Troubleshooting PDF
Troubleshooting PDF
Troubleshooting PDF
May 2007
Troubleshooting
C18 Marine Auxiliary Engine
MGS1-Up (Generator Set)
CYG1-Up (Engine)
i01658146
Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 135
Injector Code - Calibrate ..................................... 138
Index Section
Index ................................................................... 140
RENR5093-01 5
Troubleshooting Section
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.
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
Table 3
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.
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.
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.
Event Code
i02778818
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
g01173198
Illustration 5
Right side engine view (typical example)
(20) Magnetic speed sensor
14 RENR5093-01
Troubleshooting Section
Table 7
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”.
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.
Be as specific as possible.
Repair Procedure
Comments on the repair procedure should include
the following types of information:
Be as specific as possible.
RENR5093-01 19
Troubleshooting Section
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
“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.
“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
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)
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.
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
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
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
• 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
• 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”.
• 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.
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.
• 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.
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.
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
• 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”.
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
• 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.
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
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
• 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.
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
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
• 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”.
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
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.
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.
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).
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 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
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
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
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.
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.
• 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.
Results: The ECM will log the diagnostic code. The ECM flags
fuel pressure as invalid data and a default value is
• OK – STOP. used.
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.
• 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
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:
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 experience reduced speed (rpm) The signal voltage from the inlet air temperature
and/or low power. sensor exceeds 4.9 VDC for eight seconds.
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.
• 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
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
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.
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
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.
• 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.
i02445665 Results:
CID 0262 FMI 03 5 Volt Sensor • OK – STOP.
DC Power Supply short to
+batt i02285570
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
• OK – STOP. Troubleshooting:
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.
i02571960 Troubleshooting:
CID 0342 FMI 02 Loss of Perform the following diagnostic procedure: “Engine
Secondary Engine Speed Speed/Timing Sensor Circuit - Test”
signal Results:
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”
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
System Response:
The ECM will log the diagnostic code. The ECM will
set fuel temperature to a default value.
• Low power
Troubleshooting:
Results:
• OK – STOP.
RENR5093-01 59
Troubleshooting Section
Troubleshooting with an
Event Code
i02353335
Event Codes
SMCS Code: 1901
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.
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.
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.
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.
Ensure that the repair eliminates the problem. The coolant level is low.
STOP. Results:
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.
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.
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.
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:
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
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:
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
• 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.
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
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.
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:
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
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
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
Expected Result:
Results:
STOP.
72 RENR5093-01
Troubleshooting Section
Diagnostic Functional
Tests
i02778788
g01174890
Illustration 9
Schematic for pressure sensor supply
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
g01159881
Illustration 12
Sensor connector
(A) +5 V supply
(B) Sensor return
(C) Signal
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.
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:
• 262-04 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.
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.
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
STOP.
STOP.
i02353334
• 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
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 −
Expected Result:
Results:
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. 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 -).
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.
Expected Result:
Results:
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
STOP.
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 +
Expected Result:
Results:
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.
g01150032
Illustration 24
Typical location of the coolant level sensor
(4) Coolant level sensor
g01094777
Illustration 25
Schematic for coolant level sensor
g01150055
Illustration 26
Engine view
(5) J2/P2 connectors
86 RENR5093-01
Troubleshooting Section
STOP.
g01132478
Illustration 28
Harness connector for the coolant level sensor
(A) +8 VDC
(B) Return
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
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.
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
STOP.
STOP.
i02347108
g01094777
Illustration 29
Schematic for digital supply
g01150138
Illustration 31
Typical location of the coolant level sensor
(2) Coolant level sensor
g01147202
Illustration 30
Typical engine view
(1) J2/P2 connectors
RENR5093-01 91
Troubleshooting Section
STOP.
• 41-03
• 41-04
Expected Result:
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:
• 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.
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.
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.
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)
g01131165
Illustration 36
Seal for ECM connector (typical example)
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:
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.
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.
g01131604
Illustration 38
Diagram for testing pin retention (typical example)
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.
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:
STOP.
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:
Results:
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.
STOP.
i02779048
g01388327
Illustration 43
Schematic for electrical power supply circuit
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
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”.
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.
STOP.
102 RENR5093-01
Troubleshooting Section
Pull-up Voltage
g01174890
Illustration 49
Schematic for the engine pressure sensors
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
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
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.
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.
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
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.
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.
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.
g01150285
Illustration 53
Schematic for the engine speed/timing circuit
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”.
Expected Result:
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.
Results:
Results:
STOP.
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.
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.
g01175264
Illustration 58
Schematic for engine temperature sensors
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
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
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.
• 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.
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.
• 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.
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.
g01152739
Illustration 63
Schematic for the injector solenoids
g01147054
Illustration 65
Left side engine view (typical example)
(2) J300/P300 Injector valve cover entry connector
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
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.
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)).
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:
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.
Expected Result:
Results:
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
• 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.
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.
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.
7. Verify that the repair eliminates the problem. Verify that the repair eliminates the problem.
STOP. STOP.
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.
STOP.
STOP.
E. Turn the keyswitch to the ON position. F. Turn the keyswitch to the OFF position.
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.
Test Step 12. Check for a Short Circuit in The reconnected injector indicates a “SHORT”.
the Supply Line to the Engine
Results:
i02312818
g01173277
Illustration 70
Schematic
g00766798
Illustration 71
Percent of throttle position versus PWM input
RENR5093-01 129
Troubleshooting Section
Expected Result:
Results:
STOP.
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
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 .
• 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
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:
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
STOP.
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
STOP.
STOP.
RENR5093-01 135
Troubleshooting Section
Calibration Procedures
i02708320
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.
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 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
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
Expected Result:
Results:
Expected Result:
Results:
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
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
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