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RENR5093-01

May 2007

Troubleshooting
C18 Marine Auxiliary Engine
MGS1-Up (Generator Set)
CYG1-Up (Engine)
i01658146

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.
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. 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 be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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.
RENR5093-01 3
Table of Contents

Table of Contents CID 0006 FMI 11 Cylinder #6 Injector fault ........... 49


CID 0041 FMI 03 8 Volt DC Supply short to +batt .. 49
CID 0041 FMI 04 8 Volt DC Supply short to
ground ................................................................. 49
Troubleshooting Section CID 0091 FMI 08 Throttle Position signal
abnormal ............................................................. 50
Electronic Troubleshooting
CID 0094 FMI 03 Fuel Pressure open/short to
System Overview .................................................... 5
+batt .................................................................... 50
Electronic Service Tools .......................................... 6
CID 0094 FMI 04 Fuel Pressure short to ground .. 50
Replacing the ECM ................................................. 9
CID 0100 FMI 03 Engine Oil Pressure open/short to
Self-Diagnostics .................................................... 10
+batt .................................................................... 51
Sensors and Electrical Connectors ........................ 11
CID 0100 FMI 04 Engine Oil Pressure short to
Engine Wiring Information .................................... 13
ground ................................................................. 51
CID 0110 FMI 03 Engine Coolant Temperature
Programming Parameters
open/short to +batt .............................................. 51
Programming Parameters ..................................... 16
CID 0110 FMI 04 Engine Coolant Temperature short
Customer Passwords ............................................ 16
to ground ............................................................. 51
Factory Passwords ............................................... 16
CID 0168 FMI 02 System Voltage intermittent/
Flash Programming .............................................. 17
erratic .................................................................. 52
Service Information Report ................................... 17
CID 0172 FMI 03 Intake Manifold Air Temp open/short
to +batt ................................................................ 52
System Configuration Parameters
CID 0172 FMI 04 Intake Manifold Air Temp short to
System Configuration Parameters ........................ 19
ground ................................................................. 52
CID 0174 FMI 03 Fuel Temperature open/short to
Troubleshooting without a Diagnostic Code
+batt .................................................................... 53
Alternator (Charging Problem) .............................. 23
CID 0174 FMI 04 Fuel Temperature short to
Battery .................................................................. 23
ground ................................................................. 53
Can Not Reach Top Engine RPM ......................... 23
CID 0190 FMI 08 Engine Speed signal abnormal .. 53
Coolant in Engine Oil ............................................ 24
CID 0247 FMI 09 J1939 Data Link
Coolant Temperature Is Too High ......................... 25
communications .................................................. 53
ECM Will Not Accept Factory Passwords ............. 27
CID 0253 FMI 11 Personality Module mechanical
ECM Will Not Communicate with Other Systems or
failure .................................................................. 54
Display Modules .................................................. 27
CID 0261 FMI 13 Engine Timing Calibration
Electronic Service Tool Will Not Communicate with
required ............................................................... 54
ECM .................................................................... 27
CID 0262 FMI 03 5 Volt Sensor DC Power Supply
Engine Cranks but Will Not Start .......................... 29
short to +batt ....................................................... 55
Engine Has Early Wear ........................................ 30
CID 0262 FMI 04 5 Volt Sensor DC Power Supply
Engine Misfires, Runs Rough or Is Unstable ........ 31
short to ground .................................................... 55
Engine Oil in Cooling System ............................... 32
CID 0268 FMI 02 Check Programmable
Engine Oil in Exhaust System .............................. 32
Parameters ......................................................... 55
Engine Stalls at Low RPM .................................... 32
CID 0273 FMI 03 Turbo Outlet Pressure open/short
Engine Vibration ................................................... 33
to +batt ................................................................ 55
Engine Will Not Crank ........................................... 34
CID 0273 FMI 04 Turbo Outlet Pressure short to
Excessive Black Smoke ........................................ 35
ground ................................................................. 56
Excessive Engine Oil Consumption ...................... 36
CID 0274 FMI 03 Atmospheric Pressure open/short
Excessive Fuel Consumption ............................... 36
to +batt ................................................................ 56
Excessive Valve Lash ........................................... 37
CID 0274 FMI 04 Atmospheric Pressure short to
Excessive White Smoke ....................................... 37
ground ................................................................. 56
Intermittent Engine Shutdown ............................... 38
CID 0342 FMI 02 Loss of Secondary Engine Speed
Intermittent Low Power or Power Cutout .............. 39
signal ................................................................... 57
Low Engine Oil Pressure ...................................... 40
CID 0342 FMI 11 Secondary Engine Speed Sensor
Low Power/Poor or No Response to Throttle ....... 41
mechanical failure ............................................... 57
Mechanical Noise (Knock) in Engine .................... 43
CID 1929 FMI 03 Fuel Return Temperature Sensor
Noise Coming from Cylinder ................................. 43
voltage high/short to +batt .................................. 57
Poor Acceleration or Response ............................ 44
CID 1929 FMI 04 Fuel Return Temperature Sensor
voltage low/short to ground ................................. 57
Troubleshooting with a Diagnostic Code
Diagnostic Codes .................................................. 46
Troubleshooting with an Event Code
CID 0001 FMI 11 Cylinder #1 Injector fault ........... 47
Event Codes ........................................................ 59
CID 0002 FMI 11 Cylinder #2 Injector fault ........... 47
E009 High Altitude Derate .................................... 61
CID 0003 FMI 11 Cylinder #3 Injector fault ........... 48
E057 Low Engine Coolant Level Derate ............... 62
CID 0004 FMI 11 Cylinder #4 Injector fault ........... 48
E059 Low Engine Coolant Level Warning ............ 63
CID 0005 FMI 11 Cylinder #5 Injector fault ........... 48
E096 High Fuel Pressure ...................................... 63
4 RENR5093-01
Table of Contents

E198 Low Fuel Pressure ...................................... 64


E199 Low Coolant Temperature ........................... 64
E255 Diagnostic Reset ......................................... 65
E264 Emergency Stop Activated .......................... 65
E360 Low Engine Oil Pressure ............................. 66
E361 High Engine Coolant Temperature .............. 67
E362 Engine Overspeed ....................................... 68
E363 High Fuel Supply Temperature .................... 68
E368 High Intake Manifold Air Temperature ......... 69

Diagnostic Functional Tests


5 Volt Engine Pressure Sensor Supply Circuit -
Test ..................................................................... 72
CAN Data Link Circuit - Test ................................. 77
Cat Data Link Circuit - Test ................................... 81
Coolant Level Sensor Circuit - Test ...................... 84
Digital Sensor Supply Circuit - Test ...................... 89
Electrical Connectors - Inspect ............................. 93
Electrical Power Supply Circuit - Test ................... 98
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 102
Engine Speed/Timing Sensor Circuit - Test ........ 107
Engine Temperature Sensor Open or Short Circuit -
Test .................................................................... 112
Injector Solenoid Circuit - Test ............................. 117
Speed Control - Test ........................................... 127
Switch Circuits - Test .......................................... 131

Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 135
Injector Code - Calibrate ..................................... 138

Index Section
Index ................................................................... 140
RENR5093-01 5
Troubleshooting Section

Troubleshooting Section Cold Mode


The ECM limits engine power during cold mode
operation. Injection timing is also modified during
Electronic Troubleshooting cold mode operation. Cold mode operation provides
the following benefits:

i02436970 • Increased cold weather starting capability


System Overview • Reduced warm-up time
SMCS Code: 1900
• Reduced white smoke
System Operation Cold mode is activated whenever the engine
temperature falls below a predetermined value. Cold
This engine is electronically controlled. Each cylinder mode remains active until the engine temperature
has an electronic unit injector. The Electronic Control rises above a predetermined value or until a time
Module (ECM) sends a signal to each injector limit is exceeded.
solenoid in order to control the operation of the fuel
injection system. Fuel Injection
Electronic Controls The ECM controls the amount of fuel that is injected
by varying the duration of the signals to the injectors.
The electronic system consists of the following The injector will pump fuel only while the injector
components: the ECM, the Electronic Unit Injectors solenoid is energized. The ECM sends a high voltage
(EUI), the wiring harness, the switches, and the signal to the solenoid. This high voltage signal
sensors. The ECM is a computer that is used to energizes the solenoid. By controlling the timing and
control the engine. The software for the computer the duration of the high voltage signal, the ECM can
is loaded via the flash file. The flash file contains control injection timing and the engine RPM.
the operating maps and the performance maps
for the engine. These maps define the following The flash file that is programmed into the ECM
characteristics of the engine: sets certain limits on the amount of fuel that can
be injected. The “FRC Fuel Limit” is used to control
• Horsepower the air/fuel ratio in order to control emissions. The
“FRC Fuel Limit” is a limit that is based on the boost
• Torque curves pressure of the engine. A higher boost pressure
indicates that there is more air in the cylinder. As
The ECM calculates the timing and the amount of fuel the boost pressure increases, the ECM calculates
that is delivered to the cylinders. These calculations an increased “FRC Fuel Limit”. When the “FRC Fuel
are based on the actual conditions and/or on the Limit” is increased, the ECM injects more fuel into the
desired conditions at any given time. cylinder. The “FRC Fuel Limit” is programmed into
the ECM at the factory. This fuel setting cannot be
The ECM compares the desired engine speed to changed by the customer.
the actual engine speed. The ECM calculates actual
engine speed from signals that are produced by the The “Rated Fuel Limit” is a limit that is based on the
engine speed/timing sensor. The desired engine power rating of the engine and on engine rpm. The
speed is calculated by the ECM with the following “Rated Fuel Limit” is a fuel map that provides the
variables: power curves and the torque curves for a specific
engine family and for a specific engine rating. The
• Throttle signal “Rated Fuel Limit” is programmed into the ECM at
the factory. This fuel setting cannot be changed by
• Input signals from engine sensors the customer.

• Certain diagnostic codes


If the desired engine speed is greater than the actual
engine speed, the ECM increases the duration of the
fuel injection. This injects more fuel into the cylinders
in order to increase the actual engine speed.
6 RENR5093-01
Troubleshooting Section

Once the ECM calculates the amount of fuel that Table 1


is required for the engine, the timing of the fuel Required Service Tools
injection cycle must be calculated. The ECM receives
information about the top center position of each Part Description
cylinder from the engine speed/timing sensor’s Number
signal. The ECM calculates the initiation of the fuel N/A 4 mm Allen Wrench
injection cycle relative to the top center position of
the piston. The injection signal is then provided to the 6V-2197 Transducer
injector at the desired time. The ECM adjusts timing 7X-1171 Transducer Adapter
for optimum engine performance, for optimum fuel
economy, and for optimum control of emissions. 7X-1695 Cable As
146-4080 Digital Multimeter Gp (RS232)
Programmable Parameters 7X-1710 Multimeter Probes
Certain parameters that affect the engine operation 7X-6370 Adapter Cable As (3-PIN BREAKOUT)
may be changed using Caterpillar Electronic 208-0059 Adapter Cable As (70-PIN BREAKOUT)
Technician (ET). These parameters are stored in
the ECM memory. Some parameters are protected 257-8718 Adapter Cable As (120-PIN BREAKOUT)
from unauthorized changes by passwords. These 167-9225 Harness (SERVICE TOOL ADAPTER)
passwords are called factory passwords.
1U-5804 Crimp Tool (12−AWG TO 18−AWG)
Passwords 175-3700 Connector Repair Kit (DEUTSCH DT)

Several system configuration parameters and most Two short jumper wires are needed to check the
logged events are protected by factory passwords. continuity of some wiring harness circuits by shorting
Factory passwords are available only to Caterpillar two adjacent terminals together in a connector. A
dealers. Refer to Troubleshooting, “Factory long extension wire may also be needed to check the
Passwords” for additional information. continuity of some wiring harness circuits.

i02728769 Optional Service Tools


Electronic Service Tools Table 2 lists the optional service tools that may be
needed during testing or repair.
SMCS Code: 0785
Table 2
Caterpillar electronic service tools are designed to
help the service technician perform the following Optional Service Tools
tasks: Part Number Description

• Information access 198-4240 Digital Pressure Indicator


or
1U-5470 Engine Pressure Group
• System diagnostics
4C-4075 Crimp Tool (4−AWG TO 10−AWG)
• System calibrations 4C-4911(1) Battery Load Tester
• System configurations 5P-7277 Voltage Tester
6V-9130(2) Temperature Adapter (MULTIMETER)
• Data link communications
8T-5319 Connector Tool Group
Required Service Tools 155-5176 AC/DC Current Probe

The tools that are listed in Table 1 are required in 285-0910 Multi-Tool Gp
order to enable a service technician to perform the (1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911
test procedures that are found in this manual. 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
Temperature Adapter Group”.
RENR5093-01 7
Troubleshooting Section

Caterpillar Electronic Technician Table 4

(ET) Standard Hardware for the Use of Cat ET


Part Number Description
Cat ET can display the following information:
N/A Personal Computer (PC)
• Parameters
Communication Adapter
• Event codes 275-5120 Gp (CAT ET TO ECM
INTERFACE)
• Diagnostic codes 237-7547(2) Adapter Cable As

• Engine configuration Parallel Port Cable


225-5985(3) (COMMUNICATION
Cat ET can be used by the technician to perform the ADAPTER)
following functions: (2) The 237-7547 Adapter Cable As is required to connect to the
Universal Serial Bus (USB) on computers that are not equipped
with a RS232 serial port.
• Diagnostic tests (3) The 225-5985 Parallel Port Cable is required to connect to
the parallel port.
• Calibrations
• Flash programming
• Configuration of the Electronic Control Module
(ECM)

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

Software Requirements for Cat ET


Part Description
Number

JERD2124 Single user license for Cat ET

Data subscription for all engines and


JERD2129
machines

Note: For more information regarding the use of Illustration 1


g01255306
Cat ET and the PC requirements for Cat ET, refer to Connecting the Communication Adapter II
the documentation that accompanies your Cat ET
(1) Personal Computer (PC)
software. (2) 237-7547 Adapter Cable As
(3) 196-0055 Adapter Cable As
Connecting Cat ET (4) 225-5985 Parallel Port Cable (COMMUNICATION ADAPTER)
(5) 275-5121 Communication Adapter As
(6) 207-6845 Adapter Cable As
Connecting with the Communication Adapter II
Note: Items (3), (5), and (6) are part of the 275-5120
Table 4 lists the standard hardware that is required in Communication Adapter Gp.
order to connect Cat ET.
Use the following procedure in order to connect Cat
ET and the Communication Adapter II.

1. Remove the electrical power from the ECM.

2. Connect communications adapter (5) to a


communications port on the PC by using one of
the following methods:
8 RENR5093-01
Troubleshooting Section

a. Connect cable (4) between the “COMPUTER”


end of communications adapter (5) and the
parallel port of PC (1). Be sure to configure
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.

6. Establish communication between Cat ET and the Illustration 2


g01297379
ECM. (1) Personal computer (PC)
(7) 261-4867 Card (PCMCIA)
7. If Cat ET and the communication adapter (8) 239-9955 Communication Radio Gp
do not communicate with the ECM, refer to (9) 259-3183 Data Link Cable As
troubleshooting without a diagnostic code
Troubleshooting, “Electronic Service Tool Will Not Note: Items (7), (8), and (9) are part of the 261-3363
Communicate with ECM”. Wireless Communication Adapter Gp.

Communicating with the Wireless Communication Use the following procedure in order to connect the
Adapter wireless communication adapter for use with Cat ET.

Table 5 lists the optional hardware that is needed 1. Remove the electrical power from the ECM.
in order to connect Cat ET by using a wireless
connection. 2. Ensure that the computer has been correctly
configured for the 261-4867 Card (PCMCIA).
Table 5 Verify that the PC card is installed in the
Optional Hardware for the Use of Cat ET computer’s PCI expansion slot.

Part Number Description 3. Connect cable (9) between communication radio


(8) and the service tool connector.
N/A Personal Computer (PC)

Wireless Communication 4. Restore the electrical power to the ECM. If Cat ET


261-3363(1) and the communication radio do not communicate
Adapter Gp
with the ECM, refer to troubleshooting without
(1) Refer to Tool Operating Manual, “Using the 261-3363 a diagnostic code Troubleshooting, “Electronic
Wireless Communication Adapter Gp” for information that is
related to the installation and the configuration. Service Tool Will Not Communicate with ECM”.
RENR5093-01 9
Troubleshooting Section

i02229491 A test ECM can be used to determine if the ECM


is faulty. Install a test ECM in place of the suspect
Replacing the ECM ECM. Flash program the correct personality module
(flash file) into the test ECM. Program the parameters
SMCS Code: 1901-510 for normal operation. The parameters must match
the parameters in the suspect ECM. Refer to the
following test steps for details. If the test ECM
resolves the problem, reconnect the suspect ECM.
The connection of any electrical equipment and Verify that the problem returns. Replace the ECM
the disconnection of any electrical equipment may only if the test ECM resolves the problem and the
cause an explosion hazard which may result in in- problem returns with the suspect ECM.
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an Note: When a new ECM is not available, you may
explosive atmosphere. need to remove an ECM from an engine that is not
in service. The interlock code for the replacement
ECM must match the interlock code for the suspect
NOTICE ECM. Be sure to record the parameters from the
Care must be taken to ensure that fluids are contained replacement ECM on the “Parameters Worksheet”.
during performance of inspection, maintenance, test- Use the “Copy Configuration/ECM Replacement”
ing, adjusting and repair of the product. Be prepared to feature that is found under the “Service” menu on the
collect the fluid with suitable containers before open- Caterpillar Electronic Technician (ET).
ing any compartment or disassembling any compo-
nent containing fluids.
NOTICE
If the personality module and engine application are
Refer to Special Publication, NENG2500, “Caterpillar
not matched, engine damage may result.
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products. Perform the following procedure in order to replace
the ECM:
Dispose of all fluids according to local regulations and
mandates. 1. Record the configuration data:

a. Connect Cat ET to the service tool connector.


NOTICE
Refer to Troubleshooting, “Electronic Service
Keep all parts clean from contaminants. Tools”.
Contaminants may cause rapid wear and shortened
b. Print the parameters from the “Configuration”
component life. screen on Cat ET. If a printer is unavailable,
record all of the parameters. Record any
The Electronic Control Module (ECM) contains no logged diagnostic codes and logged event
moving parts. Replacement of the ECM can be codes for your records.
costly. Replacement can also be a time consuming
task. Follow the troubleshooting procedures in this c. Use the “Copy Configuration/ECM
manual in order to be sure that replacing the ECM Replacement” feature that is found under the
will correct the problem. Verify that the suspect ECM “Service” menu on Cat ET. Select “Load from
is the cause of the problem. ECM” in order to copy the configuration data
from the suspect ECM.
Note: Ensure that the ECM is receiving power and
that the ECM is properly wired to the negative battery Note: If the “Copy Configuration” process fails and
circuit before a replacement of the ECM is attempted. the parameters were not obtained in Step 1.b, the
Refer to Troubleshooting, “Electrical Power Supply parameters must be obtained elsewhere. Some of the
Circuit - Test”. parameters are stamped on the engine information
plate. Most of the parameters must be obtained from
the factory.

2. Remove the ECM:

a. Turn off the electrical power from the ECM.

b. Disconnect the P1 and P2 connectors from the


ECM.
10 RENR5093-01
Troubleshooting Section

e. If the “Copy Configuration” process from Step


NOTICE 1.b was unsuccessful, manually program the
Use a suitable container to catch any fuel that might ECM parameters. The parameters must match
spill. Clean up any spilled fuel immediately. the parameters from Step 1.b.

f. Program the engine monitoring system, if


NOTICE necessary.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that g. Calibrate the timing. Refer to Troubleshooting,
will be disconnected. Fit a suitable cover over discon- “Engine Speed/Timing Sensor - Calibrate”.
nected fuel system component.
i02378227
c. Remove the fuel lines (if equipped) from the
ECM. Self-Diagnostics
d. Disconnect the ECM ground strap. SMCS Code: 1901

e. Remove the mounting bolts from the ECM. The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
3. Install the replacement ECM: with engine operation. When a problem is detected, a
code is generated. An alarm may also be generated.
a. Use the old mounting hardware to install the There are two types of codes:
replacement ECM.
• Diagnostic
b. Connect the fuel lines (if equipped).
• Event
c. Verify that the fuel lines are installed correctly.
The fuel lines must not put tension on the ECM. Diagnostic Code – When a problem with the
Rubber grommets are used to protect the ECM electronic system is detected, the ECM generates a
from excessive vibration. The ECM should diagnostic code. This indicates the specific problem
move slightly in the rubber grommets. If the with the circuitry.
ECM cannot be moved slightly, check that the
fuel lines are not pulling the ECM against one Diagnostic codes can have two different states:
side of the grommets.
• Active
d. Connect the ECM ground strap.
• Logged
e. Connect the P1 and P2 connectors. Tighten
the allen head screws on each ECM Active Code
connector. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for the correct torque An active diagnostic code indicates that an active
values. problem has been detected. Active codes require
immediate attention. Always service active codes
4. Configure the replacement ECM: prior to servicing logged codes.

a. Turn on the electrical power to the ECM. Logged Code

b. Flash program the personality module into Every generated code is stored in the permanent
the ECM. Refer to Troubleshooting, “Flash memory of the ECM. The codes are logged.
Programming” for the correct procedure.

c. Use Cat ET to match the engine application


and the interlock code if the replacement ECM
was used for a different application.

d. If the “Copy Configuration” process from


Step 1.b was successful, return to the “Copy
Configuration/ECM Replacement” screen on
Cat ET and select “Program ECM”. Proceed to
Step 4.f when programming is complete.
RENR5093-01 11
Troubleshooting Section

Logged codes may not indicate that a repair is


needed. The problem may have been temporary. The
problem may have been resolved since the logging
of the code. If the system is powered, it is possible
to generate an active diagnostic code whenever a
component is disconnected. When the component is
reconnected, the code is no longer active. 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.

Event Code

An event code is generated by the detection of an


abnormal engine operating condition. For example,
an event code will be generated if the oil pressure is
too low. In this case, the event code indicates the
symptom of a problem.

i02778818

Sensors and Electrical


Connectors
SMCS Code: 1439; 7553-WW
12 RENR5093-01
Troubleshooting Section

g01388212
Illustration 3
Components for the engine’s control system
RENR5093-01 13
Troubleshooting Section

C18 Engines

g01172356
Illustration 4
Left side engine view (typical example)
(1) Engine coolant temperature sensor (7) Turbocharger outlet pressure sensor (14) Fuel pressure sensor
(2) Coolant level sensor (8) J60 Service tool connector (15) Atmospheric sensor
(3) Fuel temperature sensor (9) J61 Customer connector (16) Engine oil pressure sensor
(4) Fuel outlet temperature sensor (10) Starting motor magnetic switch (SMMS) (17) P400 Timing calibration probe connector
(5) Valve cover connectors for the injector (11) Secondary engine speed/timing sensor (18) J2/P2 ECM connectors
solenoids (12) Primary engine speed/timing sensor (19) J1/P1 ECM connectors
(6) Intake manifold air temperature sensor (13) Timing calibration port

i02433503

Engine Wiring Information


SMCS Code: 1408

The wiring schematics are revised periodically.


The wiring schematics will change as updates are
made to the engine’s harness. For the most current
information, always check the revision number of the
schematic. Use the schematic with the latest revision
number.

g01173198
Illustration 5
Right side engine view (typical example)
(20) Magnetic speed sensor
14 RENR5093-01
Troubleshooting Section

Harness Wire Identification Welding on Applications that are


Equipped with an Electronic Control
Caterpillar identifies all wires with eleven solid colors.
The circuit number is stamped on the wire at a 25 mm
Module (ECM)
(1 inch) spacing. Table 6 lists the wire colors and the
Proper welding procedures are necessary in order
color codes.
to avoid damage to the engine’s electronic control
Table 6 module, sensors, and associated components.
Remove the component that requires welding. When
Color Codes for the Harness Wire welding on an application that is equipped with an
Color Code Color Color Code Color ECM and removal of the component is not possible,
the following procedure must be followed. This
BK Black GN Green procedure provides the minimum amount of risk to
BR Brown BU Blue the electronic components.
RD Red PU Purple
NOTICE
OR Orange GY Gray Do not ground the welder to electrical components
YL Yellow WH White such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
PK Pink components, electrical components, and other com-
ponents.
For example, a wire identification of A701-GY on the
schematic would signify a gray wire with the circuit Clamp the ground cable from the welder to the com-
number A701. A701-GY identifies the power circuit ponent that will be welded. Place the clamp as close
for the No. 1 Injector solenoid. as possible to the weld. This will help reduce the pos-
sibility of damage.
Another wire identification on the schematic is the
size of the wire. The size of the wire will follow the 1. Stop the engine. Remove the electrical power
wire color. Wire size or gauge is referred to as AWG from the ECM.
(American Wire Gauge). AWG is a description of the
diameter of the wire. 2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is installed,
For example, a code of 150-OR-14 on the schematic open the switch.
would indicate that the orange wire in circuit 150 is a
14 AWG wire.

If the gauge of the wire is not listed, the wire is 16


AWG.

Conversion of AWG Numbers to Metric


Measurements
Table 7 shows the various AWG numbers that are
used for the wires. The metric equivalent for the
diameter of each AWG number are also shown.

Table 7

Metric Equivalents for AWG Numbers


AWG Diameter AWG Diameter
Number (mm) Number (mm)
20 0.8 14 1.6
18 1.0 12 2.0
16 1.3 4 3.2 g01143634
Illustration 6
Service welding guide (typical diagram)
RENR5093-01 15
Troubleshooting Section

3. Connect the welding ground cable as close


as possible to the area that will be welded.
Components which may be damaged by welding
include bearings, hydraulic components, and
electrical/electronic components.

4. Protect the wiring harness from welding debris


and spatter.

5. Weld the materials by using standard welding


methods.
16 RENR5093-01
Troubleshooting Section

Programming Parameters 5. When the “Read Customer Passwords” screen


appears, record the customer passwords. The
customer passwords may then be used to change
i02253984 parameters that are customer programmable.
Programming Parameters
i02433393
SMCS Code: 1901
Factory Passwords
The Caterpillar Electronic Technician (ET) can be
used to view certain parameters that can affect the SMCS Code: 0785
operation of the engine. Cat ET can also be used
to change certain parameters. The parameters are NOTICE
stored in the Electronic Control Module (ECM). Some Operating the engine with a flash file not designed for
of the parameters are protected from unauthorized that engine will damage the engine. Be sure the flash
changes by passwords. Parameters that can be file is correct for your engine.
changed have a tattletale number. The tattletale
number shows if a parameter has been changed. Note: Factory passwords are provided only to
Caterpillar dealers.
i02419716
Factory passwords are required to perform each of
Customer Passwords the following functions:

SMCS Code: 0785 • Program a new Electronic Control Module (ECM).


Customer passwords may be used to protect When an ECM is replaced, the system
customer parameters from being changed. The configuration parameters must be programmed
passwords are programmed into the Electronic into the new ECM. A new ECM will allow these
Control Module (ECM) with the Caterpillar Electronic parameters to be programmed once without factory
Technician (ET). One password may be programmed passwords. After the initial programming, some
or both passwords may be programmed. If parameters are protected by factory passwords.
customer passwords are not programmed, customer
parameters may be changed by anyone. • Clear event codes.
To obtain customer passwords, contact the owner of Most event codes require the use of factory
the engine. If the owner has forgotten the customer passwords to clear the code once the code has
passwords, customer passwords may be read by been logged. Clear these codes only when you are
using Cat ET. Factory passwords are required in certain that the problem has been corrected.
order to read customer passwords.
• Unlock parameters.
Use the following procedure in order to read customer
passwords with Cat ET: Factory passwords are required in order to unlock
certain system configuration parameters. Refer
1. Select the “Information” menu. Then select to Troubleshooting, “System Configuration
“Passwords”. Parameters”.

2. When the “Factory Password” screen appears, Since factory passwords contain alphabetic
record the information that is listed on the “Factory characters, the Caterpillar Electronic Technician (ET)
Passwords Worksheet”. Refer to programming must be used to perform these functions. In order to
parameters Troubleshooting, “Factory Passwords obtain factory passwords, proceed as if you already
Worksheet” for additional information. have the password. If factory passwords are needed,
Cat ET will request the factory passwords and Cat ET
3. Obtain the factory passwords. The information will display the information that is required to obtain
that is recorded on the “Factory Passwords the passwords. For the worksheet that is used for
Worksheet” must be provided. When you obtain acquiring factory passwords, refer to programming
the factory passwords, a permanent record of your parameters Troubleshooting, “Factory Passwords
access is generated at Caterpillar. Worksheet”.

4. From the “Factory Password” screen, enter the


factory passwords.
RENR5093-01 17
Troubleshooting Section

i02419726 “WinFlash” Error Messages


Flash Programming If you receive any error messages during flash
programming, click on the “Cancel” button in order
SMCS Code: 1901-591 to stop the process. Access the information about
the “ECM Summary” under the “Information” menu.
Flash Programming – This is a method of Make sure that you are flashing the correct file for
programming or updating the flash file in an engine’s your engine.
Electronic Control Module (ECM).

Caterpillar Electronic Technician (ET) is used to flash i02278907


program a file into the memory of the engine’s ECM.
Service Information Report
If you do not have the flash file, use the “Flash File
Search” tool on the Service Technician Workbench SMCS Code: 0336
(STW) to obtain the flash file for your engine.
Alternatively, use the “Service Software Files” feature After verifying the correct repair has been performed
on SIS Web to obtain the flash file for your engine. on the engine, it is critical to provide brief, detailed
You must have the engine serial number in order to information. This information helps Caterpillar better
search for the flash file. After locating the correct serve you and the customer.
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference. Recommendations
Programming a Flash File Customer’s Complaint
1. Establish communication between Cat ET and the Obtain as much information from the customer
engine’s ECM. as possible. Investigate any written information
that is available and document any information
2. Select “WinFlash” from the “Utilities” menu on Cat that is gathered from the customer. The following
ET. information is of particular importance:

Note: If “WinFlash” will not communicate with the • Indicate if the diagnostic lamp was flashing.
ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, “Electronic Service Tool Will • Indicate if the warning lamp was flashing, or if the
Not Communicate with ECM”. lamp was on continuously.

3. Program the flash file into the ECM. • Indicate the symptoms of engine operation that are
present.
a. Select the engine ECM under the “Detected
ECMs”. Be as specific as possible.

b. Press the “Browse” button in order to select the Cause of Failure


name of the flash file that will be programmed
into the ECM. Comments on the cause of failure should include
the number of diagnostic codes that were logged.
c. When the correct flash file is selected, press Comments should also indicate if the code was an
the “Open” button. active code. Indicate the source of the problem. Also
indicate the method that was used to discover the
d. Verify that the “File Values” match the problem. Examples of the methods that were used to
application. If the “File Values” do not match discover the problem could be one of the following
the application, obtain the correct flash file. methods:
e. When the correct flash file is selected, press • A specific procedure in the manual was followed.
the “Begin Flash” button.
• A visual inspection indicated that wire abrasion on
f. Cat ET will indicate when flash programming the engine harness existed.
has been successfully completed.
• An engine dynamometer test indicated that the
4. Start the engine and check for proper operation. power was below the specification at 1700 rpm
Repair any active diagnostic or event codes. due to the loss of the no. 4 injector and an engine
dynamometer test indicated that the power was
below the specification at all engine speeds above
1700 rpm due to the loss of the no. 4 injector.
18 RENR5093-01
Troubleshooting Section

Be as specific as possible.

Repair Procedure
Comments on the repair procedure should include
the following types of information:

• The wiring harness was repaired.


• The Full Load Setting (FLS) was changed per the
factory’s instructions.

Be as specific as possible.
RENR5093-01 19
Troubleshooting Section

System Configuration “Equipment ID”


Parameters “Equipment ID” allows the customer to enter a
description into the ECM in order to identify the
installation. A maximum of 17 characters may be
i02353414 entered in the field. This parameter is only for
System Configuration reference by the customer. This parameter is not
required.
Parameters
“Personality Module Part Number”
SMCS Code: 1901
The “Personality Module Part Number” is the part
System configuration parameters are parameters number in the Caterpillar system that indicates the
that affect emissions and power of the engine software version that currently resides in the engine
applications. Default values for the parameters are ECM.
programmed into the Electronic Control Module
(ECM) at the factory. Some parameters may be
changed by the customer in order to suit the needs
“Personality Module Release Date”
of the specific application. System configuration
The “Personality Module Release Date” is the date of
parameters consist of “Selected Engine Rating
release for the software in the personality module.
Parameters”, “ECM Identification Parameters”,
“Security Access Parameters”, “I/O Configuration
Parameters” and “System Parameters”. The “ECM “ECM Serial Number”
Identification Parameters” must be programmed if
the ECM is replaced. If the flash file is updated, it is The “ECM Serial Number” is stored in the memory of
not necessary to reprogram the “ECM Identification the ECM. The “ECM Serial Number” can be accessed
Parameters”. Proper values for these parameters are by the use of the service tool.
available using Caterpillar Electronic Technician (ET).
Certain configuration parameters are also stamped “Total Tattletale”
on the engine information plate.
The “Total Tattletale” parameter counts the number
Parameter Descriptions of changes to system parameters.

“Rating Selection” “Low Idle Speed”

The “Rating Selection” corresponds to the selected “Low Idle Speed” is the minimum allowable operating
set of performance maps for the application. This speed for the engine.
selected set of performance maps comes out of
several unique sets of maps that may be resident in “Engine Acceleration Rate”
the flash file. Changing the “Rating Selection” may
create a mismatch in the interlock code. “Engine Acceleration Rate” is the maximum ramp
rate in order to reach desired engine speed.
“ECM Serial Number”
“Engine Speed Droop”
The “ECM Serial Number” identifies the ECM that
is installed on the engine. If the ECM is replaced, The “Engine Speed Droop” determines the change
the ECM serial number must be programmed with in the reduction of engine speed at full load from the
factory passwords. engine speed at no load. Droop can be adjusted
for stability of engines with different rates of speed
“Engine Serial Number” changes. “Engine Speed Droop” allows the operator
to equalize the load between engines that are
Program the “Engine Serial Number” to match the operating in parallel.
engine serial number that is stamped on the engine
information plate. If the ECM is replaced, the engine “Droop Mode Selection”
serial number from the engine information plate must
be programmed into the new ECM. “Droop Mode Selection” allows the customer to select
either droop or isochronous mode.
20 RENR5093-01
Troubleshooting Section

“Droop/Isochronous Switch Enable”


The “Droop/Isochronous Switch Enable” allows the
customer to enable the “Droop Mode Selection”
parameter.

“FLS” (Full Load Setting)


“FLS” is a number that represents the adjustment to
the fuel system that was made at the factory in order
to fine tune the fuel system. The correct value for
this parameter is stamped on the engine information
plate. Factory passwords are required.

“FTS” (Full Torque Setting)


“FTS” is similar to “FLS”. Factory passwords are
required.

“Injector Codes”
Note: The injector codes are not part of the
“Configuration” screen on the electronic service tool.
“Injector Codes Calibration” can be found under
“Calibrations” in the “Service” menu on the electronic
service tool.

The injector code is a number that is found on each


of the unit injectors. The ECM uses this number to
compensate for manufacturing variations between
individual injectors. If you replace any of the unit
injectors, you must reprogram the code for the new
injectors. Also, if you replace the ECM, you must
reprogram all of the injector codes.

“Customer Password # 1”
This parameter allows the customer to lock out
certain parameters by entering a password. Customer
passwords must be used to unlock any parameters
that are protected by customer passwords before the
parameter can be changed. Factory passwords are
required if this password is lost.

“Customer Password # 2”
This parameter allows the customer to lock out
certain parameters by entering a password. Customer
passwords must be used to unlock any parameters
that are protected by customer passwords before the
parameter can be changed. Factory passwords are
required if this password is lost.
RENR5093-01 21
Troubleshooting Section

Parameter Table
Table 8

System Configuration Parameters


Required
Parameter Available Range or Options Default
Password
Selected Engine Ratings
“Rating Selection” Software Dependent 1 Read Only(1)
“ECM Identification Parameters”
“Engine Serial Number” 0XX00000 or XXX00000 Blank Factory
“Equipment ID” 17 alphanumeric characters Blank Customer
“Personality Module Description” Software Dependent Read Only(1)
“Personality Module Part Number” Software Dependent Read Only(1)
“Personality Module Release Date” Software Dependent Read Only(1)
“ECM Serial Number” Hardware Dependent Blank Read Only(1)
“Security Access Parameters”
Total Tattletale 0 to 65535 0 Read Only(1)
“Engine/Gear Parameters”
“Low Idle Speed” 600 to 1200 rpm 1200 Customer
“Engine Accelleration Rate” 5 - 2000 rpm/sec 500 Customer
“Engine Speed Droop” 0.0 - 8.0 % “0.0 %” Customer
“Droop/Isochronous Switch Enable (optional)” “Enabled” or “Disabled” “Enabled” Customer
“Droop Mode Selection” “Droop” or “Isochronous” “Droop” Customer
Software
“Governor Gain Factor” 0 - 40,000 Customer
dependent
Software
“Governor Minumum Stability Factor” 0 - 40,000 Customer
dependent
“Governor Maximum Stability Factor” 0 - 40,000 “Enabled” Customer
Software
“High Altitude” “Enabled” or “Disabled” Customer
dependent
“Coolant Level Sensor Installation Status” “Installed” or “Not Installed” “Not Installed” Customer
“System Parameters”
“FLS” Programmed at the Factory Factory
“FTS” Programmed at the Factory Factory
“Passwords”
“Customer Password #1” 8 alphanumeric characters Blank Customer
“Customer Password #2” 8 alphanumeric characters Blank Customer
(1) This parameter can be viewed only. No changes are allowed.
22 RENR5093-01
Troubleshooting Section

Parameter Worksheet
Table 9
Parameter Worksheet
Engine Parameters
“Personality Module Part Number”
“Pesonality Module Release Date”
“Equipment ID”
“Engine Serial Number”
“ECM Serial Number”
“FLS”
“FTS”
“Total Tattletale”
“Low Idle Speed”
“Engine Acceleration Rater”
“Engine Speed Droop”
“Droop/Isochronous Switch Status”
“Droop Mode Selection”
“Governor Gain Factor”
“Governor Minumum Stability Factor”
“Governor Maximum Stability Factor”
“High Altitude Pressure”
“Coolant Level Sensor Installation Status”
“Customer Password # 1”
“Customer Password # 2”
Information from Engine Information Plate
“Engine Serial Number”
“FLS”
“FTS”
Injector Codes
Injector Code (1)
Injector Code (2)
Injector Code (3)
Injector Code (4)
Injector Code (5)
Injector Code (6)

Note: Compare the FLS and the FTS from the


ECM with the values that are listed on the Engine
Information Plate. The FLS and the FTS should only
be changed because of a mechanical change in
the engine. The use of the wrong parameters could
cause damage to the engine. The use of the wrong
parameters may also void the Caterpillar warranty.
RENR5093-01 23
Troubleshooting Section

Troubleshooting without a i02475244

Diagnostic Code Battery


SMCS Code: 1401-035
i02121176
Refer to Special Instruction, SEHS7633, “Battery
Alternator Test Procedure” for the proper testing procedures.
(Charging Problem)
Probable Causes
SMCS Code: 1405-035
• Worn battery
• Switched battery circuit
The connection of any electrical equipment and
the disconnection of any electrical equipment may Recommended Actions
cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip- Worn Battery
ment or disconnect any electrical equipment in an
explosive atmosphere. 1. Verify that the battery is no longer able to hold a
charge.
Refer to Special Instruction, REHS0354, “Charging
System Troubleshooting” for the proper testing 2. Replace the battery.
procedures.
Switched Battery Circuit
Probable Causes 1. Verify that a switched battery circuit drained the
battery by being left in the ON position.
• Alternator drive belts
2. Charge the battery.
• Charging circuit
3. Verify that the battery is able to maintain a charge.
• Regulator
• Alternator i02349101

Recommended Actions Can Not Reach Top Engine


RPM
Alternator Drive Belts
SMCS Code: 1915-035
1. Inspect the condition of the alternator drive belts.
If the alternator drive belts are worn or damaged, Note: If the problem occurs during high engine loads
replace the belts. then refer to Troubleshooting, “Low Power/Poor or
No Response to Throttle”.
2. Check the tension on the alternator drive belts.
Adjust the tension, if necessary. Probable Causes
Charging Circuit • Diagnostic codes
Inspect the battery cables, wiring, and connections in • Event codes
the charging circuit. Clean all connections and tighten
all connections. Replace any faulty parts. • Throttle signal

Alternator or Regulator • Boost pressure

Verify that the alternator or the regulator is operating • Fuel supply


correctly. Refer to Special Instruction, REHS0354,
“Charging System Troubleshooting” for the proper • Air inlet and exhaust system
testing procedures. Repair the alternator or replace
the alternator, as needed. • Accessory equipment
24 RENR5093-01
Troubleshooting Section

• Specific conditions • Replacement of the fuel filters

Recommended Actions • Service on the low pressure fuel supply circuit


• Replacement of unit injectors
Diagnostic Codes and Event Codes
4. Refer to the Operation and Maintenance Manual
Certain diagnostic codes and/or event codes may manual for the procedure.
cause poor performance. Connect the electronic
service tool and check for active codes and/or logged Note: A sight glass in the fuel supply line is helpful in
codes. Troubleshoot any codes that are present diagnosing air in the fuel.
before continuing with this procedure.
5. Cold weather adversely affects the characteristics
Throttle Signal of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
Monitor “Throttle Position” on Caterpillar Electronic the characteristics of the fuel during cold weather
Technician (ET). Verify that you can achieve full operation.
throttle. Refer to Troubleshooting, “Speed Control -
Test” for the proper troubleshooting procedure. 6. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
Use Cat ET to check the operation of the low to the Systems Operation/Testing and Adjusting
idle switch. If a problem with the switch circuit is manual for the correct pressure values. If the fuel
suspected, refer to Troubleshooting, “Switch Circuits pressure is low, replace the fuel filters. If the fuel
- Test”. pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
Boost Pressure fuel pressure regulating valve.

1. Use Cat ET to monitor the “Fuel Position” and Air Inlet and Exhaust System
the “Rated Fuel Limit” during engine operation. If
“Fuel Position” does not equal “Rated Fuel Limit” 1. Check for an air filter restriction. Clean plugged air
there may be a problem with the engine’s inlet filters or replace plugged air filters. Refer to the
air system. Check for the proper operation of the Operation and Maintenance Manual.
following components:
2. If air shutoff valves are installed, verify that the air
• Turbocharger shutoff valves are fully opened.

• Wastegate control valve (if equipped) 3. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to the Systems
Refer to Systems Operation/Testing and Adjusting Operation/Testing and Adjusting for information on
for specific information. the air inlet and exhaust system.

2. Monitor the status of the boost pressure sensor on Accessory Equipment


Cat ET for normal operation. Ensure that the value
for boost pressure is reasonable. Ensure that the Check all accessory equipment for problems that
boost pressure fluctuates with the demand of the may create excessive load on the engine. Repair
engine. any damaged components or replace any damaged
components.
Fuel Supply
i02381103
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
Coolant in Engine Oil
lines and/or replace the lines. SMCS Code: 1348-035; 1395-035
2. Check the fuel tank for foreign objects which may
block the fuel supply. Probable Causes
3. Prime the fuel supply system if any of the following • Engine oil cooler core
procedures have been performed:
• Cylinder head gasket
RENR5093-01 25
Troubleshooting Section

• Cylinder head • Air in coolant


• Cylinder liner • Water pump
• Cylinder block • Environmental conditions

Recommended Actions • Shunt line restriction


• Radiator or heat exchanger
Engine Oil Cooler Core
• Water temperature regulator
1. Check for leaks in the oil cooler core. If a leak is
found, install a new oil cooler core. Refer to the • Coolant temperature sensor
Disassembly and Assembly manual.
• Engine coolant flow
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters. • Exhaust restriction
Refer to the Operation and Maintenance Manual.
• Excessive load
Cylinder Head Gasket
• Combustion gas in the coolant
1. Remove the cylinder head. Refer to the
Disassembly and Assembly manual. Recommended Repairs
2. Check the cylinder liner projection. Refer to the
Systems Operation/Testing and Adjusting manual. Low Coolant Level

3. Install a new cylinder head gasket and new water


seals in the spacer plate. Refer to the Disassembly
and Assembly manual. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Cylinder Head stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Check for cracks in the cylinder head. If a crack pressure cap slowly in order to relieve the pres-
is found, repair the cylinder head and/or replace sure.
the cylinder head. Refer to the Disassembly and
Assembly manual. Note: Low coolant level can be the result of
overheating rather than the cause.
Cylinder Liner
Check the coolant level.
Check for cracked cylinder liners. Replace any
cracked cylinder liners. Refer to the Disassembly and Run the engine to operating temperature.
Assembly manual.
Inspect the cooling system for leaks. Check for the
Cylinder Block presence of coolant in the engine oil. This would
indicate an internal coolant leak.
Inspect the cylinder block for cracks. If a crack is
found, repair the cylinder block or replace the cylinder Determine whether the leak occurs before the engine
block. overheats.

Add coolant, if necessary. If leaking is found, make


i02422808 the necessary repairs.
Coolant Temperature Is Too
Air in Coolant
High
Air can enter the cooling system if the pressure cap
SMCS Code: 1395-035 is not operating properly. Check the operation of the
pressure cap. Replace the pressure cap, if necessary.
Probable Causes
If the coolant has been changed recently, ensure that
• Low coolant level the air has been purged from the cooling system.
Refer to Systems Operation/Testing and Adjusting.
26 RENR5093-01
Troubleshooting Section

The supply pressure to the water pump must be Water Temperature Regulator
sufficient in order to prevent cavitation. Measure the
supply pressure at the inlet to the water pump. Check the water temperature regulators for proper
operation. Refer to Systems Operation/Testing and
Water Pump Adjusting.

The engine will overheat if the water pump is not Replace the water temperature regulators, if
operating properly. Measure the coolant pressure necessary.
at the outlet of the water pump. Make sure that the
water pump is in good condition. Coolant Temperature Sensor

Environmental Conditions Compare the reading for the coolant temperature


from the Caterpillar Electronic Technician (ET) to
Determine if the ambient air temperature is within the the reading for the coolant temperature from a
design specifications for the cooling system. mechanical gauge. The temperature should rise
steadily as the engine is warmed. Ensure that
Ensure that the engine’s exhaust does not heat the the temperature is reasonable. Refer to Systems
radiator or the heat exchanger. Operation/Testing and Adjusting.

Check for high inlet air temperature. If the reading on Cat ET for the coolant temperature
is not reasonable, troubleshoot the circuit and the
Determine the cause of the high air temperature. coolant temperature sensor. Refer to the diagnostic
Make corrections, when possible. functional test Troubleshooting, “Engine Temperature
Sensor Open or Short Circuit - Test”.
Refer to Systems Operation/Testing and Adjusting.
Engine Coolant Flow
Shunt Line Restriction
Insufficient coolant through the engine can be
If the cooling system is equipped with a shunt line, identified by checking the coolant temperature at
check for a restriction in the line. A restricted shunt various points in the cooling system.
line can cause cavitation in the water pump. Remove
the restriction or replace the shunt line. During normal operation, measure temperatures at
several different points in the cooling system. This
will help to identify possible locations of restrictions.
Radiator or Heat Exchanger
If a buildup of deposit in the cooling system is
Measure the coolant temperature at the inlet to the
suspected, clean the cooling system.
engine.
If the flow of coolant through the engine is not
Radiator
sufficient, determine the cause of the obstruction.
Make necessary repairs.
If the engine is equipped with a radiator, check the
fins of the radiator for obstructions. Check the fan
for proper operation. Exhaust Restriction

If the radiator fins are obstructed, clean the fins. If the Check the back pressure of the exhaust system.
fan does not operate properly, make the necessary Refer to the engine’s Technical Marketing Information.
repairs.
If the back pressure exceeds the specifications for
Heat Exchanger the engine, determine the cause of the excessive
back pressure. Make the necessary repairs.
If the engine is equipped with a heat exchanger,
check for sufficient flow and temperature of the Excessive Load
cooling water through the heat exchanger. If the
flow of cooling water through the heat exchanger is Make sure that the load is not excessive. Reduce the
insufficient, determine the location of the obstruction. load. If necessary, disengage the driven equipment
and test the engine for high coolant temperature.
RENR5093-01 27
Troubleshooting Section

Combustion Gas in the Coolant i02480112

Check the cooling system for combustion gas. This ECM Will Not Communicate
can be identified by small air bubbles in the coolant with Other Systems or Display
during engine operation. Identify the source of the
combustion gas. Make the necessary repairs. Modules
SMCS Code: 1901-035
i02419115

ECM Will Not Accept Factory Probable Causes


Passwords • Wiring and/or electrical connectors
SMCS Code: 1901-035
• Cat Data Link
Probable Causes • CAN data link (if equipped)
One of the following items may not be recorded • Electronic Control Module (ECM)
correctly on the Caterpillar Electronic Technician
(ET): Recommended Actions
• Passwords 1. Check for correct installation of the connectors for
the Electronic Control Module (ECM) J1/P1, J2/P2
• Serial numbers and J3/P3. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
• Total tattletale
2. Connect the electronic service tool to the
• Reason code service tool connector. If the ECM does not
communicate with the electronic service tool,
Recommended Actions refer to troubleshooting without a diagnostic code
Troubleshooting, “Electronic Service Tool Will Not
1. Verify that the correct passwords were entered. Communicate with ECM”.
Check every character in each password. Remove
the electrical power from the engine for 30 3. Troubleshoot the Cat Data Link for possible
seconds and then retry. problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”.
2. Verify that Cat ET is on the “Factory Password”
screen. 4. Troubleshoot the CAN data link (if equipped)
for possible problems. Refer to the diagnostic
3. Use Cat ET to verify that the following information functional test Troubleshooting, “CAN Data Link
has been entered correctly: Circuit - Test”.

• Engine serial number i02429900

• Serial number for the electronic control module Electronic Service Tool Will
• Serial number for Cat ET Not Communicate with ECM
• Total tattletale SMCS Code: 0785-035; 1901-035

• Reason code Probable Causes


• Configuration for the communications adapter
• Electrical connectors
• Communication adapter and/or cables
• Electrical power supply to the service tool
connector
28 RENR5093-01
Troubleshooting Section

• Caterpillar Electronic Technician (ET) and related 2. Disconnect the communication adapter and the
hardware cables from the service tool connector. Reconnect
the communication adapter to the service tool
• Electrical power supply to the Electronic Control connector.
Module (ECM)
3. Verify that the correct cable is being used between
• Flash file the communication adapter and the service tool
connector. Refer to electronic troubleshooting
• Cat Data Link Troubleshooting, “Electronic Service Tools”.

Recommended Actions Electrical Power Supply to the Service


Tool Connector
Start the engine. If the engine starts, but the ECM
will not communicate with Cat ET, continue with Verify that battery voltage is present between
this procedure. If the engine will not start, refer terminals A and B of the service tool connector. If the
to the troubleshooting without a diagnostic code communication adapter is not receiving power, the
procedure Troubleshooting, “Engine Cranks but Will display on the communication adapter will be blank.
Not Start”. If the engine will not crank, refer to the
troubleshooting without a diagnostic code procedure Cat ET and Related Hardware
Troubleshooting, “Engine Will Not Crank”.
In order to eliminate Cat ET and the related hardware
Configuration for the Communications as the problem, connect Cat ET to a different engine.
Adapter If the same problem occurs on a different engine,
check Cat ET and the related hardware in order to
1. Access “Preferences” under the “Utilities” menu determine the cause of the problem.
on Cat ET.
Electrical Power Supply to the Electronic
2. Verify that the correct “Communications Interface Control Module (ECM)
Device” is selected.
Check power to the ECM. Refer to the diagnostic
3. Verify that the correct port is selected for use by functional test Troubleshooting, “Electrical Power
the communication adapter. Supply Circuit - Test”.
Note: The most commonly used port is “COM 1”. Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
4. Check for any hardware that is utilizing the
same port as the communications adapter. If any
devices are configured to use the same port, exit Flash File
or close the software programs for that device.
Ensure that the correct flash file is properly installed
in the ECM.
Electrical Connectors
Note: A new ECM is not programmed to any specific
Check for correct installation of the J1/P1 and engine until a flash file has been installed. The engine
J2/P2 ECM connectors and of the service tool will not start and the engine will not communicate
connector. Refer to the diagnostic functional test with Cat ET until the flash file has been downloaded.
Troubleshooting, “Electrical Connectors - Inspect”. Refer to programming parameters Troubleshooting,
“Flash Programming”.
Communication Adapter and/or Cables
Cat Data Link
1. If you are using a “Communication Adapter II”,
ensure that the firmware and driver files for the Troubleshoot the Cat Data Link for possible
communication adapter are the most current files problems. Refer to the diagnostic functional test
that are available. If the firmware and driver files Troubleshooting, “Cat Data Link Circuit - Test”.
do not match, the communication adapter will not
communicate with Cat ET.
RENR5093-01 29
Troubleshooting Section

i02349327 Starting Motor, Solenoid, or Starting


Engine Cranks but Will Not Circuit
Start Remove the starter and visually inspect the pinion of
the starter and the flywheel ring gear for damage.
SMCS Code: 1000-035
Test the operation of the starting motor solenoid.
Probable Causes Check the condition of the engine wiring for the
starting motor solenoid. Test the operation of the
starting motor.
• Diagnostic codes and event codes
If necessary, repair the starter or the starter circuit.
• Electronic Control Module (ECM)
• Engine shutdown switches Engine Speed/Timing

• Starting motor, solenoid, or starting circuit 1. Crank the engine and observe the engine speed
on the Cat ET status screen. If Cat ET indicates
• Engine speed/timing zero rpm, refer to Troubleshooting, “Engine
Speed/Timing Sensor Circuit - Test”.
• Unit injector
Note: Upon initial cranking, the status for engine
• Fuel supply speed may indicate that the engine speed signal is
abnormal. This message will be replaced with an
• Combustion engine speed once the ECM is able to calculate a
speed from the signal.
Recommended Actions 2. If an engine speed is present, check the sensor
installation. If the sensor is not properly installed,
Diagnostic Codes and Event Codes the ECM may read engine speed, but the ECM
cannot determine the tooth pattern. The ability for
Certain diagnostic codes and/or event codes may the ECM to read the tooth pattern is necessary
prevent the engine from starting. Connect the to determine the cylinder position. Engine speed
Caterpillar Electronic Technician (ET) and check for is present when engine speed is greater than
active codes and/or for logged codes. Troubleshoot 50 rpm. Refer to Troubleshooting, “Engine
any codes that are present before continuing with Speed/Timing Sensor Circuit - Test”.
this procedure.
Unit Injector
Electronic Control Module
1. Ensure that the J300/P300 injector valve cover
If the ECM is not receiving battery voltage, the ECM entry connector is fully connected and free of
will not operate. Refer to Troubleshooting, “Electrical corrosion.
Power Supply Circuit - Test”.
2. Perform the “Injector Solenoid Test” on Cat ET in
Starting Aids order to determine if all of the injector solenoids
are being energized by the ECM. Refer to
If cold ambient conditions exist, check operation of Troubleshooting, “Injector Solenoid Circuit - Test”
starting aids. Verify that the ether system is operating for additional information.
correctly. Refer to Troubleshooting, “Ether Injection
System - Test”. Fuel Supply

Engine Shutdown Switches 1. Visually check the fuel level. Do not rely on the fuel
gauge only. If necessary, add fuel. If the engine
The engine shutdown switches must be in the RUN has been run out of fuel, it will be necessary
position in order to start the engine. Use Cat ET to to purge the air from the fuel system. Refer to
verify the status of the shutdown switches. When an Operation and Maintenance Manual, “Fuel System
engine shutdown switch is used to shut down the - Prime” for the correct procedure.
engine, the keyswitch must be turned to the RUN
position for at least 15 seconds before restarting the 2. Check the fuel lines for the following problems:
engine. restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
30 RENR5093-01
Troubleshooting Section

3. Check the fuel tank for foreign objects which may Recommended Actions
block the fuel supply.
Incorrect Engine Oil
4. Check for air in the low pressure fuel supply
system if any of the following procedures have Use engine oil that is recommended and change the
been performed: engine oil at the interval that is recommended by the
engine’s Operation and Maintenance Manual.
• Replacement of the fuel filters
Contaminated Engine Oil
• Service on the low pressure fuel supply circuit
Drain the crankcase and refill the crankcase with
• Replacement of unit injectors clean engine oil. Install new engine oil filters. Refer to
Note: A sight glass in the low pressure supply line is the engine’s Operation and Maintenance Manual.
helpful in diagnosing air in the fuel. Refer to Testing
and Adjusting for more information. If the oil filter bypass valve is open, the oil will not be
filtered. Check the oil filter bypass valve for a weak
5. Purge air from the low pressure fuel supply circuit. spring or for a broken spring. If the spring is broken,
Refer to Operation and Maintenance Manual, replace the spring. Refer to the engine’s Disassembly
“Fuel System - Prime” for the correct procedure. and Assembly manual. Make sure that the oil bypass
valve is operating correctly.
6. Check the fuel filters.
Contaminated Air
7. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and Inspect the air inlet system for leaks. Inspect all of
Maintenance Manual for information on improving the gaskets and the connections. Repair any leaks.
the characteristics of the fuel during cold weather
operation. Inspect the air filter. Replace the air filter, if necessary.

8. Check the fuel pressure during engine cranking. Contaminated Fuel


Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting, “Fuel Inspect the fuel filter. Replace the fuel filter, if
System” for the correct pressure values. If the fuel necessary.
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel Contaminants in the fuel such as hydrogen sulfide
transfer pump, fuel transfer pump coupling, and and sulfur can lead to the formation of acids in the
fuel pressure regulating valve. crankcase. Obtain a fuel analysis.

Combustion Low Oil Pressure


Check the engine for combustion problems. 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.
i02549485

Engine Has Early Wear An indicator for the engine oil pressure may indicate
sufficient pressure, but a component is worn due to a
SMCS Code: 1000-035 lack of lubrication. In such a case, look at the passage
for the engine oil supply to the component. Refer
to the Systems Operation/Testing and Adjusting
Probable Causes manual.

• Incorrect engine oil


• Contaminated engine oil
• Contaminated air
• Contaminated fuel
• Low oil pressure
RENR5093-01 31
Troubleshooting Section

i02513923 Throttle Signal


Engine Misfires, Runs Rough Monitor throttle signal on Cat ET. Verify that the
or Is Unstable throttle signal is stable from the low idle position to
the high idle position.
SMCS Code: 1000-035
Unit Injectors
Note: If the symptom is intermittent and the symptom
cannot be repeated, refer to troubleshooting without 1. Use Cat ET to determine if there are any active
a diagnostic code Troubleshooting, “Intermittent Low diagnostic codes for the unit injectors.
Power or Power Cutout”. If the symptom is consistent
and the symptom can be repeated, continue with this 2. Perform the “Injector Solenoid Test” on Cat ET in
procedure. order to determine if all of the injector solenoids
are being energized by the ECM.
Probable Causes 3. Perform the “Cylinder Cutout Test” on Cat ET in
order to identify any misfiring cylinder(s). Refer
• Diagnostic codes to the diagnostic functional test Troubleshooting,
“Injector Solenoid Circuit - Test”.
• Electrical connectors
• Cold mode Fuel Supply

• Throttle signal 1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
• Unit injectors problems are found with the fuel lines, repair the
lines and/or replace the lines.
• Fuel supply
2. Check the fuel tank for foreign objects which may
• Air inlet and exhaust system block the fuel supply.

3. Prime the fuel system if any of the following


Recommended Actions procedures have been performed:
Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine
• Replacement of the fuel filters
operating temperature, etc), test the engine under
those conditions. Troubleshooting the symptom
• Service on the low pressure fuel supply circuit
under other conditions can give misleading results.
• Replacement of unit injectors
Diagnostic Codes 4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Check for active diagnostic codes on the Caterpillar Maintenance Manual for information on improving
Electronic Technician (ET). Troubleshoot any active the characteristics of the fuel during cold weather
codes before continuing with this procedure. operation.

Electrical Connectors 5. Check the fuel pressure during engine cranking.


Check the fuel pressure after the fuel filter. Refer
Check for correct installation of the J1/P1 and to Systems Operation/Testing and Adjusting, “Fuel
J2/P2 Electronic Control Module (ECM) connectors System” for the correct pressure values. If the fuel
and the unit injector connectors. Refer to the pressure is low, replace the fuel filters. If the fuel
diagnostic functional test Troubleshooting, “Electrical pressure is still low, check the following items: fuel
Connectors - Inspect”. transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve.
Cold Mode
Air Inlet and Exhaust System
Use Cat ET to verify that the engine has exited cold
mode. Cold mode operation may cause the engine to 1. Check for an air filter restriction. Clean plugged air
run rough and the engine power may be limited. filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual.
32 RENR5093-01
Troubleshooting Section

2. Check the air inlet and exhaust system for • Worn valve guides
restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and • Worn piston rings
Exhaust System”.
• Scored cylinder liners or worn cylinder liners
i02173692
Recommended Actions
Engine Oil in Cooling System
Failed Turbocharger Seals
SMCS Code: 1348-035; 1350-035
Check the inlet manifold and the exhaust manifold for
Probable Causes oil. If oil is present, replace the turbocharger.

• Engine oil cooler core Worn Valve Guide Seals or Faulty Valve
Guide Seals
• Cylinder head gasket
Inspect the valve guide seals for wear and for
Recommended Actions damage. Replace the valve guide seals, if necessary.

Engine Oil Cooler Core Worn Valve Guides


1. Inspect the engine oil cooler core for leaks. If a Inspect the valve guides for wear. Refer to the
leak is found, replace the oil cooler core. Refer to Specification manual for the maximum permissible
Disassembly and Assembly, “Engine Oil Cooler wear of the valve guides. If necessary, recondition
- Remove”. the cylinder head.

2. Drain the crankcase and refill the crankcase with Worn Piston Rings
clean engine oil. Install new engine oil filters.
Refer to the Operation and Maintenance Manual Piston rings that have excessive wear can cause
for more information. too much pressure in the crankcase. The additional
pressure in the crankcase will cause more than
Cylinder Head Gasket the normal amount of crankcase blowby from the
crankcase breather. Use the 8T-2700 Blowby/Air
1. Remove the cylinder head. Refer to Disassembly Flow Indicator to check the amount of crankcase
and Assembly, “Cylinder Head - Remove” for the blowby. The test procedure is in Special Instruction,
correct procedure. SEHS8712. Inspect piston rings and install new
parts, as required.
2. Check the cylinder liner projection. Refer to
Systems Operation/Testing and Adjusting for the Scored Cylinder Walls or Worn Cylinder
correct procedure.
Walls
3. Install a new cylinder head gasket and new water
Inspect the cylinder liners for damage. Hone the
seals in the spacer plate. Refer to Disassembly
cylinder liners in order to remove the scoring. If
and Assembly, “Cylinder Head - Install” for the
necessary, install new liners.
correct procedure.

i02455784
i02234636

Engine Oil in Exhaust System Engine Stalls at Low RPM


SMCS Code: 1915-035
SMCS Code: 1050-035; 1348-035

Probable Causes Probable Causes

• Failed turbocharger seals • Unit injectors

• Worn valve guide seals or faulty valve guide seals • Fuel supply
• Air supply
RENR5093-01 33
Troubleshooting Section

• Engine idle 6. Check the fuel pressure after the fuel filter
while the engine is being cranked. For the
• Accessory equipment correct pressure values, refer to the Systems
Operation/Testing and Adjusting manual. If the
Recommended Actions fuel pressure is low, replace the fuel filters. If the
fuel pressure is still low, check the following items:
fuel transfer pump, fuel transfer pump coupling,
Unit Injectors and fuel pressure regulating valve.
1. Check for correct installation of the J1/P1 and
J2/P2 connectors for the Electronic Control
Air Supply
Module (ECM). Check for correct installation of the
Check for restrictions in the air inlet system. Refer to
J300/P300 connectors for the unit injectors. Refer
Systems Operation/Testing and Adjusting.
to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
Engine Idle
2. Perform the “Injector Solenoid Test” with the
Caterpillar Electronic Technician (ET) in order to Check the parameter for the low engine idle (if
determine if all of the injector solenoids are being applicable). Refer to Troubleshooting, “System
energized by the ECM. Configuration Parameters”.

3. Perform the “Cylinder Cutout Test” with Cat ET Accessory Equipment


in order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test Check all accessory equipment for problems that
Troubleshooting, “Injector Solenoid Circuit - Test”. may create excessive load on the engine. Repair
any damaged components or replace any damaged
Fuel Supply components.

1. Check the fuel pressure. Refer to Systems


i02419766
Operation/Testing and Adjusting.
Engine Vibration
2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If SMCS Code: 1000-035
problems are found with the fuel lines, repair the
lines and/or replace the lines.
Probable Causes
3. Check the fuel tank for foreign objects which may
block the fuel supply. • Vibration damper
• Engine supports
NOTICE
Do not crank the engine continuously for more than • Driven equipment
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. • Engine misfiring or running rough

4. Prime the fuel system if any of the following Recommended Actions


procedures have been performed:
Vibration Damper
• Replacement of the fuel filters
Check the vibration damper for damage. Install a
• Service on the low pressure fuel supply circuit new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace
• Replacement of unit injectors any damaged bolts. Refer to the Disassembly and
Assembly manual.
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting. Engine Supports

5. Cold weather adversely affects the characteristics Inspect the mounts and the brackets while you run
of the fuel. Refer to the Operation and the engine through the speed range. Look for mounts
Maintenance Manual. and brackets that are loose and/or broken. Tighten
all of the mounting bolts. Install new components, if
necessary.
34 RENR5093-01
Troubleshooting Section

Driven Equipment Battery Cables and/or Batteries


Check the alignment and the balance of the driven 1. Inspect the battery disconnect switch, bus bars,
equipment. battery posts, and battery cables for loose
connections and corrosion. If the battery cables
Engine Misfiring or Running Rough are corroded, remove the battery cables and clean
the battery cables. Tighten any loose connections.
Refer to troubleshooting without a diagnostic code
Troubleshooting, “Engine Misfires, Runs Rough or 2. Inspect the batteries.
Is Unstable”.
a. Charge the batteries. Refer to Special
Instruction, SEHS7633, “Battery Test
i02349504 Procedure”.
Engine Will Not Crank b. Load test the batteries. Refer to Special
Instruction, SEHS9249, “Use of 4C-4911
SMCS Code: 1000-035 Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”.
Probable Causes
Starting Motor Solenoid and/or Starting
• Engine shutdown switch Circuit
• Battery cables 1. Test the operation of the starting motor solenoid.
• Batteries 2. Check the wiring to the starting motor solenoid.
• Starting circuit
Starting Motor and/or Flywheel Ring Gear
• Starting motor solenoid
1. Test the operation of the starting motor.
• Starting motor
2. Inspect the starter pinion and the flywheel ring
• Flywheel ring gear gear for damage. Ensure that the pinion gear does
not bind with the flywheel ring gear during starting.
• Driven equipment
Driven Equipment and/or Engine
• Engine accessories Accessories
• Hydraulic cylinder lock 1. Ensure free movement of the driveline.

• Internal engine problem 2. Ensure that the timing pin was not left in the
flywheel housing.
Recommended Actions
3. Remove any engine accessories that may lock
Engine Shutdown Switch up the engine. Inspect the condition of the
accessories.
Verify that the engine shutdown switch is in the RUN
position. If the switch is in the OFF position, fuel The following list illustrates examples of engine
accessories that may lock up the engine:
injection is disabled. Some engine shutdown devices
will prevent the engine from being cranked. If the
condition of the engine shutdown switch is suspect, • Fuel transfer pump
refer to Troubleshooting, “Switch Circuits - Test” for
troubleshooting information. • Air compressor

Ensure that other engine shutdown devices are not • Engine oil pump
preventing the engine from being cranked. Check
the application for a starter relay that is actuated by Hydraulic Cylinder Lock
another controller. Check for a security system that
may be preventing the engine from being started. Check for fluid in the cylinders (hydraulic cylinder
lock) by removing the individual unit injectors.
RENR5093-01 35
Troubleshooting Section

Note: Be sure to drain the fuel from the cylinder head 4. Repair any leaks that were found. Remove
prior to removing the injectors. Fuel will flow from the any restrictions that were found. Replace any
cylinder head into the cylinders when the unit injector damaged components that were found.
is removed.
Engine Speed/Timing
Internal Engine Problem
1. Check the calibration of the engine speed/timing
1. Disassemble the engine. Refer to Disassembly sensor. Refer to Troubleshooting, “Engine
and Assembly. Speed/Timing Sensor - Calibrate”.

2. Inspect the internal components for the following 2. Verify that the crankshaft and the camshaft drive
conditions: gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
• Seizure
Atmospheric Pressure Sensor
• Broken components
1. Remove the sensor.
• Bent components
2. Remove debris, moisture, or ice from the sensor.
i02432467
3. Install the sensor.
Excessive Black Smoke
4. Check the Caterpillar Electronic Technician (ET)
SMCS Code: 1088-035 for active diagnostic codes on the sensor. If no
active diagnostic code exists, the sensor may be
used. The correct reading for the atmospheric
Probable Causes pressure is between 50 kPa (7.25 psi) and
100 kPa (14.5 psi).
• Air inlet or exhaust system
• Engine speed/timing sensor Boost Pressure Sensor, “Fuel Position”,
and/or “FRC Fuel Limit”
• Atmospheric pressure sensor
1. Monitor the status of “Fuel Position” and “Rated
• Boost pressure sensor Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit”
• “Fuel Position” and/or “FRC Fuel Limit” and “Fuel Position” is less than “FRC Fuel Limit”,
the Electronic Control Module (ECM) is providing
• Flash file the correct control. Otherwise, proceed to the next
Step.
• Fuel quality
2. Verify that there are no active diagnostic codes for
• Valve adjustment the boost pressure sensor.

3. Monitor the status of “Boost Pressure” and


Recommended Actions “Atmospheric Pressure” on Cat ET. When the
engine is not running, “Boost Pressure” should be
Air Inlet or Exhaust System 0 kPa (0 psi).
1. Check the air inlet system for restrictions and/or Note: A problem with the “FRC Fuel Limit” will only
for leaks. cause black smoke during acceleration. A problem
with the “FRC Fuel Limit” will not cause black smoke
a. Check for an air filter restriction. during steady state operation.
b. Perform a visual inspection of the system for
restrictions and/or for leaks in the air inlet
Flash File
piping .
Verify that the correct flash file is installed. Refer
to Troubleshooting, “Flash Programming” for
2. Ensure that the turbocharger is in good repair.
information.
3. Check the exhaust system for restrictions.
36 RENR5093-01
Troubleshooting Section

Fuel Quality Internal Engine Wear


Cold weather adversely affects the characteristics of Internal engine wear can cause excessive oil leakage
the fuel. Refer to Operation and Maintenance Manual into the combustion area of the cylinders. Excessive
for information on improving the characteristics of the wear on the following components may cause oil
fuel during cold weather operation. consumption:

Valve Adjustment • Piston rings

Check the valve adjustment. Refer to Systems • Valve guides


Operation/Testing and Adjusting for information on
valve adjustments. Check for excessive crankcase blowby at the
engine crankcase breather. Refer to Systems
Operation/Testing and Adjusting.
i02410997

Excessive Engine Oil i02430014

Consumption Excessive Fuel Consumption


SMCS Code: 1348-035 SMCS Code: 1250-035

Probable Causes Probable Causes


• Oil leaks • Engine operation
• Oil level • Fuel leaks
• Turbocharger seal • Fuel quality
• Internal engine wear • Engine speed/timing

Recommended Actions • Unit injectors

Oil Leaks • Air inlet and exhaust system

Check the engine compartment for oil leaks. Repair • Accessory equipment
any oil leaks that are identified.
Recommended Actions
Oil Level
Engine Operation
Check the engine oil level. Too much oil in the engine
crankcase can cause the engine to consume oil. Use the Caterpillar Electronic Technician (ET) to
Remove excessive engine oil from the crankcase. check the “Current Totals” for excessive idle time
and/or for a high load factor which would be indicative
Ensure that the dipstick is properly calibrated of poor operating habits.
and/or that the dipstick is correct for the application.
Calibrate the dipstick and/or replace the dipstick. Note: Engine operation may also be affected by
environmental conditions such as wind and snow.
Turbocharger
Fuel Leaks
Check for turbocharger shaft seal leakage. Remove
the air inlet piping and the exhaust outlet piping from Check the fuel pressure during engine cranking.
the turbocharger. Check the compressor wheel and Check the fuel pressure after the fuel filter. Refer
the turbine for evidence of an oil leak. If necessary, to Systems Operation/Testing and Adjusting for the
repair the turbocharger or replace the turbocharger. correct pressure values. If the fuel pressure is low,
Refer to Systems Operation/Testing and Adjusting. replace the fuel filters. If the fuel pressure is still low,
check the following items: fuel transfer pump, fuel
transfer pump coupling, and fuel pressure regulating
valve.
RENR5093-01 37
Troubleshooting Section

Fuel Quality Recommended Actions


Cold weather adversely affects the characteristics Lubrication
of the fuel. Refer to the Operation and Maintenance
Manual for information on improving the 1. Remove the valve mechanism covers. Refer to
characteristics of the fuel during cold weather the engine’s Disassembly and Assembly manual
operation. for the correct procedure.

Engine Speed/Timing 2. Check the lubrication in the valve compartment.


Ensure that there is adequate engine oil flow in
Perform a speed/timing sensor calibration. Refer to the valve compartment. The passages for the
the calibration procedure Troubleshooting, “Engine engine oil must be clean.
Speed/Timing Sensor - Calibrate”.
Valve Lash
Unit Injectors
Adjust the engine valve lash. Refer to the engine’s
1. Check for correct installation of the J1/P1 Systems Operation/Testing and Adjusting manual for
and J2/P2 Electronic Control Module (ECM) the correct procedure.
connectors and the unit injector connectors. Refer
to the diagnostic functional test Troubleshooting, Valve Train Components
“Electrical Connectors - Inspect”.
1. Inspect the following components of the valve
2. Perform the “Injector Solenoid Test” on Cat ET in train:
order to determine if all of the injector solenoids
are being energized by the ECM. • Rocker arms
3. Perform the “Cylinder Cutout Test” on Cat ET • Roller followers (rocker arm)
in order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test • Camshaft
Troubleshooting, “Injector Solenoid Circuit - Test”.
• Valve stems
Air Inlet and Exhaust System
• Valve guides
1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter • Rocker shafts
or replace the air filter.
2. Check the components for the following conditions:
2. Check the air inlet and exhaust system for abnormal wear, excessive wear, straightness, and
restrictions and/or for leaks. Refer to Systems cleanliness. Replace parts, if necessary.
Operation/Testing and Adjusting.
Note: If you replace the camshaft, you must also
Accessory Equipment replace the roller followers (rocker arm).

Check all accessory equipment for problems that 3. Adjust the engine valve lash. Refer to the engine’s
may create excessive load on the engine. Repair Systems Operation/Testing and Adjusting manual
any damaged components or replace any damaged for the correct procedure.
components.
i02520406

i02285926
Excessive White Smoke
Excessive Valve Lash
SMCS Code: 1088-035
SMCS Code: 1105-035
Note: Some white smoke may be present during
cold start-up conditions when the engine is operating
Probable Causes normally. If the white smoke persists, there may be
a problem.
• Lubrication
• Valve lash Probable Causes
• Valve train components • Diagnostic codes
38 RENR5093-01
Troubleshooting Section

• Starting aids (if applicable) If no smoke is present, there may be a problem


with the fuel quality or there may be a problem
• Water temperature regulators with the fuel supply.

• Unit injectors 2. Check the fuel quality. Refer to Systems


Operation/Testing and Adjusting.
• Flash file
3. Check the fuel pressure. Refer to Testing and
• Fuel supply Adjusting.

• Cooling system 4. Ensure that the fuel system has been primed.
Refer to Testing and Adjusting.
• Component wear
5. Check for fuel supply lines that are restricted.
Recommended Actions 6. Cold weather adversely affects the characteristics
of the fuel. Refer to the applicable Operation and
Diagnostic Codes Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Check for active diagnostic codes on the Caterpillar operation.
Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure. 7. Check for air in the fuel system. Refer to Systems
Operation/Testing and Adjusting.
Starting Aids (If Applicable)
Cooling System
If cold ambient conditions exist, check the operation
of starting aids. Refer to the appropriate diagnostic Check for an internal coolant leak. Check for coolant
functional test for troubleshooting information. in the engine oil, coolant in the cylinders, and
coolant in the exhaust system. Refer to Systems
Water Temperature Regulators Operation/Testing and Adjusting.

Check the water temperature regulators for correct Component Wear


operation. Refer to Systems Operation/Testing and
Adjusting. Check the following components for excessive wear:

Unit Injectors • Valves


Use Cat ET to perform the cylinder cutout test. Try • Pistons
to simulate the conditions for the test that were
experienced during operation. Cut out each cylinder • Rings
individually for approximately one minute in order
to help identify a misfiring cylinder. If the specific • Cylinder liners
cylinder is identified, proceed to the diagnostic
functional test Troubleshooting, “Injector Solenoid
i02477276
Circuit - Test”.
Intermittent Engine Shutdown
Flash File
SMCS Code: 1000-035
Verify that the flash file is installed. The flash file that
is installed in the Electronic Control Module (ECM) Note: Use this procedure only if the engine shut
will be displayed on the “Configuration” screen on down completely and it was necessary to restart the
Cat ET. engine.

Fuel Supply Probable Causes


1. Monitor the exhaust for smoke while the engine • Diagnostic codes
is being cranked.
• Event codes
RENR5093-01 39
Troubleshooting Section

• Electrical connections Fuel Supply


• Unit injector connectors 1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
• Fuel supply problems are found with the fuel lines, repair the
lines and/or replace the lines.
• Engine shutdown switch (if applicable)
2. Check the fuel tank for foreign objects which may
Note: If the problem only occurs under certain block the fuel supply.
conditions such as full load or engine operating
temperature, then perform the test under those NOTICE
operating conditions. Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
Recommended Actions minutes before cranking the engine again.

Diagnostic Codes or Event Codes 3. Prime the fuel system if any of the following
procedures have been performed:
Certain diagnostic codes or event codes may cause
the engine to shutdown. Connect the Caterpillar • Replacement of the fuel filters
Electronic Technician (ET) and check for active codes
and/or logged codes. Troubleshoot any codes that • Service on the low pressure fuel supply circuit
are present before continuing with this procedure.
• Replacement of unit injectors
Electrical Connections
Refer to the Operation and Maintenance Manual.
1. Inspect the wiring from the Electronic Control
Module (ECM) to the breaker panel. Refer to the Note: A sight glass in the fuel supply line is helpful in
Schematic for the engine. Inspect any device that diagnosing air in the fuel.
has been installed for circuit protection. Ensure
that battery power is present at the ECM. Ensure 4. Cold weather adversely affects the characteristics
that the ground circuits are providing electrical of the fuel. Refer to the Operation and
continuity to the ECM. Refer to the diagnostic Maintenance Manual.
functional test Troubleshooting, “Electrical Power
Supply Circuit - Test”. 5. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
2. Check the circuit between the ECM and the to the Systems Operation/Testing and Adjusting.
keyswitch. Refer to the Schematic for the engine. If the fuel pressure is low, replace the fuel filters.
Also, ensure that all electrical connectors are in If the fuel pressure is still low, check the following
good repair. Refer to the diagnostic functional items: fuel transfer pump, fuel transfer pump
test Troubleshooting, “ Electrical Connectors - coupling, and fuel pressure regulating valve.
Inspect”.
Engine Shutdown Switch (If Applicable)
3. Check the state of each of the circuit breakers.
Reset the circuit breakers if the circuit breakers Use Cat ET to monitor the status of the engine
are tripped. Prior to returning the engine to shutdown switches. Check for status indicators
service, determine the condition that caused the that are active due to the engine shutdown switch.
circuit breaker to trip. Make the necessary repairs. Determine the cause for the shutdown and make any
repairs necessary.
4. Aftermarket engine protection devices usually
interrupt power to the ECM. Check for correct
installation and operation of aftermarket engine i02433904
protection devices. It may be necessary to bypass
aftermarket devices in order to continue testing. Intermittent Low Power or
Power Cutout
Unit Injector Connectors
SMCS Code: 1000-035
Check the unit injector connectors J300/P300 and
associated wiring for damage, or for intermittent Note: Use this procedure only if the engine does not
problems. Refer to the diagnostic functional test shut down completely.
Troubleshooting, “Electrical Connectors - Inspect”.
40 RENR5093-01
Troubleshooting Section

Probable Causes Fuel Supply


• Diagnostic codes 1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
• Event codes problems are found with the fuel lines, repair the
lines and/or replace the lines.
• Throttle signal
2. Check the fuel tank for foreign objects and debris
• Power supply for the Electronic Control Module which may block the fuel supply.
(ECM)
3. Prime the fuel system if any of the following
• Fuel supply components have been serviced recently:

Recommended Actions • Fuel filters

Note: If the problem only occurs under certain • Low pressure fuel supply circuit
conditions, test the engine under those conditions.
Examples of certain conditions are high engine • Unit injectors
speed, full load and engine operating temperature.
Note: A sight glass in the low pressure supply line
Troubleshooting the symptoms under other
is helpful in diagnosing air in the fuel. For more
conditions can give misleading results.
information, refer to Systems Operation/Testing and
Adjusting, “Air in Fuel - Test”.
Diagnostic Codes and Event Codes
4. Cold weather adversely affects the characteristics
Certain diagnostic codes and/or event codes may of the fuel. Refer to the Operation and
cause poor performance. Connect the Caterpillar Maintenance Manual for information on improving
Electronic Technician (ET) and check for active codes the characteristics of the fuel during cold weather
and/or for logged codes. Troubleshoot any codes that operation.
are present before continuing with this procedure.
5. Check the fuel pressure while the engine is being
Throttle Signal cranked. Refer to Systems Operation/Testing
and Adjusting, “Fuel System” for the correct
Monitor the status for “Throttle Position” on Cat ET. test procedure. If the fuel pressure is below
Verify that the status for “Throttle Position” is stable the specification, replace the fuel filters. If the
and that the engine is able to reach high idle engine fuel pressure remains below the specification,
speed. Refer to Troubleshooting, “Throttle Position check the following items: fuel transfer pump, fuel
Sensor Circuit - Test” for information that is related to pressure relief valve, and fuel pressure regulator
troubleshooting the circuit for the throttle signal. valve. Refer to Systems Operation/Testing and
Adjusting for more information.
ECM Power Supply
i02430113
1. Inspect the circuit between the ECM and
the batteries. Refer to the Electrical System Low Engine Oil Pressure
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to SMCS Code: 1348-035-LP
Troubleshooting, “Electrical Power Supply Circuit
- Test” for more information. NOTICE
Do not operate engine with low oil pressure. Engine
2. Inspect the circuit between the ECM and damage will result. If measured engine oil pressure is
the keyswitch. Refer to the Electrical System low, discontinue engine operation until the problem is
Schematic. Inspect the wires, the connectors, corrected.
and the components in the circuit. Refer to
Troubleshooting, “Electrical Power Supply Circuit
- Test” for more information. Probable Causes
• Engine oil level
• Engine oil filters and oil filter bypass valve
RENR5093-01 41
Troubleshooting Section

• Engine oil pump i02404207

• Engine oil cooler Low Power/Poor or No


Response to Throttle
• Fuel dilution
SMCS Code: 1000-035
• Engine wear
Probable Causes
Recommended Actions
• Diagnostic codes
Engine Oil Level
• Event codes
Inspect the engine oil level. If engine oil is low add
engine oil. Refer to the Operation and Maintenance • Cold mode
Manual.
• Throttle signal
Engine Oil Filters and Oil Filter Bypass
Valve • Electrical connectors

Check the service records of the engine for • Unit injectors


information that is related to the last oil change. If
necessary, perform an oil change on the engine and • Intake manifold pressure sensor
replace the engine oil filters.
• Air inlet and exhaust system
Check the operation of oil filter bypass valve. Clean
the bypass valve and the housing. If necessary, • Parameters
install new parts.
• Fuel supply
Engine Oil Pump
Recommended Actions
Check for blockage of the inlet screen for the engine
oil pump. Check the components of the engine oil Note: If the problem only occurs under certain
pump for excessive wear. If necessary, repair the oil conditions, test the engine under those conditions.
pump or replace the oil pump. Examples of certain conditions are high engine
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
Oil Cooler conditions can give misleading results.
Check the engine’s oil cooler for plugging or
blockage. Clean the engine oil cooler core(s) and/or Diagnostic Codes and Event Codes
install new engine oil cooler core(s).
Certain diagnostic codes and/or event codes may
cause poor performance. Connect Caterpillar
Fuel Dilution Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
Check for presence of fuel in lubricating oil. Refer are present before continuing with this procedure.
to the troubleshooting without a diagnostic code
procedure Troubleshooting, “Fuel Dilution of Engine
Oil”. Cold Mode
1. Use Cat ET to verify that the engine has exited
Engine Wear cold mode. Cold mode operation may cause the
engine to run rough and engine power may be
Inspect the camshaft and/or camshaft bearings limited.
for excessive wear. Inspect the crankshaft and/or
crankshaft bearings. Excessive wear to discrete 2. Observe the coolant temperature on the Cat ET
components may be an indication of a blocked oil status screen. Verify that the reading is valid.
passage. Use an oil pressure gauge to check the
oil pressure at the main oil gallery. This will help
determine if the excessive wear is from low system
pressure or from passages that are blocked.
42 RENR5093-01
Troubleshooting Section

Throttle Signal Air Inlet and Exhaust System


Monitor the status for “Throttle Position” on Cat ET. 1. Observe the indicator lamps. Check for an air
Verify that the status for “Throttle Position” is stable filter restriction indicator. Clean plugged air
and that the engine is able to reach high idle speed. filters or replace plugged air filters. Refer to the
Refer to the appropriate diagnostic test for your Operation and Maintenance Manual for additional
application: information.

• Troubleshooting, “Throttle Position Sensor Circuit - 2. Check the air inlet and exhaust system for
Test” restrictions and/or for leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
• Troubleshooting, “Throttle Switch Circuit - Test” Exhaust System”.

• Troubleshooting, “Speed Control - Test” Parameters


Electrical Connectors If the ECM has been replaced, compare the values on
the Engine Information Plate to following parameters
Check for correct installation of the J1/P1 and J2/P2 from Cat ET:
Electronic Control Module (ECM) connectors and the
unit injector connectors. Refer to Troubleshooting, • FRC offset
“Electrical Connectors - Inspect”.
• Full Load Setting (FLS)
Unit Injectors
• Full Torque Setting (FTS)
1. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids Fuel Supply
are being energized by the ECM.
1. Check the fuel lines for the following problems:
2. Perform the “Cylinder Cutout Test” on Cat ET in restrictions, collapsed lines, and pinched lines. If
order to identify any misfiring cylinder(s). Refer to problems are found with the fuel lines, repair the
Troubleshooting, “Injector Solenoids Circuit - Test” lines and/or replace the lines.
for more information.
2. Check the fuel tank for foreign objects which may
Intake Manifold Pressure Sensor block the fuel supply.

1. Monitor the status of “Fuel Position”, “Rated Fuel 3. Prime the fuel system if any of the following
Limit”, and “FRC Fuel Limit” on Cat ET while procedures have been performed:
the engine is operating under full load. These
parameters should reflect the information below. • Replacement of the fuel filters
Table 10 • Service on the low pressure fuel supply circuit
“Fuel Position” = “Rated Fuel Limit”
• Replacement of unit injectors
and
Note: A sight glass in the low pressure supply line is
“Fuel Position” < “FRC Fuel Limit”
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting, “Air in Fuel - Test”
If “Fuel Position” equals “Rated Fuel Limit” and for more information.
“Fuel Position” is less than “FRC Fuel Limit”, the
electronics are operating correctly. Otherwise, NOTICE
proceed with the next Step. Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
2. Monitor the status of “Boost Pressure” and minutes before cranking the engine again.
“Atmospheric Pressure” for normal operation
on Cat ET. When the engine is not running, the
correct value for “Boost Pressure” is 0 kPa (0 psi). 4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
RENR5093-01 43
Troubleshooting Section

5. Check the fuel pressure after the fuel filter i02477338


while the engine is being cranked. Refer to
Systems Operation/Testing and Adjusting, “Fuel Noise Coming from Cylinder
System” for the correct pressure values. If the
fuel pressure is low, replace the fuel filters. If SMCS Code: 1000-035
the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump Probable Causes
coupling, and fuel pressure regulating valve. Refer
to Systems Operation/Testing and Adjusting for • Diagnostic codes
more information.
• Fuel quality
i02286073
• Unit injectors
Mechanical Noise (Knock) in
• Valve lash
Engine
• Cylinder head and related components
SMCS Code: 1000-035

The probable root causes are listed below: Recommended Actions


• Faulty accessory Diagnostic Codes
• Damage to valve train components Check for active diagnostic codes on the Caterpillar
Electronic Technician (ET). Troubleshoot any active
• Failure of connecting rod bearing codes before continuing with this procedure.

• Crankshaft bearings Fuel Quality


Perform the following checks: Refer to Operation and Maintenance Manual for
information on the characteristics of the fuel.
1. Isolate the source of the noise. Remove
the suspect engine accessories. Inspect
the suspect engine accessories. Repair the
Unit Injectors
engine accessories and/or replace the engine
1. Check the connectors at the Electronic Control
accessories.
Module (ECM). Check for correct installation
2. Remove the valve cover from the suspect of the J1/P1 and J2/P2 ECM connectors. Also,
thoroughly inspect the unit injector wiring harness
cylinder(s). Check the following items for damage:
from the ECM to the J300/P300 valve cover entry
camshaft, valve rotocoil, valve springs, roller
followers (rocker arm), rocker shaft, bridges, and connector. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
injectors. Check for valves that do not move freely.
Remove the cylinder head and inspect the valves.
Replace any damaged parts. If damage has 2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
occurred, ensure that the following components
are being energized by the ECM.
are free of contamination: cylinder liner, piston,
and exhaust system. Replace any damaged parts.
3. Perform the “Cylinder Cutout Test” on Cat ET
in order to identify any injectors that may be
3. Inspect the connecting rod bearings and the
bearing surfaces (journals) on the crankshaft. misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
Check the piston pin for excessive wear. Replace
any damaged parts.
Valve Lash
4. Check main journals of the crankshaft and the
main journal bearings for excessive wear. Replace Check the engine valve lash settings. Inspect the
any damaged parts. valve train for sufficient lubrication. Check damage to
valve train components which may cause excessive
valve lash. Repair any problems that are found.
Refer to troubleshooting without a diagnostic code
Troubleshooting, “Excessive Valve Lash”.
44 RENR5093-01
Troubleshooting Section

Cylinder Head and Related Components Throttle Position Sensor


Check for signs of damage and/or wear to the valves, Monitor “Throttle Status” on Cat ET. Verify that the
cylinder head gasket, etc. Inspect the condition of throttle position is stable and that the engine is able
the camshafts. to reach high idle rpm. Refer to Troubleshooting,
“Throttle Position Sensor Circuit - Test” for the proper
troubleshooting procedure.
i02433203

Poor Acceleration or Response Electrical Connectors


SMCS Code: 1000-035 Check for correct installation of the J1/P1 and J2/P2
connectors for the Electronic Control Module (ECM).
Check for correct installation of the JH300/P300
Probable Causes unit injector connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.
• Engine “Derated”
• Cold mode operation Unit Injectors

• Flash file 1. Use Cat ET to determine if there are any active


diagnostic codes for the unit injectors.
• Throttle position sensor
2. Perform the injector solenoid test on Cat ET in
• Electrical connectors order to determine if all of the injector solenoids
are being energized by the ECM. Refer to
• Unit injectors Troubleshooting, “Injector Solenoid Circuit - Test”
for the proper procedure.
• Fuel Position, Rated Fuel Limit, and FRC Fuel
Position 3. Perform the cylinder cutout test on Cat ET in order
to identify any injectors that might be misfiring.
• Air inlet and exhaust system Refer to Troubleshooting, “Injector Solenoid
Circuit - Test” for the proper procedure.
• Fuel supply
Fuel Position, Rated Fuel Limit, and FRC
Recommended Actions Fuel Position
1. Monitor the status of “Fuel Position” and “Rated
Engine “Derated”
Fuel Limit” while the engine is operating under full
The engine may be derated due to dirty air filters load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit”,
or other factors. Use the Caterpillar Electronic
the electronics are operating correctly. Otherwise,
Technician (ET) in order to check for engine derates.
proceed to the next Step.
Cold Mode Operation 2. Verify that there are no active diagnostic codes for
the boost pressure sensor.
Monitor the status screen on Cat ET in order to verify
that the engine has exited cold mode. Observe the 3. Monitor the “Boost Pressure” and “Atmospheric
reading for coolant temperature on the Cat ET. Refer Pressure” for normal operation. When the engine
to Troubleshooting, “System Overview” for additional is not running, “Boost Pressure” should be 0 kPa
information. (0 psi).

Flash File Air Inlet and Exhaust System


Verify that the correct flash file is installed. 1. Check for an air filter restriction indicator. Clean
plugged air filters or replace plugged air filters.
Refer to the Operation and Maintenance Manual.
RENR5093-01 45
Troubleshooting Section

2. Check the air inlet and exhaust system for


restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.

Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.

2. Check the fuel tank for foreign objects which may


block the fuel supply.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

3. Prime the fuel system if any of the following


procedures have been performed:

• Replacement of the fuel filters


• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Testing
and Adjusting for more information.

4. Cold weather adversely affects the characteristics


of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.

5. Check the fuel pressure after the fuel filter while


the engine is being cranked. Refer to Testing and
Adjusting for the correct pressure values. If the
fuel pressure is low, replace the fuel filters. If
the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve. Refer
to Systems Operation/Testing and Adjusting for
more information.
46 RENR5093-01
Troubleshooting Section

Troubleshooting with a Illustration 7 is an example of the operating range


of a sensor.
Diagnostic Code
i02769238

Diagnostic Codes
SMCS Code: 1900

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
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 an ECM. Diagnostic codes may consist of the
component identifier (CID), and the failure mode
identifier (FMI).

Component Identifier (CID) – The CID indicates the


component that generated the code. For example,
the CID number 1 identifies the fuel injector for the
number one cylinder.

Failure Mode Identifier (FMI) – The FMI indicates


the type of failure.

Suspect Parameter Number (SPN) – The SPN is a


three digit code which is assigned to each component
in order to identify data via the data link to the ECM.
This is used on the diagnostics for the CAN data link. Illustration 7
g01365757

Example of the typical operating range of a sensor


Refer to Troubleshooting, “Diagnostic Code Cross
Reference” for the complete list of the diagnostic (1) This area represents the normal operating range of the engine
parameter.
codes and a description of each code. There is a (2) In these areas, the engine is operating in an unsafe operating
troubleshooting procedure for every diagnostic code. range of the monitored parameter. An event code will be
Refer to Troubleshooting, “Troubleshooting With A generated for the monitored parameter. The sensor circuit
Diagnostic Code”. does not have an electronic problem. Refer to Troubleshooting,
“Troubleshooting with an Event Code” for additional information
on event codes.
When a diagnostic code is activated, the Electronic (3) In these areas, the signal from the sensor is outside of the
Control Module (ECM) transmits information about operating range of the sensor. The sensor circuit has an
the code over the J1939 data link. Some J1939 electronic problem. A diagnostic code will be generated for
devices may display the code. However, the code the sensor circuit.
will be displayed with a SPN-FMI code. Refer to
Troubleshooting, “Diagnostic Code Cross Reference” Active Diagnostic Codes
for a cross-reference between SPN-FMI codes and
diagnostic codes. An active diagnostic code represents a problem with
the electronic control system. Correct the problem
Do not confuse diagnostic codes with event codes. as soon as possible.
Event codes alert the operator that an abnormal
operating condition such as low oil pressure or high
coolant temperature has been detected. Refer to
Troubleshooting, “Troubleshooting with an Event
Code” for additional information on event codes.
RENR5093-01 47
Troubleshooting Section

When the ECM generates an active diagnostic code, If the cause of the diagnostic code is a problem in the
the “Active Alarm” indicator (“Engine Control Alarm common wire, two cylinders will be affected because
Status” on Cat ET) is activated in order to alert the of the shared common wire for the injectors.
operator. If the condition that generated the code
is momentary, the message disappears from the System Response:
list of active diagnostic codes. The diagnostic code
becomes logged. The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
Logged Diagnostic Codes
When the ECM generates a diagnostic code, the The injector may not operate while the condition
exists.
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 Possible Performance Effect:
generated:
• The engine may misfire.
• The hour of the first occurrence of the code
• The engine may experience low power.
• The hour of the last occurrence of the code Troubleshooting:
• The number of occurrences of the code Perform the following diagnostic procedure: “Injector
This information is a valuable indicator for Solenoid Circuit - Test”
troubleshooting intermittent problems.
Results:
A code is cleared from memory when one of the
following conditions occur: • OK – STOP.

• The service technician manually clears the code. i02457853

• The code does not recur for 100 hours. CID 0002 FMI 11 Cylinder #2
• A new code is logged and there are already ten
Injector fault
codes in memory. In this case, the oldest code is SMCS Code: 1290-038
cleared.
Conditions Which Generate This Code:
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that
The Electronic Control Module (ECM) is attempting
did not result in complaints. The most likely cause
to operate the injector. The ECM detects an open or
of an intermittent problem is a faulty connection a short in the circuit for the injector.
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the failure
If the cause of the diagnostic code is a problem in the
of an electronic module. Diagnostic codes that are common wire, two cylinders will be affected because
logged repeatedly may indicate a problem that needs
of the shared common wire for the injectors.
special investigation.
System Response:
Note: Always clear logged diagnostic codes after
investigating and correcting the problem which
The ECM will log the diagnostic code. The ECM will
generated the code. continue to attempt to operate the injector after the
code has been logged.
i02457823
The injector may not operate while the condition
CID 0001 FMI 11 Cylinder #1 exists.
Injector fault Possible Performance Effect:
SMCS Code: 1290-038
• The engine may misfire.
Conditions Which Generate This Code:
• The engine may experience low power.
The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open or
a short in the circuit for the injector.
48 RENR5093-01
Troubleshooting Section

Troubleshooting: i02457916

Perform the following diagnostic procedure: “Injector CID 0004 FMI 11 Cylinder #4
Solenoid Circuit - Test” Injector fault
Results: SMCS Code: 1290-038

• OK – STOP. Conditions Which Generate This Code:

i02457905
The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open or
CID 0003 FMI 11 Cylinder #3 a short in the circuit for the injector.
Injector fault If the cause of the diagnostic code is a problem in the
common wire, two cylinders will be affected because
SMCS Code: 1290-038 of the shared common wire for the injectors.
Conditions Which Generate This Code: System Response:
The Electronic Control Module (ECM) is attempting The ECM will log the diagnostic code. The ECM will
to operate the injector. The ECM detects an open or continue to attempt to operate the injector after the
a short in the circuit for the injector. code has been logged.
If the cause of the diagnostic code is a problem in the The injector may not operate while the condition
common wire, two cylinders will be affected because exists.
of the shared common wire for the injectors.
Possible Performance Effect:
System Response:

The ECM will log the diagnostic code. The ECM will
• The engine may misfire.
continue to attempt to operate the injector after the
code has been logged.
• The engine may experience low power.
Troubleshooting:
The injector may not operate while the condition
exists. Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
Possible Performance Effect:
Results:
• The engine may misfire.
• OK – STOP.
• The engine may experience low power.
Troubleshooting: i02458023

Perform the following diagnostic procedure: “Injector CID 0005 FMI 11 Cylinder #5
Solenoid Circuit - Test” Injector fault
Results: SMCS Code: 1290-038

• OK – STOP. Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting


to operate the injector. The ECM detects an open or
a short in the circuit for the injector.

If the cause of the diagnostic code is a problem in the


common wire, two cylinders will be affected because
of the shared common wire for the injectors.
RENR5093-01 49
Troubleshooting Section

System Response: Results:

The ECM will log the diagnostic code. The ECM will • OK – STOP.
continue to attempt to operate the injector after the
code has been logged.
i01959369

The injector may not operate while the condition


exists.
CID 0041 FMI 03 8 Volt DC
Supply short to +batt
Possible Performance Effect:
SMCS Code: 1439-038
• The engine may misfire.
Conditions Which Generate This Code:
• The engine may experience low power.
The Electronic Control Module (ECM) detects the
Troubleshooting: following conditions:

Perform the following diagnostic procedure: “Injector • The 8 volt supply is more than 8.8 VDC for more
Solenoid Circuit - Test” than one second.

Results: • The ECM has been powered for more than three
seconds.
• OK – STOP.
System Response:
i02458033 The ECM will log the diagnostic code and the ECM
CID 0006 FMI 11 Cylinder #6 will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. An
Injector fault active diagnostic code may not cause any noticeable
effect on engine response unless the voltage is
SMCS Code: 1290-038 above 12 or 13 VDC.

Conditions Which Generate This Code: Possible Performance Effect:

The Electronic Control Module (ECM) is attempting The engine may be limited to low idle.
to operate the injector. The ECM detects an open or
a short in the circuit for the injector. Note: The 8 volt supply provides power to the
accelerator pedal position sensor.
If the cause of the diagnostic code is a problem in the
common wire, two cylinders will be affected because Troubleshooting:
of the shared common wire for the injectors.
Perform the following diagnostic procedure: “Digital
System Response: Sensor Supply Circuit - Test”

The ECM will log the diagnostic code. The ECM will Results:
continue to attempt to operate the injector after the
code has been logged. • OK – STOP.
The injector may not operate while the condition
i01959371
exists.

Possible Performance Effect:


CID 0041 FMI 04 8 Volt DC
Supply short to ground
• The engine may misfire.
SMCS Code: 1439-038
• The engine may experience low power.
Conditions Which Generate This Code:
Troubleshooting:
The Electronic Control Module (ECM) detects the
Perform the following diagnostic procedure: “Injector following conditions:
Solenoid Circuit - Test”
• The 8 volt supply is less than 7.2 VDC for more
than one second.
50 RENR5093-01
Troubleshooting Section

• The ECM has been powered for more than three Troubleshooting:
seconds.
Perform the following diagnostic procedure: “Speed
System Response: Control - Test”

The ECM will log the diagnostic code and the ECM Results:
will trigger a snapshot. The check engine lamp will
illuminate while this diagnostic code is active. An • OK – STOP.
active diagnostic code may not cause any noticeable
effect on engine response unless the voltage drops
i02424760
below 6.5 VDC.

Possible Performance Effect:


CID 0094 FMI 03 Fuel Pressure
open/short to +batt
The engine may be limited to low idle.
SMCS Code: 1439-038; 1718-038
Note: The 8 volt supply provides power to the
accelerator pedal position sensor. Conditions Which Generate This Code:

Troubleshooting: The Electronic Control Module (ECM) reads signal


voltage that is above normal.
Perform the following diagnostic procedure: “Digital
Sensor Supply Circuit - Test” System Response:

Results: The ECM will log the diagnostic code. The ECM flags
fuel pressure as invalid data and a default value is
• OK – STOP. used.

Possible Performance Effect:


i02119137

CID 0091 FMI 08 Throttle • There are no performance effects.


Position signal abnormal Troubleshooting:

SMCS Code: 1439-038; 1913-038 Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) detects all of
the following conditions: • OK – STOP.
• Either the duty cycle is greater than 95 percent i02424763
or less than five percent for one second, or the
sensor frequency is greater than 1000 Hz or less
than 150 Hz for two seconds.
CID 0094 FMI 04 Fuel Pressure
short to ground
• There are no active diagnostic codes for the digital
sensor supply (8 Volt DC). SMCS Code: 1439-038; 1718-038

• The ECM has been powered for at least three Conditions Which Generate This Code:
seconds.
The Electronic Control Module (ECM) reads signal
System Response: voltage that is below normal.

The ECM will log the diagnostic code. The ECM flags System Response:
the throttle position as invalid data and a default
value of 0 percent is used. The ECM will log the diagnostic code. The ECM flags
fuel pressure as invalid data and a default value is
Possible Performance Effect: used.

• Reduced engine speed (low idle)


RENR5093-01 51
Troubleshooting Section

Possible Performance Effect: Troubleshooting:

• There are no performance effects. Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Troubleshooting:
Results:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” • OK – STOP.
Results:
i02427669

• OK – STOP. CID 0110 FMI 03 Engine


Coolant Temperature
i02378792
open/short to +batt
CID 0100 FMI 03 Engine Oil
Pressure open/short to +batt SMCS Code: 1439-038-CLT; 1906-038

SMCS Code: 1439-038-OC; 1924-038 Conditions Which Generate This Code:

The signal voltage from the engine coolant


Conditions Which Generate This Code:
temperature sensor is above normal.
The signal voltage from the engine oil pressure
System Response:
sensor is above 4.8 VDC for at least eight seconds.
The Electronic Control Module (ECM) will log the
System Response:
diagnostic code. The ECM flags coolant temperature
The Electronic Control Module (ECM) will log the as invalid data and a default value is used. The
engine will not go into cold mode.
diagnostic code. The ECM flags oil pressure as
invalid data and a default value of 600 kPa (87 psi)
is used. Possible Performance Effect:

Troubleshooting: • The engine may misfire.

Perform the following diagnostic procedure: “Engine • The engine may experience reduced speed (rpm)
and/or low power.
Pressure Sensor Open or Short Circuit - Test”
Troubleshooting:
Results:
Perform the following diagnostic procedure: “Engine
• OK – STOP. Temperature Sensor Open or Short Circuit - Test”

i02424648 Results:
CID 0100 FMI 04 Engine Oil • OK – STOP.
Pressure short to ground
i02427678
SMCS Code: 1439-038-OC; 1924-038
CID 0110 FMI 04 Engine
Conditions Which Generate This Code:
Coolant Temperature short to
The Electronic Control Module (ECM) detects a ground
signal voltage that is below normal.
SMCS Code: 1439-038-CLT; 1906-038
System Response:
Conditions Which Generate This Code:
The code is logged. The ECM flags oil pressure as
invalid data and a default value is used. The signal voltage from the engine coolant
temperature sensor is below normal.
Possible Performance Effect:

• There are no performance effects.


52 RENR5093-01
Troubleshooting Section

System Response: i02378820

The Electronic Control Module (ECM) will log the CID 0172 FMI 03 Intake
diagnostic code. The ECM flags coolant temperature Manifold Air Temp open/short
as invalid data and a default value is used. The
engine will not go into cold mode. to +batt
Possible Performance Effect: SMCS Code: 1439-038-AI; 1921-038

• The engine may misfire. Conditions Which Generate This Code:

• The engine may experience reduced speed (rpm) The signal voltage from the inlet air temperature
and/or low power. sensor exceeds 4.9 VDC for eight seconds.

Troubleshooting: System Response:

Perform the following diagnostic procedure: “Engine The Electronic Control Module (ECM) logs the
Temperature Sensor Open or Short Circuit - Test” diagnostic code. The ECM flags Inlet air temperature
as invalid data and a default temperature of 85 °C
Results: (185 °F) is used.

• OK – STOP. Possible Performance Effect:

• Low power
i02458713
Troubleshooting:
CID 0168 FMI 02 System
Voltage intermittent/erratic Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
SMCS Code: 1401-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
While the engine is running, the battery voltage drops
below 9 VDC intermittently, or the battery voltage
i02378836
drops below 9 VDC three times in a seven second
period. CID 0172 FMI 04 Intake
System Response: Manifold Air Temp short to
The Electronic Control Module (ECM) will log the
ground
diagnostic code. SMCS Code: 1439-038-AI; 1921-038
Possible Performance Effect: Conditions Which Generate This Code:
• The engine may misfire and/or shutdown The signal voltage from the inlet air temperature
sensor dropped below 0.2 VDC for eight seconds.
Troubleshooting:
System Response:
Perform the following diagnostic procedure:
“Electrical Power Supply Circuit - Test” The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags Inlet air temperature
Results: as invalid data and a default value of 85 °C (185 °F)
is used.
• OK – STOP.
Possible Performance Effect:

• Low power
RENR5093-01 53
Troubleshooting Section

Troubleshooting: Possible Performance Effect:

Perform the following diagnostic procedure: “Engine • There are no performance effects.
Temperature Sensor Open or Short Circuit - Test”
Troubleshooting:
Results:
Perform the following diagnostic procedure: “Engine
• OK – STOP. Temperature Sensor Open or Short Circuit - Test”

Results:
i02385225

CID 0174 FMI 03 Fuel • OK – STOP.


Temperature open/short to
i02476539
+batt
CID 0190 FMI 08 Engine Speed
SMCS Code: 1439-038; 1922-038
signal abnormal
Conditions Which Generate This Code: SMCS Code: 1439-038-VF; 1907-038
The Electronic Control Module (ECM) detects signal
Conditions Which Generate This Code:
voltage that is above normal.
The Electronic Control Module (ECM) detects a loss
System Response:
of the signal from the primary engine speed/timing
sensor and the engine speed did not pass through
The ECM will log the diagnostic code. The ECM flags
the range of 350 rpm to 500 rpm.
fuel temperature as invalid data and a default value
is used. System Response:
Possible Performance Effect:
The ECM logs the diagnostic code. The check engine
lamp will illuminate after a delay. The ECM will default
• Low power to the signal from the secondary engine speed/timing
sensor.
Troubleshooting:
Possible Performance Effect:
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
• There are no performance effects.
Results:
Note: If the signals from both engine speed/timing
sensors are lost, then the engine will shut down.
• OK – STOP.
Troubleshooting:
i02424798
Perform the following diagnostic procedure: “Engine
CID 0174 FMI 04 Fuel Speed/Timing Sensor Circuit - Test”
Temperature short to ground Results:
SMCS Code: 1439-038; 1922-038
• OK – STOP.
Conditions Which Generate This Code:
i02490447
The Electronic Control Module (ECM) detects signal
voltage that is below normal. CID 0247 FMI 09 J1939 Data
System Response:
Link communications
SMCS Code: 1901-038
The ECM will log the diagnostic code. The ECM flags
fuel temperature as invalid data and a default value
Conditions Which Generate This Code:
is used.
The Electronic Control Module (ECM) has detected a
loss of communications with the J1939 data link.
54 RENR5093-01
Troubleshooting Section

Ensure that all flash files in the control system are Expected Result:
current.
The correct flash file was installed and the diagnostic
System Response: code is no longer active.

The ECM will log the diagnostic code. Results:

Possible Performance Effect: • OK – The correct flash file was installed and the
diagnostic code is no longer active. STOP.
• The engine may not operate properly and/or the
equipment may not have engine speed control. • Not OK – The diagnostic code is still active.
Troubleshooting: Repair: Call your Technical Engine Technical
Communicator (TC) for more information.
Perform the following diagnostic procedure: “CAN
Data Link Circuit - Test” STOP.

Results:
i02348802

• OK – STOP. CID 0261 FMI 13 Engine Timing


i02475721
Calibration required
CID 0253 FMI 11 Personality SMCS Code: 1439-038; 1912-038

Module mechanical failure Conditions Which Generate This Code:

SMCS Code: 1902-038 The timing has not been calibrated since the
Electronic Control Module (ECM) was installed or the
Conditions Which Generate This Code: calibration is incorrect.

The Electronic Control Module (ECM) detects one of System Response:


the following conditions:
The ECM will log the diagnostic code.
• The software that was installed into the ECM is for
a different application. The ECM uses default timing.

• An older ECM does not support the newer flash file Possible Performance Effect:
that was installed into the ECM.
• Engine misfires
System Response:
• Low power
This diagnostic code will only be active.
• Reduced engine speed
Possible Performance Effect:
• White exhaust smoke
• The engine will not start.
• Increased exhaust emissions
Troubleshooting:
Troubleshooting:
Install the Correct Flash File into the ECM
Perform the following diagnostic procedure: “Engine
A. Install the correct flash file into the ECM. Refer Speed/Timing Sensor - Calibrate”
to Troubleshooting, “Flash Programming” for
information that is related to the installation of Results:
ECM software.
• OK – STOP.
B. Clear the diagnostic code.

Note: Clearing this diagnostic code requires factory


passwords.
RENR5093-01 55
Troubleshooting Section

i02445665 Results:
CID 0262 FMI 03 5 Volt Sensor • OK – STOP.
DC Power Supply short to
+batt i02285570

SMCS Code: 1439-038


CID 0268 FMI 02 Check
Programmable Parameters
Conditions Which Generate This Code:
SMCS Code: 1901-038
The voltage level of the 5 volt supply is above normal.
Conditions Which Generate This Code:
System Response:
The Electronic Control Module (ECM) detects that
The Electronic Control Module (ECM) will log the one or more of the programmable parameters have
diagnostic code. The ECM flags all 5 volt sensors not been programmed.
as invalid data and the respective default values are
used. The parameters that have not been programmed
are listed on the “Active Diagnostic” screen on the
Possible Performance Effect: Caterpillar Electronic Technician (ET).

• The engine may experience low power. System Response:

Troubleshooting: The diagnostic code is not logged. Any


unprogrammed parameters are set to the default
Perform the following diagnostic procedure: “5 Volt value. Engine performance may be affected. This is
Engine Pressure Sensor Supply Circuit - Test” dependent on the unprogrammed parameters.

Results: Possible Performance Effect:

• OK – STOP. Low power

Troubleshooting:
i02445677

CID 0262 FMI 04 5 Volt Sensor Program the parameters. Refer to Troubleshooting,
“System Configuration Parameters” for additional
DC Power Supply short to information.
ground Results:
SMCS Code: 1439-038
• OK – STOP.
Conditions Which Generate This Code:
i02378875
The 5 volt sensor supply voltage drops below normal.
CID 0273 FMI 03 Turbo Outlet
System Response:
Pressure open/short to +batt
The Electronic Control Module (ECM) logs the
SMCS Code: 1439-038; 1917-038
diagnostic code. The ECM flags all 5 volt sensors
as invalid data and the respective default values are
Conditions Which Generate This Code:
used.

Possible Performance Effect: With an engine speed of zero rpm, the signal voltage
for the turbocharger outlet pressure sensor exceeds
4.95 VDC for at least two seconds.
• The engine may experience low power.
System Response:
Troubleshooting:

Perform the following diagnostic procedure: “5 Volt The Electronic Control Module (ECM) logs the
diagnostic code. The ECM flags the turbocharger
Engine Pressure Sensor Supply Circuit - Test”
outlet pressure as invalid data. A default value of
100 kPa (14.5 psi) is used.
56 RENR5093-01
Troubleshooting Section

Possible Performance Effect: System Response:

• Low power The Electronic Control Module (ECM) will log


the diagnostic code. The ECM flags atmospheric
Troubleshooting: pressure as invalid data and a default value of
100 kPa (15 psi) is used.
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” Possible Performance Effect:

Results: Low power

• OK – STOP. Troubleshooting:

Perform the following diagnostic procedure: “Engine


i02378876
Pressure Sensor Open or Short Circuit - Test”
CID 0273 FMI 04 Turbo Outlet Results:
Pressure short to ground
• OK – STOP.
SMCS Code: 1439-038; 1917-038

Conditions Which Generate This Code: i02473210

The signal voltage for the turbocharger outlet


CID 0274 FMI 04 Atmospheric
pressure sensor falls below 0.5 VDC for two seconds. Pressure short to ground
System Response: SMCS Code: 1439-038-AI; 1923-038

The Electronic Control Module (ECM) logs the Conditions Which Generate This Code:
diagnostic code. The ECM flags turbocharger outlet
pressure as invalid data. A default value of 100 kPa The signal voltage from the atmospheric pressure
(14.5 psi) is used. sensor is below normal.

Possible Performance Effect: System Response:

• Low power The Electronic Control Module (ECM) will log


the diagnostic code. The ECM flags atmospheric
Troubleshooting: pressure as invalid data and a default value is used.

Perform the following diagnostic procedure: “Engine Possible Performance Effect:


Pressure Sensor Open or Short Circuit - Test”
• The engine may experience low power.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
i02281091

CID 0274 FMI 03 Atmospheric Results:

Pressure open/short to +batt • OK – STOP.


SMCS Code: 1439-038-AI; 1923-038

Conditions Which Generate This Code:

The signal voltage from the atmospheric pressure


sensor is above 4.8 VDC for at least eight seconds.
RENR5093-01 57
Troubleshooting Section

i02571960 Troubleshooting:
CID 0342 FMI 02 Loss of Perform the following diagnostic procedure: “Engine
Secondary Engine Speed Speed/Timing Sensor Circuit - Test”

signal Results:

SMCS Code: 1439-038-VF; 1907-038 • OK – STOP.


Conditions Which Generate This Code:
i02024258
The signal from the secondary engine speed/timing
sensor is intermittent or lost for less than one second. CID 1929 FMI 03 Fuel Return
Temperature Sensor voltage
System Response:
high/short to +batt
The Electronic Control Module (ECM) will log the
diagnostic code. SMCS Code: 1439-038-TA; 1922-038

There should not be a noticeable change in engine Conditions Which Generate This Code:
response unless the signal for the primary engine
speed/timing sensor is lost. The loss of signals from The Electronic Control Module (ECM) detects the
both speed/timing sensors will shut down the engine. following conditions:

Possible Performance Effect: • The ECM reads signal voltage that is above 4.8
VDC for eight seconds.
The engine may misfire or the engine may run rough
during starting. • The ECM has been powered for at least two
seconds.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor Circuit - Test” The ECM will log the diagnostic code. The ECM will
set fuel temperature to a default value.
Results:
Possible Performance Effect:
• OK – STOP.
• Low power
i02120367 Troubleshooting:
CID 0342 FMI 11 Secondary Perform the following diagnostic procedure: “Engine
Engine Speed Sensor Temperature Sensor Open or Short Circuit - Test”

mechanical failure Results:

SMCS Code: 1439-038-VF; 1907-038 • OK – STOP.


Conditions Which Generate This Code:
i02024265
The signal for the secondary speed/timing sensor is
intermittent or lost. CID 1929 FMI 04 Fuel Return
Temperature Sensor voltage
System Response:
low/short to ground
The Electronic Control Module (ECM) will log the
diagnostic code. SMCS Code: 1439-038-TA; 1922-038

Possible Performance Effect: Conditions Which Generate This Code:

There should not be a noticeable change in engine The Electronic Control Module (ECM) detects the
response unless the signal for the primary sensor following conditions:
is also lost. The loss of both sensors will shut down
the engine.
58 RENR5093-01
Troubleshooting Section

• The ECM reads signal voltage that is below 0.2


VDC for eight seconds.

• The ECM has been powered for at least two


seconds.

System Response:

The ECM will log the diagnostic code. The ECM will
set fuel temperature to a default value.

Possible Performance Effect:

• Low power
Troubleshooting:

Perform the following diagnostic procedure: “Engine


Temperature Sensor Open or Short Circuit - Test”

Results:

• OK – STOP.
RENR5093-01 59
Troubleshooting Section

Troubleshooting with an
Event Code
i02353335

Event Codes
SMCS Code: 1901

Event codes alert the operator that an abnormal


engine operating condition such as low oil pressure
or high coolant temperature has been detected.
When the event code is generated, this indicates that
an event has taken place.

Active of Event Codes


An event code represents a problem with engine
operation. Correct the problem as soon as
possible.

Event codes are listed in ascending numerical order.


The code with the lowest number is listed first.

Illustration 8 is an example of the operating range of


a temperature sensor. Do not use the Illustration to
troubleshoot temperature sensors.

g01138880
Illustration 8
Example of the typical operating range of a temperature sensor
(1) This area represents the normal operating range of the
parameter. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC.
(2) In this area, the temperature above 107 °C (225 °F) is higher
than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.
(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
electronic problem will generate a diagnostic code. Refer to
Troubleshooting, “Troubleshooting with a Diagnostic Code” for
additional information on diagnostic codes.

Events are represented in two formats. In the first


format, the “E” means that the code is an event
code. The “XXX” represents a numeric identifier for
the event code. This is followed by a description of
the code. If a warning, a derate, or a shutdown is
applicable, the numeric identifiers are different. Refer
to the following example:

• E004 Engine Overspeed Shutdown


In the second format, the “E” means that the code is
an event code. The “XXX-X” represents a numeric
identifier for the event code. The fourth “X” identifies
the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the
following example:
60 RENR5093-01
Troubleshooting Section

• E360-1 Low Oil Pressure Warning Troubleshooting


• E360-2 Low Oil Pressure Derate For basic troubleshooting of the engine, perform the
following steps in order to diagnose a malfunction:
• E360-3 Low Oil Pressure Shutdown
1. Obtain the following information about the
The definition for a warning, a derate, and a shutdown complaint:
are defined below:
• The event and the time of the event
Warning – This condition represents a serious
problem with engine operation. However, this • Determine the conditions for the event. The
condition does not require a derate or a shutdown. conditions will include the engine rpm and the
load.
Derate – For this condition, the Electronic Control
Module (ECM) reduces the engine’s power in order • Determine if there are any systems that were
to help prevent possible engine damage. installed by the dealer or by the customer that
could cause the event.
Shutdown – For this condition, the ECM shuts down
the engine in order to help prevent possible engine • Determine whether any additional events
damage. occurred.

Logged Event Codes 2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
When the ECM generates an event code the ECM due to error of the operator.
logs the code in permanent memory. The ECM has
an internal diagnostic clock. The ECM will record 3. Narrow the probable cause. Consider the operator
the following information when an event code is information, the conditions of operation, and the
generated: history of the engine.

4. Perform a visual inspection. Inspect the following


• The hour of the first occurrence of the code items:
• The hour of the last occurrence of the code
• Fuel supply
• The number of occurrences of the code
• Oil level
Logged events are listed in chronological order. The
most recent event code is listed first. • Oil supply

This information can be helpful for troubleshooting • Wiring


intermittent problems. Logged codes can also be
used to review the performance of the engine. • Connectors
Be sure to check the connectors. This is very
Clearing Event Codes important for problems that are intermittent. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
A code is cleared from memory when one of the
following conditions occur: If these steps do not resolve the problem, identify
the procedures in this manual that best describe the
• The code does not recur for 100 hours. event. Check each probable cause according to the
tests that are recommended.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared. Trip Points for the Monitoring
System
• The service technician manually clears the code.
The monitoring system determines the level of action
Always clear logged event codes after investigating that is taken by the ECM in response to a condition
and correcting the problem which generated the that can damage the engine. When any of these
code. conditions occur, the appropriate event code will trip.
RENR5093-01 61
Troubleshooting Section

Table 11 contains the conditions that are monitored


and the default trip points for each condition. Each
condition has an associated parameter. The settings
for each parameter can be viewed with the Caterpillar
Electronic Technician (ET). The trip points for some
of the parameters may be adjustable with Cat ET.

Table 11
Trip Points for the Monitoring System
Time Delay in
Event Default Set Points
Parameter Action Seconds
Code Value
Range Default Range Default
55 kPa (8 psi)
92.5 kPa
High Altitude E009 Derate Off None 0 to
(13.4 psi)
98 kPa (14 psi)
Warning Off 4 to 60 30 None On
Low Coolant Level E059
Derate Off 4 to 60 30 None On
High Fuel Pressure E096 Warning On 1 to 30 2 Maps are not programmable. (1)

Low Fuel Pressure E198 Warning On 1 to 30 2 Maps are not programmable. (1)

17 °C (62 °F)
Low Coolant Temperature E199 Warning On 1 to 60 5 to 24 °C (75 °F)
29 °C (84 °F)
Warning On 30
Low Engine Oil Pressure E360 1 to 30 Maps are not programmable. (1)
Shutdown Off 2
90 °C (194 °F)
103 °C
Warning On None 5 to
(217 °F)
103 °C (217 °F)
90 °C (194 °F)
High Engine Coolant 105 °C
E361 Derate Off None 5 to
Temperature (221 °F)
107 °C (224 °F)
90 °C (194 °F)
106 °C
Shutdown On None 20 to
(222 °F)
107 °C (224 °F)
Warning None 0.6 None 2200
Engine Overspeed E362 On
Shutdown 0-5 0 1200-2400 2300
65 °C (149 °F)
High Fuel Temperature E363 Warning On 1 to 30 30 to 80 °C (176 °F)
85 °C (185 °F)
High Intake Manifold Air
E368 Warning On 1 to 30 4 None 75 °C (167 °F)
Temperature
(1) The maps may be different. The maps depend on the model of the engine.

i02424858 System Response:


E009 High Altitude Derate The ECM will log the diagnostic event.
SMCS Code: 1901-038 Possible Performance Effect:
Conditions Which Generate This Code: E009-2 (Derate)
The Electronic Control Module (ECM) detects • The engine will be derated.
atmospheric pressure that is too low. Information
on default settings and ranges for this event can
be found in troubleshooting with an event code
Troubleshooting, “Event Codes”.
62 RENR5093-01
Troubleshooting Section

Troubleshooting: Possible Performance Effect:

• The engine is being operated at an altitude that E057(2)


is too high.
• Engine power is derated.
• There may be a problem with the atmospheric
pressure sensor. Troubleshooting:

Check for Diagnostic Codes • The coolant level is most likely low.
A. Connect the Caterpillar Electronic Technician (ET) • Air may be trapped in the cooling system.
to the service tool connector.
• There may be a problem with the coolant level
B. Restore the electrical power to the ECM. sensor.

C. Check for any active diagnostic codes or logged Check the Coolant Level
diagnostic codes. Wait at least 30 seconds in
order for the codes to become active.

Expected Result: Pressurized System: Hot coolant can cause seri-


ous burns. To open the cooling system filler cap,
No diagnostic codes are present. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Results: pressure cap slowly in order to relieve the pres-
sure.
• OK – The engine is still derated. The engine is
being operated at an altitude that is too high. STOP.
A. Stop the engine.
• Not OK
B. After allowing the engine to cool, check the coolant
Repair: Repair the diagnostic codes that are level. Refer to the Operation and Maintenance
present. Refer to the appropriate topic in the Manual.
“Troubleshooting With a Diagnostic Code” section
of this manual. Expected Result:

Ensure that the repair eliminates the problem. The coolant level is low.

STOP. Results:

• OK – The coolant level is low.


i02515083

E057 Low Engine Coolant Repair: Check the cooling system for leaks. Repair
any problems that are found. Refill the cooling
Level Derate system to the proper level.

SMCS Code: 1395-038-LO STOP.

Conditions Which Generate This Code: • Not OK – The coolant level is not low.
The coolant level is below the coolant level sensor. Repair: There may be air in the cooling system.
Information on default settings and ranges for this For information on checking the cooling system,
event code can be found in Troubleshooting, “Event refer to the engine’s Systems Operation/Testing
Codes”. and Adjusting manual.

System Response: Ensure that any repairs eliminate the problem.

The Electronic Control Module (ECM) will log the STOP.


event.
• Not OK – The coolant level is not low.
RENR5093-01 63
Troubleshooting Section

Repair: There may be a problem with the coolant Note: If the coolant has been changed recently,
level sensor. Refer to the diagnostic functional test ensure that the air has been purged from the
Troubleshooting, “Coolant Level Sensor Circuit - cooling system. Refer to Systems Operation/Testing
Test”. and Adjusting, “Cooling System” for additional
information.
Ensure that any repairs eliminate the problem.
Expected Result:
STOP.
The coolant level is low.
i02450212
Results:
E059 Low Engine Coolant
• OK – The coolant level is low.
Level Warning
Repair: Check the cooling system for leaks. Repair
SMCS Code: 1395-038-LO any problems that are found. Refill the cooling
system to the proper level.
Conditions Which Generate This Code:
STOP.
The Electronic Control Module (ECM) detects a low
coolant level. Information on default settings and • Not OK – The coolant level is not low.
ranges for this event can be found in Troubleshooting,
“Event Codes”. Repair: There may be a problem with the coolant
level sensor. Refer to the diagnostic functional test
System Response: Troubleshooting, “Coolant Level Sensor Circuit -
Test” in order to verify that the coolant level sensor
The ECM will log the event. is operating correctly.

Possible Performance Effect: There may be an intermittent problem. Monitor the


operation of the engine and repair any problems.
• There are no performance effects.
Ensure that the repair eliminates the original
Troubleshooting: problem.

• The coolant level is most likely low. STOP.

• There may be a problem with the coolant level


sensor. i02495388

Check the Coolant Level


E096 High Fuel Pressure
SMCS Code: 1250-038-HQ

Conditions Which Generate This Code:


Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, The Electronic Control Module (ECM) detects a high
stop the engine and wait until the cooling system fuel pressure. Information on default settings and
components are cool. Loosen the cooling system ranges for this event can be found in Troubleshooting,
pressure cap slowly in order to relieve the pres- “Event Codes”.
sure.
System Response:
A. Stop the engine.
The ECM will log the event.
B. Allow the engine to cool. Check the coolant level.
Possible Performance Effect:
Refer to the Operation and Maintenance Manual
for the proper procedure.
E096(1)
Note: The coolant level sensor should be completely
immersed in coolant. • There are no performance effects.
64 RENR5093-01
Troubleshooting Section

Troubleshooting: Possible Performance Effect:

Check the Fuel System’s Components E198(1)

A. Inspect the pressure relief valve that is in the body • There are no performance effects.
of fuel transfer pump. Check for damage to the
spring or to the valve assembly. Check the Fuel System’s Components
B. Verify that the pressure regulating valve in the fuel A. Inspect the pressure relief valve that is in the body
manifold is operating correctly. Check for damage of fuel transfer pump. Check for damage to the
or for dirt in the valve assembly. spring or to the valve assembly.

C. Check the return line from the fuel filter base to B. Verify that the pressure regulating valve in the fuel
the fuel tank for damage or collapse. manifold is operating correctly. Check for damage
or for dirt in the valve assembly.
Expected Result:
C. Check the return line from the fuel filter base to
There is a problem in the pressure relief valve, in the the fuel tank for damage or collapse.
pressure regulating valve, or in the return line to the
fuel tank. Expected Result:

Results: There is a problem in the pressure relief valve, in the


pressure regulating valve, or in the return line to the
• OK – A problem was found in the pressure relief fuel tank.
valve, in the pressure regulating valve, or in the
return line to the fuel tank. Results:

Repair: Make the necessary repairs. Verify that • OK – A problem was found in the pressure relief
the repair eliminates the problem. valve, in the pressure regulating valve, or in the
return line to the fuel tank.
Refer to Systems Operation/Testing and Adjusting.
Repair: Make the necessary repairs. Verify that
STOP. the repair eliminates the problem.

• Not OK – A mechanical problem has not been Refer to Systems Operation/Testing and Adjusting.
found with the fuel system.
STOP.
Repair: If an electrical problem with the sensor
circuit is suspected, refer to the diagnostic • Not OK – A mechanical problem has not been
functional test Troubleshooting, “Engine Pressure found with the fuel system.
Sensor Open or Short Circuit - Test”.
Repair: If an electrical problem with the sensor
STOP. circuit is suspected, refer to the diagnostic
functional test Troubleshooting, “Engine Pressure
Sensor Open or Short Circuit - Test”.
i02495623

E198 Low Fuel Pressure STOP.

SMCS Code: 1250-038-LP i02353357

Conditions Which Generate This Code: E199 Low Coolant Temperature


The Electronic Control Module (ECM) detects a SMCS Code: 1350-038-TA
problem with the engine’s fuel pressure. Information
on default settings and ranges for this event code Conditions Which Generate This Code:
can be found in Troubleshooting, “Event Codes”.
The Electronic Control Module (ECM) detects a low
System Response: coolant temperature. Information on default settings
and ranges for this event code can be found in
The ECM will log the event. Troubleshooting, “Event Codes”.
RENR5093-01 65
Troubleshooting Section

System Response: Possible Performance Effect:

The event code will be logged. If an engine derate was active for a code that is no
longer present, the derate will be cancelled.
Possible Performance Effect:
Verify that the “Diagnostic Reset” Switch
E198-1(Warning) was Toggled
None A. Verify that the engine is not running.

Perform a Check of the Cooling System. B. Verify that the run/stop switch is in the STOP
position.
A. Check that the coolant temperature regulators are
functioning correctly. C. Verify that the “Diagnostic Reset” switch was
toggled.
B. If equipped, check the correct operation of the
jacket water heater. Expected Result:

Refer to the Systems Operation/Testing and Adjusting The “Diagnostic Reset” switch was toggled.
manual for information on testing the cooling system
for an overcooling condition. Results:

Expected Result: • OK – The “Diagnostic Reset” switch was toggled.


A problem with the cooling system has been Repair: The ECM cleared all diagnostic codes and
identified. event codes that were in a latched condition.

Results: STOP.

• OK – The problem has been identified. • Not OK – The “Diagnostic Reset” switch was not
toggled.
Repair: Repair the problem. Monitor the operation
of the engine after the repair has been completed. Repair: Refer to the diagnostic functional test
Ensure that the repair eliminates the problem. Troubleshooting, “Switch Circuits - Test” in order
to determine the reason that the diagnostic reset
STOP. input to the ECM is giving an incorrect signal.

STOP.
i02012810

E255 Diagnostic Reset i02342292

SMCS Code: 1901-038 E264 Emergency Stop


Conditions Which Generate This Code: Activated
The Electronic Control Module (ECM) detects the SMCS Code: 7418-038
following conditions:
Conditions Which Generate This Code:
• The run/stop switch is in the STOP position. The Electronic Control Module (ECM) detects an
open circuit on the emergency stop input to the ECM.
• The engine is not running.
System Response:
• The conditions which caused the diagnostic code
or the event code to occur are no longer present.
The ECM disables the injection signals to the injector
solenoids.
• The ECM detects a short circuit to ground on the
diagnostic reset input to the ECM.
Possible Performance Effect:
System Response:
The engine will shut down.
The ECM will clear all diagnostic codes and event
codes that are in a latched condition without shutting
off power to the ECM.
66 RENR5093-01
Troubleshooting Section

Verify the Cause of the Emergency Stop Troubleshooting:


Shutdown
There may be a problem with the engine’s lubrication
A. Talk to the operator and determine the reason for system.
the emergency stop shutdown.
Check the Engine’s Lubrication System
B. Verify that the condition for the emergency stop
shutdown has been resolved. A. Check the engine oil level. If the oil level is below
the oil pump’s supply tube, the oil pump will not
Expected Result: have the ability to supply enough lubrication to
the engine components. If the engine oil level is
The reason for the emergency stop shutdown has low, add engine oil in order to obtain the correct
been determined. The reason for the emergency stop engine oil level.
shutdown has been resolved.
B. Check the following problems that may occur to
Results: the engine oil pump:

• OK – The reason for the emergency stop a. Air leakage in the supply side of the oil pump
shutdown has been determined. The reason for will also cause cavitation and loss of oil
the emergency stop shutdown has been resolved. pressure. Check the supply side of the oil pump
and make necessary repairs.
Repair: The emergency stop condition can be
reset by performing the following steps: b. Oil pump gears that have too much wear will
cause a reduction in oil pressure. Repair the
1. Reset the emergency stop switch to the OFF engine oil pump.
position.
c. If the engine is equipped with a scavenge
2. Cycle power to the ECM. If a “Diagnostic Reset” pump, the scavenge pump may not be
switch is installed, toggle the “Diagnostic Reset” supplying oil to the main engine oil pump.
switch in order to clear the emergency stop
condition without shutting off power to the ECM. C. The inlet screen of the oil suction tube for the
engine oil pump can have a restriction. This
STOP. restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on
the oil pickup tube and remove any material that
i02486798
may be restricting engine oil flow. Low engine oil
E360 Low Engine Oil Pressure pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the
SMCS Code: 1348-038-LP oil pickup tube for cracks or a damaged O-ring
seal.
Conditions Which Generate This Code:
D. If the engine oil bypass valves are held in the open
The Electronic Control Module (ECM) detects a position, a reduction in the oil pressure can be the
problem with the engine’s oil pressure. Information result. This may be due to debris in the engine
on default settings and ranges for this event can be oil. If the engine oil bypass valves are stuck in
found in Troubleshooting, “Event Codes”. the open position, remove each engine oil bypass
valve and clean each bypass valve in order to
System Response: correct this problem. You must also clean each
bypass valve bore.
The event code will be logged.
E. Engine oil that is contaminated with fuel or coolant
Possible Performance Effect: will cause low engine oil pressure. High engine
oil level in the crankcase can be an indication of
E360(1) contamination.

F. Excessive clearance at engine bearings will


• There are no performance effects. cause low engine oil pressure. Check the engine
E360(3) components for excessive bearing clearance.

G. An oil line that is open, broken, or disconnected


• The engine will be shut down. will cause low engine oil pressure.
RENR5093-01 67
Troubleshooting Section

Expected Result: b. Check internally for debris, dirt, or deposits on


the radiator core. Debris, dirt, or deposits will
An inspection of the engine’s lubrication system restrict the flow of coolant through the radiator.
indicated a problem. Check the filler cap. The inability of the cooling
system to sustain a constant pressure in the
Results: radiator will cause the boiling point of the
coolant to be lower. This will cause cavitation.
• OK – There is a problem in the engine’s lubrication
system. C. Check the mixture of antifreeze and water. Make
sure that the recommendations in the Operation
Repair: Repair the problem. Ensure that the repair and Maintenance Manual are followed.
eliminates the problem.
D. Check the water temperature regulators. A water
STOP. temperature regulator that does not open, or a
water temperature regulator that partially opens
will cause overheating.
i02350352

E361 High Engine Coolant E. Check the water pump. A water pump with a
damaged impeller does not pump enough coolant.
Temperature Remove the water pump and check for damage
to the impeller.
SMCS Code: 1395-038-TA
F. If the cooling system for this application is
Conditions Which Generate This Code: equipped with a fan, check the operation of
the fan. A fan that is not turning at the correct
The Electronic Control Module (ECM) detects a speed can cause improper air speed across the
problem with the engine’s coolant temperature. radiator core. The lack of proper air flow across
Information on default settings and ranges for this the radiator core can cause the coolant not to cool
event code can be found in Troubleshooting, “Event to the proper temperature differential. A loose fan
Codes”. drive belt could limit the operation of the fan.

System Response: G. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
The event code will be logged. common causes of air in the cooling system are
the incorrect filling of the cooling system and
Possible Performance Effect: combustion gas leakage into the cooling system.
Combustion gas can get into the system through
361-1 internal cracks, a damaged cylinder head, or a
leaking cylinder head gasket.
None
H. Check the cooling system hoses and clamps.
Troubleshooting: Damaged hoses with leaks can normally be seen.
Also, hoses can soften during operation. The soft
There may be a problem with the engine’s cooling areas of the hose can become kinked or crushed
system. during operation. These areas of the hose may
collapse during engine operation. This will restrict
Check the Engine’s Cooling System the flow of coolant. Hoses become soft and/or get
cracks after a period of time. The inside of a hose
A. Verify that the cooling system is filled to the proper can also deteriorate, and the loose particles of
level. If the coolant level is too low, air will get into the hose can become a restriction in the cooling
the cooling system. Air in the cooling system will system.
cause a reduction in coolant flow.
I. If the cooling system for this application is
B. Check the radiator or the heat exchanger for an equipped with an expansion tank, check the shunt
obstruction. line for the expansion tank. The shunt line must be
submerged in the expansion tank. A restriction of
a. Check for debris or damage between the fins the shunt line from the expansion tank to the inlet
of the radiator core. Debris between the fins of of the jacket water pump will cause a reduction in
the radiator core restricts air flow through the water pump efficiency. A reduction in water pump
radiator core. efficiency will result in low coolant flow.
68 RENR5093-01
Troubleshooting Section

J. If the cooling system for this application i02486716


is equipped with an aftercooler, check the
aftercooler. A restriction of air flow through the E362 Engine Overspeed
aftercooler can cause overheating. Check for
debris or deposits which would prevent the free SMCS Code: 7410-038; 7427-038
flow of air through the aftercooler.
Conditions Which Generate This Code:
K. Check for a restriction in the air inlet system. A
restriction of the air that is coming into the engine The Electronic Control Module (ECM) detects
can cause high cylinder temperatures. High an overspeed condition. Information on default
cylinder temperatures cause higher than normal settings and ranges for this event can be found in
temperatures in the cooling system. Troubleshooting, “Event Codes”.

L. Check for a restriction in the exhaust system. System Response:


A restriction of the air that is coming out of the
engine can cause high cylinder temperatures. The event code will be logged.

M. Consider high ambient temperatures. When Possible Performance Effect:


ambient temperatures are too high for the rating
of the cooling system, there is not enough of a E362(1)
temperature difference between the ambient air
and coolant temperatures. • There are no performance effects.
N. Consider high altitude operation. The cooling E362(3)
capability of the cooling system is reduced at
higher altitudes. A pressurized cooling system that • The engine will be shut down.
is large enough to prevent the coolant from boiling
must be used. Troubleshooting:

O. The engine may be continuously operating in The operator may be operating the engine incorrectly.
the lug condition. When an excessive load is
applied to the engine, the engine will run in the lug Talk to the Operator
condition. When the engine is operating in the lug
condition, engine rpm does not increase with an Determine the events that caused the overspeed.
increase of fuel. This lower engine rpm causes a
reduction in coolant flow through the system while Results:
the increased fuel increases the amount of heat
that is generated by the engine. • OK – STOP.

Expected Result: i02778974

A thorough inspection of the cooling system revealed E363 High Fuel Supply
a problem.
Temperature
Results:
SMCS Code: 1250-038-TA
• OK – There is a problem with the cooling system. Conditions Which Generate This Code:
Repair: Repair the problem. Ensure that the repair
eliminates the problem. The Electronic Control Module (ECM) detects a
high temperature for the fuel supply. Information
STOP. on default settings and ranges for this event code
can be found in troubleshooting with an event code
Troubleshooting, “Event Codes”.

System Response:

The ECM logs the event code.


RENR5093-01 69
Troubleshooting Section

Possible Performance Effect: a. Check the condition of the lines for the fuel
return from the engine to the tank. Check for
E363(1) lines that are collapsed or kinked. Check for
deterioration and swelling of the fuel lines.
• Low power
b. Verify that the pressure regulating valve in the
Troubleshooting: fuel filter base is operating correctly. Check for
damage or for dirt in the valve assembly.
A high fuel supply temperature can cause scuffing of
the plunger inside the barrel of the injectors. This can Expected Result:
lead to damaged injectors or failed injectors.
There is a problem in the pressure regulating valve,
If an E363 is logged repeatedly over a period of time, or in the return line to the fuel tank.
use the histogram data from Caterpillar Electronic
Technician (ET) to determine the operating conditions Results:
during the logged codes. Check the engine speed,
load, and coolant temperature during the events. • OK – A problem was found in the pressure
This will help determine if the high fuel temperature regulating valve or in the return line to the fuel tank.
is due to operation of the engine.
Repair: Make the necessary repairs. Verify that
Extreme ambient air temperature can contribute to the repair eliminates the problem.
heating the fuel that is inside the fuel tank. Determine
the ambient temperature during the event. This can Refer to Systems Operation/Testing and Adjusting
be compounded by a low fuel level in the tank. As for information that is related to testing the fuel
unused fuel passes through the cylinder head, heat system.
is collected by the fuel in order to cool the injectors.
The unused fuel is returned to the tank. If the volume STOP.
of fuel in the fuel tank is low, less fuel is available to
absorb the heat from the return fuel. • Not OK – A mechanical problem has not been
found with the fuel system.
A restriction to the flow of fuel in the fuel return to the
fuel tank may also cause a high fuel temperature. Repair: If an electrical problem with the
temperature sensor circuit is suspected, refer to
Test Step 1. Check the Operating Troubleshooting, “Engine Pressure Sensor Open or
Conditions of the Engine Short Circuit - Test” for the correct troubleshooting
procedure.
A. Connect Cat ET to the service tool connector.
STOP.
B. Turn the keyswitch to the ON position.
i02399447
C. View the histogram data from Cat ET for the times
during the occurrences of the events. E368 High Intake Manifold Air
Use the histogram data to determine if the Temperature
operating conditions of the engine contributed to
the high fuel temperature. SMCS Code: 1087-038

Expected Result: Conditions Which Generate This Code:

The histogram data did not indicate that an operating The Electronic Control Module (ECM) detects
condition contributed to the high fuel temperature. a problem with the engine’s intake manifold air
temperature. Information on default settings and
Continue to the next test step. ranges for this event can be found in Troubleshooting,
“Event Codes”.
Test Step 2. Check the Fuel System’s
Components System Response:

A. Check for a restriction to the flow of return fuel to The event code will be logged.
the fuel tank.
Possible Performance Effect:

E368-1
70 RENR5093-01
Troubleshooting Section

None i. Check the water temperature regulator. A water


temperature regulator that does not open, or a
Troubleshooting: water temperature regulator that only opens
part of the way can cause overheating.
Perform the following Inspections
j. If the cooling system is equipped with an
A. Check for Cooling System Problems expansion tank, check the shunt line for
the expansion tank. The shunt line must
a. Verify that the cooling system is filled to the remain submerged in the coolant for proper
proper level. If the coolant level is too low, operation. A restriction of the shunt line from
air will get into the cooling system. Air in the the expansion tank to the inlet of the jacket
cooling system may cause cavitation. This will water pump will cause a reduction in water
cause a reduction in coolant flow which can pump efficiency. A reduction in water pump
damage a cooling system. efficiency will result in low coolant flow.

b. Check the quality of the coolant. Ensure that k. If the cooling system is equipped with an
the coolant meets specifications for the engine. aftercooler, check the aftercooler. A restriction
of air flow through the air to air aftercooler can
c. If equipped, check for adequate coolant cause overheating of the engine. Check for
flow through the radiator. Check the inlet debris or deposits which would prevent the free
temperature of the coolant at the radiator flow of air through the aftercooler.
inlet. Compare the reading to the regulated
temperature. If the temperature is OK, check l. The engine may be running excessively in the
the outlet temperature of the coolant at the lug condition. When the load that is applied to
radiator outlet. A high temperature differential the engine is too large, the engine will run in
indicates an insufficient flow rate. the lug condition. When the engine is running in
the lug condition, engine rpm does not increase
d. Check for air in the cooling system. Air can with an increase of fuel. This lower engine rpm
enter the cooling system in different ways. causes a reduction in coolant flow through the
The most common causes of air in the cooling system. The lug condition causes excess heat
system are the incorrect filling of the cooling from the increase in fuel consumption.
system and combustion gas leakage into
the cooling system. Combustion gas can get B. Check for High Ambient Air Temperature
into the system through a cracked cylinder
liner, damaged cylinder liner seals, a cracked a. Determine if the ambient air temperature
cylinder head, or a damaged cylinder head is within the design specifications for the
gasket. cooling system. When ambient temperatures
are too high for the rating of the cooling
e. Check the cooling system hoses and clamps. system, there is not enough of a temperature
Damaged hoses with leaks can normally be difference between the ambient air and coolant
seen. Hoses that have no visual leaks can temperatures.
soften during operation. The soft areas of the
hose can become kinked during operation. b. Determine the cause of the high air
These areas can also collapse during temperature. Correct the situation, when
operation. These areas of the hose can restrict possible.
the coolant flow. Hoses become soft and/or get
cracks after a period of time. The inside of a C. Check for High Inlet Air Restriction and/or
hose can deteriorate, and the loose particles of High Altitude Operation
the hose can restrict the coolant flow.
a. When inlet air pressure is low, the turbocharger
f. If a sea water strainer is used in the application, works harder in order to achieve the desired
verify that the sea water strainer is not plugged. inlet manifold pressure. This increases inlet air
temperature.
g. Check the heat exchanger for a restriction to
the flow of water. b. Measure the inlet air pressure while the engine
is operating under load. For specific data, refer
h. Check the water pump. A water pump with to the Technical Marketing Information for the
a damaged impeller does not pump enough engine.
coolant. Remove the water pump and check for
damage to the impeller.
RENR5093-01 71
Troubleshooting Section

c. Check for plugged air filters. Check for


obstructions to the air inlet. A restriction of
the air that enters the engine can cause
high cylinder temperatures. High cylinder
temperatures cause higher than normal
temperatures in the cooling system.

d. Replace the air filters and/or remove the


obstruction from the air inlet.

e. Consider high altitude operation. The cooling


capability of the cooling system is reduced
at higher altitudes. A pressurized cooling
system that has been designed for the higher
altitudes must be used. Ensure that the engine
is configured for high altitude operation.

D. Check for Exhaust System Restriction

Check for a restriction in the exhaust system.


A restriction of the air that is coming out of the
engine can cause high cylinder temperatures.

Expected Result:

A problem has been found in the cooling system


and/or the related engine systems.

Results:

• OK – A thorough inspection revealed a problem.


Repair: Repair the problem. Ensure that the repair
eliminates the problem.

STOP.
72 RENR5093-01
Troubleshooting Section

Diagnostic Functional
Tests
i02778788

5 Volt Engine Pressure Sensor


Supply Circuit - Test
SMCS Code: 1439-038

System Operation Description:

The Electronic Control Module (ECM) creates a


regulated voltage of 5.0 ± 0.2 VDC that is supplied
to terminal A of the harness connectors for these
sensors:

• Turbocharger outlet pressure sensor


• Atmospheric pressure sensor
• Fuel pressure sensor
• Engine oil pressure sensor
This procedure covers the following diagnostic codes:

• 262-03 5 Volt Sensor DC Power Supply short to


+batt

• 262-04 5 Volt Sensor DC Power Supply short to


ground

A +5 V diagnostic code is probably caused by a


short circuit to ground or a short circuit to another
voltage source in the harness. The next likely cause
is a problem with a sensor. The least likely cause is
a problem with the ECM.
RENR5093-01 73
Troubleshooting Section

g01174890
Illustration 9
Schematic for pressure sensor supply

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

g01174896
Illustration 10
Left side engine view (typical example)
(1) Fuel pressure sensor
(2) Turbocharger outlet pressure sensor
(3) Atmospheric pressure sensor
(4) Engine oil pressure sensor
(5) J2/P2 ECM connector

B. Thoroughly inspect ECM connector (5). Also,


thoroughly inspect the connectors for each
pressure sensor. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.
74 RENR5093-01
Troubleshooting Section

g01159881
Illustration 12
Sensor connector
(A) +5 V supply
(B) Sensor return
(C) Signal

C. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connectors that are associated
with the circuit.

D. Check the allen head screw for 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


for pinch points from the pressure sensors back
to the ECM.

g01174894
Expected Result:
Illustration 11
P2 ECM connector All connectors, pins and sockets are completely
(P2-2) +5 V sensor supply coupled and/or inserted and the harness and wiring
(P2-3) Sensor return are free of corrosion, of abrasion and of pinch points.
(P2-14) Atmospheric pressure
(P2-16) Fuel pressure
(P2-24) Engine oil pressure Results:
(P2-40) Turbocharger outlet pressure
• 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.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.
RENR5093-01 75
Troubleshooting Section

Test Step 2. Check for Active Diagnostic Note: Be sure to wiggle the harness during the
Codes following measurements in order to reveal an
intermittent condition.
A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to D. Measure the voltage between terminals A and B
Troubleshooting, “Electronic Service Tools”. at each sensor connector on the engine harness.

B. Turn the keyswitch to the ON position. E. Turn the keyswitch to the OFF position.

C. Observe the “Active Diagnostic” screen on Cat ET. F. Connect all of the sensors.
Wait at least 15 seconds so that any codes may
become active. Look for these codes: Expected Result:

• 262-03 Each voltage measurement is 5.0 ± 0.2 VDC.

• 262-04 Results:

D. Determine if the problem is related to a -03 • OK – Each voltage measurement is 5.0 ± 0.2 VDC.
diagnostic code or to a -04 diagnostic code.
Repair: Replace all wires to the original
Expected Result: configuration. Clear all diagnostic codes. Check
for active diagnostic codes. If the problem is
No diagnostic codes are active. intermittent, refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
Results:
STOP.
• OK – No diagnostic codes are active.
• Not OK – At least one voltage measurement is not
Repair: If any of the above codes are logged 5.0 ± 0.2 VDC. There is a problem with the wiring
and the engine is not running properly, refer to harness or a connector. There may be a problem
Troubleshooting, “Troubleshooting Without a with the ECM. Proceed to Test Step 5.
Diagnostic Code”.
Test Step 4. Disconnect the +5 V Pressure
If the engine is running properly at this time, there Sensors and Check for Active Diagnostic
may be an intermittent problem in a harness Codes
that is causing the codes to be logged. Refer to
Troubleshooting, “Electrical Connectors - Inspect”. A. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes.
STOP.
Note: Wait at least 15 seconds in order for the
• Active -03 code – A -03 diagnostic code is active. diagnostic codes to become active.
Proceed to Test Step 3.
B. Disconnect the following sensors one at a time
• Active -04 code – A -04 diagnostic code is active. at the sensor connector:
Proceed to Test Step 4.
• Turbocharger outlet pressure sensor
Test Step 3. Check the Supply Voltage at
the Sensor Connector • Engine oil pressure sensor
A. Turn the keyswitch to the OFF position. • Fuel pressure sensor
B. Disconnect the harness connectors for the • Atmospheric pressure sensor
following sensors:
Expected Result:
• Turbocharger outlet pressure sensor
The 262-04 diagnostic code deactivates when a
• Engine oil pressure sensor particular sensor is disconnected.

• Fuel pressure sensor Results:

• Atmospheric pressure sensor • OK – The 262-04 diagnostic code deactivates


when a particular sensor is disconnected.
C. Turn the keyswitch to the ON position.
76 RENR5093-01
Troubleshooting Section

Repair: Connect the suspect sensor. If the code B. Install the wire jumper between P2-2 (+5 V supply)
returns, replace the sensor. and P2-3 (sensor return).

Connect all of the connectors. Verify that the Note: Wiggle the harness during the following
problem is resolved. measurements in order to reveal any intermittent
short condition.
STOP.
C. Measure the resistance between terminals A and
• Not OK – The 262-04 diagnostic code remains B at the harness connector for each pressure
after all of the sensors are disconnected. Leave sensor.
the sensors disconnected. Proceed to Test Step 5.
D. Remove the wire jumper.
Test Step 5. Check the +5 V Supply Wire
for a Short in the Wiring Harness Expected Result:

A. Turn the keyswitch to the OFF position. The resistance is less than five Ohms for each
measurement.
B. Disconnect the J2/P2 ECM connectors.
Results:
C. Verify that all of the pressure sensors are
disconnected. • OK – Each measurement is less than five Ohms.
Proceed to Test Step 7.
Note: Wiggle the harness during the following
measurements in order to reveal any intermittent • Not OK – At least one resistance measurement is
short condition. greater than five Ohms. The +5 V supply wire or
the return wire has excessive resistance. There
D. Measure the resistance between terminal P2-2 may be a problem in a connector.
(+5 V supply) and all of the other terminals on the
P2 ECM connectors. Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify
E. Measure the resistance between terminal P2-2 that the problem is resolved.
and the engine ground.
STOP.
Expected Result:
Test Step 7. Check the +5 V Supply at the
Each resistance measurement indicates an open ECM
circuit.
A. Remove terminal P2-2 (+5 V supply) from the
Results: P2 connector. Install a wire jumper with socket
terminals on both ends into the P2-2 location.
• OK – Each resistance measurement indicates an
open circuit. Proceed to Test Step 6. B. Connect the J2/P2 ECM connectors.

• Not OK – At least one of the resistance C. Turn the keyswitch to the ON position.
measurements does not indicate an open circuit.
D. Measure the voltage between the wire jumper in
Repair: A +5 V supply wire has a problem. There P2-2 and the engine ground.
may be a problem with a connector. Repair the
wire and/or the connector, when possible. Replace E. Turn the keyswitch to the OFF position.
parts, if necessary. Verify that the problem is
resolved. F. Restore both wires to the original configuration.

STOP. Expected Result:

Test Step 6. Check the +5 V Supply and Both voltage measurements are 5.0 ± 0.2 VDC.
the Sensor Return for an Open Circuit
Results:
A. Fabricate a jumper wire that can be used to
jumper two terminals at the ECM connector. Crimp • OK – Both voltage measurements are 5.0 ± 0.2
pins to each end of the jumper wire. VDC.
RENR5093-01 77
Troubleshooting Section

Repair: Clear all diagnostic codes. Check for active


diagnostic codes. If the problem is intermittent,
refer to Troubleshooting, “Electrical Connectors -
Inspect”.

STOP.

• Not OK – At least one voltage measurement is not


5.0 ± 0.2 VDC.

Repair: Replace the ECM. Refer to


Troubleshooting, “Replacing the ECM”.

STOP.

i02353334

CAN Data Link Circuit - Test


SMCS Code: 1901-038

System Operation Description:

The CAN data link is used to communicate


information between the Electronic Control Module
(ECM) and other modules. Use this procedure to
troubleshoot any suspect problems with the CAN
data link.

This procedure covers the 247-09 J1939 Data Link


communications.

This procedure identifies the following problems:

• Faulty connectors
• Missing termination resistors
• Short circuits
• Open circuits
• Faulty J1939 display
78 RENR5093-01
Troubleshooting Section

g01175308
Illustration 13
Schematic for the CAN data link

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

g01149983
Illustration 15
Engine view (typical example)
(2) J61 customer connector
(3) J63 service tool connector
g01146374
Illustration 14
Engine view (typical example) B. Thoroughly inspect connectors (1), (2), and (3).
(1) J1/P1 ECM conntctors
Thoroughly inspect the connectors for each
module that is connected to the CAN data link.
Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
RENR5093-01 79
Troubleshooting Section

g01123351
Illustration 17
J61/P61 terminals that are associated with the CAN data link
(16) CAN shield
(17) CAN data link +
(18) CAN data link −

g01102141 C. Perform a 45 N (10 lb) pull test on each of the


Illustration 16
wires that are associated with the CAN data link.
P1 terminals that are associated with the CAN data link
(P1-34) CAN data link − D. Check the allen head screw on each ECM
(P1-42) CAN shield connector for the proper torque. Also, check the
(P1-50) CAN data link +
allen head screw on the customer connector
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct
torque values.

E. Check the wiring harnesses for abrasion, for


corrosion and for pinch points.

Expected Result:

All connectors, pins and sockets are completely


coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion and of pinch points.

Results:

• OK – The harness and the wiring appear to be


OK. Proceed to Test Step 2.

• Not OK – There is a problem in the wiring harness.


80 RENR5093-01
Troubleshooting Section

Repair: Repair the connectors and/or the wiring. Repair: Verify that two terminating resistors exist
Replace parts, if necessary. Ensure that all of the on the data link. One resistor must be located on
seals are properly in place and ensure that the each end of the data link. The engine is shipped
connectors are completely coupled. Verify that the with one terminating resistor that is installed
problem is resolved. between the ECM and the customer connector.

STOP. Refer to the appropriate electrical schematic in


order to determine the missing resistor. Replace
Test Step 2. Check for Active Diagnostic the missing resistor. Verify that the problem is
Codes resolved.

A. Connect the Caterpillar Electronic Technician STOP.


(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”. • Not OK – The resistance is less than 57 Ohms.
Proceed to Test Step 4.
B. Turn the keyswitch to the ON position.
• Not OK – The resistance is greater than 126
C. Observe the active diagnostic code screen on Ohms. Proceed to Test Step 5.
Cat ET. Wait at least 15 seconds so that any
diagnostic codes may become active. Check for a Test Step 4. Check for a Short Circuit
247-09 diagnostic code.
A. Disconnect the J1/P1 ECM connector.
Expected Result:
B. Remove the terminating resistors from the CAN
No diagnostic codes are active. data link.

Results: C. If a J1939 display is installed, disconnect the


display.
• OK – No codes are active.
D. Measure the resistance between the points that
Repair: The problem may be intermittent. If the are listed in Table 12. Be sure to wiggle the wires
problem is intermittent, refer to Troubleshooting, in the harnesses as you make each resistance
“Electrical Connectors - Inspect”. measurement.

STOP. Table 12
Resistance Measurements for the CAN Data Link
• Not OK – A 247-09 diagnostic code is active.
Proceed to Test Step 3. Connector and Terminal
Terminal
Test Step 3. Verify the Proper Installation P1-50 (CAN data link +) All of the other terminals on
of the CAN Data Link the P1 connector
Engine ground
A. Disconnect the J1939 display.
P1-34 (CAN data link -) All of the other terminals on
B. Disconnect the P1 connector and measure the the P1 connector
resistance between terminals P1-50 (CAN data Engine ground
link +) and P1-34 (CAN data link -).

Expected Result: Expected Result:

The resistance is between 57 and 63 Ohms. Each check of the resistance indicates an open
circuit.
Results:
Results:
• OK – The resistance is between 57 and 63 Ohms.
Proceed to Test Step 6. • OK – Each check of the resistance indicates an
open circuit. Proceed to Test Step 5.
• Not OK – The resistance is between 114 Ohms
and 126 Ohms. A terminating resistor is missing.
RENR5093-01 81
Troubleshooting Section

• Not OK – At least one check of the resistance If the display does not operate correctly on the
does not indicate an open circuit. There is a short original engine, there may be a problem with the
circuit in a harness. There may be a problem with ECM.
a connector.
It is unlikely that the ECM has failed. Perform
Repair: Repair the wiring and/or the connector. this entire procedure again. Replace the ECM if
Replace part, if necessary. Verify that the problem the display does not operate correctly. Refer to
is resolved. Troubleshooting, “Replacing the ECM”.

STOP. STOP.

Test Step 5. Check for an Open Circuit • Not OK – The J1939 display does not operate
properly on another engine.
A. Verify that all of the connections are disconnected.
Repair: Replace the J1939 display. Verify that the
B. Fabricate a jumper wire. Use the jumper wire in problem is resolved.
order to create a short circuit between terminals G
and F on the service tool connector. STOP.

C. Measure the resistance between terminals P1-50


i02351698
(CAN data link +) and P1-34 (CAN data link -).

D. Remove the jumper wire from the service tool


Cat Data Link Circuit - Test
connector. SMCS Code: 1901-038
Expected Result: System Operation Description:
The resistance is less than ten Ohms. Note: This procedure checks for an open circuit
or for a short circuit in the Cat Data Link. If you
Results: are experiencing problems with communications
between the Caterpillar Electronic Technician (ET)
• OK – The resistance is less than ten Ohms. There and the Electronic Control Module (ECM), refer
is not an open circuit. Proceed to Test Step 6. to Troubleshooting, “Electronic Service Tool Will
Not Communicate with ECM” before you use this
• Not OK – The resistance is more than ten Ohms. procedure.
There is an open circuit or excessive resistance in
the circuit. There may be a problem in a connector. The Cat Data Link is the standard data link that
is used by the ECM to communicate with Cat ET.
Repair: Repair the wiring and/or the connector. The ECM communicates with Cat ET in order to
Replace part, if necessary. Verify that the problem share status information and diagnostic information.
is resolved. Cat ET can also be used to configure the ECM
parameters. This information will not be available if
STOP. communication fails between the ECM and Cat ET.
Test Step 6. Check the J1939 Display
A. Connect the J1939 display to another engine.

B. Operate the engine and monitor the J1939 display.

Expected Result:

The J1939 display operates properly.

Results:

• OK – The J1939 display operates properly on


another engine.
g01167527
Illustration 18
Repair: Connect the display to the original engine. Schematic for the Cat Data Link
If the display operates correctly, there may be
a problem with an electrical connector. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
82 RENR5093-01
Troubleshooting Section

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

g01146374
Illustration 19
Engine view (typical example)
(1) J1/P1 ECM connectors

g01104274
Illustration 21
P1 terminals that are associated with the Cat Data Link
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −

g01149983
Illustration 20
Engine view (typical example)
(2) P61 customer connector
(3) P63 service tool connector

B. Thoroughly inspect connectors (1), (2), and (3).


Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
RENR5093-01 83
Troubleshooting Section

Repair: Repair the connectors and/or the wiring.


Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
original problem is resolved.

STOP.

Test Step 2. Check for a Short Circuit


A. Disconnect the J1 connector.

B. Disconnect Cat ET from the service tool connector.

C. Measure the resistance between the points that


are listed in Table 13. Be sure to wiggle the wires
in the harnesses as you make each resistance
measurement.

Table 13
Resistance Measurements for the Cat Data Link
Connector and Terminal
Terminal
P1-8 (Cat Data Link +) All of the other terminals on
the P1 connector
Ground stud
g01119122
Illustration 22 P1-9 (Cat Data Link -) All of the other terminals on
J61 and P61 terminals that are associated with the Cat Data Link the P1 connector
(6) Cat Data Link − Ground stud
(7) Cat Data Link +

C. Perform a 45 N (10 lb) pull test on each of the Expected Result:


wires that are associated with the Cat Data Link.
Each check of the resistance indicates an open
D. Check the allen head screw on each ECM circuit.
connector for the proper torque. Also, check the
allen head screw on the customer connector Results:
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct • OK – Each check of the resistance indicates an
torque values. open circuit. Proceed to Test Step 3.

Expected Result: • Not OK – At least one check of the resistance


does not indicate an open circuit. There is a short
All connectors, pins, and sockets are completely circuit in the harness or in a connector.
inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points. Repair: Repair the connectors and/or the wiring.
Replace parts, if necessary. Verify that the original
Results: problem is resolved.

• OK – The harness and the connectors appear to STOP.


be OK. Proceed to Test Step 2.
Test Step 3. Check for an Open Circuit
• Not OK – The connectors and/or the wiring are
not OK. A. Fabricate a jumper wire. Use the jumper wire in
order to create a short circuit between terminals
J63-D (Cat Data Link +) and J63-E (Cat Data Link
−).

B. Measure the resistance between P1-8 (Cat Data


Link +) and P1-9 (Cat Data Link −).
84 RENR5093-01
Troubleshooting Section

Expected Result:

Each check of the resistance is less than ten Ohms.

Results:

• OK – Each check of the resistance is less than


ten Ohms.

Repair: Perform the following procedure:

1. Connect the J1/P1 connectors. Connect Cat ET


to the service tool connector.

2. Check the Cat Data Link for proper operation. g01150024


If the data link does not operate correctly, there Illustration 23
may be a problem with the ECM. Coolant level sensor
(1) Sensor
Temporarily install a new ECM. Check the Cat (2) Sensor probe (brass dowel)
Data Link again. If the new ECM solves the (3) Plastic cover
problem, install the original ECM and verify that
the original problem returns. If the new ECM Coolant level sensor (1) contains no moving
operates correctly and the original ECM does parts. The sensor provides the same function as
not operate correctly, replace the original ECM. a switch. The state of the switch is dependent on
Verify that the problem is resolved. the capacitance value that is detected. The sensor
contains a probe (2) that is covered with plastic (3).
STOP.
When the probe is immersed in coolant, the sensor
• Not OK – At least one check of the resistance is senses a particular capacitance. The sensor’s
greater than ten Ohms. There is an open circuit or electronics react by sinking the signal to the digital
excessive resistance in the harness. There may be return (ground).
a problem with a connector.
When the probe is not immersed in coolant, the
Repair: Repair the wiring and/or the connectors. capacitance value changes. The change in the
Replace parts, if necessary. Verify that the original capacitance value is detected by the sensor’s
problem is resolved. electronic circuits. The sensor sources approximately
+5 VDC to the signal wire. The Electronic Control
STOP. Module (ECM) detects the voltage and the ECM
activates a E059 event code.

i02412605 A E059 event code is probably caused by a low


coolant level. The next likely cause is a problem with
Coolant Level Sensor Circuit a wiring harness or with the sensor. The least likely
- Test cause is a problem with the ECM.

SMCS Code: 1439-038-CLT Note: If the coolant has been changed recently,
ensure that the air has been purged from the
System Operation Description: cooling system. Refer to Systems Operation/Testing
and Adjusting, “Cooling System” for additional
Use this procedure to troubleshoot any suspect information.
problems with the coolant level sensor.

The coolant level sensor monitors the engine coolant


level in order to warn the operator in the event that
the coolant level is low. The coolant level sensor is
located on the side of the expansion tank.
RENR5093-01 85
Troubleshooting Section

g01150032
Illustration 24
Typical location of the coolant level sensor
(4) Coolant level sensor

g01094777
Illustration 25
Schematic for coolant level sensor

Pressurized System: Hot coolant can cause seri-


ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Remove the electrical power from the ECM.

g01150055
Illustration 26
Engine view
(5) J2/P2 connectors
86 RENR5093-01
Troubleshooting Section

B. Thoroughly inspect connectors (5). Inspect Results:


the connectors for sensor (4). Refer to
Troubleshooting, “Electrical Connectors - Inspect” • OK – The connectors and wiring are OK. Proceed
for details. to Test Step 2.

• Not OK – There is a problem with the connectors


and/or the wiring.

Repair: Repair the wiring and connectors or


replace the wiring or the connectors. Ensure that
all of the seals are properly connected. Verify that
the repair eliminates the problem.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check the Supply Voltage at


the Sensor Connector
A. Disconnect the coolant level sensor.

B. Restore the electrical power to the ECM.

g01132478
Illustration 28
Harness connector for the coolant level sensor
(A) +8 VDC
(B) Return

C. Measure the voltage between terminals A (+8


VDC) and B (return) at the harness connector for
g01093451
Illustration 27 the coolant level sensor.
P2 ECM connector
(P2-4) +8 V digital supply D. Remove the electrical power from the ECM.
(P2-5) Digital sensor return
(P2-6) Coolant level sensor Expected Result:

C. Perform a 45 N (10 lb) pull test on each of the The voltage measurement is 8.0 ± 0.4 VDC.
wires that are associated with the circuit for the
coolant level sensor. Results:

D. Check the allen head screw on each ECM • OK – The voltage measurement is 8.0 ± 0.4 VDC.
connector for the proper torque. Refer to The supply voltage is reaching the sensor. Proceed
Troubleshooting, “Electrical Connectors - Inspect” to Test Step 3.
for the correct torque values.
• Not OK – The voltage measurement is not 8.0 ±
Expected Result: 0.4 VDC. The digital sensor supply voltage is not
reaching the sensor.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Repair: Refer to Troubleshooting, “Digital Sensor
are free of corrosion, of abrasion or of pinch points. Supply Circuit - Test”.

STOP.
RENR5093-01 87
Troubleshooting Section

Test Step 3. Check the Coolant Level Expected Result:

The status changes from “OK” to “Low” when the


sensor is disconnected.
Pressurized System: Hot coolant can cause seri- Results:
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• OK – The status is “Low” when the sensor is
disconnected. Proceed to Test Step 5.
pressure cap slowly in order to relieve the pres-
sure.
• Not OK – The status is “OK” when the sensor is
disconnected. Proceed to Test Step 6.
A. Stop the engine.
Test Step 5. Short the Harness and
B. After allowing the engine to cool, check the coolant Monitor the Status of “Coolant Level”
level. Refer to the Operation and Maintenance
Manual for the proper procedure to check the A. Restore the electrical power to the ECM and
coolant level. monitor the status of “Coolant Level” on Cat ET.

Note: If the coolant has been changed recently, B. Install a jumper wire between terminals B (return)
ensure that the air has been purged from the and C (signal) on the harness connector for the
cooling system. Refer to Systems Operation/Testing coolant level sensor.
and Adjusting, “Cooling System” for additional
information. C. Monitor the status of “Coolant Level” on Cat ET
while the jumper wire is installed.
Expected Result:
D. Remove the jumper wire.
The coolant is at the proper level.
E. Remove the electrical power from the ECM.
Results:
Expected Result:
• OK – The coolant is at the proper level. Proceed
to Test Step 4. The status changes from “Low” to “OK” when the
jumper wire is installed.
• Not OK – The coolant level is low.
Results:
Repair: Add coolant according to the procedure in
the Operation and Maintenance Manual. • OK – The status changes from “Low” to “OK”
when the jumper wire is installed. The ECM and
Verify that the repair eliminates the problem. the wiring to the coolant level sensor are OK.
Identify the source of the coolant leak and fix the
problem. Repair: Perform the following procedure:

STOP.

Test Step 4. Disconnect the Coolant Pressurized System: Hot coolant can cause seri-
Level Sensor and Monitor the Status of ous burns. To open the cooling system filler cap,
“Coolant Level” stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
A. Connect the Caterpillar Electronic Technician pressure cap slowly in order to relieve the pres-
(ET) to the service tool connector. Refer to sure.
Troubleshooting, “Electronic Service Tools”.

B. Disconnect the J800/P800 connectors. 1. Drain the coolant below the level of the coolant
level sensor.
C. Restore the electrical power to the ECM.
2. Reconnect the sensor.
D. Monitor the status of “Coolant Level” on Cat ET.
3. Restore the electrical power to the ECM and
E. Remove the electrical power from the ECM. monitor the status of “Coolant Level” on Cat ET.

4. Remove the electrical power from the ECM.


88 RENR5093-01
Troubleshooting Section

If the status of the “Coolant Level” is “OK”, Note: Wiggle the harness during the following
replace the sensor. Verify that the problem is measurements in order to reveal an intermittent
resolved. condition.

If the status for the coolant level is “Low”, fill the B. Measure the resistance between the points that
cooling system according to the procedure in are listed in Table 14. Be sure to wiggle the wires
the Operation and Maintenance Manual. Return in the harnesses as you make each resistance
the engine to service. measurement.

STOP. Table 14
Resistance Measurements for the Circuit for
• Not OK – Shorting the harness does not affect the the Coolant Level Sensor
status on Cat ET. Proceed to Test Step 6.
Connector and Terminal
Terminal
Test Step 6. Check for Opens in the
Wiring P2-6 (engine coolant All of the other terminals on
level) the P2 connector
A. Remove the electrical power from the ECM.
All of the terminals on the P1
connector
B. Disconnect the J2/P2 ECM connector and the
J800/P800 coolant level sensor connector. Engine ground

C. Measure the resistance between the following Expected Result:


terminals:
Each check of the resistance indicates an open
• P2-4 (digital sensor supply +8 V) to P800-A circuit.
(digital sensor supply +8 V)
Results:
• P2-5 (digital sensor return) to P800-B (digital
sensor return) • OK – Each check of the resistance indicates an
open circuit. Proceed to Test Step 8.
• P2-6 (coolant level sensor) to P800-C (coolant
level sensor) • Not OK – At least one check of the resistance
does not indicate an open circuit. There is a
Expected Result: problem in the harness. There may be a problem
in a connector.
The resistance is less than five Ohms for each
measurement. Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify
Results: that the problem is resolved.
• OK – The resistance is less than five Ohms for STOP.
each measurement. There are no opens in the
wiring. Proceed to Test Step 7. Test Step 8. Create a Short Circuit at the
ECM
• Not OK – The resistance is greater than five Ohms
for each measurement. There is an open circuit A. Remove P2-5 sensor return and P2-6 low coolant
or excessive resistance in the harness or the level signal.
connectors.
B. Install the ends of a jumper wire into locations
Repair: Repair the circuit. P2-5 and P2-6. This will create a short circuit at
the ECM connectors.
Verify that the repair eliminates the problem.
C. Restore the electrical power to the ECM and
STOP. monitor the status of “Coolant Level” on Cat ET.
Test Step 7. Check the Wiring for a Short D. Remove the jumper wire. Monitor the status of
Circuit “Coolant Level” on Cat ET.
A. Remove the electrical power from the ECM.
RENR5093-01 89
Troubleshooting Section

Expected Result: The Electronic Control Module (ECM) creates a


regulated voltage of 8.0 ± 0.4 VDC that is supplied to
The status is “Low” when the jumper wire is not terminal A of the harness connector for the coolant
connected. The status is “OK” when the jumper wire level sensor.
is connected.
A +8 V diagnostic code is probably caused by a short
Results: circuit to ground or a short circuit to another voltage
source in the harness. The next likely cause is a
• OK – The status is “Low” when the jumper wire is problem with the sensor. The least likely cause is a
not connected. The status is “OK” when the jumper problem with the ECM.
wire is connected. The ECM is properly reading
the switch input.

Repair: Perform the following procedure:

1. Remove the jumper wire from the ECM


connector.

2. Install the two terminals into the correct


locations on the ECM connector. Perform a pull
test on the two wires in order to verify proper
installation of the terminals.

The problem appears to be resolved. The


original problem was probably caused by a
poor electrical connection. Return the engine
to service.

STOP.

• Not OK – The status is “Low” when the jumper


wire is connected. The ECM is not reading the
switch input.

Repair: Temporarily install a new ECM. Refer to


Troubleshooting, “Replacing the ECM”.

If the new ECM works correctly, install the original


ECM and verify that the problem returns. If the new
ECM works correctly and the original ECM does
not work correctly, replace the original ECM. Verify
that the problem is resolved.

STOP.

i02347108

Digital Sensor Supply Circuit


- Test
SMCS Code: 1439-038

System Operation Description:

Use this procedure to troubleshoot any suspect


problems with the +8 V digital supply.

This procedure covers the following diagnostic codes:

• 41-03 8 Volt DC Supply short to +batt


• 41-04 8 Volt DC Supply short to ground
90 RENR5093-01
Troubleshooting Section

g01094777
Illustration 29
Schematic for digital supply

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

g01150138
Illustration 31
Typical location of the coolant level sensor
(2) Coolant level sensor

B. Thoroughly inspect connectors (1) and (2). Also


inspect the wiring from the ECM to the coolant
level sensor. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.

g01147202
Illustration 30
Typical engine view
(1) J2/P2 connectors
RENR5093-01 91
Troubleshooting Section

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Verify that all of
the seals are properly in place and verify that the
connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check for Active Diagnostic


Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.

B. Turn the keyswitch to the ON position.

C. Monitor Cat ET for active diagnostic codes. Check


and record any active codes.

Note: Wait at least 15 seconds in order for the


diagnostic codes to become active.

Check for the following diagnostic codes for the


digital supply:

• 41-03
• 41-04
Expected Result:

No diagnostic codes that relate to the digital supply


are active.
g01093451
Illustration 32
Results:
P2 ECM connector
(P2-4) +8 V digital supply
(P2-5) Digital sensor return
• OK – No diagnostic code for the digital supply is
(P2-6) Coolant level sensor
active. Proceed to Test Step 3 in order to verify that
the sensor is receiving the correct supply voltage.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the circuit that is associated with the • Not OK - Active 41-03 – A 41-03 diagnostic code
digital sensor supply. is active. Proceed to Test Step 3.

D. Check the allen head screw on each ECM • Not OK - Active 41-04 – A 41-04 diagnostic code
connector for the proper torque. Refer to is active. Proceed to Test Step 4.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values. Test Step 3. Check for Supply Voltage at
the Sensor’s Connector
E. Check the harness and wiring for abrasions and
for pinch points from the sensor to the ECM. A. Turn the keyswitch to the OFF position.

Expected Result: B. Disconnect the harness connector for the coolant


level sensor.
The harness and the wiring are OK.
C. Turn the keyswitch to the ON position.
Results:
D. Measure the voltage between terminals A and B
at the harness connector.
• OK – Proceed to Test Step 2.
• Not OK Expected Result:

The voltage is 8.0 ± 0.4 VDC.


92 RENR5093-01
Troubleshooting Section

Results: D. Measure the resistance between the points that


are listed in Table 15. Be sure to wiggle the wires
• OK – The voltage is 8.0 ± 0.4 VDC. The voltage is in the harnesses as you make each resistance
correct. The problem appears to be resolved. measurement.

Repair: Connect the sensor’s connectors. Clear Table 15


all diagnostic codes. Check for active diagnostic Resistance Measurements for the Wiring Harness
codes. If the problem is intermittent, refer to
Troubleshooting, “Electrical Connectors - Inspect”. Connector and Terminal
Terminal
STOP. P2-4 (+ 8 VDC) All of the other terminals on
the P2 connector
• Not OK – The voltage is not 8.0 ± 0.4 VDC. The All of the terminals on the P1
voltage is incorrect. Proceed to Test Step 5.
connector
Test Step 4. Disconnect the +8 V Sensor Engine ground
and Monitor Active Diagnostic Codes
Expected Result:
A. Use Cat ET to check for active diagnostic codes.
Check and record any active codes. All of the resistance measurements indicate an open
circuit.
B. Disconnect the harness connector for the coolant
level sensor. Results:
C. Wait for 15 seconds after the sensor is
disconnected. Check for an active diagnostic code
• OK – All of the resistance measurements indicate
an open circuit. Proceed to Test Step 6.
on Cat ET.

Expected Result:
• Not OK – At least one resistance measurement
does not indicate an open circuit. There is a short
circuit in a wiring harness. There may be a problem
The 41-04 diagnostic code deactivates when the with a connector.
sensor is disconnected.
Repair: Repair the wiring and/or the connector.
Results: Replace parts, if necessary. Verify that the problem
is resolved.
• OK – The 41-04 diagnostic code deactivates
when the sensor is disconnected. There may be a STOP.
problem with the sensor.
Test Step 6. Check the +8 V Supply and
Repair: Connect the sensor and verify that the the Sensor Common for an Open Circuit
code recurs. If the code recurs, replace the sensor.
A. Use a jumper wire to create a short circuit between
Return all wiring to the original configuration. terminals P2-4 (+8 VDC) and P2-5 (return).
Clear all diagnostic codes. Verify that the repair
eliminates the problem. Note: Wiggle the harness during the following
measurements in order to reveal any intermittent
STOP. short condition.
• Not OK – The 41-04 diagnostic code stays active B. Measure the resistance between terminals A and
when the sensor is disconnected. Leave the sensor B at the harness connector for the coolant level
disconnected. Proceed to Test Step 5. sensor.
Test Step 5. Check the +8 V Supply Wire C. Remove the jumper wire.
for a Short Circuit
Expected Result:
A. Turn the keyswitch to the OFF position.
The resistance is less than ten Ohms.
B. Disconnect the J1/P1 and J2/P2 ECM connectors.

C. Verify that the coolant level sensor is disconnected.


RENR5093-01 93
Troubleshooting Section

Results: i02378207

• OK – The resistance is less than ten Ohms. The Electrical Connectors - Inspect
circuit is not open. Proceed to Test Step 7.
SMCS Code: 7553-040-WW
• Not OK – The resistance is greater than ten Ohms.
The +8 V supply wire or the sensor common has System Operation Description:
excessive resistance. There may be a problem in a
connector. Most electrical problems are caused by poor
connections. The following procedure will assist in
Repair: Repair the wire and/or the connector, detecting problems with connectors and with wiring.
when possible. Replace parts, if necessary. Verify If a problem is found correct the condition and verify
that the problem is resolved. that the problem is resolved.

STOP. Intermittent electrical problems are sometimes


resolved by disconnecting and reconnecting
Test Step 7. Check the +8 V Supply at the connectors. It is very important to check for diagnostic
ECM codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
A. Remove the terminal from location P2-4. Install a the connector. If the status of a diagnostic code is
jumper wire into the connector at location P2-4. changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
B. Remove the terminal from location P2-5. Install a likely reasons are loose terminals, improperly crimped
jumper wire into the connector at location P2-5. terminals, moisture, corrosion, and inadequate
mating of a connection.
C. Turn the keyswitch to the ON position.
Follow these guidelines:
D. Measure the voltage between the jumper wires.
• Always use a 1U-5804 Crimp Tool to service
E. Turn the keyswitch to the OFF position. Deutsch HD and DT connectors. Never solder the
terminals onto the wires. Refer to “SEHS9615,
F. Return the wiring to the original configuration. Servicing Deutsch HD and DT Style Connectors”.

Expected Result: • Always use a 147-6456 Wedge Removal Tool to


remove wedges from DT connectors. Never use a
The voltage is 8.0 ± 0.4 VDC. screwdriver to pry a wedge from a connector.

Results: • Always use a breakout harness for a voltmeter


probe or a test light. Never break the insulation
• OK – The voltage is 8.0 ± 0.4 VDC. The problem of a wire in order to access to a circuit for
appears to be resolved. measurements.

Repair: Clear all diagnostic codes. Check for active • If a wire is cut, always install a new terminal for
diagnostic codes. If the problem is intermittent, the repair.
refer to Troubleshooting, “Electrical Connectors -
Inspect”.

STOP. The connection of any electrical equipment and


the disconnection of any electrical equipment may
• Not OK – The voltage is not 8.0 ± 0.4 VDC. The cause an explosion hazard which may result in in-
voltage is incorrect. jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an
Repair: Replace the ECM. Refer to explosive atmosphere.
Troubleshooting, “Replacing the ECM”.

STOP.
94 RENR5093-01
Troubleshooting Section

Test Step 1. Check Connectors for B. Ensure that the sealing plugs are in place. If
Moisture and Corrosion any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into
the connector. Refer to Illustration 34.

g01131019
Illustration 35
Seal for a three-pin connector (typical example)

g01131211
Illustration 33
Leaky seal at the connector (typical example)

A. Inspect all wiring harnesses. Ensure that the


routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 33. This will create a
path for the entrance of moisture. Verify that the
seals for the wires are sealing correctly.

g01131165
Illustration 36
Seal for ECM connector (typical example)

C. Disconnect the suspect connector and inspect the


connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.

D. Thoroughly inspect the connectors for evidence


of moisture entry.

Note: It is normal to see some minor seal abrasion


on connector seals. Minor seal abrasion will not allow
Illustration 34
g01131276 the entry of moisture.
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
RENR5093-01 95
Troubleshooting Section

If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:

• Missing seals • Exposed insulation


• Improperly installed seals • Rubbing of a wire against the engine
• Nicks in exposed insulation • Rubbing of a wire against a sharp point
• Improperly mated connectors B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
Moisture can also travel to a connector through check all of the fasteners in order to verify that the
the inside of a wire. If moisture is found in a harness is not compressed. Pull back the harness
connector, thoroughly check the connector’s sleeves in order to check for a flattened portion
harness for damage. Also check other connectors of wire. A fastener that has been overtightened
that share the harness for moisture. flattens the harness. This damages the wires that
are inside the harness.
Note: The ECM is a sealed unit. If moisture is found
in an ECM connector, the ECM is not the source of Expected Result:
the moisture. Do not replace the ECM.
The wires are free of abrasion, of nicks, and of cuts
Expected Result: and the harness is properly clamped.

The harness wiring, connectors, and seals are in Results:


good condition. There is no evidence of moisture in
the connectors. • OK – The harness is OK. Proceed to Test Step 3.
Results: • Not OK – There is damage to the harness.
• OK – The harness wiring, connectors, and seals Repair: Repair the wires or replace the wires,
are in good condition. Proceed to Test Step 2. as required. Verify that the repair eliminates the
problem.
• Not OK – A problem has been found with the
harness or the connectors. STOP.

Repair: Repair the connectors or the wiring, as Test Step 3. Inspect the Connector
required. Ensure that all of the seals are properly Terminals
in place. Ensure that the connectors have been
reattached. A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
If corrosion is evident on the pins, sockets or the Verify that the terminals are properly aligned in
connector, use only denatured alcohol to remove the connector and verify that the terminals are
the corrosion. Use a cotton swab or a soft brush properly located in the connector.
to remove the corrosion.
Expected Result:
If moisture was found in the connectors, run the
engine for several minutes and check again for The terminals are properly aligned and the terminals
moisture. If moisture reappears, the moisture is appear undamaged.
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to Results:
replace the wires.
• OK – The terminals are OK. Proceed to Test Step
Verify that the repair eliminates the problem. 4.

STOP. • Not OK – The terminals of the connector are


damaged.
96 RENR5093-01
Troubleshooting Section

Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
Verify that the repair eliminates the problem.

STOP.

Test Step 4. Perform a Pull Test on Each


Wire Terminal Connection

g01131604
Illustration 38
Diagram for testing pin retention (typical example)

A. Verify that the sockets provide good retention for


the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
g01131435
pin by the socket.
Illustration 37
Receptacle lock wedge (typical example) Expected Result:

A. Ensure that the locking wedge for the connector The sockets provide good retention for the new pin.
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not Results:
installed properly.
• OK – The terminals are OK. Proceed to Test Step
B. Perform the 45 N (10 lb) pull test on each wire. 6.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire • Not OK – Terminals are damaged.
should remain in the connector body. This test
checks whether the wire was properly crimped Repair: Use the 1U-5804 Crimp Tool to replace
in the terminal and whether the terminal was the damaged terminals. Verify that the repair
properly inserted into the connector. eliminates the problem.

Expected Result: STOP.

Each terminal and each connector easily withstands Test Step 6. Check the Locking
45 N (10 lb) of pull and each wire remains in the Mechanism of the Connectors
connector body.
A. Ensure that the connectors lock properly. After
Results: locking the connectors, ensure that the two halves
cannot be pulled apart.
• OK – All terminals pass the pull test. Proceed to
Test Step 5. B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
• Not OK – A wire has been pulled from a terminal the connector returns to the locked position.
or a terminal has been pulled from the connector.
Expected Result:
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as The connector will securely lock. The connector and
required. Verify that the repair eliminates the the locking mechanism are without cracks or breaks.
problem.

STOP.
RENR5093-01 97
Troubleshooting Section

Results:

• OK – The connectors are in good repair. Proceed


to Test Step 7.

• Not OK – The connector’s locking mechanism is


damaged or missing.

Repair: Repair the connector or replace the


connector, as required. Verify that the repair
eliminates the problem.

STOP.

Test Step 7. Check the Allen Head Screws g01132863


on the Connectors Illustration 41
Allen head screw for the 40 pin ECM connector (typical example)
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen c. Torque the allen head screw for the 40 pin ECM
head screw are not damaged. connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).

A. Connect the ECM connectors.

g01133047
Illustration 42
Allen head screw for the 40 pin customer connector and the 70 pin
g01132827
Illustration 39 customer connector (typical example)
Allen head screw for the 120 pin ECM connector (typical example)
B. Connect the customer connector.
a. Torque the allen head bolt for the 120 pin ECM
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). 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 lb in).

Expected Result:

The ECM connector is secure and the allen head


screws are properly torqued.

Results:

• OK – The ECM connectors and the customer


connector is properly connected. Proceed to Test
Step 8.

• Not OK – The allen head screws for the ECM


g01132849 connector or the customer connector is damaged.
Illustration 40
Allen head screw for the 70 pin ECM connector (typical example)

b. Torque the allen head screw for the 70


pin ECM connector to 6.0 + 1.5 - 0.5 N·m
(55 + 13 - 4 lb in).
98 RENR5093-01
Troubleshooting Section

Repair: Repair the connector or replace the Also, use this procedure if you have been directed
connector, as required. Verify that the repair from Troubleshooting, “Electronic Service Tool Will
eliminates the problem. Not Communicate with ECM” or Troubleshooting,
“Engine Cranks but Will Not Start”.
STOP.
Unswitched battery voltage is supplied through the
Test Step 8. Perform the “Wiggle Test” on customer connector to the ECM at P1-48, P1-52, and
the Caterpillar Electronic Technician (ET) P1-53. The negative battery is supplied to the ECM
at P1-61, P1-63, and P1-65. The ECM receives the
A. Select the “Wiggle Test” from the diagnostic tests input from the keyswitch at P1-70 when the keyswitch
on Cat ET. is in the ON position or in the STOP position. When
the ECM detects battery voltage at this input, the
B. Choose the appropriate group of parameters to ECM will power up. When battery voltage is removed
monitor. from this input, the ECM will power down.

C. Press the “Start” button. Wiggle the wiring harness The cause of an intermittent power supply to the
in order to reproduce intermittent problems. ECM can occur on either the positive side or on
the negative side of the battery circuit. Both sides
If an intermittent problem exists, the status will be are routed from the ECM to the battery. The three
highlighted and an audible beep will be heard. connections for the unswitched +Battery must be
routed through a dedicated protective device (circuit
Expected Result: breaker).

No intermittent problems were indicated during the The engine ECM requires the input for the keyswitch
“Wiggle Test”. to be powered in order to maintain communications
with the electronic service tool.
Results:
For intermittent problems such as intermittent
• OK – No intermittent problems were found. The shutdowns that could be caused by engine wiring,
harness and connectors appear to be OK. If you temporarily bypassing the engine wiring may be an
were sent from another procedure, return to the effective means of determining the root cause. If
procedure and continue testing. If this test has the symptoms disappear with the bypass wiring, the
resolved the problem, return the engine to service. engine wiring is the cause of the problem. A means
STOP. of bypassing engine wiring is explained in this test
procedure.
• Not OK – At least one intermittent problem was
indicated.

Repair: Repair the harness or the connector. Verify


that the repair eliminates the problem.

STOP.

i02779048

Electrical Power Supply Circuit


- Test
SMCS Code: 1401-038

System Operation Description:

This procedure tests whether proper voltage is being


supplied to the Engine Control Module (ECM).

Use this procedure to troubleshoot the system when


one of the following diagnostic codes is active or
easily repeated:

• 168-02 System Voltage intermittent/erratic


RENR5093-01 99
Troubleshooting Section

g01388327
Illustration 43
Schematic for electrical power supply circuit

Test Step 1. Inspect Electrical Connectors


and Wiring
A. Turn the keyswitch to the OFF position.

g01388311
Illustration 45
Left side engine view (typical example)
(2) Customer connector
(3) Service tool connector
g01146374
Illustration 44
Left side engine view (typical example) B. Thoroughly inspect connectors (1), (2), and (3).
(1) J1/P1 ECM connector
Inspect the terminal connections from the battery
to the ECM. Also, inspect the connections from the
keyswitch to the ECM. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.
100 RENR5093-01
Troubleshooting Section

g01172799
Illustration 47
Terminal locations at the customer connector that are associated
with the electrical power supply
(1) +Battery
(5) +Battery
(8) +Battery
(19) Run/stop switch
g01172797 (30) Keyswitch
Illustration 46
Terminal locations at the P1 ECM connector that are associated
with the electrical power supply
(P1-40) Run/stop switch
(P1-48) +Battery
(P1-52) +Battery
(P1-53) +Battery
(P1-61) −Battery
(P1-63) −Battery
(P1-65) −Battery
(P1-70) Keyswitch Illustration 48
g01388321

Terminal locations at the service tool connector that are associated


with the power supply
(A) Keyswitch
(B) −Battery

C. Perform a 45 N (10 lb) pull test on each of the


wires that are associated with the electrical power
supply.

D. Check the allen head screw on the ECM connector


for the proper torque. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Connectors - Inspect” for the correct torque
values.
RENR5093-01 101
Troubleshooting Section

E. Check the harness and wiring for abrasions and • Not OK – The battery voltage is not within
for pinch points from the battery to the ECM. Also, specifications. Proceed to Test Step 3.
check the harness and wiring for abrasions and
for pinch points from the keyswitch to the ECM. • Not OK – The voltage at the keyswitch is not within
specifications.
Expected Result:
Repair: Trace the wiring for the keyswitch from the
All connectors, pins, and sockets are completely ECM through the keyswitch circuit to the batteries.
coupled and/or inserted. The harness and wiring are Find the problem and repair the problem. Check
free of corrosion, of abrasion, and of pinch points. the circuit protection for the circuit and for the
wiring. Verify that the repairs eliminate the problem.
Results:
STOP.
• OK – The connectors and wiring are OK. Proceed
to Test Step 2. Test Step 3. Check the Batteries
• Not OK – There is a problem with the connectors A. Measure no-load battery voltage at the battery
or wiring. posts.

Repair: Repair the connectors or wiring and/or B. Load test the batteries. Use the 4C-4911
replace the connectors or wiring. Ensure that all of Battery Load Tester. Refer to Special Instruction,
the seals are properly in place and ensure that the SEHS9249, “Use of 4C-4911 Battery Load Tester
connectors are completely coupled. for 6, 8 and 12 Volt Lead Acid Batteries” and
Special Instruction, SEHS7633, “Battery Test
STOP. Procedure”.

Test Step 2. Check the Battery Voltage at Expected Result:


the ECM
The batteries pass the load test. The measured
A. Disconnect the J1/P1 ECM connector. voltage is the minimum specification for a 12V or 24V
system.
B. Turn the keyswitch to the ON position.
Results:
C. Measure the voltage between P1-48 Unswitched
+Battery and P1-61 -Battery. • OK – The batteries are OK.
D. Measure the voltage between P1-52 Unswitched Repair: Check the wiring between the batteries
+Battery and P1-63 -Battery. and the ECM for shorts.

E. Measure the voltage between P1-53 Unswitched Check the connectors between the batteries and
+Battery and P1-65 -Battery. the ECM for moisture and/or corrosion.

F. Measure the voltage between P1-70 Switched Repair the wiring and/or the connectors.
+Battery (keyswitch) and P1-63 -Battery.
Verify that the repair eliminates the problem.
Expected Result:
STOP.
The measured voltage is between 11.0 VDC and 13.5
VDC for a 12 volt system and between 22.0 VDC and • Not OK – The battery voltage is low or the battery
27.0 VDC for a 24 volt system with no suspected did not pass the load test.
intermittent problems at this time.
Repair: Recharge or replace the faulty batteries.
Results: Verify that the repair eliminates the problem.

• OK – The ECM is receiving the correct voltage. STOP.

Repair: If an intermittent condition is suspected,


refer to Troubleshooting, “Electrical Connectors -
Inspect”.

STOP.
102 RENR5093-01
Troubleshooting Section

i02778800 If the sensor is disconnected at the sensor connector,


the presence of pull-up voltage at the sensor
Engine Pressure Sensor Open connector indicates that the wires from the sensor
or Short Circuit - Test connector to the ECM are OK. If the sensor is
disconnected at the sensor connector, the absence
SMCS Code: 1439-038-PX of pull-up voltage at the sensor connector indicates
a problem in the signal wire. If the sensor is
System Operation Description: disconnected at the sensor connector and the voltage
at the sensor connector is different from pull-up
Use this procedure to troubleshoot any suspect voltage, the signal wire is shorted to another wire in
problems with the following sensors: the harness.

• Fuel pressure sensor


• Engine oil pressure sensor
• Turbocharger outlet pressure sensor
• Atmospheric pressure sensor
This procedure covers the following open circuit
diagnostic codes and short circuit diagnostic codes:

• 94-03 Fuel Pressure open/short to +batt


• 94-04 Fuel Pressure short to ground
• 100-03 Engine Oil Pressure open/short to +batt
• 100-04 Engine Oil Pressure short to ground
• 273-03 Turbo Outlet Pressure open/short to +batt
• 273-04 Turbo Outlet Pressure short to ground
• 274-03 Atmospheric Pressure open/short to +batt
• 274-04 Atmospheric Pressure short to ground
The 5 volt sensor supply provides power to all
5 volt sensors. The Electronic Control Module
(ECM) supplies 5.0 ± 0.2 VDC to terminal A of
each sensor connector. The sensor return from the
ECM connector goes to terminal B of each sensor
connector. The sensor supply is output short circuit
protected. A short circuit to the +Battery will not
damage the circuit inside the ECM.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage on


the circuit for the sensor signal wire. The ECM uses
this pull-up voltage in order to detect a problem in the
signal circuit. When the ECM detects the presence
of a voltage that is above a threshold on the signal
circuit, the ECM will generate a -03 diagnostic code
for the sensor.
RENR5093-01 103
Troubleshooting Section

g01174890
Illustration 49
Schematic for the engine pressure sensors

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

g01174896
Illustration 50
Sensor locations
(1) Fuel pressure sensor
(2) Turbocharger outlet pressure sensor
(3) Atmospheric pressure sensor
(4) Engine oil pressure sensor
(5) J2/P2 ECM connector

B. Thoroughly inspect the connectors that are for


pressure sensors (1), (2), (3), and (4). Also,
thoroughly inspect ECM connector (5). Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
104 RENR5093-01
Troubleshooting Section

g01159881
Illustration 52
Terminal locations at the sensor connector that are for the engine
pressure sensors
(Terminal A) +5 V sensor supply
(Terminal B) Sensor return
(Terminal C) Signal

C. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connectors that are associated
with the circuit.

D. Check the allen head screw for 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


for pinch points from the pressure sensors back
to the ECM.
g01174894
Illustration 51 Expected Result:
Terminal locations at the P2 ECM connector that are for the engine
pressure sensors All connectors, pins, and sockets are completely
(P2-2) +5 V sensor supply coupled and/or inserted. The harness and wiring are
(P2-3) Sensor return free of corrosion, of abrasion, and of pinch points.
(P2-14) Atmospheric pressure
(P2-16) Fuel pressure
(P2-24) Engine oil pressure Results:
(P2-40) Turbocharger outlet pressure
• OK – The harness and wiring are OK. Proceed
to Test Step 2.

• Not OK – There is a problem in the connectors


and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.
RENR5093-01 105
Troubleshooting Section

Test Step 2. Check the Supply Voltage at D. Determine if the problem is related to an -03
the Sensor Connector diagnostic code or an -04 diagnostic code.

A. Turn the keyswitch to the OFF position. Expected Result:

B. Disconnect the harness connectors for the No diagnostic codes are active.
following sensors:
Results:
• Turbocharger outlet pressure sensor
• OK – No diagnostic codes are active for the engine
• Engine oil pressure sensor pressure sensors.

• Fuel pressure sensor Repair: The problem may have been related
to a faulty connection in the harness. Carefully
• Atmospheric pressure sensor reinspect the connectors and wiring. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
C. Turn the keyswitch to the ON position.
STOP.
Note: Be sure to wiggle the harness during the
following measurements in order to reveal an • Not OK – A -04 diagnostic code is active at this
intermittent condition. time. Proceed to Test Step 4.

D. Measure the voltage between terminals A and B • Not OK – A -03 diagnostic code is active at this
at each sensor connector on the engine harness. time. Proceed to Test Step 5.

E. Turn the keyswitch to the OFF position. Test Step 4. Disconnect the Suspect
Sensor and Check for an Open Circuit
F. Connect all of the sensors.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Disconnect the sensor connector of the suspect
Each voltage measurement is 5.0 ± 0.2 VDC. sensor with the active -04 diagnostic code.

Results: C. Turn the keyswitch to the ON position. Wait at


least 15 seconds for activation of the diagnostic
• OK – Each voltage measurement is 5.0 ± 0.2 VDC. codes.
The voltage is correct at the sensor connectors.
Proceed to Test Step 3. D. Access the “Active Diagnostic Code” screen on
Cat ET. Check for an active -03 diagnostic code.
• Not OK – At least one voltage measurement is not
5.0 ± 0.2 VDC. E. Turn the keyswitch to the OFF position.

Repair: Expected Result:


There is a problem with the supply
circuit for the pressure sensors. Refer to An -03 diagnostic code is now active for the
Troubleshooting, “5 Volt Engine Pressure Sensor disconnected sensor.
Supply Circuit - Test”.
Results:
STOP.
• OK – An -04 diagnostic code was active before you
Test Step 3. Check for Active Diagnostic disconnected the sensor. An -03 diagnostic code
Codes became active after the sensor was disconnected.

A. Connect Caterpillar Electronic Technician (ET) to Repair: Temporarily connect a new sensor to the
the service tool connector. harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic
B. Turn the keyswitch to the ON position. codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently
C. Observe the “Active Diagnostic” screen on Cat ET. install the new sensor. Clear any logged diagnostic
Wait at least 15 seconds so that any codes may codes.
become active. Look for an active diagnostic code
for an engine pressure sensor. STOP.
106 RENR5093-01
Troubleshooting Section

• Not OK – A -04 diagnostic code is still active for Expected Result:


the suspect sensor. There is a short circuit between
the sensor harness connector and the ECM. Leave Each resistance measurement indicates an open
the sensor disconnected. Proceed to Test Step 8. circuit.

Test Step 5. Check the Pull-up Voltage at Results:


the Sensor Connector
• OK – Each resistance measurement indicates an
A. Turn the keyswitch to the ON position. open circuit. Proceed to Test Step 7.

B. Disconnect the suspect sensor. • Not OK – At least one resistance measurement


does not indicate an open circuit.
C. Measure the voltage between terminal C (signal)
and terminal B (sensor return) at the sensor Repair: There is a short circuit in the wiring for the
connector. sensor. There may be a problem with a connector.
Repair the wiring and/or the connector. Replace
D. Turn the keyswitch to the OFF position. parts, if necessary. Verify that the problem is
resolved.
Expected Result:
STOP.
The voltage is greater than 5.5 VDC.
Test Step 7. Create a Short at the Suspect
Results: Sensor Connector
• OK – The voltage is greater than 5.5 VDC. The A. Turn the keyswitch to the OFF position.
signal wire to the ECM from the sensor connector
is OK. B. Install a jumper wire with socket terminals on each
end between terminals B (sensor return) and C
Repair: The open circuit is in the sensor or the (signal) on the harness connector for the suspect
wire between the sensor and the sensor connector. sensor.
Replace the sensor. Do not install the sensor in
the engine. Verify that no diagnostic codes are C. Turn the keyswitch to the ON position.
active for the suspect sensor before permanently
installing the sensor. D. Wait at least 15 seconds for activation of a -04
diagnostic code.
STOP.
Note: Monitor the “Active Diagnostic Codes” screen
• Not OK – The voltage is not greater than 5.5 VDC. on Cat ET before installing the jumper wire and after
The voltage is incorrect. Proceed to Test Step 6. installing the jumper wire.

Test Step 6. Check the Signal Wire for a E. Remove the jumper wire.
Short Circuit
F. Turn the keyswitch to the OFF position.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Disconnect the J2/P2 ECM connectors.
An -04 diagnostic code was active when the jumper
C. Disconnect the harness connector for the suspect wire was installed. An -03 diagnostic code became
sensor. active when the jumper wire was removed.

D. Identify the terminal for the signal wire on the Results:


ECM connector that is appropriate for the suspect
sensor. Measure the resistance between the • OK – The engine harness and the ECM are OK.
appropriate terminal and the remaining terminals
on both ECM connectors.

E. Connect the J2/P2 ECM connectors. Connect the


connectors for the suspect sensor.
RENR5093-01 107
Troubleshooting Section

Repair: Temporarily connect a new sensor to the G. Remove the jumper wire. Return the wiring to the
harness, but do not install the new sensor in the original configuration.
engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active Expected Result:
diagnostic codes for the new sensor, permanently
install the new sensor. Clear any logged diagnostic A -03 diagnostic code is active when the sensor
codes. Verify that the problem is resolved. signal wire is removed from the ECM connector. A
-04 diagnostic code is active when the signal wire is
STOP. connected to the engine ground stud.

• Not OK – The -03 diagnostic code remains active Results:


with the jumper in place. There is an open circuit
between the ECM and the sensor connector. • OK – The ECM is operating properly. The problem
Proceed to Test Step 8. is in the wiring between the ECM and the sensor
connector.
Test Step 8. Check the Operation of the
ECM Repair: If the code is active for more than one
sensor, the problem is most likely in the return wire
A. Turn the keyswitch to the OFF position. for the sensor. Repair the return wire for the sensor
or replace the harness.
B. Check the operation of the ECM by creating an
open at the ECM. If the code is only active for one sensor, the
problem is most likely in the signal wire for the
a. Disconnect the J2/P2 ECM connector. sensor. Repair the signal wire for the sensor.

b. Remove the signal wire for the suspect sensor STOP.


from the ECM connector.
• Not OK – One of the following conditions exists:
c. Connect the ECM connector. The -03 diagnostic code is not active when the
sensor signal wire is disconnected. The -04
d. Turn the keyswitch to the ON position. diagnostic code is not active when the wire jumper
is installed.
e. Monitor the “Active Diagnostic Code” screen
on Cat ET. Wait at least 15 seconds so that any Repair: Replace the ECM. Refer to
codes may become active. Troubleshooting, “Replacing the ECM”.
Verify that the problem is resolved.
A -03 diagnostic code should be active for the
suspect sensor. STOP.

f. Turn the keyswitch to the OFF position.


i02352188

C. Check the operation of the ECM by creating a


short circuit at the ECM:
Engine Speed/Timing Sensor
Circuit - Test
a. Disconnect the J2/P2 ECM connector.
SMCS Code: 1439-038-VF; 1912-038
b. Install a jumper wire between the terminal for
the sensor’s signal wire and the engine ground System Operation Description:
stud.
Use this procedure to troubleshoot any suspect
c. Connect the ECM connector. problems with the following sensors:

D. Turn the keyswitch to the ON position. • Primary engine speed/timing sensor


E. Monitor the “Active Diagnostic Code” screen on • Secondary engine speed/timing sensor
Cat ET. Wait at least 15 seconds so that any
codes may become active. This procedure covers the following diagnostic codes:

A short circuit diagnostic code (-04) should be • 320-02 Speed/Timing Sensor Loss of Signal
active when the wire jumper is installed.
• 320-11 Speed/Timing Sensor mechanical failure
F. Turn the keyswitch to the OFF position.
• 342-02 Loss of Secondary Engine Speed signal
108 RENR5093-01
Troubleshooting Section

• 342-11 Secondary Engine Speed Sensor • Ensure that the sensor has a face seal inside the
mechanical failure connector body. If a seal is damaged or missing,
replace the seal.
The engine uses two engine speed/timing sensors:
• Ensure that the sensor is fully seated into the
Primary engine speed/timing sensor – The engine before tightening the bracket bolt.
primary engine speed/timing sensor detects the
reference for engine speed and timing from a timing • Ensure that the connector is latched on both sides.
ring with a notched pattern that has been machined
onto a portion of the crankshaft gear. • Ensure that the harness is properly secured, and
ensure that the harness is attached to the harness
Secondary engine speed/timing sensor – The clip.
secondary engine speed/timing sensor detects the
reference for engine speed and timing from a timing
ring with a notched pattern that has been machined
onto a portion of the camshaft gear.

Each of the engine speed/timing sensors produces


a signal as the respective timing ring rotates past
the tip of the sensor. The Electronic Control Module
(ECM) uses these signals to determine the engine
speed and the engine timing.

When the timing has been determined, the ECM


triggers each injector in the correct firing order at the
correct time. The actual timing and duration of each
injection is based on engine rpm, load, and demand.

If the engine is running and the signal from one


sensor is lost, no noticeable change in engine
performance will be noticed. If the engine is running
and the signals from both sensors are lost, fuel
injection will be terminated and the engine will be
shut down by the ECM.

The engine will start when only one sensor signal is


present. The engine will not start if the signals from
both sensors are lost.

Both sensors are magnetic sensors. The two sensors


are not interchangeable. Do not switch the positions
of the sensors. The two sensors must be replaced as
a pair. If the sensors are replaced, a timing calibration
is not necessary for the engine.

If a replacement of the ECM is required, the ECM


parameters and the timing calibration can be
transferred from the suspect ECM to the replacement
ECM. Timing calibration will not be necessary. This
feature requires the Caterpillar Electronic Technician
(ET) and this feature is only possible if the existing
ECM can communicate with Cat ET. Use the “Copy
Configuration - ECM Replacement” feature on Cat
ET.

When the sensors are being installed, complete


all of the following tasks:

• Lubricate the O-ring with oil.


RENR5093-01 109
Troubleshooting Section

g01150285
Illustration 53
Schematic for the engine speed/timing circuit

Test Step 1. Check for Diagnostic Codes Results:

A. Connect Cat ET to the service tool connector. • No Engine rpm – Engine rpm is not indicated on
Refer to Troubleshooting, “Electronic Service Cat ET. Proceed to Test Step 2.
Tools”.
• Active Code – There is an active diagnostic
B. Turn the keyswitch to the ON position. code or a logged diagnostic code for an engine
speed/timing sensor. Proceed to Test Step 4.
C. Start the engine and run the engine until the
engine is at the normal operating temperature. • No Codes – None of the codes that are listed are
active or logged.
Note: If the engine will not start, monitor the engine
rpm on Cat ET while the engine is being cranked. Cat Repair: Refer to the appropriate symptoms in
ET may need to be powered from another battery Troubleshooting, “Troubleshooting Without a
while the engine is being cranked. Diagnostic Code”.

D. Check for the following diagnostic codes: STOP.

• 190-02 Test Step 2. Check the Installation of the


Sensors and the Bracket
• 190-11
• 342-02
• 342-11
Note: If the diagnostic code is logged but not active,
run the engine until the engine is at normal operating
temperature. The problem may only occur when the
engine is at the normal operating temperature. If
the engine will not start, monitor the engine rpm on
the electronic service tool while the engine is being
cranked. The electronic service tool may need to be
powered from another battery while the engine is
being cranked. This is done so the electronic service
tool will not reset.

Expected Result:

One or both of the diagnostic codes that are listed


above are logged or active.
g01176097
Illustration 54
Note: If the engine will not start and Cat ET displayed
Typical engine speed/timing sensor
0 rpm during cranking, select “No Engine rpm”.
(1) Mounting flange
(2) Mounting surface
110 RENR5093-01
Troubleshooting Section

A. Visually inspect each sensor assembly without Repair: Obtain a new sensor assembly. Perform
removing the sensor assembly from the engine. the following procedure in order to properly install
Ensure that flange (1) is installed squarely against the sensor assembly:
surface (2).
1. Lubricate each O-ring with engine oil.
Remove the suspect sensor assembly from the
engine. 2. Fully seat the sensor assembly in the engine.

Note: If the sensor assembly will not fully seat into


the engine, replace the sensor assembly.

3. Tighten the bracket bolt.

4. Connect the sensor’s electrical connectors.


Verify that the connector is latched.

5. Ensure that the harness is properly secured,


and that the tie-wraps are placed in the correct
location.

Verify that the problem is resolved.


g01167704
Illustration 55 STOP.
Typical engine speed/timing sensor
(3) O-ring Test Step 3. Inspect the Electrical
Connectors and the Wiring
B. Ensure that one O-ring (3) is installed on the
sensor. Check the O-ring for damage. Replace
the O-ring, if necessary.

Results:

• OK – The sensor’s components are OK.


Repair: Perform the following procedure in order
to properly install the sensor assembly:

1. Lubricate the O-ring with engine oil.

2. Fully seat the sensor assembly in the engine.

Note: If the sensor assembly will not fully seat into


the engine, replace the sensor assembly.

3. Tighten the bracket bolt.

4. Connect the sensor’s electrical connectors.


Verify that the connectors are latched on both Illustration 56
g01175131
sides. Engine components for the engine speed/timing sensors
(4) J402/P402 connectors for the secondary engine speed/timing
5. Ensure that the harness is properly secured, sensor
and that the tie-wraps are placed in the correct (5) J401/P401 connectors for the primary engine speed/timing
location. sensor
(6) J2/P2 ECM connector
Proceed to Test Step 4.
A. Thoroughly inspect connectors (4), (5), and (6).
• Not OK – At least one of the sensor assembly’s Refer to Troubleshooting, “Electrical Connectors
components is not OK. - Inspect”.
RENR5093-01 111
Troubleshooting Section

Results:

• OK – The harness and connectors appear to be


OK. Proceed to Test Step 4.

• Not OK – The connectors and/or wiring are not


OK.

Repair: Repair the wiring and/or the connectors.


Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.

STOP.

Test Step 4. Measure the Sensor


Resistance Through the Engine Harness
A. Turn the keyswitch to the OFF position.

B. Disconnect the P2 connector at the ECM.

C. If you are troubleshooting a problem with the


primary engine speed/timing sensor, perform the
following procedure:

a. Measure the sensor’s resistance between


P2-48 (primary engine speed/timing +) and
P2-49 (primary engine speed/timing -).

Resistance ........................... 110 to 200 Ohms

D. If you are troubleshooting a problem with the


Illustration 57
g01175138 secondary engine speed/timing sensor, perform
the following procedure:
P2 terminals that are associated with the engine speed/timing
sensors
a. Measure the sensor’s resistance between
(P2-48) Primary engine speed/timing −
(P2-49) Primary engine speed/timing +
P2-58 (secondary engine speed/timing +) and
(P2-58) Secondary engine speed/timing + P2-59 (secondary engine speed/timing -).
(P2-59) Secondary engine speed/timing −
Resistance ....................... 1000 to 1200 Ohms
B. Perform a 45 N (10 lb) pull test on each of
the wires that are associated with the engine Expected Result:
speed/timing sensors.
The resistance measurements are within the
C. Check the allen head screw on each ECM specifications.
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect” Results:
for the correct torque values.
• OK – The resistance measurements are within
D. Check the harness and the wiring for abrasion the specifications. The wiring appears to be OK.
and for pinch points from each sensor back to the There could be a problem with the sensor or with
ECM. the ECM. Proceed to Test Step 6.

Expected Result: • Not OK – At least one of the resistance


measurements is not within the specifications.
All of the connectors, pins and sockets are completely Proceed to Test Step 5.
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, and of pinch points.
112 RENR5093-01
Troubleshooting Section

Test Step 5. Measure the Sensor d. Connect each connector and verify that the
Resistance at the Sensor Connector latch tab of each connector is latched on both
sides.
A. Disconnect the engine harness from the suspect
sensor. e. Ensure that the harness is properly secured,
and ensure that the harness is attached to the
B. For the primary engine speed/timing sensor, harness clip.
measure the resistance between J401-2 (primary
engine speed/timing +) to J401-1 (primary engine B. Reconnect all of the connectors.
speed/timing −).
C. Clear any diagnostic codes.
Resistance ................................ 110 to 200 Ohms
D. Start the engine. Run the engine until the engine
C. For the secondary engine speed/timing sensor, is at normal operating temperature. The problem
measure the resistance between J402-2 may only occur when the engine is at the normal
(secondary engine speed/timing +) to J402-1 operating temperature.
(secondary engine speed/timing −).
Expected Result:
Resistance ............................ 1000 to 1200 Ohms
No diagnostic codes for the engine speed/timing
Expected Result: sensor are activated.

The resistance measurement for the suspect sensor Results:


is within the specification.
• OK – No diagnostic codes for the engine
Results: speed/timing sensor are activated. Resume normal
operation. STOP.
• OK – The resistance measurement for the suspect
sensor is within the specification. The sensor’s • Not OK – The diagnostic code for the engine
resistance measurement at the P2 connector was speed/timing sensor remains. Replacing the
incorrect. There is a problem with the wiring. There sensor did not solve the problem. There may be a
may be a problem with a connector. problem with the ECM.

Repair: Repair the connection and/or the wiring, Repair: It is unlikely that the ECM has failed. Exit
when possible. Replace parts, if necessary. this procedure and perform this procedure again.
Twisted pair wiring is required. The wiring must If the problem is not resolved, install a new ECM.
have at least one twist per inch. Verify that the Refer to Troubleshooting, “Replacing the ECM”.
problem is resolved. Verify that the original problem is resolved.

STOP. STOP.

• Not OK – The resistance measurement for the i02353307


suspect sensor is not within the specification.
There is a problem with the sensor. Proceed to
Test Step 6.
Engine Temperature Sensor
Open or Short Circuit - Test
Test Step 6. Check the Sensor
SMCS Code: 1439-038-TA; 1906-038
A. Temporarily replace the suspect sensor. Perform
the following procedure in order to replace the System Operation Description:
sensor assembly.
Use this procedure to troubleshoot any suspect
Note: Do not switch the positions of the sensors. The problems with the following sensors:
sensors are not interchangeable. A timing calibration
is not required when the sensors are replaced. • Coolant temperature sensor
a. Lubricate the O-ring seals with oil. • Fuel temperature sensor
b. Fully seat the sensor into the front housing. • Inlet manifold temperature sensor
c. Tighten the bracket bolt. • Fuel outlet temperature sensor
RENR5093-01 113
Troubleshooting Section

This procedure covers the following diagnostic codes:

• 110-03 Engine Coolant Temperature open/short


to +batt

• 110-04 Engine Coolant Temperature short to


ground

• 172-03 Intake Manifold Air Temp open/short to


+batt

• 172-04 Intake Manifold Air Temp short to ground


• 174-03 Fuel Temperature open/short to +batt
• 174-04 Fuel Temperature short to ground
• 1929-03 Fuel Return Temperature Sensor
high/short to +batt

• 1929-04 Fuel Return Temperature Sensor


low/short to ground

The troubleshooting procedures for the diagnostic


codes of each temperature sensor are identical.
The temperature sensors are passive sensors that
have two terminals. The temperature sensors do not
require supply voltage from the Electronic Control
Module (ECM).

g01175264
Illustration 58
Schematic for engine temperature sensors

Test Step 1. Inspect the Electrical


Connectors and the Wiring
A. Turn the keyswitch to the OFF position.
114 RENR5093-01
Troubleshooting Section

g01175267
Illustration 59
Left side engine view (typical engine view)
(1) Engine coolant temperature sensor
(2) Fuel temperature sensor
(3) Fuel outlet temperature sensor
(4) Inlet air temperature sensor
(5) J2/P2 ECM connector

B. Thoroughly inspect connector (5). Also, thoroughly


inspect the connectors for temperature sensors
(1), (2), (3), and (4). Refer to Troubleshooting,
“Electrical Connectors - Inspect”.

g01150540
Illustration 60
P2 terminals that are associated with the engine temperature
sensors
(P2-18) Sensor return
(P2-32) Engine coolant temperature
(P2-33) Fuel temperature
(P2-34) Fuel outlet
(P2-35) Inlet air temperature

g01146837
Illustration 61
Harness connector for the temperature sensors
(1) Signal
(2) Return

C. Perform a 45 N (10 lb) pull test on each of the


wires that are associated with the temperature
sensors.
RENR5093-01 115
Troubleshooting Section

D. Check the allen head screw on each ECM Repair: The problem may have been related
connector for the proper torque. Refer to to a faulty connection in the harness. Carefully
Troubleshooting, “Electrical Connectors - Inspect” reinspect the connectors and wiring. Refer to
for the correct torque values. Troubleshooting, “Electrical Connectors - Inspect”
for additional information.
E. Check the harness and wiring for abrasions and
for pinch points from each sensor to the ECM. STOP.

Expected Result: • Not OK – An -04 diagnostic code is active at this


time. Proceed to Test Step 3.
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are • Not OK – An -03 diagnostic code is active at this
free of corrosion, of abrasion, and of pinch points. time. Proceed to Test Step 4.

Results: Test Step 3. Disconnect the Suspect


Sensor in Order to Create an Open Circuit
• OK – The connectors and wiring appear to be OK.
Proceed to Test Step 2. A. Turn the keyswitch to the OFF position.

• Not OK – There is a problem in the connectors B. Disconnect the suspect sensor from the engine
and/or wiring. harness.

Repair: Repair the wiring and/or the connectors. C. Turn the keyswitch to the ON position. Wait at
Replace parts, if necessary. Ensure that all of the least 15 seconds for activation of the diagnostic
seals are properly in place and ensure that the codes.
connectors are completely coupled.
D. Use Cat ET to check for an active -03 diagnostic
Verify that the repair eliminates the problem. code for the suspect sensor.

STOP. E. Turn the keyswitch to the OFF position.

Test Step 2. Check for Active Diagnostic Expected Result:


Codes
An -03 diagnostic code is now active for the suspect
A. Connect Caterpillar Electronic Technician (ET) to sensor.
the service tool connector.
Results:
B. Turn the keyswitch to the ON position.
• OK – An -04 diagnostic code was active before
C. Check for active diagnostic codes on Cat ET. disconnecting the sensor. An -03 diagnostic code
Check and record any active diagnostic codes. became active after the sensor was disconnected.
There may be a problem with the sensor.
Note: Wait at least 15 seconds in order for the
diagnostic codes to become active. Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the
D. Look for an -03 diagnostic code or an -04 engine. Verify that there are no active diagnostic
diagnostic code. codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently
Expected Result: install the new sensor. Clear any logged diagnostic
codes.
No diagnostic codes are active.
Verify that the repair eliminates the problem.
Results:
STOP.
• OK – No diagnostic codes are active. The problem
appears to be resolved. • Not OK – The -04 diagnostic code is still present.
Leave the sensor disconnected. Proceed to Test
Step 7.
116 RENR5093-01
Troubleshooting Section

Test Step 4. Check the Pull-up Voltage at Expected Result:


the Sensor Connector
Each check of the resistance indicates an open
A. Disconnect the suspect sensor at the sensor circuit.
connector.
Results:
B. Turn the keyswitch to the ON position.
• OK – Each check of the resistance indicates an
C. Measure the voltage between terminal 1 (signal) open circuit. Proceed to Test Step 6.
and terminal 2 (return) at the harness connector.
• Not OK – At least one check of the resistance does
D. Turn the keyswitch to the OFF position. not indicate an open circuit. There is a problem
with the wiring. There may be a problem with a
Expected Result: connector.

The voltage is 5.5 ± 0.5 VDC. Repair: Repair the wiring and/or the connectors.
Replace parts, if necessary.
Results:
Verify that the original problem is resolved.
• OK – The voltage is 5.5 ± 0.5 VDC. The correct
pull-up voltage is present at the harness connector STOP.
for the suspect sensor.
Test Step 6. Create a Short at the Suspect
Repair: The open circuit is in the sensor or the Sensor Connector
wire between the sensor and the sensor connector.
Replace the sensor. Do not install the sensor in A. Turn the keyswitch to the OFF position.
the engine. Verify that no diagnostic codes are
active for the suspect sensor before permanently B. Install a jumper wire between terminals 1 and 2 on
installing the sensor. the harness connector for the suspect sensor.

STOP. C. Turn the keyswitch to the ON position.

• Not OK – The voltage is not 5.5 ± 0.5 VDC. D. Wait at least 15 seconds for activation of the -04
Proceed to Test Step 5. diagnostic code.

Test Step 5. Check the Signal Wire for a Note: Use Cat ET to check for active diagnostic
Short Circuit codes before installing the jumper wire and after
installing the jumper wire.
A. Turn the keyswitch to the OFF position.
E. Remove the jumper wire. Check for an -04
B. Disconnect the P1 and P2 connectors. diagnostic code again.

C. Measure the resistance between the terminal F. Turn the keyswitch to the OFF position.
for the suspect sensor’s signal wire at the ECM
connector and all of the remaining terminals on Expected Result:
the P2 connector.
An -04 diagnostic code is active when the jumper
D. Measure the resistance between the terminal wire is installed. An -03 diagnostic code is active
for the suspect sensor’s signal wire at the ECM when the jumper wire is removed.
connector and all of the terminals on the P1
connector. Results:

E. Measure the resistance between the terminal • OK – The engine harness and the ECM are OK.
for the suspect sensor’s signal wire at the ECM
connector and the engine ground.

F. Connect the J1/P1 and J2/P2 connectors.


RENR5093-01 117
Troubleshooting Section

Repair: Temporarily connect a new sensor to the Expected Result:


harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic A -03 diagnostic code is active when the sensor
codes for the sensor. If there are no active signal wire is removed from the ECM connector. A
diagnostic codes for the sensor, permanently -04 diagnostic code is active when the signal wire
install the new sensor. Clear any logged diagnostic is connected to ground.
codes.
Results:
STOP.
• OK – The ECM is working properly. The problem
• Not OK – The -03 diagnostic code remains active is in the wiring between the ECM and the sensor
with the jumper in place. Proceed to Test Step 7. connector.

Test Step 7. Check the Operation of the Repair: If the code is active for more than one
ECM sensor, the problem is most likely in the return wire
for the sensor. Repair the return wire for the sensor
A. Turn the keyswitch to the OFF position. or replace the harness.

B. Check the operation of the ECM by creating an If the code is only active for one sensor, the
open circuit at the ECM: problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor.
a. Disconnect the P2 ECM connector.
STOP.
b. Remove the signal wire for the suspect sensor
from the P2 connector. • Not OK – One of the following conditions exists:
The -03 diagnostic code is not active when the
c. Turn the keyswitch to the ON position. Monitor sensor signal wire is disconnected. The -04
the “Active Diagnostic Code” screen on Cat diagnostic code is not active when the wire jumper
ET. Wait at least 15 seconds for activation of is installed.
the code.
Repair: Replace the ECM. Refer to
A -03 diagnostic code should be active for the Troubleshooting, “Replacing the ECM”.
suspect sensor. Verify that the problem is resolved.

d. Turn the keyswitch to the OFF position. STOP.

C. Check the operation of the ECM by creating a


i02302042
short at the ECM:

a. Disconnect the P2 ECM connector.


Injector Solenoid Circuit - Test
SMCS Code: 1290-038
b. Crimp a terminal onto a jumper wire that is long
enough to connect from the ECM connector to System Operation Description:
engine ground. Install the terminal of the jumper
wire into the appropriate terminal location of Use this procedure under the following circumstances:
the ECM connector for the suspect sensor.
Ground the other end of the jumper wire.
• 1-11 Injector Cylinder #1 fault
c. Connect the P2 connector.
• 2-11 Injector Cylinder #2 fault
d. Turn the keyswitch to the ON position. • 3-11 Injector Cylinder #3 fault
e. Monitor the “Active Diagnostic Code” screen on
• 4-11 Injector Cylinder #4 fault
Cat ET. Wait at least 15 seconds for activation
of the code.
• 5-11 Injector Cylinder #5 fault
An -04 diagnostic code should be active when • 6-11 Injector Cylinder #6 fault
the wire jumper is installed.
• The procedure Troubleshooting, “Troubleshooting
f. Remove the wire jumper. Return all wiring to without a Diagnostic Code” directed you to this test.
the original configuration.
118 RENR5093-01
Troubleshooting Section

Perform this procedure under conditions that are


identical to the conditions that exist when the problem
occurs. Typically, problems with the injector solenoid
occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).

The engine has electronic unit injectors that are


mechanically actuated and electronically energized.
The Electronic Control Module (ECM) sends a 105
volt pulse to each injector solenoid. The pulse is
sent at the proper time and at the correct duration
for a given engine load and speed. The solenoid
is mounted on top of the fuel injector body. The
105 volt pulse can be individually cut out to aid in
troubleshooting misfire problems.

If an open is detected in the solenoid circuit, a


diagnostic code is generated. The ECM continues
to try to fire the injector. If a short is detected, a
diagnostic code is generated. 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.

The injector codes must be programmed into the


ECM. The injector code is a four digit number (last
four digits of the serial number for the injector) that is
g01147070
found on each of the unit injectors. The ECM uses this Illustration 62
number to compensate for manufacturing variations Electronic Unit Injector (EUI)
between individual injectors. If you replace any of the
unit injectors, you must reprogram the code for the
new injectors. Also, if you replace the ECM, you must
reprogram all of the injector codes. The ECM will
generate a 268-02 Check Programable Parameters if
the injector codes have not been programmed.

For more information, refer to the calibration


procedure Troubleshooting, “Injector Code -
Calibrate”.
RENR5093-01 119
Troubleshooting Section

g01152739
Illustration 63
Schematic for the injector solenoids

Test Step 1. Inspect the Electrical


Connectors and the Wiring

Electrical shock hazard. The electronic unit injec-


tor system uses 90-120 volts.

A. Turn the keyswitch to the OFF position.

g01147054
Illustration 65
Left side engine view (typical example)
(2) J300/P300 Injector valve cover entry connector

B. Thoroughly inspect connectors (1) and (2). Refer


to Troubleshooting, “Electrical Connectors -
Inspect” for details.

g01147202
Illustration 64
Left side engine view (typical example)
(1) J2/P2 ECM connector
120 RENR5093-01
Troubleshooting Section

g01153072
Illustration 67
J300 terminals for the injector solenoids
(J300-1) Injector 1 return
(J300-2) Injector 2 return
(J300-3) Injector 3 return
(J300-4) Injector 4 return
(J300-5) Injector 5 return
(J300-6) Injector 6 return
(J300-8) Injector 5 & 6 supply
(J300-10) Injector 3 & 4 supply
(J300-12) Injector 1 & 2 supply

C. Perform a 45 N (10 lb) pull test on each of the


wires in the ECM connector and each of the wires
that are associated with injector solenoids.

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.
g01152825
Illustration 66 E. Check the harness and wiring for abrasions and
P2 terminals for the injector solenoids for pinch points from the injectors to the ECM.
(P2-36) Injector 1 return
(P2-37) Injector 2 return Expected Result:
(P2-38) Injector 3 return
(P2-39) Injector 4 return All connectors, pins, and sockets should be
(P2-44) Injector 1 & 2 supply
(P2-45) Injector 3 & 4 supply completely coupled and/or inserted. The harness and
(P2-46) Injector 5 & 6 supply wiring should be free of corrosion, of abrasion, and
(P2-54) Injector 5 return of pinch points.
(P2-55) Injector 6 return
Results:

• OK – Proceed to Test Step 2.


• Not OK – There is a problem with the connectors
and/or wiring.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.
RENR5093-01 121
Troubleshooting Section

Test Step 2. Check for Logged Diagnostic H. Select the “4 Cylinder Cutout Test” which is the
Codes default test.

A. Connect the Caterpillar Electronic Technician (ET) I. Follow the instructions that are provided in the
to the service tool connector. “Cylinder Cutout test”. The cylinder cutout tests
are interactive so the procedure is guided to the
B. Turn the keyswitch to the ON position. finish.

C. Monitor the “Logged Diagnostic Codes” screen Expected Result:


on Cat ET.
The variation of the fuel rate for all cylinders is within
Expected Result: specifications.

One or more of the following diagnostic codes has Results:


been logged:
• OK – The variation of the fuel rate for all cylinders
• 1-11 is within specifications.

• 2-11 Repair: If the engine is misfiring or if the


engine has low power, refer to the diagnostic
• 3-11 procedure Troubleshooting, “Engine Misfires,
Runs Rough or Is Unstable” and the diagnostic
• 4-11 procedure Troubleshooting, “Low Power/Poor or
No Response to Throttle”.
• 5-11
If a diagnostic code results from running the
• 6-11 “Cylinder Cutout Test”, proceed to Test Step 4.

Results: • Not OK – A problem was found with one of the


cylinders. Proceed to Test Step 4.
• OK – There are logged diagnostic codes for the
injectors. Proceed to Test Step 4. Test Step 4. Use the Injector Solenoid
Test to Test the Injector Solenoids
• Not OK – There are no logged diagnostic codes
for the injectors. Proceed to Test Step 3. A. Start the engine.

Test Step 3. Check the Variation of the B. Allow the engine to warm up to normal operating
Injectors Between Each of the Cylinders temperature (approximately 77 °C (171 °F)).

A. Connect Cat ET to the service tool connector. C. Stop the engine.

B. Start the engine. D. Turn the keyswitch to the ON position.

C. Allow the engine to warm up to normal operating E. Access the “Injector Solenoid Test” by accessing
temperature (approximately 77 °C (171 °F)). the following display screens in order:

D. After the engine is warmed to operating • “Diagnostics”


temperature, access the “Cylinder Cutout Test” on
Cat ET by accessing the following display screens • “Diagnostic Tests”
in order:
• “Injector Solenoid Test”
• “Diagnostics”
F. Activate the test.
• “Diagnostic Tests”
Note: The test is in the “Interactive Diagnostic Tests”.
• “Cylinder Cutout Test” Do not confuse the injector solenoid test with the
cylinder cutout test. The cylinder cutout test is used
E. Shut off all parasitic loads. to shut off fuel to a specific cylinder while the engine
is running. The injector solenoid test is used in order
F. Set the engine speed to 1200 ± 20 rpm. to actuate the injector solenoids. This allows the click
of the injector solenoids to be heard when the engine
G. Select the start button at the bottom of the screen is not running in order to determine that the circuit is
for the cylinder cutout test. functioning properly.
122 RENR5093-01
Troubleshooting Section

G. As each solenoid is energized by the ECM an Test Step 6. Use the Injector Solenoid
audible click can be heard at the valve cover. Test to Check for Opens in the Engine
Listen for a click at each valve cover. A black Wiring Harness
square will appear over the cylinder number on
the Cat ET when the cylinder is being fired.

H. Perform the injector solenoid test at least two


times.

Expected Result:

All cylinders indicate “OK”.

Results:

• OK – There is not an electronic problem with the


injectors at this time.
g01153124
Repair: If the cylinder cutout test returned a “NOT Illustration 68
OK” for any injector, refer to Troubleshooting, J300/P300 Injector valve cover entry connector (terminal side)
“Engine Misfires, Runs Rough or Is Unstable”. (P300-1) Injector 1 return
(P300-2) Injector 2 return
STOP. (P300-3) Injector 3 return
(P300-4) Injector 4 return
(P300-5) Injector 5 return
• Not OK – Note the cylinders that indicate “OPEN” (P300-6) Injector 6 return
and/or “SHORT”. Proceed to Test Step 5. (P300-8) Injector 5 & 6 supply
(P300-10) Injector 3 & 4 supply
Test Step 5. Use the Injector Solenoid (P300-12) Injector 1 & 2 supply
Test to Check for Shorts in the Engine
Wiring Harness

Electrical shock hazard. The electronic unit injec-


tor system uses 90-120 volts.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts. A. Turn the keyswitch to the OFF position.

A. Turn the keyswitch to the OFF position. B. Disconnect the J300/P300 injector valve cover
entry connector.
B. Disconnect the J300/P300 injector valve cover
entry connector at the valve cover base. C. Fabricate a jumper wire 100 mm (4 inch) long.
Crimp a Deutsch pin to both ends of the wire.
C. Turn the keyswitch to the ON position.
D. Insert one end of the jumper wire into the
D. Perform the injector solenoid test at least two connector socket for supply wire of the problem
times. injector. Insert the other end of the jumper wire
into the appropriate socket for the suspect injector
Expected Result: in the P300 valve cover connector. For example, if
injector 5 is the problem injector, insert the jumper
All cylinders indicate “OPEN”. in terminal 5 and in terminal 8 of the P300 injector
valve cover entry connector.
Results:
E. Turn the keyswitch to the ON position.
• OK – Proceed to Test Step 6. F. Perform the injector solenoid test at least two
times.
• Not OK – Record the cylinder numbers that
indicate a short circuit. Proceed to Test Step 7.
G. Turn the keyswitch to the OFF position.
RENR5093-01 123
Troubleshooting Section

H. Repeat this test for each suspect Injector. Ensure Results:


that the injector solenoid test is disabled before
handling the jumper wires. • OK – All cylinders indicate “OPEN”.
Expected Result: Repair: The short circuit is in the engine harness.
Repair the engine harness or replace the engine
Cat ET displays “SHORT” for the cylinder with the harness, as required. Clear all diagnostic codes
jumper wire. after completing this test step.

Results: Verify that the repair eliminates the problem.

• OK 1 - “SHORT” – The results that were recorded STOP.


from Test Step 4 indicated that only one injector
had an “OPEN” or “SHORT”, or that one injector • Not OK – At least one cylinder indicates “SHORT”.
had an “OPEN” but the other injector on the
injector’s supply line had a “SHORT”. Proceed to Repair: Perform the following repair:
Test Step 9.
1. Temporarily connect a test ECM.
• OK 2- “SHORT” – The results that were recorded
from Test Step 4 indicated that two injectors that 2. Remove all jumpers and replace all connectors.
share an injector’s supply line are open. Proceed
to Test Step 10. 3. Recheck the system for active diagnostic codes.

• OK 3 - “SHORT” – The results that were recorded 4. Repeat the test step.
from Test Step 4 indicated that two injectors that
share an injector’s supply line are shorted. Proceed 5. If the problem is resolved with the test ECM,
to Test Step 11. reconnect the suspect ECM.

• Not OK - “OPEN” – Cat ET displays “Open” for 6. If the problem returns with the suspect ECM,
the cylinder with the jumper wire. Proceed to Test replace the ECM.
Step 8.
7. Verify that the repair eliminates the problem.
Test Step 7. Use the Injector Solenoid
Test to Check the ECM for Short Circuits STOP.

Test Step 8. Check the ECM for an Open


Circuit
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.

Electrical shock hazard. The electronic unit injec-


A. Ensure that the keyswitch is in the OFF position. tor system uses 90-120 volts.
B. Disconnect the J2/P2 ECM connector from the
ECM and check for evidence of moisture entry. A. Ensure that the keyswitch is in the OFF position.

C. Turn the keyswitch to the ON position. B. Disconnect the engine harness from the J2 ECM
connector. Install a breakout T to the ECM. Do not
D. Perform the injector solenoid test at least two connect the P2 ECM connector to the breakout T.
times.
C. Use a jumper wire to short between the socket
Expected Result: of the injector and the socket for the supply line
of the suspect injector.
All cylinders indicate “OPEN” when the P2 ECM
connector is disconnected from the ECM. D. Turn the keyswitch to the ON position.

Note: When the engine harness is disconnected E. Perform the injector solenoid test at least two
all of the diagnostic codes for supply voltage to the times.
sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step. Note: When the ECM connector is disconnected
all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step.
124 RENR5093-01
Troubleshooting Section

F. Turn the keyswitch to the OFF position. D. Attach a jumper wire to both terminals of the
injector harness for the two injectors that share
Expected Result: a supply line.

Cat ET displays “SHORT” for the cylinder with the E. Turn the keyswitch to the ON position.
jumper wire.
F. Perform the injector solenoid test at least two
Results: times.

• OK – The ECM is OK. G. Turn the keyswitch to the OFF position.

Repair: There is a open in the harness between Expected Result:


the P300 Injector valve cover entry connector
and the P2 ECM connector. Replace the engine The cylinders with the short in place indicate an
harness or repair the engine harness, as required. “OPEN”.

Verify that the repair eliminates the problem. Results:

STOP. • OK – The problem appears to be in the engine


harness under the valve cover.
• Not OK
Repair: Perform the following repair:
Repair: Perform the following repair:
1. Replace the engine harness under the valve
1. Temporarily connect a test ECM. cover.

2. Remove all jumpers and replace all connectors. 2. Run the injector solenoid test in order to check
the installation of the new harness before
3. Recheck the system for active diagnostic codes. installing the valve covers.

4. Repeat the test step. 3. Verify that the repair eliminates the problem.

5. If the problem is resolved with the test ECM, STOP.


reconnect the suspect ECM.
• Not OK – Both injectors indicate “SHORT”.
6. If the problem returns with the suspect ECM,
replace the ECM. Repair: Replace both injectors.

7. Verify that the repair eliminates the problem. Verify that the repair eliminates the problem.

STOP. STOP.

Test Step 9. Check the Injector Harness


Under the Valve Cover

Electrical shock hazard. The electronic unit injec-


tor system uses 90-120 volts.

A. Ensure that the keyswitch is in the OFF position.

B. Remove the valve cover.

C. Disconnect each of the injectors that indicate an


“OPEN” from the wiring harness. Ensure that each
of the connectors from the disconnected injector
harness does not touch other components and
short to ground.
RENR5093-01 125
Troubleshooting Section

Test Step 10. Check the Engine Harness 2. Run the injector solenoid test in order to check
Under the Valve Cover for an Open the installation of the new harness before
Circuit in the Supply Line installing the valve covers.

3. Verify that the repair eliminates the problem.

STOP.

• Not OK – Both injectors indicate “SHORT”.


Repair: Replace both injectors.

Verify that the repair eliminates the problem.

STOP.

Test Step 11. Check the Engine Harness


Under the Valve Cover for Short Circuits
Illustration 69
g01147088
in the Injector Wires
Connector terminals for the solenoid connector

Electrical shock hazard. The electronic unit injec-


Electrical shock hazard. The electronic unit injec- tor system uses 90-120 volts.
tor system uses 90-120 volts.
A. Ensure that the keyswitch is in the OFF position.
A. Ensure that the keyswitch is in the OFF position.
B. Remove the valve cover.
B. Remove the valve cover.
C. Disconnect each of the injectors that indicate a
C. Disconnect each of the injectors that indicate an “SHORT” from the wiring harness. Ensure that
“OPEN” from the wiring harness. Ensure that each each of the connectors from the disconnected
of the connectors from the disconnected injector injector harness does not touch other components
harness does not touch other components and and short to ground.
short to ground.
D. Turn the keyswitch to the ON position.
D. Attach a jumper wire to both terminals of the
injector harness for the two injectors that share E. Perform the injector solenoid test at least two
a supply line. times.

E. Turn the keyswitch to the ON position. F. Turn the keyswitch to the OFF position.

F. Perform the injector solenoid test at least two Expected Result:


times.
Both cylinders indicate an “OPEN”.
Expected Result:
Results:
The cylinders with the short in place indicate an
“OPEN”. • OK – Neither of the injector wires are shorted to
the engine.
Results:
Repair: Leave the injector wires disconnected.
• OK – The problem appears to be in the engine
harness under the valve cover. Proceed to Test Step 12.

Repair: Perform the following repair: • Not OK – There is a short in the injector harness
under the valve cover.
1. Replace the engine harness under the valve
cover. Repair: Replace the injector harness under the
valve cover.
126 RENR5093-01
Troubleshooting Section

Verify that the repair eliminates the problem. E. Turn the keyswitch to the OFF position.

STOP. Expected Result:

Test Step 12. Check for a Short Circuit in The reconnected injector indicates a “SHORT”.
the Supply Line to the Engine
Results:

• OK – The injector has an internal short.


Electrical shock hazard. The electronic unit injec- Repair: Replace the Injector.
tor system uses 90-120 volts.
Verify that the repair eliminates the problem.
A. Ensure that the keyswitch is in the OFF position.
STOP.
B. Disconnect the J2/P2 ECM connector.
• Not OK – The injector is OK. There may be a
C. Locate the supply line for the problem injector in problem with the other injector. Proceed to Test
the P2 connector. Measure the resistance from Step 14.
the terminal to the engine ground stud connection.
Test Step 14. Check for a Short Circuit
Expected Result: in the Other Injector

The multimeter indicates that the resistance is


greater than five Ohms.
Electrical shock hazard. The electronic unit injec-
Results:
tor system uses 90-120 volts.
• OK – The harness is not shorted to ground.
A. Ensure that the keyswitch is in the OFF position.
Repair: Reconnect the engine harness to the ECM.
B. Reconnect the other disconnected injector.
Proceed to Test Step 13.
C. Turn the keyswitch to the ON position.
• Not OK
D. Perform the injector solenoid test at least two
Repair: Replace the injector harness under the times.
valve cover.
Expected Result:
Verify that the repair eliminates the problem.
The reconnected injector indicates a “SHORT”.
STOP.
Results:
Test Step 13. Check for a Short Circuit in
the Injector • OK – The injector has an internal short.
Repair: Replace the faulty injector. Restore the
wiring to the proper injectors.
Electrical shock hazard. The electronic unit injec- Verify that the repair eliminates the problem.
tor system uses 90-120 volts.
STOP.
A. Ensure that the keyswitch is in the OFF position.
• Not OK – This injector is OK.
B. Reconnect one of the two disconnected injectors.
Repair: There may be an intermittent problem. If
C. Turn the keyswitch to the ON position. the problem is intermittent, refer to the diagnostic
functional test Troubleshooting, “Electrical
D. Perform the injector solenoid test at least two Connectors - Inspect”.
times.
STOP.
RENR5093-01 127
Troubleshooting Section

i02312818

Speed Control - Test


SMCS Code: 1439-038; 1913-038

System Operation Description:

The rotary position sensor provides a throttle signal


to the engine’s Electronic Control Module (ECM). The
output for rated speed is a pulse width modulated
signal (PWM) at a constant frequency. The throttle
signal varies with the position of the rotary position
sensor. The output signal is referred to as a duty
cycle or as a Pulse Width Modulated signal (PWM).
The output signal is expressed as a percentage
between 0 and 100 percent for the speed adjust.

The ECM calculates the desired engine rpm from the


rated speed signal. The rated speed signal is valid
when the duty cycle is in the range of 5 to 95 percent.
If the ECM determines that the rated speed signal is
invalid, the engine rpm will be set to the programmed
low idle.

Some applications may choose not to use the


rotary position sensor. Some applications may use
a load sharing module. The load sharing module is
configured to provide the engine control with a rated
speed signal. The signal has the same characteristics
as the above defined signal. Some of these load
sharing modules can not provide a signal until the
engine is running. In these cases, troubleshooting
should be performed while the engine is running.
128 RENR5093-01
Troubleshooting Section

g01173277
Illustration 70
Schematic

g00766798
Illustration 71
Percent of throttle position versus PWM input
RENR5093-01 129
Troubleshooting Section

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:

• OK – The connectors and wiring are okay. Proceed


to Test Step 2.

• Not OK – The connectors and/or wiring are not


okay.

Repair: Repair the connectors or wiring and/or


replace the connectors or wiring.

STOP.

Test Step 2. Check the Supply Voltage to


the Rotary Position Sensor
A. Connect one probe of a voltmeter to the +Battery
terminal of the rotary position sensor. Connect one
probe of the voltmeter to the −Battery terminal of
the rotary position sensor.

B. Turn the keyswitch to the ON position.

C. Measure the battery voltage at the rotary position


sensor.

Expected Result:

Illustration 72
g01173295 The supply voltage is between 11.0 VDC and 13.5
VDC for a 12 Volt system and the supply voltage
P1 ECM connector
is between 22.0 VDC and 27.0 VDC for a 24 Volt
(P1-66) Primary speed signal system.
(P1-44) Droop-Isoch switch
(P1-68) Secondary speed signal
Results:
Test Step 1. Check for Connector
Damage. • OK – The supply voltage is reaching the rotary
position sensor. Proceed to Test Step 5.
A. Turn the keyswitch to the OFF position.
• Not OK – The supply voltage is not reaching the
B. Thoroughly inspect the J61/P61 customer rotary position sensor. Proceed to Test Step 3.
connector, the J1/P1 ECM connector, the J2/P2
ECM connector and any related connectors. Test Step 3. Measure the No-Load Battery
Refer to Troubleshooting, “Electrical Connectors - Voltage
Inspect” for details.
A. Measure the no-load battery voltage at the battery
C. Perform a 45 N (10 lb) pull test on each of the posts.
wires in the connectors.
Note: Load test the batteries by using the 4C-4911
D. Check each connectors (allen head screw) for Battery Load Tester. Refer to Special Instruction,
the proper torque. Refer to Troubleshooting, SEHS9249, “Use of the 4C-4911 Battery Load
“Electrical Connectors - Inspect” for details. Tester” and Special Instruction, SEHS7633, “Battery
Test Procedure” for further assistance.
E. Check the harness and wiring for abrasions and
for pinch points from the battery to the ECM.
130 RENR5093-01
Troubleshooting Section

Expected Result: Results:

The no-load voltage is at least 11.0 VDC for a 12 Volt • OK – A valid signal appears at the customer
system and the no-load voltage is at least 22.0 VDC connector. Your application is equipped with an
for a 24 Volt system. The batteries pass the load test. engine control. Proceed to Test Step 5 .

Results: • OK – A valid signal appears at the customer


connector. Your application is not equipped with an
• OK – The voltage is in the range at the battery engine control. Proceed to Test Step 6.
posts.
• Not OK – A valid signal is not present at the
Repair: Repair the wiring between the battery and customer connector.
the rotary position sensor.
Repair: Perform the following diagnostic
STOP. procedure.

• Not OK – The voltage is out of the range at the 1. Verify that a valid signal is present at the rotary
battery posts. position sensor. If a valid signal is present at the
rotary position sensor, repair the corresponding
Repair: The battery voltage is out of the range. signal wire between the customer connectors
J61:10 or J61:4and the rotary position sensor.
1. Replace the batteries.
2. If a valid signal is not present at the speed
2. Repeat the battery test. control, replace the rotary position sensor. Verify
that the repair fixes the problem.
3. Verify that the problem is eliminated.
STOP.
4. Clear all logged diagnostic codes.
Test Step 5. Check the Duty Cycle at the
STOP. Engine Control Connector (if applicable)
Test Step 4. Check the Duty Cycle at the A. Turn the keyswitch to the OFF position.
Customer Connector
B. Remove the wire M971-BR from the engine
A. Turn the keyswitch to the OFF position. control connector.

B. Remove the signal wires from the customer C. Turn the keyswitch to the ON position.
connector P61:10 and P61:4.
D. Fabricate a jumper wire. Measure the duty cycle
C. Turn the keyswitch to the ON position. between wire M971-BR and the −Battery.

D. Measure the duty cycle between P61:10 and the E. Move the throttle from low idle to high idle and
−Battery. Measure the duty cycle between P61:4 monitor the duty cycle output of the throttle
and the −Battery. position sensor on the multimeter.

E. Move the throttle from low idle to high idle and F. Turn the keyswitch to the OFF position.
monitor the duty cycle output of the throttle
position sensor on the multimeter. G. Reconnect the wire M971-BR to the engine control
connector.
F. Turn the keyswitch to the OFF position.
Expected Result:
G. Reconnect the signal wires to the customer
connector. The duty cycle is between 5 percent and 10 percent
when the throttle is at low idle. The duty cycle is
Expected Result: between 90 percent to 95 percent when the throttle
is at high idle.
The duty cycle is between 5 percent and 10 percent
when the throttle is at low idle. The duty cycle is Results:
between 90 percent to 95 percent when the throttle
is at high idle. • OK – A valid signal appears at the engine control
connector. Proceed to Test Step 6.
RENR5093-01 131
Troubleshooting Section

• Not OK – A valid signal is not present on the i02352985


M971-BR at the engine control connector.
Switch Circuits - Test
Repair: Replace the wire M971-BR between the
connectors. SMCS Code: 1435-038

STOP. System Operation Description:

Test Step 6. Check the Duty Cycle at the Switch circuits may have problems such as faulty
ECM wiring, faulty switches, or faulty connectors. Use the
following diagnostic procedures in order to diagnose
A. Remove the wire M971-BR from ECM connector problems with these switch circuits and repair these
P1:66. Remove the wire M974-YL from ECM switch circuits:
connector P1:68.
• Diagnostic reset switch
B. Turn the keyswitch to the ON position.
• Droop-isochronous switch
C. Measure the duty cycle between wire M971-BR
and the −Battery. Measure the duty cycle between • Low idle switch
wire M974-YL and the −Battery.
• Maintenance clear switch
D. Move the throttle from low idle to high idle and
monitor the duty cycle output of the throttle • Remote engine stop switch
position sensor on the multimeter.
• Run/stop switch
Expected Result:
The switches are normally open or normally closed.
The duty cycle is between 5 percent and 10 percent
when the throttle is at low idle. The duty cycle is
between 90 percent to 95 percent when the throttle
is at high idle.

Results:

• OK – The duty cycle is in the range.


Repair:

1. Turn the keyswitch to the OFF position.

2. Reconnect the original wiring.

3. Turn the keyswitch to the ON position.

4. Check for the active diagnostic code 91-08.

If the diagnostic code 91-08 is present, replace


the ECM. Refer to the diagnostic procedure
Troubleshooting, “Replacing the ECM”. Illustration 73
g01121934

Typical switch inputs


STOP.
Test Step 1. Check the Electrical
• Not OK – The signal is not present at the ECM. Connectors and the Wiring
Repair: Replace the wires between the ECM A. Place the keyswitch in the OFF position.
connector and the customer connector.

STOP.
132 RENR5093-01
Troubleshooting Section

g01146374
Illustration 74
Location of the Electronic Control Module (ECM) (typical example)
(1) J1/P1 ECM connectors

g01175187
Illustration 76
P1 terminals for the various switches
(P1-22) Maintenance clear switch
(P1-23) Remote engine stop switch
(P1-40) Run/stop switch
(P1-41) Diagnostic reset switch
(P1-46) Droop-isochronous switch
(P1-47) Low idle switch

g01146383
Illustration 75
Location of the customer connector (typical example)
(2) P61 customer connector

B. Thoroughly inspect connectors (1) and (2).


Thoroughly inspect the connections for the
suspect switch. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.
RENR5093-01 133
Troubleshooting Section

Repair: Repair the wiring and/or the connector.


Replace parts, if necessary. Ensure that all of the
seals are properly connected. Verify that the repair
eliminates the problem.

STOP.

Test Step 2. Test the Switch for Proper


Operation
A. Disconnect the P1 connector.

B. Refer to Table 16. Determine the P1 terminal for


the suspect switch.

Table 16
Terminals for the Switch Inputs
Name of the J61/P61
P1 Terminals
Switch Terminals
Diagnostic reset
41 37
switch
Droop-
isochronous 46 34
switch
Low idle switch 47 35
g01175207 Maintenance
Illustration 77 22 36
clear switch
P61/J61 terminals for the various switches
Remote engine
(19) Run/stop switch 23 39
(34) Droop-isochronous switch stop switch
(35) Low idle switch
Run/stop switch 40 19
(36) Maintenance clear switch
(37) Diagnostic reset switch
(39) Remote engine stop switch
C. Connect one lead of a multimeter to the P1
terminal for the suspect switch. Connect the other
C. Perform a 45 N (10 lb) pull test on each of the meter lead to engine ground.
wires in the circuit for the suspect switch.
Note: Wiggle the harnesses during the following
D. Check the allen head screw on each ECM measurements in order to reveal any intermittent
connector for the proper torque. Also, check the short condition.
allen head screw on the customer connector
for the proper torque. Refer to Troubleshooting, D. Measure the resistance between the P1 terminal
“Electrical Connectors - Inspect” for the correct for the suspect switch and engine ground.
torque values.
E. Activate the switch and measure the resistance
E. Check the harness and wiring for abrasions and again.
for pinch points from the battery to the ECM.
Expected Result:
Expected Result:
One resistance measurement indicates an open
All connectors, pins, and sockets are completely circuit. The other resistance measurement is less
coupled and/or inserted, and the harness and wiring than ten Ohms.
are free of corrosion, of abrasion and of pinch points.
Results:
Results:
• OK – One resistance measurement indicates an
• OK – The wiring and connectors appear to be OK. open circuit. The other resistance measurement
Proceed to Test Step 2. is less than ten Ohms.
• Not OK – There is a problem with the wiring and/or
a connector.
134 RENR5093-01
Troubleshooting Section

Repair: The switch is operating correctly. The


wiring does not have a short circuit or an open
circuit. Operate the engine and check the switch
for proper operation.

If the switch does not operate correctly, there may


be a short circuit between the circuit for the suspect
switch and another circuit. Carefully reinspect the
components. Refer to Troubleshooting, “Electrical
Inspectors - Inspect”. Locate the short circuit and
make repairs.

STOP.

• Not OK – Both resistance measurements indicate


an open circuit or both resistance measurements
are less than ten Ohms.

Repair: There is a problem with the circuit for the


switch. The problem could be in the switch, in the
wiring, or in a connector.

Carefully reinspect the components. Refer to


Troubleshooting, “Electrical Inspectors - Inspect”.

If the inspection does not identify the faulty


component, replace the switch and test the switch
again.

If the problem is not resolved, repair the wiring or


the connector. Replace parts, if necessary. Verify
that the problem is resolved.

STOP.
RENR5093-01 135
Troubleshooting Section

Calibration Procedures
i02708320

Engine Speed/Timing Sensor -


Calibrate
SMCS Code: 1439-524; 1912-524

System Operation Description:

Use this procedure if the diagnostic code in Table


17 is active.

Table 17
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
22-13 “Engine Timing Calibration A timing calibration is required for a The code is logged.
Not Performed” new engine. A timing calibration is also
required after a repair to the front gear
261-13 Engine Timing Calibration train, the camshaft, or the crankshaft
calibration required has been completed. The code may
also become active after replacing
an Electronic Control Module (ECM)
that fails to communicate.
261-11 Engine Timing Offset fault The wiring to the sensors may The code is logged.
have the wrong polarity. There
may be a mechanical problem with
the front gear train.

The ECM has the ability to compensate for Table 18


mechanical differences between the Top Center (TC) Required Special Tools
of the flywheel and the TC of the timing gear on the
camshaft. Part Number Description
7X-1171 Transducer Adapter
An “Engine Timing Calibration Not Performed” code
is activated if a timing calibration is required. 6V-2197 Transducer
7X-1695 Cable As
TC of the Flywheel – The ECM determines the
TC of the flywheel via a signal from a magnetic 170-3519 Harness (1)

transducer. The transducer is installed into the side (1) This item is not required if the engine harness has a connector
of the engine block. The transducer creates a signal for timing calibration.
as a notch on a crankshaft counterweight rotates
past the transducer. Test Step 1. Install the Transducer
Adapter
TC of the Timing Gear – The ECM determines the
TC of the timing gear by signals from the engine A. Remove the electrical power from the ECM.
speed/timing sensors.
B. Use the appropriate engine turning tool to put
Any offset between the TC of the flywheel and the either the No. 1 piston or the No. 6 piston at top
TC of the timing gear is stored into the memory of center. Refer to the Systems Operation/Testing
the ECM. and Adjusting.

Note: A timing calibration will not increase the C. Refer to Table 19. After the top center position has
available engine power. been located, rotate the crankshaft for the number
of degrees that is applicable to your engine model.
Table 18 lists the special tools that are required in Be sure to rotate the crankshaft in the direction of
order to perform this procedure. rotation that is specified in the Table.
136 RENR5093-01
Troubleshooting Section

Table 19 A. Apply clean engine oil to a 2D-6392 O-Ring Seal.


Crankshaft Rotation
Install the O-ring seal on the end of the 6V-2197
Transducer.
Engine Number of Direction of Rotation
Model Degrees B. Push the transducer through the transducer
C7 100 Normal Rotation adapter until the transducer contacts the
crankshaft counterweight.
C-9 85 Normal Rotation
C-10 60 Opposite Normal Rotation C. Withdraw the transducer 1.0 mm (0.04 inch) and
hand tighten the nut on the adapter sleeve in
C11 75 Normal Rotation order to secure the transducer. Move the O-ring
C-12 60 Opposite Normal Rotation seal against the adapter.

C13 75 Normal Rotation Continue to the next test step.


C-15 60 Opposite Normal Rotation
Test Step 3. Connect the 7X-1695 Cable
C15 60 Opposite Normal Rotation As
C-16 60 Opposite Normal Rotation
A. If the engine harness is equipped with a connector
C18 30 Opposite Normal Rotation for timing calibration, connect the 7X-1695 Cable
As to the connector for timing calibration and to
D. Refer to Table 20. Locate the engine’s timing the transducer.
calibration port.

Table 20
Location of the Timing Calibration Port
Engine Crankshaft Engine Location
Model Counterweight
C7 3 Left Side
C-9 3 Left Side
C-10 8 Right Side
C11 8 Left Side
C-12 8 Right Side
C13 8 Left Side
C-15 2 Left Side
C15 2 Left Side
C-16 2 Left Side
C18 2 Left Side

E. Remove the plug from the timing calibration port.

F. Thread the transducer adapter into the port.

Continue to the next test step. Illustration 78


g01345358

Connecting the 7X-1695 Cable As to an ADEM III ECM


Test Step 2. Install the Transducer

NOTICE
If the crankshaft is not in the correct position when the
transducer is installed, the transducer will be damaged
when the engine is started.
RENR5093-01 137
Troubleshooting Section

d. Install the yellow wire of the 170-3519


Harness into the appropriate location.

Note: Ensure that each wire is installed into the


correct location. The timing calibration will not be
successful if the wires are installed incorrectly.

e. Connect the 7X-1695 Cable As to the


connector for timing calibration and to the
transducer.

Continue to the next test step.

Test Step 4. Start the Engine and Check


for Diagnostic Codes
A. Connect Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”.

B. Start the engine and run the engine until the


engine is at the normal operating temperature.

C. Check for active diagnostic codes. Wait at least 30


seconds in order for the codes to become active.

The engine must not have any active diagnostic


g01345359
codes during the timing calibration except for a
Illustration 79 261-13 Engine Timing Calibration required.
Connecting the 7X-1695 Cable As to an ADEM IV ECM
Expected Result:
B. If the engine harness is not equipped with a
connector for timing calibration, perform the There are no active diagnostic codes or there is only
following procedure: a code for timing calibration that is active at this time.

Note: Refer to Illustration 78 or 79. The 170-3519 Results:


Harness can be connected to the P1 connector or
to the P2 connector. Select the connector with the • OK – There are no active diagnostic codes or there
easiest access. is only a code that is active for timing calibration at
this time. Proceed to Test Step 5.
a.
• Not OK – There is at least one active code that is
Table 21 not a code for timing calibration.
Locations for Connection of the 170-3519 Harness
Repair: Troubleshoot and repair any active
Locations Locations Locations diagnostic codes before you continue with this
on the on the on the P1 procedure.
Wire Color 70−pin P2 120−pin Connector
Connector P2
Connector STOP.

White 22 26 24 Test Step 5. Calibrate the Engine


Yellow 23 36 25 Speed/Timing Sensor
A. Set the engine speed to 1100 ± 50 rpm. The
b. Refer to Table 21. Remove the sealing plugs engine speed must be steady within this rpm
from the appropriate terminals. Do not discard range in order for the calibration to be successful.
the sealing plugs. The sealing plugs may
be reinstalled when the timing calibration is B. After the engine has warmed up, access the
complete. “Timing Calibration” screen on the Cat ET. Access
the following display screens in order:
c. Disregard the pin-outs on the label of the
harness. Install the white wire of the 170-3519 • Service
Harness into the appropriate location.
138 RENR5093-01
Troubleshooting Section

• Calibrations • Verify that the timing calibration probe is installed


correctly.
• Timing Calibration
• Verify that the engine speed is correct and that
C. To calibrate the timing, select “Continue” on Cat the engine speed is stable. If the engine speed
ET. Wait until Cat ET indicates that the timing is is unstable, refer to troubleshooting without
calibrated. a diagnostic code Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable”.
Expected Result:
• There may be a problem with the transducer or
Cat ET indicates that the timing is calibrated. with the cables. Obtain a new transducer and/or
a new cable and repeat the timing calibration.
Results:
STOP.
• OK – Cat ET indicates that the timing is calibrated.
i02149153
Repair: Perform the following procedure:

1. Set the engine speed to low idle.


Injector Code - Calibrate
SMCS Code: 1290-524
Note: Disconnect the 7X-1695 Cable As before
you exit the “Timing Calibration” screen. Otherwise, System Operation Description:
diagnostic codes may be activated.
If any of the following conditions have occurred,
2. Disconnect the 7X-1695 Cable As. calibrate the injector trim codes:
3. Exit the “Timing Calibration” screen on Cat ET.
• Replacement of the Electronic Control Module
(ECM)
4. Remove the electrical power from the ECM.

5. Remove the transducer and remove the adapter.


• Replacement of any of the unit injectors
A special code is stamped on the top of each unit
6. Install the plug into the timing calibration port. injector. The injector trim code allows the ECM to
compensate for variances in manufacturing.
7. If you installed a 170-3519 Harness, you may
remove the harness or you may permanently Note: Changing the injector trim codes will not
install the harness for future use. If you remove increase the power that is available to the engine.
the harness, install the sealing plugs into
the unused cavities of the ECM connector. Test Step 1. Record Injector Trim Codes
Otherwise, moisture and debris will enter the
connector. A. Use Table 22 to record the injector trim code and
the corresponding cylinder number for each unit
If you choose to permanently install the harness, injector that will be replaced.
fasten the harness to the existing engine wiring
harness with cable ties. Also, install a 3E-3364 Table 22
Receptacle and two 8T-8737 Seal Plugs on
the 2-pin connector in order to prevent moisture Injector Trim Code
and debris from entering the connector. Cylinder Old New

8. Return the engine to service. 1


2
STOP.
3
• Not OK – The timing calibration was unsuccessful. 4
5
Repair: The following conditions can cause the
timing calibration to fail: 6

• If the crankshaft and camshaft gears have been


reassembled incorrectly, the timing will not
calibrate.
RENR5093-01 139
Troubleshooting Section

Note: If the ECM is replaced, all injector trim codes


must be recorded. The injector trim codes can be
found in “Calibrations” under the “Service” menu on
the Caterpillar Electronic Technician (ET).

Expected Result:

All injector trim codes were obtained.

Results:

• OK – All injector trim codes were obtained.


Proceed to Test Step 2.

• Not OK – The injector trim codes were not


obtained.

Repair: Remove the valve cover and record the


injector trim code and the corresponding cylinder
number for each unit injector.

Proceed to Test Step 2.

Test Step 2. Replace Hardware


A. Replace the suspect unit injectors and/or the ECM.

B. Record the injector trim code and the


corresponding cylinder number for each unit
injector.

Expected Result:

All hardware was successfully replaced and the new


injector trim codes were recorded.

Results:

• OK – The hardware was successfully replaced.


Proceed to Test Step 3.

Test Step 3. Enter Injector Trim Codes


into the ECM
A. Connect Cat ET to the service tool connector.

B. Turn the keyswitch to the ON position.

C. Open the “Injector Codes Calibration” in


“Calibrations” under the “Service” menu on Cat ET.

D. Enter the new injector trim code for each cylinder.

Results:

• OK – STOP.
140 RENR5093-01
Index Section

Index
Numerics CID 0174 FMI 04 Fuel Temperature short to
ground.................................................................. 53
5 Volt Engine Pressure Sensor Supply Circuit - CID 0190 FMI 08 Engine Speed signal abnormal.. 53
Test ...................................................................... 72 CID 0247 FMI 09 J1939 Data Link
communications................................................... 53
CID 0253 FMI 11 Personality Module mechanical
A failure ................................................................... 54
CID 0261 FMI 13 Engine Timing Calibration
Alternator (Charging Problem)............................... 23 required................................................................ 54
Probable Causes ............................................... 23 CID 0262 FMI 03 5 Volt Sensor DC Power Supply
Recommended Actions...................................... 23 short to +batt........................................................ 55
CID 0262 FMI 04 5 Volt Sensor DC Power Supply
short to ground..................................................... 55
B CID 0268 FMI 02 Check Programmable
Parameters .......................................................... 55
Battery ................................................................... 23 CID 0273 FMI 03 Turbo Outlet Pressure open/short
Probable Causes ............................................... 23 to +batt................................................................. 55
Recommended Actions...................................... 23 CID 0273 FMI 04 Turbo Outlet Pressure short to
ground.................................................................. 56
CID 0274 FMI 03 Atmospheric Pressure open/short
C to +batt................................................................. 56
CID 0274 FMI 04 Atmospheric Pressure short to
Calibration Procedures ........................................ 135 ground.................................................................. 56
CAN Data Link Circuit - Test.................................. 77 CID 0342 FMI 02 Loss of Secondary Engine Speed
Can Not Reach Top Engine RPM .......................... 23 signal ................................................................... 57
Probable Causes ............................................... 23 CID 0342 FMI 11 Secondary Engine Speed Sensor
Recommended Actions...................................... 24 mechanical failure................................................ 57
Cat Data Link Circuit - Test.................................... 81 CID 1929 FMI 03 Fuel Return Temperature Sensor
CID 0001 FMI 11 Cylinder #1 Injector fault............ 47 voltage high/short to +batt ................................... 57
CID 0002 FMI 11 Cylinder #2 Injector fault............ 47 CID 1929 FMI 04 Fuel Return Temperature Sensor
CID 0003 FMI 11 Cylinder #3 Injector fault............ 48 voltage low/short to ground.................................. 57
CID 0004 FMI 11 Cylinder #4 Injector fault............ 48 Coolant in Engine Oil............................................. 24
CID 0005 FMI 11 Cylinder #5 Injector fault............ 48 Probable Causes ............................................... 24
CID 0006 FMI 11 Cylinder #6 Injector fault............ 49 Recommended Actions...................................... 25
CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 49 Coolant Level Sensor Circuit - Test ....................... 84
CID 0041 FMI 04 8 Volt DC Supply short to Coolant Temperature Is Too High .......................... 25
ground.................................................................. 49 Probable Causes ............................................... 25
CID 0091 FMI 08 Throttle Position signal Recommended Repairs ..................................... 25
abnormal.............................................................. 50 Customer Passwords ............................................ 16
CID 0094 FMI 03 Fuel Pressure open/short to
+batt..................................................................... 50
CID 0094 FMI 04 Fuel Pressure short to ground... 50 D
CID 0100 FMI 03 Engine Oil Pressure open/short to
+batt..................................................................... 51 Diagnostic Codes .................................................. 46
CID 0100 FMI 04 Engine Oil Pressure short to Active Diagnostic Codes .................................... 46
ground.................................................................. 51 Diagnostic Codes............................................... 46
CID 0110 FMI 03 Engine Coolant Temperature Logged Diagnostic Codes.................................. 47
open/short to +batt............................................... 51 Diagnostic Functional Tests................................... 72
CID 0110 FMI 04 Engine Coolant Temperature short Digital Sensor Supply Circuit - Test ....................... 89
to ground.............................................................. 51
CID 0168 FMI 02 System Voltage intermittent/
erratic................................................................... 52 E
CID 0172 FMI 03 Intake Manifold Air Temp open/short
to +batt................................................................. 52 E009 High Altitude Derate ..................................... 61
CID 0172 FMI 04 Intake Manifold Air Temp short to E057 Low Engine Coolant Level Derate................ 62
ground.................................................................. 52 E059 Low Engine Coolant Level Warning ............. 63
CID 0174 FMI 03 Fuel Temperature open/short to E096 High Fuel Pressure ...................................... 63
+batt..................................................................... 53 E198 Low Fuel Pressure ....................................... 64
RENR5093-01 141
Index Section

E199 Low Coolant Temperature ............................ 64 Event Codes .......................................................... 59


E255 Diagnostic Reset .......................................... 65 Active of Event Codes........................................ 59
E264 Emergency Stop Activated........................... 65 Clearing Event Codes ........................................ 60
E360 Low Engine Oil Pressure.............................. 66 Logged Event Codes ......................................... 60
E361 High Engine Coolant Temperature ............... 67 Trip Points for the Monitoring System................ 60
E362 Engine Overspeed ....................................... 68 Troubleshooting ................................................. 60
E363 High Fuel Supply Temperature..................... 68 Excessive Black Smoke ........................................ 35
E368 High Intake Manifold Air Temperature.......... 69 Probable Causes ............................................... 35
ECM Will Not Accept Factory Passwords.............. 27 Recommended Actions...................................... 35
Probable Causes ............................................... 27 Excessive Engine Oil Consumption....................... 36
Recommended Actions...................................... 27 Probable Causes ............................................... 36
ECM Will Not Communicate with Other Systems or Recommended Actions...................................... 36
Display Modules .................................................. 27 Excessive Fuel Consumption ................................ 36
Probable Causes ............................................... 27 Probable Causes ............................................... 36
Recommended Actions...................................... 27 Recommended Actions...................................... 36
Electrical Connectors - Inspect.............................. 93 Excessive Valve Lash............................................ 37
Electrical Power Supply Circuit - Test.................... 98 Probable Causes ............................................... 37
Electronic Service Tool Will Not Communicate with Recommended Actions...................................... 37
ECM..................................................................... 27 Excessive White Smoke ........................................ 37
Probable Causes ............................................... 27 Probable Causes ............................................... 37
Recommended Actions...................................... 28 Recommended Actions...................................... 38
Electronic Service Tools .......................................... 6
Caterpillar Electronic Technician (ET).................. 7
Optional Service Tools ......................................... 6 F
Required Service Tools ........................................ 6
Electronic Troubleshooting ...................................... 5 Factory Passwords ................................................ 16
Engine Cranks but Will Not Start ........................... 29 Flash Programming ............................................... 17
Probable Causes ............................................... 29 Programming a Flash File.................................. 17
Recommended Actions...................................... 29
Engine Has Early Wear ......................................... 30
Probable Causes ............................................... 30 I
Recommended Actions...................................... 30
Engine Misfires, Runs Rough or Is Unstable......... 31 Important Safety Information ................................... 2
Probable Causes ............................................... 31 Injector Code - Calibrate...................................... 138
Recommended Actions...................................... 31 Injector Solenoid Circuit - Test.............................. 117
Engine Oil in Cooling System ................................ 32 Intermittent Engine Shutdown ............................... 38
Probable Causes ............................................... 32 Probable Causes ............................................... 38
Recommended Actions...................................... 32 Recommended Actions...................................... 39
Engine Oil in Exhaust System ............................... 32 Intermittent Low Power or Power Cutout............... 39
Probable Causes ............................................... 32 Probable Causes ............................................... 40
Recommended Actions...................................... 32 Recommended Actions...................................... 40
Engine Pressure Sensor Open or Short Circuit -
Test .................................................................... 102
Engine Speed/Timing Sensor - Calibrate ............ 135 L
Engine Speed/Timing Sensor Circuit - Test ......... 107
Engine Stalls at Low RPM ..................................... 32 Low Engine Oil Pressure ....................................... 40
Probable Causes ............................................... 32 Probable Causes ............................................... 40
Recommended Actions...................................... 33 Recommended Actions...................................... 41
Engine Temperature Sensor Open or Short Circuit - Low Power/Poor or No Response to Throttle ........ 41
Test ..................................................................... 112 Probable Causes ............................................... 41
Engine Vibration .................................................... 33 Recommended Actions...................................... 41
Probable Causes ............................................... 33
Recommended Actions...................................... 33
Engine Will Not Crank ........................................... 34 M
Probable Causes ............................................... 34
Recommended Actions...................................... 34 Mechanical Noise (Knock) in Engine..................... 43
Engine Wiring Information ..................................... 13
Harness Wire Identification ................................ 14
N

Noise Coming from Cylinder.................................. 43


Probable Causes ............................................... 43
Recommended Actions...................................... 43
142 RENR5093-01
Index Section

Poor Acceleration or Response............................. 44


Probable Causes ............................................... 44
Recommended Actions...................................... 44
Programming Parameters ..................................... 16

Replacing the ECM.................................................. 9

Self-Diagnostics..................................................... 10
Sensors and Electrical Connectors ........................ 11
C18 Engines ...................................................... 13
Service Information Report.................................... 17
Recommendations ............................................. 17
Speed Control - Test............................................ 127
Switch Circuits - Test ........................................... 131
System Configuration Parameters......................... 19
Parameter Descriptions ..................................... 19
Parameter Table................................................. 21
System Overview..................................................... 5
Passwords ........................................................... 6
Programmable Parameters.................................. 6
System Operation ................................................ 5

Table of Contents..................................................... 3
Troubleshooting Section.......................................... 5
Troubleshooting with a Diagnostic Code ............... 46
Troubleshooting with an Event Code..................... 59
Troubleshooting without a Diagnostic Code .......... 23
RENR5093-01 143
Index Section
©2007 Caterpillar
All Rights Reserved Printed in U.S.A.

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