renr2418!02!01 all troubleshooting

RENR2418-02November 2005

TroubleshootingC7 and C9 Industrial EnginesJRA1-Up (Engine)JSC1-Up (Engine)MBD1-Up (Engine)JTF1-Up (Engine)

i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

RENR2418-02 3Table of Contents

Table of Contents

Troubleshooting Section

Electronic TroubleshootingSystem Overview .................................................... 5Electronic Service Tools .......................................... 6Replacing the ECM ................................................. 9Self-Diagnostics .................................................... 10Sensors and Electrical Connectors ........................ 11Engine Wiring Information .................................... 15

Programming ParametersProgramming Parameters ..................................... 17Customer Passwords ............................................ 17Factory Passwords ............................................... 17Factory Passwords Worksheet ............................. 18Flash Programming .............................................. 18Injector Trim File ................................................... 19Service Information Report ................................... 19

System Configuration ParametersSystem Configuration Parameters ........................ 21

Troubleshooting without a Diagnostic CodeAlternator (Charging Problem) .............................. 28Battery .................................................................. 28Can Not Reach Top Engine RPM ......................... 28Coolant in Engine Oil ............................................ 30Coolant Temperature Is Too High ......................... 30ECM Will Not Accept Factory Passwords ............. 31ECM Will Not Communicate with Other Systems orDisplay Modules .................................................. 31Electronic Service Tool Will Not Communicate withECM .................................................................... 31Engine Cranks but Will Not Start .......................... 32Engine Has Early Wear ........................................ 34Engine Misfires, Runs Rough or Is Unstable ........ 35Engine Oil in Cooling System ............................... 36Engine Oil Temperature Is Too High ..................... 36Engine Stalls at Low RPM .................................... 37Engine Vibration ................................................... 37Engine Will Not Crank ........................................... 38Excessive Black Smoke ........................................ 39Excessive Engine Oil Consumption ...................... 40Excessive Fuel Consumption ............................... 40Excessive Valve Lash ........................................... 41Excessive White Smoke ....................................... 41Exhaust Temperature Is Too High ......................... 42Fuel in Cooling System ......................................... 43Fuel Dilution of Engine Oil .................................... 43Intermittent Engine Shutdown ............................... 44Intermittent Low Power or Power Cutout .............. 45Low Engine Oil Pressure ...................................... 46Low Power/Poor or No Response to Throttle ....... 46Mechanical Noise (Knock) in Engine .................... 48Noise Coming from Cylinder ................................. 49Poor Acceleration or Response ............................ 49Valve Rotator or Spring Lock Is Free .................... 51

Troubleshooting with a Diagnostic Code

Flash Codes .......................................................... 52Diagnostic Codes .................................................. 52Diagnostic Code Cross Reference ....................... 53CID 0001 FMI 05 Cylinder #1 Injector opencircuit ................................................................... 56CID 0001 FMI 06 Cylinder #1 Injector short ......... 56CID 0002 FMI 05 Cylinder #2 Injector opencircuit ................................................................... 57CID 0002 FMI 06 Cylinder #2 Injector short ......... 57CID 0003 FMI 05 Cylinder #3 Injector opencircuit ................................................................... 57CID 0003 FMI 06 Cylinder #3 Injector short ......... 57CID 0004 FMI 05 Cylinder #4 Injector opencircuit ................................................................... 58CID 0004 FMI 06 Cylinder #4 Injector short ......... 58CID 0005 FMI 05 Cylinder #5 Injector opencircuit ................................................................... 58CID 0005 FMI 06 Cylinder #5 Injector short ......... 59CID 0006 FMI 05 Cylinder #6 Injector opencircuit ................................................................... 59CID 0006 FMI 06 Cylinder #6 Injector short ......... 59CID 0041 FMI 03 8 Volt DC Supply short to +batt .. 59CID 0041 FMI 04 8 Volt DC Supply short toground ................................................................. 60CID 0042 FMI 05 Injector Actuation Valve opencircuit ................................................................... 60CID 0042 FMI 06 Injector Actuation Valve short toground ................................................................. 60CID 0091 FMI 08 Throttle Position signalabnormal ............................................................. 61CID 0091 FMI 13 Throttle Position calibrationrequired ............................................................... 61CID 0094 FMI 03 Fuel Pressure open/short to+batt .................................................................... 61CID 0094 FMI 04 Fuel Pressure short to ground .. 61CID 0100 FMI 03 Engine Oil Pressure open/short to+batt .................................................................... 62CID 0100 FMI 04 Engine Oil Pressure short toground ................................................................. 62CID 0100 FMI 10 Engine Oil Pressure Sensorabnormal rate of change ..................................... 62CID 0102 FMI 03 Boost Pressure Sensor short to+batt .................................................................... 63CID 0102 FMI 04 Boost Pressure Sensor short toground ................................................................. 63CID 0102 FMI 10 Boost Pressure Sensor abnormalrate of change ..................................................... 63CID 0110 FMI 03 Engine Coolant Temperatureopen/short to +batt .............................................. 64CID 0110 FMI 04 Engine Coolant Temperature shortto ground ............................................................. 64CID 0111 FMI 02 Engine Coolant Level Sensor Lossof Signal .............................................................. 64CID 0164 FMI 02 Injector Actuation Pressure signalerratic .................................................................. 65CID 0164 FMI 03 Injector Actuation Pressure voltagehigh ..................................................................... 65CID 0164 FMI 04 Injector Actuation Pressure voltagelow ....................................................................... 65CID 0164 FMI 11 Injector Actuation Pressure systemfault ..................................................................... 66CID 0168 FMI 00 System Voltage High ................ 66CID 0168 FMI 01 System Voltage Low ................. 67

4 RENR2418-02Table of Contents

CID 0168 FMI 02 System Voltage intermittent/erratic .................................................................. 67CID 0172 FMI 03 Intake Manifold Air Temp open/shortto +batt ................................................................ 67CID 0172 FMI 04 Intake Manifold Air Temp short toground ................................................................. 68CID 0190 FMI 08 Engine Speed signal abnormal .. 68CID 0247 FMI 09 J1939 Data Linkcommunications .................................................. 68CID 0253 FMI 02 Personality Module mismatch .. 68CID 0261 FMI 13 Engine Timing Calibrationrequired ............................................................... 69CID 0262 FMI 03 5 Volt Sensor DC Power Supplyshort to +batt ....................................................... 69CID 0262 FMI 04 5 Volt Sensor DC Power Supplyshort to ground .................................................... 69CID 0268 FMI 02 Check ProgrammableParameters ......................................................... 70CID 0274 FMI 03 Atmospheric Pressure open/shortto +batt ................................................................ 70CID 0274 FMI 04 Atmospheric Pressure short toground ................................................................. 70CID 0342 FMI 08 Secondary Engine Speed signalabnormal ............................................................. 71CID 0617 FMI 05 Air Inlet Heater Relay open/currentbelow normal ....................................................... 71CID 0617 FMI 06 Air Inlet Heater Relaygrounded/current above norm ............................. 71CID 1835 FMI 03 Auxiliary Pressure Sensoropen/short to +batt .............................................. 72CID 1835 FMI 04 Auxiliary Pressure Sensor short toground ................................................................. 72CID 1836 FMI 03 Auxiliary Temperature Sensoropen/short to +batt .............................................. 72CID 1836 FMI 04 Auxiliary Temperature Sensor shortto ground ............................................................. 72CID 2417 FMI 05 Ether Injection Control Solenoidcurrent low .......................................................... 73CID 2417 FMI 06 Ether Injection Control Solenoidcurrent high ......................................................... 73

Troubleshooting with an Event CodeEvent Codes ........................................................ 74E096 High Fuel Pressure ...................................... 75E360 Low Engine Oil Pressure ............................. 76E361 High Engine Coolant Temperature .............. 77E362 Engine Overspeed ....................................... 78E443 High Auxiliary Pressure ............................... 79E445 High Auxiliary Temperature ......................... 80E539 High Intake Manifold Air Temperature ......... 81E2143 Low Engine Coolant Level ......................... 81

Diagnostic Functional Tests5 Volt Engine Pressure Sensor Supply Circuit -Test ..................................................................... 83Air Inlet Heater Circuit - Test ................................. 91Air Shutoff System - Test ...................................... 98CAN Data Link Circuit - Test ............................... 105Cat Data Link Circuit - Test ................................. 109Coolant Level Sensor Circuit - Test ..................... 112Diagnostic Lamp Circuit - Test ............................. 116

Digital Sensor Supply Circuit - Test .................... 120Electrical Connectors - Inspect ........................... 124Electrical Power Supply Circuit - Test ................. 129Engine Pressure Sensor Open or Short Circuit -Test ................................................................... 133Engine Speed/Timing Sensor Circuit - Test ........ 141Engine Temperature Sensor Open or Short Circuit -Test ................................................................... 147Ether Injection System - Test .............................. 155Injection Actuation Pressure - Test ..................... 160Injection Actuation Pressure Control Valve Circuit -Test ................................................................... 167Injection Actuation Pressure Sensor - Test ......... 172Injector Solenoid Circuit - Test ............................ 177Maintenance Due Lamp Circuit - Test ................. 184PTO Switch Circuit - Test .................................... 188Switch Circuits - Test .......................................... 193Throttle Position Sensor Circuit - Test ................ 197Warning Lamp Circuit - Test ................................ 201

Calibration ProceduresEngine Speed/Timing Sensor - Calibrate ............ 205Throttle Position Sensor - Calibrate .................... 207

Index Section

Index ................................................................... 210

RENR2418-02 5Troubleshooting Section

Troubleshooting Section

Electronic Troubleshootingi02439954

System OverviewSMCS Code: 1900

System OperationThe engine utilizes a Hydraulic Electronic UnitInjector (HEUI) fuel system. A solenoid on eachinjector meters the amount of fuel that is deliveredby the injector. An axial piston pump that is referredto as the unit injector hydraulic pump pressurizesoil in order to activate the injector. An ElectronicControl Module (ECM) sends a signal to the injectionactuation pressure control valve in order to controlinjection pressure. Another electrical signal is sent toeach injector solenoid in order to inject fuel.

Electronic Controls

The electronic system for the engine consists of theECM, the wiring harness, the engine sensors, theswitches, the injection actuation pressure controlvalve, the unit injector hydraulic pump, the HEUIinjectors and the interface for a particular application.The ECM is the computer. The flash file is thesoftware for the computer. The flash file containsthe operating maps. The operating maps define thefollowing characteristics of the engine:

• Horsepower

• Torque curves

The ECM determines the timing and the amountof fuel that is delivered to the cylinders. Thisdetermination is based on the actual conditions andthe desired conditions at any given time.

The ECM compares the desired engine speed tothe actual engine speed. The actual engine speed isdetermined via a signal from the engine speed/timingsensor. If the desired engine speed is greater thanthe actual engine speed, the ECM injects more fuelin order to increase the actual engine speed.

Fuel Injection

The ECM controls the amount of fuel that isinjected by varying the signals to the injectors. Theinjectors will pump fuel only if the injector solenoid isenergized. The ECM sends a high voltage signal tothe solenoid. This high voltage signal energizes thesolenoid. By controlling the timing and the duration ofthe high voltage signal, the ECM can control injectiontiming and the amount of fuel that is injected.

The ECM limits engine power during cold modeoperation and the ECM modifies injection timingduring cold mode operation. Cold mode operationprovides the following benefits:

• Increased cold weather starting capability

• Reduced warm-up time

• Reduced white smoke

Cold mode is activated whenever the engine coolanttemperature falls below 18 °C (64 °F). Cold moderemains active until the engine coolant temperaturerises above 20 °C (68 °F) or until the engine hasbeen running for 14 minutes.

The flash file inside the ECM sets certain limits onthe amount of fuel that can be injected. The “FRCFuel Limit” is used to control the air/fuel ratio forcontrol of emissions. The “FRC Fuel Limit” is a limitthat is based on the turbocharger outlet pressure.A higher turbocharger outlet pressure indicates thatthere is more air in the cylinder. When the ECMsenses a higher turbocharger outlet pressure, theECM increases the “FRC Fuel Limit”. When the ECMincreases the “FRC Fuel Limit”, the ECM allowsmore fuel into the cylinder. The “FRC Fuel Limit” isprogrammed into the flash file at the factory. The“FRC Fuel Limit” cannot be changed.

The “Rated Fuel Limit” is a limit that is based on thepower rating of the engine and on the engine speed.The “Rated Fuel Limit” is similar to the rack stopsand the torque spring on a mechanically governedengine. The “Rated Fuel Limit” provides the powercurves and the torque curves for a specific enginefamily and for a specific engine rating. The “RatedFuel Limit” is programmed into the flash file at thefactory. The “Rated Fuel Limit” cannot be changed.

Once the ECM determines the amount of fuel thatis required, the ECM must determine the timingof the fuel injection. The ECM determines the topcenter position of each cylinder from the enginespeed/timing sensor’s signal. The ECM calculateswhen fuel injection should occur relative to the topcenter position. The ECM also provides the signalto the injector at the desired time. The ECM adjuststiming for optimum engine performance, optimumfuel economy, and optimum control of white smoke.

6 RENR2418-02Troubleshooting Section

Injection Actuation Pressure ControlSystem

The injection actuation pressure control valve(IAPCV) that is internal to the unit injector hydraulicpump is a precision displacement control actuator.This actuator changes the pump outlet flow thatis based on the control current that is supplied bythe ECM. The variable displacement unit injectorhydraulic pump pressurizes only the amount of highpressure oil that is needed by the injectors.

Starting Aids

The following devices (if equipped) are used in orderto improve the starting of the engine in cold weatherconditions.

• Air inlet heater

• Ether injection

The ECM controls the air inlet heater. The etherinjection system can be controlled by the ECM or bythe operator.

Programmable ParametersCertain parameters that affect the engine operationmay be changed with electronic service tools.The parameters are stored in the ECM, and theparameters are protected from unauthorized changesby passwords.

PasswordsSeveral system configuration parameters andmost logged events are protected by passwords.Refer to programming parameters Troubleshooting,“Customer Passwords” and refer to programmingparameters Troubleshooting, “Factory Passwords”.

i02437007

Electronic Service ToolsSMCS Code: 0785

Caterpillar electronic service tools are designed tohelp the service technician perform the followingtasks:

• Information access

• System diagnostics

• System calibrations

• System configurations

• Data link communications

Required Service ToolsThe tools that are listed in Table 1 are required inorder to enable a service technician to perform thetest procedures that are found in this manual.

Table 1

Required Service Tools

PartNumber

Description

N/A 4 mm Allen Wrench

6V-2197 Transducer

7X-1171 Transducer Adapter

7X-1695 Cable As

146-4080 Digital Multimeter Gp (RS232)

7X-1710 Multimeter Probes

7X-6370 Adapter Cable As (3-PIN BREAKOUT)

208-0059 Adapter Cable As (70-PIN BREAKOUT)

257-8718 Adapter Cable As (120-PIN BREAKOUT)

167-9225 Harness (SERVICE TOOL ADAPTER)

1U-5804 Crimp Tool (12−AWG TO 18−AWG)

175-3700 Connector Repair Kit (DEUTSCH DT)

Two short jumper wires are needed to check thecontinuity of some wiring harness circuits by shortingtwo adjacent terminals together in a connector. Along extension wire may also be needed to check thecontinuity of some wiring harness circuits.

Optional Service ToolsTable 2 lists the optional service tools that may beneeded during testing or repair.


Table 2

Optional Service Tools

Part Number Description

198-4240or

1U-5470

Digital Pressure Indicator

Engine Pressure Group

4C-4075 Crimp Tool (4−AWG TO 10−AWG)

4C-4911(1) Battery Load Tester

5P-7277 Voltage Tester

6V-9130(2) Temperature Adapter (MULTIMETER)

8T-5319 Connector Tool Group

155-5176 AC/DC Current Probe(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911Battery 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-9130Temperature Adapter Group”.

Caterpillar Electronic Technician(ET)Cat ET can display the following information:

• Parameters

• Event codes

• Diagnostic codes

• Engine configuration

Cat ET can be used by the technician to perform thefollowing functions:

• Diagnostic tests

• Calibrations

• Flash programming

• ECM configuration

Table 3 lists the software that is required in order touse Cat ET.

Table 3

Software Requirements for Cat ET

PartNumber

Description

JERD2124 Single user license for Cat ET

JERD2129 Data Subscription for All Engines andMachines

Note: For more information regarding the use ofCat ET and the PC requirements for Cat ET, refer tothe documentation that accompanies your Cat ETsoftware.

Connecting Cat ET

Connecting with the Communication Adapter II

Table 4 lists the standard hardware that is required inorder to connect Cat ET.

Table 4

Standard Hardware for the Use of Cat ET


N/A Personal Computer (PC)

171-4400(1)Communication AdapterGp (CAT ET TO ECMINTERFACE)

237-7547(2) Adapter Cable As(1) The 7X-1700 Communication Adapter Gp may also be used.(2) The 237-7547 Adapter Cable As is required to connect to theUniversal Serial Bus (USB) on computers that are not equippedwith a RS232 serial port.

g01178796Illustration 1Connecting Cat ET

(1) Personal computer (PC)(2) 196-0055 Adapter Cable As(3) 171-4401 Communication Adapter As(4) 207-6845 Adapter Cable As

Note: Items (2), (3), and (4) are part of the 171-4400Communication Adapter Gp.

Use the following procedure in order to connect CatET and the Communication Adapter II.

1. Turn the keyswitch to the OFF position.


2. Connect cable (2) between the “COMPUTER”end of communication adapter (3) and the RS232serial port of PC (1).

Note: The 237-7547 Adapter Cable As is requiredto connect to the USB port on computers that are notequipped with a RS232 serial port.

3. Connect cable (4) between the “DATA LINK” endof communication adapter (3) and the service toolconnector.

4. Place the keyswitch in the ON position. IfCat ET and the communication adapter donot communicate with the Electronic ControlModule (ECM), refer to troubleshooting withouta diagnostic code Troubleshooting, “ElectronicService Tool Will Not Communicate with ECM”.

Communicatingwith theWireless CommunicationAdapter

Table 5 lists the optional hardware that is neededin order to connect Cat ET by using a wirelessconnection.

Table 5

Optional Hardware for the Use of Cat ET


N/A Personal Computer (PC)

261-3363(1) Wireless CommunicationAdapter Gp

(1) Refer to Tool Operating Manual, “Using the 261-3363Wireless Communication Adapter Gp” for information that isrelated to the installation and the configuration.

g01178799Illustration 2

(1) Personal computer (PC)(5) 261-4867 Card (PCMCIA)(6) 239-9955 Communication Radio Gp(7) 259-3183 Data Link Cable As

Note: Items (5), (6), and (7) are part of the 261-3363Wireless Communication Adapter Gp.

Use the following procedure in order to connect thewireless communication adapter for use with Cat ET.

1. Remove the electrical power from the ECM.

2. Ensure that the computer has been correctlyconfigured for the 261-4867 Card (PCMCIA).Verify that the PC card is installed in thecomputer’s PCI expansion slot.

3. Connect cable (7) between communication radio(6) and the service tool connector.

4. Restore the electrical power to the ECM. If Cat ETand the communication radio do not communicatewith the ECM, refer to troubleshooting withouta diagnostic code Troubleshooting, “ElectronicService Tool Will Not Communicate with ECM”.


i02411078

Replacing the ECMSMCS Code: 1901-510

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

The Electronic Control Module (ECM) contains nomoving parts. Replacement of the ECM can becostly. Replacement can also be a time consumingtask. Follow the troubleshooting procedures in thismanual in order to be sure that replacing the ECMwill correct the problem. Verify that the suspect ECMis the cause of the problem.

Note: Ensure that the ECM is receiving power andthat the ECM is properly wired to the negative batterycircuit before a replacement of the ECM is attempted.Refer to Troubleshooting, “Electrical Power SupplyCircuit - Test”.

A test ECM can be used to determine if the ECMis faulty. Install a test ECM in place of the suspectECM. Flash program the correct flash file into the testECM. Program the parameters for normal operation.The parameters must match the parameters in thesuspect ECM. Refer to the following test steps fordetails. If the test ECM resolves the problem, connectthe suspect ECM. Verify that the problem returns.If the problem returns when the suspect ECM isconnected, replace the suspect ECM.

NOTICEIf the flash file and engine application are not matched,engine damage may result.

Perform the following procedure in order to replacethe ECM:

1. Record the configuration data:

a. Connect Cat ET to the service tool connector.Refer to Troubleshooting, “Electronic ServiceTools”.

b. Print the parameters from the “Configuration”screen on Cat ET. If a printer is unavailable,record all of the parameters. Record anylogged diagnostic codes and logged eventcodes for your records. Record the injectorcodes from the “Calibrations” screen in the“Service” menu on Cat ET.

Note: The injector trim code is a number that is foundon each of the unit injectors. The ECM uses thisnumber to compensate for manufacturing variationsbetween individual injectors. If you replace any of theunit injectors, you must reprogram the trim code forthe new injectors. Also, if you replace the ECM, youmust reprogram all of the trim codes.

c. Use the “Copy Configuration/ECMReplacement” feature that is found under the“Service” menu on Cat ET. Select “Load fromECM” in order to copy the configuration datafrom the suspect ECM.

Note: If the “Copy Configuration” process fails andthe parameters were not obtained in Step 1.b, theparameters must be obtained elsewhere. Some of theparameters are stamped on the engine informationplate. Most of the parameters must be obtained fromthe factory.

2. Remove the ECM:

a. Remove the electrical power from the ECM.

b. Disconnect the P1 and P2 connectors fromthe ECM.

NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

c. Remove the fuel lines (if equipped) from theECM.

d. Disconnect the ECM ground strap.

e. Remove the mounting bolts from the ECM.

3. Install the replacement ECM:

a. Use the old mounting hardware to install thereplacement ECM.


b. Connect the fuel lines (if equipped).

c. Verify that the fuel lines are installed correctly.The fuel lines must not put tension on the ECM.Rubber grommets are used to protect the ECMfrom excessive vibration. The ECM shouldmove slightly in the rubber grommets. If theECM cannot be moved slightly, check that thefuel lines are not pulling the ECM against oneside of the grommets.

d. Connect the ECM ground strap.

e. Connect the P1 and P2 connectors. Tightenthe allen head screws for each ECM connectorto the proper torque. Refer to Troubleshooting,“Electrical Connectors - Inspect” for the correcttorque values.

4. Configure the replacement ECM:

a. Flash program the flash file into the ECM.Refer to Troubleshooting, “Flash Programming”for the correct procedure.

b. Use Cat ET to match the engine applicationand the interlock code if the replacement ECMwas used for a different application.

c. If the “Copy Configuration” process fromStep 1.b was successful, return to the “CopyConfiguration/ECM Replacement” screen onCat ET and select “Program ECM”. Proceed toStep 4.e when programming is complete.

d. If the “Copy Configuration” process from Step1.b was unsuccessful, manually program theECM parameters. The parameters must matchthe parameters from Step 1.b.

e. Program the engine monitoring system, ifnecessary.

f. Calibrate the fuel injectors. Refer toTroubleshooting, “Injector Code - Calibrate”.

g. Calibrate the timing. Refer to Troubleshooting,“Engine Speed/Timing Sensor - Calibrate”.

i02378227

Self-DiagnosticsSMCS Code: 1901

The Electronic Control Module (ECM) has the abilityto detect problems with the electronic system andwith engine operation. When a problem is detected, acode is generated. An alarm may also be generated.There are two types of codes:

• Diagnostic

• Event

Diagnostic Code – When a problem with theelectronic system is detected, the ECM generates adiagnostic code. This indicates the specific problemwith the circuitry.

Diagnostic codes can have two different states:

• Active

• Logged

Active Code

An active diagnostic code indicates that an activeproblem has been detected. Active codes requireimmediate attention. Always service active codesprior to servicing logged codes.

Logged Code

Every generated code is stored in the permanentmemory of the ECM. The codes are logged.

Logged codes may not indicate that a repair isneeded. The problem may have been temporary. Theproblem may have been resolved since the loggingof the code. If the system is powered, it is possibleto generate an active diagnostic code whenever acomponent is disconnected. When the component isreconnected, the code is no longer active. Loggedcodes may be useful to help troubleshoot intermittentproblems. Logged codes can also be used to reviewthe performance of the engine and of the electronicsystem.

Event Code

An event code is generated by the detection of anabnormal engine operating condition. For example,an event code will be generated if the oil pressure istoo low. In this case, the event code indicates thesymptom of a problem.


i02428849

Sensors and ElectricalConnectorsSMCS Code: 1900-NS; 7553-WW

Table 6

Connector Function

J1/P1 ECM Connector (70−Pin)

J2/P2 ECM Connector (120−Pin)

J61/P61 Customer Connector (40-Pin)(1)

J63 Engine Service Tool Connector(1)

J66 Customer Supplied Service ToolConnector

J100/P100 Engine Coolant Temperature Sensor

J103/P103 Intake Manifold Air TemperatureSensor

J142/P142 Auxiliary Temperature Sensor

J200/P200 Boost Pressure Sensor

J201/P201 Engine Oil Pressure Sensor

J203/P203 Atmospheric Pressure Sensor

J204/P204 Injection Actuation Pressure Sensor

J209/P209 Fuel Pressure Sensor

J220/P220 Auxiliary Pressure Sensor

J300/P300 Injector Solenoid Harness

P400 Engine Timing Calibration

J401/P401 Primary Engine Speed/TimingSensor

J402/P402 Secondary Engine Speed/TimingSensor

J403/P403 Throttle Position Sensor

J500/P500 Injection Actuation Pressure ControlValve

J501/P501 Air Inlet Heater Relay

J800/P800 Engine Coolant Level Sensor(1) This connector is part of the optional 194-1091 ElectronicControl Wiring Gp.



Components for the engine’s control system


Cross-Reference for the P1 ECMConnector and the J61 CustomerConnector

g01120826Illustration 4Terminal locations on the P1 ECM connector and J61 customerconnector

Table 7 provides a cross-reference between the P1ECM connector and the J61 customer connector.

Table 7

Cross-Reference for the P1 ECM Connectorand the J61 Customer Connector

TerminalDescription

P1 J61

+5 VDC for the pressure sensors 2 14

Return for the analog sensors 3 15

+8 VDC for the digital sensors 4 8

Return for the digital sensors 5 9

Maintenance clear switch 6 12

Torque limit switch 7 2

CAT Data Link + 8 7

CAT Data Link − 9 6

Ether relay 10 22

Air shutoff solenoid 11 4

Auxiliary pressure sensor 15 33(continued)

(Table 7, contd)

Cross-Reference for the P1 ECM Connectorand the J61 Customer Connector

TerminalDescription

P1 J61

Auxiliary temperature sensor 16 11

Ether starting aid switch 22 38

Diagnostic lamp 28 24

Warning lamp 29 25

Maintenance due lamp 30 13

J1939 (−) 34 18

PTO interrupt switch 41 19

J1939 shield 42 16

Remote shutdown switch 44 27

Intermediate engine speed switch 45 28

+Battery 48 1

Coolant level sensor 49 36

J1939 (+) 50 17

+Battery 52 31

+Battery 53 32

Overspeed verify switch 54 40

PTO enable switch 56 29

PTO ramp up switchPTO set switch 58 30

PTO ramp down switchPTO resume switch 60 39

-Battery 61 N/C(1)

-Battery 63 N/C(1)

-Battery 65 N/C(1)

Throttle position 66 10

Air shutoff solenoid 67 5

Keyswitch 70 26(1) No connection


Component Location


Component locations for C9 industrial engines(1) Engine coolant temperature sensor(2) Connector for the injection actuation

pressure control valve(3) Air inlet heater relay(4) Injection actuation pressure sensor(5) Boost pressure sensor(6) Intake manifold air temperature sensor(7) Connector for the injector solenoid

harness(8) Atmospheric pressure sensor(9) Ground stud

(10) Service tool connector(11) Customer connector(12) Optional 194-1091 Electronic Control

Wiring Gp(13) P400 connector for engine timing

calibration(14) J2/P2 connector(15) J1/P1 connector(16) Primary engine speed/timing sensor(17) Secondary engine speed/timing sensor(18) Engine oil pressure sensor


g01120762Illustration 6The location of the fuel pressure sensor depends on the engine’sconfiguration.(19) Fuel pressure sensor

i02157279

Engine Wiring InformationSMCS Code: 1408

The wiring schematics are revised periodically. Thewiring schematics will change with updates to theharness wire. For the most current information,always check the revision number of the schematic.Use the schematic with the latest revision number.

Harness Wire IdentificationCaterpillar identifies all wires with eleven solid colors.The circuit number is stamped on the wire at a 25 mm(1 inch) spacing. Table 8 lists the wire colors and thecolor codes.

Table 8

Color Codes for the Harness Wire

Color Code Color Color Code Color

BK Black GN Green

BR Brown BU Blue

RD Red PU Purple

OR Orange GY Gray

YL Yellow WH White

PK Pink

For example, a wire identification of A701-GY on theschematic would signify a gray wire with the circuitnumber A701. A701-GY identifies the power circuitfor the No. 1 Injector solenoid.

Another wire identification on the schematic is thesize of the wire. The size of the wire will follow thewire color. Wire size or gauge is referred to as AWG(Americal Wire Gauge). AWG is a description of thediameter of the wire.

For example, a code of 150-OR-14 on the schematicwould indicate that the orange wire in circuit 150 is a14 AWG wire.

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

Conversion of AWG Numbers to MetricMeasurements

Table 9 shows the various AWG numbers that areused for the wires. The metric equivalent for thediameter of each AWG number are also shown.

Table 9

Metric Equivalents for AWG Numbers

AWGNumber

Diameter(mm)

AWGNumber

Diameter(mm)

20 0.8 14 1.6

18 1.0 12 2.0

16 1.3 4 3.2


Welding on a Machine that is Equippedwith an Electronic Engine Control System

Proper welding procedures are necessary in orderto avoid damage to the engine’s electronic controlmodule, sensors, and associated components. Thecomponent that requires welding should be removed.When welding on a machine that is equipped withan electronic engine control system and removalof the component is not possible, the followingprocedure must be followed. This procedure providesthe minimum amount of risk to the electroniccomponents.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train bearings, hydrauliccomponents, electrical components, and other com-ponents.

Clamp the ground cable from the welder to the com-ponent that will be welded. Place the clamp as closeas possible to the weld. This will help reduce the pos-sibility of damage.

1. Stop the engine. Turn the keyswitch to the OFFposition.

2. Disconnect the negative battery cable from thebattery. If a battery disconnect switch is installed,open the switch.

g01100101Illustration 7The welding current will not cause damage to any of the associatedcomponents.

3. Connect the welding ground cable as closeas possible to the area that will be welded.Components which may be damaged by weldinginclude bearings, hydraulic components, andelectrical/electronic components.

4. Protect the wiring harness from welding debrisand from spatter.

5. Weld the materials by using standard weldingmethods.


Programming Parametersi02253984

Programming ParametersSMCS Code: 1901

The Caterpillar Electronic Technician (ET) can beused to view certain parameters that can affect theoperation of the engine. Cat ET can also be usedto change certain parameters. The parameters arestored in the Electronic Control Module (ECM). Someof the parameters are protected from unauthorizedchanges by passwords. Parameters that can bechanged have a tattletale number. The tattletalenumber shows if a parameter has been changed.

i02419716

Customer PasswordsSMCS Code: 0785

Customer passwords may be used to protectcustomer parameters from being changed. Thepasswords are programmed into the ElectronicControl Module (ECM) with the Caterpillar ElectronicTechnician (ET). One password may be programmedor both passwords may be programmed. Ifcustomer passwords are not programmed, customerparameters may be changed by anyone.

To obtain customer passwords, contact the owner ofthe engine. If the owner has forgotten the customerpasswords, customer passwords may be read byusing Cat ET. Factory passwords are required inorder to read customer passwords.

Use the following procedure in order to read customerpasswords with Cat ET:

1. Select the “Information” menu. Then select“Passwords”.

2. When the “Factory Password” screen appears,record the information that is listed on the “FactoryPasswords Worksheet”. Refer to programmingparameters Troubleshooting, “Factory PasswordsWorksheet” for additional information.

3. Obtain the factory passwords. The informationthat is recorded on the “Factory PasswordsWorksheet” must be provided. When you obtainthe factory passwords, a permanent record of youraccess is generated at Caterpillar.

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

5. When the “Read Customer Passwords” screenappears, record the customer passwords. Thecustomer passwords may then be used to changeparameters that are customer programmable.

i02170317

Factory PasswordsSMCS Code: 0785

NOTICEOperating the engine with a Personality Module notdesigned for that engine will damage the engine. Besure the Personality Module is correct for your engine.

Note: Factory passwords are provided only toCaterpillar dealers.

Factory passwords are required to perform each ofthe following functions:

• Program a new Electronic Control Module (ECM).

When an ECM is replaced, the systemconfiguration parameters must be programmedinto the new ECM. A new ECM will allow theseparameters to be programmed once without factorypasswords. After the initial programming, someparameters are protected by factory passwords.

• Clear event codes.

Most event codes require the use of factorypasswords to clear the code once the code hasbeen logged. Clear these codes only when you arecertain that the problem has been corrected.

• Unlock parameters.

If a parameter has been locked out, factorypasswords are required to unlock the parameter.Refer to Troubleshooting, “System ConfigurationParameters” for additional information.

Since factory passwords contain alphabeticcharacters, the Caterpillar Electronic Technician (ET)must be used to perform these functions. In order toobtain factory passwords, proceed as if you alreadyhave the password. If factory passwords are needed,Cat ET will request the factory passwords andCat ET will display the information that is requiredto obtain the passwords. For the worksheet thatis used for acquiring factory passwords, refer toTroubleshooting, “Factory Passwords Worksheet”.


i02334692

Factory Passwords WorksheetSMCS Code: 0785

Note: A mistake in recording these parameters willresult in incorrect passwords.

Some of the following information is required toobtain factory passwords:

Table 10

Dealer Code

Customer’s Name

Address

Telephone Number

Information From Engine Information Plate

Engine Serial Number

Full Load Setting

Full Torque Setting

Information From Engine Hour Meter

Engine Hours

Information From Factory Password EntryScreen on ET

Electronic Service ToolSerial Number

Engine Serial Number

ECM Serial Number

Total Tattletale

Reason Code

From Interlock(1)

To Interlock(1)

Factory Passwords

Factory Password (No. 1)

Factory Password (No. 2)(1) This parameter is required when the engine is being rerated.This parameter is displayed only when the engine is beingrerated.

i02419726

Flash ProgrammingSMCS Code: 1901-591

Flash Programming – This is a method ofprogramming or updating the flash file in an engine’sElectronic Control Module (ECM).

Caterpillar Electronic Technician (ET) is used to flashprogram a file into the memory of the engine’s ECM.

If you do not have the flash file, use the “Flash FileSearch” tool on the Service Technician Workbench(STW) to obtain the flash file for your engine.Alternatively, use the “Service Software Files” featureon SIS Web to obtain the flash file for your engine.You must have the engine serial number in order tosearch for the flash file. After locating the correctflash file, download the flash file to your PC. Writedown the name of the flash file for future reference.

Programming a Flash File1. Establish communication between Cat ET and theengine’s ECM.

2. Select “WinFlash” from the “Utilities” menu on CatET.

Note: If “WinFlash” will not communicate with theECM, refer to troubleshooting without a diagnosticcode Troubleshooting, “Electronic Service Tool WillNot Communicate with ECM”.

3. Program the flash file into the ECM.

a. Select the engine ECM under the “DetectedECMs”.

b. Press the “Browse” button in order to select thename of the flash file that will be programmedinto the ECM.

c. When the correct flash file is selected, pressthe “Open” button.

d. Verify that the “File Values” match theapplication. If the “File Values” do not matchthe application, obtain the correct flash file.

e. When the correct flash file is selected, pressthe “Begin Flash” button.

f. Cat ET will indicate when flash programminghas been successfully completed.

4. Start the engine and check for proper operation.Repair any active diagnostic or event codes.


“WinFlash” Error Messages

If you receive any error messages during flashprogramming, click on the “Cancel” button in orderto stop the process. Access the information aboutthe “ECM Summary” under the “Information” menu.Make sure that you are flashing the correct file foryour engine.

i02428583

Injector Trim FileSMCS Code: 1290

The Caterpillar Electronic Technician (ET) is used toload the injector trim files into the Electronic ControlModule (ECM).

The injector trim files must be loaded into the ECM ifany of the following conditions occur:

• An injector is replaced.

• The ECM is replaced.

• “Injector Code” is displayed below a 268-02diagnostic code on Cat ET.

• Injectors are exchanged between cylinders.

Exchanging Injectors

Exchanging injectors can help determine if acombustion problem is in the injector or in thecylinder. If two injectors that are currently installedin the engine are exchanged between cylinders,the injector trim files can also be exchanged. Pressthe “Exchange” button at the bottom of the “InjectorTrim Calibration” screen on Cat ET. Select the twoinjectors that will be exchanged and press the “OK”button. The tattletale for the injectors that wereexchanged will increase by one.

Note: The injector serial number and the injectorconfirmation code are located on the injector.

1. Record the injector serial number and the injectorconfirmation code for each injector.

2. Click on “Service Software Files” in SIS Web.

3. Enter the serial number for the injector in thesearch field.

4. Download the injector trim file to the PC. Repeatthis procedure for each injector, as required.

5. Connect Cat ET to the service tool connector. Referto electronic troubleshooting Troubleshooting,“Electronic Service Tools”.

6. Select the following menu options on Cat ET:

• Service

• Calibrations

• Injector Trim Calibration

7. Select the appropriate cylinder.

8. Click on the “Change” button.

9. Select the appropriate injector trim file from thePC.

10.Click on the “Open” button.

11. If you are prompted by Cat ET enter the injectorconfirmation code into the field.

12.Click on the “OK” button.

The injector trim file is loaded into the ECM.

13.Repeat the procedure for each cylinder, asrequired.

i02278907

Service Information ReportSMCS Code: 0336

After verifying the correct repair has been performedon the engine, it is critical to provide brief, detailedinformation. This information helps Caterpillar betterserve you and the customer.

Recommendations

Customer’s Complaint

Obtain as much information from the customeras possible. Investigate any written informationthat is available and document any informationthat is gathered from the customer. The followinginformation is of particular importance:

• Indicate if the diagnostic lamp was flashing.

• Indicate if the warning lamp was flashing, or if thelamp was on continuously.

• Indicate the symptoms of engine operation that arepresent.

Be as specific as possible.


Cause of Failure

Comments on the cause of failure should includethe number of diagnostic codes that were logged.Comments should also indicate if the code was anactive code. Indicate the source of the problem. Alsoindicate the method that was used to discover theproblem. Examples of the methods that were used todiscover the problem could be one of the followingmethods:

• A specific procedure in the manual was followed.

• A visual inspection indicated that wire abrasion onthe engine harness existed.

• An engine dynamometer test indicated that thepower was below the specification at 1700 rpmdue to the loss of the no. 4 injector and an enginedynamometer test indicated that the power wasbelow the specification at all engine speeds above1700 rpm due to the loss of the no. 4 injector.


Repair Procedure

Comments on the repair procedure should includethe following types of information:

• The wiring harness was repaired.

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



System ConfigurationParameters

i02213820

System ConfigurationParametersSMCS Code: 1901

System configuration parameters affect the emissionsand the power of the engine. Default values for theparameters are programmed at the factory. Someparameters may be changed by the customer inorder to suit the needs of the specific application.

Parameter Descriptions

“Equipment ID”

“Equipment ID” allows the customer to enter adescription into the Electronic Control Module (ECM)in order to identify the machine. A maximum of17 characters may be entered in the field. Thisparameter is only for reference by the customer. Thisparameter is not required.

“Engine Serial Number”

Program the “Engine Serial Number” to match theengine serial number that is stamped on the engineinformation plate. If the ECM is replaced, the engineserial number from the engine information plate mustbe programmed into the new ECM.

Note: When you are requesting factory passwords,always use the engine serial number that isprogrammed in the ECM.

“Rating Number”

The “Rating Number” corresponds to the selectedset of performance maps for the application. Thisselected set of performance maps comes out ofseveral unique sets of maps that are resident in theflash file. The dealer and/or the OEM will need toselect the appropriate rating tier, if more than onerating tier is present. The rating tiers are A through E.

Note: Factory passwords are required in order tochange the “Rating Number”.

“Top Engine Limit” (TEL)


“TEL” is a customer programmable parameter thatdefines the maximum allowable engine speed formaximum power. “TEL” can be programmed up tothe maximum rated engine speed. “TEL” is definedalong the engine’s lug curve.

“Engine Accel. Rate”

“Engine Accel. Rate” determines the rate of changeof the engine speed (acceleration or deceleration)during PTO operation. This rate of change is alsoused to achieve intermediate engine speed.

“Low Idle Speed”

“Low Idle Speed” is the minimum allowable operatingspeed for the engine. This parameter can beprogrammed between 600 and 1400 rpm.

“PTO Mode”

“PTO Mode” allows the ECM to be programmed toeither one of the two PTO configurations that areavailable.

“Ramp Up/Ramp Down” – When “PTO Mode” isprogrammed to “Ramp Up/Ramp Down”, the ECMallows PTO operation with traditional features.

“Set/Resume” – When “PTO Mode” is programmedto “Set/Resume”, the ECM allows PTO operation withenhanced features.


“High Idle Speed”


“High Idle Speed” is the maximum no-load enginespeed when the throttle or the PTO switch is in themaximum position.

Note: “High Idle Speed” cannot be programmedlower than “TEL”.

“Intermediate Engine Speed”

“Intermediate Engine Speed” defines the speedfor the engine when the intermediate enginespeed switch is activated. This parameter can beprogrammed to any engine speed between “Low IdleSpeed” and “TEL”. Engine speed will increase orengine speed will decrease at the rate that is definedby the programmed value for “Engine Accel. Rate”.

“Maximum Engine Torque Limit”


“Engine Torque Limit” can be used to limit torqueoutput to the programmed value when the torquelimit switch is activated.

“FLS” (Full Load Setting)

“FLS” is a number that represents the adjustment tothe fuel system that was made at the factory in orderto fine tune the fuel system. The correct value forthis parameter is stamped on the engine informationplate. Factory passwords are required in order tochange this parameter.

“FTS” (Full Torque Setting)

“FTS” is similar to “FLS”. Factory passwords arerequired in order to change this parameter.

“Ether Control”

Program the “Ether Control” to “Enabled” if anether injection system is installed on the engine.This allows the ECM to control ether injection. Ifthe engine is not equipped with ether, program thisparameter to “Disabled”.

“Air Shutoff”

“Air Shutoff” allows the ECM to be programmed foroperation of an air shutoff system. If this parameteris programmed to “Installed”, the ECM will activatethe air shutoff solenoid in the event of an engineoverspeed condition.


Note: If an engine overspeed occurs and “Air Shutoff”is programmed to “Enabled”, the switched power tothe ECM must be cycled and the air shutoff solenoidmust be manually reset before the engine will restart.

“Maintenance Indicator Mode”

The ECM records data that is related to equipmentmaintenance. The ECM will activate the maintenanceindicator lamp when scheduled maintenance isdue. The maintenance indicator lamp can be resetby actuating the maintenance clear switch. Themaintenance interval may be based on operatinghours or on fuel consumption. The ECM providesinformation that pertains to maintenance intervalsand the last maintenance that was performed.

“PM1 Interval”

“PM1 Interval” allows the customer to define themaintenance interval if “Maintenance Indicator Mode”is programmed to one of the manual options. Referto the engine’s Operation and Maintenance Manualfor more information.

“Throttle Position Sensor”

Program the “Throttle Position Sensor” to “Installed”if a throttle position sensor is used for desired speedcontrol. Otherwise program this parameter to “NotInstalled”.

“Coolant Level Sensor”

Program the “Coolant Level Sensor” to “Installed”if a coolant level sensor is installed on the engine.Otherwise program this parameter to “Not Installed”.

“Direct Fuel Control Mode”

Program the “Direct Fuel Control Mode” to “Enabled”if an external governor is used. Once this parameteris enabled, the governing system in the ECM isdisabled. Otherwise program this parameter to“Disabled”.

“Aux Press Sensor Installation Status”

Program “Aux Press Enable” to “Installed” if anauxiliary pressure sensor is installed. This will allowthe display for the Engine Monitoring System (EMS)to monitor the pressure of another system. Programthis parameter to “Not Installed” if an auxiliarypressure sensor is not installed.

“Aux Temp Sensor Installation Status”

Program “Aux Temp Enable” to “Installed” if anauxiliary temperature sensor is installed. This willallow the display for the Engine Monitoring System(EMS) to monitor the temperature of another system.Program this parameter to “Not Installed” if anauxiliary temperature sensor is not installed.


System Configuration ParametersTable 11

System Configuration Parameters

Parameter Available Range or Options Default RequiredPassword

ECM Identification Parameters

“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None

“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None

“ECM Serial Number” “Read Only” (1)

“Personality Module PartNumber” Software Dependent Read Only (1)

“Software Gp Release Date” Software Dependent Read Only (1)

Selected Engine Rating

“Rating Number” Software Dependent Customer

“Rated Power” Software Dependent Read Only (1)

“Rated Peak Torque” Software Dependent Read Only (1)

“Top Engine Speed Range” Software Dependent Read Only (1)

“Test Spec” Software Dependent Read Only (1)

“Top Engine Limit” Software Dependent Customer

“Engine Accel. Rate” 50 to 1000 50 None

“Low Idle Speed” 600 to 1400 700 None

“PTO Mode” “Ramp Up/Ramp Down”“Set/Resume” “Ramp Up/Ramp Down” None

“High Idle Speed” 1800 to 2310 2310 Customer

“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None

“Maximum Engine Torque Limit” Software Dependent None

“Customer Password #1” 8 alphanumeric characters Blank Customer

“Customer Password #2” 8 alphanumeric characters Blank Customer

“FLS” (Full Load Setting) - 128 to 127 0 Factory

“FTS” (Full Torque Setting) -128 to 127 0 Factory

“Ether Control” “No Ether”“Continuous Flow” “No Ether” None

“Air Shutoff” “Enabled”“Disabled” “Disabled” None

“Maintenance Indicator Mode”

“OFF”“Auto Fuel”“Auto Hour”“Man Fuel”“Man Hour”

“OFF” None

“PM1 Interval”100 to 750 Hours

or3785 to 28390 L (1000 to 7500 US gal)

250 Hoursor

9463 L (2500 US gal)None

“Throttle Position Sensor” “Installed”“Not Installed” “Not Installed” None

(continued)


(Table 11, contd)

System Configuration Parameters

Parameter Available Range or Options Default RequiredPassword

“Coolant Level On” “Installed”“Not Installed” “Not Installed” None

“Direct Fuel Control Mode” “Installed”“Not Installed” “Not Installed” Factory

“Last Tool to change CustomerParameters” Read Only (1)

“Last Tool to change SystemParameters” Read Only (1)

“Aux Temp Sensor InstallationStatus”

“On”“Off” “Off” None

“Aux Press Sensor InstallationStatus”

“On”“Off” “Off” None

“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.

Parameters Worksheet

Note: A mistake in recording this information willresult in incorrect passwords.

Table 12

Engine Parameters

ECM Identification Parameters

“Equipment ID”


“ECM Serial Number”

“Personality Module PartNumber”

“Software Gp ReleaseDate”

Selected Engine Rating

“Rating Number”

“Rated Power”

“Rated Peak Torque”

“Top Engine Speed Range”

“Test Spec”

“Top Engine Limit”

“Engine Accel Rate”

(continued)

(Table 12, contd)

Engine Parameters

“Low Idle Speed”

“PTO Mode”

“High Idle Speed”

“Intermediate EngineSpeed”

“Maximum Engine TorqueLimit”

“Customer Password #1”

“Customer Password #2”

“FLS”

“FTS”

“Ether Control”

“Air Shutoff”

“Maintenance IndicatorMode”

“PM1 Interval”

“Throttle Position Sensor”

“Coolant Level Sensor”

(continued)


(Table 12, contd)

Engine Parameters

“Direct Fuel Control Mode”

“Last Tool to changeCustomer Parameters”

“Last Tool to changeSystem Parameters”

“Aux Press TempInstallation Status”

“Aux Press SensorInstallation Status”

“Total Tattletale”

Information from Engine Information Plate


“FLS”

“FTS”

Injector Codes

Injector Code (1)

Injector Code (2)

Injector Code (3)

Injector Code (4)

Injector Code (5)

Injector Code (6)

Note: Compare the FLS and the FTS from theECM with the values that are listed on the engineinformation plate. Only change the FLS and the FTSbecause of a mechanical change in the engine. Theuse of the wrong parameters could cause damage tothe engine. The use of the wrong parameters mayalso void the Caterpillar warranty.

Monitoring SystemThe monitoring system determines the level of actionthat is taken by the ECM in response to a conditionthat can damage the engine. The monitoring of thevarious sensors by the ECM can be turned “On” or“Off”. These conditions are identified by the ECMfrom the signals that are produced from the followingsensors:

• Engine oil pressure sensor

• Engine coolant temperature sensor

• Engine speed/timing sensors

• Inlet air temperature sensor

• Boost pressure sensor

• Coolant level sensor

• Fuel temperature sensor

• Fuel pressure sensor

• Auxiliary temperature sensor

• Auxiliary pressure sensor

The monitoring system can be locked out. In orderto change the settings, the monitoring system mustbe unlocked. Access the “Parameter Lockout” underthe “Service” menu on the Caterpillar ElectronicTechnician (ET) in order to unlock the monitoringsystem.

Warnings, derates, and shutdowns can be disabledfor any parameter or for all of the parameters.


Table 13

Settings for the Monitoring System

Time Delay inSeconds Set Points

Parameter EventCode Action Default

ValueRange Default Range Default

E057 Derate On 1 to 54 10

E058 Shutdown Off 1 to 54 10“Low Coolant Level”

E059 Warning On 1 to 54 10

None

“High Fuel Pressure” E096 Warning On None 8 Maps are not programmable. (1)

Warning

DerateOn 8

“Low Engine Oil Pressure” E360

Shutdown Off

None

4

Maps are not programmable.(1)

Warning None 1085 °C (185 °F)

to110 °C (230 °F)

110 °C(230 °F)

Derate

On

1 to 54 1086 °C (187 °F)

to111 °C (232 °F)

“High Engine CoolantTemperature” E361

Shutdown Off 1 to 54 1087 °C (189 °F)

to111 °C (232 °F)

111 °C(232 °F)

C11/C13

C151800-2600 2600

Warning

C18 1800-2500 2500

C11/C13

C151800-2800 2800

“Engine Overspeed” E362

Shutdown

On None 1

C18 1800-2700 2700

Warning 1 to 54 3070 °C (158 °F)

to90 °C (194 °F)

90 °C (194 °F)

Derate

On

1 to 54 10“High Fuel Temperature” E363

Shutdown Off 1 to 54 10

71 °C (160 °F)to

91 °C (196 °F)91 °C (196 °F)

Warning On 1 to 54 4

Derate 1 to 54 3“High Auxiliary Pressure”(2) E443

ShutdownOff

1 to 54 3

0 kPa (0 psi)to

3150 kPa (457 psi)

1500 kPa(218 psi)

Warning On 1 to 54 4 105 °C(221 °F)

Derate 1 to 54 4 106 °C(223 °F)

“High AuxiliaryTemperature”(2) E445

ShutdownOff

1 to 54 4

0 °C (0 °F)to

140 °C (284 °F)107 °C(224 °F)

Warning None 8 75 °C (167 °F)“High Engine Air InletTemperature” E539

DerateOn

1 to 54 8None

79 °C (174 °F)(1) The maps may be different. The maps depend on the model of the engine.(2) The engine must be equipped with the appropriate sensor.


Troubleshooting without aDiagnostic Code

i02121176

Alternator(Charging Problem)SMCS Code: 1405-035

The connection of any electrical equipment andthe disconnection of any electrical equipmentmaycause an explosion hazard which may result in in-jury or death. Do not connect any electrical equip-ment or disconnect any electrical equipment in anexplosive atmosphere.

Refer to Special Instruction, REHS0354, “ChargingSystem Troubleshooting” for the proper testingprocedures.

Probable Causes• Alternator drive belts

• Charging circuit

• Regulator

• Alternator

Recommended Actions

Alternator Drive Belts

1. Inspect the condition of the alternator drive belts.If the alternator drive belts are worn or damaged,replace the belts.

2. Check the tension on the alternator drive belts.Adjust the tension, if necessary.

Charging Circuit

Inspect the battery cables, wiring, and connections inthe charging circuit. Clean all connections and tightenall connections. Replace any faulty parts.

Alternator or Regulator

Verify that the alternator or the regulator is operatingcorrectly. Refer to Special Instruction, REHS0354,“Charging System Troubleshooting” for the propertesting procedures. Repair the alternator or replacethe alternator, as needed.

i02349055

BatterySMCS Code: 1401-035

Refer to Special Instruction, REHS0354, “ChargingSystem Troubleshooting” for the proper testingprocedures.

Probable Causes• Worn battery

• Switched battery circuit

Recommended Actions

Worn Battery

1. Verify that the battery is no longer able to hold acharge.

2. Replace the battery.

Switched Battery Circuit

1. Verify that a switched battery circuit drained thebattery by being left in the ON position.

2. Charge the battery.

3. Verify that the battery is able to maintain a charge.

i02370484

Can Not Reach Top EngineRPMSMCS Code: 1915-035

Note: If this problem occurs only under load, refer toTroubleshooting, “Low Power/Poor or No Responseto Throttle”.

Probable Causes• Diagnostic codes

• Event codes


• Programmable parameters

• Cold mode

• Altitude derate

• Throttle signal

• Rated fuel position and/or FRC fuel position


• Fuel supply

• Air inlet and exhaust system

• Accessory equipment

Recommended Actions

Diagnostic Codes and Event Codes

Certain diagnostic codes and/or event codes maycause poor performance. Connect the CaterpillarElectronic Technician (ET) and check for active codesand logged codes. Troubleshoot any codes that arepresent before continuing with this procedure.

Programmable Parameters

Check the following parameters on Cat ET:

• “Throttle Position Sensor”

• “Desired Speed Input Configuration”

• “Direct Fuel Control Mode”

Determine the type of throttle that is used in theapplication. Program the parameters to match thetype of throttle that is used. Refer to Troubleshooting,“Throttle Position Sensor Circuit - Test” for moreinformation.

Note: The engine will have poor performance if theparameters are not programmed correctly.

Cold Mode

Connect Cat ET to the service tool connector. Verifythat the engine has exited cold mode. A status flagwill appear if the engine is operating in cold mode.This may limit engine speed.

Altitude Derate

The engine may be derated due to high elevation.Connect Cat ET to the service tool connector. Checkfor an active engine derate on the status screens.

Note: There are no event codes that are associatedwith the altitude derate.

Throttle Signal

Connect Cat ET to the service tool connector. Viewthe status for the throttle position on the statusscreen. Operate the throttle from the Low Idleposition to the High Idle position. The status shouldbe 0 percent at low idle and the status should be 100percent at high idle. If the status can not operatein the full range, refer to Troubleshooting, “ThrottlePosition Sensor - Calibrate”.

Diagnostic codes that are related to the J1939 datalink will prevent correct operation of the throttle if thethrottle position is transmitted over the data link. Ifthere is a problem with the data link, the engine willremain at low idle until the data link is repaired.

Boost Pressure Sensor, Rated FuelPosition and/or FRC Fuel Position

1. With the engine at full load, monitor “Fuel Position”and “Rated Fuel Limit” on the status screen. If“Fuel Position” does not equal “Rated Fuel Limit”then check air inlet manifold pressure.

2. Verify that there are no active diagnostic codesthat are associated with the boost pressure sensoror with the atmospheric pressure sensor.

3. Monitor boost pressure and atmospheric pressureon the status screen for normal operation.

Note: Atmospheric pressure is not a defaultparameter on a status screen. You must manuallyselect the parameter for the atmospheric pressure inorder to monitor the atmospheric pressure sensor.

Fuel Supply

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

2. Check the fuel tank for foreign objects which mayblock the fuel supply.

3. Check for air in the low pressure fuel supplysystem if any of the following procedures havebeen performed:

• Replacement of the fuel filters

• Service on the low pressure fuel supply circuit

• Replacement of unit injectors


4. Prime the low pressure fuel supply circuit. Referto Operation and Maintenance Manual, “FuelSystem - Prime” for the correct procedure.

Note: A sight glass in the low pressure supply line ishelpful in diagnosing air in the fuel.

5. Cold weather adversely affects the characteristicsof the fuel. Refer to the Operation andMaintenance Manual for information on improvingthe characteristics of the fuel during cold weatheroperation.

6. Check the fuel pressure during engine cranking.Check the fuel pressure on the outlet side ofthe fuel filter. Refer to Specifications for correctpressure values. If the fuel pressure is low,replace the fuel filters. If the fuel pressure is stilllow, check the following items: fuel transfer pump,fuel transfer pump coupling, and fuel pressureregulating valve.

Air Inlet and Exhaust System

1. Clean plugged air filters or replace plugged airfilters. Refer to the Operation and MaintenanceManual.

2. Check the air inlet and exhaust system forrestrictions and/or leaks. Refer to Testing andAdjusting, “Air Inlet and Exhaust System”.

Accessory Equipment

Check all accessory equipment for problems thatmay create excessive load on the engine. Repairany damaged components or replace any damagedcomponents.

i02381103

Coolant in Engine OilSMCS Code: 1348-035; 1395-035

Probable Causes• Engine oil cooler core

• Cylinder head gasket

• Cylinder head

• Cylinder liner

• Cylinder block

Recommended Actions

Engine Oil Cooler Core

1. Check for leaks in the oil cooler core. If a leak isfound, install a new oil cooler core. Refer to theDisassembly and Assembly manual.

2. Drain the crankcase and refill the crankcase withclean engine oil. Install new engine oil filters.Refer to the Operation and Maintenance Manual.

Cylinder Head Gasket

1. Remove the cylinder head. Refer to theDisassembly and Assembly manual.

2. Check the cylinder liner projection. Refer to theSystems Operation/Testing and Adjusting manual.

3. Install a new cylinder head gasket and new waterseals in the spacer plate. Refer to the Disassemblyand Assembly manual.

Cylinder Head

Check for cracks in the cylinder head. If a crackis found, repair the cylinder head and/or replacethe cylinder head. Refer to the Disassembly andAssembly manual.

Cylinder Liner

Check for cracked cylinder liners. Replace anycracked cylinder liners. Refer to the Disassembly andAssembly manual.

Cylinder Block

Inspect the cylinder block for cracks. If a crack isfound, repair the cylinder block or replace the cylinderblock.

i02194394

Coolant Temperature Is TooHighSMCS Code: 1395-035

Refer to Systems Operation/Testing and Adjusting,“Cooling System - Check” for information ondetermining the cause of this condition.


i02419115

ECM Will Not Accept FactoryPasswordsSMCS Code: 1901-035

Probable CausesOne of the following items may not be recordedcorrectly on the Caterpillar Electronic Technician(ET):

• Passwords

• Serial numbers

• Total tattletale

• Reason code

Recommended Actions1. Verify that the correct passwords were entered.Check every character in each password. Removethe electrical power from the engine for 30seconds and then retry.

2. Verify that Cat ET is on the “Factory Password”screen.

3. Use Cat ET to verify that the following informationhas been entered correctly:

• Engine serial number

• Serial number for the electronic control module

• Serial number for Cat ET

• Total tattletale

• Reason code

i02424497

ECM Will Not Communicatewith Other Systems or DisplayModulesSMCS Code: 1901-035

Probable Causes• Wiring and/or electrical connectors

• Cat Data Link

• CAN data link (if equipped)

• Electronic Control Module (ECM)

Recommended Actions1. Check for correct installation of the connectors forthe Electronic Control Module (ECM) J1/P1, J2/P2and J3/P3. Refer to the diagnostic functionaltest Troubleshooting, “Inspecting ElectricalConnectors”.

2. Connect the electronic service tool to theservice tool connector. If the ECM does notcommunicate with the electronic service tool,refer to troubleshooting without a diagnostic codeTroubleshooting, “Electronic Service Tool Will NotCommunicate with ECM”.

3. Troubleshoot the Cat Data Link for possibleproblems. Refer to the diagnostic functional testTroubleshooting, “Cat Data Link Circuit - Test”.

4. Troubleshoot the CAN data link (if equipped)for possible problems. Refer to the diagnosticfunctional test Troubleshooting, “CAN Data LinkCircuit - Test”.

i02429900

Electronic Service Tool WillNot Communicate with ECMSMCS Code: 0785-035; 1901-035

Probable Causes• Configuration for the communications adapter

• Electrical connectors

• Communication adapter and/or cables

• Electrical power supply to the service toolconnector

• Caterpillar Electronic Technician (ET) and relatedhardware

• Electrical power supply to the Electronic ControlModule (ECM)

• Flash file

• Cat Data Link


Recommended ActionsStart the engine. If the engine starts, but the ECMwill not communicate with Cat ET, continue withthis procedure. If the engine will not start, referto the troubleshooting without a diagnostic codeprocedure Troubleshooting, “Engine Cranks but WillNot Start”. If the engine will not crank, refer to thetroubleshooting without a diagnostic code procedureTroubleshooting, “Engine Will Not Crank”.

Configuration for the CommunicationsAdapter

1. Access “Preferences” under the “Utilities” menuon Cat ET.

2. Verify that the correct “Communications InterfaceDevice” is selected.

3. Verify that the correct port is selected for use bythe communication adapter.

Note: The most commonly used port is “COM 1”.

4. Check for any hardware that is utilizing thesame port as the communications adapter. If anydevices are configured to use the same port, exitor close the software programs for that device.

Electrical Connectors

Check for correct installation of the J1/P1 andJ2/P2 ECM connectors and of the service toolconnector. Refer to the diagnostic functional testTroubleshooting, “Electrical Connectors - Inspect”.

Communication Adapter and/or Cables

1. If you are using a “Communication Adapter II”,ensure that the firmware and driver files for thecommunication adapter are the most current filesthat are available. If the firmware and driver filesdo not match, the communication adapter will notcommunicate with Cat ET.

2. Disconnect the communication adapter and thecables from the service tool connector. Reconnectthe communication adapter to the service toolconnector.

3. Verify that the correct cable is being used betweenthe communication adapter and the service toolconnector. Refer to electronic troubleshootingTroubleshooting, “Electronic Service Tools”.

Electrical Power Supply to the ServiceTool Connector

Verify that battery voltage is present betweenterminals A and B of the service tool connector. If thecommunication adapter is not receiving power, thedisplay on the communication adapter will be blank.

Cat ET and Related Hardware

In order to eliminate Cat ET and the related hardwareas the problem, connect Cat ET to a different engine.If the same problem occurs on a different engine,check Cat ET and the related hardware in order todetermine the cause of the problem.

Electrical Power Supply to the ElectronicControl Module (ECM)

Check power to the ECM. Refer to the diagnosticfunctional test Troubleshooting, “Electrical PowerSupply Circuit - Test”.

Note: If the ECM is not receiving battery voltage, theECM will not communicate.

Flash File

Ensure that the correct flash file is properly installedin the ECM.

Note: A new ECM is not programmed to any specificengine until a flash file has been installed. The enginewill not start and the engine will not communicatewith Cat ET until the flash file has been downloaded.Refer to programming parameters Troubleshooting,“Flash Programming”.

Cat Data Link

Troubleshoot the Cat Data Link for possibleproblems. Refer to the diagnostic functional testTroubleshooting, “Cat Data Link Circuit - Test”.

i02431479

Engine Cranks but Will NotStartSMCS Code: 1000-035

Probable Causes• Fuel supply

• Diagnostic codes and event codes


• Electrical power to the Electronic Control Module(ECM)

• Starting aids

• Engine shutdown switches

• Air shutoff system

• Starting motor, solenoid, or starting circuit

• Engine speed/timing

• Unit injector

• Combustion

Recommended Actions

Fuel Supply

1. Visually check the fuel level. Do not rely on the fuelgauge only. If necessary, add fuel. If the enginehas been run out of fuel, it will be necessaryto purge the air from the fuel system. Refer toOperation and Maintenance Manual, “Fuel System- Prime” for the correct procedure.



4. Prime the fuel system if any of the followingprocedures have been performed:




Note: A sight glass in the low pressure supply line ishelpful in diagnosing air in the fuel. Refer to Testingand Adjusting for more information.

5. Check the fuel filters.


7. Check the fuel pressure during engine cranking.Check the fuel pressure after the fuel filter. Referto Systems Operation/Testing and Adjusting, “FuelSystem” for the correct pressure values. If the fuelpressure is low, replace the fuel filters. If the fuelpressure is still low, check the following items: fueltransfer pump, fuel transfer pump coupling, andfuel pressure regulating valve.


Certain diagnostic codes and/or event codes mayprevent the engine from starting. Connect theCaterpillar Electronic Technician (ET) and check foractive codes and/or for logged codes. Troubleshootany codes that are present before continuing withthis procedure.

Electrical Power Supply to the ECM

If the ECM is not receiving battery voltage, the ECMwill not operate. Refer to Troubleshooting, “ElectricalPower Supply Circuit - Test”.

Starting Aids

If cold ambient conditions exist, check operation ofstarting aids. Verify that the ether system is operatingcorrectly. Refer to Troubleshooting, “Ether InjectionSystem - Test”.

Engine Shutdown Switches

The engine shutdown switches must be in the RUNposition in order to start the engine. Use Cat ET toverify the status of the shutdown switches. When anengine shutdown switch is used to shut down theengine, the keyswitch must be turned to the RUNposition for at least 15 seconds before restarting theengine.

Air Shutoff System

Check the air shutoff mechanism. If an engineoverspeed has occurred, the keyswitch must becycled. There may be a manual reset for the airshutoff mechanism that is on the engine. Refer toTroubleshooting, “Air Shutoff System - Test” forinformation.

Starting Motor, Solenoid, or StartingCircuit

Remove the starter and visually inspect the pinion ofthe starter and the flywheel ring gear for damage.

Test the operation of the starting motor solenoid.Check the condition of the engine wiring for thestarting motor solenoid. Test the operation of thestarting motor.


If necessary, repair the starter or the starter circuit.

Engine Speed/Timing

1. Crank the engine and observe the engine speedon the Cat ET status screen. If Cat ET indicateszero rpm, refer to Troubleshooting, “EngineSpeed/Timing Sensor Circuit - Test”.

Note: Upon initial cranking, the status for enginespeed may indicate that the engine speed signal isabnormal. This message will be replaced with anengine speed once the ECM is able to calculate aspeed from the signal.

2. If an engine speed is present, check the sensorinstallation. If the sensor is not properly installed,the ECM may read engine speed, but the ECMcannot determine the tooth pattern. The ability forthe ECM to read the tooth pattern is necessaryto determine the cylinder position. Engine speedis present when engine speed is greater than50 rpm. Refer to Troubleshooting, “EngineSpeed/Timing Sensor Circuit - Test”.

Unit Injector

1. Ensure that the valve cover connectors for theinjector harnesses are fully connected and free ofcorrosion.

2. Perform the “Injector Solenoid Test” on Cat ET inorder to determine if all of the injector solenoidsare being energized by the ECM. Refer toTroubleshooting, “Injector Solenoid Circuit - Test”for additional information.

Combustion

Check the engine for combustion problems.

i02170800

Engine Has Early WearSMCS Code: 1000-035

Probable Causes• Incorrect engine oil

• Contaminated engine oil

• Contaminated air

• Contaminated fuel

• Low oil pressure

Recommended Actions

Incorrect Engine Oil

Use engine oil that is recommended and change theengine oil at the interval that is recommended by theengine’s Operation and Maintenance Manual.

Contaminated Engine Oil

Drain the crankcase and refill the crankcase withclean engine oil. Install new engine oil filters. Referto the engine’s Operation and Maintenance Manualfor more information.

If the oil filter bypass valve is open, the oil will not befiltered. Check the oil filter bypass valve for a weakspring or for a broken spring. If the spring is broken,replace the spring. Refer to the engine’s Disassemblyand Assembly manual. Make sure that the oil bypassvalve is operating correctly.

Contaminated Air

Inspect the air inlet system for leaks. Inspect all ofthe gaskets and the connections. Repair any leaks.

Inspect the air filter. Replace the air filter, if necessary.

Contaminated Fuel

Inspect the fuel filter. Replace the fuel filter, ifnecessary.

Contaminants in the fuel such as hydrogen sulfideand sulfur can lead to the formation of acids in thecrankcase. Obtain a fuel analysis.

Low Oil Pressure

When some components of the engine show bearingwear in a short time, the cause can be a restriction ina passage for engine oil.

An indicator for the engine oil pressure may indicatesufficient pressure, but a component is worn dueto a lack of lubrication. In such a case, look at thepassage for the engine oil supply to the component.Refer to Systems Operation/Testing and Adjusting,“Lubrication System” for additional information.


i02424560

Engine Misfires, Runs Roughor Is UnstableSMCS Code: 1000-035

Note: If the symptom is intermittent and the symptomcannot be repeated, refer to Troubleshooting,“Intermittent Low Power or Power Cutout”. If thesymptom is consistent and the symptom can berepeated, continue with this procedure.




• Cold mode

• Throttle signal

• Unit injectors

• Fuel supply


Recommended ActionsNote: If the symptom only occurs under certainoperating conditions (high idle, full load, engineoperating temperature, etc), test the engine underthose conditions. Troubleshooting the symptomunder other conditions can give misleading results.

Diagnostic Codes

Check for active diagnostic codes on the CaterpillarElectronic Technician (ET). Troubleshoot any activecodes before continuing with this procedure.



• Throttle Position Sensor

• Direct Fuel Control Mode




Check the connectors for the Electronic ControlModule (ECM) and the connectors for theunit injectors for correct installation. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

Cold Mode

Use Cat ET to verify that the engine has exited coldmode. Cold mode operation may cause the engine torun rough and the engine power may be limited.

Throttle Signal

Monitor the throttle signal on Cat ET. Verify that thethrottle signal is stable from the low idle position tothe high idle position.

Unit Injectors

1. Use Cat ET to determine if there are any activediagnostic codes for the unit injectors.

2. Perform the injector solenoid test on Cat ET inorder to determine if all of the injector solenoidsare being energized by the ECM. Refer toTroubleshooting, “Injector Solenoid Circuit - Test”for the proper procedure.

3. Perform the cylinder cutout test on Cat ET in orderto identify any injectors that might be misfiring.Refer to Troubleshooting, “Injector SolenoidCircuit - Test” for the proper procedure.

Fuel Supply







Note: A sight glass in the low pressure supply line ishelpful in diagnosing air in the fuel.



5. Check the fuel pressure during engine cranking.Check the fuel pressure after the fuel filter. Referto Systems Operation/Testing and Adjusting, “FuelSystem” for the correct pressure values. If the fuelpressure is low, replace the fuel filters. If the fuelpressure is still low, check the following items: fueltransfer pump, fuel transfer pump coupling, andfuel pressure regulating valve.


1. Check for an air filter restriction. Clean plugged airfilters or replace plugged air filters. Refer to theOperation and Maintenance Manual for additionalinformation.

2. Check the air inlet and exhaust system forrestrictions and/or for leaks. Refer to SystemsOperation/Testing and Adjusting, “Air Inlet andExhaust System”.

i02173692

Engine Oil in Cooling SystemSMCS Code: 1348-035; 1350-035

Probable Causes• Engine oil cooler core

• Cylinder head gasket

Recommended Actions

Engine Oil Cooler Core

1. Inspect the engine oil cooler core for leaks. If aleak is found, replace the oil cooler core. Refer toDisassembly and Assembly, “Engine Oil Cooler -Remove”.

2. Drain the crankcase and refill the crankcase withclean engine oil. Install new engine oil filters.Refer to the Operation and Maintenance Manualfor more information.

Cylinder Head Gasket

1. Remove the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head - Remove” for thecorrect procedure.

2. Check the cylinder liner projection. Refer toSystems Operation/Testing and Adjusting for thecorrect procedure.

3. Install a new cylinder head gasket and new waterseals in the spacer plate. Refer to Disassemblyand Assembly, “Cylinder Head - Install” for thecorrect procedure.

i02424562

Engine Oil Temperature Is TooHighSMCS Code: 1348-035-TA

Probable Causes• Oil specifications

• Engine oil temperature reading

• Engine oil cooler bypass valve

• High coolant temperature

• Engine oil cooler

Recommended Actions

Oil Specifications

Inspect the engine oil level. If necessary, add thecorrect engine oil. Check the condition of the engineoil.

For information on oil specifications and/orinformation on oil analysis, refer to the Operation andMaintenance manual .

Engine Oil Temperature Reading

Compare the engine oil temperature reading fromthe Caterpillar Electronic Technician (ET) to thetemperature from a 6V-9130 Temperature Adapter.Verify that the readings are reasonably close.

Engine Oil Cooler Bypass Valve

Clean the engine oil cooler bypass valve and inspectthe engine oil cooler bypass valve. Clean the bore forthe valve. Ensure that the bypass valve is not stuckin the open position. Replace the bypass valve, ifnecessary. Refer to Disassembly and Assembly.

High Coolant Temperature

Check for a high coolant temperature. Resolveany problems with active event codes beforeproceeding. If necessary, refer to troubleshootingwithout a diagnostic code Troubleshooting, “CoolantTemperature Is Too High”.


Engine Oil Cooler

Check for a damaged engine oil cooler or forblockage in the engine oil cooler. Look for a restrictionin the passages for engine oil in the engine oil cooler.Clean the engine oil cooler core or replace the engineoil cooler core.

i02429936

Engine Stalls at Low RPMSMCS Code: 1915-035

Probable Causes• Unit injectors

• Fuel supply

• Air supply


Recommended Actions

Unit Injectors

1. Check for correct installation of the J1/P1 andJ2/P2 connectors for the Electronic ControlModule (ECM). Check for correct installation of theJ300/P300 connectors for the unit injectors. Referto the diagnostic functional test Troubleshooting,“Electrical Connectors - Inspect”.

2. Perform the “Injector Solenoid Test” with theCaterpillar Electronic Technician (ET) in order todetermine if all of the injector solenoids are beingenergized by the ECM.

3. Perform the “Cylinder Cutout Test” with Cat ETin order to identify any injectors that might bemisfiring. Refer to the diagnostic functional testTroubleshooting, “Injector Solenoid Circuit - Test”.

Fuel Supply

1. Check the fuel pressure. Refer to SystemsOperation/Testing and Adjusting.



NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.





Note: A sight glass in the low pressure supply line ishelpful in diagnosing air in the fuel. Refer to SystemsOperation/Testing and Adjusting.

5. Cold weather adversely affects the characteristicsof the fuel. Refer to the Operation andMaintenance Manual.

6. Check the fuel pressure after the fuel filterwhile the engine is being cranked. For thecorrect pressure values, refer to the SystemsOperation/Testing and Adjusting manual. If thefuel pressure is low, replace the fuel filters. If thefuel pressure is still low, check the following items:fuel transfer pump, fuel transfer pump coupling,and fuel pressure regulating valve.

Air Supply

Check for restrictions in the air inlet system. Refer toSystems Operation/Testing and Adjusting.

Accessory Equipment


i02419766

Engine VibrationSMCS Code: 1000-035

Probable Causes• Vibration damper

• Engine supports

• Driven equipment

• Engine misfiring or running rough


Recommended Actions

Vibration Damper

Check the vibration damper for damage. Install anew vibration damper, if necessary. Inspect themounting bolts for damage and/or for wear. Replaceany damaged bolts. Refer to the Disassembly andAssembly manual.

Engine Supports

Inspect the mounts and the brackets while you runthe engine through the speed range. Look for mountsand brackets that are loose and/or broken. Tightenall of the mounting bolts. Install new components, ifnecessary.

Driven Equipment

Check the alignment and the balance of the drivenequipment.

Engine Misfiring or Running Rough

Refer to troubleshooting without a diagnostic codeTroubleshooting, “Engine Misfires, Runs Rough orIs Unstable”.

i02214238

Engine Will Not CrankSMCS Code: 1000-035

Probable Causes• Batteries

• Battery cables

• Starting circuit

• Starting motor solenoid

• Starting motor

• Flywheel ring gear

• Transmission

• Engine accessories

• Hydraulic cylinder lock

• Internal engine problem

Recommended Actions

Batteries and/or Battery Cables

1. Inspect the main power switch, battery posts,and battery cables for loose connections andfor corrosion. If the battery cables are corroded,remove the battery cables and clean the batterycables. Tighten any loose connections.

2. Inspect the batteries.

a. Charge the batteries. Refer to SpecialInstruction, SEHS7633, “Battery TestProcedure”.

b. Load test the batteries. Refer to SpecialInstruction, SEHS9249, “Use of 4C-4911Battery Load Tester for 6, 8 and 12 Volt LeadAcid Batteries”.

Starting Motor Solenoid or StartingCircuit

1. Test the operation of the starting motor solenoid.

2. Check the wiring to the starting motor solenoid.

Starting Motor or Flywheel Ring Gear

1. Test the operation of the starting motor.

2. Inspect the starter motor pinion and the flywheelring gear for damage.

Transmission or Engine Accessories

1. Ensure free movement of the driveline.

2. Ensure that the timing pin was not left in theflywheel housing.

3. Remove any engine accessories that may lock upthe engine and inspect any engine accessoriesthat may lock up the engine.

The following list illustrates examples of engineaccessories that may lock up the engine:

• Hydraulic pump that is driven from the rear geargroup

• Air compressor

• Engine oil pump

• Other components that are driven by the engine


Hydraulic Cylinder Lock

Check for fluid in the cylinders (hydraulic cylinderlock) by removing the individual unit injectors.

Note: Drain the fuel from the cylinder head. Fuel willflow from the cylinder head into the cylinders whenthe unit injector is removed.

Internal Engine Problem

Disassemble the engine. Refer to the Disassemblyand Assembly manual. Inspect the internalcomponents for the following conditions:

• Seizure

• Broken components

• Bent components

i02432467

Excessive Black SmokeSMCS Code: 1088-035

Probable Causes• Air inlet or exhaust system

• Engine speed/timing sensor

• Atmospheric pressure sensor


• “Fuel Position” and/or “FRC Fuel Limit”

• Flash file

• Fuel quality

• Valve adjustment

Recommended Actions

Air Inlet or Exhaust System

1. Check the air inlet system for restrictions and/orfor leaks.

a. Check for an air filter restriction.

b. Perform a visual inspection of the system forrestrictions and/or for leaks in the air inletpiping .

2. Ensure that the turbocharger is in good repair.

3. Check the exhaust system for restrictions.

4. Repair any leaks that were found. Removeany restrictions that were found. Replace anydamaged components that were found.

Engine Speed/Timing

1. Check the calibration of the engine speed/timingsensor. Refer to Troubleshooting, “EngineSpeed/Timing Sensor - Calibrate”.

2. Verify that the crankshaft and the camshaft drivegears are set with the proper orientation. Refer tothe Disassembly and Assembly manual.

Atmospheric Pressure Sensor

1. Remove the sensor.

2. Remove debris, moisture, or ice from the sensor.

3. Install the sensor.

4. Check the Caterpillar Electronic Technician (ET)for active diagnostic codes on the sensor. If noactive diagnostic code exists, the sensor may beused. The correct reading for the atmosphericpressure is between 50 kPa (7.25 psi) and100 kPa (14.5 psi).

Boost Pressure Sensor, “Fuel Position”,and/or “FRC Fuel Limit”

1. Monitor the status of “Fuel Position” and “RatedFuel Limit” while the engine is operating under fullload. If “Fuel Position” equals “Rated Fuel Limit”and “Fuel Position” is less than “FRC Fuel Limit”,the Electronic Control Module (ECM) is providingthe correct control. Otherwise, proceed to the nextStep.

2. Verify that there are no active diagnostic codes forthe boost pressure sensor.

3. Monitor the status of “Boost Pressure” and“Atmospheric Pressure” on Cat ET. When theengine is not running, “Boost Pressure” should be0 kPa (0 psi).

Note: A problem with the “FRC Fuel Limit” will onlycause black smoke during acceleration. A problemwith the “FRC Fuel Limit” will not cause black smokeduring steady state operation.

Flash File

Verify that the correct flash file is installed. Referto Troubleshooting, “Flash Programming” forinformation.


Fuel Quality

Cold weather adversely affects the characteristics ofthe fuel. Refer to Operation and Maintenance Manualfor information on improving the characteristics of thefuel during cold weather operation.

Valve Adjustment

Check the valve adjustment. Refer to SystemsOperation/Testing and Adjusting for information onvalve adjustments.

i02410997

Excessive Engine OilConsumptionSMCS Code: 1348-035

Probable Causes• Oil leaks

• Oil level

• Turbocharger seal

• Internal engine wear

Recommended Actions

Oil Leaks

Check the engine compartment for oil leaks. Repairany oil leaks that are identified.

Oil Level

Check the engine oil level. Too much oil in the enginecrankcase can cause the engine to consume oil.Remove excessive engine oil from the crankcase.

Ensure that the dipstick is properly calibratedand/or that the dipstick is correct for the application.Calibrate the dipstick and/or replace the dipstick.

Turbocharger

Check for turbocharger shaft seal leakage. Removethe air inlet piping and the exhaust outlet piping fromthe turbocharger. Check the compressor wheel andthe turbine for evidence of an oil leak. If necessary,repair the turbocharger or replace the turbocharger.Refer to Systems Operation/Testing and Adjusting.

Internal Engine Wear

Internal engine wear can cause excessive oil leakageinto the combustion area of the cylinders. Excessivewear on the following components may cause oilconsumption:

• Piston rings

• Valve guides

Check for excessive crankcase blowby at theengine crankcase breather. Refer to SystemsOperation/Testing and Adjusting.

i02430014

Excessive Fuel ConsumptionSMCS Code: 1250-035

Probable Causes• Engine operation

• Fuel leaks

• Fuel quality

• Engine speed/timing

• Unit injectors



Recommended Actions

Engine Operation

Use the Caterpillar Electronic Technician (ET) tocheck the “Current Totals” for excessive idle timeand/or for a high load factor which would be indicativeof poor operating habits.

Note: Engine operation may also be affected byenvironmental conditions such as wind and snow.

Fuel Leaks

Check the fuel pressure during engine cranking.Check the fuel pressure after the fuel filter. Referto Systems Operation/Testing and Adjusting for thecorrect pressure values. If the fuel pressure is low,replace the fuel filters. If the fuel pressure is still low,check the following items: fuel transfer pump, fueltransfer pump coupling, and fuel pressure regulatingvalve.


Fuel Quality

Cold weather adversely affects the characteristicsof the fuel. Refer to the Operation and MaintenanceManual for information on improving thecharacteristics of the fuel during cold weatheroperation.

Engine Speed/Timing

Perform a speed/timing sensor calibration. Refer tothe calibration procedure Troubleshooting, “EngineSpeed/Timing Sensor - Calibrate”.

Unit Injectors

1. Check for correct installation of the J1/P1and J2/P2 Electronic Control Module (ECM)connectors and the unit injector connectors. Referto the diagnostic functional test Troubleshooting,“Electrical Connectors - Inspect”.

2. Perform the “Injector Solenoid Test” on Cat ET inorder to determine if all of the injector solenoidsare being energized by the ECM.

3. Perform the “Cylinder Cutout Test” on Cat ETin order to identify any injectors that might bemisfiring. Refer to the diagnostic functional testTroubleshooting, “Injector Solenoid Circuit - Test”.


1. Inspect the air filter for a restriction. If the air filtershows signs of being plugged, clean the air filteror replace the air filter.

2. Check the air inlet and exhaust system forrestrictions and/or for leaks. Refer to SystemsOperation/Testing and Adjusting.

Accessory Equipment


i02424626

Excessive Valve LashSMCS Code: 1105-035

Probable Causes• Lubrication

• Valve lash

• Valve train components

Recommended Actions

Lubrication

1. Remove the valve mechanism covers. Refer tothe engine’s Disassembly and Assembly manual.

2. Check the lubrication in the valve compartment.Ensure that there is adequate engine oil flow inthe valve compartment. The passages for theengine oil must be clean.

Valve Lash

Adjust the engine valve lash. Refer to the engine’sSystems Operation/Testing and Adjusting manual.

Valve Train Components

1. Inspect the following components of the valvetrain:

• Rocker arms

• Pushrods

• Valve lifters

• Camshaft

• Valve stems

• Rocker shafts

2. Check the components for the following conditions:abnormal wear, excessive wear, straightness, andcleanliness. Replace parts, if necessary.

Note: If you replace the camshaft, you must alsoreplace the valve lifters.

3. Adjust the engine valve lash. Refer to the engine’sSystems Operation/Testing and Adjusting manual.

i02312564

Excessive White SmokeSMCS Code: 1088-035

Note: Some white smoke may be present duringcold start-up conditions when the engine is operatingnormally. If the white smoke persists, there may bea problem.

Probable Causes• Starting aids

• Water temperature regulators


• Unit injectors

• Flash file

• Fuel supply

• Cooling system

• Component wear

Recommended Actions

Starting Aids

Air Inlet Heater (If Equipped)

Ensure that the air inlet heater is functioning properly.For additional information, refer to Troubleshooting,“Air Inlet Heater Circuit - Test”.

Ether Injection System (If Equipped)

Ensure that the ether injection system is programmedto “On”.

Ensure that the ether injection system is functioningproperly. For additional information, refer toTroubleshooting, “Ether Injection System - Test”.

Water Temperature Regulators

Check the water temperature regulators for correctoperation. Refer to Systems Operation/Testing andAdjusting, “Cooling System” for the proper procedure.

Unit Injectors

Use Cat ET to perform the cylinder cutout test. Tryto simulate the conditions for the test that wereexperienced during operation. Cut out each cylinderindividually for approximately one minute in orderto isolate any misfiring cylinders. If the misfirecan be isolated to a specific cylinder, proceed toTroubleshooting, “Injector Solenoid Circuit - Test”.

Flash File

Verify that the correct flash file is installed in theEngine Control Module (ECM).

Fuel Supply

1. Monitor the exhaust for smoke while the engineis being cranked.

If no smoke is present, there may be a problemwith the fuel quality or there may be a problemwith the fuel supply.

2. Check the fuel pressure. Refer to SystemsOperation/Testing and Adjusting, “Fuel SystemPressure - Test”.

3. Ensure that the fuel system has been primed.Refer to the engine’s Operation and MaintenanceManual for the correct procedure.

4. Check for fuel supply lines that are restricted.


Cooling System

Check for an internal coolant leak. Check for coolantin the engine oil, coolant in the cylinders, andcoolant in the exhaust system. Refer to SystemsOperation/Testing and Adjusting, “Cooling System -Test”.

Component Wear

Check the following components for excessive wear:

• Valves

• Pistons

• Rings

• Cylinder liners

i02332993

Exhaust Temperature Is TooHighSMCS Code: 1088-035-TA





Recommended Actions

Diagnostic Codes

Connect the Caterpillar Electronic Technician (ET)and check for active diagnostic codes. Troubleshootany active diagnostic codes before continuing withthis procedure.


Check for correct installation of the J2/P2 ElectronicControl Module (ECM) connector and of theJ300/P300 connector that is for the injectors. Referto Troubleshooting, “Electrical Connectors - Inspect”for more information.


1. Check the air inlet manifold pressure. Check forair inlet restrictions and/or leaks. Refer to SystemsOperation/Testing and Adjusting, “Air Inlet andExhaust System” for more information.

2. Check for leaks between the exhaust manifoldand the turbocharger. Check for exhaustrestrictions. Refer to Systems Operation/Testingand Adjusting, “Air Inlet and Exhaust System” formore information.

i01405833

Fuel in Cooling SystemSMCS Code: 1350-035

Probable Causes• Internal cylinder head

Recommended Actions

Internal Cylinder Head

1. Remove the valve mechanism covers.

2. Remove the fuel supply and the fuel return linefrom the cylinder head.

3. Cap the fuel return connector and apply 700 kPa(100 psi) maximum air pressure to the fuel supplyconnector. Check for fuel leakage around the unitinjectors. If leakage is present, remove the unitinjector and install a new O-ring seal.

i02119587

Fuel Dilution of Engine OilSMCS Code: 1348-035

Probable Causes• Leaking seals on the case of the unit injector or onthe barrel of the unit injector

• Leaking seals on the fuel line adapter for thecylinder head

• Excessive leakage from the unit injector tip orbreakage of the unit injector tip

• Cracked fuel supply manifold

• Leaking seal on the fuel transfer pump

Recommended Actions

Leaking Seals on the Case of the UnitInjector or on the Barrel of the UnitInjector

Look for signs of damage to the seals for the unitinjectors. Replace any seals that are leaking.

Leaking Seals on the Fuel Line Adapterfor the Cylinder Head

Look for signs of damage to the seals on the fuel lineadapter for the cylinder head. Repair any leaking fuellines or components and/or replace any leaking fuellines or components.

Excessive Leakage from the Unit InjectorTip or Breakage of the Unit Injector Tip

Look for signs of damage to the unit injectors. Ifnecessary, repair the unit injectors or replace the unitinjectors.

Cracked Fuel Supply Manifold

Look for signs of damage to the fuel supply manifold.

Leaking Fuel Transfer Pump Seal

Ensure that the weep hole is not plugged. Ifnecessary, repair the fuel transfer pump or replacethe fuel transfer pump.


i02432824

Intermittent Engine ShutdownSMCS Code: 1000-035

Note: Use this procedure only if the engine shutdown completely and it was necessary to restart theengine.

Probable Causes• Diagnostic codes or event codes

• Operating conditions

• Electrical connections

• Faulty remote shutdown

• Circuit breakers

• Fuel supply

• Faulty overspeed verify switch

Note: If the problem only occurs under certainconditions such as high engine speed, full load orengine operating temperature, then perform the testunder those operating conditions.

Recommended Actions

Diagnostic Codes or Event Codes

Certain diagnostic codes and/or event codesmay cause the engine to shutdown. Connect theCaterpillar Electronic Technician (ET) and check foractive codes and/or for logged codes. Troubleshootany codes that are present before continuing withthis procedure.

Operating Conditions

The engine may be shut down due to low pressurelevels or other factors. Connect Cat ET and check foractive shutdowns or diagnostic codes.

If a shutdown is active, “Injection Disabled” willappear in the third box of any status screen on CatET.

An engine shutdown event will appear on a J1939device if the device is capable of displaying diagnosticcodes.

Electrical Connections

1. Check the following connectors for properinstallation:

• J1/P1 and J2/P2 connectors for the ElectronicControl Module (ECM)

• J61/P61 Customer connectors

• J300/P300 Connectors for the injector solenoidharness

• J401/P401 and J402/P402 Engine speed/timingsensor connectors

2. Check the associated wiring for the followingconditions: damage, abrasion, corrosion, andincorrect attachment.

Refer to Troubleshooting, “Electrical Connectors- Inspect”.

Note: Aftermarket engine protection devices usuallyinterrupt power to the ECM. Check for correctinstallation and for operation of aftermarket engineprotection devices. It may be necessary to bypassthe aftermarket devices in order to continue testing.

Faulty Remote Shutdown

1. Access the status screen that displays the remoteshutdown switch status. The remote shutdownswitch status on Cat ET is called “User Shutdown”.

2. Refer to Table 14. Measure the voltage betweeneach terminal that is listed and the engine ground.

Table 14

“User Shutdown” Status Measured Voltage atJ1-44 or P61-27

ON <0.9 VDC

OFF >10 VDC

3. If the voltage is not in the proper range, refer toTroubleshooting, “Switch Circuits - Test”.

Circuit Breakers

Check the circuit breakers. The circuit breakers mayexceed the trip point due to overheating. Reset thecircuit breakers if the circuit breakers are tripped.


Fuel Supply

Check for a problem with the fuel supply. Verifythat the fuel pressure is correct. Verify that thefuel pressure sensor is installed. Refer to SystemsOperation/Testing and Adjusting, “Fuel System” foradditional information.

Faulty Overspeed Verify Switch (IfEquipped)

The overspeed verify switch allows the servicetechnician to quickly verify that the overspeedprotection system is operating correctly. When theoverspeed verify switch is activated, the enginewill shut down when the engine speed reaches 75percent of the overspeed setpoint.

A problem with the circuit for the overspeed verifyfeature may be causing the engine to shut down.There are no diagnostic codes or event codes thatare associated with the overspeed verify feature.Refer to Troubleshooting, “Switch Circuits - Test”.

i02433196

Intermittent Low Power orPower CutoutSMCS Code: 1000-035

Note: Use this procedure only if the engine does notshut down completely.


• Event codes

• Throttle signal


• Injection actuation pressure

• Fuel supply

Recommended Actions


Certain diagnostic codes and/or event codes maycause poor performance. Connect the CaterpillarElectronic Technician (ET) and check for active codesand logged codes. Troubleshoot any codes that arepresent before continuing with this procedure.

Throttle Signal

View the status for the throttle position on thestatus screen. Operate the throttle from the low idleposition to the high idle position. The status shouldbe 0 percent at low idle and the status should be100 percent at high idle. Refer to Troubleshooting,“Throttle Position Sensor - Calibrate” if either valueis incorrect.



1. Inspect the battery wires from the ElectronicControl Module (ECM) back to the batterycompartment. Refer to the Electrical SystemSchematic. Inspect the wires and the power relay.Check the power and ground connections tothe ECM. Refer to the diagnostic functional testTroubleshooting, “Electrical Power Supply Circuit- Test” for more information.

Injection Actuation Pressure

Ensure that the injection actuation system isoperating properly. Refer to Troubleshooting,“Injection Actuation Pressure - Test”.

Fuel Supply








Note: A sight glass in the low pressure supply line ishelpful in diagnosing air in the fuel. Refer to SystemsOperation/Testing and Adjusting, “Fuel System” formore information.


4. Cold weather adversely affects the characteristicsof the fuel. Refer to Special Publication,SEBU6250, “Caterpillar Machine FluidsRecommendations” for information on improvingthe characteristics of the fuel during cold weatheroperation.

5. Check the fuel pressure after the fuel filter whilethe engine is being cranked. Refer to SystemsOperation/Testing and Adjusting, “Fuel SystemPressure - Test” for the correct pressure values.If the fuel pressure is low, replace the fuel filters.If the fuel pressure is still low, check the followingitems: fuel transfer pump, fuel transfer pumpcoupling, and fuel pressure regulating valve. Referto Systems Operation/Testing and Adjusting, “FuelSystem” for additional information.

i02430113

Low Engine Oil PressureSMCS Code: 1348-035-LP

NOTICEDo not operate engine with low oil pressure. Enginedamage will result. If measured engine oil pressure islow, discontinue engine operation until the problem iscorrected.

Probable Causes• Engine oil level

• Engine oil filters and oil filter bypass valve

• Engine oil pump

• Engine oil cooler

• Fuel dilution

• Engine wear

Recommended Actions

Engine Oil Level

Inspect the engine oil level. If engine oil is low addengine oil. Refer to the Operation and MaintenanceManual.

Engine Oil Filters and Oil Filter BypassValve

Check the service records of the engine forinformation that is related to the last oil change. Ifnecessary, perform an oil change on the engine andreplace the engine oil filters.

Check the operation of oil filter bypass valve. Cleanthe bypass valve and the housing. If necessary,install new parts.

Engine Oil Pump

Check for blockage of the inlet screen for the engineoil pump. Check the components of the engine oilpump for excessive wear. If necessary, repair the oilpump or replace the oil pump.

Oil Cooler

Check the engine’s oil cooler for plugging orblockage. Clean the engine oil cooler core(s) and/orinstall new engine oil cooler core(s).

Fuel Dilution

Check for presence of fuel in lubricating oil. Referto the troubleshooting without a diagnostic codeprocedure Troubleshooting, “Fuel Dilution of EngineOil”.

Engine Wear

Inspect the camshaft and/or camshaft bearingsfor excessive wear. Inspect the crankshaft and/orcrankshaft bearings. Excessive wear to discretecomponents may be an indication of a blocked oilpassage. Use an oil pressure gauge to check theoil pressure at the main oil gallery. This will helpdetermine if the excessive wear is from low systempressure or from passages that are blocked.

i02214503

Low Power/Poor or NoResponse to ThrottleSMCS Code: 1000-035

Probable Causes• Programmable parameters

• Diagnostic codes

• Event codes


• Injector trim codes

• Engine rating


• Cold mode

• Altitude derate


• PTO enable switch

• Intermediate speed switch

• Throttle signal

• Circuit for electronic unit injectors

• Fuel supply

• Boost pressure sensor (intake manifold air), ratedfuel position and/or FRC fuel position


Recommended ActionsNote: If the problem only occurs under certainconditions, test the engine under those conditions.Examples of certain conditions are high rpm, full loadand engine operating temperature. Troubleshootingthe symptoms under other conditions can givemisleading results.


Verify that the complaint is not due to a normaloperation such as a programmed parameter.Connect the electronic service tool and verify that theparameters are programmed correctly.


Certain diagnostic codes and/or event codes maycause poor performance. Connect the CaterpillarElectronic Technician (ET) and check for active codesand for logged codes. Troubleshoot any codes thatare present before continuing with this procedure.

Injector Trim Codes

If any of the injectors or the Electronic Control Module(ECM) have been replaced, ensure that the injectortrim codes have been programmed to the correctvalues. Refer to Troubleshooting, “Injector Code -Calibrate” for additional information.

Engine Rating

Verify that the correct engine rating is being used forthe application.



• Throttle Position Sensor

• Desired Speed Input Configuration

• Direct Fuel Control Mode



Cold Mode

Monitor the status screen on Cat ET in order to verifythat the engine has exited cold mode. Observe thereading for coolant temperature on Cat ET. Refer toTroubleshooting, “System Overview” for additionalinformation.

Altitude Derate

The engine may be derated due to high elevation.Connect Cat ET to the service tool connector. Checkfor an active engine derate on the status screens.

Note: There are no event codes that are associatedwith the altitude derate.

Electrical Connections to the ECM

1. Check the following connectors for properinstallation:

• J1/P1 and J2/P2 ECM connectors

• J61/P61 Customer connectors

• J300/P300 Connectors for the injector solenoidharness

• J401/P401 and J402/P402 EngineSpeed/Timing Sensor connectors

2. Check the associated wiring for the followingconditions: damage, abrasion, corrosion, andincorrect attachment.

Refer to Troubleshooting, “Electrical Connectors- Inspect”.


Note: Aftermarket engine protection devices usuallyinterrupt power to the ECM. Check for correctinstallation and for operation of aftermarket engineprotection devices. It may be necessary to bypassthe aftermarket devices in order to continue testing.

PTO Enable Switch

Verify that the “PTO Enable Switch” is “Not Engaged”.If the value of the parameter does not match theposition of the switch, there is a problem withthe circuit for the PTO enable switch. Refer toTroubleshooting, “Switch Circuits - Test”.

If the value of the “PTO Enable Switch” parametermatches the position of the switch, continue to nextstep.

Intermediate Speed Switch

Verify that the value of the “Intermediate SpeedSwitch” matches the position of the switch. If thevalue of the parameter does not match the positionof the switch, there is a problem with the circuitfor the switch for the intermediate speed. Refer toTroubleshooting, “Switch Circuits - Test”.

If the value of the “Intermediate Speed Switch”parameter matches the position of the switch,continue to next step.

Throttle Signal

View the status for the throttle position on the statusscreen. Operate the throttle from the low idle positionto the high idle position. The status should be 0percent at low idle and the status should be 100percent at high idle. If the status cannot operate inthe full range, refer to Troubleshooting, “ThrottlePosition Sensor - Calibrate”.


Circuit for the Electronic Unit Injector

Inspect the J2/P2 ECM connector and the J300/P300unit injector connector for proper connections. Referto Troubleshooting, “ Electrical Connectors - Inspect”.Cut out each cylinder in order to isolate the misfiringcylinder or cylinders. If the results are inconclusive,shut off half of the cylinders and repeat the cylindercutout test on the active cylinders that are remainingin order to locate those cylinders that are missing.Refer to Troubleshooting, “Injector Solenoid Circuit -Test”.

Fuel Supply

Check for a problem with the fuel supply. Verifythat the fuel pressure is correct. Verify that the fuelpressure sensor P209/J209 is installed. For furtherinformation, refer to Systems Operation/Testing andAdjusting, “Fuel System”.

Boost Pressure Sensor, Rated FuelPosition and/or FRC Fuel Position

1. With the engine at full load, monitor “Fuel Position”and “Rated Fuel Limit” on the status screen. If“Fuel Position” does not equal “Rated Fuel Limit”,then check the boost pressure.

2. Verify that there are no active diagnostic codesthat are associated with the boost pressure sensoror with the atmospheric pressure sensor.

3. Monitor the boost pressure and the atmosphericpressure for normal operation on the statusscreen.

Note: Atmospheric pressure is not a defaultparameter on the status screen.


Check the air inlet and exhaust systems forrestrictions and for leaks. Refer to SystemsOperation/Testing and Adjusting, “Air Inlet andExhaust System”. Replace the plugged air filtersor clean the plugged air filters according to theguidelines in the engine’s Operation and MaintenanceManual. Repair any leaks that are found in thesystem.

i02281043

Mechanical Noise (Knock) inEngineSMCS Code: 1000-035

Probable Causes• Driven equipment

• Cylinder head and related components

• Gear train

• Crankshaft and related components

• Piston


Recommended Repairs

Driven Equipment

Inspect the alignment and the balance of the drivenequipment. Inspect the coupling. If necessary,disconnect the driven equipment and test the engine.

Cylinder Head and Related Components

Inspect the components of the valve train for goodcondition. Check for signs of damage and/or wearto the valves, cylinder head gasket, etc. Inspect thecondition of the camshafts. If a camshaft is replaced,new valve lifters must be installed.

Gear Train

Inspect the condition of the gear train.

Inspect the engine oil filters for nonferrous material.Flaking of nonferrous material could indicate worngear train bearings.

Crankshaft

Inspect the crankshaft and the related components.Inspect the connecting rod bearings and the bearingsurfaces on the crankshaft. Make sure that thebearings are in the correct position.

Look for worn thrust plates and wear on thecrankshaft.

Check the counterweight bolts.

Piston

Make sure that the piston pin is correctly installed.

Inspect the condition of the pistons accordingto Guidelines for Reusable Parts and SalvageOperations.

i02424645

Noise Coming from CylinderSMCS Code: 1000-035


• Fuel quality

• Unit injectors

• Valve lash

Recommended Actions

Diagnostic Codes

Check for active diagnostic codes on the CaterpillarElectronic Technician (ET). Troubleshoot any activecodes before continuing with this procedure.

Fuel Quality

Refer to Operation and Maintenance Manual forinformation on the characteristics of the fuel.

Unit Injectors

1. Check the connectors at the Electronic ControlModule (ECM). Check for correct installation ofthe J1/P1 and J2/P2 ECM connectors. Also,thoroughly inspect the unit injector wiring harnessfrom the ECM to the J300/P300 valve cover entryconnector. Refer to the diagnostic functional testTroubleshooting, “Electrical Connectors - Inspect”.

2. Perform the “Injector Solenoid Test” on Cat ET inorder to determine if all of the injector solenoidsare being energized by the ECM.

3. Perform the “Cylinder Cutout Test” on Cat ETin order to identify any injectors that may bemisfiring. Refer to the diagnostic functional testTroubleshooting, “Injector Solenoid Circuit - Test”.

Valve Lash

Check the engine valve lash settings. Checkdamage to valve train components which may causeexcessive valve lash. Repair any problems that arefound. Refer to troubleshooting without a diagnosticcode Troubleshooting, “Excessive Valve Lash”.

i02433203

Poor Acceleration or ResponseSMCS Code: 1000-035

Probable Causes• Engine “Derated”

• Cold mode operation

• Flash file

• Throttle position sensor


• Unit injectors


• Fuel Position, Rated Fuel Limit, and FRC FuelPosition


• Fuel supply

Recommended Actions

Engine “Derated”

The engine may be derated due to dirty air filtersor other factors. Use the Caterpillar ElectronicTechnician (ET) in order to check for engine derates.

Cold Mode Operation

Monitor the status screen on Cat ET in order to verifythat the engine has exited cold mode. Observe thereading for coolant temperature on the Cat ET. Referto Troubleshooting, “System Overview” for additionalinformation.

Flash File

Verify that the correct flash file is installed.

Throttle Position Sensor

Monitor “Throttle Status” on Cat ET. Verify that thethrottle position is stable and that the engine is ableto reach high idle rpm. Refer to Troubleshooting,“Throttle Position Sensor Circuit - Test” for the propertroubleshooting procedure.


Check for correct installation of the J1/P1 and J2/P2connectors for the Electronic Control Module (ECM).Check for correct installation of the JH300/P300unit injector connectors. Refer to Troubleshooting,“Electrical Connectors - Inspect”.

Unit Injectors

1. Use Cat ET to determine if there are any activediagnostic codes for the unit injectors.

2. Perform the injector solenoid test on Cat ET inorder to determine if all of the injector solenoidsare being energized by the ECM. Refer toTroubleshooting, “Injector Solenoid Circuit - Test”for the proper procedure.

3. Perform the cylinder cutout test on Cat ET in orderto identify any injectors that might be misfiring.Refer to Troubleshooting, “Injector SolenoidCircuit - Test” for the proper procedure.

Fuel Position, Rated Fuel Limit, and FRCFuel Position

1. Monitor the status of “Fuel Position” and “RatedFuel Limit” while the engine is operating under fullload. If “Fuel Position” equals “Rated Fuel Limit”and “Fuel Position” is less than “FRC Fuel Limit”,the electronics are operating correctly. Otherwise,proceed to the next Step.

2. Verify that there are no active diagnostic codes forthe boost pressure sensor.

3. Monitor the “Boost Pressure” and “AtmosphericPressure” for normal operation. When the engineis not running, “Boost Pressure” should be 0 kPa(0 psi).


1. Check for an air filter restriction indicator. Cleanplugged air filters or replace plugged air filters.Refer to the Operation and Maintenance Manual.

2. Check the air inlet and exhaust system forrestrictions and/or leaks. Refer to SystemsOperation/Testing and Adjusting, “Air Inlet andExhaust System”.

Fuel Supply








Note: A sight glass in the low pressure supply line ishelpful in diagnosing air in the fuel. Refer to Testingand Adjusting for more information.



5. Check the fuel pressure after the fuel filter whilethe engine is being cranked. Refer to Testing andAdjusting for the correct pressure values. If thefuel pressure is low, replace the fuel filters. Ifthe fuel pressure is still low, check the followingitems: fuel transfer pump, fuel transfer pumpcoupling, and fuel pressure regulating valve. Referto Systems Operation/Testing and Adjusting formore information.

i01405939

Valve Rotator or Spring LockIs FreeSMCS Code: 1109-035

Probable Causes• Cracked valve rotator

• Broken spring locks

• Broken valve spring(s)

• Broken valve

Recommended Actions1. Determine the cause of an engine overspeed thatwould crack the valve rotator. Repair the condition.

2. Inspect the following components for damage:

• Valve rotators

• Spring locks

• Valve springs

• Valves

Note: Ensure that the valve has not contacted thepiston. If the valve has contacted the piston, checkthe exhaust system for debris.

3. Replace any damaged components.


Troubleshooting with aDiagnostic Code

i02085761

Flash CodesSMCS Code: 1900

Flash codes are a simple way to alert the operatorthat a problem exists with the engine’s control systemor with the engine’s operation. Each flash code isa two digit number. The diagnostic lamp flashes inorder to identify the flash code.

EXAMPLE

Note: Flash Code 27 would flash on the diagnosticlamp in the following manner:

• Two short flashes

• Hesitation

• Seven short flashes

For the descriptions of the flash codes, refer toTroubleshooting, “Diagnostic Code Cross Reference”.

i02432846

Diagnostic CodesSMCS Code: 1900

Diagnostic CodesDiagnostic codes alert the operator that a problem inthe electronic system has been detected. Diagnosticcodes also indicate the nature of the problem tothe service technician. The Caterpillar ElectronicTechnician (ET) is a software program that isdesigned to run on a personal computer. Diagnosticcodes may be viewed on a personal computer thathas Cat ET software. Diagnostic codes consist ofthe component identifier (CID) and the failure modeidentifier (FMI).

Component Identifier (CID) – The CID is a numberwith three or four digits. The CID indicates thecomponent that generated the code. For example,the CID number 0001 identifies the fuel injector forthe number one cylinder.

Failure Mode Identifier (FMI) – The FMI is a twodigit code that indicates the type of failure.

Suspect Parameter Number (SPN) – The SPN is athree digit code which is assigned to each componentin order to identify data via the data link to the ECM.This is used on the diagnostics for the CAN data link.

Refer to Troubleshooting, “Diagnostic Code CrossReference” for the complete list of the diagnosticcodes and a description of each code. There is atroubleshooting procedure for every diagnostic code.Refer to Troubleshooting, “Troubleshooting With ADiagnostic Code”.

When a diagnostic code is activated, the ElectronicControl Module (ECM) transmits information aboutthe code over the J1939 data link. Some J1939devices may display the code. However, the codewill be displayed with a SPN-FMI code. Refer toTroubleshooting, “Diagnostic Code Cross Reference”for a cross-reference between SPN-FMI codes anddiagnostic codes.

Do not confuse diagnostic codes with event codes.Event codes alert the operator that an abnormaloperating condition such as low oil pressure or highcoolant temperature has been detected. Refer toTroubleshooting, “Troubleshooting with an EventCode” for additional information on event codes.


g01117578Illustration 11Output voltage from a typical analog temperature sensor

Illustration 11 indicates the signal range for a typicalanalog sensor. Diagnostic codes will be generated ifthe sensor’s output signal is below 0.2 VDC or above4.8 VDC.

Active Diagnostic CodesAn active diagnostic code represents a problem withthe electronic control system. Correct the problemas soon as possible.

When the ECM generates an active diagnostic code,the “Active Alarm” indicator (“Engine Control AlarmStatus” on Cat ET) is activated in order to alert theoperator. If the condition that generated the codeis momentary, the message disappears from thelist of active diagnostic codes. The diagnostic codebecomes logged.

Logged Diagnostic CodesWhen the ECM generates a diagnostic code, theECM logs the code in permanent memory. TheECM has an internal diagnostic clock. Each ECMwill record the following information when a code isgenerated:

• The hour of the first occurrence of the code

• The hour of the last occurrence of the code

• The number of occurrences of the code

This information is a valuable indicator fortroubleshooting intermittent problems.

A code is cleared from memory when one of thefollowing conditions occur:

• The service technician manually clears the code.

• The code does not recur for 100 hours.

• A new code is logged and there are already tencodes in memory. In this case, the oldest code iscleared.

Some diagnostic codes may be easily triggered.Some diagnostic codes may log occurrences thatdid not result in complaints. The most likely causeof an intermittent problem is a faulty connectionor damaged wiring. The next likely cause is acomponent failure. The least likely cause is the failureof an electronic module. Diagnostic codes that arelogged repeatedly may indicate a problem that needsspecial investigation.

Note: Always clear logged diagnostic codes afterinvestigating and correcting the problem whichgenerated the code.

i02428890

Diagnostic Code CrossReferenceSMCS Code: 1900

Problems with the electronic control system arereported via these types of codes: flash codes,SPN/FMI codes, diagnostic codes, and event codes.

For information on flash codes, refer toTroubleshooting, “Flash Codes”.

For information on SPN/FMI codes, refer toTroubleshooting, “Diagnostic Codes”.

For information on diagnostic codes, refer toTroubleshooting, “Diagnostic Codes”.


For information on event codes, refer toTroubleshooting, “Event Codes”.

Use Table 15 as a cross-reference between thevarious types of codes.

Table 15

Cross Reference for Diagnostic Codes

Flash Code SPN(1)/FMI CodeDiagnostic Code

orEvent Code

Description of Code

1835-15 High Auxiliary Pressure Warning

1835-16 High Auxiliary Pressure Derate

1835-00

E443(2)

High Auxiliary Pressure Shutdown

1836-15 High Auxiliary Temperature Warning

1836-16 High Auxiliary Temperature Derate

1836-00

E445(2)

High Auxiliary Temperature Shutdown

626-05 2417-05 Ether Injection Control Solenoid open/short to +batt

626-06 2417-06 Ether Injection Control Solenoid short to ground

1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt

1835-04 1835-04 Auxiliary Pressure Sensor short to ground

1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt

1836-04 1836-04 Auxiliary Temperature Sensor short to ground

N/A

111-02 111-02 Engine Coolant Level Sensor Loss of Signal

678-03 41-03 8 Volt DC Supply short to +batt

678-04 41-04 8 Volt DC Supply short to ground

620-03

1079-03262-03 5 Volt Sensor DC Power Supply short to +batt

620-04

21

1079-04262-04 5 Volt Sensor DC Power Supply short to ground

100-03 100-03 Engine Oil Pressure open/short to +batt

100-04 100-04 Engine Oil Pressure short to ground24

100-10 100-10 Engine Oil Pressure abnormal rate of change

102-03 102-03 Boost Pressure Sensor short to +batt

102-04 102-04 Boost Pressure Sensor short to ground25

102-10 102-10 Boost Pressure Sensor abnormal rate of change

108-03 274-03 Atmospheric Pressure open/short to +batt26

108-04 274-04 Atmospheric Pressure short to ground

110-03 110-03 Engine Coolant Temperature open/short to +batt27

110-04 110-04 Engine Coolant Temperature short to ground

28 91-13 91-13 Throttle Position calibration required

32 91-08 91-08 Throttle Position signal abnormal(continued)


(Table 15, contd)



orEvent Code

Description of Code

190-08 190-08 Engine Speed signal abnormal34

723-08 342-08 Secondary Engine Speed signal abnormal

190-15 Engine Overspeed Warning35

190-00E362(2)

Engine Overspeed Shutdown

94-03 94-03 Fuel Pressure open/short to +batt37

94-04 94-04 Fuel Pressure short to ground

105-03 172-03 Intake Manifold Air Temp open/short to +batt38

105-04 172-04 Intake Manifold Air Temp short to ground

164-02 164-02 Injector Actuation Pressure signal erratic

164-03 164-03 Injector Actuation Pressure voltage high

164-04 164-04 Injector Actuation Pressure voltage low39

164-11 164-11 Injector Actuation Pressure system fault

42 637-13 261-13 Engine Timing calibration required

100-17 Low Engine Oil Pressure Warning

100-18 Low Engine Oil Pressure Derate46

100-01

E360(2)

Low Engine Oil Pressure Shutdown

729-05 617-05 Air Inlet Heater Relay open/current below normal49

729-06 617-06 Air Inlet Heater Relay grounded/current above norm

168-00 168-00 System Voltage high

168-01 168-01 System Voltage low51

168-02 168-02 System Voltage intermittent/erratic

56 630-02 268-02 Check Programmable Parameters

58 639-09 247-09 J1939 Data Link communications

110-15 High Engine Coolant Temperature Warning

110-16 High Engine Coolant Temperature Derate61

110-00

E361(2)

High Engine Coolant Temperature Shutdown

111-17 Low Engine Coolant Level Warning

111-18 Low Engine Coolant Level Derate

62

111-01

E2143(2)

Low Engine Coolant Level Shutdown

63 94-15 E096 High Fuel Pressure Warning

1636-15 High Inlet Air Temperature Warning64

1636-00E539(2)

High Inlet Air Temperature Shutdown

174-15 High Fuel Temperature Warning

174-16 High Fuel Temperature Derate65

174-00

E363(2)

High Fuel Temperature Shutdown

651-05 001-05 Cylinder #1 Injector open circuit71

651-06 001-06 Cylinder #1 Injector short(continued)


(Table 15, contd)



orEvent Code

Description of Code


652-06 002-06 Cylinder #2 Injector short








656-06 006-06 Cylinder #6 Injector short(1) Suspect Parameter Number(2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order to designate a warning, a derate,or a shutdown.

i02430358

CID 0001 FMI 05 Cylinder #1Injector open circuitSMCS Code: 1290-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attemptingto operate the injector. The ECM detects an opencircuit in the circuit for the injector.

System Response:

The ECM will log the diagnostic code. The ECM willcontinue to attempt to operate the injector after thecode has been logged.

Possible Performance Effect:

• The engine may misfire.

• The engine may experience low power.

Troubleshooting:

Perform the following diagnostic procedure: “InjectorSolenoid Circuit - Test”

Results:

• OK – STOP.

i02430360

CID 0001 FMI 06 Cylinder #1Injector shortSMCS Code: 1290-038


The Electronic Control Module (ECM) is attempting tooperate the injector. The ECM detects a short circuitin the circuit for the injector.

System Response:





Troubleshooting:


Results:

• OK – STOP.


i02430362




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02430363




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02430365




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02430366




System Response:






Troubleshooting:


Results:

• OK – STOP.

i02430368




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02430370




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02430371




System Response:






Troubleshooting:


Results:

• OK – STOP.

i02430373




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02430375




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02430376




System Response:





Troubleshooting:


Results:

• OK – STOP.

i02419277

CID 0041 FMI 03 8 Volt DCSupply short to +battSMCS Code: 5574-038


The voltage level of the 8 volt supply is above normal.


System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The ECM flags all digital sensorsas invalid data and all digital sensors are set to therespective default values.



Troubleshooting:

Perform the following diagnostic procedure: “DigitalSensor Supply Circuit - Test”

Results:

• OK – STOP.

i02419278

CID 0041 FMI 04 8 Volt DCSupply short to groundSMCS Code: 5574-038


The voltage level of the 8 volt supply is below normal.

System Response:

The Electronic Control Module (ECM) logs thediagnostic code. The ECM flags all digital sensorsas invalid data and all digital sensors are set to therespective default values.



Troubleshooting:

Perform the following diagnostic procedure: “DigitalSensor Supply Circuit - Test”

Results:

• OK – STOP.

i02275031

CID 0042 FMI 05 InjectorActuation Valve open circuitSMCS Code: 1714-038


The Electronic Control Module (ECM) detects anopen circuit in the circuit for the injection actuationpressure control valve (IAPCV).

System Response:

The diagnostic code may be viewed on a displaymodule or on the Caterpillar Electronic Technician(ET).


• Engine misfires

• Low power

• Reduced engine speed (rpm)

• Engine shutdown

Troubleshooting:

Perform the following diagnostic procedure: “InjectionActuation Pressure Control Valve Circuit - Test”

Results:

• OK – STOP.

i02275041

CID 0042 FMI 06 InjectorActuation Valve short togroundSMCS Code: 1714-038


The Electronic Control Module (ECM) detectsexcessive current flow in the circuit for the injectionactuation pressure control valve (IAPCV).

System Response:

The diagnostic code may be viewed on a displaymodule or on the Caterpillar Electronic Technician(ET).



• Engine misfires

• Low power

• Reduced engine speed (rpm)

• Engine shutdown

Troubleshooting:

Perform the following diagnostic procedure: “InjectionActuation Pressure Control Valve Circuit - Test”

Results:

• OK – STOP.

i02417388

CID 0091 FMI 08 ThrottlePosition signal abnormalSMCS Code: 1913-038


The Electronic Control Module (ECM) detects anincorrect frequency on the throttle signal.

System Response:

The code is logged. The ECM flags the throttleposition as invalid data and a default value of zeropercent is used.


• The engine speed is limited to low idle.

Troubleshooting:

Perform the following diagnostic procedure: “ThrottlePosition Sensor Circuit - Test”

Results:

• OK – STOP.

i02426246

CID 0091 FMI 13 ThrottlePosition calibration requiredSMCS Code: 1913-038


The duty cycle of the signal from the throttle that isconnected to the primary throttle input is incorrect.

System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The ECM flags the throttle positionas invalid data and a default value of zero percentis used.


• The engine speed is limited to low idle.

Troubleshooting:

Perform the following diagnostic procedure: “ThrottlePosition Sensor - Calibrate”

Results:

• OK – STOP.

i02416290

CID 0094 FMI 03 Fuel Pressureopen/short to +battSMCS Code: 1718-038


The Electronic Control Module (ECM) detects asignal voltage from the sensor that is above normal.

System Response:

The code is logged. The ECM flags fuel pressure asinvalid data and a default value is used.


• None

Troubleshooting:

Perform the following diagnostic procedure: “EnginePressure Sensor Open or Short Circuit - Test”

Results:

• OK – STOP.

i02416295

CID 0094 FMI 04 Fuel Pressureshort to groundSMCS Code: 1718-038


The Electronic Control Module (ECM) detects asignal voltage that is below normal.


System Response:

The code is logged. The ECM flags fuel pressure asinvalid data and a default value is used.


• None

Troubleshooting:


Results:

• OK – STOP.

i02416374

CID 0100 FMI 03 Engine OilPressure open/short to +battSMCS Code: 1924-038


The Electronic Control Module (ECM) detects asignal voltage that is above normal.

System Response:

The code is logged. The ECM flags oil pressure asinvalid data and a default value is used.


• None

Troubleshooting:


Results:

• OK – STOP.

i02416377

CID 0100 FMI 04 Engine OilPressure short to groundSMCS Code: 1924-038



System Response:

The code is logged. The ECM flags oil pressure asinvalid data and a default value is used.


• None

Troubleshooting:


Results:

• OK – STOP.

i02437737

CID 0100 FMI 10 Engine OilPressure Sensor abnormalrate of changeSMCS Code: 1924-038


This code indicates that the 5 volt supply is missingfrom the sensor connector.

During normal engine operation, the oil pressurefluctuates slightly. When the 5 volt supply is missingfrom the oil pressure sensor, the signal from theoil pressure sensor goes to a midrange value. Thesignal does not fluctuate. If the signal from the oilpressure sensor remains abnormally steady for morethan 30 seconds, the Engine Control Module (ECM)activates this code.

System Response:

A snapshot is triggered. The ECM uses a defaultvalue for the oil pressure.


• There are no performance effects.

Troubleshooting:

Repair the Open Circuit

A. Repair the supply wire or replace the supply wirebetween the ECM and the sensor.

Expected Result:

The problem is resolved.


Results:

• OK – The problem is resolved. STOP.

• Not OK – The problem is not resolved.

Repair: Replace the sensor.

STOP.

i02411901

CID 0102 FMI 03 BoostPressure Sensor short to +battSMCS Code: 1917-038


The signal voltage from the boost pressure sensor isabove normal.

System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The ECM will flag the boost pressureas invalid data and a default value is used for theboost pressure.


Low power

Troubleshooting:


Results:

• OK – STOP.

i02411905

CID 0102 FMI 04 BoostPressure Sensor short togroundSMCS Code: 1917-038


The signal voltage from the boost pressure sensor isbelow normal.

System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The ECM will flag the boost pressureas invalid data and a default value is used for theboost pressure.


Low power

Troubleshooting:


Results:

• OK – STOP.

i02433370

CID 0102 FMI 10 BoostPressure Sensor abnormalrate of changeSMCS Code: 1917-038


This code indicates that the 5 volt supply is missingfrom the sensor connector.

System Response:

During normal engine operation, the boost pressurefluctuates slightly. When the 5 volt supply is missingfrom the boost pressure sensor, the signal from theboost pressure sensor goes to a midrange value.The signal does not fluctuate. If the signal from theboost pressure sensor remains abnormally steady formore than 30 seconds, the Engine Control Module(ECM) activates this code.

A snapshot is triggered. The ECM sets the value ofthe boost pressure to 100 kPa (14.5 psi).


The engine power is reduced.

Troubleshooting:

Repair the Open Circuit

A. Repair the open circuit on the supply wire betweenthe ECM and the sensor.

Expected Result:

The problem is resolved.

Results:


• Not OK – The problem is not resolved.


Repair: Replace the sensor.

STOP.

i02214851

CID 0110 FMI 03 EngineCoolant Temperatureopen/short to +battSMCS Code: 1906-038


The Electronic Control Module (ECM) detects thefollowing conditions:

• The engine has been running for more than sevenminutes.

• The signal voltage from the engine coolanttemperature sensor is greater than 4.95 VDC formore than eight seconds.

System Response:

The ECM will log the diagnostic code if the enginehas been running for more than seven minutes. Thecheck engine lamp will illuminate after a delay.

The ECM will set the value of the coolant temperatureto a default value.

The engine will not go into cold mode while thisdiagnostic code is active.

The ECM will activate the cooling fan after this codehas been active for more than eight seconds.


None

Troubleshooting:

Perform the following diagnostic procedure: “EngineTemperature Sensor Open or Short Circuit - Test”

Results:

• OK – STOP.

i02214871

CID 0110 FMI 04 EngineCoolant Temperature short togroundSMCS Code: 1906-038



The engine has been running for more than sevenminutes.

The signal voltage from the engine coolanttemperature sensor is less than 0.2 VDC for morethan eight seconds.

System Response:

The ECM will log the diagnostic code. The checkengine lamp will illuminate after a delay.

The ECM will set the value of the coolant temperatureto a default value.

The engine will not go into cold mode while thediagnostic code is active.

The ECM will activate the cooling fan after this codehas been active for more than eight seconds.

Troubleshooting:


Results:

• OK – STOP.

i02290633

CID 0111 FMI 02 EngineCoolant Level Sensor Loss ofSignalSMCS Code: 5574-038-CLT


The signal from the coolant level sensor is missing.


System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The diagnostic code may be viewedon a display module or on the electronic service tool.

Troubleshooting:

Perform the following diagnostic procedure: “CoolantLevel Sensor Circuit - Test”

Results:

• OK – STOP.

i02388568

CID 0164 FMI 02 InjectorActuation Pressure signalerraticSMCS Code: 1925-038



If the engine is not running, the followingconditions must be met.

• The actual injection actuation pressure remainsabove 3 MPa (435 psi) for at least three seconds.

• Cold mode is not active.

If the engine is running, the following conditionsmust be met.

• The actual injection actuation pressure and thedesired injection actuation pressure differ by morethan 2 MPa (290 psi) for at least ten seconds.

• The change in injection actuation pressure wasnot consistent with the change in the current to thecontrol valve.

• Cold mode is not active.

System Response:

The ECM will log the diagnostic code. The statusof “Injection Actuation Pressure” on CaterpillarElectronic Technician (ET) will revert to a defaultvalue.


• Low power

Troubleshooting:

Perform the following diagnostic procedure: “InjectionActuation Pressure Sensor - Test”

Results:

• OK – STOP.

i02427705

CID 0164 FMI 03 InjectorActuation Pressure voltagehighSMCS Code: 1925-038


The signal from the injection actuation pressuresensor is above normal. Cold mode is not active.

System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The ECM will flag injection actuationpressure as invalid data and a default value is used.The ECM will set the current for the control valve to afixed value.



• The engine may experience poor idle quality.

Troubleshooting:


Results:

• OK – STOP.

i02427714

CID 0164 FMI 04 InjectorActuation Pressure voltagelowSMCS Code: 1925-038


The signal from the injection actuation pressuresensor is below normal. Cold mode is not active.


System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The ECM will flag injection actuationpressure as invalid data and a default value will beused. The ECM will set the current for the controlvalve to a fixed value.



• The engine may experience poor idle quality.

Troubleshooting:


Results:

• OK – STOP.

i02120334

CID 0164 FMI 11 InjectorActuation Pressure systemfaultSMCS Code: 1925-038


The Electronic Control Module (ECM) detects one ofthe following conditions:

• The actual injection actuation pressure and thedesired injection actuation pressure differ by morethan 3 MPa (435 psi).

• The current to the injection actuation pressurecontrol valve is at either the maximum output or theminimum output for an excessive period of time.

Note: The diagnostic code indicates a mechanicalproblem. The ECM and the electronic control systemare operating correctly.

System Response:

The ECM will log the diagnostic code. The diagnosticcode may be viewed on a display module or on theCaterpillar Electronic Technician (ET).


• Low power

• Unstable idle

• Difficult to start at normal operating temperatures

• Easy to start below normal operating temperatures

Troubleshooting:

Note: The problem may only exist at operatingtemperature. Air may be trapped in the injectionactuation system if the system has been servicedrecently. Start the engine and run the engine at 1500rpm for a few minutes in order to remove the trappedair.

Perform the following diagnostic procedure: “InjectionActuation Pressure - Test”

Results:

• OK – STOP.

i02424772

CID 0168 FMI 00 SystemVoltage HighSMCS Code: 1401-038


The Electronic Control Module (ECM) detects thefollowing condition:

• For 12 volt systems, the ECM reads battery voltagethat is above 16 VDC.

• For 24 Volt systems, the ECM reads batteryvoltage that is above 32 VDC.

Note: Excessive voltage to the ECM may damagethe ECM.

System Response:

The ECM will log the diagnostic code.



Troubleshooting:

Perform the following diagnostic procedure:“Electrical Power Supply Circuit - Test”

Results:

• OK – STOP.


i02437120

CID 0168 FMI 01 SystemVoltage LowSMCS Code: 1401-038


The Electronic Control Module (ECM) has beenpowered for at least three seconds. The ECM detectsthe following condition:

• For 12 volt systems, the ECM reads battery voltagethat is below 9 VDC.

• For 24 volt systems, the ECM reads battery voltagethat is below 18 VDC.

System Response:



• Engine misfires

• Engine shutdown

• Hard starting

• Clattering noise from the starting motor duringengine cranking

Troubleshooting:


Results:

• OK – STOP.

i02415969

CID 0168 FMI 02 SystemVoltage intermittent/erraticSMCS Code: 1401-038


While the engine is running, the battery voltage dropsbelow 9 VDC intermittently, or the battery voltagedrops below 9 VDC three times in a seven secondperiod.

System Response:

The Electronic Control Module (ECM) will log thediagnostic code.


The engine may experience the followingperformance effects:

• Engine misfire

• Engine shutdown

Troubleshooting:


Results:

• OK – STOP.

i02258949

CID 0172 FMI 03 IntakeManifold Air Temp open/shortto +battSMCS Code: 1921-038


The engine coolant temperature is above −10 °C(14 °F). The signal voltage from the intake manifoldair temperature sensor is greater than 4.95 VDC formore than eight seconds.

System Response:

The Electronic Control Module (ECM) will log thediagnostic code. The ECM flags engine coolanttemperature as invalid data and a default value of40 °C (104 °F) is used.


None

Troubleshooting:


Results:

• OK – STOP.


i02424787

CID 0172 FMI 04 IntakeManifold Air Temp short togroundSMCS Code: 1921-038



System Response:

The code is logged. The ECM will flag the intakemanifold air temperature as invalid data and theintake manifold air temperature is set to a defaultvalue.


• The engine may experience hard starting and/orrough running.

• The engine may smoke.

Troubleshooting:


Results:

• OK – STOP.

i02421359

CID 0190 FMI 08 Engine Speedsignal abnormalSMCS Code: 1907-038


The Electronic Control Module (ECM) receives erraticdata from the engine speed/timing sensor.

System Response:

The code is logged.


• The engine may not start.

• The engine will run rough.

Troubleshooting:

Perform the following diagnostic procedure: “EngineSpeed/Timing Sensor Circuit - Test”

Results:

• OK – STOP.

i02048968

CID 0247 FMI 09 J1939 DataLink communicationsSMCS Code: 1901-038


The Electronic Control Module (ECM) has detected aloss of communications with the J1939 data link.

System Response:



The engine may not operate properly. The equipmentmay not have engine speed control.

Perform the following diagnostic procedure: “CANData Link Circuit - Test”

Results:

• OK – STOP.

i02428636

CID 0253 FMI 02 PersonalityModule mismatchSMCS Code: 1902-038


The flash file that is used for replacement is fora different engine family or for a different engineapplication.

System Response:

Caterpillar Electronic Technician (ET) will not be ableto clear the code.


• The fuel injection system is disabled and theengine will not start.


Troubleshooting:

Check the Part Number of the Flash File

A. Restore the electrical power to the ElectronicControl Module (ECM).

B. Verify that the part number for the flash file agreeswith the latest update that is available on ServiceTechnician Workbench (STW), or on SIS Web.

Expected Result:

The correct flash file is installed in the ECM.

Results:

• OK – The correct flash file is installed in the ECM.

Repair: The engine will not start until the 253-02diagnostic code is cleared. Clearing this coderequires factory passwords.

Acquire factory passwords. Clear the 253-02diagnostic code. Return the engine to service.

STOP.

• Not OK – The correct flash file is not installed inthe ECM.

Repair: Flash program the ECM with the correctflash file. Refer to programming parametersTroubleshooting, “Flash Programming”. Verify thatthe problem is resolved.

STOP.

i02348802

CID 0261 FMI 13 Engine TimingCalibration requiredSMCS Code: 1912-038


The timing has not been calibrated since theElectronic Control Module (ECM) was installed or thecalibration is incorrect.

System Response:


The ECM uses default timing.


• Engine misfires

• Low power

• Reduced engine speed

• White exhaust smoke

• Increased exhaust emissions

Troubleshooting:

Perform the following diagnostic procedure: “EngineSpeed/Timing Sensor - Calibrate”

Results:

• OK – STOP.

i02416460

CID 0262 FMI 03 5 Volt SensorDC Power Supply short to+battSMCS Code: 5574-038


The Electronic Control Module (ECM) detects anabove normal voltage on the 5 volt supply.

System Response:

The code is logged. The check engine lamp willilluminate while this diagnostic code is active. TheECM sets all of the pressure sensors to the defaultvalues.


• The engine power is derated.

Troubleshooting:

Perform the following diagnostic procedure: “5 VoltEngine Pressure Sensor Supply Circuit - Test”

Results:

• OK – STOP.

i02416463

CID 0262 FMI 04 5 Volt SensorDC Power Supply short togroundSMCS Code: 5574-038


The Electronic Control Module (ECM) detects abelow normal voltage on the 5 volt supply.


System Response:

The code is logged. The check engine lamp willilluminate while this diagnostic code is active. TheECM sets all of the pressure sensors to the defaultvalue.


• The engine power is derated.

Troubleshooting:

Perform the following diagnostic procedure: “5 VoltEngine Pressure Sensor Supply Circuit - Test”

Results:

• OK – STOP.

i02437740

CID 0268 FMI 02 CheckProgrammable ParametersSMCS Code: 1901-038


The Electronic Control Module (ECM) detects one ofthe following conditions:

• One or more of the programmable parameters hasnot been programmed.

• One or more of the injector trim files are notprogrammed.

System Response:

The diagnostic code will only be active. The checkengine lamp is illuminated while this diagnostic codeis active.


Engine performance may be affected byunprogrammed parameters. The unprogrammedparameters determine the action that is taken by theECM. The ECM may use a default torque map or theECM may limit the engine to low idle.

Troubleshooting:

Check the Programmable Parameters

Program the missing parameters, if necessary.Refer to Troubleshooting, “System ConfigurationParameters”.

Load any missing injector trim files, if necessary.Refer to programming parameters Troubleshooting,“Injector Trim File”.

Results:


i02281091

CID 0274 FMI 03 AtmosphericPressure open/short to +battSMCS Code: 1923-038


The signal voltage from the atmospheric pressuresensor is above 4.8 VDC for at least eight seconds.

System Response:

The Electronic Control Module (ECM) will logthe diagnostic code. The ECM flags atmosphericpressure as invalid data and a default value of100 kPa (15 psi) is used.


Low power

Troubleshooting:


Results:

• OK – STOP.

i02397806

CID 0274 FMI 04 AtmosphericPressure short to groundSMCS Code: 1923-038


The signal voltage from the atmospheric pressuresensor is below normal.

System Response:

The Electronic Control Module (ECM) will logthe diagnostic code. The ECM flags atmosphericpressure as invalid data and a default value is used.



Low power

Troubleshooting:


Results:

• OK – STOP.

i02286859

CID 0342 FMI 08 SecondaryEngine Speed signal abnormalSMCS Code: 1907-038



• The engine speed is greater than 120 rpm.

• The pattern for the timing ring is incorrect for fiveseconds.

System Response:

The ECM will log the diagnostic code. The ECM flagsthe secondary engine speed signal as invalid dataand a default value of zero rpm is used.


• Engine misfires

• Engine shutdown

Note: The engine will shut down only if the primaryengine speed/timing sensor and the secondaryengine speed/timing sensor are abnormal.

Troubleshooting:

Perform the following diagnostic procedure: “EngineSpeed/Timing Sensor Circuit - Test”

Results:

• OK – STOP.

i02424828

CID 0617 FMI 05 Air InletHeater Relay open/currentbelow normalSMCS Code: 4493-038


The Electronic Control Module (ECM) detects anopen circuit while attempting to energize the air inletheater relay.

System Response:

The ECM logs the diagnostic code. The air inletheater will be disabled or the air inlet heater will runcontinuously.


• The engine may experience hard starting and/orthe engine may emit excessive white smoke.

Troubleshooting:

Perform the following diagnostic procedure: “Air InletHeater Circuit - Test”

Results:

• OK – STOP.

i02424832

CID 0617 FMI 06 Air Inlet HeaterRelay grounded/current abovenormSMCS Code: 4493-038


The Electronic Control Module (ECM) detectsexcessive current while attempting to energize theair inlet heater relay.

System Response:

The ECM logs the diagnostic code. The air inletheater will be disabled or the air inlet heater will runcontinuously.


• The engine may experience hard starting and/orthe engine may emit excessive white smoke.


Troubleshooting:

Perform the following diagnostic procedure: “Air InletHeater Circuit - Test”

Results:

• OK – STOP.

i02427110

CID 1835 FMI 03 AuxiliaryPressure Sensor open/short to+battSMCS Code: 5574-038-PX


The Electronic Control Module (ECM) detects asignal voltage that is above normal.

System Response:

The ECM logs the diagnostic code. The value of theauxiliary pressure is set to a default value.



Troubleshooting:


Results:

• OK – STOP.

i02427111

CID 1835 FMI 04 AuxiliaryPressure Sensor short togroundSMCS Code: 5574-038-PX


The Electronic Control Module (ECM) detects asignal voltage from the auxiliary pressure sensor thatis below normal.

System Response:

The ECM logs the diagnostic code. The value of theauxiliary pressure is set to a default value.



Troubleshooting:


Results:

• OK – STOP.

i02214960

CID 1836 FMI 03 AuxiliaryTemperature Sensoropen/short to +battSMCS Code: 5574-038-TA


The signal voltage from the auxiliary temperaturesensor is greater than 8.5 VDC.

System Response:

The ECM logs the diagnostic code. The value of theauxiliary temperature is set to a default value.


• None


Results:

• OK – STOP.

i02427113

CID 1836 FMI 04 AuxiliaryTemperature Sensor short togroundSMCS Code: 5574-038-TA


The Electronic Control Module (ECM) detects asignal voltage from the auxiliary temperature sensorthat is below normal.


System Response:

The ECM logs the diagnostic code. The value of theauxiliary temperature is set to a default value.



Troubleshooting:


Results:

• OK – STOP.

i02418270

CID 2417 FMI 05 Ether InjectionControl Solenoid current lowSMCS Code: 5479-038


The Electronic Control Module (ECM) detects lowcurrent in the circuit.

System Response:

The code is logged.


• The engine may be difficult to start.

Troubleshooting:

Perform the following diagnostic procedure: “EtherInjection System - Test”

Results:

• OK – STOP.

i02418652

CID 2417 FMI 06 Ether InjectionControl Solenoid current highSMCS Code: 5479-038


The Electronic Control Module (ECM) detectsexcessive current flow in the circuit.

System Response:

The code is logged.


• The engine may be difficult to start.

Troubleshooting:

Perform the following diagnostic procedure: “EtherInjection System - Test”

Results:

• OK – STOP.


Troubleshooting with anEvent Code

i02275527

Event CodesSMCS Code: 1901

Event codes alert the operator that an abnormalengine operating condition such as low oil pressure orhigh coolant temperature has been detected. Whenthe event code is generated, the event is active.

Active Event CodesAn active event code represents a problem withengine operation. Correct the problem as soon aspossible.

Active event codes are listed in ascending numericalorder. The code with the lowest number is listed first.

When certain event codes are activated, theElectronic Control Module (ECM) also generates aflash code that will be displayed on the diagnosticlamp. Refer to Troubleshooting, “Diagnostic CodeCross Reference” for a cross-reference betweenevent codes and flash codes.

Illustration 12 is an example of the operating range ofan oil temperature sensor. Do not use the Illustrationto troubleshoot the oil temperature sensor. g01139661Illustration 12

Example of the typical operating range of an oil temperature sensor(1) This area represents the normal temperature range for the

engine oil. The normal output voltage of the sensor is between0.2 VDC and 4.2 VDC.

(2) In this area, the oil temperature above 107 °C (225 °F) is higherthan normal. The output voltage of the sensor will generate anevent code. The sensor does not have an electronic problem.

(3) In these areas, the output voltage of the sensor is too highor too low. The voltage is outside of the normal range. Theelectronic problem will generate a diagnostic code. Refer toTroubleshooting, “Troubleshooting with a Diagnostic Code” foradditional information on diagnostic codes.

The following format is used for event codes:

“EXXX (Y) Description of the event”

The “E” means that the code is an event code. The“XXX” represents a numeric identifier for the eventcode. The “(Y)” represents a numeric identifier for theseverity of the event. This is followed by a descriptionof the event. Refer to the following example:

“E004 (3) Engine Overspeed Shutdown”


In this example, the number 3 indicates the severityof the event. The ECM has three levels of responseto events:

Warning (1) – This condition represents a seriousproblem with engine operation. However, thiscondition does not require a derate or a shutdown.

Derate (2) – For this condition, the ECM reducesthe engine’s power in order to help prevent possibleengine damage.

Shutdown (3) – For this condition, the ECM shutsdown the engine in order to help prevent possibleengine damage.

Responses to certain events may be programmedinto the ECM. Refer to Troubleshooting, “SystemConfiguration Parameters”.

Logged Event CodesWhen the ECM generates an event code the ECMlogs the code in permanent memory. The ECM hasan internal diagnostic clock. The ECM will recordthe following information when an event code isgenerated:

• The hour of the first occurrence of the code

• The hour of the last occurrence of the code

• The number of occurrences of the code

Logged events are listed in chronological order. Themost recent event code is listed first.

This information can be helpful for troubleshootingintermittent problems. Logged codes can also beused to review the performance of the engine.

Clearing Event CodesA code is cleared from memory when one of thefollowing conditions occur:

• The code does not recur for 100 hours.

• A new code is logged and there are already tencodes in memory. In this case, the oldest code iscleared.

• The service technician manually clears the code.

Always clear logged event codes after investigatingand correcting the problem which generated thecode.

TroubleshootingFor basic troubleshooting of the engine, perform thefollowing steps in order to diagnose a malfunction:

1. Obtain the following information about thecomplaint from the operator:

• The event and the time of the event

• Determine the conditions for the event. Theconditions will include the engine rpm and theload.

• Determine if there are any systems that wereinstalled by the dealer or by the customer thatcould cause the event.

• Determine whether any additional eventsoccurred.

2. Verify that the complaint is not due to normalengine operation. Verify that the complaint is notdue to error of the operator.

3. Narrow the probable cause. Consider the operatorinformation, the conditions of operation, and thehistory of the engine.

4. Perform a visual inspection. Inspect the followingitems:

• Fuel supply

• Oil level

• Oil supply

• Wiring

• Connectors

Be sure to check the connectors. This is veryimportant for problems that are intermittent. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

If these steps do not resolve the problem, identifythe procedures in this manual that best describe theevent. Check each probable cause according to thetests that are recommended.

i02231322

E096 High Fuel PressureSMCS Code: 1250-038-HQ


The following conditions occur:

• The engine has been running for 65 seconds.

• The fuel pressure is at least 758 kPa (110 psi) foreight seconds.


Note: The warning will be cancelled if the fuelpressure drops below 733 kPa (106 psi) for fourseconds.

System Response:

The ECM will log the code.


Engine operation is not affected.

Troubleshooting:

Check the Fuel System

Check the pressure of the fuel system. Refer toSystems Operation/Testing and Adjusting, “FuelSystem Pressure - Test” for more information.

Results:

• OK – STOP.

i02116608

E360 Low Engine Oil PressureSMCS Code: 1348-038-LP



360-1

• The engine has been running for at least tenseconds.

• There are no active diagnostic codes for the oilpressure sensor or for the atmospheric pressuresensor.

• Engine oil pressure is in the “WARNING REGION”in Illustration 13 for eight seconds.

Note: The warning will be cancelled if the oil pressurerises 21 kPa (3 psi) above the set point for 20seconds.

360-2



• Engine oil pressure is in the “DERATE/SHUTDOWNREGION” in Illustration 13 for eight seconds.

Note: The derate will be cancelled if the oil pressurerises 21 kPa (3 psi) above the set point for 20seconds.

360-3



• Engine oil pressure is in the “DERATE/SHUTDOWNREGION” in Illustration 13 for four seconds.


Engine oil pressure versus engine speed

System Response:

360-1

The warning lamp will flash while the warning isactive.

The Electronic Control Module (ECM) will generate a46 flash code that will be displayed via the diagnosticlamp.

The ECM will generate a E360-1 event code.

The ECM will generate a SPN 100-FMI 17 eventcode on the J1939 data link. The event code may bedisplayed on a receiving device on the J1939 datalink.


360-2

The warning lamp will flash while the derate is active.

The ECM will generate a 46 flash code that will bedisplayed via the diagnostic lamp.


Caterpillar Electronic Technician (ET) will display“Engine Derate” in the first “Engine Status” box onany Cat ET status screen.


360-3

The warning lamp will flash.





360-1


360-2

The ECM will derate power by 17.5 percent persecond up to a maximum of 35 percent while thederate is active.

360-3

The engine will shut down.

Troubleshooting:

Refer to Troubleshooting, “Low Engine Oil Pressure”.

Results:

• OK – STOP.

i02433558

E361 High Engine CoolantTemperatureSMCS Code: 1395-038-TA



361-1

• The engine has been running for three minutes.

• There are no active diagnostic codes for thecoolant temperature sensor.

• The coolant temperature has exceeded the setpoint for ten seconds.

Note: The warning will be cancelled if the coolanttemperature rises 2 °C (36 °F) above the set pointfor 20 seconds.

361-2




Note: The derate will be cancelled if the coolanttemperature rises 2 °C (36 °F) above the set pointfor 45 seconds.

361-3




System Response:

361-1






361-2






361-3






361-1


361-2

The ECM will derate power by 25 percent. The ECMwill derate power an additional 25 percent for every1 °C (2 °F) over 111 °C (232 °F). The power will bederated at one percent per second.

361-3


Troubleshooting:

Check the cooling system. Refer to Testing andAdjusting, “Cooling System - Check”.

Results:

• OK – STOP.

i02116568

E362 Engine OverspeedSMCS Code: 7410-038; 7427-038



362-1

• At least one engine speed/timing sensor does nothave an active diagnostic code.

• The engine speed has exceeded the set point.

Note: The warning will be cancelled if the enginespeed is reduced to 200 rpm below the set point.

362-3

• At least one engine speed/timing sensor does nothave an active diagnostic code.

• The engine speed has exceeded the set point.

System Response:

362-1





362-3







362-1


362-3

The engine will be shut down.

Troubleshooting:

Determine the events that caused the overspeed.Make corrections in order to prevent the overspeedfrom recurring.

Results:

• OK – STOP.

i02172516

E443 High Auxiliary PressureSMCS Code: 5095-038-AX



443-1


• There are no active diagnostic codes for theauxiliary pressure sensor.

• The pressure that is sensed by the auxiliarypressure sensor has exceeded the set point forfour seconds.

Note: The warning will be cancelled if the pressurefalls 40 kPa (6 psi) below the set point for twoseconds.

443-2



• The pressure that is sensed by the auxiliarypressure sensor has exceeded the set point forthree seconds.

Note: The derate will be cancelled if the pressure falls40 kPa (6 psi) below the set point for two seconds.

443-3



• The pressure that is sensed by the auxiliarypressure sensor has exceeded the set point forthree seconds.

System Response:

443-1




443-2





443-3





443-1


443-2

The ECM will derate power by 25 percent. The powerwill be derated at one percent per second.

443-3



Troubleshooting:

Verify that the set points are valid for the application.

Determine the events that caused the high pressurecondition. Make corrections in order to prevent thehigh pressure from recurring.

Results:

• OK – STOP.

i02433576

E445 High AuxiliaryTemperatureSMCS Code: 5095-038-AX



445-1


• There are no active diagnostic codes for theauxiliary temperature sensor.

• The temperature that is sensed by the auxiliarytemperature sensor has exceeded the set point forfour seconds.

Note: The warning will be cancelled if the temperaturefalls 2 °C (4 °F) below the set point for two seconds.

445-2




Note: The derate will be cancelled if the temperaturefalls 2 °C (4 °F) below the set point for two seconds.

445-3




System Response:

445-1




445-2





445-3





445-1


445-2

The ECM will derate power by 25 percent. The powerwill be derated at one percent per second.

445-3



Troubleshooting:

Verify that the set points are valid for the application.

Determine the events that caused the hightemperature condition. Make corrections in order toprevent the high temperature from recurring.

Results:

• OK – STOP.

i02433579

E539 High Intake Manifold AirTemperatureSMCS Code: 1050-038-TA



539-1


• There are no active diagnostic codes for the intakemanifold air temperature sensor.

• The intake manifold air temperature is at least75 °C (167 °F) for eight seconds.

Note: The warning will be cancelled if the intakemanifold air temperature drops below 73 °C (163 °F)for four seconds.

539-2


• There are no active diagnostic codes for the intakemanifold air temperature sensor.

• The intake manifold air temperature is at least79 °C (174 °F) for eight seconds.

Note: The derate will be cancelled if the intakemanifold air temperature drops below 77 °C (171 °F)for 25 seconds.

System Response:

539-1





539-2







539-1


539-2

The ECM will derate power by three percent at 79 °C(174 °F). The ECM will derate power an additional 3percent for every 2 °C (1 °F) above 79 °C (174 °F) upto a 20 percent derate at 85 °C (185 °F).

Troubleshooting:

Check the air inlet system. Refer to SystemsOperation/Testing and Adjusting, “Air Inlet andExhaust System” for more information.

Results:

• OK – STOP.

i02221421

E2143 Low Engine CoolantLevelSMCS Code: 1395-038-LO



2143-1

• The engine has been running for one minute.


• There are no active diagnostic codes for thecoolant level sensor.

• The signal from the coolant level sensor indicatesthat the coolant level is low.

• The low coolant level persists for the programmedperiod of time.

2143-2





Note: The derate will be cancelled if the coolant levelrises above the low level for at least five seconds.

2143-3





System Response:

2143-1





2143-2






2143-3






2143-1


2143-2

The ECM will derate power by one percent persecond up to a maximum of 35 percent while thederate is active.

2143-3


Troubleshooting:

Check the cooling system. Refer to SystemsOperation/Testing and Adjusting, “Cooling System”.

Results:

• OK – STOP.


Diagnostic FunctionalTests

i02289813

5 Volt Engine Pressure SensorSupply Circuit - TestSMCS Code: 5574-038

System Operation Description:

The Electronic Control Module (ECM) creates aregulated voltage of 5.0 ± 0.2 VDC that is suppliedto terminal A of the harness connectors for thesesensors:

• Injection actuation pressure sensor





• Auxiliary pressure sensor (if equipped)

This procedure covers the following diagnostic codes:

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

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

• 100-10 Engine Oil Pressure Sensor abnormal rateof change

• 102-10 Boost Pressure Sensor abnormal rate ofchange

A +5 V diagnostic code is probably caused by ashort circuit to ground or a short circuit to anothervoltage source in the harness. The next likely causeis a problem with a sensor. The least likely cause isa problem with the ECM.



Schematic for the 5 volt supply

Test Step 1. Inspect the ElectricalConnectors and the Wiring

A. Turn the keyswitch to the OFF position.


g01121143Illustration 15Left side view(1) Boost pressure sensor(2) Atmospheric pressure sensor(3) J2/P2 connectors(4) J1/P1 connectors(5) Engine oil pressure sensor



B. Thoroughly inspect connectors (3) and (4).Thoroughly inspect the connectors for eachpressure sensor. Refer to Troubleshooting,“Electrical Connectors - Inspect”.


P2 terminals that are associated with the 5 volt supply for thepressure sensors(P2-17) Return(P2-54) Return(P2-72) +5 VDC(P2-80) +5 VDC


g01123207Illustration 18P1 terminals that are associated with the 5 volt supply for thepressure sensors(P1-2) +5 VDC(P1-3) Return


J61/P61 terminals that are associated with the 5 volt supply for thepressure sensors(14) +5 VDC(15) Return


Connectors for the sensors(A) Supply(B) Return(C) Signal

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the pressure sensorsupply.


D. Check the allen head screw on each ECMconnector for the proper torque. Refer toTroubleshooting, “Electrical Connectors - Inspect”for the correct torque values.

E. Check the allen head screw on the customerconnector for the proper torque. Refer toTroubleshooting, “Electrical Connectors - Inspect”for the correct torque value.

F. Check the harness and the wiring for abrasionand for pinch points from each sensor back to theECM.

Expected Result:

All of the connectors, pins and sockets are completelycoupled and/or inserted and the harness and wiringare free of corrosion, of abrasion and of pinch points.

Results:

• OK – The harness and connectors appear to beOK. Proceed to Test Step 2.

• Not OK – The connectors and/or wiring are notOK.

Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled. Verify that therepair eliminates the problem.

STOP.

Test Step 2. Check for Active DiagnosticCodes

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

B. Turn the keyswitch to the ON position.

C. Observe the “Active Diagnostic” screen on Cat ET.Wait at least 15 seconds so that any codes maybecome active. Look for these codes:

• 262-03

• 262-04

• 100-10

• 102-10

Expected Result:

One of the above codes is active.

Results:

• Active 03 code – An 03 diagnostic code is active.Proceed to Test Step 3.

• Active 04 code – An 04 diagnostic code is active.Proceed to Test Step 5.

• Active 10 code – A 10 diagnostic code is active.Proceed to Test Step 4.

• No active codes – None of the above codes areactive.

Repair: If any of the above codes are loggedand the engine is not running properly, refer toTroubleshooting, “Troubleshooting Without aDiagnostic Code”.

If the engine is running properly at this time, theremay be an intermittent problem in a harnessthat is causing the codes to be logged. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

STOP.

Test Step 3. Check the Voltage on the +5V Supply Wire


B. Disconnect the harness connectors for thefollowing sensors:

• Injection actuation pressure sensor J500/P500

• Boost pressure sensor J200/P200

• Atmospheric pressure sensor J203/P203

• Fuel pressure sensor J209/P209

• Engine oil pressure sensor J201/P201

• Auxiliary pressure sensor J220/P220 (ifequipped)

C. Turn the keyswitch to the ON position.

Note: Be sure to wiggle the harness during thefollowing measurements in order to reveal anintermittent condition.

D. Measure the voltage between terminals A and Bat each sensor connector on the engine harness.

Expected Result:

Each voltage measurement is 5.0 ± 0.2 VDC.


Results:

• OK – Each voltage measurement is 5.0 ± 0.2 VDC.

Repair: Connect all of the sensor connectors.Clear all diagnostic codes. Check for activediagnostic codes. If the problem is intermittent,refer to Troubleshooting, “Electrical Connectors- Inspect”.

STOP.

• Not OK – At least one voltage measurement is not5.0 ± 0.2 VDC. There is a problem with the wiringor with the ECM. Proceed to Test Step 6.

Test Step 4. Check the Voltage on the +5V Supply Wire for the Suspect Sensor


B. Disconnect the harness connectors for thesuspect sensor.


Note: Be sure to wiggle the harness during thefollowing measurement in order to reveal anintermittent condition.

D. Measure the voltage between terminals A and Bon the harness connector for the suspect sensor.

Expected Result:

The voltage measurement is 5.0 ± 0.2 VDC.

Results:

• Yes – The voltage measurement is 5.0 ± 0.2VDC. The 5 volt supply is present at the harnessconnector for the suspect sensor. However, thereis an active 10 diagnostic code.

Repair: Replace the suspect sensor.

Verify that the problem is resolved.

STOP.

• No – The voltage measurement is not 5.0 ± 0.2VDC. The 5 volt supply is not present at theharness connector. There is a problem with thewiring or with the ECM. Proceed to Test Step 6.

Test Step 5. Disconnect the +5 V PressureSensors and Check for Active DiagnosticCodes

A. Disconnect the following sensors one at a time:







B. Wait for 15 seconds after you disconnect eachsensor. Look for the active 262-04 code todeactivate.

Expected Result:

The 262-04 diagnostic code deactivates when aparticular sensor is disconnected.

Results:

• OK – The 262-04 diagnostic code deactivateswhen a particular sensor is disconnected.

Repair: Connect the suspect sensor. If the codereturns, replace the sensor.

Connect all of the connectors. Verify that theproblem is resolved.

STOP.

• Not OK – The 262-04 diagnostic code remainsafter all of the sensors are disconnected. Leavethe sensors disconnected. Proceed to Test Step 6.

Test Step 6. Check the +5 V Supply Wirefor a Short to Engine Ground or a ShortCircuit


B. Disconnect the J2/P2 ECM connector. Disconnectthe J1/P1 ECM connector.

C. Verify that all of the pressure sensors aredisconnected.

Note: Wiggle the harness during the followingmeasurements in order to reveal an intermittentcondition.

D. Measure the resistance between terminal P2-72(+5 V Supply) and all of the other terminals on theP2 connector.

E. Measure the resistance between terminal P2-72and the engine ground.

F. Measure the resistance between terminal P2-80(+5 V Supply) and all of the other terminals on theP2 connector.


G. Measure the resistance between terminal P2-80and the engine ground.

H. Measure the resistance between terminal P1-2(+5 V Supply) and all of the remaining terminalson the P1 connector.

a. Measure the resistance between terminal P1-2and the engine ground.

Expected Result:

Each resistance measurement indicates an opencircuit.

Results:

• OK – Each resistance measurement indicates anopen circuit. Proceed to Test Step 7.

• Not OK – At least one of the resistancemeasurements does not indicate an open circuit. A+5 V supply wire has a problem. There may be aproblem with a connector.

Repair: Repair the wire and/or the connector,when possible. Replace parts, if necessary. Verifythat the problem is resolved.

STOP.

Test Step 7. Check the +5 V Supply andthe Sensor Common for an Open Circuit

A. Install a wire jumper between terminals P2-72 (+5V Supply) and P2-3 (Sensor Common).

B. Install a wire jumper between terminals P1-2 (+5V Supply) and P1-3 (Sensor Common).

Note: Wiggle the harness during the followingmeasurements in order to reveal any intermittentshort condition.

C. Measure the resistance between terminals A andB at the harness connector for each pressuresensor.

Expected Result:

Each resistance measurement is less than ten Ohms.

Results:

• OK – Each measurement is less than ten Ohms.Proceed to Test Step 8.

• Not OK – At least one resistance measurement isgreater than ten Ohms. The +5 V supply wire orthe return wire has excessive resistance. Theremay be a problem in a connector.


STOP.

Test Step 8. Check the +5 V Supply at theECM

A. Remove terminal 72 (+5 V Supply) from theP2 connector. Install a wire jumper with socketterminals on both ends into P2-72.

B. Connect ECM connectors J2/P2.

C. Remove terminal 2 (+5 V Supply) from the P1connector. Install a wire jumper with socketterminals on both ends into P1-2.

D. Connect ECM connectors J1/P1.

E. Turn the keyswitch to the ON position.

F. Measure the voltage between the wire jumper inP1-2 and the engine ground.

G. Measure the voltage between the wire jumper inP2-2 and the engine ground.

H. Turn the keyswitch to the OFF position.

I. Restore both wires to the original configuration.

Expected Result:

Both voltage measurements are 5.0 ± 0.2 VDC.

Results:

• OK – Both voltage measurements are 5.0 ± 0.2VDC.

Repair: Clear all diagnostic codes. Check for activediagnostic codes. If the problem is intermittent,refer to Troubleshooting, “Electrical Connectors- Inspect”.

STOP.

• Not OK – At least one voltage measurement isnot 5.0 ± 0.2 VDC.

Repair: Replace the ECM. Refer toTroubleshooting, “Replacing the ECM”.

STOP.


i02216153

Air Inlet Heater Circuit - TestSMCS Code: 1090-038


Use this procedure to troubleshoot any suspectproblems with the air inlet heater circuit.


• 617-05 Air Inlet Heater Relay open/current belownormal

• 617-06 Air Inlet Heater Relay grounded/currentabove norm

The air inlet heater improves the engine’s ability tostart when the engine is cold. A reduction of whitesmoke is also a benefit of the air inlet heater.

The Electronic Control Module (ECM) activates theair inlet heater via the air inlet heater relay. The airinlet heater is activated according to the followingcycles:

• Power up cycle

• Preheat cycle

• Crank cycle

• Running cycle

• Postheat cycle

Power Up Cycle – The ECM activates the air inletheater for two seconds after the ECM is first poweredup regardless of temperature or engine speed.

Preheat Cycle – If the coolant temperature is lessthan 49 °C (120 °F), the ECM activates the air inletheater for 30 seconds. If the operator attempts to startthe engine before the end of the preheat cycle, theECM will begin using the strategy for the crank cycle.

Crank Cycle – When the engine is cranking andthe coolant temperature is less than 49 °C (120 °F),the air inlet heater will remain on while the engineis cranking. If the engine fails to start, the ECM willrevert to the preheat cycle.

Running Cycle – The air inlet heater will remainon after the engine has started. If the coolanttemperature does not reach 49 °C (120 °F) within fiveminutes, the ECM will use the postheat cycle.

Postheat Cycle – The air inlet heater will cycleon and off if the coolant temperature is still lessthan 49 °C (120 °F). The heater will turn on for 30seconds. Then, the heater will turn off for 10 seconds.This cycle continues for 15 minutes. The cycle endsif the coolant temperature exceeds 49 °C (120 °F).


g01118538Illustration 21Schematic for the air inlet heater





Typical component locations for the air inlet heater(1) Air inlet heater(2) Air inlet heater relay(3) Ground connection for the air inlet heater(4) J2/P2 connectors(5) Circuit breaker


B. Thoroughly inspect the J501/P501 air inlet heaterrelay connectors and connector (4). Inspect theconnections on air inlet heater relay (2) andair inlet heater (1). Refer to Troubleshooting,“Electrical Connectors - Inspect”.


P2 terminals that are associated with the air inlet heater(P2-5) Air inlet heater(P2-79) Air inlet heater

C. Perform a 45 N (10 lb) pull test on each of thewires in the connectors that are associated withthe circuit.

D. Check the allen head screw on the ECM connectorfor the proper torque of 6 ± 1 N·m (55 ± 9 lb in).

E. Check the harness and wiring for abrasion andfor pinch points from the air inlet heater back tothe ECM and from the air inlet heater back to thebattery.

Expected Result:

All connectors, pins and sockets are completelycoupled and/or inserted and the harness and wiringare free of corrosion, of abrasion and of pinch points.

Results:

• OK – The harness and the connectors appear tobe OK. Proceed to Test Step 2.

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

Repair: Repair the connectors and/or the wiring.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled. Verify that therepair eliminates the problem.

STOP.




C. Observe the “Active Diagnostic” screen on Cat ET.Wait at least 15 seconds so that any codes maybecome active. Look for these codes:

• 617-05

• 617-06

Expected Result:


Results:

• Active 617-05 code – A 617-05 diagnostic code isactive. Proceed to Test Step 3.

• Active 617-06 – A 617-06 diagnostic code isactive. Proceed to Test Step 5.


• No active codes – None of the above codes areactive. There may be a problem with the highpower circuit. Proceed to Test Step 6.

Test Step 3. Check for an Open Circuitto the Relay


Small terminals for the typical air inlet heater relay

A. Disconnect the wires from the small terminals ofthe air inlet heater relay.

B. Install a test lamp across the wires.

C. Start the “Air Inlet Heater Override” on Cat ET andobserve the test lamp.

Note: Do not leave the “Air Inlet Heater Override”ON. This prevents unnecessary cycling of the air inletheater and the battery from discharging. The “AirInlet Heater Override” has a one minute timer thatdisables the test when the time expires.

D. Stop the “Air Inlet Heater Override” and turn thekeyswitch to the OFF position.

Expected Result:

The test lamp turned on while the override was active.

Results:

• OK – The test lamp turned on while the overridewas active. The open circuit is in the relay.

Repair: Replace the air inlet heater relay. Clearany diagnostic codes. Verify that the problem isresolved.

STOP.

• Not OK – The test lamp did not turn on while theoverride was active. Proceed to Test Step 4.

Test Step 4. Check the Wiring Betweenthe ECM and the Relay

A. Disconnect the J2/P2 connectors.

Note: Be sure to wiggle the harness during thefollowing measurements in order to reveal anintermittent condition.

B. Measure the resistance between terminals P2-5and P501-1.

C. Measure the resistance between terminals P2-79and P501-2.

Expected Result:

Both of the resistance measurements are less thanten Ohms.

Results:

• OK – Both of the resistance measurements areless than ten Ohms.

Repair: Connect the wires to the relay’ssmall terminals. Replace the ECM. Refer toTroubleshooting, “Replacing the ECM”.

STOP.

• Not OK – At least one of the resistancemeasurements is more than ten Ohms. There is aproblem with the wiring between the ECM and theair inlet heater relay. There may be a problem witha connector.


STOP.

Test Step 5. Check for a Short Circuit inthe Wiring to the Relay


Small terminals for the typical air inlet heater relay

A. Disconnect the wires from the small terminals forthe air inlet heater relay.



C. Observe the “Active Diagnostic” screen on CatET. Wait at least 15 seconds so that any codesmay become active.

D. Turn the keyswitch to the OFF position.

Expected Result:

The short circuit diagnostic code (617-06) changedto an open circuit diagnostic code (617-05) when thewires to the relay were disconnected.

Results:

• OK – The short circuit diagnostic code (617-06)changed to an open circuit diagnostic code(617-05) when the wires to the relay weredisconnected. The short circuit is in the relay.

Repair: Replace the relay. Clear the diagnosticcodes.


STOP.

• Not OK – The short circuit diagnostic code(617-06) remained when the wires to the relaywere disconnected. There is a problem in thewiring between the ECM and the relay. There maybe a problem with a connector.


STOP.

Test Step 6. Check for Battery Voltage atthe Relay

A. Connect a test lamp between the +Battery side ofthe air inlet heater relay and the engine ground.

Expected Result:

The test lamp turns ON.

Results:

• OK – The test lamp turns ON. Battery voltage isreaching the relay. Proceed to Test Step 7.

• Not OK – The test lamp does not turn ON. Batteryvoltage is not reaching the relay.

Repair: Verify that the circuit breaker is not tripped.

If the circuit breaker is not tripped, there is an opencircuit in the wiring between the battery and therelay. There may be a problem with a connection.

Repair the wire and/or the connection, whenpossible. Replace parts, if necessary. Verify thatthe problem is resolved.

STOP.

Test Step 7. Check for Voltage Output atthe Relay

A. Connect a test lamp between the output terminalof the air inlet heater relay and the engine ground.

Note: Observe the test lamp. The test lamp shouldbe off, since the relay is not energized. If the testlamp is on, ensure that the test lamp is connected tothe output side of the relay.


C. Run the “Air Inlet Heater Override” on Cat ET andobserve the test lamp.

Note: Do not leave the “Air Inlet Heater Override”ON. This prevents unnecessary cycling of the air inletheater and the battery from discharging. The “AirInlet Heater Override” has a one minute timer thatdisables the test when the time expires.

D. Stop the “Air Inlet Heater Override” and turn thekeyswitch to the OFF position.

Expected Result:

The test lamp turned on when the “Air Inlet HeaterOverride” was enabled.

Results:

• OK – The test lamp turned on when the “Air InletHeater Override” was enabled. The air inlet heaterrelay and the +Battery connection to the air inletheater relay are operating correctly. Proceed toTest Step 8.

• Not OK – The test lamp did not turn on when the“Air Inlet Heater Override” was enabled.

Repair: Replace the relay.


STOP.


Test Step 8. Check the Wiring Betweenthe Relay and the Heater and Betweenthe Heater and the Engine Block

g01118615Illustration 26Left side view

(1) Wire(2) Bar

A. Measure the resistance of wire (1) that connectsthe relay to the air inlet heater.

B. Measure the resistance of bar (2) that connectsthe air inlet heater to the engine block.

Expected Result:

Both of the resistance measurements are less thanten Ohms.

Results:

• OK – Both of the resistance measurements areless than ten Ohms. Proceed to Test Step 9.

• Not OK – At least one of the resistancemeasurements is more than ten Ohms. There is anopen circuit in the wiring. There may be a problemwith a connector.


STOP.

Test Step 9. Measure the Current throughthe Heater

g01118617Illustration 27Left side view

(1) Wire(2) Terminal(3) Terminal

A. Connect a 155-5176 AC/DC Current Probe or anequivalent inductive pickup clamp around wire (1)between the relay and the air inlet heater.

B. Connect the current probe to a multimeter.


D. Run the “Air Inlet Heater Override” on Cat ET andobserve the current reading on the multimeter.

Note: Do not leave the “Air Inlet Heater Override”On. Avoid unnecessary cycling of the air inlet heaterin order to prevent the battery from discharging. The“Air Inlet Heater Override” has a one minute timer inorder to disable the test when the time expires.

E. While the override is active, measure the voltagebetween terminals (2) and (3).

F. Stop the “Air Inlet Heater Override” and turn thekeyswitch to the OFF position.

Expected Result:

For 12 volt systems, the current reading is between82 and 102 Amperes. The voltage is reading isapproximately 11 VDC.

For 24 volt systems, the current reading is between77 and 95 Amperes. The voltage reading isapproximately 22 VDC.

Note: If the voltage reading does not match thespecified value, you will need to adjust the currentvalue accordingly. For slightly lower voltages, thecurrent value will be slightly lower. For slightly highervoltages, the current value will be slightly higher.


Results:

• OK – The readings are within the specified ranges.

Repair: The readings are within the specifiedranges. The air inlet heater circuit appears to beoperating correctly at this time. If an intermittentproblem is suspected, refer to Troubleshooting,“Electrical Connectors - Inspect”.

STOP.

• Not OK – The voltage reading and/or the currentreading is not within the specified ranges.

Repair: Replace the air inlet heater.


STOP.

i02433599

Air Shutoff System - TestSMCS Code: 1078-038


This procedure checks the circuits for the air shutoffsystem. The Electronic Control Module (ECM) doesnot provide diagnostics for the circuits that are for theair shutoff system.

There are two conditions which can cause the ECMto activate the air shutoff:

Engine Overspeed – The first condition occurswhen the ECM detects an engine overspeedcondition. The ECM energizes the air shutoff solenoidand the fuel injection is disabled. The air shutoffsystem is latched by the ECM until the keyswitch iscycled.

System test – The second condition occurs whena test of the air shutoff system is performed. Theoverspeed verify switch can be activated by theoperator in order to perform this test. The enginespeed is then increased to 75 percent of theprogrammed overspeed setpoint. The ECM activatesthe air shutoff system as the engine speed exceeds75 percent of the programmed overspeed setpoint.The ECM energizes the air shutoff solenoid and fuelinjection is disabled. The air shutoff system is latchedby the ECM until the keyswitch is cycled.

Note: If the “Air Shutoff” parameter is set to “NotInstalled”, the functionality for the overspeed verifyswitch remains operational. If the switch is activatedduring engine operation, the ECM will disableinjection for any engine speed over 75 percent ofthe programmed overspeed setpoint. As the enginespeed drops below 75 percent of the programmedoverspeed setpoint, the injection is again enabled bythe ECM. This functionality is not latched by the ECMand the functionality is disabled when the switch isturned off.

For some air shutoff systems, after the air shutoffmechanism has been tripped, a manual reset of themechanism may be necessary.



Schematic for the air shutoff system


A. Remove electrical power from the ECM.

B. Verify that the air shutoff mechanisms are set tothe OPEN position.


ECM connectors (typical example)

(1) J1/P1 ECM connectors


Customer connector (typical example)(2) J61 customer connector



Air shutoff mechanism(3) Terminals for the air shutoff solenoid

C. Thoroughly inspect connectors (1) and (2).Also, thoroughly inspect connections (3) at theair shutoff solenoid. Refer to Troubleshooting,“Electrical Connectors - Inspect”.

g01212804Illustration 32P1 terminals for the air shutoff system(P1-11) Air shutoff relay(P1-54) Overspeed verify switch(P1-67) Return


Terminal locations at the P61 customer connector that areassociated with the air shutoff system(4) Air shutoff relay(5) Return(40) Overspeed verify switch


D. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the circuit for theair shutoff system.

E. Check the allen head screw on each ECMconnector for the proper torque. Also, check theallen head screw on the customer connectorfor the proper torque. Refer to Troubleshooting,“Electrical Connectors - Inspect” for the correcttorque values.

F. Check the harness and the wiring for abrasionand for pinch points from the air shutoff solenoidto the ECM.

Expected Result:

All connectors, pins, and sockets are completelycoupled and/or inserted, and the harness and wiringare free of corrosion, of abrasion and of pinch points.

Results:

• OK – The connectors and wiring appear to be OK.Proceed to Test Step 2.


Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled. Verify that theproblem is resolved.

STOP.

Test Step 2. Test the Operation of theControl Solenoid for the Air Shutoff Relay



Location of the test lamp

B. Remove the wire from the output of the air shutoffrelay.

C. Connect a test lamp between the output of thesolenoid for the air shutoff relay and engineground.

D. Start the engine.

E. Activate the overspeed verify switch.

F. Monitor the test lamp while you increase theengine speed past 75 percent of the programmedoverspeed setpoint.

G. Stop the engine.

H. Remove the test lamp from the circuit. Restore thewiring to the original configuration.

Expected Result:

The test lamp illuminated when the engine speedincreased past 75 percent of the programmedoverspeed setpoint.

Results:

• OK – The test lamp illuminated. The air shutoffrelay is operating correctly. Proceed to Test Step 3.

• Not OK – The test lamp did not illuminate. Novoltage is present at the output of the relay.Proceed to Test Step 4.

Test Step 3. Test for Voltage at the AirShutoff Solenoid

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

g01212806Illustration 35Location of the test lamp

B. Disconnect the wire from the positive terminal ofthe air shutoff solenoid.

C. Connect a test lamp between the wire for thepositive terminal of the air shutoff relay and engineground.





G. Stop the engine.

Expected Result:


Results:

• OK – The test lamp illuminated.

Repair: The voltage is present at the air shutoffsolenoid. Check for continuity of the ground circuitfor the air shutoff solenoid before proceeding. Ifthe ground circuit is OK, replace the air shutoffsolenoid. Verify that the problem is resolved.

STOP.

• Not OK – The test lamp did not illuminate.

Repair: System voltage was not present at the airshutoff solenoid. There is a problem in the wiringbetween the output of the air shutoff relay and theinput of the air shutoff solenoid . There may be aproblem in a connector. Repair the wiring and/orthe connector. Replace parts, if necessary. Verifythat the problem is resolved.

STOP.

Test Step 4. Test the Control Input Voltageat the Air Shutoff Relay


B. Disconnect the wires from the control input of theair shutoff relay at the relay.

C. Connect the test lamp between the two controlwires.




G. Stop the engine.

Expected Result:


Results:

• OK – The test lamp illuminated. Control inputvoltage is reaching the relay. Proceed to Test Step6.

• Not OK – The test lamp did not illuminate. Thevoltage from the ECM was not present at the coilof the air shutoff relay. Restore the wiring to theoriginal configuration. Proceed to Test Step 5.

Test Step 5. Check the Output Voltage forthe Air Shutoff Relay at the ECM


B. Disconnect the P1 ECM connector.

C. Fabricate a jumper wire that is long enough toreach from the P1-54 ECM connector to engineground. Crimp a connector socket to one end ofthe jumper wire.

D. Remove the wire from terminal location P1-54(overspeed verify switch) at the ECM connector.Insert the jumper wire into this terminal location.

E. Fabricate two other jumper wires that can beused as test leads at the ECM connector. Crimp aconnector socket to one end of each jumper wire.

F. Remove the wires from terminal locations P1-11(air shutoff solenoid) and P1-67 (solenoid return)at the ECM connector. Insert one of the jumperwires into each of these terminal locations.

G. Connect the J1/P1 ECM connectors.

H. Connect the loose end of the jumper wire that is interminal location P1-54 to the engine ground stud.

I. Connect the leads of the voltage test lamp to theloose ends of the other two jumper wires that arein the P1 ECM connector.

J. Start the engine.

K. Monitor the test lamp while you increase theengine speed past 75 percent of the programmedoverspeed setpoint.

L. Stop the engine.


Expected Result:


Results:


Repair: The ECM is operating correctly. Performthe following procedure:

1. Verify the continuity of the ground circuit for theoverspeed verify switch.

2. Isolate the overspeed verify switch from thecircuit. Close the switch and measure thecontinuity across the switch. Open the switchand measure the continuity across the switch.

3. Verify the continuity of the circuit betweenthe overspeed verify switch and the P1 ECMconnector.

4. Restore the wiring to the original configuration.

If the overspeed verify switch is OK and thecircuit has continuity from the P1 and theengine ground stud, there is a problem in thewiring between the P1 ECM connector and theair shutoff relay.

Repair the circuit connectors or wiring and/orreplace the circuit connectors or wiring. Verify thatthe problem is resolved.

STOP.

• Not OK – The test lamp did not illuminate.

Repair: Restore the wiring to the originalconfiguration. There is a problem with the ECM.Replace the ECM. Refer to Troubleshooting,“Replacing the ECM”.

STOP.

Test Step 6. Test the Diode for the ControlCircuit

g00761537Illustration 36Diode leads

A. Disconnect the air shutoff relay’s control wires atthe relay.

B. Remove the diode from the air shutoff relay.

C. Select the “Diode Check” function on a digitalvoltmeter.

D. Refer to Illustration 36. Place the red lead of thedigital voltmeter on the diode at location (A). Placethe black lead of the digital voltmeter on the diodeat location (B).

E. Measure the voltage drop across the diode.

Expected Result:

The voltage drop across the diode is less than onevolt.

Results:

• OK – The voltage drop across the diode is lessthan one volt. The voltage drop across the diode isOK. Proceed to Test Step 7.

• Not OK – The voltage drop across the diode isgreater than one volt.

Repair: The diode is damaged. Replace the diode.Verify that the problem is resolved.

STOP.

Test Step 7. Test the Diode for CurrentFlow

A. Reverse the position of the leads for the digitalvoltmeter.

B. Measure the voltage drop across the diode.

Expected Result:

For a diode that is operating properly, the digitalvoltmeter will indicate an OL across the diode.

Results:

• OK – The digital voltmeter indicates an OL acrossthe diode for this measurement. The diode is OK.Proceed to Test Step 8.

• Not OK – The digital voltmeter does not indicatean OL across the diode.

Repair: The diode is damaged. Replace the diode.Verify that the problem is resolved.

STOP.

Test Step 8. Check the Voltage from theKeyswitch to the Voltage Input of the AirShutoff Relay



g01165747Illustration 37Location of the test lamp

B. Remove the wire at the voltage input of the airshutoff relay.

C. Connect the test lamp between the wire for thevoltage input and the terminal for the voltage inputat the air shutoff relay.

D. Turn the keyswitch to the ON position.

E. Check the test lamp.

F. Turn the keyswitch to the OFF position.

Expected Result:

The test lamp illuminates.

Results:


Repair: The relay contacts are not passing thesecondary voltage to the circuit for the air shutoffsolenoid. Replace the air shutoff relay. Verify thatthe problem is resolved.

STOP.

• Not OK – The test lamp did not illuminate. Inputvoltage is not reaching the relay. Proceed to TestStep 9.

Test Step 9. Check the Harness betweenthe Keyswitch and the Air Shutoff Relay


B. Remove the wire from terminal R (keyswitch) ofthe keyswitch.


D. Measure the voltage between terminal B(+Battery) of the keyswitch and engine ground.

Refer to Illustration 28 for details.

E. Measure the voltage between terminal R(keyswitch) of the keyswitch and engine ground.


Expected Result:

Voltage is present on terminal B (+Battery) andterminal R (keyswitch) at the keyswitch.

Results:

• OK – Voltage is present on terminal B and terminalR at the keyswitch.

Repair: If voltage is present on terminal R, repairthe wire between the keyswitch and the air shutoffrelay. Verify that the breaker is not tripped. Returnall wiring to the original configuration. Verify thatthe problem is eliminated.

STOP.

• Not OK – Voltage is not present on terminal B atthe keyswitch.

Repair: If voltage is not present on terminalB, repair the wire between the +Battery andthe keyswitch. Verify that the breaker is nottripped. Verify that the battery disconnect switchis operating correctly. Check the battery’sno-load voltage. Return all wiring to the originalconfiguration. Verify that the problem is eliminated.

STOP.

• Not OK – Voltage is not present on terminal R atthe keyswitch.

Repair: If voltage is present on terminal B of thekeyswitch but not present on terminal R, replacethe keyswitch. Return all wiring to the originalconfiguration. Verify that the problem is eliminated.

STOP.


i02433602

CAN Data Link Circuit - TestSMCS Code: 1901-038


The CAN data link is used to communicateinformation between the Electronic Control Module(ECM) and other modules. Use this procedure totroubleshoot any suspect problems with the CANdata link.

This procedure covers the 247-09 J1939 Data Linkcommunications.

This procedure identifies the following problems:

• Faulty connectors

• Missing termination resistors

• Short circuits

• Open circuits

• Faulty J1939 display

g01119843Illustration 38Schematic for the CAN data link





Engine view (typical example)(1) J1/P1 ECM conntctors


Engine view (typical example)

(2) J61 customer connector(3) J63 service tool connector

B. Thoroughly inspect connectors (1), (2), and (3).Thoroughly inspect the connectors for eachmodule that is connected to the CAN data link.Refer to Troubleshooting, “Electrical Connectors- Inspect”.

g01215698Illustration 41P1 terminals that are associated with the CAN data link(P1-34) CAN data link −(P1-42) CAN shield(P1-50) CAN data link +



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

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the CAN data link.



F. Check the wiring harnesses for abrasion, forcorrosion and for pinch points.

Expected Result:

All connectors, pins and sockets are completelycoupled and/or inserted. The harness and wiring arefree of corrosion, of abrasion and of pinch points.

Results:

• OK – The harness and the wiring appear to beOK. Proceed to Test Step 2.

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

Repair: Repair the connectors and/or the wiring.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled. Verify that theproblem is resolved.

STOP.




C. Observe the active diagnostic code screen onCat ET. Wait at least 15 seconds so that anydiagnostic codes may become active. Check for a247-09 diagnostic code.

Expected Result:

No diagnostic codes are active.

Results:

• OK – No codes are active.

Repair: The problem may be intermittent. If theproblem is intermittent, refer to Troubleshooting,“Electrical Connectors - Inspect”.

STOP.

• Not OK – A 247-09 diagnostic code is active.Proceed to Test Step 3.

Test Step 3. Verify the Proper Installationof the CAN Data Link

A. Disconnect the J1939 display.

B. Disconnect the P1 connector and measure theresistance between terminals P1-50 (CAN datalink +) and P1-34 (CAN data link -).

Expected Result:

The resistance is between 57 and 63 Ohms.

Results:

• OK – The resistance is between 57 and 63 Ohms.Proceed to Test Step 6.

• Not OK – The resistance is between 114 Ohmsand 126 Ohms. A terminating resistor is missing.


Repair: Verify that two terminating resistors existon the data link. One resistor must be located oneach end of the data link. The engine is shippedwith one terminating resistor that is installedbetween the ECM and the customer connector.

Refer to the appropriate electrical schematic inorder to determine the missing resistor. Replacethe missing resistor. Verify that the problem isresolved.

STOP.

• Not OK – The resistance is less than 57 Ohms.Proceed to Test Step 4.

• Not OK – The resistance is greater than 126Ohms. Proceed to Test Step 5.

Test Step 4. Check for a Short Circuit

A. Disconnect the J1/P1 ECM connector.

B. Remove the terminating resistors from the CANdata link.

C. If a J1939 display is installed, disconnect thedisplay.

D. Measure the resistance between the points thatare listed in Table 16. Be sure to wiggle the wiresin the harnesses as you make each resistancemeasurement.

Table 16

Resistance Measurements for the CAN Data Link

Connector andTerminal

Terminal

All of the other terminals onthe P1 connector

P1-50 (CAN data link +)

Engine ground


P1-34 (CAN data link -)

Engine ground

Expected Result:

Each check of the resistance indicates an opencircuit.

Results:

• OK – Each check of the resistance indicates anopen circuit. Proceed to Test Step 5.

• Not OK – At least one check of the resistancedoes not indicate an open circuit. There is a shortcircuit in a harness. There may be a problem witha connector.

Repair: Repair the wiring and/or the connector.Replace part, if necessary. Verify that the problemis resolved.

STOP.

Test Step 5. Check for an Open Circuit

A. Verify that all of the connections are disconnected.

B. Fabricate a jumper wire. Use the jumper wire inorder to create a short circuit between terminals Gand F on the service tool connector.

C. Measure the resistance between terminals P1-50(CAN data link +) and P1-34 (CAN data link -).

D. Remove the jumper wire from the service toolconnector.

Expected Result:

The resistance is less than ten Ohms.

Results:

• OK – The resistance is less than ten Ohms. Thereis not an open circuit. Proceed to Test Step 6.

• Not OK – The resistance is more than ten Ohms.There is an open circuit or excessive resistance inthe circuit. There may be a problem in a connector.

Repair: Repair the wiring and/or the connector.Replace part, if necessary. Verify that the problemis resolved.

STOP.

Test Step 6. Check the J1939 Display

A. Connect the J1939 display to another engine.

B. Operate the engine and monitor the J1939 display.

Expected Result:

The J1939 display operates properly.

Results:

• OK – The J1939 display operates properly onanother engine.


Repair: Connect the display to the original engine.If the display operates correctly, there may bea problem with an electrical connector. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

If the display does not operate correctly on theoriginal engine, there may be a problem with theECM.

It is unlikely that the ECM has failed. Performthis entire procedure again. Replace the ECM ifthe display does not operate correctly. Refer toTroubleshooting, “Replacing the ECM”.

STOP.

• Not OK – The J1939 display does not operateproperly on another engine.

Repair: Replace the J1939 display. Verify that theproblem is resolved.

STOP.

i02403866

Cat Data Link Circuit - TestSMCS Code: 1901-038


Note: This procedure checks for an open circuitor for a short circuit in the Cat Data Link. If youare experiencing problems with communicationsbetween the Caterpillar Electronic Technician (ET)and the Electronic Control Module (ECM), referto Troubleshooting, “Electronic Service Tool WillNot Communicate with ECM” before you use thisprocedure.

The Cat Data Link is the standard data link thatis used by the ECM to communicate with Cat ET.The ECM communicates with Cat ET in order toshare status information and diagnostic information.Cat ET can also be used to configure the ECMparameters. This information will not be available ifcommunication fails between the ECM and Cat ET.

g01167527Illustration 43Schematic for the Cat Data Link


A. Remove the electrical power from the (engine)ECM.

g01167488Illustration 44Engine view (typical example)(1) J1/P1 ECM connectors



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

B. Thoroughly inspect connectors (1), (2), and (3).Refer to Troubleshooting, “Electrical Connectors- Inspect”.

g01202018Illustration 46P1 terminals that are associated with the Cat Data Link(P1-8) Cat Data Link +(P1-9) Cat Data Link −



J61 and P61 terminals that are associated with the Cat Data Link(6) Cat Data Link −(7) Cat Data Link +

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the Cat Data Link.

D. Check the allen head screw on each ECMconnector for the proper torque. Also, check theallen head screw on the customer connectorfor the proper torque. Refer to Troubleshooting,“Electrical Connectors - Inspect” for the correcttorque values.

Expected Result:

All connectors, pins, and sockets are completelyinserted and coupled. The harness and wiring arefree of corrosion, of abrasion, and of pinch points.

Results:

• OK – The harness and the connectors appear tobe OK. Proceed to Test Step 2.

• Not OK – The connectors and/or the wiring arenot OK.

Repair: Repair the connectors and/or the wiring.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled. Verify that theoriginal problem is resolved.

STOP.

Test Step 2. Check for a Short Circuit

A. Disconnect the J1 connector.

B. Disconnect Cat ET from the service tool connector.

C. Measure the resistance between the points thatare listed in Table 17. Be sure to wiggle the wiresin the harnesses as you make each resistancemeasurement.

Table 17

Resistance Measurements for the Cat Data Link


Terminal


P1-8 (Cat Data Link +)

Ground stud


P1-9 (Cat Data Link -)

Ground stud

Expected Result:


Results:


• Not OK – At least one check of the resistancedoes not indicate an open circuit. There is a shortcircuit in the harness or in a connector.

Repair: Repair the connectors and/or the wiring.Replace parts, if necessary. Verify that the originalproblem is resolved.

STOP.

Test Step 3. Check for an Open Circuit

A. Fabricate a jumper wire. Use the jumper wire inorder to create a short circuit between terminalsJ63-D (Cat Data Link +) and J63-E (Cat Data Link−).

B. Measure the resistance between P1-8 (Cat DataLink +) and P1-9 (Cat Data Link −).


Expected Result:

Each check of the resistance is less than ten Ohms.

Results:

• OK – Each check of the resistance is less thanten Ohms.

Repair: Perform the following procedure:

1. Connect the J1/P1 connectors. Connect Cat ETto the service tool connector.

2. Check the Cat Data Link for proper operation. Ifthe Data Link does not operate correctly, theremay be a problem with the ECM.

Temporarily install a new ECM. Check the CatData Link again. If the new ECM solves theproblem, install the original ECM and verify thatthe original problem returns. If the new ECMoperates correctly and the original ECM doesnot operate correctly, replace the original ECM.Verify that the problem is resolved.

STOP.

• Not OK – At least one check of the resistance isgreater than ten Ohms. There is an open circuit orexcessive resistance in the harness. There may bea problem with a connector.

Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Verify that the originalproblem is resolved.

STOP.

i02433613

Coolant Level Sensor Circuit- TestSMCS Code: 5574-038-CLT


Use this procedure to troubleshoot any suspectproblems with the engine coolant level sensor.

The engine coolant level sensor provides a means ofmonitoring the engine coolant level in order to warnthe operator in the event that the coolant level is low.The engine coolant level sensor is usually located inthe top tank of the radiator. The sensor should beimmersed in coolant at all times.

When the sensor is immersed in coolant, an internalswitch is closed. When the internal switch closes,the signal for the engine coolant level is groundedthrough the sensor return. The Electronic ControlModule (ECM) detects the ground on the input for theengine coolant level. If the signal is not present, anevent code is generated.

Verify that the coolant level has been programmedto “Enabled” on the configuration screen on theCaterpillar Electronic Technician (ET). If the coolantlevel is not programmed, Cat ET will display“Unavailable” for the parameter.


g01119821Illustration 48Schematic of the engine coolant level sensor

Test Step 1. Check the Coolant Level

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

A. Stop the engine. Allow the engine to cool.

B. Check the coolant level. Refer to the engine’sOperation and Maintenance Manual for the properprocedure.

Expected Result:

The coolant level is low.

Results:

• OK – The coolant level is low.

Repair: Add coolant according to the procedure inthe Operation and Maintenance Manual. Identifythe source of the coolant leak and fix the problem.Verify that the original problem is resolved.

STOP.

• Not OK – The coolant is at the proper level.Proceed to Test Step 2.



g01121173Illustration 49Engine components for the engine coolant level sensor(1) P61 customer connector(2) J1/P1 connectors


g01119186Illustration 50Rear view of a typical radiator with a engine coolant level sensor

B. Thoroughly inspect connectors (1) and (2). Inspectthe J800/P800 connectors for the engine coolantlevel sensor. Refer to Troubleshooting, “ElectricalConnectors - Inspect”.

g01215707Illustration 51P1 terminals that are associated with the engine coolant levelsensor(P1-3) Return(P1-4) +8 VDC (digital sensor supply)(P1-49) Engine coolant level



J61 and P61 terminals that are associated with the engine coolantlevel sensor(8) +8 VDC (digital sensor supply)(15) Return(36) Engine coolant level

C. Perform a 45 N (10 lb) pull test on each of the wiresin the ECM connector, the customer connector,and the sensor connector that is associated withthe circuit for the engine coolant level sensor.



Expected Result:

All connectors, pins, and sockets are completelycoupled and/or inserted, and the harness and wiringare free of corrosion, of abrasion, and of pinch points.

Results:

• OK – The connectors and wiring are OK. Proceedto Test Step 3.


Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all ofthe seals are properly connected. Verify that theoriginal problem is resolved.

STOP.

Test Step 3. Short the Harness andMonitor the Status of the “Coolant Level”

A. Connect Cat ET to the service tool connector.Refer to Troubleshooting, “Electronic ServiceTools”.

B. Disconnect the J800/P800 connectors for theengine coolant level sensor.

C. Install a jumper wire between P800-B (DigitalSensor Return) and P800-C (Coolant LevelSensor).


E. Monitor the status of “Coolant Level” on Cat ETwhile the jumper wire is installed.


G. Remove the jumper wire.

H. Connect the J800/P800 connectors.

Expected Result:

The status of the “Coolant Level” is “OK” when thejumper wire is installed.

Results:

• OK – The status of the “Coolant Level” is “OK”when the jumper wire is installed. The ECM, thesignal wire, and the return wire are OK. Proceedto Test Step 4.

• Not OK – The status of the “Coolant Level” is not“OK” when the jumper wire is installed. Proceedto Test Step 5.

Test Step 4. Check the Supply Voltage atthe Sensor Connector



C. Measure the voltage between terminals P800-A(+8 VDC digital sensor supply) and P800-B(Return) at the harness connector for the enginecoolant level sensor.



Expected Result:

The voltage between terminals A (+8 V digital supply)and B (sensor return) is 8.0 ± 0.4 VDC.

Results:

• OK – The supply voltage is reaching the sensor.

Repair: Replace the engine coolant level sensor.Verify that the original problem is resolved.

STOP.

• Not OK – The supply voltage is not reaching thesensor.

Repair: Refer to Troubleshooting, “DigitalSensor Supply Circuit - Test” for the appropriatetroubleshooting procedure.

STOP.

Test Step 5. Create a Short Circuit at theECM P1 Connector

A. Remove terminals P1-3 and P1-49. Install ajumper wire into open terminals P1-3 and P1-49.

B. Turn the keyswitch to the ON position and monitorthe status of “Coolant Level” on Cat ET while thejumper wire is installed.

C. Remove the jumper wire. Monitor the status of“Coolant Level” on Cat ET.


Expected Result:

The status of the switch is “OK” when the jumper wireis connected. The status of the switch is “Low” whenthe jumper wire is not connected.

Results:

• OK – The status of the switch is “OK” when thejumper wire is connected. The status of the switchis “Low” when the jumper wire is not connected.The ECM is properly reading the switch input.However, the ECM did not detect the jumper wire atthe sensor connector. There is a problem with thewiring. There may be a problem with a connector.

Repair: Repair the wiring and/or the connector.Replace parts, if necessary. Verify that the originalproblem is resolved.

STOP.

• Not OK – The ECM is not reading the switch input.

Repair: Replace the ECM. Refer toTroubleshooting, “Replacing the ECM”.Verify that the original problem is resolved.

STOP.

i02433636

Diagnostic Lamp Circuit - TestSMCS Code: 7431-038-NQ


The diagnostic lamp is used to inform the operator ofactive diagnostic codes and active event codes.

The Electronic Control Module (ECM) provides apath to ground for the diagnostic lamp. When theECM connects the diagnostic lamp to ground thediagnostic lamp will turn on.


Schematic for the diagnostic lamp

Test Step 1. Check the Operation of theDiagnostic Lamp

A. Turn the keyswitch to the ON position.

B. Monitor the diagnostic lamp.

Expected Result:

The diagnostic lamp turns on for five seconds. Then,the diagnostic lamp turns off. If a diagnostic code isactive, the diagnostic lamp will flash.


Results:

• Yes – The diagnostic lamp turns on for fiveseconds. Then, the diagnostic lamp turns off. Thediagnostic lamp appears to be operating correctlyat this time. STOP.

• No – The diagnostic lamp did not turn on for fiveseconds. Check the bulb. Replace the bulb if thebulb is not OK. If the bulb is OK, proceed to TestStep 2.




Left side view(1) P61 customer connector(2) J1/P1 ECM connectors

B. Thoroughly inspect connectors (1) and (2). Inspectthe connections on the diagnostic lamp. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

g01215717Illustration 55P1 terminals that are associated with the diagnostic lamp(P1-28) Diagnostic lamp(P1-65) −Battery



J61 and P61 terminals that are associated with the diagnostic lamp(24) Diagnostic lamp

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the diagnostic lamp.



F. Check the harness and wiring for abrasions andfor pinch points from the diagnostic lamp to theECM.

Expected Result:

All of the connectors, pins, and sockets arecompletely coupled and/or inserted, and the harnessand wiring are free of corrosion, of abrasion or ofpinch points.

Results:

• OK – The connectors and the wiring are OK.Proceed to Test Step 3.

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

Repair: Repair the connector and/or the wiring.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled. Verify that theproblem is resolved.

STOP.

Test Step 3. Test the Diagnostic LampCircuit at the ECM Connector


B. Connect a jumper wire between terminal P1-28and engine ground.

C. Turn the keyswitch to the ON position and observethe diagnostic lamp.

D. Remove the jumper wire and observe thediagnostic lamp.

Expected Result:

The diagnostic lamp turned on while the jumper wirewas connected. The diagnostic lamp turned off whenthe jumper wire was removed.

Results:

• OK – The diagnostic lamp turned on while thejumper wire was connected. The diagnostic lampturned off when the jumper wire was removed.The circuit for the diagnostic lamp is functioningproperly. Proceed to Test Step 6.

• Not OK – The diagnostic lamp did not turn on.There is a problem with the circuit for the diagnosticlamp. Proceed to Test Step 4.

Test Step 4. Test the Diagnostic LampCircuit at the Diagnostic Lamp

A. Disconnect wire F404-RD from the diagnosticlamp.

B. Connect a jumper wire between the diagnosticlamp’s open terminal and engine ground.

C. Turn the keyswitch to the ON position and observethe diagnostic lamp.

D. Remove the jumper wire and observe thediagnostic lamp.


Expected Result:

The diagnostic lamp turned on while the jumper wirewas connected. The diagnostic lamp turned off whenthe jumper wire was removed.

Results:

• OK – The diagnostic lamp turned on while thejumper wire was connected. The diagnostic lampturned off when the jumper wire was removed.The +Battery side of the circuit for the diagnosticlamp is functioning properly. There is a problemwith the return wire between the diagnostic lampand the P1 connector.

Repair: Repair wire F404-RD between thediagnostic lamp and P1-28. Verify that the problemis resolved.

STOP.

• Not OK – The diagnostic lamp did not turn onwhen the jumper wire was connected. There is aproblem with the +Battery side of the circuit for thediagnostic lamp. Proceed to Test Step 5.

Test Step 5. Check the Voltage from theKeyswitch to the Diagnostic Lamp


B. Remove the wire from the terminal R of thekeyswitch.


D. Measure the voltage on terminal B of thekeyswitch to engine ground.

E. Measure the voltage on terminal R of thekeyswitch to engine ground.


Expected Result:

Voltage is present on terminal B and terminal R atthe keyswitch.

Results:


Repair: If voltage is present on terminal R, repairthe wire between the keyswitch and the diagnosticlamp. Verify that the breaker is not tripped. Returnall wiring to the original configuration. Verify thatthe problem is resolved.

STOP.


Repair: If voltage is not present on terminal B,repair the wire between the +Battery and thekeyswitch. Check the battery’s no-load voltage.Return all wiring to the original configuration. Verifythat the problem is resolved.

STOP.


Repair: If voltage is present on terminal B of thekeyswitch but not present on terminal R, replacethe keyswitch. Return all wiring to the originalconfiguration. Verify that the problem is resolved.

STOP.

Test Step 6. Check the Operation of theECM

A. Remove terminal P1-28.

B. Fabricate a jumper wire 100 mm (4 inch) long.Crimp a Deutsch pin to both ends of the wire.

C. Insert the jumper into P1-28.

D. Connect the J1/P1 connectors.

E. Connect one probe of a voltage test lamp to thejumper wire in P1-28.

F. Connect the other probe of the voltage test lampto +Battery.

G. Turn the keyswitch to the ON position. Wait forten seconds.


Expected Result:

The test lamp turned ON for five seconds. Then, thetest lamp turned OFF.

Results:

• OK – The test lamp turned ON for five seconds.Then, the test lamp turned OFF. The ECM isoperating correctly. The problem appears to beresolved.

Repair: The problem may be intermittent. If theproblem is intermittent, refer to the diagnosticfunctional test Troubleshooting, “ElectricalConnectors - Inspect”.

STOP.


• Not OK – The test lamp did not turn on for fiveseconds. There is a problem with the ECM.

Repair: Temporarily connect a test ECM. Referto Troubleshooting, “Replacing the ECM”. Checkthe operation of the diagnostic lamp when the testECM is installed.

If the problem is resolved with the test ECM,connect the suspect ECM. If the problem returnswith the suspect ECM, replace the ECM. Verify thatthe problem is resolved.

STOP.

i02433728

Digital Sensor Supply Circuit- TestSMCS Code: 5574-038


The Electronic Control Module (ECM) supplies aregulated voltage of 8.0 ± 0.4 VDC to terminal Aof the engine coolant level sensor. This sensor isoptional equipment.


• 041-03 8 Volt DC Supply short to +batt

• 041-04 8 Volt DC Supply short to ground

A +8 V diagnostic code is probably caused by ashort circuit to ground or a short circuit to anothervoltage source in the harness. The next likely causeis a problem with a sensor. The least likely cause isa problem with the ECM.


Schematic for the digital sensor supply






B. Thoroughly inspect connectors (1) and (2). Inspectthe connectors for each digital sensor. Refer toTroubleshooting, “Electrical Connectors - Inspect”for details.

g01215738Illustration 59P1 ECM connector(P1-4) +8 VDC (digital sensor supply)(P1-5) Return



J61 and P61 customer connectors(8) +8 VDC (digital sensor supply)(9) Return

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the digital sensorsupply.


E. Check the harness and wiring for abrasions andfor pinch points from the battery to the ECM.

Expected Result:


Results:




STOP.




C. Observe the active diagnostic code screen on CatET. Wait at least 15 seconds so that any codesmay become active. Look for these codes:

• 041-03 8 Volt DC Supply short to +batt

• 041-04 8 Volt DC Supply short to ground

Expected Result:

One of the above diagnostic codes is active.

Results:






STOP.



B. Disconnect the harness connectors for the enginecoolant level sensor J800/P800.



D. Measure the voltage between terminals A and Bat the harness connector for the sensor.

Expected Result:


Results:

• OK – The voltage measurement is 8.0 ± 0.4 VDC.

Repair: Connect the sensor connectors. Clearall diagnostic codes. Check for active diagnosticcodes. If the problem is intermittent, refer toTroubleshooting, “Electrical Connectors - Inspect”.

STOP.

• Not OK – The voltage measurement is not 8.0 ±0.4 VDC. There is a problem with the wiring or withthe ECM. Proceed to Test Step 5.

Test Step 4. Disconnect the +8 V DigitalSensor and Check for Active DiagnosticCodes

A. Disconnect the Engine coolant level sensor.

B. Wait for 15 seconds after you disconnect eachsensor. Look for the active 041-04 diagnostic codeto deactivate.

Expected Result:

The 041-04 diagnostic code deactivates when aparticular sensor is disconnected.

Results:

• OK – The 041-04 diagnostic code deactivateswhen a particular sensor is disconnected.

Repair: Connect the suspect sensor. If thediagnostic code returns, replace the sensor.

Connect all of the connectors. Verify that theproblem is resolved.

STOP.

• Not OK – The 041-04 diagnostic code remainsafter all of the sensors are disconnected. Leavethe sensors disconnected. Proceed to Test Step 5.

Test Step 5. Check the +8 V Supply Wirefor a Short Circuit


B. Disconnect the J1/P1 and J2/P2 connectors.

C. Verify that all of the digital sensors aredisconnected.

Note: Wiggle the harness during the followingmeasurements in order to reveal an intermittentcondition.

D. Measure the resistance between P1-4 (+8 Vsupply) and the remaining terminals on the P1and P2 connectors.

E. Measure the resistance between P1-4 (+8 VDCsupply) and the engine ground.

Expected Result:


Results:


• Not OK – At least one check of the resistancedoes not indicate an open circuit. A +8 V supplywire has a problem. There may be a problem witha connector.


STOP.

Test Step 6. Check the +8 V Supply andthe Sensor Common for an Open Circuit

A. Install a jumper wire between terminals P1-4 (+8V supply) and P1-5 (Return).

Note: Wiggle the harness during the followingmeasurement in order to reveal any intermittent shortcondition.

B. Measure the resistance between terminals A andB at the harness connector for each digital sensor.

C. Remove the jumper wire.

Expected Result:

Each resistance measurement is less than ten Ohms.

Results:

• OK – Each resistance measurement is less thanten Ohms. Proceed to Test Step 7.

• Not OK – At least one resistance measurementis more than ten Ohms. A +8 V supply wire or areturn wire has excessive resistance. There maybe a problem with a connector.


Repair: Repair the wires and/or the connector,when possible. Replace parts, if necessary. Verifythat the problem is resolved.

STOP.

Test Step 7. Check the +8 V Supply at theECM

A. Remove terminal 4 from the P1 connector. Installa jumper wire with socket terminals on both endsinto P1-4.

B. Remove terminal 5 from the P1 connector. Installa jumper wire with socket terminals on both endsinto P1-5.

C. Connect the P1 connector.


E. Measure the voltage between the jumper wiresin P1-4 and P1-5.


G. Restore all wiring to the original configuration.

Expected Result:


Results:

• OK – The voltage measurement is 8.0 ± 0.4 VDC.

Repair: Clear all diagnostic codes. Check for activediagnostic codes. If the problem is intermittent,refer to Troubleshooting, “Electrical Connectors- Inspect”.

STOP.

• Not OK – The voltage measurement is not 8.0 ±0.4 VDC.


STOP.

i02378207

Electrical Connectors - InspectSMCS Code: 7553-040-WW


Most electrical problems are caused by poorconnections. The following procedure will assist indetecting problems with connectors and with wiring.If a problem is found correct the condition and verifythat the problem is resolved.

Intermittent electrical problems are sometimesresolved by disconnecting and reconnectingconnectors. It is very important to check for diagnosticcodes immediately before disconnecting a connector.Also check for diagnostic codes after reconnectingthe connector. If the status of a diagnostic code ischanged due to disconnecting and reconnecting aconnector, there are several possible reasons. Thelikely reasons are loose terminals, improperly crimpedterminals, moisture, corrosion, and inadequatemating of a connection.

Follow these guidelines:

• Always use a 1U-5804 Crimp Tool to serviceDeutsch HD and DT connectors. Never solder theterminals onto the wires. Refer to “SEHS9615,Servicing Deutsch HD and DT Style Connectors”.

• Always use a 147-6456 Wedge Removal Tool toremove wedges from DT connectors. Never use ascrewdriver to pry a wedge from a connector.

• Always use a breakout harness for a voltmeterprobe or a test light. Never break the insulationof a wire in order to access to a circuit formeasurements.

• If a wire is cut, always install a new terminal forthe repair.

The connection of any electrical equipment andthe disconnection of any electrical equipmentmaycause an explosion hazard which may result in in-jury or death. Do not connect any electrical equip-ment or disconnect any electrical equipment in anexplosive atmosphere.


Test Step 1. Check Connectors forMoisture and Corrosion

g01131211Illustration 61Leaky seal at the connector (typical example)

A. Inspect all wiring harnesses. Ensure that therouting of the wiring harness allows the wires toenter the face of each connector at a perpendicularangle. Otherwise, the wire will deform the sealbore. Refer to Illustration 61. This will create apath for the entrance of moisture. Verify that theseals for the wires are sealing correctly.


Diagram for the installation of a connector plug (typical example)(1) Electronic Control Module (ECM) connector(2) Correctly inserted plug(3) Incorrectly inserted plug

B. Ensure that the sealing plugs are in place. If anyof the plugs are missing, replace the plug. Ensurethat the plugs are inserted correctly into theconnector. Refer to Illustration 62.

g01131019Illustration 63Seal for a three-pin connector (typical example)


Seal for ECM connector (typical example)

C. Disconnect the suspect connector and inspect theconnector seal. Ensure that the seals are in goodcondition. If necessary, replace the connector.

D. Thoroughly inspect the connectors for evidenceof moisture entry.

Note: It is normal to see some minor seal abrasionon connector seals. Minor seal abrasion will not allowthe entry of moisture.


If moisture or corrosion is evident in the connector,the source of the moisture entry must be found andthe source of the moisture entry must be repaired.If the source of the moisture entry is not repaired,the problem will recur. Simply drying the connectorwill not fix the problem. Check the following itemsfor the possible moisture entry path:

• Missing seals

• Improperly installed seals

• Nicks in exposed insulation

• Improperly mated connectors

Moisture can also travel to a connector throughthe inside of a wire. If moisture is found in aconnector, thoroughly check the connector’sharness for damage. Also check other connectorsthat share the harness for moisture.

Note: The ECM is a sealed unit. If moisture is foundin an ECM connector, the ECM is not the source ofthe moisture. Do not replace the ECM.

Expected Result:

The harness wiring, connectors, and seals are ingood condition. There is no evidence of moisture inthe connectors.

Results:

• OK – The harness wiring, connectors, and sealsare in good condition. Proceed to Test Step 2.

• Not OK – A problem has been found with theharness or the connectors.

Repair: Repair the connectors or the wiring, asrequired. Ensure that all of the seals are properlyin place. Ensure that the connectors have beenreattached.

If corrosion is evident on the pins, sockets or theconnector, use only denatured alcohol to removethe corrosion. Use a cotton swab or a soft brushto remove the corrosion.

If moisture was found in the connectors, run theengine for several minutes and check again formoisture. If moisture reappears, the moisture iswicking into the connector. Even if the moistureentry path is repaired, it may be necessary toreplace the wires.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check the Wires for Damageto the Insulation

A. Carefully inspect each wire for signs of abrasion,of nicks, and of cuts.

Inspect the wires for the following conditions:

• Exposed insulation

• Rubbing of a wire against the engine

• Rubbing of a wire against a sharp point

B. Check all of the wiring harness fasteners in orderto verify that the harness is properly secured. Alsocheck all of the fasteners in order to verify that theharness is not compressed. Pull back the harnesssleeves in order to check for a flattened portionof wire. A fastener that has been overtightenedflattens the harness. This damages the wires thatare inside the harness.

Expected Result:

The wires are free of abrasion, of nicks, and of cutsand the harness is properly clamped.

Results:

• OK – The harness is OK. Proceed to Test Step 3.

• Not OK – There is damage to the harness.

Repair: Repair the wires or replace the wires,as required. Verify that the repair eliminates theproblem.

STOP.

Test Step 3. Inspect the ConnectorTerminals

A. Visually inspect each terminal in the connector.Verify that the terminals are not damaged.Verify that the terminals are properly aligned inthe connector and verify that the terminals areproperly located in the connector.

Expected Result:

The terminals are properly aligned and the terminalsappear undamaged.

Results:

• OK – The terminals are OK. Proceed to Test Step4.

• Not OK – The terminals of the connector aredamaged.


Repair: Repair the terminals and/or replace theterminals, as required.


STOP.

Test Step 4. Perform a Pull Test on EachWire Terminal Connection


Receptacle lock wedge (typical example)

A. Ensure that the locking wedge for the connectoris installed properly. Terminals cannot be retainedinside the connector if the locking wedge is notinstalled properly.

B. Perform the 45 N (10 lb) pull test on each wire.Each terminal and each connector should easilywithstand 45 N (10 lb) of tension and each wireshould remain in the connector body. This testchecks whether the wire was properly crimpedin the terminal and whether the terminal wasproperly inserted into the connector.

Expected Result:

Each terminal and each connector easily withstands45 N (10 lb) of pull and each wire remains in theconnector body.

Results:

• OK – All terminals pass the pull test. Proceed toTest Step 5.

• Not OK – A wire has been pulled from a terminalor a terminal has been pulled from the connector.

Repair: Use the 1U-5804 Crimp Tool to replacethe terminal. Replace damaged connectors, asrequired. Verify that the repair eliminates theproblem.

STOP.

Test Step 5. Check Individual PinRetention into the Socket

g01131604Illustration 66Diagram for testing pin retention (typical example)

A. Verify that the sockets provide good retention forthe pins. Insert a new pin into each socket oneat a time in order to check for a good grip on thepin by the socket.

Expected Result:

The sockets provide good retention for the new pin.

Results:

• OK – The terminals are OK. Proceed to Test Step6.

• Not OK – Terminals are damaged.

Repair: Use the 1U-5804 Crimp Tool to replacethe damaged terminals. Verify that the repaireliminates the problem.

STOP.

Test Step 6. Check the LockingMechanism of the Connectors

A. Ensure that the connectors lock properly. Afterlocking the connectors, ensure that the two halvescannot be pulled apart.

B. Verify that the latch tab of the connector isproperly latched. Also verify that the latch tab ofthe connector returns to the locked position.

Expected Result:

The connector will securely lock. The connector andthe locking mechanism are without cracks or breaks.

Results:

• OK – The connectors are in good repair. Proceedto Test Step 7.


• Not OK – The connector’s locking mechanism isdamaged or missing.

Repair: Repair the connector or replace theconnector, as required. Verify that the repaireliminates the problem.

STOP.

Test Step 7. Check the Allen Head Screwson the Connectors

Visually inspect the allen head screws for the ECMconnectors. Ensure that the threads on each allenhead screw are not damaged.

A. Connect the ECM connectors.

g01132827Illustration 67Allen head screw for the 120 pin ECM connector (typical example)

a. Torque the allen head bolt for the 120 pin ECMconnector to 7.0 ± 0.5 N·m (60 ± 4 lb in).


Allen head screw for the 70 pin ECM connector (typical example)

b. Torque the allen head screw for the 70pin ECM connector to 6.0 + 1.5 - 0.5 N·m(55 + 13 - 4 lb in).

g01132863Illustration 69Allen head screw for the 40 pin ECM connector (typical example)

c. Torque the allen head screw for the 40 pin ECMconnector to 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01133047Illustration 70Allen head screw for the 40 pin customer connector and the 70 pincustomer connector (typical example)

B. Connect the customer connector.

Torque the allen head screw for the 40 pincustomer connector and the 70 pin customerconnector to 2.25 ± 0.25 N·m (20 ± 2 lb in).

Expected Result:

The ECM connector is secure and the allen headscrews are properly torqued.

Results:

• OK – The ECM connectors and the customerconnector is properly connected. Proceed to TestStep 8.

• Not OK – The allen head screws for the ECMconnector or the customer connector is damaged.


Repair: Repair the connector or replace theconnector, as required. Verify that the repaireliminates the problem.

STOP.

Test Step 8. Perform the “Wiggle Test” onthe Caterpillar Electronic Technician (ET)

A. Select the “Wiggle Test” from the diagnostic testson Cat ET.

B. Choose the appropriate group of parameters tomonitor.

C. Press the “Start” button. Wiggle the wiring harnessin order to reproduce intermittent problems.

If an intermittent problem exists, the status will behighlighted and an audible beep will be heard.

Expected Result:

No intermittent problems were indicated during the“Wiggle Test”.

Results:

• OK – No intermittent problems were found. Theharness and connectors appear to be OK. If youwere sent from another procedure, return to theprocedure and continue testing. If this test hasresolved the problem, return the engine to service.STOP.

• Not OK – At least one intermittent problem wasindicated.

Repair: Repair the harness or the connector. Verifythat the repair eliminates the problem.

STOP.

i02289857

Electrical Power Supply Circuit- TestSMCS Code: 1401-038


Use this procedure to troubleshoot any suspectproblems with the electrical power supply.


• 168-00 System Voltage High

• 168-01 System Voltage Low

• 168-02 System Voltage intermittent/erratic

This procedure tests whether proper voltage is beingsupplied to the Electronic Control Module (ECM).

Unswitched battery voltage is supplied through thecustomer connector to the ECM at P1-48, P1-52, andP1-53. The negative battery is supplied to the ECMat P1-61, P1-63, and P1-65. The ECM receives theinput from the keyswitch at P1-70 when the keyswitchis in the ON position or the START position. Whenthe ECM detects battery voltage at this input, theECM will power up. When battery voltage is removedfrom this input, the ECM will power down.

The cause of an intermittent power supply to the ECMcan occur on either the positive side or the negativeside of the battery circuit. Both sides are routed fromthe ECM to the battery. The three connections forthe unswitched +Battery should be routed through adedicated protective device (circuit breaker).

The engine ECM requires the keyswitch to be in theON position in order to maintain communications withthe electronic service tool.



Schematic diagram for the electrical power supply




g01120079Illustration 72Left side view(1) P61 customer connector(2) J1/P1 ECM connectors

B. Thoroughly inspect connectors (1) and (2).Inspect the connections for the battery andthe connections to the keyswitch. Refer toTroubleshooting, “Electrical Connectors - Inspect”for details.

g01104383Illustration 73P1 terminals that are associated with the electrical power supply(P1-44) Shutdown(P1-48) +Battery(P1-52) +Battery(P1-53) +Battery(P1-61) −Battery(P1-63) −Battery(P1-65) −Battery(P1-70) Keyswitch



J61 and P61 terminals that are associated with the electricalpower supply(1) +Battery(2) -Battery(3) -Battery(9) -Battery(26) Keyswitch(27) Shutdown(31) +Battery(32) +Battery

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the electrical powersupply.


E. Check the harness and wiring for abrasions andfor pinch points from the battery to the ECM. Also,check the harness and wiring for abrasions andfor pinch points from the keyswitch to the ECM.

Expected Result:


Results:

• OK – The connectors and wiring are okay. Proceedto Test Step 2.

• Not OK – There is a problem with the connectorsor wiring.

Repair: Repair the connectors or wiring and/orreplace the connectors or wiring. Ensure that all ofthe seals are properly in place and ensure that theconnectors are completely coupled.

STOP.

Test Step 2. Check the Battery Voltage atthe ECM



C. Measure the voltage between P1-52 (UnswitchedPositive Battery) and P1-63 (Negative Battery).

D. Measure the voltage between P1-48 (UnswitchedPositive Battery) and P1-61 (Negative Battery).

E. Measure the voltage between P1-53 (UnswitchedPositive Battery) and P1-65 (Negative Battery).

F. Measure the voltage between P1-70 (Keyswitch)and P1-63 (Negative Battery).

Expected Result:

The measured voltage is between 11.0 VDC and 13.5VDC for a 12 volt system and between 22.0 VDC and27.0 VDC for a 24 volt system with no suspectedintermittent problems at this time.

Results:

• OK – The ECM is receiving the correct voltage.

Repair: If an intermittent condition is suspected,refer to Troubleshooting, “Electrical Connectors- Inspect”.

STOP.

• Battery voltage is out of range – Proceed to TestStep 3.

• Keyswitch voltage out of range

Repair: Trace the wiring for the keyswitch from theECM through the keyswitch circuit to the batteries.Find the problem and repair the problem. Checkthe circuit protection for the circuit and for thewiring.


Verify that the repairs eliminate the problem.

STOP.

Test Step 3. Check the Batteries

A. Measure the no-load battery voltage at the batteryposts.

B. Load test the batteries. Use the 4C-4911Battery Load Tester. Refer to Special Instruction,SEHS9249, “Use of 4C-4911 Battery Load Testerfor 6, 8 and 12 Volt Lead Acid Batteries” andSpecial Instruction, SEHS7633, “Battery TestProcedure”.

Expected Result:

The batteries pass the load test. The measuredvoltage is the minimum specification for a 12V or 24Vsystem.

Results:

• OK – The batteries are OK.

Repair: Check the wiring between the batteriesand the ECM for shorts.

Check the connectors between the batteries andthe ECM for moisture and/or corrosion.

Repair the wiring and/or the connectors.


STOP.

• Not OK – The battery voltage is low or the batterydid not pass the load test.

Repair: Recharge or replace the faulty batteries.Verify that the repair eliminates the problem.

STOP.

i02433741

Engine Pressure Sensor Openor Short Circuit - TestSMCS Code: 5574-038-PX


Use this procedure to troubleshoot any suspectproblems with the following sensors:

• Injection actuation pressure sensor





• Auxiliary pressure sensor (if equipped)


• 094-03 Fuel Pressure open/short to +batt

• 094-04 Fuel Pressure short to ground

• 100-03 Engine Oil Pressure open/short to +batt

• 100-04 Engine Oil Pressure short to ground

• 102-03 Boost Pressure Sensor short to +batt

• 102-04 Boost Pressure Sensor short to ground

• 274-03 Atmospheric Pressure open/short to +batt

• 274-04 Atmospheric Pressure short to ground

The troubleshooting procedures for the diagnosticcodes of each pressure sensor are identical. TheEngine Control Module (ECM) sends a 5 volt supplyto terminal A of each sensor. The sensor commonconnection is connected to terminal B of each sensor.The signal voltage from terminal C of each sensor issent to the appropriate ECM connector.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage onthe circuit for the sensor signal wire. The ECM usesthis pull-up voltage in order to detect an open in thesignal circuit. When the ECM detects the presence ofa voltage that is above a threshold on the signal wire,the ECM will generate a -03 diagnostic code.

If the sensor is disconnected at the sensor connector,the presence of pull-up voltage at the sensorconnector indicates that the signal wire and the returnwire from the sensor connector to the ECM are good.

If the sensor is disconnected at the sensor connector,the absence of pull-up voltage at the sensorconnector indicates an open in the signal wire, anopen in the return wire, or a short to ground.

If the sensor is disconnected at the sensor connectorand the voltage on the signal wire at the sensorconnector is different from pull-up voltage, the signalwire is shorted to another wire in the harness.



Schematic for the engine pressure sensors

Test Step 1. Inspect the ElectricalConnectors and Wiring



g01121143Illustration 76Left side view(1) Boost pressure sensor(2) Atmospheric pressure sensor(3) J2/P2 connectors(4) J1/P1 connectors(5) Engine oil pressure sensor



B. Thoroughly inspect connectors (3) and (4).Thoroughly inspect the connectors for eachengine pressure sensor. Refer to Troubleshooting,“Electrical Connectors - Inspect”.


P2 terminals that are associated with the engine pressure sensors(P2-15) Boost pressure(P2-17) Return(P2-28) Engine oil pressure(P2-40) Fuel pressure(P2-54) Return(P2-57) Atmospheric pressure(P2-72) +5 VDC(P2-80) +5 VDC(P2-85) Injection actuation pressure


g01123384Illustration 79P1 terminals that are associated with the engine pressure sensors(P1-2) +5 VDC(P1-3) Return(P1-15) Auxiliary pressure


Connectors for the sensors(A) Supply(B) Return(C) Signal


J61 and P61 terminals that are associated with the enginepressure sensors(14) +5 VDC(15) Return(33) Auxiliary pressure


C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the engine pressuresensors.

D. Check the allen head screw on each ECMconnector for the proper torque. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

E. Check the harness and wiring for abrasions andfor pinch points from each sensor back to theECM.

Expected Result:

All connectors, pins, and sockets are completelycoupled and/or inserted. The harness and wiring arefree of corrosion, of abrasion, and of pinch points.

Results:

• OK – The harness and wiring are OK. Proceedto Test Step 2.

• Not OK – There is a problem in the wiring and/orthe connectors.

Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled.


STOP.



B. Disconnect the harness connectors for thefollowing sensors:








D. Measure the voltage between terminals A (+5VDC) and B (Return) at each sensor connectoron the engine harness.

E. Turn the keyswitch to the OFF position.

F. Connect all of the sensors.

Expected Result:

Each voltage measurement is 5.0 ± 0.2 VDC.

Results:

• OK – Each voltage measurement is 5.0 ± 0.2VDC. Proceed to Test Step 3.

• Not OK – At least one voltage measurement isnot 5.0 ± 0.20 VDC.

Repair: Refer to Troubleshooting, “5 Volt EnginePressure Sensor Supply Circuit - Test”.

STOP.




C. Observe the “Active Diagnostic” screen on Cat ET.Wait at least 15 seconds so that any codes maybecome active. Look for an active diagnostic codefor an engine pressure sensor.

D. Determine if the problem is related to a -03diagnostic code or a -04 diagnostic code.

Expected Result:


Results:

• OK – No diagnostic codes are active for the enginepressure sensors.



STOP.

• Active -04 code – An 04 diagnostic code is active.Proceed to Test Step 4.


• Active -03 code – An 03 diagnostic code is active.Proceed to Test Step 5.

Test Step 4. Disconnect the SuspectSensor in Order to Create an Open Circuit


B. Disconnect the sensor connector of the sensorwith the -04 diagnostic code.

C. Turn the keyswitch to the ON position. Wait atleast 15 seconds for activation of the diagnosticcodes.

D. Access the “Active Diagnostic Code” screen onCat ET. Check for an active 03 diagnostic code forthe disconnected sensor.


Expected Result:

A -03 diagnostic code is now active for thedisconnected sensor.

Results:

• OK – A -04 diagnostic code was active before youdisconnected the sensor. A -03 diagnostic codebecame active after the sensor was disconnected.

Repair: Temporarily connect a new sensor to theharness, but do not install the new sensor in theengine. Verify that there are no active diagnosticcodes for the sensor. If there are no activediagnostic codes for the sensor, permanentlyinstall the new sensor. Clear any logged diagnosticcodes.

STOP.

• Not OK – A -04 diagnostic code was active beforeyou disconnected the sensor. The -04 diagnosticcode remained after the sensor was disconnected.Leave the sensor disconnected. Proceed to TestStep 8.

Test Step 5. Check the Pull-up Voltage atthe Sensor Connector


B. Disconnect the suspect sensor.

C. Measure the voltage between terminals C (signal)and B (sensor return) at the harness connectorfor the sensor.


Expected Result:

The voltage is 11 ± 2 VDC.

Results:

• OK – The voltage is 11 ± 2 VDC. The signal wireto the ECM from the sensor connector is OK.

Repair: The open circuit is in the sensor or thewire between the sensor and the sensor connector.Temporarily connect a new sensor to the engineharness. Do not install the sensor in the engine.Verify that no diagnostic codes are active for thenew sensor before you permanently install thesensor.

STOP.

• Not OK – The voltage is not 11 ± 2 VDC. Proceedto Test Step 6.

Test Step 6. Check the Signal Wire for aShort Circuit


B. Disconnect the J1/P1 and J2/P2 connectors.

C. Disconnect the harness connector for the suspectsensor.

D. Identify the terminal for the signal wire on theECM connector that is appropriate for the suspectsensor. Measure the resistance between theappropriate terminal and the remaining terminalson both ECM connectors.

E. Measure the resistance between the appropriateterminal and the engine ground.

F. Connect J1/P1 and J2/P2 connectors. Connectthe connectors for the suspect sensor.

Expected Result:


Results:


• Not OK – At least one resistance measurementdoes not indicate an open circuit. There is aproblem in the wiring for the sensor. There may bea problem with a connector.

Repair: Repair the wiring and/or the connector.Replace parts, if necessary.



STOP.

Test Step 7. Create a Short at the SuspectSensor Connector


B. Install a jumper wire with Deutsch sockets oneach end between terminals B (sensor return)and C (signal) on the harness connector for thesuspect sensor.


Note: Monitor the “Active Diagnostic Codes” screenon the electronic service tool before installing thejumper wire and after installing the jumper wire.

D. Observe the “Active Diagnostic Codes” screenon Cat ET. Wait at least 15 seconds so thatany codes may become active. Look for a -04diagnostic code.

E. Remove the jumper wire.


Expected Result:

A -04 diagnostic code was active when the jumperwire was installed. A -03 diagnostic code becameactive when the jumper wire was removed.

Results:

• OK – A -04 diagnostic code was active when thejumper wire was installed. A -03 diagnostic codebecame active when the jumper wire was removed.The engine harness and the ECM are OK.

Repair: Temporarily connect a new sensor to theharness, but do not install the new sensor in theengine. Verify that there are no active diagnosticcodes for the sensor. If there are no activediagnostic codes for the new sensor, permanentlyinstall the new sensor. Clear any logged diagnosticcodes.


STOP.

• Not OK – A -04 diagnostic code was active whenthe jumper wire was installed. The -04 coderemained when the jumper wire was removed.Proceed to Test Step 8.



B. Check the operation of the ECM by creating anopen at the ECM:

a. Disconnect the appropriate ECM connector.

b. Remove the signal wire for the suspect sensorfrom the ECM connector.

c. Remove the return wire for the suspect sensorfrom the ECM connector.

Note: Disconnecting the return wire from the ECMwill generate an open circuit diagnostic code forall sensors that are connected to the return wire.Ignore the additional codes. Troubleshoot the originaldiagnostic code and clear the codes when you arefinished.

d. Connect the ECM connector.


D. Monitor the “Active Diagnostic Code” screen onCat ET. Wait at least 15 seconds so that anycodes may become active.

A -03 diagnostic code should be active for thesuspect sensor.


F. Check the operation of the ECM by creating ashort circuit at the ECM:

a. Disconnect the appropriate ECM connector.

b. Install a jumper wire between the two terminalsfor the sensor’s signal wire and the sensor’sreturn wire.

c. Connect the ECM connector.

G. Turn the keyswitch to the ON position.

H. Monitor the “Active Diagnostic Code” screen onCat ET. Wait at least 15 seconds so that anycodes may become active.

A short circuit diagnostic code (04) should beactive when the wire jumper is installed.

I. Turn the keyswitch to the OFF position.

J. Remove the jumper wire. Return the wiring to theoriginal configuration.


Expected Result:

A -03 diagnostic code was active when the signalwire was removed from the ECM connector. A -04diagnostic code became active when the signal wirewas connected to the return wire.

Results:

• OK – The ECM is operating properly. There is aproblem in the wiring between the ECM and thesensor connector.

Repair: If the code is active for more than onesensor, the problem is most likely in the return wirefor the sensor. The problem may be in a connector.Repair the return wire and/or the connector.Replace parts, if necessary.

If the code is only active for one sensor, theproblem is most likely in the signal wire for thesensor. Repair the signal wire and/or the connector.Replace parts, if necessary.


STOP.

• Not OK – One of the following conditions exists:The -03 diagnostic code is not active when thesignal wire is disconnected. The -04 diagnosticcode is not active when the wire jumper is installed.

Repair: Replace the ECM. Refer toTroubleshooting, “Replacing the ECM”.Verify that the problem is resolved.

STOP.

i02428908

Engine Speed/Timing SensorCircuit - TestSMCS Code: 1912-038



• Primary engine speed/timing sensor

• Secondary engine speed/timing sensor


• 190-08 Engine Speed abnormal

• 342-08 Secondary Engine Speed signal abnormal

The engine uses two engine speed/timing sensors.Both sensors detect the reference for engine speedand timing from a unique pattern on the camshaftgear. The Electronic Control Module (ECM) usesthe pattern of the pulses in order to determine theposition of the crankshaft. The ECM measures thetime between the pulses that are created by thesensors as the gears rotate in order to determine rpm.

Under normal operation, the secondary enginespeed/timing sensor is used to determine timingfor starting purposes. The secondary enginespeed/timing sensor is used to determine whenthe piston in the No. 1 cylinder is at the top of thecompression stroke. When the timing has beenestablished, the primary engine speed/timing sensoris then used to determine engine speed.

When the timing has been established, the ECMtriggers each injector in the correct firing order at thecorrect time. The actual timing and duration of eachinjection is based on engine rpm and on load.

If the engine is running and the signal from onesensor is lost, no noticeable change in engineperformance will be noticed. If the engine is runningand the signals from both sensors are lost, fuelinjection will be terminated and the engine will beshut down by the ECM.

The engine will start when only one sensor signal ispresent. The engine will not start if the signals fromboth sensors are lost.

Both sensors are magnetic sensors. The two sensorsare not interchangeable. Do not switch the positionsof the sensors. Replace the sensors as a set. If thesensors are replaced, a timing calibration is notnecessary.

If a replacement of the ECM is required, the ECMparameters and the timing calibration can betransferred from the suspect ECM to the replacementECM. Timing calibration will not be necessary. Thisfeature requires the Caterpillar Electronic Technician(ET) and this feature is only possible if the existingECM can communicate with Cat ET. Use the “CopyConfiguration - ECM Replacement” feature on CatET.

Complete all of the following tasks when youinstall the speed/timing sensors:

• Ensure that an O-ring is installed on each sensor.If an O-ring is damaged or missing, replace theO-ring.

• Lubricate the O-rings with oil.

• Ensure that the sensor assembly is fully seatedinto the engine before tightening the bracket bolt.


• Ensure that each electrical connector is latchedon both sides.

• Ensure that the harness is properly secured, andensure that each tie-wrap is placed in the correctlocation.


Schematic for the engine speed/timing sensors

Test Step 1. Check for Diagnostic Codes



C. Start the engine and run the engine until theengine is at normal operating temperature.

Note: If the engine will not start, monitor the enginerpm on Cat ET while the engine is being cranked. CatET may need to be powered from another batterywhile the engine is being cranked.

D. Look for these codes on Cat ET:

• 190-08

• 342-08

Expected Result:

One or both of the diagnostic codes that are listedabove are logged or active.

Note: If the engine will not start and Cat ET displayed0 rpm during cranking, select “No Engine rpm”.

Results:

• No Engine rpm – Engine rpm is not indicated onCat ET. Proceed to Test Step 2.

• 190-08 or 342-08 code – There is an activediagnostic code or a logged diagnostic code forthe engine speed/timing sensor. Proceed to TestStep 4.

• No codes – Neither code is active or logged.

Repair: Refer to the appropriate symptoms inTroubleshooting, “Troubleshooting Without aDiagnostic Code”.

STOP.

Test Step 2. Check the Installation of theSensor Assembly




Left side view(1) Engine(2) Flanges(3) Bracket

B. Visually inspect the sensor assembly withoutremoving the sensor assembly from the engine.Flanges (2) must be flush against engine (1) inorder to ensure proper operation.

Inspect bracket (3). Verify that the bracket allowsthe flanges to be flush against the engine.

Verify that the bracket is not bent. If the bracket isbent or if an obstruction is preventing the sensorassembly from being installed correctly, the enginewill not start.

Note: The bracket cannot be replaced separately.

C. Remove the sensor assembly from the engine.


Sensor assembly(4) O-ring

D. Ensure that one O-ring (4) is installed on eachsensor. Check the O-rings for damage. Replacethe O-rings, if necessary.

Results:

• OK – The sensor assembly’s components are OK.

Repair: Perform the following procedure in orderto properly install the sensor assembly:

1. Lubricate each O-ring with engine oil.

2. Fully seat the sensor assembly in the engine.

Note: If the sensor assembly will not fully seat intothe engine, replace the sensor assembly.

3. Tighten the bracket bolt.

4. Connect the sensor’s electrical connectors.Verify that the connectors are latched on bothsides.

5. Ensure that the harness is properly secured,and that the tie-wraps are placed in the correctlocation.

Proceed to Test Step 3.

• Not OK – At least one of the sensor assembly’scomponents is not OK.

Repair: Obtain a new sensor assembly. Performthe following procedure in order to properly installthe sensor assembly:


1. Lubricate each O-ring with engine oil.

2. Fully seat the sensor assembly in the engine.

Note: If the sensor assembly will not fully seat intothe engine, replace the sensor assembly.

3. Tighten the bracket bolt.

4. Connect the sensor’s electrical connectors.Verify that the connectors are latched on bothsides.

5. Ensure that the harness is properly secured,and that the tie-wraps are placed in the correctlocation.


STOP.



g01120293Illustration 85Left side view(1) P400 connector for engine timing

calibration(2) J2/P2 connectors

(3) J401/P401 connectors for the primaryengine speed/timing sensor

(4) J402/P402 connectors for the secondaryengine speed/timing sensor

A. Thoroughly inspect connectors (1), (2), (3),and (4). Refer to Troubleshooting, “ElectricalConnectors - Inspect”.


g01099116Illustration 86P2 terminations for the engine speed/timing sensors

(P2-25) Primary engine speed/timing −(P2-26) TDC probe +(P2-35) Primary engine speed/timing +(P2-36) TDC probe −(P2-46) Secondary engine speed/timing +(P2-47) Secondary engine speed/timing −

B. Perform a 45 N (10 lb) pull test on each ofthe wires that are associated with the enginespeed/timing sensors.

C. Check the torque of the allen head screws forthe ECM connectors. Refer to Troubleshooting,“Electrical Connectors - Inspect”.

D. Check the harness and the wiring for abrasionand for pinch points from each sensor back to theECM.

Expected Result:

All of the connectors, pins and sockets are completelycoupled and/or inserted and the harness and wiringare free of corrosion, of abrasion and of pinch points.

Results:

• OK – The harness and connectors appear to beOK. Proceed to Test Step 4.


Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled. Verify that therepair eliminates the problem.

STOP.

Test Step 4. Measure the SensorResistance through the Engine Harness


B. If you are troubleshooting a problem with theprimary engine speed/timing sensor, perform thefollowing procedure:

a. Measure the sensor’s resistance betweenP2-25 (Primary engine speed/timing +) andP2-35 (Primary engine speed/timing -).

b. Check for an intermittent open circuit or for ashort circuit by moving the harness while youtake the resistance measurement. Pull thewires that are directly behind the sensor orshake the wires that are directly behind thesensor.

Resistance ............................ 75 to 230 Ohms

C. If you are troubleshooting a problem with thesecondary engine speed/timing sensor, performthe following procedure:

a. Measure the sensor’s resistance betweenP2-47 (Secondary engine speed/timing +) andP2-46 (Secondary engine speed/timing -).

b. Check for an intermittent open circuit or for ashort circuit by moving the harness while youtake the resistance measurement. Pull thewires that are directly behind the sensor orshake the wires that are directly behind thesensor.

Resistance ........................ 600 to 1800 Ohms


Expected Result:

The resistance measurement is within thespecifications.

Results:

• OK – The resistance measurement is within thespecifications. Neither a short circuit nor an opencircuit is indicated.


1. Temporarily install a new ECM. Refer toTroubleshooting, “Replacing the ECM”.

2. Start the engine. Run the engine until the engineis at normal operating temperature.

3. If the problem is resolved with the test ECM,connect the original ECM and verify that theproblem recurs.

4. If the problem returns with the original ECM,replace the ECM.


STOP.

• Not OK – The readings are not within thespecifications. The sensor resistance is not withinthe acceptable range when the sensor resistanceis measured through the engine harness. Proceedto Test Step 5.

Test Step 5. Measure the Resistance ofthe Sensor

A. Disconnect the harness connector for the suspectsensor.

B. Thoroughly inspect the sensor’s connectors.Refer to Troubleshooting, “Electrical Connectors- Inspect”.

C. Measure the sensor’s resistance betweenterminals A and B.

Expected Result:

For the primary engine speed/timing sensor, theresistance measurement is between 75 and 230Ohms. For the secondary engine speed/timingsensor, the resistance measurement is between 600and 1800 Ohms.

Results:

• OK – The reading is within the specification. Thereis a problem with the wiring between the enginespeed/timing sensor and the ECM. There may bea problem with a connector.

Repair: Repair the wiring and/or the connector.Replace parts, if necessary. Verify that the problemis resolved.

STOP.

• Not OK – The reading is not within thespecification. There is an electrical problem withthe engine speed/timing sensor.

Repair: Perform the following procedure in orderto check and install the new sensor assembly:

1. Before you install the new sensor assembly,measure the resistance of the new sensors.

If the resistance measurements of the newsensors are within the specifications, install thenew sensor assembly in the engine accordingto the following procedure:

a. Loosen the bolt and remove the bolt thatholds the sensor assembly to the engine.

b. Ensure that O-rings are installed on the newsensor assembly. Verify that the O-rings arefree of damage.

c. Seat the sensor assembly and tighten thebolt.

If the sensor will not seat, replace the sensor.

d. Ensure that the harness is secured in theproper location.

2. Verify that the repair eliminates the problem.

STOP.

i02433750

Engine Temperature SensorOpen or Short Circuit - TestSMCS Code: 5574-038-TA



• Coolant temperature sensor

• Intake manifold air temperature sensor

• Auxiliary temperature sensor


• 110-03 Engine Coolant Temperature open/shortto +batt


• 110-04 Engine Coolant Temperature short toground

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

• 172-04 Intake Manifold Air Temp short to ground

• 1836-03 Auxiliary Temperature Sensor open/shortto +batt

• 1836-04 Auxiliary Temperature Sensor short toground

The troubleshooting procedures for the diagnosticcodes of each temperature sensor are identical.The temperature sensors are passive sensors thathave two terminals. The temperature sensors do notrequire supply voltage from the Electronic ControlModule (ECM).

Pull-up Voltage

The ECM continuously outputs a pull-up voltage onthe circuit for the sensor signal wire. The ECM usesthis pull-up voltage in order to detect an open in thesignal circuit. When the ECM detects the presence ofa voltage that is above a threshold on the signal wire,the ECM will generate a -03 diagnostic code.

If the sensor is disconnected at the sensor connector,the presence of pull-up voltage at the sensorconnector indicates that the signal wire and the returnwire from the sensor connector to the ECM are good.

If the sensor is disconnected at the sensor connector,the absence of pull-up voltage at the sensorconnector indicates an open in the signal wire, anopen in the return wire, or a short to ground.

If the sensor is disconnected at the sensor connectorand the voltage on the signal wire at the sensorconnector is different from pull-up voltage, the signalwire is shorted to another wire in the harness.



Schematic for the engine temperature sensors




g01121203Illustration 88Left side view(1) Engine coolant temperature sensor(2) Intake manifold air temperature sensor

(3) J61/P61 Customer connector(4) J2/P2 connectors

(5) J1/P1 connectors

B. Thoroughly inspect connectors (3), (4), and(5). Inspect the sensor connectors. Refer toTroubleshooting, “Electrical Connectors - Inspect”.



P2 terminations for the engine temperature sensors(P2-13) Engine coolant temperature(P2-30) Return(P2-56) Intake manifold air temperature

g01121228Illustration 90J1/P1 terminals that are associated with the engine temperaturesensors(3) Return(16) Auxiliary temperature



J61/P61 terminals that are associated with the engine temperaturesensors(11) Auxiliary temperature(15) Return

g01120369Illustration 92Harness connector for the temperature sensors

(1) Signal(2) Return

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the temperaturesensors.

D. Check the allen head screw on the ECMconnectors for the proper torque. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

E. Check the allen head screw on the customerconnectors for the proper torque of 2.25 ± .25 N·m(20 ± 2 lb in).

F. Check the harness and wiring for abrasions andfor pinch points from each sensor to the ECM.

Expected Result:


Results:


• Not OK – There is a problem in the connectorsand/or wiring.

Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled.


STOP.


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


C. Monitor the active diagnostic code screen on CatET. Check and record any active diagnostic codes.

Note: Wait at least 15 seconds in order for thediagnostic codes to become active.

D. Look for an 03 diagnostic code or an 04 diagnosticcode.

Expected Result:


Results:

• OK – No diagnostic codes are active.

Repair: The problem may have been relatedto a faulty connection in the harness. Carefullyreinspect the connectors and wiring. Refer toTroubleshooting, “Electrical Connectors - Inspect”for additional information.

STOP.

• Not OK – An 04 diagnostic code is active at thistime. Proceed to Test Step 3.

• Not OK – An 03 diagnostic code is active at thistime. Proceed to Test Step 4.


Test Step 3. Disconnect the SuspectSensor in Order to Create an Open Circuit


B. Disconnect the suspect sensor from the engineharness.

C. Turn the keyswitch to the ON position. Wait atleast 15 seconds for activation of the diagnosticcodes.

D. Access the “Active Diagnostic Codes” screen onCat ET and check for an active 03 diagnostic codefor the suspect sensor.


Expected Result:

An 03 diagnostic code is now active for the suspectsensor.

Results:

• OK – An 04 diagnostic code was active beforedisconnecting the sensor. An 03 diagnostic codebecame active after the sensor was disconnected.



STOP.

• Not OK – The 04 diagnostic code is still present.Leave the sensor disconnected. Proceed to TestStep 7.

Test Step 4. Check the Pull-up Voltage atthe Sensor Connector

A. Disconnect the suspect sensor at the sensorconnector.


C. Measure the voltage between terminal 1 (signal)and terminal 2 (return) at the harness connector.


Expected Result:

The voltage is 5.5 ± 0.5 VDC.

Results:

• OK – The voltage is 5.5 ± 0.5 VDC. The correctpull-up voltage is present at the harness connectorfor the suspect sensor.

Repair: The open circuit is in the sensor or thewire between the sensor and the sensor connector.Replace the sensor. Do not install the sensor inthe engine. Verify that no diagnostic codes areactive for the suspect sensor before permanentlyinstalling the sensor.

STOP.

• Not OK – The voltage is not 5.5 ± 0.5 VDC.Proceed to Test Step 5.



B. Disconnect the P1 and P2 connectors.

C. Measure the resistance between the terminalfor the suspect sensor’s signal wire at the ECMconnector and all of the remaining terminals onthe P2 connector.

D. Measure the resistance between the terminalfor the suspect sensor’s signal wire at the ECMconnector and all of the remaining terminals onthe P1 connector.

E. Measure the resistance between the terminalfor the suspect sensor’s signal wire at the ECMconnector and the engine ground.

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

Expected Result:


Results:


• Not OK – At least one check of the resistance doesnot indicate an open circuit. There is a problemwith the wiring. There may be a problem with aconnector.

Repair: Repair the wiring and/or the connectors.Replace parts, if necessary.

Verify that the original problem is resolved.

STOP.


Test Step 6. Create a Short at the SuspectSensor Connector


B. Install a jumper wire between terminals 1 and 2 onthe harness connector for the suspect sensor.


D. Wait at least 15 seconds for activation of the 04diagnostic code.

Note: Monitor the “Active Diagnostic Codes” screenon Cat ET before installing the jumper wire and afterinstalling the jumper wire.

E. Remove the jumper wire. Check for an 04diagnostic code again.


Expected Result:

An 04 diagnostic code is active when the jumper wireis installed. An 03 diagnostic code is active when thejumper wire is removed.

Results:

• OK – The engine harness and the ECM are OK.


STOP.

• Not OK – The 03 diagnostic code remains activewith the jumper in place. Proceed to Test Step 7.



B. Check the operation of the ECM by creating anopen circuit at the ECM:

a. Remove the signal wire for the suspect sensorfrom the appropriate ECM connector.

b. Remove terminal P2-30 (return).

Note: Disconnecting the return wire from the ECMwill generate an 03 diagnostic code for all sensorsthat are connected to the return wire. Troubleshootthe original diagnostic code. Clear the loggeddiagnostic codes when you are finished.

c. Turn the keyswitch to the ON position. Monitorthe “Active Diagnostic Code” screen on CatET. Wait at least 15 seconds for activation ofthe code.

An 03 diagnostic code should be active for thesuspect sensor.

C. Check the operation of the ECM by creating ashort at the ECM:

a. Install a wire jumper between the terminals forthe sensor signal wire and the return wire.

b. Monitor the “Active Diagnostic Code” screen onCat ET. Wait at least 15 seconds for activationof the code.

An 04 diagnostic code should be active whenthe wire jumper is installed.

c. Remove the wire jumper. Return all wiring tothe original configuration.

Expected Result:

An 03 diagnostic code is active when the sensorsignal wire is removed from the ECM connector. An04 diagnostic code is active when the signal wire isconnected to the return wire.

Results:

• OK – The ECM is working properly. The problemis in the wiring between the ECM and the sensorconnector.

Repair: If the code is active for more than onesensor, the problem is most likely in the return wirefor the sensor. Repair the return wire for the sensoror replace the harness.

If the code is only active for one sensor, theproblem is most likely in the signal wire for thesensor. Repair the signal wire for the sensor.

STOP.

• Not OK – One of the following conditions exists:The 03 diagnostic code is not active when thesensor signal wire is disconnected. The 04diagnostic code is not active when the wire jumperis installed.


Repair: Replace the ECM. Refer toTroubleshooting, “Replacing the ECM”.Verify that the original problem is resolved.

STOP.

i02426465

Ether Injection System - TestSMCS Code: 1456-038


Before you test the ether injection system,remove the ether canister from the system.

Use this procedure to troubleshoot any suspectproblems with the ether injection system.


• 2417-05 Ether Injection Control Solenoid currentlow

• 2417-06 Ether Injection Control Solenoid currenthigh

The ether injection system is used to improve coldweather starting of the engine. The Electronic ControlModule (ECM) controls the ether injection systemduring the start cycle. The ether injection system hastwo modes of operation:

Automatic mode – In the automatic mode, if theengine coolant temperature is below 0 °C (32 °F)and the engine speed is zero rpm, the ether injectionsystem is actuated by the ECM. Ether is injectedcontinuously until the engine starts (50 rpm belowlow idle). Ether will continue to be injected for a shortduration after engine starting that is dependent onambient conditions.

Manual mode – In the manual mode, the ECMenergizes the ether solenoid for a single shot of ether.

Manual mode is activated by pressing the etherstarting aid switch. A short burst of ether is injectedwhen the ether starting aid switch is pressed. In themanual mode, the ether injection system can beenabled if all of the following conditions are met:

• The ether starting aid switch is pressed.

• The intake manifold air temperature is less than0 °C (32 °F).

• There are no active diagnostic codes for both theengine coolant temperature sensor and the intakemanifold air temperature sensor.

If a problem is suspected with the ether starting aidswitch, refer to Troubleshooting, “Switch Circuits -Test”.

Test Mode – A test mode is available in CaterpillarElectronic Technician (ET). The test mode allows thetechnician to activate the ether system. The test isfunctional when the engine speed is zero rpm. Theether injection solenoid is activated for a ten secondduration when the test is activated. The test can befound in the “Override Parameters” screen in Cat ET.


g01213005Illustration 93Schematic of the ether injection system



g01167488Illustration 94Engine view (typical example)

(1) J1/P1 ECM connectors

g01146383Illustration 95Engine view (typical example)

(2) P61 customer connector

g01170983Illustration 96Ether starting aid group (typical example)(3) Ether injection solenoid


B. Thoroughly inspect connectors (1) and (2). Also,thoroughly inspect the connectors for solenoid(3). Refer to the diagnostic functional testTroubleshooting, “Electrical Connectors - Inspect”.

g01212950Illustration 97P1 terminals for the ether injection system

(P1-10) Ether injection solenoid(P1-22) Override switch

g01212957Illustration 98P61 terminals for the ether injection system(22) Ether injection solenoid(38) Override switch

g01155187Illustration 99Terminal locations at the harness connector for the ether solenoid(1) Ether injection solenoid(2) Chassis ground

C. Perform a 45 N (10 lb) pull test on each of thewires in the ECM connector that are associatedwith the ether injection system.

D. Check the allen head screw on each ECMconnector for the proper torque. Also check theallen head screw on the customer connectorfor the proper torque. Refer to Troubleshooting,“Electrical Connectors - Inspect” for the correcttorque values.

E. Check the harness and the wiring for abrasion andfor pinch points from the ether injection solenoidto the ECM.

Expected Result:


Results:

• OK – The connectors and wiring appear to be OK.Proceed to Test Step 2.


Repair: Repair the connectors and/or the wiring.Replace parts, if necessary. Verify that the problemis resolved.

STOP.

Test Step 2. Check the Ether Canister forStarting Fluid


B. Remove the ether canister from the ether valve.Determine if the canister contains fluid.

Expected Result:

The ether canister is not empty.


Results:

• OK – The ether canister is not empty. Do not installthe ether canister. Proceed to Test Step 3.

• Not OK – The ether canister is empty.

Repair: Replace the empty ether canister with afull ether canister. Verify that the original problemis resolved.

STOP.


Note: The ether canister must be removed prior toperforming this procedure.


B. Restore electrical power to the engine ECM.

C. Proceed to the “Diagnostic Overrides” screen onCat ET.

D. Activate the ether injection system. The systemwill activate for ten seconds.

E. Monitor the active diagnostic code screen on CatET. Check and record any active diagnostic codes.


F. Look for a 05 diagnostic code or a 06 diagnosticcode.

G. Remove electrical power from the engine ECM.

Expected Result:


Results:

• No active codes – Neither diagnostic code isactive.

Repair: The problem seems to be resolved. Theproblem may have been caused by a poor electricalconnection. Carefully reinspect the connectors andthe wiring. Refer to Troubleshooting, “ElectricalConnectors - Inspect”.

STOP.

• Not OK – A 05 code is active at this time. TheECM is detecting a low current condition in thecircuit. Proceed to Test Step 5.

• Not OK – A 06 code is active at this time. TheECM is detecting excessive current in the circuit.Proceed to Test Step 4.

Test Step 4. Create an Open at theHarness Connector for the EtherInjection Solenoid

A. Disconnect the harness connector for the ethersolenoid.

B. Restore electrical power to the engine ECM.

C. Proceed to the “Diagnostic Overrides” screen onCat ET.

D. Activate the ether injection system. The systemwill activate for ten seconds.

E. Monitor the active diagnostic code screen on CatET. Look for an active 05 code.


F. Remove electrical power from the engine ECM.

Expected Result:

A 05 code is now active.

Results:

• OK – A 06 code was active before the connectorwas disconnected. A 05 code became active afterthe connector was disconnected.

Repair: The circuit for the ether solenoid is OK.Temporarily connect a new solenoid to the harness,but do not install the new solenoid. After connectingthe new solenoid to the harness, verify that thereare no active codes for the ether injection system.

If there are no active codes for the ether injectionsystem, permanently install the new solenoid.Clear any logged diagnostic codes.

STOP.

• Not OK – A 06 code was active before theconnector was disconnected. The 06 coderemained active after the connector wasdisconnected. There is a problem in the circuitfor the ether injection solenoid. There may be aproblem with the ECM. Leave the connector for thesolenoid disconnected. Proceed to Test Step 6.


Test Step 5. Create a Short at theConnector for the Ether InjectionSolenoid

A. Disconnect the harness connector for the ethersolenoid.

B. Fabricate a jumper wire that is long enough tocreate a short circuit between terminal 1 andterminal 2 at the harness connector for the ethersolenoid. Crimp connector pins to each end of thejumper wire.

C. Install the jumper wire between terminals 1 and 2of the harness connector.

D. Restore electrical power to the engine ECM.

E. Proceed to the “Diagnostic Overrides” screen onCat ET.

F. Activate the ether injection system. The systemwill activate for ten seconds.

G. Monitor the active diagnostic code screen on CatET. Look for an active 06 code.


H. Remove electrical power from the engine ECM.

I. Remove the jumper wire from the harnessconnector.

Expected Result:

A 06 code is now active.

Results:

• OK – A 05 code was active before the jumper wirewas installed. A 06 code became active after thejumper wire was installed.

Repair: The engine harness and the ECM areOK. Temporarily connect a new solenoid to theharness, but do not install the new solenoid. Verifythat there are no active diagnostic codes for thesolenoid. If there are no active diagnostic codesfor the solenoid after the installation of the newsolenoid, permanently install the new solenoid.Clear any logged diagnostic codes.

STOP.

• Not OK – A 05 code was active before the jumperwire was installed. The 05 code remained activeafter the jumper wire was installed. Remove thejumper wire and connect the connector. Proceedto Test Step 6.


A. Disconnect the J1/P1 ECM connectors.

B. Fabricate a jumper wire that is long enough tocreate a test circuit from the ECM connector to theengine ground stud. Crimp a connector socket toone end of the jumper wire.

C. Remove the wire from terminal location J1-10(ether injection solenoid) at the ECM connector.Install the jumper wire into this terminal location.

D. Connect the J1/P1 ECM connectors.

E. Check the operation of the ECM by creatingan open at the ECM:

a. Hold the loose end of the jumper wire awayfrom any ground source in order to create anopen circuit condition.

b. Restore electrical power to the ECM.

c. Proceed to the “Diagnostic Overrides” screenon Cat ET.

d. Activate the ether injection system. The systemwill activate for ten seconds.

e. Monitor the active diagnostic code screen onCat ET. Look for an active 05 code. Recordthe result.


f. Remove electrical power from the ECM.

F. Check the operation of the ECM by creating ashort at the ECM.

a. Short the jumper wire to the engine groundstud.

b. Restore electrical power to the ECM.

c. Proceed to the “Diagnostic Overrides” screenon Cat ET.

d. Activate the ether injection system. The systemwill activate for ten seconds.

e. Monitor the active diagnostic code screen onCat ET. Look for an active 06 code. Recordthe result.


G. Remove electrical power from the engine ECM.


H. Restore the wiring to the original configuration.

Expected Result:

A 05 code is active when the loose end of the jumperwire is open. A 06 code is active when the loose endof the jumper wire is grounded.

Results:

• OK – A 05 code is active when the loose end ofthe jumper wire is open. A 06 code is active whenthe loose end of the jumper wire is grounded.

Repair: The ECM is operating properly. Theproblem is in the circuit for the ether solenoid. Theproblem may be in the harness between the ECMand the ether solenoid’s harness connector or theharness between the ground connection and theether solenoid’s harness connector. Repair theconnectors or wiring and/or replace the connectorsor wiring. Refer to Illustration 93 for details.

STOP.

• Not OK – One of the following conditions exists:A 05 code is not active when the loose end of thejumper wire is open. A 06 code is not active whenthe loose end of the jumper wire is grounded.

Repair: The ECM is not responding correctly.Replace the ECM. Refer to Troubleshooting,“Replacing the ECM”. Verify that the problem isresolved.

STOP.

i02414578

Injection Actuation Pressure -TestSMCS Code: 1714-038


Use the steps that follow to check the operation offuel systems that utilize Hydraulic Electronic UnitInjectors (HEUI). Circle the appropriate answer in theResults section of each step. Complete the pages.Return the pages with any of the requested partsthrough the part return system.


Left side engine view (typical example)(1) J500/P500 Injection Actuation Pressure Control Valve (IAPCV)

connector(2) Injection Actuation Pressure (IAP) sensor(3) J2/P2 Engine Control Module (ECM) connector

Test Step 1. Symptoms

The following symptoms may occur if there is aproblem with the HEUI fuel system:

• The engine cranks but the engine will not start.

• The engine runs rough.

• The engine is erratic or unstable at idle or running.

• Low power

• The following fault codes might be currently activecodes or logged event codes: 164-00, 164-02, and164-11.

Complete the following test steps. Circle theappropriate answers in the Results section of eachtest step and return the pages with the fuel systemcomponent.

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


B. Restore the electrical power to the ECM. DO NOTSTART THE ENGINE.

C. Print the “Lifetime Totals” and the “Configuration”screen.

D. Check for active diagnostic codes.

Expected Result:

There are no active diagnostic codes with theelectrical power restored to the ECM and the engineOFF.

Results:

• OK – There are no active codes. Proceed to TestStep 2.

• Not OK – Active codes are present.

Repair: Refer to diagnostic functional testsTroubleshooting, “Engine Pressure Sensor Openor Short Circuit - Test” if 164-03 or 164-04 is active.

Refer to diagnostic functional testsTroubleshooting, “Injection Actuation PressureSensor - Test” if 164-02 is active.

Contact your Engine Technical Communicator (TC)if 164-00 or 164-11 is active.

STOP.

Test Step 2. Check the Engine Oil Level

A. Check the engine oil level.

B. If the engine oil level is low add oil to the engine.

C. Try to start the engine.

Expected Result:

The engine starts.

Results:

• Yes – The engine starts. Proceed to Test Step 7.

• No – The engine does not start. Proceed to TestStep 3.

Test Step 3. The Engine Cranks but theEngine Will Not Start

Your answer from the previous step indicated that theengine oil level is within specifications. Do not replacethe injection actuation pressure sensor at this time.

A. Crank the engine. Observe the status for “InjectionActuation Pressure” and “Engine Speed” on CatET while the engine is cranking. Record thefollowing data:

________________ Desired injection actuationpressure

________________ Actual injection actuationpressure

________________ Observed engine speed

________________ Engine coolant temperature

________________ Observed “Injection ActuationOutput Percent”

Expected Result:

The desired injection actuation pressure and theactual injection actuation pressure are within 1 MPa(145 psi).

Results:

• OK – The desired injection actuation pressure andthe actual injection actuation pressure are within1 MPa (145 psi).

Repair: The HEUI fuel system is functioningcorrectly. Refer to troubleshooting without adiagnostic code Troubleshooting, “Engine Cranksbut Will Not Start”.

STOP.

• Not OK – The desired injection actuation pressureand the actual injection actuation pressure are notwithin 1 MPa (145 psi). Proceed to Test Step 4.

Test Step 4. Use a Test Lamp to Checkfor the Presence of Current

A. Disconnect the J500/P500 IAPCV connector fromthe unit injector hydraulic pump.

Note: Do not insert any wire that is larger than18 AWG into the P500 harness connector. Do notinsert the probe for the voltage test lamp into theP500 harness connector. These actions will spreadthe sockets of the connector which will damagethe connector. Damaged connectors could causeintermittent connections.

B. Insert a 186-3735 Connector Pin into each of theharness connector sockets at connector P500.

C. Connect a voltage test lamp to the connector pinsthat are inserted in the P500 connector.

D. Crank the engine and watch the test lamp.


Expected Result:

The test lamp illuminates while the engine is cranking.

Results:

• OK – The test lamp illuminates while the engineis cranking. The ECM is operating correctly andthe wiring harness to the pump is probably OK.Proceed to Test Step 5.

• Not OK – The test lamp does not illuminate whilethe engine is cranking.

Repair: Refer to diagnostic functional testsTroubleshooting, “Injection Actuation PressureControl Valve Circuit - Test”.

STOP.

Test Step 5. Check the Oil Pressure at thePump (Deadhead Test)

Escaping fluid under pressure, even a pinhole sizeleak, can penetrate body tissue, causing seriousinjury, and possible death. If fluid is injected intoyour skin, it must be treated immediately by a doc-tor familiar with this type of injury.

Always use a board or cardboard when checkingfor a leak.

A. Disconnect the high pressure oil line from theunit injector hydraulic pump. Install a 8T-0852Pressure Gauge onto the outlet port of the pump.

Note: Ensure that the pump is supplying oil only tothe gauge.

Note: The pressure readings may vary betweengauges.

B. Install a 224-9282 Adapter Cable As at theJ500/P500 connectors. Connect one end of theadapter cable to the IAPCV and connect the otherend to the harness connector.

Note: There must be a continuous electricalconnection between the ECM and the unit injectorhydraulic pump. The improper connection or theincomplete connection of the adapter cable mayprovide incorrect results.

C. Connect a multimeter that is capable of measuringcurrent that is 0 to 1,000 milliamperes in serieswith the adapter cable. Select the lowest currentrange for the multimeter that is greater than oneamp.

Note: If the multimeter is not set to the correct scale,the following measurement may provide misleadingresults.

D. Crank the engine and record the following data:

________________ Observed pressure reading fromthe pressure gauge

________________ Observed engine speed fromCat ET

________________ Observed “Injection ActuationOutput Percent” from Cat ET

________________ Current reading from theammeter

Expected Result:

The oil pressure is above 26.5 MPa (3840 psi) andthe current is above 400 mA.

Results:

• OK – The oil pressure is above 26.5 MPa(3840 psi) and the current is above 400 mA. Returnthe system to the original configuration. Proceedto Test Step 6.

• Not OK, Result 1 – The oil pressure is below26.5 MPa (3840 psi) and the current is above 400mA.

Repair: Replace the unit injector hydraulic pump. Ifthe drive gear on the pump is loose, do not attemptto tighten the drive gear and reuse the pump.Verify that the repair eliminates the problem. Ifthe problem remains after the repair, contact yourEngine Technical Communicator (TC).

After the unit injector hydraulic pump has beenreplaced, the engine may need to be cranked fora significant length of time in order to fill the pumpwith oil. Clear any diagnostic codes or event codesthat activated during the initial start-up. Retest thesystem.

STOP.

• Not OK, Result 2 – The current is below 400 mA.


STOP.


Test Step 6. Check the High Pressure OilSystem for Leaks

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.

A. Remove the valve cover and inspect the highpressure oil system for oil leaks.

B. While the engine is being cranked, look around theinjector bores for any signs of oil leakage. Inspectthe spill ports on the injectors for an excessivedischarge of oil. All six injectors should spill thesame amount of oil.

C. While the engine is being cranked, perform the“Injection Actuation Pressure Test”. Run the test atthe highest step in order to maximize any possibleleaks.

Expected Result:

No leaks are apparent.

Results:

• OK – There are no apparent leaks. Contactyour Engine Technical Communicator (TC) forassistance. STOP.

• Not OK – There are oil leaks.

Repair: Replace the O-ring on the injector orreplace the damaged injector.

STOP.

Test Step 7. Engine Starts

A. Start the engine.

B. Check for the following codes on Cat ET:

• 42-11 Inject Actuation Control Valve open/short

• 164-00 High Injector Actuation Pressure

• 164-02 Injector Actuation Pressure signal erratic

• 164-11 Injector Actuation Pressure system fault

Expected Result:

164-00 or 164-11 is active or logged.

Place a check beside the codes that are active orlogged.

• ________________ 42-11

• ________________ 164-00

• ________________ 164-02

• ________________ 164-11

Results:

• 164-00 or 164-11 is active or logged – 164-00 or164-11 is active or logged. 164-02 or 42-11 mayalso be active or logged. Proceed to Test Step 8.

• 164-02 is active or logged – 164-02 is active orlogged, but 164-00 and 164-11 are not active orlogged.

Repair: Refer to diagnostic functional testsTroubleshooting, “Injection Actuation PressureSensor - Test” for information on troubleshootingthe active 164-02 code.

STOP.

Test Step 8. Evaluate the Quality of theOil

Extended oil drain intervals may cause elevatedlevels of soot in the engine oil. The elevated levelsof soot may also deplete the additive package of theoil. This can affect the operation of the high pressureoil system.

Record the current drain interval.

________________ Machine model

________________ Engine serial number

________________ Drain interval

________________ Hours since last oil change

Expected Result:

The customer has not exceeded the suggested oilchange interval and an oil change does not need tobe performed.

Results:

• OK – The customer has not exceeded thesuggested oil change interval. Proceed to TestStep 9.

• Not OK – The customer has exceeded thesuggested oil change interval.


Repair: Before you proceed, ask the customerto authorize an oil change with a new oil filter.Oil changes are not covered by the warranty.After the engine oil and the oil filter have beenchanged, operate the engine until normal operatingtemperature has been reached. Run the engine upand down through the operating rpm range for 10to 15 minutes. This will purge any trapped air ordebris that is in the system.

If the problem persists, or if the problem recurs in ashort period or time, proceed to Test Step 9.

Test Step 9. Check the System with the“Injection Actuation Pressure Test”



A. Remove the plug from the secondary outlet porton the unit injector hydraulic pump.

B. Install a 8T-0852 Pressure Gauge in thesecondary outlet port.

C. Start the engine.

D. Access the “Injection Actuation Pressure Test” inthe “Diagnostics Menu” of Cat ET and begin thetest.

Note: The “Injection Actuation Pressure Test” canincrease the injection actuation pressure or the“Injection Actuation Pressure Test” can decrease theinjection actuation pressure. The test adjusts the oilpressure in steps.

E. Record the pressure readings from the pressuregauge and from Cat ET.

Table 18

Step Manual Pressuregauge

Cat ET Difference

1

2

3

4

F. Remove the gauge from the unit injector hydraulicpump. Install the plug into the secondary outletport. Tighten the plug to a torque of 34 ± 3 N·m(25 ± 2 lb ft).

Expected Result:

The pressure that was measured with the pressuregauge for each step and the pressure that wasdisplayed on Cat ET for each step are within1379 kPa (200 psi).

Note: Under some situations, the injection actuationpressure may not change. Use this step to comparethe pressure reading from the pressure gauge to thepressure reading that is displayed on Cat ET.

Results:

• OK – The pressures are within 1379 kPa(200 psi). The injection actuation pressure sensoris operating properly. Do not replace the sensor.Proceed to Test Step 10.

• Not OK – The pressures are not within 1379 kPa(200 psi). The injection actuation pressure sensormay be faulty. Replace the sensor and repeatthis test step. If the problem persists, verify theaccuracy of the pressure gauge. Install the originalsensor onto the engine and proceed to Test Step10.

Test Step 10. Use a Test Lamp to Checkfor the Presence of Current

A. Disconnect J500/P500 IAPCV connector from theunit injector hydraulic pump.

Note: Do not insert any wire that is larger than18 AWG into the P500 harness connector. Do notinsert the probe for the voltage test lamp into theP500 harness connector. These actions will spreadthe sockets of the connector which will damagethe connector. Damaged connectors could causeintermittent connections.

B. Insert a 186-3735 Connector Pin into each of theP500 harness connector sockets.

C. Connect a voltage test lamp to the connector pinsthat are inserted in the P500 connector.

D. Crank the engine and watch the test lamp.

Expected Result:

The test lamp illuminates while the engine is cranking.


Results:

• OK – The test lamp illuminates while the engineis cranking. The ECM is operating correctly andthe wiring harness to the pump is probably OK.Proceed to Test Step 11.

• Not OK – The test lamp does not illuminate whilethe engine is cranking.


STOP.

Test Step 11. Perform the “InjectionActuation Pressure Test” at Low Idle andat High Idle

Start the engine. Run the “Injection ActuationPressure Test” at low idle and at high idle.

Note: There should not be any noticeable lag inthe reaction to the injection pressure. The pressurechanges should be instantaneous.

Record the data in the following tables:

Table 19

Low Idle

StepActual injection

actuationpressure from

Cat ET

Desired injectionactuation pressure

from Cat ET

1

2

3

4

Table 20

High Idle

StepActual injection

actuationpressure from

Cat ET

Desired injectionactuation pressure

from Cat ET

1

2

3

4

Expected Result:

The actual injection actuation pressure for each stepand the desired injection actuation pressure for eachstep are within 1379 kPa (200 psi).

Note: Under some situations, the injection actuationpressure may not change. Use this step to comparethe pressure from the pressure gauge to the pressurethat is displayed by Cat ET.

Results:

• OK – The actual injection actuation pressure andthe desired injection actuation pressure are within1379 kPa (200 psi).

Repair: Contact your Engine TechnicalCommunicator (TC) for assistance.

STOP.

• Not OK – The actual injection actuation pressureand the desired injection actuation pressure are notwithin 1379 kPa (200 psi). Proceed to Test Step 12.

Test Step 12. Check the Oil Pressure atthe Pump (Deadhead Test)



A. Disconnect the high pressure oil line from theunit injector hydraulic pump. Install a 8T-0852Pressure Gauge onto the outlet port of the pump.

Note: Ensure that the pump is supplying oil only tothe gauge.


B. Install a 224-9282 Adapter Cable As at theJ500/P500 connectors. Connect one end of theadapter cable to the IAPCV and connect the otherend to the harness connector.

Note: There must be a continuous electricalconnection between the ECM and the unit injectorhydraulic pump. The improper connection or theincomplete connection of the adapter cable mayprovide incorrect results.

C. Connect a multimeter that is capable of measuringcurrent that is 0 to 1,000 milliampere in series withthe adapter cable. Select the lowest current rangefor the multimeter that is greater than one amp.


Note: If the multimeter is not set to the correct scale,the following measurement may provide misleadingresults.

D. Crank the engine and record the following data:

________________ Observed pressure reading fromthe pressure gauge

________________ Observed engine speed fromCat ET


________________ Current reading from theammeter

Expected Result:

The oil pressure is above 26.5 MPa (3843 psi) andthe current is above 400 mA.

Results:

• OK – The oil pressure is above 26.5 MPa(3840 psi) and the current is above 400 mA.Remove the adapter cable from the circuit. Leavethe pressure gauge installed on the pump. Proceedto Test Step 13.

• Not OK - Result 1 – The oil pressure is below26.5 MPa (3840 psi) and the current is above 400mA.

Repair: Replace the unit injector hydraulic pump.If the drive gear on the pump is loose, do notattempt to tighten the drive gear and reuse thepump. Verify that the repair eliminates the problem.If the problem remains after the repair, contactyour Engine Technical Communicator (TC) forassistance.


STOP.

• Not OK - Result 2 – The current is below 400 mA.


STOP.

Test Step 13. Disconnect J500/P500Connector and Check the Oil Pressure

A. Disconnect the J500/P500 connector at the unitinjector hydraulic pump.

B. Crank the engine and record the oil pressure.


________________ Observed pressure reading from thepressure gauge

________________ Observed engine speed from Cat ET


Expected Result:

The oil pressure is below 8 MPa (1160 psi).

Results:

• OK – The pressure reading is below 8 MPa(1160 psi). The unit injector hydraulic pump isworking properly. Proceed to Test Step 14.

• No – The unit injector hydraulic pump is faulty.

Repair: The unit injector hydraulic pump is faulty.Replace the unit injector hydraulic pump. Verify thatthe repair eliminates the problem. If the problemremains after the repair, contact your EngineTechnical Communicator (TC) for assistance.


STOP.

Test Step 14. Check the High PressureOil System for Leaks

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.

A. Remove the valve cover and inspect the highpressure oil system for oil leaks.


B. While the engine is being cranked, look around theinjector bores for any signs of oil leakage. Inspectthe spill ports on the injectors for an excessivedischarge of oil. All six injectors should spill thesame amount of oil.

C. While the engine is being cranked, perform the“Injection Actuation Pressure Test”. Run the test atthe highest step in order to maximize any possibleleaks.

Expected Result:

No leaks are apparent.

Results:

• OK – There are no apparent leaks. Contactyour Engine Technical Communicator (TC) forassistance. STOP.

• Not OK – There are oil leaks.

Repair: Replace the O-ring on the injector orreplace the damaged injector. Verify that the repaireliminates the original problem.

STOP.

i02433756

Injection Actuation PressureControl Valve Circuit - TestSMCS Code: 1714-038


Use this procedure to troubleshoot any suspectproblems with the Injection Actuation PressureControl Valve (IAPCV).


• 42-05 Injector Actuation Valve open circuit

• 42-06 Injector Actuation Valve short to ground

Note: Do not use this procedure to troubleshoot anactive 164-11 Injector Actuation Pressure systemfault, unless you have been directed to this procedurefrom another section of this document.

The IAPCV is internal to the unit injector hydraulicpump. The IAPCV is a precision displacement controlactuator. This actuator changes the pump outlet flowthat is based on the control current that is supplied bythe Electronic Control Module (ECM). The variabledisplacement unit injector hydraulic pump pressurizesonly the amount of high pressure oil that is needed.

The ECM software contains performance maps. Theperformance maps have a desired actuation pressurefor every engine operating condition. The ECM sendsa control current to the IAPCV. This signal creates anactual actuation pressure that matches the desiredactuation pressure. If the actual actuation pressuredoes not match the desired actuation pressure, theECM will increase the control current or the ECM willdecrease the control current to the IAPCV in order toadjust pump outlet flow.

The following problems can cause a 42-05 diagnosticcode:

• An open circuit in the wiring

• An open circuit in the IAPCV

• A short to ground on the return wire

The following problems can cause a 42-06 diagnosticcode:

• The control wire has a short to the +Battery.

• The return wire has a short to the +Battery.

• A short circuit in the IAPCV

• A short to ground on the control wire


g01121315Illustration 101Schematic for the injection actuation pressure control valve



g01121264Illustration 102Left side view(1) Connector for the IAPCV (2) J2/P2 connectors


B. Thoroughly inspect connectors (1) and (2). Referto Troubleshooting, “Electrical Connectors -Inspect”.

g01121316Illustration 103P2 terminations for the IAPCV(P2-10) Control (P2-20) Return

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the IAPCV.

D. Check the allen head screw on the ECM connectorfor the proper torque. Refer to Troubleshooting,“Electrical Connectors - Inspect”.

E. Check the harness and wiring for abrasion and forpinch points from the IAPCV back to the ECM.

Note: Ensure that the seal is installed on the harnessconnector for the injection actuation pressure controlvalve.

Expected Result:


Results:





STOP.





D. Observe the “Active Diagnostic” screen on Cat ET.Wait at least 15 seconds so that any codes maybecome active. Look for these codes:

• 42-05

• 42-06


Expected Result:


Results:

• Active code – One of the above codes is active.Proceed to Test Step 3.




STOP.

Test Step 3. Measure the Resistance ofthe Injection Actuation Pressure ControlValve’s Solenoid


B. Disconnect the J204/P204 connectors.

Note: Ensure that the seal on the P204 connectorremains on the connector when the connector isdisconnected.

C. Measure the resistance between terminals P204-1(Control) and P204-2 (Return) on the IAPCV.Record the value of the resistance measurement.

Expected Result:

The resistance measurement is between 6.5 and10.5 Ohms.

Results:

• OK – The resistance measurement is between6.5 and 10.5 Ohms. Connect the J204/P204connectors. Proceed to Test Step 4.

• Not OK – The resistance measurement is notbetween 6.5 and 10.5 Ohms. The solenoid’sresistance is not within the specification.

Repair: Replace the unit injector hydraulic pump.Verify that the problem is resolved.

STOP.

Test Step 4. Check the Wiring for an OpenCircuit



C. Measure the resistance between terminals P2-10(Control) and P2-20 (Return).

Expected Result:

The resistance measurement is within two Ohms ofthe value that was measured in the previous TestStep.

Results:

• OK – The resistance measurement is within twoOhms of the value that was measured in theprevious Test Step. Proceed to Test Step 5.

• Not OK – The resistance measurement is notwithin two Ohms of the value that was measuredin the previous Test Step. There is a problem withthe wiring harness. There may be a problem with aconnector.


STOP.

Test Step 5. Check the Wiring for a ShortCircuit


Note: Ensure that the seal on the P204 connectorremains on the connector when the connector isdisconnected.

B. Disconnect the P1 connector.

C. Measure the resistance between the points thatare listed in Table 21. Be sure to wiggle the wiresin the harnesses as you make each resistancemeasurement.


Table 21

Resistance Measurements for the Wiring Harness


Terminal


All of the terminals on the P1connector

P2-10 (Control)

Engine ground


All of the terminals on the P1connector

P2-20 (Return)

Engine ground

Expected Result:

All of the resistance measurements indicate an opencircuit.

Results:

• OK – All of the resistance measurements indicatean open circuit. Proceed to Test Step 6.

• Not OK – At least one resistance measurementdoes not indicate an open circuit. There is aproblem with a wiring harness. There may be aproblem with a connector.


STOP.

Test Step 6. Check the ECM by Crankingthe Engine

Note: This Test Step may activate additionaldiagnostic codes. Ignore the codes and monitor thetest lamp. Clear the codes at the end of the Test Step.

A. Verify that the J204/P204 connectors aredisconnected.

Note: Do not insert any wire that is larger than 18AWG into the J204 harness connector. Do not insertthe probe for the voltage test lamp into the harnessconnector. These actions will spread the socketsof the connector which will damage the connector.Damaged connectors could cause intermittentconnections.

B. Insert a Deutsch connector pin into each socketof the J204 harness connector.

C. Connect a voltage test lamp to the connector pinsthat are inserted in the J204 connector. Crank theengine and observe the test lamp.

Expected Result:

The voltage test lamp illuminates when the engineis cranking.

Results:

• OK – The voltage test lamp illuminates whenthe engine is cranking. Remove the connectorpins from the P204 connector. Connect all of theelectrical connectors. Clear any diagnostic codes.Proceed to Test Step 7.

• Not OK – The voltage test lamp does not illuminatewhen the engine is cranking.


STOP.

Test Step 7. Perform the “InjectionActuation Pressure Test”


B. Crank the engine three times at 30 secondsintervals. This will purge the air from the system.

C. Connect the J204/P204 connectors.


E. Run the “Injection Actuation Pressure Test”. The“Injection Actuation Pressure Test” is located inthe “Diagnostics” menu on Cat ET. Step throughall of the pressure ranges.

Note: This is not the “Injection Act Press Driver Test”.

F. After performing the “Injection Actuation PressureTest”, check for the following active diagnosticcodes:

• 42-05

• 42-06

Expected Result:

The test is successful. There are no diagnostic codes.

Results:

• OK – The problem appears to be resolved. Theoriginal problem was probably caused by a poorelectrical connection. STOP.

• Not OK – There is a problem with the IAPCV.


Repair: Replace the unit injector hydraulic pump.Verify that the problem is resolved.

STOP.

i02433789

Injection Actuation PressureSensor - TestSMCS Code: 1925-038


Use this procedure to troubleshoot any suspectproblems with the injection actuation pressure sensor.

This procedure covers the following diagnostic code:

• 164-02 Injector Actuation Pressure signal erratic

Note: This procedure can check the accuracy ofthe injection actuation pressure sensor against apressure gauge.

The injection actuation pressure sensor measuresthe pressure of the oil in the high pressure oilmanifold. The high pressure oil in the manifold isused to actuate the injectors and the high pressureoil is used to control the fuel injection pressure. TheECM uses the reading from the injection actuationpressure sensor in order to control the operation ofthe injection actuation pressure control valve.


Schematic for the injection actuation pressure sensor


A. Connect the Caterpillar Electronic Technician(ET) to the service tool connector. Refer toTroubleshooting, “Electronic Service Tool”.


Note:

C. Observe the “Active Diagnostic” screen on CatET. Wait at least 15 seconds so that any codesmay become active. Look for an active 164-02diagnostic code.


Note: If a 164-03 Injector Actuation Pressure voltagehigh or 164-04 Injector Actuation Pressure voltagelow code is active, refer to Troubleshooting, “EnginePressure Sensor Open or Short Circuit - Test”.

Expected Result:

The 164-02 diagnostic code is active.

Results:

• Active code – The 164-02 diagnostic code isactive. Proceed to Test Step 3.

• No active code – The 164-02 diagnostic code isnot active. Proceed to Test Step 2.

Test Step 2. Try to Start the Engine

Try to start the engine.

Expected Result:

The engine starts.

Results:

• OK – The engine starts. There are no active codesfor the injection actuation pressure sensor and theengine starts.

Repair: There may be an intermittent problem ina harness that is causing the code to be logged.Refer to Troubleshooting, “Electrical Inspectors -Inspect”.

STOP.

• Not OK – The engine does not start.

Repair: Refer to Troubleshooting, “Engine Cranksbut Will Not Start”.

STOP.




g01121360Illustration 105Left side view(1) J500/P500 connectors for the injection

actuation pressure sensor(2) J2/P2 connectors




P2 terminals that are associated with the injection actuationpressure sensor(P2-17) Return(P2-72) +5 VDC(P2-85) Injection Actuation pressure


Connectors for the injection actuation pressure sensor(A) Supply(B) Return(C) Signal

C. Perform a 45 N (10 lb) pull test on each ofthe wires that are associated with the injectionactuation pressure sensor.

D. Check the allen head screw on the ECM connectorfor the proper torque. Refer to Troubleshooting,“Electrical Connectors - Inspect”.

E. Check the harness and wiring for abrasion and forpinch points from the sensor back to the ECM.

Expected Result:


Results:


• Not OK – There is a problem in the wiring and/or aconnector.

Repair: Repair the wiring and/or the connector.Replace parts, if necessary. Ensure that all of theseals are properly in place and ensure that theconnectors are completely coupled.


STOP.


Test Step 4. Check the Status of theSensor


B. Check the value of the “Injection ActuationPressure” on Cat ET.

Note: The following codes will cause the value of the“Injection Actuation Pressure” to default to 17500 kPa(2538 psi).

• 164-03 Injector Actuation Pressure voltage high

• 164-04 Injector Actuation Pressure voltage low

Expected Result:

The value of the “Injection Actuation Pressure” is0 kPa (0 psi).

Results:

• OK – The value of the “Injection ActuationPressure” is 0 kPa (0 psi). Proceed to Test Step 6.

• Not OK – The value of the “Injection ActuationPressure” is above 0 kPa (0 psi). Proceed to TestStep 5.

Test Step 5. Check the Voltage Supply tothe Injection Actuation Pressure Sensor



C. Connect a 3-terminal breakout T to the P500harness connector only.


E. Measure the voltage between terminals A and Bat the breakout T.

Expected Result:

The voltage reading is 5 ± 0.2 VDC.

Results:

• OK – The voltage is within the specified range.Proceed to Test Step 6.

• Not OK – The voltage is not within the specifiedrange.

Repair: Refer to Troubleshooting, “Analog SensorSupply Circuit - Test”.

STOP.

Test Step 6. Compare the Sensor’sOutput to a Pressure Gauge

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.


B. Install a 8T-0852 Pressure Gauge to an oil porton the side of the cylinder head or to the port onthe top of the fuel transfer pump.


D. Go to the “Injection Actuation Pressure Test” onthe diagnostic menu of Cat ET.

E. Start the “Injection Actuation Pressure Test”.

F. Refer to Table 22. Observe the value of the“Injection Actuation Pressure” on Cat ET. Vary theengine speed in order to obtain each “InjectionActuation Pressure” value that is listed in theTable. For each pressure value, observe thereading on the pressure gauge.


Table 22

Comparison of Pressure Readings

“Injection ActuationPressure” Values on

Cat ET

Range of AcceptablePressure Values on the

Pressure Gauge

6000 kPa (870 psi) 4000-7800 kPa (580-1130psi)

10000 kPa (1450 psi) 8000-11800 kPa(1160-1710 psi)

15000 kPa (2175 psi) 13000-16800 kPa(1885-2435 psi)

23000 kPa (3336 psi) 21000-24800 kPa(3045-3595 psi)

Expected Result:

Each value on the pressure gauge is within thespecification.

Results:

• OK – Each value on the pressure gauge is withinthe specification. The injection actuation pressuresensor and the ECM are working properly.

Repair: The problem appears to be resolved. Theoriginal diagnostic code was probably caused byan intermittent problem in an electrical connector.If the code continues to be logged, refer toTroubleshooting, “Electrical Connectors - Inspect”.

STOP.

• Not OK – At least one of the values on thepressure gauge is not within the specification.

Repair: Install a new injection actuation pressuresensor and repeat the test.

If the new sensor corrects the problem, leave thenew sensor in place.

If the new sensor does not correct the problem, thepressure gauge is faulty. Obtain a new pressuregauge and repeat the test.

STOP.

i02429285

Injector Solenoid Circuit - TestSMCS Code: 1290-038


Use this procedure for the following conditions:

• A suspected problem with an injector solenoid

• You have been directed to this procedure fromTroubleshooting, “Troubleshooting without aDiagnostic Code”.

• There is an active diagnostic code for an injectorsolenoid.

Use this procedure for the following diagnostic codes:

• 1-05 Cylinder #1 Injector open circuit

• 1-06 Cylinder #1 Injector short











Perform this procedure under conditions that areidentical to the conditions that exist when the problemoccurs. Typically, problems with the injector solenoidoccur when the engine is warmed up and/or whenthe engine is under vibration (heavy loads).

These engines have Electronic Unit Injectors (EUI)that are hydraulically actuated and electronicallycontrolled. The Engine Control Module (ECM) sendsa high voltage signal to each injector solenoid. Thesignal is sent with the proper injection duration andinjection timing for the current engine load andspeed. The injector solenoid is mounted on top ofthe fuel injector body.

If an open circuit condition is detected in the solenoidcircuit, a diagnostic code is generated. The ECM willcontinue to try to fire the injector. If a short circuitcondition is detected, a diagnostic code is generated.The ECM will disable the solenoid circuit. The ECMwill periodically try to fire the injector. If the shortcircuit condition remains, this sequence of events willbe repeated until the problem is corrected.

Note: Refer to Illustration 108. Two injector solenoidsshare a supply wire. For this reason, an opencircuit or a short circuit in a supply wire could causediagnostic codes for two injector solenoids.


When an injector is replaced, an injector trim filemust be programmed into the ECM. If the ECM isreplaced, all injector trim files must be programmedinto the new ECM. Refer to Troubleshooting, “InjectorTrim File” for more information.

The Caterpillar Electronic Technician (ET) includesthe following tests that aid in troubleshooting theinjector solenoids:

“Cylinder Cutout Test”

The “Cylinder Cutout Test” is used on an enginein order to determine the individual cylinderperformance while the engine is running. As oneor more cylinders are cut out during the test, the“Cylinder Cutout Test” uses “Fuel Position” in orderto evaluate the performance of the cylinders thatare cut out. As the different cylinders are cut out, acomparison of the change in “Fuel Position” is usedto identify cylinders that are weak or misfiring. Onereason for a cylinder that is weak or misfiring is aninjector that is malfunctioning.

The “Cylinder Cutout Test” can be used to isolate amalfunctioning injector in order to avoid replacementof injectors that are in good condition.

During the test, when a cylinder is cut out, anincrease in “Fuel Position” will be noticed for theremaining cylinders. This increase in “Fuel Position”represents an increase in the amount of fuel thatmust be delivered by the remaining cylinders in orderto maintain the desired engine speed.

When a weak cylinder (malfunctioning injector) is cutout, the increase in “Fuel Position” will not be as largeas the increase for a cylinder that has an acceptablelevel of performance.

Note: Prior to running the “Cylinder Cutout Test”, allactive diagnostic codes must be repaired.

“Injector Solenoid Test”

Use the “Injector Solenoid Test” to diagnose an opencircuit or a short circuit in the wiring for the injectorsolenoids. With the engine stopped, the “InjectorSolenoid Test” will briefly activate each injectorsolenoid. An audible click can be heard as eachsolenoid is activated. After performing the test, CatET will indicate the status of the solenoid as “OK”,“Open”, or “Short”.


g01123451Illustration 108Schematic for the injector solenoids


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

A. Turn the keyswitch to the OFF position. A strongelectrical shock hazard is present if the keyswitchis not turned off.


g01121683Illustration 109Left side view(1) J300/P300 connectors(2) J2/P2 connectors


g01099568Illustration 110P2 terminals that are associated with the injector solenoids

(P2-99) Injector 5 & 6 supply(P2-104) Injector 3 & 4 supply(P2-105) Injector 5 return(P2-106) Injector 3 return(P2-107) Injector 6 return(P2-108) Injector 4 return(P2-115) Injector 1 & 2 supply(P2-116) Injector 1 return(P2-118) Injector 2 return



P300 terminals that are associated with the injector solenoids(P300-1) Injector 1 supply(P300-2) Injector 2 supply(P300-3) Injector 3 supply(P300-4) Injector 4 supply(P300-5) Injector 5 supply(P300-6) Injector 6 supply(P300-13) Injector 6 return(P300-14) Injector 5 return(P300-15) Injector 4 return(P300-16) Injector 3 return(P300-17) Injector 2 return(P300-18) Injector 1 return

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with injector solenoids.

D. Check the allen head screw on the ECMconnectors for the proper torque. Refer toTroubleshooting, “Electrical Connectors - Inspect”for the proper torque value.

E. Check the harness and the wiring for abrasionand for pinch points from the P300 connector tothe ECM.

Expected Result:

All connectors, pins, and sockets are completelycoupled and/or inserted and the harness and wiringare free of corrosion, of abrasion, or of pinch points.

Results:

• OK – The harness and wiring are OK. Proceedto Test Step 2.

• Not OK – There is a problem in the connectorsand/or wiring.



STOP.

Test Step 2. Check for Logged DiagnosticCodes for the Injector Solenoids

A. Establish communication between Cat ET andthe ECM. Refer to Troubleshooting, “ElectronicService Tools”.

B. Check Cat ET for logged diagnostic codes relatedto the injector solenoids.

Expected Result:

There are no logged diagnostic codes for the injectorsolenoids .

Results:

• OK – No diagnostic codes for the injector solenoidsare logged. The injector solenoids are operatingcorrectly. There may be a mechanical problem withthe injector’s fuel delivery. Proceed to Test Step 3.

• Not OK – A diagnostic code is logged for oneor more injector solenoid. There is an electricalproblem with an injector solenoid or with the circuit.Proceed to Test Step 4.

Test Step 3. Perform the “Cylinder CutoutTest”


B. Allow the engine to warm up to normal operatingtemperature 77 °C (171 °F).

C. Access the “Cylinder Cutout Test” by accessingthe following display screens:

• “Diagnostics”

• “Diagnostic Tests”

• “Cylinder Cutout Test”

D. Shut off all parasitic loads such as air compressorswhich could affect the results of the test.

E. Follow the instructions that are given on thescreen.

F. To start the test, select the start button at thebottom of the screen.


G. Use Cat ET to manually cut out the cylindersin order to identify injectors that may have aperformance problem. Highlight a cylinder andselect the “Change” button at the bottom of thescreen. The injector for that cylinder will bedisabled. Check for a difference in the sound, feel,or power of the engine. Also, look for a change tothe operating parameters that are displayed onthe “Cylinder Cutout Test” screen.

Expected Result:

The cylinder cutout test indicates that all of theinjectors are operating correctly.

Results:

• OK – The cylinder cutout test indicates that all ofthe injectors are operating correctly.

Repair: If a problem with the fuel system issuspected and diagnostic codes are not active orlogged, refer to Systems Operation/Testing andAdjusting for information that is related to the lowpressure fuel system.

STOP.

• Not OK – The cylinder cutout test indicates that atleast one of the injectors is not operating correctly.Proceed to Test Step 4.

Test Step 4. Perform the “InjectorSolenoid Test”


B. Allow the engine to warm up to normal operatingtemperature 77 °C (171 °F).

C. Stop the engine.

D. Restore the electrical power to the ECM.

E. Access the “Injector Solenoid Test” by accessingthe following display screens:

• “Diagnostics”

• “Diagnostic Tests”

• “Injector Solenoid Test”

F. Activate the “Injector Solenoid Test”.

G. As each solenoid is energized by the ECM, anaudible click can be heard at the valve cover.Allow the “Injector Solenoid Test” to continue untileach cylinder is activated at least two times.

Expected Result:

All cylinders indicate “OK” on Cat ET.

Results:

• OK – There is not an electronic problem with theinjectors at this time.

Repair: The problem appears to be resolved.There may be an intermittent problem in theharness. The problem may have been caused by apoor electrical connection in a connector.

If the codes continue to be logged, refer toTroubleshooting, “Electrical Connectors - Inspect”.

If the engine is misfiring or if the engine has lowpower, refer to Troubleshooting, “Engine Misfires,Runs Rough or Is Unstable” or Troubleshooting,“Low Power/Poor or No Response to Throttle”.

STOP.

• Not OK - “Open” – Note the cylinder that indicates“Open”. Proceed to Test Step 5.

• Not OK - “Short” – Note the cylinder that indicates“Short”. Proceed to Test Step 6.

Test Step 5. Check the Harness betweenthe ECM and the Valve Cover Base for anOpen Circuit


A. Remove the electrical power from the ECM.

B. Disconnect the P300 connector at the valve coverbase.

C. Restore the electrical power to the ECM.

D. Fabricate a jumper wire that will be long enoughto short circuit two terminal locations at the P300connector. Crimp a connector pin to each end ofthe jumper wire.

E. Insert one end of the jumper wire into the P300connector socket for the suspect injector’s supplywire. Insert the other end of the jumper wireinto the P300 connector socket for the suspectinjector’s return wire. This will replace the injectorsolenoid with a short circuit.

F. Perform the “Injector Solenoid Test” at least twotimes.


G. Repeat this test for each suspect circuit. Stopthe “Injector Solenoid Test” before handling thejumper wire.

Restore the wiring to the original configuration.

Expected Result:

Cat ET displays “Short” for each circuit that wasjumpered.

Results:

• OK – Cat ET displays “Short” for each circuit thatwas jumpered. The harness between the ECM andthe P300 connector does not have an open circuit.Proceed to Test Step 7.

• Not OK – Cat ET displays “Open” for the cylinderwith the jumper wire. There is a problem in thewiring between the ECM and the P300 connector.There may be a problem with the ECM. Proceedto Test Step 8.

Test Step 6. Check the Harness betweenthe ECM and the Valve Cover Base for aShort Circuit




C. Restore the electrical power to the ECM.

D. Perform the “Injector Solenoid Test” at least twotimes.

Expected Result:

All of the cylinders in the appropriate bank indicate“Open” on Cat ET.

Results:

• OK – All cylinders indicate “Open” on Cat ET. TheECM and the engine harness are OK. Proceed toTest Step 7.

• Not OK – One or more cylinders indicate “Short”on Cat ET. Note the cylinders that indicate “Short”.Proceed to Test Step 8.

Test Step 7. Check the Injector HarnessUnder the Valve Cover for an OpenCircuit or a Short Circuit



B. Remove the valve cover in order to gain accessto the suspect injector.

C. Disconnect the harness connector from thesuspect injector.

D. Thoroughly clean the terminals on the injectorsolenoid and on the harness connector.

E. Use a jumper wire to short circuit the connectorterminals for the suspect injector. This will replacethe injector solenoid with a short circuit.

F. Restore the electrical power to the ECM.

G. Perform the “Injector Solenoid Test” at least twotimes.

Note: The injector solenoid that shares the supplywire of the injector that is short circuited may indicatea false test result. Disregard this test result.

H. Remove the electrical power from the ECM.

I. Remove the jumper wire from the injectorconnector. This will replace the injector solenoidwith an open circuit.

J. Restore the electrical power to the ECM.

K. Perform the “Injector Solenoid Test” at least twotimes.

L. Remove the electrical power from the ECM.

Expected Result:

Cat ET displays “Short” for the cylinder with thejumper wire and “Open” when the jumper wire isremoved.

Results:

• OK – Cat ET displays the correct status duringthe test.

Repair: The harness wiring is OK. Replace thefaulty injector. Verify that the problem is resolved.

STOP.


• Not OK – Cat ET did not display the correct statusduring the test.

Repair: There is a problem with the injectorharness under the valve cover. There may be aproblem with a connector. Repair the wiring and/orthe connector, when possible. Replace parts, ifnecessary.

STOP.

Test Step 8. Check the ECM for ProperOperation



B. Fabricate a jumper that is long enough to reachfrom the P2 ECM connector to the engine groundstud. Crimp a connector socket to one end of thejumper wire.

C. Disconnect the P2 connector.

D. Remove the supply wire from the terminal locationfor the suspect injector at the ECM connector.Install the jumper wire into this socket.

E. Connect the J2/P2 connectors.

F. Verify that the ECM will detect an open circuit forthe suspect injector:

a. Ensure that the jumper wire is not in contactwith a ground source or another circuit. Do nottouch the jumper wire during the test. A strongelectrical shock hazard is present at the jumperwire while the test is running.

b. Restore the electrical power to the ECM.

c. Perform the “Injector Solenoid Test” at leasttwo times.

d. Remove the electrical power from the ECM.

Cat ET displays “Open” for the two injectorsthat share the supply wire.

G. Verify that the ECM detects a short circuit for thesuspect injector:

a. Connect the jumper wire to the engine groundstud. Do not touch the jumper wire during thetest. A strong electrical shock hazard is presentat the jumper wire while the test is running.

b. Restore the electrical power to the ECM.

c. Perform the “Injector Solenoid Test” at leasttwo times.

d. Remove the electrical power from the ECM.

Cat ET displays “Short” for the two injectorsthat share the supply wire.

Expected Result:

Cat ET displays the correct status for each test circuit.

Results:

• OK – The ECM detects the correct status of thecircuit.

Repair: The ECM is OK. The problem is in theengine harness or in a connector. Inspect theconnectors for moisture and for corrosion. Repairthe wiring and/or the connector, when possible.Replace parts, if necessary. Clear all diagnosticcodes after you complete this test step.

STOP.

• Not OK – The ECM does not detect the correctstatus of the circuit.

Repair: There is a problem with the ECM. Replacethe ECM. Refer to Troubleshooting, “Replacing theECM”. Verify that the problem is resolved.

STOP.

i02433826

Maintenance Due Lamp Circuit- TestSMCS Code: 7431-038


The maintenance due lamp is a maintenanceindicator that is based on the PM levels that areprogrammed into the Electronic Control Module(ECM). The lamp will turn ON when the programmedinterval is met.

Use this procedure in order to troubleshoot anysuspect problems with the circuit for the maintenancedue lamp.



Schematic for the maintenance due lamp

The ECM provides a path to ground for the lamp.When the ECM connects the lamp to ground thelamp will turn on.

Test Step 1. Check for Normal Operationof the Maintenance Due Lamp

A. Monitor the maintenance due lamp.

a. Turn the keyswitch to the ON position. Themaintenance due lamp should turn on for fiveseconds. Then, the lamp should turn off.

Note: The lamp will only turn off if a condition thatrequires maintenance does not exist.

Expected Result:

The maintenance due lamp turns on and themaintenance due lamp turns off per the abovedescription.

Results:

• OK – The maintenance due lamp appears tooperating correctly at this time. STOP.

• Not OK – The maintenance due lamp is notfunctioning correctly. Check the bulb. Replace thebulb if the bulb is not OK. If the bulb is OK, proceedto Test Step 2.




B. Thoroughly inspect connectors (1) and (2). Inspectthe connections on the maintenance due lamp.Refer to Troubleshooting, “Electrical Connectors- Inspect”.


g01102466Illustration 114P1 terminals that are associated with the maintenance due lamp(P1-13) Maintenance due lamp


J61 and P61 terminals that are associated with the maintenancedue lamp(13) Maintenance due lamp

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the maintenancedue lamp.

D. Check the allen head screw on the ECMconnectors for the proper torque. Refer toTroubleshooting, “Electrical Connectors - Inspect”.

E. Check the harness and wiring for abrasions andfor pinch points from the maintenance due lampto the ECM.

Expected Result:


Results:





STOP.

Test Step 3. Test the Maintenance DueLamp Circuit at the ECM Connector



C. Turn the keyswitch to the ON position. Observethe maintenance due lamp.

D. Remove the jumper wire and observe themaintenance due lamp.

Expected Result:

The maintenance due lamp turned on while thejumper was connected. The maintenance due lampturned off when the jumper was removed.

Results:

• OK – The maintenance due lamp turned on whilethe jumper was connected. The maintenance duelamp turned off when the jumper was removed.The maintenance due lamp circuit is functioningproperly. Proceed to Test Step 6.

• Not OK – The maintenance due lamp did notturn on. There is a problem with the circuit for themaintenance due lamp. Proceed to Test Step 4.

Test Step 4. Test the Circuit at theMaintenance Due Lamp

A. Disconnect wire F424-YL from the maintenancedue lamp.

B. Connect a jumper wire between the lamp’s openterminal and engine ground.

C. Turn the keyswitch to the ON position. Observethe maintenance due lamp.

D. Disconnect the jumper wire and observe themaintenance due lamp.

Expected Result:

The maintenance due lamp turns on while the jumperis connected. The maintenance due lamp turns offwhen the jumper is disconnected.

Results:

• OK – The maintenance due lamp turned on whilethe jumper wire was connected. The maintenancedue lamp turned off when the jumper wire wasremoved. The +Battery side of the circuit for themaintenance due lamp is functioning properly.There is a problem with the return wire betweenthe maintenance due lamp and the P1 connector.

Repair: Repair wire F424-YL between themaintenance due lamp and terminal P1-30. Verifythat the problem is resolved.

STOP.

• Not OK – The maintenance due lamp did not turnon when the jumper wire was connected. There isa problem with the +Battery side of the circuit forthe maintenance due lamp. Proceed to Test Step 5.

Test Step 5. Check the Voltage from theKeyswitch to the Maintenance Due Lamp







Expected Result:


Results:


Repair: If voltage is present on terminal R,repair the wire between the keyswitch and themaintenance due lamp. Verify that the breakeris not tripped. Return all wiring to the originalconfiguration. Verify that the problem is resolved.

STOP.




STOP.



STOP.










Expected Result:


Results:


Repair: The problem may be intermittent. If theproblem is intermittent, refer to Troubleshooting,“Electrical Connectors - Inspect”.

STOP.


Repair: Temporarily connect a test ECM. Referto Troubleshooting, “Replacing the ECM”. Checkthe operation of the maintenance due lamp whenthe test ECM is installed.

If the problem is resolved with the test ECM,connect the suspect ECM. If the problem returnswith the suspect ECM, replace the ECM. Verify thatthe problem is resolved.

STOP.

i02433829

PTO Switch Circuit - TestSMCS Code: 7332-038


Use this procedure to troubleshoot any suspectproblems with the circuits for the power take-offcontrols (PTO). The PTO controls provide analternative method of controlling the desired enginespeed.

The Electronic Control Module (ECM) provides thePTO speed control function. The PTO speed controlfunction requires the following inputs:

• PTO switches

• The “PTO Mode” parameter

The PTO switches enable the PTO speed controlfunction and the PTO switches control the desiredengine speed.

The “PTO Mode” parameter determines the modeof operation. There are two modes of operation:“Ramp Up/Ramp Down” and “Set/Resume”. Usethe Caterpillar Electronic Technician (ET) in order tochange the value of the parameter.

“Ramp Up/Ramp Down” Mode

This mode uses three inputs. The inputs are providedby two switches. Refer to Illustration 116.


g01121879Illustration 116Schematic for the PTO inputs for the “Ramp Up/Ramp Down” mode of operation

Placing the PTO Enable switch to the “Enable”position transfers the control of the desired enginespeed from the throttle position sensor to the PTOspeed control function. The PTO Ramp Up/Downswitch controls the desired engine speed.

The PTO Ramp Up/Down switch is spring loaded tothe normally open position. When the switch is heldin the “Ramp Up” position, the desired engine speedincreases according to the value of the “Engine AccelRate” parameter. When the switch is released, thedesired engine speed maintains the set speed. Afterthe desired engine speed has been set, momentarilyplacing the switch in the “Ramp Up” positionincreases the desired engine speed by 20 rpm.

When the PTO Ramp Up/Down switch is held in the“Ramp Down” position, the desired engine speeddecreases according to the value of the “Engine AccelRate” parameter. When the switch is released, thedesired engine speed maintains the set speed. Afterthe desired engine speed has been set, momentarilyplacing the switch in the “Ramp Down” positiondecreases the desired engine speed by 20 rpm.

If the “PTO Ramp Up” and “PTO Ramp Down” inputsare connected to the −Battery at the same time, theECM will ignore the inputs. The desired engine speedwill not change.

“Set/Resume” Mode

This mode uses four inputs. The inputs are providedby three switches. Refer to Illustration 117.



Schematic for the PTO inputs for the “Set/Resume” mode of operation

Placing the PTO Enable switch to the “Enable”position transfers the control of the desired enginespeed from the throttle position sensor to the PTOspeed control function. The PTO Interrupt switchmomentarily transfers control back to the throttleposition sensor. The PTO Set/Resume switchcontrols the desired engine speed.

The PTO Set/Resume switch is spring loaded to thenormally open position. If the switch is momentarilyplaced in the “Set” position, the desired engine speedwill be set to the current engine speed. If the switchis held in the “Set” position, the desired engine speedwill increase according to the value of the “EngineAccel Rate” parameter. After the desired enginespeed has been set, the desired engine speed willincrease by 20 rpm when the PTO ramp up/downswitch is momentarily placed in the “Set” position.

If the PTO Set/Resume switch is momentarily placedin the “Resume” position, the desired engine speedwill be set to the current engine speed. If the switchis held in the “Resume” position, the desired enginespeed will decrease according to the value of the“Engine Accel Rate” parameter. After the desiredengine speed has been set, the desired enginespeed will decrease by 20 rpm when the switch ismomentarily placed in the “Resume” position.

If the “PTO Set” and “PTO Resume” inputs areconnected to the −Battery at the same time, the ECMwill ignore the inputs. The desired engine speed willnot change.






g01102468Illustration 119P1 terminals that are associated with the PTO(P1-41) Input from the PTO interrupt switch(P1-56) Input from the PTO enable switch(P1-58) Input from the PTO ramp up switch or set switch(P1-60) Input for PTO ramp down switch or resume switch



J61/P61 terminals that are associated with the PTO(19) Input from the PTO interrupt switch(29) Input from the PTO enable switch(30) Input from the PTO ramp up switch or set switch(39) Input for PTO ramp down switch or resume switch

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the circuits for thePTO switches.



F. Check the harness and wiring for abrasions andfor pinch points from the battery to the ECM.

Expected Result:

All connectors, pins, and sockets are completelycoupled and/or inserted, and the harness and wiringare free of corrosion, of abrasion or of pinch points.

Results:

• OK – The connectors and wiring are OK. If theengine is equipped with a customer connector,proceed to Test Step 2. Otherwise, proceed to TestStep 3.


Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all of theseals are properly connected. Verify that the repaireliminates the problem.

STOP.

Test Step 2. Check the Inputs from theSwitches at the J61 Customer Connector

A. Disconnect the J61 connector.

B. Refer to Table 23. Connect a voltage test lampbetween the input for the suspect switch circuitand terminal J61-31 (+Battery).

Table 23

J61 Terminals for the Inputs from the PTO Switches

Switch J61 Terminals

PTO enable switch 29

PTO ramp up switch or setswitch 58

PTO ramp down switch orresume switch 60

PTO interrupt switch 41

C. Observe the voltage test lamp as you operate thesuspect switch.

Expected Result:

The voltage test lamp turns on when the switch isclosed. The voltage test lamp turns off when theswitch is opened.

Results:

• OK – The voltage test lamp turns on when theswitch is closed. The voltage test lamp turns offwhen the switch is opened. The circuit is operatingcorrectly. Connect the J61 connector. Proceed toTest Step 3.

• Not OK – The voltage test lamp does not turnon when the switch is closed. Alternatively, thevoltage test lamp does not turn off when the switchis opened. There is a problem with the suspectswitch and/or the wiring.




STOP.

Test Step 3. Check the Inputs from theSwitches at the J1 Connector

A. Disconnect the P1 connector.

B. Refer to Table 24. Connect a voltage test lampbetween the input for the suspect switch circuitand terminal J1-48 (+Battery).

Table 24

J1 Terminals for the Inputs from the PTO Switches

Switch J1 Terminals

PTO Enable Switch 56

PTO Ramp Up Switch orSet Switch 58

PTO Ramp Down Switchor Resume Switch 60

PTO Interrupt Switch 41

C. Observe the voltage test lamp as you operate thesuspect switch.

Expected Result:

The voltage test lamp turns ON when the switch isclosed. The voltage test lamp turns OFF when theswitch is opened.

Results:

• OK – The voltage test lamp turns ON when theswitch is closed. The voltage test lamp turns OFFwhen the switch is opened. The switch circuit isoperating correctly. The problem may be in theECM.

Repair: It is unlikely that the ECM has failed. Exitthis procedure and perform this procedure again.If the problem is not resolved, temporarily install anew ECM. Refer to Troubleshooting, “Replacingthe ECM”.

If the problem is resolved with the new ECM,install the original ECM and verify that the problemreturns. IF the new ECM operates correctly and theoriginal ECM does not operate correctly, replacethe original ECM.

STOP.

• Not OK – The voltage test lamp does not turn onwhen the switch is closed. Alternatively, the voltagetest lamp does not turn off when the switch isopened. There is a problem in the wiring betweenthe J1 connector and the switch. There may be aproblem in a connector.

Repair: Repair the wiring and/or the connector.Replace parts, if necessary. Verify that the repaireliminates the problem.

STOP.

i02433846

Switch Circuits - TestSMCS Code: 1435-038


Switch circuits may have problems such as faultywiring, faulty switches, or faulty connectors. Use thefollowing diagnostic procedures in order to diagnoseproblems with these switch circuits and repair theseswitch circuits:

• Maintenance clear switch

• Torque limit switch

• Ether starting aid switch

• PTO interrupt switch

• Remote shutdown switch

• Intermediate engine speed switch

• Overspeed verify switch

• PTO enable switch

• PTO ramp up switch

• PTO set switch

• PTO ramp down switch

• PTO resume switch

The switches are normally open or normally closed.



Typical switch inputs

Test Step 1. Check the ElectricalConnectors and the Wiring

A. Place the keyswitch in the OFF position.

g01120532Illustration 122Left side view(1) P61 customer connector(2) J1/P1 Electronic Control Module (ECM) connectors

B. Thoroughly inspect connectors (1) and (2).Thoroughly inspect the connections for thesuspect switch. Refer to Troubleshooting,“Electrical Connectors - Inspect”.


g01121943Illustration 123P1 terminals for the various switches(P1-6) Maintenance clear switch(P1-7) Torque limit switch(P1-22) Ether starting aid switch(P1-41) PTO interrupt switch(P1-44) Remote shutdown switch(P1-45) Intermediate engine speed switch(P1-54) Overspeed verify switch(P1-56) PTO enable switch(P1-58) PTO ramp up switch or set switch(P1-60) PTO ramp down switch or resume switch


P61/J61 terminals for the various switches(2) Torque limit switch(12) Maintenance clear switch(19) PTO interrupt switch(27) Remote shutdown switch(28) Intermediate engine speed switch(29) PTO enable switch(30) PTO ramp up switch or set switch(38) Ether starting aid switch(39) PTO ramp down switch or resume switch(40) Overspeed verify switch

C. Perform a 45 N (10 lb) pull test on each of thewires in the circuit for the suspect switch.



F. Check the harness and wiring for abrasions andfor pinch points from the battery to the ECM.

Expected Result:



Results:

• OK – The wiring and connectors are OK. Proceedto Test Step 2.

• Not OK – There is a problem with the wiring and/ora connector.

Repair: Repair the wiring and/or the connector.Replace parts, if necessary. Ensure that all of theseals are properly connected. Verify that the repaireliminates the problem.

STOP.

Test Step 2. Test the Switch for ProperOperation


B. Refer to Table 25. Determine the P1 terminal forthe suspect switch.

Table 25

Terminals for the Switch Inputs

Name of theSwitch P1 Terminals J61/P61

Terminals

Maintenanceclear switch 6 12

Torque limitswitch 7 2

Ether starting aidswitch 22 38

PTO interruptswitch 41 19

Remoteshutdown switch 44 27

Intermediateengine speedswitch

45 28

Overspeed verifyswitch 54 40

PTO enableswitch 56 29

PTO ramp upswitch or setswitch

58 30

PTO ramp downswitch or resumeswitch

60 39

C. Connect a meter lead to the P1 terminal for thesuspect switch. Connect the other meter lead toengine ground.

Note: Wiggle the harnesses during the followingmeasurements in order to reveal any intermittentshort condition.

D. Measure the resistance between the P1 terminalfor the suspect switch and engine ground.

E. Activate the switch and measure the resistanceagain.

Expected Result:

When the switch is open, the resistance measurementindicates an open circuit. When the switch is closed,the resistance measurement is less than ten Ohms.

Results:

• OK – One resistance measurement indicates anopen circuit. The other resistance measurementis less than ten Ohms. The switch is operatingcorrectly. The wiring does not have a short circuitor an open circuit.

Repair: Operate the engine and check the switchfor proper operation.

If the switch does not operate correctly, there maybe a short circuit between the circuit for the suspectswitch and another circuit. Carefully reinspect thecomponents. Refer to Troubleshooting, “ElectricalInspectors - Inspect”. Locate the short circuit andmake repairs.

STOP.

• Not OK – Both resistance measurements indicatean open circuit or both resistance measurementsare less than ten Ohms. There is a problem withthe circuit for the switch.

Repair: The problem could be in the switch, in thewiring, or in a connector.

Carefully reinspect the components. Refer toTroubleshooting, “Electrical Inspectors - Inspect”.

If the inspection does not identify the faultycomponent, replace the switch and test the switchagain.

If the problem is not resolved, repair the wiring orthe connector. Replace parts, if necessary. Verifythat the problem is resolved.

STOP.


i02433840

Throttle Position SensorCircuit - TestSMCS Code: 1913-038


The throttle position sensor eliminates the mechanicalthrottle and governor linkages. The sensor that isinstalled depends on the engine’s configuration.

g01123466Illustration 125Electronic throttle position sensor


Throttle position sensor with a lever

g01122050Illustration 127Throttle position sensor with a knob

Refer to Illustration 128. The sensor creates a PulseWidth Modulated (PWM) signal. The duty cyclevaries with the throttle position. The signal has a lowduty cycle when the throttle is at low idle. The signalhas a high duty cycle when the throttle is at high idle.The Electronic Control Module (ECM) processes thesignal in order to control the engine speed.


Duty cycle versus throttle position

The signal from the throttle position sensor has aspecific frequency. The frequency of the signal mustbe between 150 Hz and 1050 Hz or the ECM willactivate a 091-08 diagnostic code.


g01122222Illustration 129Schematic for the throttle position sensor




Left side view(1) P61 customer connector(2) J1/P1 connectors

B. Thoroughly inspect connectors (1) and (2). Inspectthe connections on the throttle position sensor.Refer to Troubleshooting, “Electrical Connectors- Inspect”.

g01122213Illustration 131P1 terminal that is associated with the throttle position sensor

(P1-66) Throttle position



J61 and P61 terminal that is associated with the throttle position(10) Throttle position

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the throttle positionsensor.



F. Check the harness and wiring for abrasions andfor pinch points from the throttle position sensorto the ECM and from the throttle position sensorto the battery.

Expected Result:


Results:

• OK – The wiring and the connectors are OK.Proceed to Test Step 2.

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

Repair: Repair the wiring and/or the connectors.Replace parts, if necessary. Ensure that all of theseals are properly connected. Verify that the repaireliminates the problem.

STOP.

Test Step 2. Check for Supply Voltage atthe Throttle Position Sensor


B. Turn the keyswitch to the ON position. The engineshould be OFF.

C. Measure the voltage between terminals P403-Aand P403-B.

Expected Result:

The supply voltage is at least 11 VDC for a 12 voltsystem. The supply voltage is at least 22 VDC for a24 volt system.

Results:

• OK – The supply voltage is at least 11 VDC for a12 volt system. The supply voltage is at least 22VDC for a 24 volt system. The supply voltage isreaching the sensor. Proceed to Test Step 3.

• Not OK – The supply voltage is incorrect.

Repair: The configuration of the wiring between the+Battery and the throttle position sensor dependson the engine’s configuration. The problem couldbe in the wiring or in a connector. There may be aproblem with the battery.

Perform the necessary repairs. Verify that theproblem is resolved.

STOP.




Note: Be sure to wiggle the harnesses during thefollowing measurements. Be sure to wiggle eachharness near each connector.

C. Measure the resistance between terminal P1-66and all of the other terminals in the P1 connector.


Expected Result:


Results:


• Not OK – At least one resistance measurementdoes not indicate an open circuit. There is aproblem with the signal wire for the throttle positionsensor.

Repair: The problem could be in the wiring or in aconnector. Repair the wiring and/or the connector,when possible. Replace parts, if necessary. Verifythat the problem is resolved.

STOP.

Test Step 4. Check the Signal Wire for anOpen Circuit

Note: Be sure to wiggle the harnesses during thefollowing measurement. Be sure to wiggle eachharness near each connector.

Measure the resistance between terminal P1-66 andterminal P403-C.

Expected Result:

The resistance measurement is less than ten Ohms.

Results:

• OK – The resistance measurement is less thanten Ohms. Connect the P403 connector. Proceedto Test Step 5.

• Not OK – The resistance measurement is greaterthan ten Ohms. There is a problem with the signalwire.

Repair: The problem could be in the wiring or in aconnector. Repair the wiring and/or the connector,when possible. Replace parts, if necessary. Verifythat the problem is resolved.

STOP.

Test Step 5. Check the Frequency of theThrottle Position Signal at the ECM


B. Connect a 208-0059 Adapter Cable As (70-PINBREAKOUT) between the P1 connector and theJ1 connector.

C. Connect a multimeter between terminals 66 and 5on the breakout t.


E. Measure the frequency of the throttle positionsignal. Slowly move the throttle from low idle tohigh idle and back to low idle while you measurethe frequency of the signal.

F. Observe the “Active Diagnostic” screen on CatET. Slowly move the throttle from the low idleposition to the high idle position. Look for a 091-08diagnostic code while you move the throttle.

Expected Result:

The frequency of the signal remains between 150Hz and 1050 Hz as you move the throttle. A 091-08diagnostic code is not activated.

Results:

• OK – The frequency of the signal remains between150 Hz and 1050 Hz as you move the throttle. A091-08 diagnostic code is not activated.


1. Turn the keyswitch to the off position.

2. Remove the 208-0059 Adapter Cable As(70-PIN BREAKOUT).

3. Connect the J1/P1 connectors.

4. Turn the keyswitch to the ON position.

5. Operate the throttle throughout the entire range.

If the problem does not recur, the problem isresolved. The original problem was probablycaused by a poor electrical connection. Returnthe engine to service.

STOP.

• Not OK – The frequency of the signal is incorrect.A 091-08 diagnostic code is activated.


1. Turn the keyswitch to the off position.

2. Replace the throttle position sensor. Check fora 091-08 diagnostic code again.


If the diagnostic code does not recur, theproblem is resolved. Return the engine toservice.

If the diagnostic code recurs, replace the ECM.Refer to Troubleshooting, “Replacing the ECM”.Verify that the problem is resolved.

STOP.

i02433855

Warning Lamp Circuit - TestSMCS Code: 7431-038


The warning lamp is a maintenance indicator that isbased on the PM levels that are programmed into theElectronic Control Module (ECM). The warning lampwill turn on when a warning, a derate, or a shutdowncondition exists.

Use this procedure to troubleshoot any suspectproblems with the circuit for the warning lamp.

g01122447Illustration 133Schematic for the warning lamp

The ECM provides a path to ground for the warninglamp. When the ECM connects the warning lamp toground the warning lamp will turn on.

Test Step 1. Check for Normal Operationof the Warning Lamp

A. Monitor the warning lamp.

a. Turn the keyswitch to the ON position. Thewarning lamp should turn on for five seconds.Then, the lamp should turn off.

Note: The lamp will only turn off only if a “Warning”, a“Derate”, or a “Shutdown” condition does not exist.

Expected Result:

The warning lamp turns on and the warning lampturns off per the above description.

Results:

• OK – The warning lamp appears to be operatingcorrectly at this time. STOP.

• Not OK – The warning lamp is not functioningcorrectly. Check the bulb. Replace the bulb if thebulb is not OK. If the bulb is OK, proceed to TestStep 2.






B. Thoroughly inspect connectors (1) and (2). Inspectthe connections on the warning lamp. Refer toTroubleshooting, “Electrical Connectors - Inspect”.


P1 terminals that are associated with the warning lamp(P1-29) Warning lamp


J61 and P61 terminals that are associated with the warning lamp(13) Warning lamp

C. Perform a 45 N (10 lb) pull test on each of thewires that are associated with the warning lamp.



F. Check the harness and wiring for abrasions andfor pinch points from the warning lamp to the ECM.

Expected Result:


Results:





STOP.

Test Step 3. Test the Warning LampCircuit at the ECM Connector



C. Turn the keyswitch to the ON position. Observethe warning lamp.

D. Remove the jumper wire and observe the warninglamp.

Expected Result:

The warning lamp turned on while the jumper wasconnected. The warning lamp turned off when thejumper was removed.

Results:

• OK – The warning lamp turned on while the jumperwas connected. The warning lamp turned off whenthe jumper was removed. The warning lamp circuitis functioning properly. Proceed to Test Step 6.

• Not OK – The warning lamp did not turn on. Thereis a problem with the circuit for the warning lamp.Proceed to Test Step 4.

Test Step 4. Test the Circuit at theWarning Lamp

A. Disconnect wire F420-GN from the warning lamp.

B. Connect a jumper wire between the lamp’s openterminal and engine ground.

C. Turn the keyswitch to the ON position. Observethe warning lamp.

D. Disconnect the jumper wire and observe thewarning lamp.

Expected Result:

The warning lamp turns on while the jumper isconnected. The warning lamp turns off when thejumper is disconnected.

Results:

• OK – The warning lamp turned on while thejumper wire was connected. The warning lampturned off when the jumper wire was removed. The+Battery side of the circuit for the warning lamp isfunctioning properly. There is a problem with thereturn wire between the warning lamp and the P1connector.

Repair: Repair wire F420-GN between the warninglamp and terminal P1-29. Verify that the problemis resolved.

STOP.

• Not OK – The warning lamp did not turn on whenthe jumper wire was connected. There is a problemwith the +Battery side of the circuit for the warninglamp. Proceed to Test Step 5.

Test Step 5. Check the Voltage from theKeyswitch to the Warning Lamp







Expected Result:


Results:


Repair: If voltage is present on terminal R, repairthe wire between the keyswitch and the warninglamp. Verify that the breaker is not tripped. Returnall wiring to the original configuration. Verify thatthe problem is resolved.

STOP.




STOP.



STOP.










Expected Result:


Results:


Repair: The problem may be intermittent. If theproblem is intermittent, refer to the diagnosticfunctional test Troubleshooting, “ElectricalConnectors - Inspect”.

STOP.


Repair: Temporarily connect a test ECM. Refer toTroubleshooting, “Replacing the ECM”. Check theoperation of the warning lamp when the test ECMis installed.

If the problem is resolved with the test ECM,reconnect the original ECM. If the problem returnswith the original ECM, replace the original ECM.Verify that the problem is resolved.

STOP.


Calibration Proceduresi02435131

Engine Speed/Timing Sensor -CalibrateSMCS Code: 1912-524


The Electronic Control Module (ECM) has the abilityto calibrate the mechanical differences between theTop Center (TC) of the flywheel and the TC of thetiming gear on the camshaft. A magnetic transducersignals the TC of the flywheel to the ECM when anotch on a counterweight passes by the transducer.The engine speed/timing sensor signals the TC ofthe timing gear to the ECM. Any offset between theTC of the flywheel and the TC of the timing gear isstored into the memory of the ECM.

Note: A timing calibration will not increase theavailable engine power.

Table 26 lists the special tools that are required inorder to perform this procedure.

Table 26

Required Special Tools


7X-1171 Transducer Adapter

6V-2197 Transducer

7X-1695 Cable As

170-3519 Harness (1)

(1) This item is not required if the engine harness has a connectorfor timing calibration.

Test Step 1. Install the TransducerAdapter


B. Use the appropriate engine turning tool to puteither the No. 1 piston or the No. 6 piston at topcenter. Refer to the Systems Operation/Testingand Adjusting.

C. Refer to Table 27. After the top center position hasbeen located, rotate the crankshaft for the numberof degrees that is applicable to your engine model.Be sure to rotate the crankshaft in the direction ofrotation that is specified in the Table.

Table 27

Crankshaft Rotation

EngineModel

Number ofDegrees

Direction of Rotation

C7 100 Normal Rotation

C-9 85 Normal Rotation

C-10 60 Opposite Normal Rotation





C15 60 Opposite Normal Rotation


C18 30 Opposite Normal Rotation

D. Refer to Table 28. Locate the engine’s timingcalibration port.

Table 28

Location of the Timing Calibration Port

EngineModel

CrankshaftCounterweight

Engine Location

C7 3 Left Side

C-9 3 Left Side

C-10 8 Right Side

C11 8 Left Side

C-12 8 Right Side

C13 8 Left Side

C-15 2 Left Side

C15 2 Left Side

C-16 2 Left Side

C18 2 Left Side

E. Remove the plug from the timing calibration port.

F. Thread the transducer adapter into the port.

Continue to the next test step.

Test Step 2. Install the Transducer

NOTICEIf the crankshaft is not in the correct position when thetransducer is installed, the transducer will be damagedwhen the engine is started.

A. Apply clean engine oil to a 2D-6392 O-Ring Seal.Install the O-ring seal on the end of the 6V-2197Transducer.


B. Push the transducer through the transduceradapter until the transducer contacts thecrankshaft counterweight.

C. Withdraw the transducer 1.0 mm (0.04 inch) andhand tighten the nut on the adapter sleeve inorder to secure the transducer. Move the O-ringseal against the adapter.


Test Step 3. Connect the 7X-1695 CableAs

A. If the engine harness is equipped with a connectorfor timing calibration, connect the 7X-1695 CableAs to the connector for timing calibration and tothe transducer.

B. If the engine harness is not equipped with aconnector for timing calibration, perform thefollowing procedure:

a. Disconnect the P2 connector from the ECM.

b. Determine the number of terminals on the P2connector.

Table 29

P2 Locations for Connection of the 7X-1695Cable As

Wire ColorLocations onthe 70−pin P2Connector

Locations onthe 120−pin P2Connector

White 22 26

Yellow 23 36

c. Refer to Table 29. Remove the sealing plugsfrom the appropriate terminals. Do not discardthe sealing plugs. The sealing plugs maybe reinstalled when the timing calibration iscomplete.

d. Install the white wire of the 170-3519 Harnessinto the appropriate location.

e. Install the yellow wire of the 170-3519Harness into the appropriate location.Disregard the pin-outs on the label of theharness.

Note: Ensure that each wire is installed into thecorrect location. The timing calibration will not besuccessful if the wires are installed incorrectly.

f. Connect the J2/P2 connectors. Tighten theallen head screw on the P2 connector to theappropriate torque. Refer to the diagnosticfunctional test Troubleshooting, “ElectricalConnectors - Inspect” for the correct torquevalue.

g. Connect the 7X-1695 Cable As to theconnector for timing calibration and to thetransducer.


Test Step 4. Start the Engine and Checkfor Diagnostic Codes

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

B. Start the engine and run the engine until theengine is at the normal operating temperature.

C. Check for active diagnostic codes. Wait at least 30seconds in order for the codes to become active.

The engine must not have any active diagnosticcodes during the timing calibration except for a261-13 Engine Timing Calibration required.

Expected Result:

There are no active diagnostic codes or there is onlyan active 261-13 diagnostic code.

Results:

• OK – There are no active diagnostic codes orthere is only an active 261-13 diagnostic code.Proceed to Test Step 5.

• Not OK – There is at least one active code thatis not 261-13.

Repair: Troubleshoot and repair any activediagnostic codes before you continue with thisprocedure.

STOP.

Test Step 5. Calibrate the EngineSpeed/Timing Sensor

A. Set the engine speed to 1100 ± 50 rpm. Theengine speed must be steady within this rpmrange in order for the calibration to be successful.

B. After the engine has warmed up, access the“Timing Calibration” screen on the Cat ET. Accessthe following display screens in order:


• Service

• Calibrations

• Timing Calibration

C. To calibrate the timing, select “Continue” on CatET. Wait until Cat ET indicates that the timing iscalibrated.

Expected Result:

Cat ET indicates that the timing is calibrated.

Results:

• OK – Cat ET indicates that the timing is calibrated.


1. Set the engine speed to low idle.

Note: Disconnect the 7X-1695 Cable As beforeyou exit the “Timing Calibration” screen. Otherwise,diagnostic codes may be activated.

2. Disconnect the 7X-1695 Cable As.

3. Exit the “Timing Calibration” screen on Cat ET.

4. Remove the electrical power from the ECM.

5. Remove the transducer and remove theadapter.

6. Install the plug into the timing calibration port.

7. If you installed a 170-3519 Harness, you mayremove the harness or you may permanentlyinstall the harness for future use. If you removethe harness, install the sealing plugs into theunused cavities of the P2 connector. Otherwise,moisture and debris will enter the connector.

If you choose to permanently install the harness,fasten the harness to the existing engine wiringharness with cable ties. Also, install a 3E-3364Receptacle and two 8T-8737 Seal Plugs onthe P400 timing calibration probe connectorin order to prevent moisture and debris fromentering the connector.

8. Return the engine to service.

STOP.

• Not OK – The timing calibration was unsuccessful.

Repair: The following conditions can cause thetiming calibration to fail:

• If the crankshaft and camshaft gears have beenreassembled incorrectly, the timing will notcalibrate.

• Verify that the timing calibration probe is installedcorrectly.

• Verify that the engine speed is correct and thatthe engine speed is stable. If the engine speedis unstable, refer to troubleshooting withouta diagnostic code Troubleshooting, “EngineMisfires, Runs Rough or Is Unstable”.

• There may be a problem with the transducer orwith the cables. Obtain a new transducer and/ora new cable and repeat the timing calibration.

STOP.

i02225548

Throttle Position Sensor -CalibrateSMCS Code: 1913-524


There are two options for calibrating the throttleposition sensor:

Mechanical Calibration – During a manualcalibration, two set screws on the throttle positionsensor are adjusted. The set screws are for low idlestop and high idle stop.

Electronic Calibration – During an electroniccalibration, the Caterpillar Electronic Technician (ET)is used to set the PWM that is equal to low idle andthe PWM that is equal to high idle.

Test Step 1. Inspect the Throttle’sComponents


B. Inspect the throttle linkage and relatedcomponents for the following conditions:

• Loose

• Bent

• Broken

• Missing

• Worn


Expected Result:

The throttle linkage and related components are ingood condition.

Results:

• OK – The throttle linkage and related componentsare in good condition. Proceed to Test Step 2.

• Not OK – The throttle linkage and relatedcomponents are not in good condition.

Repair: Repair the throttle linkage. Replace parts,if necessary. Continue with this procedure whenthe components for the throttle linkage are in goodcondition.

STOP.

Test Step 2. Determine the Type ofCalibration

Determine the type of calibration to be performed.

Results:

• Mechanical – Proceed to Test Step 3.

• Electronic – Proceed to Test Step 5.

Test Step 3. Adjust the Throttle at LowIdle


B. Turn the keyswitch to the ON position. Do not startthe engine.

C. Observe the value of the “Throttle Position” onCat ET.

D. Move the throttle to low idle. Adjust the throttlelinkage and adjust the low idle set screw until the“Throttle Position” is zero percent.

E. Increase the throttle. Verify that the value of the“Throttle Position” increases.

Expected Result:

When the throttle is at low idle, the “Throttle Position”is zero percent. As you increase the throttle, thevalue of the “Throttle Position” increases.

Results:

• OK – When the throttle is at low idle, the “ThrottlePosition” is zero percent. As you increase thethrottle, the value of the “Throttle Position”increases. The low idle adjustment is correct.Proceed to Test Step 4.

• Not OK – When the throttle is at low idle, the“Throttle Position” is zero percent. Alternatively, asyou increase the throttle, the value of the “ThrottlePosition” does not increase. There is a problemwith the throttle position sensor.

Repair: Refer to Troubleshooting, “Throttle PostionSensor Circuit - Test”.

STOP.

Test Step 4. Adjust the Throttle at HighIdle

A. Move the throttle to high idle. Adjust the throttlelinkage and/or adjust the high idle set screw untilthe “Throttle Position” is 100 percent.

Note: When you adjust the high idle on some typesof linkage, the low idle adjustment may change.

B. Verify that low idle is correctly adjusted. Makeadjustments, if necessary.

Expected Result:

When the throttle is at high idle, the “Throttle Position”is 100 percent. When the throttle is at low idle, the“Throttle Position” is zero percent.

Results:

• OK – When the throttle is at high idle, the “ThrottlePosition” is 100 percent. When the throttle is at lowidle, the “Throttle Position” is 0 percent. Calibrationof the throttle is complete. STOP.

• Not OK – The high idle position and/or the low idleposition cannot be adjusted to the specification. Anelectronic calibration is required. Proceed to TestStep 5.

Test Step 5. Calibrate the Throttle at LowIdle


B. Turn the keyswitch to the ON position. Do not startthe engine.

C. Move the throttle to low idle.


D. Observe the “Throttle Position” on the statusscreen of Cat ET.

E. Verify that the “Throttle Position” is zero percent.

Expected Result:

The “Throttle Position” is zero percent when thethrottle is at low idle.

Results:

• OK – The “Throttle Position” is zero percent whenthe throttle is at low idle. Proceed to Test Step 6.

• Not OK – The “Throttle Position” is not zeropercent when the throttle is at low idle.


1. Adjust the value of the “Throttle Input Low IdleDuty Cycle Setpoint” on the “Configuration”screen of Cat ET.

2. Verify that the “Throttle Position” is zero percentwhen the throttle is at low idle.

Proceed to Test Step 6.

Test Step 6. Configure the Calibration forHigh Idle

A. Move the throttle to high idle.

B. Check the “Throttle Position” on the status screenof Cat ET.

C. Verify that the “Throttle Position” is 100 percent.

Expected Result:

The “Throttle Position” is 100 percent when thethrottle is in high idle.

Results:

• OK – The “Throttle Position” is 100 percent whenthe throttle is at high idle. Calibration of the throttleis complete. STOP.

• Not OK – The “Throttle Position” is not 100 percentwhen the throttle is at high idle.


1. Adjust the “Throttle Input High Idle Duty CycleSetpoint” on the “Configuration” screen on CatET.

2. Verify that the “Throttle Position” is 100 percentwhen the throttle is at high idle.

STOP.

210 RENR2418-02Index Section

Index

Numerics

5 Volt Engine Pressure Sensor Supply Circuit -Test ...................................................................... 83

A

Air Inlet Heater Circuit - Test.................................. 91Air Shutoff System - Test ....................................... 98Alternator (Charging Problem)............................... 28Probable Causes ............................................... 28Recommended Actions...................................... 28

B

Battery ................................................................... 28Probable Causes ............................................... 28Recommended Actions...................................... 28

C

Calibration Procedures ........................................ 205CAN Data Link Circuit - Test................................ 105Can Not Reach Top Engine RPM.......................... 28Probable Causes ............................................... 28Recommended Actions...................................... 29

Cat Data Link Circuit - Test.................................. 109CID 0001 FMI 05 Cylinder #1 Injector opencircuit ................................................................... 56CID 0001 FMI 06 Cylinder #1 Injector short .......... 56CID 0002 FMI 05 Cylinder #2 Injector opencircuit ................................................................... 57CID 0002 FMI 06 Cylinder #2 Injector short .......... 57CID 0003 FMI 05 Cylinder #3 Injector opencircuit ................................................................... 57CID 0003 FMI 06 Cylinder #3 Injector short .......... 57CID 0004 FMI 05 Cylinder #4 Injector opencircuit ................................................................... 58CID 0004 FMI 06 Cylinder #4 Injector short .......... 58CID 0005 FMI 05 Cylinder #5 Injector opencircuit ................................................................... 58CID 0005 FMI 06 Cylinder #5 Injector short .......... 59CID 0006 FMI 05 Cylinder #6 Injector opencircuit ................................................................... 59CID 0006 FMI 06 Cylinder #6 Injector short .......... 59CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 59CID 0041 FMI 04 8 Volt DC Supply short toground.................................................................. 60CID 0042 FMI 05 Injector Actuation Valve opencircuit ................................................................... 60CID 0042 FMI 06 Injector Actuation Valve short toground.................................................................. 60CID 0091 FMI 08 Throttle Position signalabnormal.............................................................. 61

CID 0091 FMI 13 Throttle Position calibrationrequired................................................................ 61CID 0094 FMI 03 Fuel Pressure open/short to+batt..................................................................... 61CID 0094 FMI 04 Fuel Pressure short to ground... 61CID 0100 FMI 03 Engine Oil Pressure open/short to+batt..................................................................... 62CID 0100 FMI 04 Engine Oil Pressure short toground.................................................................. 62CID 0100 FMI 10 Engine Oil Pressure Sensorabnormal rate of change...................................... 62CID 0102 FMI 03 Boost Pressure Sensor short to+batt..................................................................... 63CID 0102 FMI 04 Boost Pressure Sensor short toground.................................................................. 63CID 0102 FMI 10 Boost Pressure Sensor abnormalrate of change...................................................... 63CID 0110 FMI 03 Engine Coolant Temperatureopen/short to +batt............................................... 64CID 0110 FMI 04 Engine Coolant Temperature shortto ground.............................................................. 64CID 0111 FMI 02 Engine Coolant Level Sensor Lossof Signal............................................................... 64CID 0164 FMI 02 Injector Actuation Pressure signalerratic................................................................... 65CID 0164 FMI 03 Injector Actuation Pressure voltagehigh...................................................................... 65CID 0164 FMI 04 Injector Actuation Pressure voltagelow ....................................................................... 65CID 0164 FMI 11 Injector Actuation Pressure systemfault ...................................................................... 66CID 0168 FMI 00 System Voltage High................. 66CID 0168 FMI 01 System Voltage Low.................. 67CID 0168 FMI 02 System Voltage intermittent/erratic................................................................... 67CID 0172 FMI 03 Intake Manifold Air Temp open/shortto +batt................................................................. 67CID 0172 FMI 04 Intake Manifold Air Temp short toground.................................................................. 68CID 0190 FMI 08 Engine Speed signal abnormal.. 68CID 0247 FMI 09 J1939 Data Linkcommunications................................................... 68CID 0253 FMI 02 Personality Module mismatch ... 68CID 0261 FMI 13 Engine Timing Calibrationrequired................................................................ 69CID 0262 FMI 03 5 Volt Sensor DC Power Supplyshort to +batt........................................................ 69CID 0262 FMI 04 5 Volt Sensor DC Power Supplyshort to ground..................................................... 69CID 0268 FMI 02 Check ProgrammableParameters .......................................................... 70CID 0274 FMI 03 Atmospheric Pressure open/shortto +batt................................................................. 70CID 0274 FMI 04 Atmospheric Pressure short toground.................................................................. 70CID 0342 FMI 08 Secondary Engine Speed signalabnormal.............................................................. 71

RENR2418-02 211Index Section

CID 0617 FMI 05 Air Inlet Heater Relay open/currentbelow normal ....................................................... 71CID 0617 FMI 06 Air Inlet Heater Relaygrounded/current above norm ............................. 71CID 1835 FMI 03 Auxiliary Pressure Sensoropen/short to +batt............................................... 72CID 1835 FMI 04 Auxiliary Pressure Sensor short toground.................................................................. 72CID 1836 FMI 03 Auxiliary Temperature Sensoropen/short to +batt............................................... 72CID 1836 FMI 04 Auxiliary Temperature Sensor shortto ground.............................................................. 72CID 2417 FMI 05 Ether Injection Control Solenoidcurrent low ........................................................... 73CID 2417 FMI 06 Ether Injection Control Solenoidcurrent high.......................................................... 73Coolant in Engine Oil............................................. 30Probable Causes ............................................... 30Recommended Actions...................................... 30

Coolant Level Sensor Circuit - Test ...................... 112Coolant Temperature Is Too High.......................... 30Customer Passwords ............................................ 17

D

Diagnostic Code Cross Reference ........................ 53Diagnostic Codes .................................................. 52Active Diagnostic Codes .................................... 53Diagnostic Codes............................................... 52Logged Diagnostic Codes.................................. 53

Diagnostic Functional Tests................................... 83Diagnostic Lamp Circuit - Test.............................. 116Digital Sensor Supply Circuit - Test ..................... 120

E

E096 High Fuel Pressure ...................................... 75E2143 Low Engine Coolant Level ......................... 81E360 Low Engine Oil Pressure.............................. 76E361 High Engine Coolant Temperature ............... 77E362 Engine Overspeed ....................................... 78E443 High Auxiliary Pressure................................ 79E445 High Auxiliary Temperature .......................... 80E539 High Intake Manifold Air Temperature.......... 81ECM Will Not Accept Factory Passwords.............. 31Probable Causes ............................................... 31Recommended Actions...................................... 31

ECM Will Not Communicate with Other Systems orDisplay Modules .................................................. 31Probable Causes ............................................... 31Recommended Actions...................................... 31

Electrical Connectors - Inspect............................ 124Electrical Power Supply Circuit - Test.................. 129Electronic Service Tool Will Not Communicate withECM..................................................................... 31Probable Causes ............................................... 31Recommended Actions...................................... 32

Electronic Service Tools .......................................... 6Caterpillar Electronic Technician (ET).................. 7Optional Service Tools ......................................... 6Required Service Tools ........................................ 6

Electronic Troubleshooting ...................................... 5Engine Cranks but Will Not Start ........................... 32Probable Causes ............................................... 32Recommended Actions...................................... 33

Engine Has Early Wear ......................................... 34Probable Causes ............................................... 34Recommended Actions...................................... 34

Engine Misfires, Runs Rough or Is Unstable......... 35Probable Causes ............................................... 35Recommended Actions...................................... 35

Engine Oil in Cooling System................................ 36Probable Causes ............................................... 36Recommended Actions...................................... 36

Engine Oil Temperature Is Too High...................... 36Probable Causes ............................................... 36Recommended Actions...................................... 36

Engine Pressure Sensor Open or Short Circuit -Test .................................................................... 133Engine Speed/Timing Sensor - Calibrate ............ 205Engine Speed/Timing Sensor Circuit - Test......... 141Engine Stalls at Low RPM..................................... 37Probable Causes ............................................... 37Recommended Actions...................................... 37

Engine Temperature Sensor Open or Short Circuit -Test .................................................................... 147Engine Vibration .................................................... 37Probable Causes ............................................... 37Recommended Actions...................................... 38

Engine Will Not Crank ........................................... 38Probable Causes ............................................... 38Recommended Actions...................................... 38

Engine Wiring Information ..................................... 15Harness Wire Identification ................................ 15

Ether Injection System - Test............................... 155Event Codes.......................................................... 74Active Event Codes............................................ 74Clearing Event Codes........................................ 75Logged Event Codes ......................................... 75Troubleshooting ................................................. 75

Excessive Black Smoke ........................................ 39Probable Causes ............................................... 39Recommended Actions...................................... 39

Excessive Engine Oil Consumption....................... 40Probable Causes ............................................... 40Recommended Actions...................................... 40

Excessive Fuel Consumption ................................ 40Probable Causes ............................................... 40Recommended Actions...................................... 40

Excessive Valve Lash............................................ 41Probable Causes ............................................... 41Recommended Actions...................................... 41

Excessive White Smoke........................................ 41Probable Causes ............................................... 41Recommended Actions...................................... 42

Exhaust Temperature Is Too High ......................... 42Probable Causes ............................................... 42Recommended Actions...................................... 43

F

Factory Passwords................................................ 17Factory Passwords Worksheet.............................. 18

Flash Codes .......................................................... 52Flash Programming ............................................... 18Programming a Flash File.................................. 18

Fuel Dilution of Engine Oil ..................................... 43Probable Causes ............................................... 43Recommended Actions...................................... 43

Fuel in Cooling System.......................................... 43Probable Causes ............................................... 43Recommended Actions...................................... 43

I

Important Safety Information ................................... 2Injection Actuation Pressure - Test ...................... 160Injection Actuation Pressure Control Valve Circuit -Test .................................................................... 167Injection Actuation Pressure Sensor - Test.......... 172Injector Solenoid Circuit - Test............................. 177Injector Trim File.................................................... 19Intermittent Engine Shutdown ............................... 44Probable Causes ............................................... 44Recommended Actions...................................... 44

Intermittent Low Power or Power Cutout............... 45Probable Causes ............................................... 45Recommended Actions...................................... 45

L

Low Engine Oil Pressure ....................................... 46Probable Causes ............................................... 46Recommended Actions...................................... 46

Low Power/Poor or No Response to Throttle ........ 46Probable Causes ............................................... 46Recommended Actions...................................... 47

M

Maintenance Due Lamp Circuit - Test ................. 184Mechanical Noise (Knock) in Engine..................... 48Probable Causes ............................................... 48Recommended Repairs ..................................... 49

N

Noise Coming from Cylinder.................................. 49Probable Causes ............................................... 49Recommended Actions...................................... 49

P

Poor Acceleration or Response............................. 49Probable Causes ............................................... 49Recommended Actions...................................... 50

Programming Parameters ..................................... 17PTO Switch Circuit - Test..................................... 188

R

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

S

Self-Diagnostics..................................................... 10Sensors and Electrical Connectors ........................ 11Component Location.......................................... 14Cross-Reference for the P1 ECM Connector andthe J61 Customer Connector ........................... 13

Service Information Report.................................... 19Recommendations............................................. 19

Switch Circuits - Test ........................................... 193System Configuration Parameters......................... 21Monitoring System ............................................. 26Parameter Descriptions ..................................... 21System Configuration Parameters ..................... 24

System Overview..................................................... 5Passwords ........................................................... 6Programmable Parameters.................................. 6System Operation ................................................ 5

T

Table of Contents..................................................... 3Throttle Position Sensor - Calibrate..................... 207Throttle Position Sensor Circuit - Test ................. 197Troubleshooting Section.......................................... 5Troubleshooting with a Diagnostic Code ............... 52Troubleshooting with an Event Code..................... 74Troubleshooting without a Diagnostic Code .......... 28

V

Valve Rotator or Spring Lock Is Free..................... 51Probable Causes ............................................... 51Recommended Actions...................................... 51

W

Warning Lamp Circuit - Test ................................ 201

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