Ib in). value is used. The ECM then calibrates all pressure
sensors against the atmospheric pressure sensor.
A pressure sensor calibration will not be successful if

there are active sensor diagnostic codes with an FMI
of 03 and/or 04. A pressure sensor calibration will not
be successful if one of the following conditions exist:
• The pressure reading is outside of an acceptable

range.
• The pressure reading varies significantly during

calibration.
1. Perform a Manual Calibration of the Sensors.

g01132863
Illustration 125
a. Select "Calibrations" from the "Service" menu
Allen head screw for the 40 pin ECM connector (typical example)
on Cat ET. Select the "Pressure Sensor
Calibration" from the "Calibrations" menu. The
d. Torque the allen head screw for the 40 pin ECM ECM will perform a pressure sensor calibration
connector to 2.25 ± 0.25 N'm (20 ± 2 Ib in). when this screen is entered.
e. Connect the customer connector.

210 KENR5404-03
i02630330
Throttle Position Sensor

Calibrate
SMCS Code: 1913-524
Use this procedure if the diagnostic code in Table

48 is active.
Table 48

• 91-13 Throttle Position Sensor The duty cycle for the throttle position The Electronic Control Module (ECM)
, calibration required sensor signal is less than 5 percent or sets the desired engine speed to
.. more than 95 percent. programmed low idle while this
1249-13 Secondary Throttle Position
diagnostic code is active. Caterpillar
calibration required
Electronic Technician (ET) will indicate
a throttle position of 0 percent while this
diagnostic code is active.
The throttle linkage should operate without binding or

without excessive drag. The calibration of the throttle
position sensor requires the use of Cat ET.
KENR5404-03 211
Section
2. Adjust the Throttle Linkage for Low Idle.
a. Connect Cat ET to the service tool connector.

TOP VIEW
b. Turn on the power to the engine's ECM. Do not
start the engine.
HIGH STOP
SET SCREW
c. Observe the throttle position on Cat ET
d. Place the throttle lever in the low idle position.

Adjust the throttle linkage or adjust the low idle
set screw until the throttle position on Cat ET
reads 0 percent
When the throttle is in the low idle position. the

duty cycle of the throttle position sensor is 5 to
10 percent. The ECM converts this duty cycle
of 5 to 10 percent into a throttle position of 0
percent
CALIBRATION
SCREW"L"
3. Adjust the Throttle Linkage for High Idle.
a. Place the throttle lever in the high idle position.

Adjust the throttle linkage or adjust the high idle
set screw until the throttle position on Cat ET
reads 100 percent
BOTTOM VIEW
When the throttle is in the high idle position.
LOW STOP the duty cycle of the throttle position sensor is
SETSCREW 90 to 95 percent. The ECM converts this duty
cycle of 90 to 95 percent into a throttle position
of 100 percent.
Adjust the throttle from the low idle position

to the high idle position. Monitor the throttle
"H" = HIGH IDLE SET POINT position on Cat ET If the throttle position Cat
"L" " LOW IDLE SET POINT ET does not read 0 to 100 percent, perform this
procedure again.
i02969123
901319129
Illustration 127
Typical example
Timing .. Calibrate
SMCS Code: 1000-524; 1900-524; 1912-524
1. Check the Throttle Linkage for Damage.
Use this procedure if the diagnostic code in Table
a. Turn off the power to the engine's ECM. 49 is active.
b. Inspect the throttle linkage for components with

the following conditions:
• Loose
• Bent
" Broken
• Missing
.. Worn
Repair any damaged components.
212 KENR5404-03
Section
Table 49

Code i Conditions which Generate this Code System Response
261-13 Engine Timing Calibration: The engine speed/timing sensor has not This will not keep the engine from
Calibration Required been calibrated. funning. The fuel injection timing may
be out of adjustment.
The engine speed/timing sensors provide engine g. Connect the 7X - 1695 cable from the engine
information to the Electronic Control Module (ECM). timing calibration probe to the connector P26.
The sensor generates a pulse signal. A loss of the
signals from the secondary engine speed/timing h. Start the engine. Allow the engine to exit cold
sensor and the primary engine speed/timing sensor mode operation.
causes the ECM to stop sending power to the fuel
injectors. 2. Calibrate the Fuel Injection Timing.
The ECM provides the engine speed/timing sensor a. Select "Calibrations" from the "Service" menu
with 12.5 ± 1.0 VDC. A unique tooth on the timing onCaterpiliar Electronic Technician (ET). Select
reference gear generates a unique duty cycle. The the "Timing Calibration" from the "Calibrations"
signal provides the ECM with information on the menu.
engine position.
Note: Engine speed will be set to 800 rpm by the
If the primary engine speed/timing sensor fails, the ECM during the calibration.
ECM will use the secondary engine speed/timing
sensor until electrical power is removed from the b. Follow the instructions on the Cat ET screen.
ECM. To prevent any unnecessary down time,
replace the primary engine speed/timing sensor at Note: If the Cat ET screen reads "COULD NOT
the earliest possible convenience. CALIBRATE", the timing has not been set. Verify that
the engine speed was stable during the testing (±
1. Install the Timing Calibration Probe. 50 rpm). If the engine speed was unstable or the
engine speed could not be controlled within ± 50 rpm
a. Turn the Engine Control Switch (ECS) to the because of mechanical factors or electrical factors,
OFF position. refer to the diagnostic procedure Troubleshooting,
"Engine Misfires, Runs Rough or Is Unstable".
b. Remove the timing calibration plug from the
flywheel housing. If all of the problems have been corrected
but the timing can not be calibrated, check
c. Examine the flywheel through the timing the cable of the 189-5746 Speed Sensor.
calibration hole. Ensure that the probe is not Check the 189 - 5746 Speed Sensor in order
inserted into the timing pin hole. If necessary, to verify that the probe is not bent. Verify that
rotate the engine crankshaft. the probe is installed correctly before restarting
this procedure.
d. Install the 6V - 3093 Transducer Adapter
into the hole for the timing calibration at the
flywheel.
e. Insert the 6V -2197 Magnetic Transducer

through the 6V - 3093 Transducer Adapter.
Insert the transducer until contact is made
with the surface of the flywheel. Move the
transducer 0.9 mm (0.04 inch) away from the
flywheel.
NOTICE
Do not install the timing calibration probe over the tim
ing pin hole at the flywheel or damage will result.
f. Tighten the nut on the 6V-3093 Transducer

Adapter.
KEI\IR5404-03 213
Index Section
Index
A E
Acceleration Is Poor or Throttle Response Is

ECM - Replace .................................................... 204
Poor ..................................................................... 35
ECM Does Not Communicate with Other
Probable Causes ............................................... 35

Modules ............................................................... 43
Recommended Actions ...................................... 35

Probable Causes ............................................... 43
Air Shutoff - Test.. .................................................. 76

Air Starting Motor Problem .................................... 37

ECM Software - Install ......................................... 203
Probable Causes ............................................... 37

Programming a Flash File ................................ 204

ECM Will Not Accept Factory Passwords ............ 201
Alternator Problem (Charging Problem and/or Noisy

Probable Causes ............................................. 201
Operation) ............................................................ 37
Recommended Actions .................................... 201
Probable Causes ............................................... 37

Electrical Connectors......... .................................... 16

Customer Connector .......................................... 17
Engine Electronic Control Module (ECM) .......... 16
Harness Connectors .......................................... 18
c Service Tool Connector for Cat ET .................... 17
Electrical Connectors - Inspect... ......................... 206
CAN Data Link - Test.. ........................................... 85

Electrical Power Supply - Test.. ............................. 93
Cat Data Link - Test.. ............................................. 89

Electronic Display Module ..................................... 12
Circuit Tests ........................................................... 76

Control Panel..................................................... 13
Component Location ............................................ ,.. 9

Power Distribution Panel .................................... 13
Engine's Electrical Components .......................... 9

Electronic Service Tool Does Not Communicate .. 201
Location of the Engine Components ............ 10-12

Electronic Service Tools .......................................... 5
Config u ration Parameters...................................... 19

Caterpillar Electronic Technician (ET) .................. 5
Customer Parameters ........................................ 21

Optional Service Tools ......................................... 5
Parameter Descriptions ..................................... 19

Required Service Tools ........................................ 5
Parameter Table ........................................... 21, 23

Electronic System Overview .................................... 8
Coolant Contains Fuel. .......................................... 37

Emergency Stop - Test........................................ 100
Probable Causes ............................................... 37

Emergency Stop (Remote) - Test.. ...................... 108

Engine Control Switch - Test ................................ 118
Coolant Contains Oil. ............................................. 38

Engine Cranks but Does Not Start ........................ 43
Probable Causes ............................................... 38

Probable Causes ............................................... 43

Coolant Temperature Is High ................................. 39

Engine Does Not Crank ......................................... 44
Probable Causes ............................................... 39

Probable Causes ............................................... 44

Coolant Temperature Is Low.................................. 40

Engine Has Early Wear ......................................... 45
Probable Causes ............................................... 41

Probable Causes ............................................... 45

Crankcase Pressure Is High .................................. 41

Engine Has Mechanical l\Ioise (Knock) ................. 46
Probable Causes ............................................... 42

Probable Causes ............................................... 46

Cylinder Is Noisy.................................................... 42
Engine Misfires, Runs Rough or Is Unstable ......... 46
Probable Causes ............................................... 42

Probable Causes ............................................... 47

Engine Overspeeds ............................................... 48
Probable Causes ............................................... 49
D Recommended Actions ...................................... 49
Engine Shutdown Is Intermittent.. .......................... 49
Diagnostic Capabilities .......................................... 14

Probable Causes ............................................... 49
Diagnostic Codes ............................................... 14

Diagnostic Trouble Codes ..................................... 24

Engine Stalls at Low RPM ..................................... 50
Active Diagnostic Codes .................................... 28

Probable Causes ............................................... 50
Cross-Reference Information for Diagnostic

Codes ............................................................... 24
Engine Top Speed Is Not Obtained ....................... 51
Diagnostic Codes ............................................... 27

Probable Causes ............................................... 51
Logged Diagnostic Codes .................................. 28

214 KENR5404-03
Index Section
Engine Vibration Is Excessive ............................... 52 o
Probable Causes............................................... 52
Recommended Actions ...................................... 52 Oil Consumption Is Excessive ............................... 59
Event Codes .......................................................... 29 Probable Causes ............................................... 59
Active Event Codes............................................ 30 Recommended Actions ...................................... 59
Clearing Event Codes ........................................ 31 Oil Contains Coolant... ........................................... 60
Cross-Reference Information for Event Codes .. 29 Probable Causes ............................................... 60
Logged Event Codes ......................................... 30 Recommended Actions ...................................... 60
Oil Pressure Map ............................................... 34 Oil Contains Fuel ................................................... 60
Parts of the Event Code ..................................... 30 Probable Causes ............................................... 60
Trip Points for the "Caterpillar Monitoring Recommended Actions ...................................... 61
System" ............................................................ 31 Oil Filter Differential Pressure Problem ................. 61
Troubleshooting ................................................. 31 Probable Causes ............................................... 62
Exhaust Has Excessive Black Smoke ................... 53 Recommended Repairs ..................................... 62
Probable Causes ............................................... 53 Oil Pressure Is Low ............................................... 62
Recommended Actions ...................................... 53 Probable Causes ............................................... 63
Exhaust Has Excessive White Smoke ................... 54 Recommended Repairs ..................................... 63
Probable Causes ............................................... 54
Exhaust Temperature Is High ................................ 55 p
Probable Causes ............................................... 56
Recommended Actions ...................................... 56 Power Is Intermittently Low or Power Cutout Is
Intermittent. .......................................................... 64
Probable Causes ............................................... 64
F Recommended Actions ...................................... 64
Prelubrication - Test... .......................................... 140
Factory Passwords .............................................. 201 Pressure Sensor - Calibrate ................................ 209
Fuel Consumption Is Excessive ............................ 56 Programmable Parameters ... ........ ........... ....... ...... 15
Probable Causes ............................................... 56
Fuel Filter Is Restricted .......................................... 57 s
Probable Causes ............................................... 58
Recommended Actions ...................................... 58 Secondary ECM Assumes Control ........................ 65
Probable Causes ............................................... 65
G Secondary ECM Indicator Lamp Problem ............. 65
Probable Causes ............................................... 65
General Information ................................................. 4 Recommended Actions ...................................... 66
Electronic Control System .................................... 4 Sensor Signal (Analog, Active) - Test.. ................ 151
Interface ............................................................... 4 Sensor Signal (Analog, Passive) - Test ............... 160
Sensor Signal (PWM) - Test.. .............................. 165
Sensor Supply - Test ........................................... 170
H Service................................................................. 201
Speed Control (Switch) - Test.. ............................ 177
High Altitude Derate Occurrence ........................... 58 Speedmming - Test... .......................................... 184
Probable Causes ............................................... 58 Starting - Test.. ........ ...................... .......... ............ 189
Recommended Actions ...................................... 58 Symptom Troubleshooting ..................................... 35
Synchronization Problem ....................................... 66
System Overview ..................................................... 8
Electronic Controls ............................................... 8
Important Safety Information ................................... 2
Injector Solenoid - Test. ....................................... 129 T
Inlet Air Is Restricted ............................................. 59
Probable Causes ............................................... 59 Table of Contents ..................................................... 3
Recommended Actions ...................................... 59 Throttle Position Sensor Calibrate ..................... 210
Introduction .............................................................. 4 Timing - Calibrate ................................................. 211
Troubleshooting Section .......................................... 4
KENR5404-03 215
Index Section
v
Valve Lash Is Excessive ........................................ 74
Probable Causes............................................... 74
Valve Rotator or Spring Lock Is Free ..................... 75
Probable Cause ................................................. 75
w
Welding Precaution ................................................. 4

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CJlTERPILLAR® KENR5404-03

3500C Marine Propulsion Engines

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema­

Table of Contents Oil Filter Differential Pressure Problem ................

Power Is Intermittently Low or Power Cutout Is

Troubleshooting Section Secondary ECM Assumes Control ....................... 65

Secondary ECM Indicator Lamp Problem ............ 65

Synchronization Problem ...................................... 66

General Information ................................................ 4

Valve Lash Is Excessive ....................................... 74

Welding Precaution ................................................. 4

Valve Rotator or Spring Lock Is Free .................... 75

Electronic Service Tools .......................................... 5

Electronic System Overview

Air Shutoff - Test ................................................... 76

System Overview .................................................... 8

CAN Data Link - Test ............................................ 85

Component Location ............................................... 9

Cat Data Link - Test .............................................. 89

Electronic Display Module .................................... 12

Electrical Power Supply - Test .............................. 93

Diagnostic Capabilities ......................................... 14

Emergency Stop - Test ..... ............................. ..... 100

Programmable Parameters ................................... 15

Emergency Stop (Remote) - Test ....................... 108

Engine Control Switch - Test ................................ 118

Injector Solenoid - Test ....................................... 129

Prelubrication - Test ............................................ 140

Configuration Parameters ..................................... 19

Sensor Signal (Analog, Active) - Test ................. 151

Sensor Signal (Analog, Passive) - Test .............. 160

Diagnostic Trouble Codes

Sensor Signal (PWM) - Test ............................... 165

Diagnostic Trouble Codes ..................................... 24

Sensor Supply - Test ........................................... 170

Speed Control (Switch) - Test ............................. 177

Speedmming - Test ............................................ 184

Event Codes ........................................................ 29

Starting - Test ............ ........................... .... ........ ... 189

Symptom Troubleshooting .................................... 35

Factory Passwords ............................................. 201

Acceleration Is Poor or Throttle Response Is

ECM Will Not Accept Factory Passwords ........... 201

Electronic Service Tool Does Not Communicate .. 201

Air Starting Motor Problem ................................... 37

Alternator Problem (Charging Problem and/or Noisy

Coolant Contains Fuel .......................................... 37

Coolant Contains Oil ............................................. 38

Coolant Temperature Is High ................................ 39

Coolant Temperature Is Low ................................. 40

Crankcase Pressure Is High ................................. 41

Cylinder Is Noisy ................................................... 42

Engine Cranks but Does Not Start ........................ 43

Engine Does Not Crank ........................................ 44

Engine Has Early Wear ........................................ 45

Engine Has Mechanical Noise (Knock) ................ 46

Failure to heed this warning can lead to prema

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