Professional Documents
Culture Documents
August 2010
Troubleshooting
3500B and 3500C Marine Propulsion
Engines
M8A1-Up (Engine)
M8B1-Up (Engine)
S2D1-Up (Engine)
S2E1-Up (Engine)
S2F1-Up (Engine)
B5G1-Up (Engine)
MRG1-Up (Engine)
PAG1-Up (Engine)
MKH1-Up (Engine)
S2J1-Up (Engine)
S2K1-Up (Engine)
S2L1-Up (Engine)
S2M1-Up (Engine)
S2N1-Up (Engine)
S2S1-Up (Engine)
S2T1-Up (Engine)
S2W1-Up (Engine)
S2X1-Up (Engine)
S2Y1-Up (Engine)
SAFETY.CAT.COM
i03991620
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5009-07 3
Table of Contents
Table of Contents MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open
circuit ................................................................... 64
MID 036 - CID 0001 - FMI 06 Injector Cylinder 1
short .................................................................... 64
Troubleshooting Section MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 open
circuit ................................................................... 64
Electronic Troubleshooting
MID 036 - CID 0002 - FMI 06 Injector Cylinder 2
System Overview .................................................... 6
short .................................................................... 65
Self-Diagnostics .................................................... 10
MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 open
Electronic Service Tools ......................................... 11
circuit ................................................................... 65
Electronic Display Module .................................... 14
MID 036 - CID 0003 - FMI 06 Injector Cylinder 3
Engine Monitoring System .................................... 16
short .................................................................... 65
MID 036 - CID 0004 - FMI 05 Injector Cylinder 4 open
Programming Parameters
circuit ................................................................... 65
Programming Parameters ..................................... 21
MID 036 - CID 0004 - FMI 06 Injector Cylinder 4
Factory Passwords ............................................... 21
short .................................................................... 66
Factory Passwords Worksheet ............................. 21
MID 036 - CID 0005 - FMI 05 Injector Cylinder 5 open
Flash Programming .............................................. 22
circuit ................................................................... 66
System Conguration Parameters ........................ 23
MID 036 - CID 0005 - FMI 06 Injector Cylinder 5
Customer Parameters Worksheet ........................ 27
short .................................................................... 66
Replacing the ECM ............................................... 29
MID 036 - CID 0006 - FMI 05 Injector Cylinder 6 open
circuit ................................................................... 66
Troubleshooting without a Diagnostic Code
MID 036 - CID 0006 - FMI 06 Injector Cylinder 6
Symptoms ............................................................. 31
short .................................................................... 67
Air Starting Motor .................................................. 31
MID 036 - CID 0007 - FMI 05 Injector Cylinder 7 open
Alternator .............................................................. 32
circuit ................................................................... 67
Can Not Reach Top Engine RPM ......................... 32
MID 036 - CID 0007 - FMI 06 Injector Cylinder 7
Coolant in Engine Oil ............................................ 33
short .................................................................... 67
Coolant Temperature Is Too High ......................... 34
MID 036 - CID 0008 - FMI 05 Injector Cylinder 8 open
ECM Will Not Accept Factory Passwords ............. 35
circuit ................................................................... 67
ECM Will Not Communicate with Other Systems or
MID 036 - CID 0008 - FMI 06 Injector Cylinder 8
Display Modules .................................................. 35
short .................................................................... 68
Electronic Service Tool Will Not Communicate with
MID 036 - CID 0009 - FMI 05 Injector Cylinder 9 open
ECM .................................................................... 35
circuit ................................................................... 68
Engine Cranks but Will Not Start .......................... 36
MID 036 - CID 0009 - FMI 06 Injector Cylinder 9
Engine Has Early Wear ........................................ 38
short .................................................................... 68
Engine Misres, Runs Rough or Is Unstable ........ 38
MID 036 - CID 0010 - FMI 05 Injector Cylinder 10
Engine Oil in Cooling System ............................... 40
open circuit .......................................................... 68
Engine Stalls at Low RPM .................................... 40
MID 036 - CID 0010 - FMI 06 Injector Cylinder 10
Engine Will Not Crank ........................................... 41
short .................................................................... 69
Excessive Engine Oil Consumption ...................... 42
MID 036 - CID 0011 - FMI 05 Injector Cylinder 11
Excessive Black Smoke ........................................ 43
open circuit .......................................................... 69
Excessive White Smoke ....................................... 44
MID 036 - CID 0011 - FMI 06 Injector Cylinder 11
Exhaust Temperature Is Too High ......................... 45
short .................................................................... 69
Fuel Dilution of Engine Oil .................................... 45
MID 036 - CID 0012 - FMI 05 Injector Cylinder 12
Fuel in Cooling System ......................................... 46
open circuit .......................................................... 69
Intermittent Engine Shutdown ............................... 46
MID 036 - CID 0012 - FMI 06 Injector Cylinder 12
Intermittent Low Power or Power Cutout .............. 47
short .................................................................... 70
Low Engine Oil Pressure ...................................... 48
MID 036 - CID 0013 - FMI 05 Injector Cylinder 13
Low Power/Poor or No Response to Throttle ....... 49
open circuit .......................................................... 70
Mechanical Noise (Knock) in Engine .................... 50
MID 036 - CID 0013 - FMI 06 Injector Cylinder 13
Noise Coming from Cylinder ................................. 51
short .................................................................... 70
Poor Fuel Consumption ........................................ 51
MID 036 - CID 0014 - FMI 05 Injector Cylinder 14
Secondary ECM Assumes Control ....................... 52
open circuit .......................................................... 70
Secondary ECM Indicator Fault ............................ 53
MID 036 - CID 0014 - FMI 06 Injector Cylinder 14
Synchronizing Switch Not Functioning Properly ... 53
short .................................................................... 71
Too Much Valve Lash ............................................ 61
MID 036 - CID 0015 - FMI 05 Injector Cylinder 15
Too Much Vibration ............................................... 61
open circuit .......................................................... 71
Valve Rotocoil or Spring Lock Is Free ................... 62
MID 036 - CID 0015 - FMI 06 Injector Cylinder 15
short .................................................................... 71
Troubleshooting with a Diagnostic Code
MID 036 - CID 0016 - FMI 05 Injector Cylinder 16
Diagnostic Codes .................................................. 63
open circuit .......................................................... 71
4 RENR5009-07
Table of Contents
MID 036 - CID 0016 - FMI 06 Injector Cylinder 16 MID 036 - CID 0274 - FMI 04 Atmospheric Pressure
short .................................................................... 72 short to ground .................................................... 80
MID 036 - CID 0091 - FMI 08 Throttle Position signal MID 036 - CID 0275 - FMI 03 Right Turbo Inlet
abnormal ............................................................. 72 Pressure open/short to +batt .............................. 80
MID 036 - CID 0091 - FMI 13 Throttle Position MID 036 - CID 0275 - FMI 04 Right Turbo Inlet
calibration required ............................................. 72 Pressure short to ground .................................... 81
MID 036 - CID 0094 - FMI 03 Fuel Pressure MID 036 - CID 0276 - FMI 03 Left Turbo Inlet
open/short to +batt .............................................. 73 Pressure open/short to +batt .............................. 81
MID 036 - CID 0094 - FMI 04 Fuel Pressure short to MID 036 - CID 0276 - FMI 04 Left Turbo Inlet
ground ................................................................. 73 Pressure short to ground .................................... 81
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0277 - FMI 08 Timing Calibration
open/short to +batt .............................................. 73 signal abnormal ................................................... 81
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0279 - FMI 03 Aftercooler Temperature
short to ground .................................................... 73 open/short to +batt .............................................. 82
MID 036 - CID 0101 - FMI 03 Crankcase Pressure MID 036 - CID 0279 - FMI 04 Aftercooler Temperature
open/short to +batt .............................................. 74 short to ground .................................................... 82
MID 036 - CID 0101 - FMI 04 Crankcase Pressure MID 036 - CID 0289 - FMI 03 Unltered Fuel Pressure
short to ground .................................................... 74 open/short to +batt .............................................. 82
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0289 - FMI 04 Unltered Fuel Pressure
Temperature open/short to +batt ......................... 74 short to ground .................................................... 83
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Temperature short to ground ............................... 74 inputs .................................................................. 83
MID 036 - CID 0168 - FMI 00 System Voltage MID 036 - CID 0337 - FMI 02 Incorrect Remote
High ..................................................................... 75 E-Stop Switch inputs ........................................... 83
MID 036 - CID 0168 - FMI 01 System Voltage MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
Low ..................................................................... 75 circuit ................................................................... 83
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short
intermittent/erratic ............................................... 75 to ground ............................................................. 84
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed MID 036 - CID 0342 - FMI 02 Loss of Secondary
signal ................................................................... 75 Engine Speed signal ........................................... 84
MID 036 - CID 0190 - FMI 03 Engine Speed MID 036 - CID 0342 - FMI 03 Secondary Engine
open/short to +batt .............................................. 76 Speed open/short to +batt .................................. 84
MID 036 - CID 0190 - FMI 07 Primary Speed Sensor MID 036 - CID 0342 - FMI 07 Secondary Speed
misinstalled ......................................................... 76 Sensor misinstalled ............................................. 84
MID 036 - CID 0190 - FMI 08 Engine Speed signal MID 036 - CID 0342 - FMI 08 Secondary Engine
abnormal ............................................................. 76 Speed signal abnormal ....................................... 85
MID 036 - CID 0248 - FMI 09 Cat Data Link not MID 036 - CID 0444 - FMI 05 Start Relay open
communicating .................................................... 76 circuit ................................................................... 85
MID 036 - CID 0253 - FMI 02 Personality Module MID 036 - CID 0444 - FMI 06 Start Relay short to
mismatch ............................................................. 77 ground ................................................................. 85
MID 036 - CID 0254 - FMI 12 Electronic Control MID 036 - CID 0446 - FMI 05 Air Shutoff Relay
Module Error ....................................................... 77 open .................................................................... 85
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0446 - FMI 06 Air Shutoff Relay
calibration required ............................................. 77 short .................................................................... 86
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC MID 036 - CID 0542 - FMI 03 Unltered Engine Oil
Power Supply short to +batt ................................ 78 Pressure open/short to +batt .............................. 86
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC MID 036 - CID 0542 - FMI 04 Unltered Engine Oil
Power Supply short to ground ............................. 78 Pressure short to ground .................................... 86
MID 036 - CID 0263 - FMI 03 Digital Sensor Supply MID 036 - CID 0827 - FMI 08 Left Exhaust
short to +batt ....................................................... 78 Temperature signal abnormal ............................. 86
MID 036 - CID 0263 - FMI 04 Digital Sensor Supply MID 036 - CID 0828 - FMI 08 Right Exhaust
short to ground .................................................... 78 Temperature signal abnormal ............................. 87
MID 036 - CID 0268 - FMI 02 Check Programmable MID 036 - CID 1249 - FMI 08 Secondary Throttle
Parameters ......................................................... 79 Position signal abnormal ..................................... 87
MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure MID 036 - CID 1249 - FMI 13 Secondary Throttle
above normal ...................................................... 79 Position calibration required ................................ 87
MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure MID 036 - CID 1495 - FMI 02 Injector Trim Codes Not
open/short to +batt .............................................. 79 Programmed ....................................................... 88
MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure MID 047 - CID 0001 - FMI 05 Injector Cylinder 1 open
short to ground .................................................... 80 circuit ................................................................... 88
MID 036 - CID 0274 - FMI 03 Atmospheric Pressure MID 047 - CID 0001 - FMI 06 Injector Cylinder 1
open/short to +batt .............................................. 80 short .................................................................... 88
RENR5009-07 5
Table of Contents
MID 047 - CID 0002 - FMI 05 Injector Cylinder 2 open MID 047 - CID 0190 - FMI 08 Engine Speed signal
circuit ................................................................... 88 abnormal ............................................................. 96
MID 047 - CID 0002 - FMI 06 Injector Cylinder 2 MID 047 - CID 0342 - FMI 02 Loss of Secondary
short .................................................................... 89 Engine Speed signal ........................................... 96
MID 047 - CID 0003 - FMI 05 Injector Cylinder 3 open MID 047 - CID 0342 - FMI 08 Secondary Engine
circuit ................................................................... 89 Speed signal abnormal ....................................... 97
MID 047 - CID 0003 - FMI 06 Injector Cylinder 3
short .................................................................... 89 Troubleshooting with an Event Code
MID 047 - CID 0004 - FMI 05 Injector Cylinder 4 open Event Codes ........................................................ 98
circuit ................................................................... 89 E007 High Aftercooler Temperature Derate .......... 99
MID 047 - CID 0004 - FMI 06 Injector Cylinder 4 E008 High Aftercooler Temperature Shutdown .. 100
short .................................................................... 90 E009 High Altitude Derate .................................. 101
MID 047 - CID 0005 - FMI 05 Injector Cylinder 5 open E012 High Crankcase Pressure Derate .............. 101
circuit ................................................................... 90 E013 High Crankcase Pressure Shutdown ........ 102
MID 047 - CID 0005 - FMI 06 Injector Cylinder 5 E015 High Engine Coolant Temperature Derate .. 103
short .................................................................... 90 E016 High Engine Coolant Temperature
MID 047 - CID 0006 - FMI 05 Injector Cylinder 6 open Shutdown .......................................................... 104
circuit ................................................................... 90 E017 High Engine Coolant Temperature
MID 047 - CID 0006 - FMI 06 Injector Cylinder 6 Warning ............................................................. 104
short .................................................................... 91 E021 High Exhaust Temperature Derate ............ 105
MID 047 - CID 0007 - FMI 05 Injector Cylinder 7 open E031 Air Inlet Restriction Derate ........................ 106
circuit ................................................................... 91 E038 Low Engine Coolant Temperature
MID 047 - CID 0007 - FMI 06 Injector Cylinder 7 Warning ............................................................. 107
short .................................................................... 91 E040 Low Engine Oil Pressure Shutdown .......... 108
MID 047 - CID 0008 - FMI 05 Injector Cylinder 8 open E043 Low System Voltage Warning .................... 109
circuit ................................................................... 91 E048 Backup ECM Took Control ......................... 110
MID 047 - CID 0008 - FMI 06 Injector Cylinder 8 E095 Fuel Filter Restriction Warning ................... 111
short .................................................................... 92 E099 Engine Oil Filter Restriction Warning .......... 112
MID 047 - CID 0009 - FMI 05 Injector Cylinder 9 open E100 Low Engine Oil Pressure Warning .............. 112
circuit ................................................................... 92 E101 High Crankcase Pressure Warning ............ 113
MID 047 - CID 0009 - FMI 06 Injector Cylinder 9 E173 High Exhaust Temperature Warning ........... 114
short .................................................................... 92 E190 Engine Overspeed Warning ....................... 115
MID 047 - CID 0010 - FMI 05 Injector Cylinder 10 E272 Inlet Air Restriction Warning ....................... 116
open circuit .......................................................... 92 E279 High Aftercooler Temperature Warning ...... 116
MID 047 - CID 0010 - FMI 06 Injector Cylinder 10
short .................................................................... 93 Diagnostic Functional Tests
MID 047 - CID 0011 - FMI 05 Injector Cylinder 11 Air Shutoff System ............................................... 118
open circuit .......................................................... 93 Analog Sensor Supply ........................................ 125
MID 047 - CID 0011 - FMI 06 Injector Cylinder 11 CAN Data Link .................................................... 128
short .................................................................... 93 Cat Data Link ...................................................... 131
MID 047 - CID 0012 - FMI 05 Injector Cylinder 12 Digital Sensor Supply ......................................... 133
open circuit .......................................................... 93 Electrical Power Supply ...................................... 136
MID 047 - CID 0012 - FMI 06 Injector Cylinder 12 Emergency Stop Switch ...................................... 142
short .................................................................... 94 Emergency Stop Switch (Remote) ...................... 148
MID 047 - CID 0013 - FMI 05 Injector Cylinder 13 Engine Control Switch (ECS) .............................. 153
open circuit .......................................................... 94 Engine Sensor Open/Short Test ......................... 161
MID 047 - CID 0013 - FMI 06 Injector Cylinder 13 Engine Speed/Timing Sensor ............................. 170
short .................................................................... 94 Injector Solenoids ............................................... 175
MID 047 - CID 0014 - FMI 05 Injector Cylinder 14 Inspecting Electrical Connectors ........................ 182
open circuit .......................................................... 94 Prelubrication System ......................................... 187
MID 047 - CID 0014 - FMI 06 Injector Cylinder 14 Secondary ECM/Personality Module .................. 192
short .................................................................... 95 Starting Motor System ....................................... 197
MID 047 - CID 0015 - FMI 05 Injector Cylinder 15 Throttle Position Sensor ..................................... 202
open circuit .......................................................... 95
MID 047 - CID 0015 - FMI 06 Injector Cylinder 15 Calibration Procedures
short .................................................................... 95 Analog Sensor - Calibrate ................................... 208
MID 047 - CID 0016 - FMI 05 Injector Cylinder 16 Engine Speed/Timing Sensor - Calibrate ............ 209
open circuit .......................................................... 95 Throttle Position Sensor - Calibrate ..................... 211
MID 047 - CID 0016 - FMI 06 Injector Cylinder 16
short .................................................................... 96 Index Section
MID 047 - CID 0190 - FMI 02 Loss of Engine Speed
signal ................................................................... 96 Index ................................................................... 214
6 RENR5009-07
Troubleshooting Section
Electronic Controls
Electronic Control Module
The ECM controls the engine operation. The ECM
consists of two main components, the control
computer (hardware) and the personality module
(software). The control computer consists of
a microprocessor and electronic circuitry. The
personality module is the software for the control
computer which contains operating maps that dene
power and torque curves. The ECM monitors the
engine parameters during operation. The ECM
supplies signals to the electronic fuel injectors.
Fuel Injection
The ECM controls the timing of the engine by varying
the signals to the electronic solenoids that control
fuel injection. Fuel is injected only while an injector
solenoid is energized by a 105 volt signal from the
ECM. By controlling the timing and duration of the
105 volt signal, the ECM controls the fuel injection
timing, the quantity of fuel and the desired engine
speed. Injection timing depends on desired engine
speed, load, and other operational factors.
g00995630
Illustration 1
Typical example
8 RENR5009-07
Troubleshooting Section
g01019029
Illustration 2
Left side view
(1) Unltered fuel pressure sensor (5) Secondary ECM connector J2 (8) Secondary engine speed/timing sensor
(2) Filtered fuel pressure sensor (6) Left exhaust temperature sensor (9) Primary engine speed/timing sensor
(3) Aftercooler temperature sensor (7) Left turbocharger compressor inlet (10) Secondary ECM connector J1
(4) Coolant temperature sensor pressure sensor (11) Secondary ECM
RENR5009-07 9
Troubleshooting Section
g01019032
Illustration 3
Right side view
(12) Right turbocharger compressor inlet (13) Right exhaust temperature sensor
pressure sensor (14) Crankcase pressure sensor
10 RENR5009-07
Troubleshooting Section
g01019034
Illustration 4
Front and rear view
(4) Coolant temperature sensor (7) Left turbocharger compressor inlet (18) Atmospheric pressure sensor
(15) Filtered engine oil pressure sensor pressure sensor (19) Primary ECM connector J1
(16) Unltered engine oil pressure sensor (6) Left exhaust temperature sensor (20) Primary ECM
(3) Aftercooler temperature sensor (13) Right exhaust temperature sensor (21) Primary ECM connector J2
(17) Turbocharger compressor outlet (12) Right turbocharger compressor inlet
pressure sensor pressure sensor
Optional Service Tools Once you have downloaded Cat ET onto your
PC, you will need a license from your Caterpillar
Table 2 lists the optional service tools that may be dealer in order to use the software. Various licenses
needed during testing or repair. are available for different users with different
requirements. Consult your Caterpillar dealer.
Table 2
Optional Service Tools Note: For more information regarding the use of
Cat ET and the PC requirements for Cat ET, refer to
Pt. No. Description the documentation that accompanies your Cat ET
198-4240 Digital Pressure Indicator software.
or or
1U-5470 Engine Pressure Group Connecting Cat ET
4C-4075 Crimp Tool (4AWG TO 10AWG)
Connecting the Communication Adapter
4C-4911(1) Battery Load Tester
5P-7277 Voltage Tester Table 4 lists the standard hardware that is required in
order to connect Cat ET.
6V-9130(2) Temperature Adapter (MULTIMETER)
8T-5319 Connector Tool Group Note: The 275-5120 Communication Adapter
Gp was canceled and replaced by the 317-7484
349-4199 AC/DC Current Probe Communication Adapter Gp. However, the 275-5120
348-5430 Multi-Tool Gp Communication Adapter Gp can still be used.
(1) Refer to Special Instructions, SEHS9249, Use of 4C-4911 Table 4
Battery Load Tester for 6, 8, and 12 v Lead Acid Batteries and
Special Instructions, SEHS7633, Battery Test Procedure. Standard Hardware for the Use of Cat ET
(2) Refer to Special Instructions, SEHS8382, Use of the 6V-9130
Temperature Adapter Group. Part Number Description
Cat ET can be used by the technician to help perform Components of the 317-7484 Communication
the following procedures: Adapter Gp
Communication Adapter
317-7485
Diagnostic tests (3)
353-5083 Cable As (USB)
Calibrations
327-8981 Cable As (DATA LINK)
Flash programming Tool Operating Manual & Software CD ROM,
NETG5057, Communication Adapter 3
Conguration of the ECM
Cat ET can display the following information: Follow the instructions for the communication
adapter. Use the following procedure in order to
Parameters connect Cat ET and the communication adapter to
a PC.
Event codes
1. Remove the electrical power from the ECM.
Diagnostic codes
Engine conguration
Always use the latest revision of Cat ET. The media
is available on CD and the media can also be
downloaded from various Caterpillar web sites.
Table 3
Cat ET displays Error #142 The interface (1) Personal computer (PC)
(7) 261-4867 Card (PCMCIA)
hardware is not responding. (8) 239-9955 Communication Radio Gp
(9) 259-3183 Data Link Cable As
14 RENR5009-07
Troubleshooting Section
Note: Items (7), (8), and (9) are part of the 261-3363
Wireless Communication Adapter Gp.
g01163897
Illustration 7
Control Panel
g01316970
Illustration 8
Control panel
(1) Marine Power Display (11) Reset 1 relay (21) Overspeed indicator
(2) ECM Ready lamp (12) Stop 1 relay (22) Emergency stop lamp
(3) Pyrometer (13) Reset 2 relay (23) STE relay
(4) Override switch (crank) (14) Stop 2 relay (24) Run 1 relay
(5) Prelube override switch (15) Horn relay (25) STPE relay
(6) Marine override switch (16) Engine control switch (ECS) (26) Run 2 relay
(7) Torque limit switch (17) Speed Control (27) ECSIR relay
(8) Local/remote switch (throttle) (18) Emergency stop switch (28) SN relay
(9) Diodes D1 to D10 (19) ECM Active lamp
(10) RSR relay (20) Alarm (horn)
g01621243
Illustration 9
Power distribution panel
(29) Circuit breaker for the primary ECM (20 (34) PPR2 relay (44) SD Notify relay
Amp) (35) Relay 4A (45) Starting motor magnetic switch 2
(30) Circuit breaker for the secondary ECM (36) Relay 4 (46) Starting motor magnetic switch 1
(20 Amp) (37) Relay 3A (47) PPR1 switch
(31) Circuit breaker for the prelube and air (38) Relay 3 (48) Air shutoff switch (ASOS)
shutoff circuits (40 Amp) (39) Relay 2A
(32) Marine Power Display (MPD) circuit (40) Relay 2
breaker (20 Amp) (41) Relay 1
(33) Starter and alternator circuit breaker (42) Air shutoff timer
(70 Amp) (43) General alarm relay
Table 6
Parameter Hysteresis
ECM Voltage 2 VDC
Oil Pressure 20 kPa (2.9 psi)
High Coolant Temperature 5 C (41 F)
Low Coolant Temperature 5 C (41 F)
Overspeed 100 rpm
Air Inlet Restriction 1.5 kPa (6.0 inch of H2O)
Altitude 0
High Exhaust Temperature 10 C (50 F)
Oil Filter Differential 10 kPa (1.5 psi)
Pressure
Fuel Filter Differential 10 kPa (1.5 psi)
Pressure
Crankcase Pressure 0.25 kPa
(1.0047 inch of H2O)
Aftercooler Water 3 C (37 F)
Temperature
High Transmission Oil 5 C (41 F)
Temperature
High Boost Pressure 0
Table 7
(Table 7, contd)
High Coolant On/Off
Temperature
Warning 102 C (216 F) 5 Seconds 90 C (194 F) 102 C 1 to 60
(216 F) Seconds
Derate 107 C (225 F) 30 90 C (194 F) 107 C 1 to 60
Seconds (225 F) Seconds
Shutdown 107 C (225 F) 5 Seconds 90 C (194 F) 107 C 1 to 60
(225 F) Seconds
Low Coolant On/Off
Temperature
Warning 80 C (176 F) 5 Seconds 63 C (145 F) 85 C (185 F) 1 to 60
Seconds
Engine On/Off
Overspeed
Warning Application 0 Seconds 1200 rpm 2400 rpm 0 to 5
Dependent Seconds
(Table 7, contd)
Aftercooler On/Off
Water
Temperature Warning 102 C (216 F) 5 Seconds 40 C (104 F) 102 C 1 to 60
(216 F) Seconds
Derate 107 C (225 F) 5 Seconds 40 C (104 F) 107C 1 to 60
(225 F) Seconds
Shutdown 107 C (225 F) 5 Seconds 40 C (104 F) 107 C 1 to 60
(225 F) Seconds
High Boost On/Off
Pressure
Derate 400 kPa (58 psi) 30 400 kPa 400 kPa 0 Seconds
Seconds (58 psi) (58 psi)
High On/Off
Transmission Oil
Temperature(2) Warning 99 C (210 F) 5 Seconds 20 C (68 F) 120 C 1 to 120
(248 F) Seconds
Low On/Off
Transmission
Oil Pressure(2) Warning 1500 kPa (218 psi) 5 Seconds 900 kPa 2900 kPa 1 to 60
(131 psi) (421 psi) Seconds
Low Engine On/Off
Coolant Level(2)
Warning ON 10 ON ON 1 to 120
Seconds Seconds
(1) Refer to the oil pressure map.
(2) Optional equipment
g01027393
Illustration 10
Oil pressure map
RENR5009-07 21
Troubleshooting Section
i02399101
Total tattletale
Factory Passwords Note: Factory passwords are only valid for the current
Cat ET screen. A different set of factory passwords
SMCS Code: 1901-038 will be required if you exit the current Cat ET screen.
A different set of passwords will be required to
change information on another Cat ET screen.
Passwords
Passwords are part of a security system that helps to Customer Passwords
prevent unauthorized changing of certain parameters.
Passwords prevent unauthorized erasing of logged Customer passwords allow the customer to restrict
events. Passwords allow the factory to control access access to parameters that can be changed by the
to engine calibration parameters. Passwords allow customer. The customer passwords cannot be longer
the customer to control access to certain engine than eight characters. The customer passwords may
parameters. consist of alphanumeric characters. The customer
has the option of entering one or two customer
passwords.
Factory Passwords
If customer passwords have been entered, then
Factory passwords are required to clear any event the customer passwords are required to change
code. Factory passwords are required to change any parameter that is customer programmable.
certain parameters such as Full Load Setting. Parameters that are customer programmable are
Factory passwords restrict changes to authorized those parameters that affect the engine speed
personnel. When the correct factory passwords have limits and the power rating within an engine family.
been entered, the changes can then be made. Refer to the diagnostic procedure Troubleshooting,
System Conguration Parameters for more detail
Note: Factory passwords are calculated on a on parameters that are customer programmable.
computer system that is only available to Caterpillar
dealers. Note: If the owner loses the owner's customer
passwords, the owner will not be able to change
In order to obtain the proper factory passwords, parameters that are protected by customer
certain information must be given to an authorized passwords. You must use factory passwords in order
Caterpillar dealer. Since the factory passwords to read the customer passwords. You may then use
contain alphabetic characters, the Caterpillar those customer passwords to change parameters
Electronic Technician (ET) can be used to perform that have been protected by customer passwords.
this function. In order to obtain the factory passwords,
proceed as if you already have the factory passwords.
At some point, if the factory passwords are actually i01562584
needed, Cat ET will request the factory passwords
and Cat ET will display the information that is required Factory Passwords Worksheet
to obtain the factory passwords.
SMCS Code: 1901-038
If you do not have the ash le, use the Flash File
Search tool on the Service Technician Workbench
(STW) to obtain the ash le for your engine.
Alternatively, use the Service Software Files feature
on SIS Web to obtain the ash le for your engine.
You must have the engine serial number in order to
search for the ash le. After locating the correct
ash le, download the ash le to your PC. Write
down the name of the ash le for future reference.
RENR5009-07 23
Troubleshooting Section
Fuel Ratio Control This parameter determines when the starting motor
will disengage.
The Fuel Ratio Control limit controls the amount
of fuel to air ratio by limiting the rack as a function Total Tattletale
of boost pressure, engine speed and altitude. The
Fuel Ratio Control function permits an offset to be The parameter counts the number of changes to
applied to the calculation for the altitude. The offset system parameters.
changes the fuel to the air ratio to a richer mixture
or a leaner mixture.
Parameter Table
Table 9
Parameter Table
Table 10
Customer Parameters
Parameter ECM Default Range Password
Equipment ID Primary N/A 17 alphanumeric No
Secondary characters
Engine Serial Number Primary 8 alphanumeric No
Secondary characters
#AA#####
ECM Serial Number Primary ECM Serial Number ECM Serial Number N/A
Secondary
Personality Module Primary N/A
Part Number Secondary
Personality Module Primary Month N/A
Release Date Secondary Year
Engine Rotation Primary Forward Forward/Reverse N/A
Secondary
Engine Location Primary Center Port No
Center
Starboard
Full Load Setting Primary Not Programmed 128 to +127 Yes
(FLS) Secondary
Full Torque Setting Primary 0 128 to +127 Yes
(FTS) Secondary
Rated Engine Speed Primary Programmed at the Factory N/A
Factory
High Idle Speed (rpm) Primary Programmed at the Factory N/A
Factory
Low Idle Speed (rpm) Primary 600 300 to 900 No
Secondary
Fuel Correction Primary 0 64 to +63.5 No
Factor
Coolant Level Sensor Primary Installed Not Installed No
Data Link
Sensor
Torque Limit Enable Primary Not installed Installed No
Status Secondary Not Installed
Maximum Engine Primary Programmed at the Factory No
Torque Limit Secondary Factory
Minimum Engine Primary Programmed at the Factory No
Torque Limit Secondary Factory
Coolant Warning Primary 40% 5 to 95% No
Engine Load Enable
Threshold
Air Shutoff Status Secondary Enabled Enabled No
Disabled
RENR5009-07 27
Troubleshooting Section
i01908609 Table 13
Worksheet Parameter
Equipment ID
SMCS Code: 1901-038
Engine Serial Number
Table 11 ECM Serial Number
Parameter Worksheet
Personality Module Part
System Conguration Number
Table 14
Parameter Worksheet
Programmable Monitoring System
Warning Trip Warning Delay Derate Trip Derate Delay Shutdown Trip Shutdown
Point Time Point Time Point Delay Time
Low System
Voltage
Low Oil
Pressure
High Coolant
Temperature
Low Coolant
Temperature
Engine
Overspeed
Air Filter
Restriction
Pressure
Altitude
High Exhaust
Temperature
Oil Filter
Differential
Pressure
Fuel Filter
Differential
Pressure
Crankcase
Pressure
Aftercooler
Water
Temperature
High
Transmission
Oil
Temperature
Low
Transmission
Oil Pressure
RENR5009-07 29
Troubleshooting Section
i01908773
NOTICE
Replacing the ECM If the personality module and engine application are
not matched, engine damage may result.
SMCS Code: 1901-038
e. Disconnect the ECM ground strap from the 9. Calibrate the fuel injectors. Refer to the diagnostic
engine. functional test Troubleshooting, Injector Codes -
Calibrate.
5. Install the replacement ECM.
10. Calibrate the injection timing. Refer to the
a. Use the old mounting hardware to install the diagnostic functional test Troubleshooting,
replacement ECM. The mounting hardware Engine Speed/Timing Sensor - Calibrate.
should be free of damage.
11. Check for diagnostic codes and for event codes.
b. Reconnect the fuel lines (if equipped).
Engine oil level 5. Repair the motor and/or replace the motor.
Engine oil supply The Air Starting Motor has a loss of power.
b. Inspect the rotor bearings. If the bearings are 4. Inspect the drive belts. Install new drive belts.
loose or damaged replace the bearings. Loosen the drive pulley. Tighten the pulley. Refer
to the Specications manual. If the belt and the
c. Inspect the rotor for scoring. Attempt to remove pulley are misaligned, adjust the belt and the
the scoring with an emery cloth. If the scoring pulley. If the alternator bearings are worn, install
cannot be removed, replace the rotor. new bearings.
d. Inspect the cylinders for cracks and/or scoring. 5. If the problem is still present, refer to Special
If necessary, replace the cylinder. Instruction, REHS0354, Charging System
Troubleshooting.
4. Check for worn seals. Plug the exhaust and apply
205 kPa (30 psi) to the inlet. Place the unit in a
i02421020
nonammable liquid for 30 seconds. If bubbles
appear, replace the motor seals. Can Not Reach Top Engine
The pinion does not engage the ywheel. RPM
The probable root cause is a broken clutch and/or SMCS Code: 1000-038; 1901-038
other parts. Replace the clutch.
Note: If this problem occurs under load, refer to
The pinion engages the ywheel but the ywheel the diagnostic procedure Troubleshooting, Low
does not turn. Power/Poor Or No Response To Throttle.
Working on the low pressure fuel supply circuit Failure of cylinder head gasket
Check the water temperature regulator. A water Inspect the impeller vanes at the jacket water pump
temperature regulator that does not open, or a water for damage and/or for erosion. Repair impeller vanes
temperature regulator that only opens part of the way and/or replace the impeller vanes.
can cause overheating.
Faulty Engine Cooling Fan (if equipped)
Radiator
1. If the fan is belt driven, check for loose drive belts.
1. Check the cooling ns on the radiator for dirt A loose fan drive belt will cause a reduction in the
and/or for debris. Remove the dirt and/or debris. air ow across the radiator. Check the fan drive
belt for proper belt tension. Adjust the tension of
Inspect the cooling ns on the radiator for damage. the fan drive belt, if necessary. Refer to Operation
Refer to the Systems Operation/Testing and and Maintenance Manual.
Adjusting manual.
2. Check the fan clutch, if equipped. A fan clutch
2. Check the radiator for internal blockage. Check or a hydraulic driven fan that is not turning at
the temperature difference between the top and the correct speed can cause improper air speed
the bottom of the radiator. across the radiator core. The lack of proper air ow
across the radiator core can cause the coolant not
to cool to the proper temperature differential.
RENR5009-07 35
Troubleshooting Section
Check operation of the pressure relief valve and the ECM Will Not Communicate
radiator cap. If necessary, clean the pressure relief with Other Systems or Display
valve and/or the radiator cap. Check that the seating
surface of the valve is clean and undamaged. If Modules
necessary, install new parts.
SMCS Code: 1901-038
i02826488
Probable Causes
ECM Will Not Accept Factory
Electronic Control Module (ECM)
Passwords
Connector or wiring problem
SMCS Code: 1901-038
Cat Data Link
Probable Causes
CAN data link (if applicable)
One of the following items may not be recorded
correctly on the Caterpillar Electronic Technician Recommended Actions
(ET):
Passwords ECM
Connect Caterpillar Electronic Technician (ET). If the
Serial numbers ECM does not communicate with the Cat ET, perform
the diagnostic functional test Troubleshooting,
Total tattletale Electronic Service Tool Will Not Communicate With
ECM.
Reason code
Connectors or Wiring
Recommended Actions
Check for correct installation of the ECM connectors.
1. Verify that the correct passwords were entered. Check any machine connector or the customer
Check every character in each password. Remove connector in the circuit for correct installation. Refer
the electrical power from the engine for 30 to the diagnostic functional test Troubleshooting,
seconds and then retry. Inspecting Electrical Connectors.
2. Verify that Cat ET is displaying the Enter Factory
Passwords dialog box. Cat Data Link
3. Use Cat ET to verify that the following information Verify that the Cat Data Link does not have an open
has been entered correctly: or short circuit. Refer to the diagnostic functional test
Troubleshooting, Cat Data Link.
Engine serial number
CAN data link (if applicable)
Serial number for the electronic control module
Verify that the CAN data link does not have an open
Serial number for Cat ET or short circuit. Refer to the diagnostic functional test
Troubleshooting, CAN Data Link.
Total tattletale
i02561494
Reason code
For additional information, refer to Troubleshooting,
Electronic Service Tool Will
Factory Passwords. Not Communicate with ECM
SMCS Code: 1901-038
Probable Causes
Conguration for the communications adapter
36 RENR5009-07
Troubleshooting Section
Electrical power supply to the Electronic Control Electrical Power Supply to the Service
Module (ECM)
Tool Connector
Flash le Verify that battery voltage is present between
terminals A and B of the service tool connector. If the
Cat Data Link communication adapter is not receiving power, the
display on the communication adapter will be blank.
Recommended Actions
Cat ET and Related Hardware
Start the engine. If the engine starts, but the ECM
will not communicate with Cat ET, continue with In order to eliminate Cat ET and the related hardware
this procedure. If the engine will not start, refer to as the problem, connect Cat ET to a different engine.
Troubleshooting, Engine Cranks but Will Not Start. If the same problem occurs on a different engine,
If the engine will not crank, refer to Troubleshooting, check Cat ET and the related hardware in order to
Engine Will Not Crank. determine the cause of the problem.
Note: The most commonly used port is COM 1. Ensure that the correct ash le is properly installed
in the ECM.
4. Check for any hardware that is utilizing the
same port as the communications adapter. If any Note: The new ECM does not have a ash le.
devices are congured to use the same port, exit The engine will not start and the engine will not
or close the software programs for that device. communicate with Cat ET until the ash le has
been installed. Refer to Troubleshooting, Flash
Programming.
Electrical Connectors
Check for correct installation of the J1/P1 and J2/P2 Cat Data Link
ECM connectors and of the service tool connector.
Refer to Troubleshooting, Inspecting Electrical Troubleshoot the Cat Data Link for possible problems.
Connectors. Refer to Troubleshooting, Cat Data Link.
1. If you are using a Communication Adapter II, Engine Cranks but Will Not
ensure that the rmware and software for the
communication adapter are the most current les
Start
that are available. If the rmware and software do SMCS Code: 1000-038; 1901-038
not match, the communication adapter will not
communicate with Cat ET. The probable root causes are listed below:
RENR5009-07 37
Troubleshooting Section
Electrical power supply b. Purge air from the low pressure fuel supply
circuit with the hand priming pump and by
Low fuel level cranking the engine in 30 second cycles. After
you crank the engine, stop for two minutes.
Fuel supply This will allow the starting motor to cool.
Loosen the vent plug for the fuel return line.
Starting aids (if applicable) The plug is located on the rear upper left side of
the engine block. Hand prime the engine again
Cranking speed if air in fuel continues. A sight glass in the low
pressure supply line is helpful in diagnosing air
Shutdown switch in the fuel.
1. Measure the voltage at the connector of the 5. Check the cranking speed of the starter.
Electronic Control Module (ECM). If the ECM is
not receiving battery voltage, the ECM will not 6. The shutdown switch should be in the OFF
power up. Refer to the diagnostic functional test position. Connect the Caterpillar Electronic
Troubleshooting, Electrical Power Supply. Technician (ET). Use Cat ET in order to verify
the status of the shutdown switch. If the Cat ET
2. Visually check the fuel level. If necessary, add will not communicate with the ECM, refer to the
fuel. Ensure the proper operation of the jacket diagnostic procedure Troubleshooting, Electronic
water heater. Repair the jacket water heater Service Tool Will Not Communicate with ECM.
and/or replace the jacket water heater. Check for When a shutdown occurs, the keyswitch must
the presence of solidied fuel (wax). be turned to the OFF position. The keyswitch
must then be turned to the ON position before the
3. Check the fuel system. Check fuel lines for the engine will start.
following problems: restrictions, collapse, pinched
line, and loose ttings. Repair the lines and/or 7. Use Cat ET to determine if any active shutdowns
replace the lines. are present. If a Shutdown is ACTIVE, determine
the reason. After you correct the problem, turn
a. Check the fuel tank for foreign objects which the keyswitch to the OFF position for at least 15
may block the fuel supply. Check for air in seconds before you try to restart the engine.
the low pressure fuel supply system after you
perform the following procedures: 8. Check for correct installation of the following
components: ECM connectors J1/P1 and
Replacing the fuel lters J2/P2, customer connector, connector for the
engine speed/timing sensor, and fuel injector
Working on the low pressure fuel supply connectors. Refer to the diagnostic functional
circuit test Troubleshooting, Inspecting Electrical
Connectors.
Replacing fuel injectors
9. The circuit breakers may exceed the trip point due
to overheating. Check the circuit breakers on the
machine. Reset the circuit breakers if the circuit
breakers are tripped.
11. Crank the engine and observe the engine Contaminated Engine Oil
rpm on Cat ET. If engine rpm is 0, refer to
the diagnostic functional test Troubleshooting, Drain the crankcase and rell the crankcase with
Engine Speed/Timing Sensor. clean engine oil. Install new engine oil lters. Refer to
the engine's Operation and Maintenance Manual.
a. Ensure that the timing reference gear is
installed correctly. The engine will not start if If the oil lter bypass valve is open, the oil will not be
the gear was installed backward. Check for ltered. Check the oil lter bypass valve for a weak
proper orientation between the crankshaft and spring or for a broken spring. If the spring is broken,
camshaft drive gears. Correct the orientation replace the spring. Refer to the engine's Disassembly
and/or replace the drive gear. Refer to and Assembly manual. Make sure that the oil bypass
Disassembly and Assembly Manual. valve is operating correctly.
12. Perform the Injector Solenoid Test. Verify Low Oil Pressure
that the ECM is energizing all the injector
solenoids. Refer to the diagnostic functional test When some components of the engine show bearing
Troubleshooting, Injector Solenoids. wear in a short time, the cause can be a restriction in
a passage for engine oil.
13. Verify that both of the air shutoff valves are open
and that both of the air shutoffs are in the starting An indicator for the engine oil pressure may indicate
position. sufcient pressure, but a component is worn due
to a lack of lubrication. In such a case, look at the
14. Check for a problem with the combustion system. passage for the engine oil supply to the component.
1. Check the fuel tank for foreign objects which may 2. If air shutoff valves are installed, verify that the air
block the fuel supply. Check for air leaks in the shutoff valves are fully opened.
suction line of the fuel pump. Prime the fuel system
after you perform the following procedures: 3. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to the Systems
Replacing the fuel lters Operation/Testing and Adjusting for information on
the air inlet and exhaust system.
Working on the low pressure fuel supply circuit
Replacing fuel injectors
2. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
40 RENR5009-07
Troubleshooting Section
i02385598
Replacement of the fuel lters
Engine Stalls at Low RPM Service on the low pressure fuel supply circuit
SMCS Code: 1000-038; 1901-038 Replacement of unit injectors
Note: A sight glass in the fuel supply line is helpful in
Probable Causes diagnosing air in the fuel.
Unit injectors 5. Cold weather adversely affects the characteristics
of the fuel. Refer to the applicable Operation and
Fuel supply Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Air shutoff valves (if applicable) or blocked air operation.
supply
6. Check the fuel pressure after the fuel lter while The secondary ECM is not connected to the
the engine is being cranked. Refer to the Systems Battery. The yellow SECONDARY ECM READY
Operation/Testing and Adjusting manual for the indicator on the panel for the Marine Power
correct pressure values. If the fuel pressure is low, Display (MPD) does not illuminate and the red
replace the fuel lters. If the fuel pressure is still OVERSPEED indicator illuminates upon an
low, check the following items: fuel transfer pump, attempt to start the engine.
fuel transfer pump coupling, and fuel pressure
regulating valve. Recommended Actions
Air Shutoff Valves (if applicable) Batteries and/or Battery Cables
1. Verify that the air shutoff valves are open.
1. Inspect the main power switch, battery posts,
and battery cables for loose connections and
2. Check for restrictions in the air inlet system. Refer for corrosion. If the battery cables are corroded,
to the Systems Operation/Testing and Adjusting
remove the battery cables and clean the battery
manual for information on the air inlet system.
cables. Tighten any loose connections.
Check the low idle setting. a. Charge the batteries. Refer to Special
Instruction, SEHS7633, Battery Test
Accessory Equipment Procedure.
Check all accessory equipment for problems that b. Load test the batteries. Refer to Special
may create excessive load on the engine. Repair Instruction, SEHS9249, Use of 4C-4911
any damaged components or replace any damaged Battery Load Tester for 6, 8 and 12 Volt Lead
components. Acid Batteries.
i02854965
Starting Motor Solenoid or Starting
Circuit
Engine Will Not Crank
1. Check the operation of the engine start switch.
SMCS Code: 1000-038; 1901-038 Monitor the engine start switch on Caterpillar
Electronic Technician (ET).
Probable Causes Refer to the appropriate troubleshooting test that
is applicable to your engine if repairs are required.
Batteries
2. Test the operation of the starting motor solenoid.
Battery cables
3. Check the wiring to the starting motor solenoid.
Starting circuit
Starting motor solenoid Starting Motor or Flywheel Ring Gear
Crank Enable Switch (if applicable) The Secondary ECM is Not Connected to
the Battery
Ensure that the crank enable switch is not faulty.
If the yellow SECONDARY ECM READY indicator
Transmission or Engine Accessories (if on the panel for the MPD does not illuminate and
applicable) the red OVERSPEED indicator illuminates upon
an attempt to start the engine, perform the following
1. If the engine's application has a transmission procedure.
neutral switch, test the operation of the
transmission neutral switch. Ensure that the 1. At the power distribution panel, open the 20 Amp
machine is in neutral gear before attempting to circuit breaker for the panel for the MPD. The
start the engine. MPD will turn off.
2. Ensure free movement of the driveline. 2. Reset the air shutoffs (if equipped). Cycle the
power to the ECM.
3. Ensure that the timing pin was not left in the
ywheel housing. 3. Start the engine.
4. Remove any engine accessories that may lock up 4. At the power distribution panel, close the 20 Amp
the engine and inspect any engine accessories circuit breaker for the panel for the MPD. The
that may lock up the engine. MPD will turn on.
The following list illustrates examples of engine Determine the reason for the secondary ECM to be
accessories that may lock up the engine: disconnected from battery power. The secondary
ECM can be connected to battery power and
Hydraulic pump that is driven from the rear gear the engine will continue running. The yellow
group SECONDARY ECM READY indicator will illuminate
on the panel for the MPD.
Air compressor
i02549516
Engine oil pump
Excessive Engine Oil
Other components that are driven by the engine Consumption
Hydraulic Cylinder Lock SMCS Code: 1300-038; 1901-038
Check for uid in the cylinders (hydraulic cylinder
lock) by removing the individual unit injectors. Probable Causes
Note: Drain the fuel from the cylinder head. Fuel will Oil leaks
ow from the cylinder head into the cylinders when
the unit injector is removed. Oil level
Check for leaks in the engine oil cooler. Check for oil b. Check for derates and for alarms.
in the engine coolant. If necessary, repair the engine
oil cooler. c. Perform a visual inspection of the system for
restrictions and/or for leaks.
Turbocharger 2. Check the exhaust system for restrictions.
Check the air inlet manifold for oil. Check for oil 3. Repair any leaks that were found. Remove
leakage past the seal rings in the impeller end of
any restrictions that were found. Replace any
the turbocharger shaft. If necessary, repair the
damaged components that were found.
turbocharger.
Fuel Injector
Valve Guides
Check that the injector trim codes have been entered.
If the valve guides are worn, reconditioning of the
Perform the Cylinder Cutout Test. Use similar
cylinder head is required.
conditions for the test that were experienced during
operation. Refer to the diagnostic functional test
Piston Rings Troubleshooting, Injector Solenoids.
i02281012
Electrical Connectors
Fuel in Cooling System 1. Check Cat ET for the following logged diagnostic
SMCS Code: 1350-038; 1901-038 codes: 168-01 and 168-02. Follow the battery
wires from the ECM back to the battery
The probable root cause is a damaged O-ring seal compartment. Refer to the electrical system
for a fuel injector. schematic. Inspect the wires and the power relay.
Check the power to the ECM and to the ground
Perform the following procedure: connections. Refer to the diagnostic functional
test Troubleshooting, Electrical Power Supply.
Remove the valve cover. Remove the fuel supply.
Disconnect the fuel return line from the cylinder head. 2. Check for correct installation of the J1/P1
Cap the fuel return connector and apply 700 kPa and J2/P2 Electronic Control Module (ECM)
(102 psi) maximum air pressure to the fuel supply connectors. Refer to Troubleshooting, Inspecting
connector. Check for fuel leakage around each fuel Electrical Connectors.
injector. If leakage is present, remove the leaking fuel
injector. Install a new O-ring seal onto the injector. 3. Inspect the battery wires from the ECM back to
Install the injector. Connect the fuel return line. Install the battery compartment. Refer to the Electrical
the valve cover. Verify that the problem is resolved. System Schematic. Inspect the wires and the
power relay. Check the power and ground
connections to the ECM. Refer to Troubleshooting,
i02526655 Electrical Power Supply for more information.
Intermittent Engine Shutdown Fuel Supply
SMCS Code: 1000-038; 1901-038
Check the fuel level in the fuel tank. Ensure that
adequate fuel is available for the application.
Note: Use this procedure only if the engine shuts
down completely and the engine must be restarted.
Check fuel lines for the following problems:
restrictions, collapse, and pinched line. Repair the
Probable Causes lines and/or replace the lines.
Engine start switch 1. Check the fuel tank for foreign objects which may
block the fuel supply. Check for air leaks in the
Engine speed/timing sensor(s) suction line of the fuel pump. Prime the fuel system
after you perform the following procedures:
Electrical connections
Replacing the fuel lters
Fuel supply
Working on the low pressure fuel supply circuit
Engine shutdown switch (if applicable)
Replacing fuel injectors
Crank without injection input (if applicable)
2. Cold weather adversely affects the characteristics
Recommended Actions of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Engine Start Switch operation.
Check the engine start switch on Cat ET. Look for
an intermittent problem in the wiring for the engine
start switch.
RENR5009-07 47
Troubleshooting Section
2. Inspect the circuit between the ECM and Engine Oil Pump
the keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors, Check for blockage of the inlet screen in the engine
and the components in the circuit. Refer to oil pump. Examine the engine oil pump for excessive
Troubleshooting, Electrical Power Supply for wear.
more information.
RENR5009-07 49
Troubleshooting Section
Check the air inlet system for the following problems: Remove the valve cover from the suspect cylinder(s).
restrictions, collapse, pinched line, and loose ttings. Check the following items for damage: camshaft,
Repair the lines and/or replace the lines. valve rotocoil, valve springs, lifters, pushrods,
bridges, and injectors. Check for valves that do not
move freely. Remove the cylinder head and inspect
Exhaust Restrictions
the valves. Replace any damaged parts. If damage
Check the exhaust system for the following problems: has occurred, clean the following components:
cylinder liner, piston, and exhaust system. Replace
restrictions, collapse, pinched line, and loose ttings.
Repair the lines and/or replace the lines. any damaged parts.
If you have replaced the ECM, check the read/change Inspect the connecting rod bearings and the bearing
surfaces (journals) on the crankshaft. Check the
system conguration parameters. Verify that the
parameters match the information on the engine piston pin for excessive wear. Replace any damaged
information plate. Verify that the correct ash le has parts.
been installed.
RENR5009-07 51
Troubleshooting Section
g00996411
Illustration 11
Wiring for the throttle in a single engine installation
Table 16
Engine Synchronization Input Active Throttle Synchronization
Status
1 2
Open Open Primary unavailable
Open Low Secondary unavailable
Low Open Primary unavailable
Low Low Primary unavailable
g00996414
Illustration 12
Wiring for the throttle in a twin engine installation
Table 17
Synchronization No Synchronization Synchronization Synchronization
Status Port Side Starboard Side
Port Engine Open Low Open
Synchronization
Input
1
Engine Open Open Low
Synchronization
Input
2
Active Throttle Primary Primary Secondary
Starboard Engine Open Open Low
Synchronization
Input
1
Engine Open Low Open
Synchronization
Input
2
Active Throttle Primary Secondary Primary
Table 18
Table 19
Engine Synchronization Input Active Throttle Starboard ECM
Synchronization
1 2 Status
Open Open Primary No
Synchronization
Open Low Secondary Synchronization
on the Port side
Low Open Primary Synchronization
on the Starboard
side
Low Low Primary Invalid
56 RENR5009-07
Troubleshooting Section
g00996416
Illustration 13
Wiring for the throttle in a triple engine installation (center as master throttle)
Table 20
Engine Synchronization Input No Synchronization Synchronization
Port Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Low
Input
1
Engine Synchronization Open Open
Input
2
Active Throttle Primary Secondary
g00996417
Illustration 14
Wiring for the throttle in a triple engine installation (Port as master throttle)
Table 21
Synchronization No Synchronization Synchronization
Status
Port Engine Synchronization Open Low
Input
1
Engine Synchronization Open Open
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
g00996418
Illustration 15
Wiring for the throttle in a triple engine installation (starboard as master throttle)
Table 22
Synchronization No Synchronization Synchronization
Status
Port Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Low
Input
1
Engine Synchronization Open Open
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
g00996419
Illustration 16
Wiring for the throttle in a triple engine installation (fourth throttle as master throttle)
Table 23
Synchronization No Synchronization Synchronization
Status
Port Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Center Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Table 24
3. Check the wiring for continuity or shorts between Not Enough Lubrication
the ECM connectors.
Check the lubrication in the valve compartment.
Check the synchronizing switch for proper Check for sufcient lubrication between the injector
operation. tappet and the rocker arm buttons.
1. Disconnect the wiring from the synchronizing Worn Bridges for Valves
switch.
Check the bridges for signs of wear. Adjust the
2. Use a voltmeter to check the resistance across bridges and/or replace the bridges. If there is too
the contacts of the synchronizing switch as much wear, install new parts. Adjust the valve lash.
the synchronizing switch is turned to different
positions.
Worn Pushrods
i02549667 Inspect the pushrods for signs of wear. If there is too
much wear, install new pushrods. Adjust the valve
Too Much Valve Lash lash.
Loose engine supports Install the new valve spring(s). Replace the valve
and/or other damaged parts.
Run the engine. Check the engine for the following
problems: loose mounts, broken mounts, loose
brackets, and broken brackets. Tighten all mounting
bolts.
Fan blade
Check the fan blade for damage. Ensure that the fan
blade is balanced.
Misring cylinder
Check for a misring cylinder. Perform the Cylinder
Cutout Test. Refer to the diagnostic functional test
Troubleshooting, Injector Solenoids.
i02549674
Probable Causes
Cracked inlet valve rotocoil
Broken spring locks
Broken valve spring(s)
RENR5009-07 63
Troubleshooting Section
Troubleshooting with a
Diagnostic Code
i01914069
Diagnostic Codes
SMCS Code: 1901-038
g00740986
Illustration 17
Typical example
When the ECM generates a diagnostic code the MID 036 - CID 0001 - FMI 06
ECM logs the code in permanent memory. The Injector Cylinder 1 short
ECM has an internal diagnostic clock. The ECM
will record the hour of the rst occurrence of the SMCS Code: 1290-038
diagnostic code. The ECM will record the hour of the
last occurrence of the diagnostic code. The ECM will Conditions Which Generate This Code:
record the number of occurrences of the code. This
information is a valuable indicator for troubleshooting The Electronic Control Module (ECM) detects a short
intermittent problems. Some diagnostic codes may circuit or short to ground in the No. 1 cylinder injector
log occurrences that did not result in complaints. solenoid.
The most likely cause of an intermittent problem is a
faulty connection or damaged wiring. The next likely System Response:
cause is a component failure. The least likely cause
is the failure of the ECM. Diagnostic codes that are The CID-FMI is logged in memory. The ECM will
logged repeatedly may indicate a problem that needs continue to operate all injectors.
special investigation.
Perform the following diagnostic procedure: Injector
If the symptoms continue, use the proper procedure Solenoids
for troubleshooting the symptoms that have been
experienced by the operator. Results:
i01954438 OK STOP.
MID 036 - CID 0001 - FMI 05 REPAIRED, OK STOP.
Injector Cylinder 1 open circuit
i01954440
SMCS Code: 1290-038
MID 036 - CID 0002 - FMI 05
Conditions Which Generate This Code: Injector Cylinder 2 open circuit
The Electronic Control Module (ECM) detects an SMCS Code: 1290-038
open circuit or short to battery voltage in the No. 1
cylinder injector solenoid. Conditions Which Generate This Code:
System Response: The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 2
The CID-FMI is logged in memory. The ECM will cylinder injector solenoid.
continue to operate all injectors.
System Response:
Perform the following diagnostic procedure: Injector
Solenoids The CID-FMI is logged in memory. The ECM will
continue to operate all injectors.
Results:
Perform the following diagnostic procedure: Injector
OK STOP. Solenoids
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 65
Troubleshooting Section
i01954441 i01954484
MID 036 - CID 0002 - FMI 06 MID 036 - CID 0003 - FMI 06
Injector Cylinder 2 short Injector Cylinder 3 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 2 cylinder injector circuit or short to ground in the No. 3 cylinder injector
solenoid. solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954483 i01954486
MID 036 - CID 0003 - FMI 05 MID 036 - CID 0004 - FMI 05
Injector Cylinder 3 open circuit Injector Cylinder 4 open circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 3 open circuit or short to battery voltage in the No. 4
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
66 RENR5009-07
Troubleshooting Section
i01954487 i01954491
MID 036 - CID 0004 - FMI 06 MID 036 - CID 0005 - FMI 06
Injector Cylinder 4 short Injector Cylinder 5 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 4 cylinder injector circuit or short to ground in the No. 5 cylinder injector
solenoid. solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954489 i01954493
MID 036 - CID 0005 - FMI 05 MID 036 - CID 0006 - FMI 05
Injector Cylinder 5 open circuit Injector Cylinder 6 open circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 5 open circuit or short to battery voltage in the No. 6
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
RENR5009-07 67
Troubleshooting Section
i01954496 i01954500
MID 036 - CID 0006 - FMI 06 MID 036 - CID 0007 - FMI 06
Injector Cylinder 6 short Injector Cylinder 7 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 6 cylinder injector circuit or short to ground in the No. 7 cylinder injector
solenoid. solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954498 i01954501
MID 036 - CID 0007 - FMI 05 MID 036 - CID 0008 - FMI 05
Injector Cylinder 7 open circuit Injector Cylinder 8 open circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 7 open circuit or short to battery voltage in the No. 8
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
68 RENR5009-07
Troubleshooting Section
i01954503 i01954506
MID 036 - CID 0008 - FMI 06 MID 036 - CID 0009 - FMI 06
Injector Cylinder 8 short Injector Cylinder 9 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 8 cylinder injector circuit or short to ground in the No. 9 cylinder injector
solenoid. solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954504 i01954507
MID 036 - CID 0009 - FMI 05 MID 036 - CID 0010 - FMI 05
Injector Cylinder 9 open circuit Injector Cylinder 10 open
SMCS Code: 1290-038
circuit
SMCS Code: 1290-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an Conditions Which Generate This Code:
open circuit or short to battery voltage in the No. 9
The Electronic Control Module (ECM) detects an
cylinder injector solenoid.
open circuit or short to battery voltage in the No. 10
cylinder injector solenoid.
System Response:
Results:
OK STOP.
REPAIRED, OK STOP. OK STOP.
REPAIRED, OK STOP.
RENR5009-07 69
Troubleshooting Section
i01954508 i01954510
MID 036 - CID 0010 - FMI 06 MID 036 - CID 0011 - FMI 06
Injector Cylinder 10 short Injector Cylinder 11 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a
circuit or a short to ground in the No. 10 cylinder short circuit or short to ground in the No. 11 cylinder
injector solenoid. injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954509 i01954511
MID 036 - CID 0011 - FMI 05 MID 036 - CID 0012 - FMI 05
Injector Cylinder 11 open Injector Cylinder 12 open
circuit circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 11 open circuit or short to battery voltage in the No. 12
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
70 RENR5009-07
Troubleshooting Section
i01954513 i01954515
MID 036 - CID 0012 - FMI 06 MID 036 - CID 0013 - FMI 06
Injector Cylinder 12 short Injector Cylinder 13 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 12 cylinder short circuit or short to ground in the No. 13 cylinder
injector solenoid. injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954514 i01954517
MID 036 - CID 0013 - FMI 05 MID 036 - CID 0014 - FMI 05
Injector Cylinder 13 open Injector Cylinder 14 open
circuit circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 13 open circuit or short to battery voltage in the No. 14
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
RENR5009-07 71
Troubleshooting Section
i01954518 i01954522
MID 036 - CID 0014 - FMI 06 MID 036 - CID 0015 - FMI 06
Injector Cylinder 14 short Injector Cylinder 15 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 14 cylinder short circuit or short to ground in the No. 15 cylinder
injector solenoid. injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954519 i01954523
MID 036 - CID 0015 - FMI 05 MID 036 - CID 0016 - FMI 05
Injector Cylinder 15 open Injector Cylinder 16 open
circuit circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 15 open circuit or short to battery voltage in the No. 16
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
72 RENR5009-07
Troubleshooting Section
i01954525 i01915026
MID 036 - CID 0016 - FMI 06 MID 036 - CID 0091 - FMI 13
Injector Cylinder 16 short Throttle Position calibration
SMCS Code: 1290-038 required
SMCS Code: 1913-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 16 cylinder
injector solenoid. The Electronic Control Module (ECM) detects the
following condition:
System Response:
The duty cycle for the throttle position sensor signal
is less than 5 percent or more than 95 percent.
The CID-FMI is logged in memory. The ECM will
continue to operate all injectors.
This diagnostic code indicates that the throttle stops
are improperly set.
Perform the following diagnostic procedure: Injector
Solenoids
System Response:
Results:
OK STOP.
REPAIRED, OK STOP.
i01954590
System Response: The desired engine speed will return to low idle while
this diagnostic code is active.
The throttle position is set to a default value of 0
percent (low idle) by the ECM. The CID-FMI is logged Troubleshooting:
in memory when the engine has been running for
three seconds and the engine is not cranking. Perform the following diagnostic procedure: Throttle
Position Sensor - Calibrate
Perform the following diagnostic procedure: Throttle
Position Sensor Results:
Results: OK STOP.
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 73
Troubleshooting Section
i01936028 i01954600
MID 036 - CID 0094 - FMI 03 MID 036 - CID 0100 - FMI
Fuel Pressure open/short to 03 Engine Oil Pressure
+batt open/short to +batt
SMCS Code: 1901-038 SMCS Code: 1924-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) reads signal
voltage that is greater than 4.8 VDC for one second. voltage that is greater than 4.8 VDC for one second.
The ECM has been powered for three seconds. The The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. diagnostic codes 262-03 and 262-04 are not active.
The code is logged. The ECM ags ltered fuel The CID-FMI is logged in memory. The ECM ags
pressure as invalid data and a default value of engine oil pressure as invalid data and a default
500 kPa (73 psi) is used. value of 500 kPa (73 psi) is used.
Perform the following diagnostic procedure: Engine Perform the following diagnostic procedure: Engine
Sensor Open/Short Test Sensor Open/Short Test
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01936029 i01954601
MID 036 - CID 0094 - FMI 04 MID 036 - CID 0100 - FMI 04
Fuel Pressure short to ground Engine Oil Pressure short to
SMCS Code: 1901-038
ground
SMCS Code: 1924-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal Conditions Which Generate This Code:
voltage that is below 0.2 VDC for one second. The
The Electronic Control Module (ECM) reads signal
ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. voltage that is below 0.2 VDC for one second. The
ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active.
System Response:
System Response:
The code is logged. The ECM ags ltered fuel
pressure as invalid data and a default value of
500 kPa (73 psi) is used. The CID-FMI is logged in memory. The ECM ags
engine oil pressure as invalid data and a default
value of 500 kPa (73 psi) is used.
Perform the following diagnostic procedure: Engine
Sensor Open/Short Test
Perform the following diagnostic procedure: Engine
Sensor Open/Short Test
Results:
Results:
OK STOP.
REPAIRED, OK STOP. OK STOP.
REPAIRED, OK STOP.
74 RENR5009-07
Troubleshooting Section
i01954609 i01954615
MID 036 - CID 0101 - FMI MID 036 - CID 0110 - FMI 03
03 Crankcase Pressure Engine Coolant Temperature
open/short to +batt open/short to +batt
SMCS Code: 1916-038 SMCS Code: 1906-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) reads signal
voltage that is greater than 4.8 VDC for one second. voltage that is greater than 4.8 VDC for one second.
The ECM has been powered for three seconds. The The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. diagnostic codes 262-03 and 262-04 are not active.
The CID-FMI is logged in memory. The ECM ags The CID-FMI is logged in memory. The ECM ags
crankcase pressure as invalid data. The engine coolant temperature as invalid data and a default
monitoring system is disabled for crankcase pressure. value of 40 C (40 F) is used.
Perform the following diagnostic procedure: Engine Perform the following diagnostic procedure: Engine
Sensor Open/Short Test Sensor Open/Short Test
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954610 i01954616
MID 036 - CID 0101 - FMI 04 MID 036 - CID 0110 - FMI 04
Crankcase Pressure short to Engine Coolant Temperature
ground short to ground
SMCS Code: 1916-038 SMCS Code: 1906-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) reads signal
voltage that is less than 0.2 VDC for one second. voltage that is less than 0.2 VDC for one second.
The ECM has been powered for three seconds. The The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. diagnostic codes 262-03 and 262-04 are not active.
The CID-FMI is logged in memory. The ECM ags The CID-FMI is logged in memory. The ECM ags
crankcase pressure as invalid data. The engine coolant temperature as invalid data and a default
monitoring system is disabled for crankcase pressure. value of 40 C (40 F) is used.
Perform the following diagnostic procedure: Engine Perform the following diagnostic procedure: Engine
Sensor Open/Short Test Sensor Open/Short Test
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
RENR5009-07 75
Troubleshooting Section
i01954667 i01954671
Results:
OK STOP.
76 RENR5009-07
Troubleshooting Section
SMCS Code: 1912-038 The diagnostic code will become active if the
following conditions exist. The engine speed is
Conditions Which Generate This Code: greater than 0 rpm. The primary engine speed/timing
signal is incorrect.
A wire on the primary engine speed/timing sensor is
disconnected and/or broken. There is a short circuit System Response:
to the +Battery terminal.
The code will become logged if the following
System Response: conditions exist. The engine speed is greater than 0
rpm. The engine speed/timing signal is incorrect for
The CID-FMI is logged in memory. On engines ve seconds. The engine speed/timing signal returns
with a secondary engine speed/timing sensor, the for ve seconds.
secondary engine speed/timing signal will be used if
the primary engine speed/timing signal is lost. On engines with a secondary engine speed/timing
sensor, the secondary engine speed/timing signal
Perform the following diagnostic procedure: Engine will be used if the primary engine speed/timing signal
Speed/Timing Sensor is abnormal.
OK STOP. Results:
i02399280 i01902426
MID 036 - CID 0253 - FMI 02 MID 036 - CID 0254 - FMI 12
Personality Module mismatch Electronic Control Module
SMCS Code: 1901-038 Error
SMCS Code: 1901-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The personality module that is used for replacement
is for a different engine family or a different engine
application. The Electronic Control Module (ECM) has detected
an internal fault.
Note: The personality module is a ash le. The
personality module is installed into the Electronic System Response:
Control Module (ECM) by ash programming.
The ECM will log the diagnostic code. Engine power
System Response: and engine performance may be affected. Any
normal ECM function may be affected.
The ECM will not log the diagnostic code. The engine
will not start. The Caterpillar Electronic Technician Possible Performance Effect:
(ET) will not be able to reset the diagnostic code.
Engine misres
Possible Performance Effect:
Low power
The engine will not start.
Reduced engine speed (rpm)
Troubleshooting:
Engine shutdown
A. Check the part number of ECM ash le. Ensure
Troubleshooting:
that the ash le part number agrees with the
original engine arrangement.
Replace the ECM. Ensure that the new ECM serial
number ends with the same two characters as the
Expected Result:
original ECM serial number. Refer to Troubleshooting,
The correct ash le is installed in the ECM. Replacing the ECM before replacing the ECM.
Results:
Results:
Repair: Reprogram the ECM with the correct The engine speed/timing sensor has not been
ash le. Refer to Troubleshooting, Flash calibrated.
Programming.
Note: This will not keep the engine from running. The
STOP. fuel injection timing may be out of adjustment.
78 RENR5009-07
Troubleshooting Section
Perform the following diagnostic procedure: Analog Perform the following diagnostic procedure: Digital
Sensor Supply Sensor Supply
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954691 i01954694
MID 036 - CID 0262 - FMI 04 5 MID 036 - CID 0263 - FMI 04
Volt Sensor DC Power Supply Digital Sensor Supply short to
short to ground ground
SMCS Code: 1408-038-NS SMCS Code: 1408-038-NS
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads an The Electronic Control Module (ECM) reads a
analog sensor supply voltage below 4.8 VDC for digital sensor supply voltage below 7.5 VDC for two
two seconds. The ECM has been powered for three seconds. The ECM has been powered for three
seconds. seconds.
Note: Normal voltage is 5.0 0.2 VDC. Note: Normal voltage is 8.0 0.4 VDC.
RENR5009-07 79
Troubleshooting Section
A. Check for parameters that have not been MID 036 - CID 0273 - FMI
programmed. 03 Turbo Outlet Pressure
Results: open/short to +batt
OK A parameter has not been programmed. SMCS Code: 1052-038
Repair: Program the missing parameter. Refer to Conditions Which Generate This Code:
the diagnostic procedure Troubleshooting, System
Conguration Parameters. The Electronic Control Module (ECM) reads signal
voltage that is greater than 4.8 VDC for one second.
STOP. The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active.
System Response:
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01936089 i01954760
MID 036 - CID 0273 - FMI 04 MID 036 - CID 0274 - FMI 04
Turbo Outlet Pressure short to Atmospheric Pressure short to
ground ground
SMCS Code: 1052-038 SMCS Code: 1923-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) reads an
voltage that is less than 0.2 VDC for one second. atmospheric pressure signal voltage below 1.7 VDC
The ECM has been powered for three seconds. The for one second. The ECM has been powered for
diagnostic codes 262-03 and 262-04 are not active. three seconds. The diagnostic codes 262-03 and
262-04 are not active.
System Response:
System Response:
The code is logged. The ECM ags turbocharger
compressor outlet pressure as invalid data and a The CID-FMI is logged in memory. The turbocharger
default value of 0 kPa (0 psi) is used. compressor inlet pressure sensor (if equipped) is
used as a backup for atmospheric pressure. The
Perform the following diagnostic procedure: Engine atmospheric pressure is set to a default value of
Sensor Open/Short Test 45 kPa (7 psi).
The code is logged. The right turbocharger The code is logged. The left turbocharger compressor
compressor inlet pressure is set to a default value of inlet pressure is set to a default value of 45 kPa
45 kPa (7 psi). (6.5 psi).
Perform the following diagnostic procedure: Engine Perform the following diagnostic procedure: Engine
Sensor Open/Short Test Sensor Open/Short Test
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954762 i01936097
MID 036 - CID 0275 - FMI 04 MID 036 - CID 0276 - FMI 04
Right Turbo Inlet Pressure Left Turbo Inlet Pressure short
short to ground to ground
SMCS Code: 1052-038 SMCS Code: 1052-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) reads signal
voltage that is less than 0.2 VDC for one second. voltage that is less than 0.2 VDC for one second.
The ECM has been powered for three seconds. The The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. diagnostic codes 262-03 and 262-04 are not active.
The CID-FMI is logged in memory. The turbocharger The code is logged. The turbocharger compressor
compressor inlet pressure is set to a default value of inlet pressure is set to a default value of 45 kPa
45 kPa (7 psi). (7 psi).
Perform the following diagnostic procedure: Engine Perform the following diagnostic procedure: Engine
Sensor Open/Short Test Sensor Open/Short Test
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i02174525 i01915091
MID 036 - CID 0276 - FMI MID 036 - CID 0277 - FMI 08
03 Left Turbo Inlet Pressure Timing Calibration signal
open/short to +batt abnormal
SMCS Code: 1052-038 SMCS Code: 1408-038-NS
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The engine speed is above low idle. The signal for
voltage that is greater than 4.8 VDC for one second. Top Center is 30 degrees.
The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active.
82 RENR5009-07
Troubleshooting Section
System Response:
OK STOP.
System Response:
Results:
OK STOP.
RENR5009-07 83
Troubleshooting Section
i01954884
Conditions Which Generate This Code:
MID 036 - CID 0336 - FMI 02 The Electronic Control Module (ECM) detects an
open circuit at the prelube relay. The ECM detects a
Incorrect ECS Switch inputs short to battery voltage at the prelube relay.
SMCS Code: 1901-038 System Response:
Conditions Which Generate This Code: The CID-FMI is logged in memory.
One line for the Engine Control Switch (ECS) is open Perform the following diagnostic procedure:
and one line is low. Prelubrication System
System Response: Results:
The CID-FMI is logged in memory. The Electronic
Control Module (ECM) will ag the ignition switch as
OK STOP.
invalid data.
REPAIRED, OK STOP.
Perform the following diagnostic procedure: Engine
Control Switch (ECS)
Results:
OK STOP.
REPAIRED, OK STOP.
84 RENR5009-07
Troubleshooting Section
i01954893 i01954901
MID 036 - CID 0338 - FMI MID 036 - CID 0342 - FMI 03
06 Pre-Lube Relay short to Secondary Engine Speed
ground open/short to +batt
SMCS Code: 1319-038 SMCS Code: 1912-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short A wire on the secondary engine speed/timing sensor
circuit at the prelube relay. is disconnected and/or broken. There is a short circuit
to the +Battery terminal.
System Response:
System Response:
The CID-FMI is logged in memory.
The CID-FMI is logged in memory.
Perform the following diagnostic procedure:
Prelubrication System Perform the following diagnostic procedure: Engine
Speed/Timing Sensor
Results:
Results:
OK STOP.
OK STOP.
REPAIRED, OK STOP.
REPAIRED, OK STOP.
i01954895
i01954905
MID 036 - CID 0342 - FMI 02
Loss of Secondary Engine MID 036 - CID 0342 - FMI 07
Speed signal Secondary Speed Sensor
misinstalled
SMCS Code: 1912-038
SMCS Code: 1912-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The engine rpm signal can not be detected. The
timing gear pattern returns within one second of The secondary engine speed/timing sensor is
being lost and battery voltage is greater than 9 VDC connected to the harness connector for the primary
for the last two seconds. The fault is logged only if engine speed/timing sensor.
the engine has been running for three seconds. The
fault will be active and logged if the Electronic Control System Response:
Module (ECM) detects an incorrect signal for one
second and the primary sensor signal is nominal. The CID-FMI is logged in memory.
The primary sensor detects an engine speed that is
greater than 100 rpm. The battery voltage is greater Perform the following diagnostic procedure: Engine
than 9 VDC for the last two seconds. Speed/Timing Sensor
Results:
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 85
Troubleshooting Section
i01954917 i01954914
MID 036 - CID 0342 - FMI 08 MID 036 - CID 0444 - FMI 06
Secondary Engine Speed Start Relay short to ground
signal abnormal SMCS Code: 1426-038
SMCS Code: 1912-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short
circuit to ground condition.
The diagnostic code will become active if the following
conditions exist. The engine speed is greater than 0
System Response:
rpm. The engine speed/timing signal is incorrect. The
code will become logged if the following conditions The CID-FMI is logged in memory.
exist. The engine speed is greater than 0 rpm. The
engine speed/timing signal is incorrect. The engine
Perform the following diagnostic procedure: Starting
speed/timing signal returns after ve seconds. Motor System
System Response:
Results:
The CID-FMI is logged in memory.
OK STOP.
Perform the following diagnostic procedure: Engine
Speed/Timing Sensor REPAIRED, OK STOP.
Results: i01954915
OK STOP.
REPAIRED, OK STOP.
86 RENR5009-07
Troubleshooting Section
i01954913 i01954910
MID 036 - CID 0446 - FMI 06 Air MID 036 - CID 0542 - FMI 04
Shutoff Relay short Unltered Engine Oil Pressure
SMCS Code: 1078-038 short to ground
SMCS Code: 1924-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
short circuit to ground. The ECM can only detect this
condition when the air shutoff relay is not energized. The Electronic Control Module (ECM) reads signal
voltage that is below 0.2 VDC for one second. The
ECM has been powered for three seconds. The
System Response:
diagnostic codes 262-03 and 262-04 are not active.
The CID-FMI is logged in memory.
System Response:
Perform the following diagnostic procedure: Air
The CID-FMI is logged in memory. The ECM ags
Shutoff System
oil pressure as invalid data and a default value of
Results: 500 kPa (73 psi) is used.
i01954911 OK STOP.
MID 036 - CID 0542 - FMI 03 REPAIRED, OK STOP.
Unltered Engine Oil Pressure
open/short to +batt i01954909
Results:
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 87
Troubleshooting Section
The code is logged. The status screen on the This diagnostic code indicates that the throttle stops
Caterpillar Electronic Technician (ET) will show the are improperly set.
parameter as invalid data.
System Response:
Perform the following diagnostic procedure: Engine
Sensor Open/Short Test
Results:
OK STOP.
REPAIRED, OK STOP.
i02660170
SMCS Code: 1439-038; 1913-038-SE The ECM sets the desired engine speed to
programmed low idle while this diagnostic code is
Conditions Which Generate This Code: active. The Caterpillar Electronic Technician (ET)
will indicate a throttle position of 0 percent while this
The Electronic Control Module (ECM) has been diagnostic code is active.
powered up for three seconds. The sensor frequency
is greater than 1000 Hz or less than 150 Hz for two Possible Performance Effect:
seconds. The duty cycle is greater than 95 percent or
less than 5 percent for one second. The desired engine speed will return to low idle while
this diagnostic code is active.
System Response:
Troubleshooting:
The throttle position is set to a default value of 0
percent (low idle) by the ECM. The CID-FMI is logged Perform the following diagnostic procedure: Throttle
in memory when the engine has been running for Position Sensor - Calibrate
three seconds and the engine is not cranking.
Results:
Perform the following diagnostic procedure: Throttle
Position Sensor OK STOP.
Results:
OK STOP.
88 RENR5009-07
Troubleshooting Section
Program the Missing Injector Trim Conditions Which Generate This Code:
Code(s).
The Electronic Control Module (ECM) detects a short
A. Connect the Caterpillar Electronic Technician (ET) circuit or short to ground in the No. 1 cylinder injector
to the service tool connector. solenoid.
Results: i01955131
Results: i01955132
Results:
OK STOP.
REPAIRED, OK STOP.
90 RENR5009-07
Troubleshooting Section
i01955133 i01955136
MID 047 - CID 0004 - FMI 06 MID 047 - CID 0005 - FMI 06
Injector Cylinder 4 short Injector Cylinder 5 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 4 cylinder injector circuit or short to ground in the No. 5 cylinder injector
solenoid. solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01955135 i01955139
MID 047 - CID 0005 - FMI 05 MID 047 - CID 0006 - FMI 05
Injector Cylinder 5 open circuit Injector Cylinder 6 open circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 5 open circuit or short to battery voltage in the No. 6
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
RENR5009-07 91
Troubleshooting Section
i01955140 i01955143
MID 047 - CID 0006 - FMI 06 MID 047 - CID 0007 - FMI 06
Injector Cylinder 6 short Injector Cylinder 7 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 6 cylinder injector circuit or short to ground in the No. 7 cylinder injector
solenoid. solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01955142 i01955144
MID 047 - CID 0007 - FMI 05 MID 047 - CID 0008 - FMI 05
Injector Cylinder 7 open circuit Injector Cylinder 8 open circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 7 open circuit or short to battery voltage in the No. 8
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
92 RENR5009-07
Troubleshooting Section
i01955145 i01955148
MID 047 - CID 0008 - FMI 06 MID 047 - CID 0009 - FMI 06
Injector Cylinder 8 short Injector Cylinder 9 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 8 cylinder injector circuit or short to ground in the No. 9 cylinder injector
solenoid. solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01955146 i01955150
MID 047 - CID 0009 - FMI 05 MID 047 - CID 0010 - FMI 05
Injector Cylinder 9 open circuit Injector Cylinder 10 open
SMCS Code: 1290-038
circuit
SMCS Code: 1290-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an Conditions Which Generate This Code:
open circuit or short to battery voltage in the No. 9
The Electronic Control Module (ECM) detects an
cylinder injector solenoid.
open circuit or short to battery voltage in the No. 10
cylinder injector solenoid.
System Response:
Results:
OK STOP.
REPAIRED, OK STOP. OK STOP.
REPAIRED, OK STOP.
RENR5009-07 93
Troubleshooting Section
i01955152 i01955155
MID 047 - CID 0010 - FMI 06 MID 047 - CID 0011 - FMI 06
Injector Cylinder 10 short Injector Cylinder 11 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 10 cylinder short circuit or short to ground in the No. 11 cylinder
injector solenoid. injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01955154 i01955156
MID 047 - CID 0011 - FMI 05 MID 047 - CID 0012 - FMI 05
Injector Cylinder 11 open Injector Cylinder 12 open
circuit circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 11 open circuit or short to battery voltage in the No. 12
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
94 RENR5009-07
Troubleshooting Section
i01955157 i01955159
MID 047 - CID 0012 - FMI 06 MID 047 - CID 0013 - FMI 06
Injector Cylinder 12 short Injector Cylinder 13 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 12 cylinder short circuit or short to ground in the No. 13 cylinder
injector solenoid. injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01955158 i01955160
MID 047 - CID 0013 - FMI 05 MID 047 - CID 0014 - FMI 05
Injector Cylinder 13 open Injector Cylinder 14 open
circuit circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 13 open circuit or short to battery voltage in the No. 14
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
RENR5009-07 95
Troubleshooting Section
i01955161 i01955163
MID 047 - CID 0014 - FMI 06 MID 047 - CID 0015 - FMI 06
Injector Cylinder 14 short Injector Cylinder 15 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 14 cylinder short circuit or short to ground in the No. 15 cylinder
injector solenoid. injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01955162 i01955164
MID 047 - CID 0015 - FMI 05 MID 047 - CID 0016 - FMI 05
Injector Cylinder 15 open Injector Cylinder 16 open
circuit circuit
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 15 open circuit or short to battery voltage in the No. 16
cylinder injector solenoid. cylinder injector solenoid.
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
96 RENR5009-07
Troubleshooting Section
i01955166 i01955209
MID 047 - CID 0016 - FMI 06 MID 047 - CID 0190 - FMI 08
Injector Cylinder 16 short Engine Speed signal abnormal
SMCS Code: 1290-038 SMCS Code: 1912-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a The diagnostic code will become active if the following
short circuit or short to ground in the No. 16 cylinder conditions exist. The engine speed is greater than 0
injector solenoid. rpm. The engine speed/timing signal is incorrect.
The CID-FMI is logged in memory. The ECM will The code will become logged if the following
continue to operate all injectors. conditions exist. The engine speed is greater than
0 rpm. The engine speed/timing signal is incorrect
Perform the following diagnostic procedure: Injector for ve seconds. The engine speed/timing signal
Solenoids returns for ve seconds. When the primary engine
speed/timing signal is abnormal, the secondary
Results: engine speed/timing signal will be used.
Results:
OK STOP.
REPAIRED, OK STOP.
i01955218
System Response:
Results:
OK STOP.
REPAIRED, OK STOP.
98 RENR5009-07
Troubleshooting Section
Troubleshooting with an
Event Code
i01909353
Event Codes
SMCS Code: 1901-038
g00740986
Illustration 20
Typical example
Engine Alarm
Engine Derate
RENR5009-07 99
Troubleshooting Section
E100 Low Engine Oil Pressure Test Step 1. Check for ACTIVE
Warning Diagnostic Codes.
E101 High Crankcase Pressure
Warning A. Start the Caterpillar Electronic Technician (ET).
E173 High Exhaust Temperature B. Turn the main power to the ON position.
Warning
E190 Engine Overspeed C. Check for any active diagnostic codes or logged
Warning diagnostic codes.
E272 Inlet Air Restriction
Warning Expected Result:
Conditions Which Generate This Code: There are no problems with the cooling system.
Engine shutdown
RENR5009-07 101
Troubleshooting Section
Repair: Repair the problem. Ensure that the repair Repair: Repair the diagnostic codes that are
eliminates the problem. present. Refer to the appropriate topic in the
Troubleshooting With a Diagnostic Code section
STOP. of this manual. Ensure that the repair eliminates
the problem.
i02399535
STOP.
E009 High Altitude Derate
i04037608
SMCS Code: 1901-038
E012 High Crankcase Pressure
Conditions Which Generate This Code:
Derate
The Electronic Control Module (ECM) detects
SMCS Code: 1901-038
atmospheric pressure that is less than 70 kPa
Conditions Which Generate This Code:
System Response:
The event is logged. The ECM limits the fuel above The engine crankcase pressure has exceeded the
setpoint and the delay time has expired.
the default altitude of 762 m (2500 ft). The ECM
will derate the engine in 3 percent increments for
every 305 m (1000 ft) increase in elevation up to a System Response:
maximum derate of 35 percent.
Then engine power is derated. The code is logged.
Possible Performance Effect:
Troubleshooting:
Low power There may be a problem with one of the following
engine components:
Troubleshooting:
Check for ACTIVE Diagnostic Codes. Test Step 1. Check the Crankcase
Breather
A. Start the Caterpillar Electronic Technician (ET).
A. Check for a plugged crankcase breather.
B. Turn the main power to the ON position.
A plugged crankcase breather will cause
C. Check for any active diagnostic codes or logged excessive crankcase pressure. Leakage of the
diagnostic codes. crankshaft seal can occur. Sealing of the piston
rings can be lost. The crankcase blowby will
Expected Result: increase the crankcase pressure.
Results:
No diagnostic codes are present.
The condition is corrected. STOP. Then engine is shut down. The code is logged.
The condition is corrected. STOP. The event is logged. The ECM derates the engine
from 0% to a maximum derate of 25% over a period
The condition is not corrected. Continue to test of 480 seconds when the coolant temperature is
Step 3. above 107 C (225 F). The fuel limiting function
will continue until the coolant temperature returns
Test Step 3. Check for Worn Engine below 102 C (215 F) or until the maximum derate
Components has been reached. After the temperature returns
below 102 C (215 F) the derate due to high coolant
A. Damaged pistons or rings can cause too much temperature will be turned off.
pressure in the crankcase. This condition will
cause the engine to run rough. There will be Possible Performance Effect:
more than the normal fumes (blowby) rising from
the crankcase breather. The breather can then Low power
become restricted quickly, causing oil leakage at
gaskets and seals that would not normally have Troubleshooting:
leakage. Blowby can also be caused by worn
valve guides or by a failed turbocharger seal. There may be a problem with the cooling system.
B. The 8T-2700 Blowby/Air Flow Indicator is used There may be a problem with the coolant
to check the amount of blowby. Refer to Special temperature sensor.
Instruction, SEHS8712, Using the 8T-2700
Blowby/Air Flow Indicator for the test procedure Test Step 1. Check for ACTIVE
for checking the blowby. Diagnostic Codes.
Expected Result: A. Start the Caterpillar Electronic Technician (ET).
A thorough inspection revealed a problem. B. Turn the main power to the ON position.
Repair: Repair the problem. Ensure that the repair No diagnostic codes are present.
eliminates the problem.
Results:
STOP.
OK No diagnostic codes are present. Proceed
to Test Step 2.
i01909398
Expected Result:
Results: Results:
B. Turn the keyswitch to the ON position. Conditions Which Generate This Code:
C. Check for any active diagnostic codes or for The Electronic Control Module (ECM) detects the
logged diagnostic codes. following condition:
Repair: Repair the diagnostic codes that are The event is logged. The ECM derates the engine
present. Refer to the appropriate topic in the at 15 second intervals in 2% increments when
Troubleshooting With a Diagnostic Code section the exhaust inlet temperature is above 750 C
of this manual. Ensure that the repair eliminates (1382 F) for 5 seconds. The fuel limiting function will
the problem. continue until the exhaust temperature returns below
740 C (1364 F) or until the maximum derate has
STOP. been reached. After the temperature returns below
740 C (1364 F) the derate due to a high exhaust
Test Step 2. Perform a Check of the temperature will be deactivated.
Cooling System.
Possible Performance Effect:
A. Perform a check of the cooling system. Refer
to the diagnostic procedure Troubleshooting, Low power
Coolant Temperature is Too High for possible
causes. Troubleshooting:
C. Check for any active diagnostic codes or logged E031 Air Inlet Restriction
diagnostic codes. Derate
Expected Result: SMCS Code: 1901-038
No diagnostic codes are present. Conditions Which Generate This Code:
Results: The Electronic Control Module (ECM) detects the
following condition:
OK No diagnostic codes are present. Proceed
to Test Step 2. The air inlet pressure for the left turbocharger
is above the default pressure of 7 kPa
Not OK Diagnostic codes are present. (28 inches of H2O) for ve seconds.
Repair: Repair the diagnostic codes that are The air inlet pressure for the right turbocharger
present. Refer to the appropriate topic in the is above the default pressure of 7 kPa
Troubleshooting With a Diagnostic Code section (28 inches of H2O) for ve seconds.
of this manual. Ensure that the repair eliminates
the problem. System Response:
STOP. The event is logged. When the air inlet restriction
exceeds 7 kPa (28 inches of H2O) the ECM will
Test Step 2. Perform a Check of the derate the engine. The ECM will derate the engine in
Cooling System. increments of 2% per 1 kPa (4 inches of H2O) up to a
maximum derate level of 25%. Air lter restriction is
A. Perform a check of the exhaust system. Refer determined by measuring the atmospheric pressure
to the diagnostic procedure Troubleshooting, and the turbocharger inlet pressures and calculating
Exhaust Temperature is Too High for possible the difference.
causes.
Possible Performance Effect:
Expected Result:
Low power
There are no problems with the exhaust system.
Troubleshooting:
Results:
There may be a problem with the air inlet system.
OK There are no problems with the exhaust
system. There may be an intermittent problem. There may be a problem with the atmospheric
pressure sensor or the left or right turbocharger
Repair: Monitor the operation of the engine. Repair inlet pressure sensors.
the problem. Ensure that the repair eliminates the
problem. Test Step 1. Check for ACTIVE
Diagnostic Codes.
STOP.
A. Start the Caterpillar Electronic Technician (ET).
Not OK There is a problem with the exhaust
system. B. Turn the main power to the ON position.
Repair: Repair the problem. Ensure that the repair C. Check for any active diagnostic codes or logged
eliminates the problem. diagnostic codes.
STOP. Expected Result:
Results:
Repair: Repair the problem. Ensure that the repair No diagnostic codes are present.
eliminates the problem.
Results:
STOP.
OK No diagnostic codes are present. Proceed
to Test Step 2.
i02658702
Expected Result:
Results:
STOP.
STOP.
i01909471
The engine has been running for at least ten Engine shutdown
seconds.
Troubleshooting:
Engine oil pressure is below the default trip line in
Illustration 21 for an additional nine seconds. There may be a problem with the engine lubrication
system.
100-03 Engine Oil Pressure open/short to +batt is
not active. There may be a problem with the engine oil
pressure sensor.
100-04 Engine Oil Pressure short to ground is
not active. Test Step 1. Check for ACTIVE
Diagnostic Codes.
A. Start the Caterpillar Electronic Technician (ET).
Expected Result:
OK No diagnostic codes are present. Proceed The event is logged. If the system voltage rises
to Test Step 2. above 22 VDC, the warning will become inactive.
OK There are no problems with engine oil No diagnostic codes are present.
pressure. There may be an intermittent problem.
Results:
Repair: Monitor the operation of the engine. Repair
the problem. Ensure that the repair eliminates the OK No diagnostic codes are present. Proceed
problem. to Test Step 2.
STOP. STOP.
Either of these two conditions can cause the code: Loose connector
The heartbeat signal from the primary Electronic Loose terminal
Control Module (ECM) to the secondary ECM is
lost. Open circuit
Two or more diagnostic codes for the injector Short circuit
solenoids are active.
Results:
System Response:
A problem was found in the circuit for the heartbeat
The secondary ECM sends a signal to the primary signal.
ECM which indicates that the secondary ECM is in
control of the engine. The primary ECM shuts down. Repair: Repair the problem. The power to the
primary ECM must be cycled before the primary
Test Step 1. Check for active codes for ECM can resume control of the engine.
the injector solenoids
STOP.
Use Caterpillar Electronic Technician (ET) to check
for active diagnostic codes for the injector solenoids. No problems were found with the circuit for the
heartbeat signal.
Results:
Repair: There could be an intermittent problem,
There are no active codes for the injector most likely a loose connection. Make a thorough
solenoids Proceed to Test Step 2. inspection of the circuit and repair the circuit, if
needed.
There are at least two active diagnostic codes for
the injector solenoids. STOP.
RENR5009-07 111
Troubleshooting Section
There may be a problem with the ltered fuel C. Check fuel quality. In temperatures below 0 C
sensor or the unltered fuel sensor. (32 F), check for solidied fuel (wax). Refer to
Special Publication, SEBD0717, Diesel Fuels
Test Step 1. Check for ACTIVE And Your Engine. Check the fuel pressure while
Diagnostic Codes. the engine is cranking. Check the fuel pressure at
the lter. If the pressure is low, check for plugged
A. Start the Caterpillar Electronic Technician (ET). fuel lters. If the fuel pressure is still low, check the
following items: fuel transfer pump, fuel transfer
B. Turn the main power to the ON position. The pump coupling, and fuel pressure regulating valve.
engine should be OFF. Check for a combustion problem.
OK No diagnostic codes are present. Proceed Repair: Monitor the operation of the engine. Repair
to Test Step 2. the problem. Ensure that the repair eliminates the
problem.
Not OK Diagnostic codes are present.
STOP.
Repair: Repair the problem. Ensure that the repair Repair: Repair the diagnostic codes that are
eliminates the problem. present. Refer to the appropriate topic in the
Troubleshooting With a Diagnostic Code section
STOP. of this manual. Ensure that the repair eliminates
the problem.
i01909632
STOP.
E099 Engine Oil Filter Test Step 2. Perform a Check of the
Restriction Warning Lubrication System.
SMCS Code: 1901-038 A. Check for dirty oil lters.
The Electronic Control Module (ECM) detects the There are problems with the oil lters.
following condition:
Results:
The oil lter differential pressure is above the
default value of 105 kPa (15 psi) for the default OK The oil lters are dirty.
time of ve seconds.
Repair: Replace the oil lters with new oil lters.
System Response: Ensure that the repair eliminates the problem.
The event is logged. The warning for the oil lter STOP.
differential pressure becomes active when the oil lter
differential pressure exceeds the default trip point Not OK There are problems with the lubrication
of 105 kPa (15 psi). The warning becomes inactive system.
when the fuel lter differential pressure decreases
below 95 kPa (14 psi). Repair: Refer to the appropriate topic in the
Troubleshooting Without a Diagnostic Code
Possible Performance Effect: section of this manual. Ensure that the repair
eliminates the problem.
None
STOP.
Troubleshooting:
i01909487
There may be a problem with the oil lters.
There may be a problem with the ltered oil sensor
E100 Low Engine Oil Pressure
or the unltered oil sensor. Warning
Test Step 1. Check for ACTIVE SMCS Code: 1901-038
Diagnostic Codes.
Conditions Which Generate This Code:
A. Start the Caterpillar Electronic Technician (ET).
The Electronic Control Module (ECM) detects all of
B. Turn the main power to the ON position. The the following conditions:
engine should be OFF.
The engine has been running for at least ten
C. Check for any active diagnostic codes or logged seconds.
diagnostic codes.
Engine oil pressure is below the default trip line in
Expected Result: Illustration 22 for an additional four seconds.
No diagnostic codes are present. 100-03 Engine Oil Pressure open/short to +batt is
not active.
Results:
100-04 Engine Oil Pressure short to ground is
OK No diagnostic codes are present. Proceed not active.
to Test Step 2.
Results:
STOP.
Expected Result:
Results:
g00994984
Illustration 22 OK There are no problems with engine oil
Oil pressure map pressure. There may be an intermittent problem.
The crankcase breather is plugged. Repair: Repair the problem. Ensure that the repair
eliminates the problem.
Repair: Clean the crankcase breather.
STOP.
STOP.
i01909644
The crankcase breather is not plugged. Continue
to Test Step 2. E173 High Exhaust
Test Step 2. Check the Crankcase Temperature Warning
Pressure Sensor
SMCS Code: 1901-038
A. Inspect the crankcase pressure sensor for
cleanliness. If the sensor is fouled, clean the Conditions Which Generate This Code:
sensor. If the condition is corrected, put the engine
back in service. If the condition is not corrected, The Electronic Control Module (ECM) detects the
proceed to the next step. following condition:
B. Replace the crankcase pressure sensor with a Exhaust inlet temperature is greater than the
sensor that is known to be good. default temperature of 600 C (1112 F) for ve
seconds.
Results:
The engine has been running for three seconds.
The condition is corrected. STOP.
The diagnostic codes CID-FMI 827-08 and
The condition is not corrected. Continue to test CID-FMI 828-08 are not active.
Step 3.
System Response:
Possible Performance Effect: Repair: Monitor the operation of the engine. Repair
the problem. Ensure that the repair eliminates the
None problem.
Troubleshooting: STOP.
There may be an exhaust restriction above Not OK There is a problem with the cooling
recommended levels. system.
There may be a problem with the cooling system. Repair: Repair the problem. Ensure that the repair
eliminates the problem.
There may be a problem with the coolant
temperature sensor. STOP.
Conditions Which Generate This Code: A. Perform a check of the air inlet system. Refer to
the Testing and Adjusting manual for information
The Electronic Control Module (ECM) detects one of on inspecting the air inlet and exhaust system.
the following conditions:
Expected Result:
The air inlet pressure for the left turbocharger is
above the default value of 7 kPa (28 inches of H2O) There are no problems with the air inlet system.
for ve seconds.
Results:
The air inlet pressure for the right turbocharger is
above the default value of 7 kPa (28 inches of H2O) OK There may be an intermittent problem.
for ve seconds.
Repair: Monitor the operation of the engine. Repair
System Response: the problem. Ensure that the repair eliminates the
problem.
The ECM will log the event.
STOP.
Possible Performance Effect:
Not OK There is a problem with the air inlet
None system.
C. Check for any active diagnostic codes or logged The Electronic Control Module (ECM) detects the
diagnostic codes. following condition:
Expected Result:
Results:
STOP.
Expected Result:
Results:
STOP.
g01029797
Illustration 23
Typical example
120 RENR5009-07
Troubleshooting Section
Repair: Repair the connectors or wiring and/or Not OK The voltage did not measure 24 3
replace the connectors or wiring. VDC for approximately 2.5 seconds. Proceed to
Test Step 4.
STOP.
Test Step 4. Test for Voltage to the Coil
Test Step 2. Test the Air Shutoff System. of the ASOS Switch at the Connector
P-C1 for the Power Distribution Panel.
A. Turn the circuit breaker for the battery to the ON
position. A. Turn the ECS to the STOP position. The engine
should be off.
B. Turn the ECS to the STOP position. The engine
should be off. B. Activate the customer's emergency stop switch.
C. Activate the customer's emergency stop switch. C. Monitor the voltage on wire F708 on pin G at
connector P-C1 of the rigid harness.
D. Monitor the air shutoff solenoids.
D. Deactivate the customer's emergency stop switch.
E. Deactivate the customer's emergency stop switch.
Expected Result:
Expected Result:
The voltage measures 24 3 VDC for approximately
The air shutoff solenoids activated. 1 second.
RENR5009-07 121
Troubleshooting Section
OK The voltage measures 24 3 VDC for F. Monitor the voltage on the voltmeter.
approximately 1 second. The circuit is operating
correctly to this point. Proceed to Test Step 5. G. Deactivate the customer's emergency stop switch.
Not OK No voltage was measured. Proceed to H. Reconnect wire G708 to the ASOS switch.
Test Step 14.
Expected Result:
Test Step 5. Test for Voltage to the Coil of
the ASOS Switch. The voltage measures 24 3 VDC for approximately
2.5 seconds.
A. Turn the ECS to the OFF/RESET position.
Results:
B. The input to the coil of the ASOS switch is
wire T708 from the diode assembly. Connect OK The voltage measures 24 3 VDC for
a voltmeter between wire T708 on the ASOS approximately 2.5 seconds. The circuit is operating
switch and the engine ground. correctly to this point.
Note: The ASOS switch is turned on for one second Repair: Repair the wire G708 between the ASOS
by the ECM. The timer keeps the ASOS switch switch and terminal I at connector P-C1 of the rigid
energized for approximately 2.5 seconds. harness.
E. Monitor the voltage on the voltmeter. Repair: Verify that 24 3 VDC is present on wire
K708 at the normally open contacts of the ASOS
F. Deactivate the customer's emergency stop switch. switch. If voltage is not present on wire K708,
check the wiring and the circuit breaker for the air
Expected Result: shutoff for problems.
The voltage measures 24 3 VDC for approximately Check wire 220 on the coil of the ASOS switch
2.5 seconds. for continuity to the Battery. If necessary, repair
the wire or replace the wire.
Results:
If wire 220 is okay and voltage is present on wire
OK The voltage measures 24 3 VDC for K708, replace the ASOS switch.
approximately 2.5 seconds. The circuit is operating
correctly to this point. Proceed to Test Step 6. STOP.
Not OK No voltage was measured. Proceed to Test Step 7. Check the Voltage at the
Test Step 10. Connector for the Air Shutoff Solenoids.
Not OK The voltage did not measure 24 3 VDC A. Turn the ECS to the OFF/RESET position.
for 2.5 seconds. Proceed to Test Step 8.
B. Disconnect the connector for the air shutoff
Test Step 6. Check for Voltage from solenoids. Disconnect the connector for the right
the ASOS Switch to the Air Shutoff and left sides of the engine.
Solenoids.
C. Connect a voltmeter between wire G708 on the
A. Turn the ECS to the OFF/RESET position. connector for the air shutoff solenoid and the
engine ground.
B. Disconnect wire G708 from the ASOS switch.
D. Turn the ECS to the STOP position. The engine
C. Connect a voltmeter to the empty terminal on the should be off.
ASOS switch. Connect the other lead of the
voltmeter to engine ground. E. Activate the customer's emergency stop switch.
D. Turn the ECS to the STOP position. The engine F. Monitor the voltage on the voltmeter.
should be off.
122 RENR5009-07
Troubleshooting Section
H. Reconnect the connectors for the air shutoff OK The voltage measures 24 3 VDC. Proceed
solenoids. to Test Step 9.
Repair: Check the wire H708 from terminal A C. Turn the ECS to the STOP position. The engine
of the connectorfor the air shutoff solenoid for should be off.
continuity to the Battery terminal. If the wire H708
to the Battery terminal is okay, replace the air D. Activate the customer's emergency stop switch.
shutoff solenoid.
E. Monitor the voltage on the voltmeter.
STOP.
F. Deactivate the customer's emergency stop switch.
Not OK The voltage did not measure 24 3 VDC
for approximately 2.5 seconds. System voltage Expected Result:
was not available at the solenoid connector.
The voltage measures 24 3 VDC for approximately
Repair: Repair the wire G708 between the 2.5 seconds.
connector for the air shutoff solenoids and terminal
I at connector P-C1 of the rigid harness. Results:
B. Disconnect wire T120 from terminal 87 of relay Repair: Check for 24 3 VDC on terminal 1 of the
R3A. connector for the timer. If voltage is not present on
terminal 1, repair the wire T120 between terminal
C. Connect a voltmeter between terminal 87 of relay 87 of relay R3A and terminal 1 of the connector
R3A and the engine ground. for the timer.
D. Turn the ECS to the STOP position. The engine If voltage is present on terminal 1 of the connector
should be off. for the timer, verify that wire 220 on terminal 2 of
the connector for the timer has continuity to the
E. Activate the customer's emergency stop switch. Battery. If wire 220 does not have continuity to the
Battery, repair the wire.
F. Monitor the voltage on the voltmeter.
Verify that 24 3 VDC is present on terminal 3
G. Deactivate the customer's emergency stop switch. of the connector for the timer. If 24 3 VDC is
not present on terminal 3 of the connector for the
H. Reconnect wire T120. timer, verify that the engine control switch is not in
the OFF/RESET position. Verify that the MPD
Expected Result: breaker is not tripped. Check the normally closed
contact of relay R1 for proper operation. Check
The voltage measures 24 3 VDC. the wire 120 between terminal 3 of the connector
for the timer and relay R1 for damage. Check
the wire A120 between relay R1 and the MPD
breaker for damage. If necessary, repair the wires.
RENR5009-07 123
Troubleshooting Section
If the voltage is present on terminal 1 and 3 of the If the voltage does not measure 24 3 VDC for
timer and wire 220 is okay, replace the timer. approximately 1 second, repair the wire F708
between the connector for the diodes and wire
STOP. F708 on pin G at connector P-C1 of the right rail.
Results: Results:
6. Deactivate the customer's emergency stop Test Step 12. Check the Voltage to
switch. Terminal 2 of the Connector for the
Diodes from the Timer.
If the voltage measures 24 3 VDC for
approximately 1 second, replace the diodes. A. Turn the ECS to the OFF/RESET position.
C. Turn the ECS to the STOP position. The engine Repair: Replace the diodes.
should be off.
STOP.
D. Activate the customer's emergency stop switch.
Test Step 14. Check the Output Driver for
E. Monitor the voltage on the voltmeter. the Air Shutoff System at the ECM.
F. Deactivate the customer's emergency stop switch. A. Turn the ECS to the OFF/RESET position.
The voltage measures 24 3 VDC. C. Remove wire F708 from ECM connector P2-13.
Install a wire jumper into P2-13.
Results:
D. Reconnect ECM connector P2.
OK The voltage measures 24 3 VDC. Proceed
to Test Step 13. E. Connect a voltmeter between the wire jumper in
P2-13 and engine ground.
Not OK The voltage did not measure 24 3
VDC. F. Turn the ECS to the STOP position. The engine
should be off.
Repair: Repair the wire T708 between the diodes
and the timer. G. Activate the customer's emergency stop switch.
Test Step 13. Check the Voltage from I. Deactivate the customer's emergency stop switch.
Terminal 3 of the Connector for the Diode
Assembly. Expected Result:
A. Turn the ECS to the OFF/RESET position. The voltage measures 24 3 VDC for one second.
F. Deactivate the customer's emergency stop switch. Not OK The voltage did not measure 24 3
VDC.
Expected Result:
Repair: Replace the ECM.
The voltage measures 24 3 VDC.
STOP.
Results:
STOP.
i01900689
g01001876
Illustration 24
Typical example
Test Step 1. Check for Connector B. Turn the Engine Control Switch (ECS) to the
Damage. OFF/RESET position.
D. Perform a 45 N (10 lb) pull test on each of the Not OK The resistance is less than 20,000 Ohms
wires in the ECM connector that are associated for each measurement.
with the circuit.
Repair: Repair the connectors or wiring and/or
E. Check the ECM connectors (allen head screw) for replace the connectors or wiring.
the proper torque of 6 1 Nm (53 9 lb in).
STOP.
F. Check the harness and the wiring for abrasion
and for pinch points. Test Step 3. Check the Analog Sensor
Supply Voltage at the Primary ECM.
Expected Result:
A. Disconnect the primary ECM connector J1/P1.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring B. Remove the wire 997 from the primary ECM
are free of corrosion, of abrasion or of pinch points. connector P1-02. Remove the wire 993 from
the primary ECM connector P1-03. Install wire
Results: jumpers into P1-02 and into P1-03.
OK The connectors and wiring are okay. Proceed C. Remove the wire A997 from the primary ECM
to Test Step 2. connector P1-18. Remove the wire A993 from
the primary ECM connector P1-35. Install wire
Not OK The connectors and/or wiring need jumpers into P1-18 and into P1-35.
repair.
Note: If you remove the sensor common from
Repair: Repair the connectors or wiring and/or the ECM, an open circuit diagnostic code will
replace the connectors or wiring. be generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the
STOP. logged diagnostic codes when you are nished.
Test Step 2. Check the Harness for D. Reconnect ECM connector J1/P1.
Shorts.
E. Turn the circuit breaker for the battery to the ON
A. Disconnect the primary ECM connector J1/P1. position.
Disconnect all of the analog sensors.
F. Turn the ECS to the STOP position. The engine
B. Measure the resistance between the analog should be off.
supply P1-02 and the analog return P1-03.
G. Measure the voltage between the wire jumper in
C. Measure the resistance between P1-18 and the analog supply P1-02 and the wire jumper in
P1-35. the analog return P1-03.
D. Measure the resistance between P1-02 and H. Measure the voltage between the wire jumper in
engine ground. the analog supply P1-18 and the wire jumper in
the analog return P1-35.
E. Measure the resistance between P1-03 and
engine ground. I. Turn the ECS to the OFF/RESET position.
F. Measure the resistance between P1-18 and J. Remove the wire jumpers. Replace the wires that
engine ground. were removed above. Reconnect ECM connector
J1/P1.
G. Measure the resistance between P1-35 and
engine ground. Expected Result:
The supply voltage is 5.0 0.2 VDC. Repair: Temporarily replace the sensor. Verify
that the new sensor solves the problem before
Results: permanently installing the new sensor.
g01027471
Illustration 25
Typical example
E. Check the ECM connectors (allen head screw) for Test Step 2. Verify Proper Installation of
the proper torque of 6 1 Nm (53 9 lb in). the Terminating Resistors.
F. Check the harness and the wiring for abrasion A. Verify that the terminating resistors are installed
and for pinch points. on the ends of the data link.
130 RENR5009-07
Troubleshooting Section
The resistance is between 60 3 Ohms. OK The resistance is more than 20,000 Ohms.
Proceed to Test Step 4.
Results:
Not OK The resistance is less than 20,000
OK The resistance is within the range. Proceed Ohms.
to Test Step 3.
Repair: There is a short in the harness wiring.
Not OK The range of the resistance is 120 Repair the connectors or wiring and/or replace the
6 Ohms. A terminating resistor is missing or connectors or wiring.
damaged.
Verify that the repair eliminates the problem.
Repair: If a termination resistor is missing, install
the missing resistor. If both resistors are present, STOP.
measure the resistance between pin A and pin B
of the termination resistor. The resistance should Test Step 4. Check for an Open Circuit
measure 120 3 Ohms. Replace the termination in the Harness.
resistor if the resistance is not 120 3 Ohms.
A. All connections should remain disconnected.
Refer to the Schematic in order to determine the
missing resistor. B. Fabricate a jumper wire. Short pin 7 and pin 8 on
the connector for the marine power display.
Verify that the repair eliminates the problem.
C. Measure the resistance between P1-50 (CAN
STOP. Data Link +) and P1-34 (CAN Data Link -) at the
primary ECM connector P1.
Test Step 3. Check for a Short Circuit in
the Harness. Expected Result:
A. Disconnect the J1/P1 ECM connector. The resistance is less than 5 Ohms.
STOP.
RENR5009-07 131
Troubleshooting Section
i02302453
g01027471
Illustration 26
Typical example
132 RENR5009-07
Troubleshooting Section
Test Step 1. Check for Connector Damage Cat Data Link to +Battery terminal
A. Turn the Engine Control Switch (ECS) to the Cat Data Link + to engine ground
OFF/RESET position. The engine should be off.
Cat Data Link to engine ground
B. Turn the circuit breaker for the battery to the OFF
position. Expected Result:
C. Thoroughly inspect the ECM connectors J1/P1 and The resistance is greater than 20,000 Ohms for each
J2/P2. Inspect all of the other connectors. Refer measurement.
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors for details. Results:
D. Perform a 45 N (10 lb) pull test on each of the OK The resistance is greater than 20,000 Ohms.
wires in the ECM connector that are associated Proceed to Test Step 3.
with the circuit.
Not OK The resistance is less than 20,000
E. Check the ECM connectors (allen head screw) Ohms. There is a short in the harness or in the
for the proper torque. Refer to Troubleshooting, connectors.
Inspecting Electrical Connectors.
Repair: Repair the connector and/or wiring or
F. Check the harness and the wiring for abrasion replace the connector and/or wiring.
and for pinch points.
STOP.
Expected Result:
Test Step 3. Check the Resistance
All connectors, pins, and sockets are completely through the Harness for an Open Circuit
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. A. Turn the ECS to the OFF/RESET position. The
engine should be off.
Results:
B. Turn the circuit breaker for the battery to the OFF
OK The connectors and wiring are okay. Proceed position.
to Test Step 2.
C. Disconnect the ECM connectors for the primary
Not OK The connectors and/or wiring need ECM and for the secondary ECM.
repair.
D. Disconnect any module that is connected to the
Repair: Repair the connectors and/or wiring or Cat Data Link.
replace the connectors and/or wiring.
E. Short the wires of the Cat Data Link together.
STOP. Create the short at P1-9 and P1-8 of the primary
ECM connector.
Test Step 2. Check for Electrical Shorts
in the Harness F. Set an ohmmeter on the 200 ohm scale. Measure
the resistance between the terminals of the Cat
A. Disconnect the ECM connectors for the primary Data Link + and the Cat Data Link . Measure
ECM and for the secondary ECM. the resistance at the connectors for the primary
ECM and the secondary ECM. Measure the
B. Disconnect any module that is connected to the resistance between the terminals of any module
Cat Data Link. that was connected to the Cat Data Link. Wiggle
the harness during the measurements in order to
C. Measure the resistance at the following points. reveal an intermittent open condition.
Wiggle the harness during the measurement in
order to reveal an intermittent short. G. Reconnect all connectors and modules.
Cat Data Link + to Battery terminal The resistance is less than ve Ohms for each
measurement.
Cat Data Link to Battery terminal
Cat Data Link + to +Battery terminal
RENR5009-07 133
Troubleshooting Section
Not OK The resistance is greater than ve Ohms Right exhaust temperature sensor The primary
for each measurement. ECM uses the signal from the sensor to monitor
right exhaust temperature. The sensor is mounted in
Repair: There is an open circuit or there is the right exhaust manifold before the turbocharger.
excessive resistance in the harness. Repair the The sensor's output frequency is 500 Hz with a
connectors and/or wiring or replace the connectors pulse width that varies with the exhaust temperature.
and/or wiring. The output signal is referred to as a duty cycle
or as a pulse width modulated signal. The output
STOP. signal is expressed as a percentage between 0 and
100 percent. The Cat ET will display the exhaust
temperature as a value between 49 C to 850 C
i01900698
(120 F to 1562 F). If the actual temperature is
Digital Sensor Supply between 40 C to 49 C (40 F to 120 F), the
display will read 30 C (86 F). If the temperature is
SMCS Code: 1901-038 above 851 C (1564 F), the display will read 851 C
(1564 F).
System Operation Description:
g00989851
Illustration 27
Typical example
Test Step 1. Check for Connector Repair: Repair the connectors or wiring and/or
Damage. replace the connectors or wiring.
E. Check the primary ECM connector (allen head D. Measure the resistance between the digital return
screw) for the proper torque of 6 1 Nm wire D998 in P1-5 and engine ground.
(53 9 lb in).
E. Measure the resistance between the digital supply
F. Check the harness and the wiring for abrasion wire 700 in P1-4 and the +Battery terminal.
and for pinch points.
F. Measure the resistance between the digital return
Expected Result: wire D998 in P1-5 and the +Battery terminal.
All connectors, pins, and sockets are completely G. Measure the resistance between the digital supply
coupled and/or inserted. The harness and wiring are P2-56 (A700-BK) and the digital return P2-66
free of corrosion, of abrasion or of pinch points. (F998-BK) on connector P2.
J. Measure the resistance between the digital supply J. Turn the battery disconnect switch to the OFF
wire A700 in P2-56 and the +Battery terminal. position.
K. Measure the resistance between the digital return K. Remove the wire jumpers and reconnect the
wire F998 in P2-66 and the +Battery terminal. primary ECM connector J1/P1.
Repair: There is a short in the wiring harness. Not OK The supply voltage is not 8.0 0.4 VDC.
Repair the connectors or wiring and/or replace the The digital sensor supplies are not producing the
connectors or wiring. correct voltage.
A. Remove the wire 700 from the ECM connector Test Step 4. Check the Digital Sensor
P1-4. Install a jumper wire into the socket for P1-4. Supply Voltage at the Sensor Connector.
B. Remove the wire D998 from the ECM connector A. Turn the battery disconnect switch to the ON
P1-5. Install a jumper wire into the socket for P1-5. position.
C. Remove the wire A700 from the ECM connector B. Turn the ECS to the STOP position. The engine
P1-4. Install a jumper wire into the socket for should be off.
P2-56.
C. Measure the digital sensor supply voltage between
D. Remove the wire F998 from the ECM connector the digital supply wire 700 in terminal-A and the
P2-66. Install a jumper wire into the socket for digital return wire D998 in terminal-B at all of the
P2-66. digital sensors.
Note: If you remove the sensor common from D. Measure the digital sensor supply voltage between
the ECM, an open circuit diagnostic code will the digital supply wire A700 in terminal-A and the
be generated for all sensors that use the sensor digital return wire F998 in terminal-B at all of the
common. Troubleshoot the original code. Delete the digital sensors.
logged diagnostic codes when you are nished.
Note: If the sensor is disconnected from the harness,
E. Turn the battery disconnect switch to the ON an open circuit diagnostic code will be generated for
position. that sensor. Troubleshoot the original code. Delete
the logged diagnostic codes when you are nished.
F. Turn the ECS to the STOP position. The engine
should be off. E. Turn the ECS to the OFF/RESET position.
G. Measure the voltage between the digital sensor F. Turn the battery disconnect switch to the OFF
supply P1-4 and the digital sensor return P1-5 at position.
the wire jumpers.
Expected Result:
H. Measure the voltage between the digital sensor
supply P2-56 and the digital sensor return P2-66 The supply voltage is 8.0 0.4 VDC.
at the wire jumpers.
STOP. STOP.
g01029806
Illustration 28
Typical example
RENR5009-07 139
Troubleshooting Section
Note: If a remotestart switch is installed, the remote D. Measure the voltage at the primary ECM and
start switch must be in the LOCAL position for this at the secondary ECM. Measure the voltage
test. between P1-53 and P1-65. Measure the voltage
between P1-52 and P1-63.
Test Step 1. Check for Connector
Damage. E. Measure the voltage between P1-70 and P1-65 at
the primary ECM.
A. Turn the ECS to the OFF/RESET position.
F. Measure the voltage between P1-70 and P1-65
B. Turn the circuit breaker for the battery to the OFF at the secondary ECM.
position.
Expected Result:
C. Verify that the circuit breakers are not tripped.
The voltage measures 24 3 VDC. The difference
D. Thoroughly inspect the ECM connectors J1/P1 and between the three voltage measurements is less
J2/P2. Inspect all of the other connectors. Refer than 0.5 VDC.
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors for details. Results:
E. Perform a 45 N (10 lb) pull test on each of the OK The ECM is receiving the correct battery
wires in the ECM connector that are associated voltage. Proceed to Test Step 5.
with the circuit.
Not OK - P1-70 The voltage is not 24 3 VDC
F. Check the ECM connector (allen head screw) for on the input for the keyswitch to the ECM. Proceed
the proper torque of 6 1 Nm (53 9 lb in). to Test Step 6.
G. Check the harness and the wiring for abrasion Not OK The voltage is incorrect at the battery
and for pinch points. connections to the ECM(s). The wiring or
components between the battery and the ECM are
Expected Result: preventing the voltage from reaching the ECM.
Proceed to Test Step 3.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Test Step 3. Check the Battery Voltage.
are free of corrosion, of abrasion or of pinch points.
A. Turn the circuit breaker for the battery to the OFF
Results: position.
OK The connectors and wiring are okay. Proceed B. Turn the ECS to the OFF/RESET position.
to Test Step 2.
C. Measure no-load battery voltage at the battery
Not OK The connectors and/or wiring need terminals. Refer to Testing and Adjusting, Test
repair. Tools for the Electrical System for the proper
procedures to check the batteries.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. D. Load test the batteries. Use the 4C-4911
Battery Load Tester. Refer to the Operating
STOP. Manual, SEHS9249. Refer to Special Instruction,
SEHS7633.
Test Step 2. Check the Voltage to the
ECM. Expected Result:
A. Disconnect the primary ECM connector and the The no-load voltage at the batteries is at least 23.5
secondary ECM connector J1/P1. VDC and the batteries pass the load test.
Note: Verify that wires D229(229) and wires Not OK The battery voltage is incorrect and/or
A287(287) have continuity from the ECM(s) to the the battery fails the load test.
Battery terminal.
140 RENR5009-07
Troubleshooting Section
Repair: The batteries or the alternator are causing Verify that voltage is not present on wire T120
the problem. Recharge the batteries or replace at the coil of relay R2. If voltage is present on
the batteries. Verify that the original condition is wire T120, check all emergency stop switches for
resolved. Refer to Testing and Adjusting, Electrical proper operation. Check for a diagnostic code for
System. an engine overspeed. If voltage is not present on
wire T120, replace relay R2.
STOP.
STOP.
Test Step 4. Check the Voltage at Relay
R2 and/or Relay R2A. Test Step 5. Check the Voltage at the
Sensor Power Supplies.
A. Turn the circuit breaker for the battery to the ON
position. A. Turn the ECS to the OFF/RESET position.
B. Measure the voltage from wire A103(103) on B. Disconnect the primary ECM connector P1/J1.
terminal 87A of relay R2 to the Battery terminal.
Measure the voltage from wire B103 on terminal Note: If you remove the sensor common from
30 of relay R2 to the Battery terminal. the ECM, an open circuit diagnostic code will
be generated for all sensors that use the sensor
C. Measure the voltage from wire C150(150) on common. Troubleshoot the original code. Delete the
terminal 87A of relay R2A to the Battery logged diagnostic codes when you are nished.
terminal. Measure the voltage from wire A150 on
terminal 30 of relay R2A to the Battery terminal. C. Check the analog supply voltage. Remove the
wire 997 from P1-2. Remove the wire 993 from
Expected Result: P1-3. Install wire jumpers into the sockets for the
above wires.
The voltage measures 24 3 VDC on all terminals.
D. Check the analog supply voltage. Remove the
Results: wire A997 from P1-18. Remove the wire A993
from P1-35. Install wire jumpers into the sockets
OK The voltage is 24 3 VDC. for the above wires.
Repair: Repair the wiring between relay R2 E. Check the digital supply voltage. Remove the wire
and/or relay R2A and the ECM(s). 700 from P1-4. Remove the wire D998 from P1-5.
Install wire jumpers into the sockets for the above
STOP. wires.
Not OK The voltage is not 24 3 VDC on F. Reconnect the primary ECM connector P1/J1.
terminal 30 of the ECM(s).
G. Disconnect the primary ECM connector P2/J2.
Repair: Verify that voltage is present on wire A150
at the breaker for the primary ECM. If voltage is H. Check the digital supply voltage. Remove the wire
present at the breaker, repair the wiring between A700 from P2-56. Remove the wire F998 from
the breaker for the primary ECM and relay R2A. P2-66. Install wire jumpers into the sockets for the
above wires.
Verify that voltage is present on wire B103 at
the breaker for the secondary ECM. If voltage is I. Reconnect the primary ECM connector P2/J2.
present at the breaker, repair the wiring between
the breaker for the secondary ECM and relay R2. J. Turn the ECS to the STOP position.
M. Turn the ECS to the OFF/RESET position. Repair: If 24 3 VDC is present on terminal 20 of
the ECS, replace the ECS.
N. Remove the wire jumpers. Replace all of the wires
that were removed in the above steps. Reconnect STOP.
the ECM connectors.
Not OK - Terminal 20 The correct voltage is not
Expected Result: present on terminal 20 of the ECS. Proceed to Test
Step 7.
The voltage measures 5.0 0.2 VDC on the analog
supplies. The voltage measures 8.0 0.4 VDC on Test Step 7. Check the Voltages at Relay
the digital supplies. R1.
Results: A. Turn the ECS to the STOP position.
OK The sensor power supplies are functioning B. Measure the voltage between wire 120 on terminal
properly. The ECM is powered up. 87A of relay R1 and engine ground.
Repair: The problem may be intermittent. If the C. Measure the voltage between wire A120 on
problem is intermittent, perform the diagnostic terminal 30 of relay R1 and engine ground.
functional test Troubleshooting, Inspecting
Electrical Connectors. D. Turn the ECS to the OFF/RESET position.
Not OK If the ECM is getting the correct voltage The voltage measures 24 3 VDC on both terminals.
at the +Battery terminal, but the ECM does not
supply the correct voltages to the sensor supplies, Results:
replace the ECM.
OK The voltage is 24 3 VDC on both terminals.
Repair: Refer to the diagnostic procedure
Troubleshooting, Replacing the ECM. Repair: The wiring between relay R1 and the
ECS needs repair. Repair the connectors or wiring
STOP. and/or replace the connectors or wiring.
A. Turn the ECS to the STOP position. Not OK The voltage is not 24 3 VDC on
terminal 30 of relay R1.
B. Measure the voltage at the ECS when the switch
is in the STOP position. Measure the voltage Repair: Verify that voltage is present on wire A120
between terminal 16 and engine ground. Measure at the MPD breaker. If voltage is present at the
the voltage between terminal 20 and engine breaker, repair the wiring between the MPD
ground. breaker and relay R1.
The voltage measures 24 3 VDC on both terminals. Not OK The voltage is not 24 3 VDC on
terminal 87A of relay R1.
Results:
Repair: Verify that voltage is not present on wire
OK The voltage is 24 3 VDC on both terminals. R907 at the coil of relay R1. If voltage is present
on wire R907, verify that the ECS is in the STOP
Repair: The wiring between the ECS and the position. If voltage is present on wire R907, check
primary ECM and/or the secondary ECM needs for a short to the +Battery on wire R907 or check
repair. Repair the connectors or wiring and/or the ECS for an internal short. If voltage is not
replace the connectors or wiring. present on wire R907, replace relay R1.
STOP. STOP.
i01988352
g01029797
Illustration 29
Typical example
144 RENR5009-07
Troubleshooting Section
G. Check the harness and the wiring for abrasion C. Monitor the voltage on wire G708 on pin I at
and for pinch points. connector P-C1 of the rigid harness.
B. Turn the ECS to the STOP position. C. Monitor the voltage on wire 354 on pin B at
connector P-C2 of the rigid harness.
C. Activate the local emergency stop switch on the
instrument panel. D. Deactivate the local emergency stop switch.
E. Deactivate the local emergency stop switch. The voltage measures 24 3 VDC.
Expected Result:
OK The voltage measures 24 3 VDC. The The voltage measures 24 3 VDC for approximately
circuit is operating correctly to this point. Proceed 2.5 seconds.
to Test Step 5.
Results:
Not OK No voltage was measured. Proceed to
Test Step 11. OK The voltage measures 24 3 VDC for
approximately 2.5 seconds. The circuit is operating
Test Step 5. Test for Voltage at the Coil of correctly to this point.
the ASOS Switch.
Repair: Repair the wire G708 between the ASOS
A. Turn the ECS to the OFF/RESET position. switch and wire G708 on pin I at connector P-C1 of
the rigid harness.
B. The input to the coil of the ASOS switch is
wire T708 from terminal 4 of the timer. Connect STOP.
a voltmeter between wire T708 on the ASOS
switch and the engine ground. Not OK The voltage did not measure 24 3 VDC
for approximately 2.5 seconds.
C. Turn the ECS to the STOP position.
Repair: Verify that 24 3 VDC is present on wire
D. Activate the local emergency stop switch. K708 at the normally open contacts of the ASOS
switch. If voltage is not present on wire K708,
E. Monitor the voltage on the voltmeter. check the wire K708 and the circuit breaker for the
air shutoff for problems.
F. Deactivate the local emergency stop switch.
If voltage is present on the wire K708, check wire
Expected Result: 220 on the coil of the ASOS switch for continuity
to the Battery. If necessary, repair the wire or
The voltage measures 24 3 VDC for approximately replace the wire. If wire 220 is okay and voltage is
2.5 seconds. present on wire K708, replace the ASOS switch.
Results: STOP.
OK The voltage measures 24 3 VDC for Test Step 7. Check the Voltage at the
approximately 2.5 seconds. The circuit is operating Connector for the Air Shutoff Solenoids.
correctly to this point. Proceed to Test Step 6.
A. Turn the ECS to the OFF/RESET position.
Not OK The voltage did not measure 24 3
VDC. Proceed to Test Step 8. B. Disconnect the connector for the air shutoff
solenoids. Disconnect the connector for the right
Test Step 6. Check for Voltage from and left sides of the engine.
the ASOS Switch to the Air Shutoff
Solenoids. C. Connect a voltmeter between wire G708 on the
connector for the air shutoff solenoid and the
A. Turn the ECS to the OFF/RESET position. engine ground.
B. Disconnect wire G708 from the ASOS switch. D. Turn the ECS to the STOP position.
C. Connect a voltmeter to the empty terminal on the E. Activate the local emergency stop switch.
ASOS switch. Connect the other lead from the
voltmeter to engine ground. F. Monitor the voltage on the voltmeter.
D. Turn the ECS to the STOP position. G. Deactivate the local emergency stop switch.
E. Activate the local emergency stop switch. H. Reconnect the connectors for the air shutoff
solenoids.
F. Monitor the voltage on the voltmeter.
Expected Result:
G. Deactivate the local emergency stop switch.
The voltage measures 24 3 VDC for approximately
H. Reconnect wire G708 to the ASOS switch. 2.5 seconds.
146 RENR5009-07
Troubleshooting Section
Results: Results:
OK The voltage measures 24 3 VDC for OK The voltage measures 24 3 VDC. Proceed
approximately 2.5 seconds. The circuit is operating to Test Step 9.
correctly to this point.
Not OK The voltage did not measure 24 3
Repair: Check the wire H708 from terminal A of the VDC. Proceed to Test Step 10.
connector for continuity to the Battery. If the wire
H708 does not have continuity to the Battery from Test Step 9. Check the Voltage at Terminal
terminal A of the connector, check for continuity 4 of the Connector for the Timer.
on wire H708 on pin H at connector P-C1 of the
rigid harness to Battery. If the wire H708 does A. Connect a voltmeter between terminal 4 of the
not have continuity to the Battery from pin H at connector for the timer and engine ground.
connector P-C1 of the rigid harness, verify that
the breaker for the prelube and air shutoff is not B. Turn the ECS to the STOP position.
tripped. If the wire H708 to the Battery terminal is
okay, replace the air shutoff solenoid. Verify that C. Activate the local emergency stop switch.
the circuit operates correctly.
D. Monitor the voltage on the voltmeter.
STOP.
E. Deactivate the local emergency stop switch.
Not OK The voltage did not measure 24 3 VDC
for approximately 2.5 seconds. System voltage Expected Result:
was not available at the solenoid connector.
The voltage measures 24 3 VDC for approximately
Repair: There is a problem in the wiring between 2.5 seconds.
the connector for the air shutoff solenoids and
wire G708 on pin I at connector P-C1 of the rigid Results:
harness. Repair the connectors or wiring and/or
replace the connectors or wiring. OK The voltage measures 24 3 VDC for
approximately 2.5 seconds.
STOP.
Repair: Repair wire T708 between the ASOS
Test Step 8. Check the Voltage at the switch and terminal 4 of the timer.
Contact of Relay R4A.
STOP.
A. Turn the ECS to the OFF/RESET position.
Not OK The voltage did not measure 24 3 VDC
B. Disconnect wire T120 from terminal 87 of relay for approximately 2.5 seconds.
R4A.
Repair: Check for 24 3 VDC on terminal 1 of the
C. Connect a voltmeter between terminal 87 of relay connector for the timer.
R4A and the engine ground.
If voltage is not present on terminal 1, repair the
D. Turn the ECS to the STOP position. wire T120 between terminal 87 of relay R4A and
terminal 1 of the connector for the timer.
E. Activate the local emergency stop switch.
If voltage is present on terminal 1 of the connector
F. Monitor the voltage on the voltmeter. for the timer, verify that wire 220 on terminal 2 of
the connector for the timer has continuity to the
G. Deactivate the local emergency stop switch. Battery. If wire 220 does not have continuity to the
Battery, repair the wire.
H. Turn the ECS to the OFF/RESET position.
Expected Result:
Verify that 24 3 VDC is present on terminal 3 of Test Step 11. Check the Voltage from the
the connector for the timer. If 24 3 VDC is not Local emergency Stop Switch to Relay
present on terminal 3 of the connector for the timer, R4A.
verify that the ECS is not in the OFF/RESET
position. Verify that the MPD breaker is not A. Turn the ECS to the OFF/RESET position.
tripped. Check the normally closed contact of relay
R1 for proper operation. Check the wire 120 B. Disconnect wire 354 from the local emergency
between terminal 3 of the connector for the timer stop switch.
and relay R1 for damage. Check the wire A120
between relay R1 and the MPD breaker for C. Connect a voltmeter to the empty terminal on the
damage. If necessary, repair the wires. local emergency stop switch. Connect the other
lead from the voltmeter to engine ground.
If the voltage is present on terminal 1 and 3 of the
timer and wire 220 is okay, replace the timer. D. Turn the ECS to the STOP position.
Test Step 10. Check the Voltage at the F. Monitor the voltage on the voltmeter.
Coil of Relay R4A.
G. Deactivate the local emergency stop switch.
A. Connect a voltmeter between wire 354 on terminal
86 of relay R4A and the engine ground. H. Reconnect wire 354.
C. Activate the local emergency stop switch. The voltage measures 24 3 VDC.
E. Deactivate the local emergency stop switch. OK The voltage measures 24 3 VDC.
Expected Result: Repair: Repair the wire 354 between the local
emergency stop switch and the wire 354 on pin B
The voltage measures 24 3 VDC. at connector P-C2 of the rigid harness.
Results: STOP.
OK The voltage measures 24 3 VDC. Not OK The voltage did not measure 24 3
VDC. Proceed to Test Step 12.
Repair: Check wire 220 on the coil of the R4A
relay for continuity to the Battery. If necessary, Test Step 12. Check the Voltage to the
repair the wire or replace the wire. Local emergency Stop Switch from Wire
120 on pin E at connector P-C2 of the
Check for 24 3 VDC on wire 120 on terminal 30 rigid harness.
of relay R4A. If 24 3 VDC is not present on wire
120, verify that the ECS is not in the OFF/RESET A. Turn the ECS to the OFF/RESET position.
position. Verify that the MPD breaker is not
tripped. Check the normally closed contact of relay B. Connect a voltmeter between wire 120 on the
R1 for proper operation. Check the wire 120 local emergency stop switch and engine ground.
between terminal 30 of the relay R4A and relay
R1 for damage. Check the wire A120 between C. Turn the ECS to the STOP position.
relay R1 and the MPD breaker for damage. If
necessary, repair the wires. D. Monitor the voltage on the voltmeter.
Repair: Replace the local emergency stop switch. The contact of relay R4A also supplies power
to terminal 1 of the connector for the timer. When
STOP. power is applied to terminal 1 of the connector for
the timer, the timer will activate. The timer outputs
Not OK The voltage did not measure 24 3 24 VDC to terminal 4 of the connector for the timer
VDC. for 2.5 seconds. The 24 VDC from terminal 4 of
the connector for the timer is applied to the coil of
Repair: Check the wire 120 on pin E at connector the air shutoff switch (ASOS). The contact of the
P-C2 of the rigid harness between the connector ASOS switch energizes the air shutoff solenoids.
and the local emergency stop switch for damage. The timer will output voltage to the coil of the ASOS
Verify that the ECS is not in the OFF/RESET switch for approximately 2.5 seconds. The ASOS
position. Verify that the MPD breaker is not switch will then deactivate removing power to the air
tripped. Check the normally closed contact of relay shutoff solenoids. This prevents damage to the air
R1 for proper operation. Check the wire A120 shutoff solenoids. A normally open switch at the air
between relay R1 and the MPD breaker for shutoff valves will close when the air shutoff solenoid
damage. If necessary, repair the wires. activates the air shutoff valve. The switch input to the
ECM noties the ECM that the air shutoff valves are
STOP. closed. The ECM will not send injection signals to the
injector solenoids until the switch inputs from the air
shutoff valves indicate that the valves are open.
i01988355
Emergency Stop Switch Relay R3A and relay R3 are energized at the
same time as the ASOS switch through terminal 3 of
(Remote) the diode assembly. Terminal 3 of the diode assembly
will energize relay R3A and relay R3 for 2.5
SMCS Code: 1901-038 seconds. The relays R3A and R3 will de-energize
after 2.5 seconds. The overspeed indicator on the
System Operation Description: instrument panel will illuminate for 2.5 seconds.
The terminal AS on the customer connector is In order to start the engine after an emergency
for the customer's remote emergency stop input stop condition, the ECS must be turned to the
to the engine's power distribution panel. When OFF/RESET position. This resets the ECM and the
the customer's remote emergency stop switch is air shutoff timer. In addition to turning the ECS to the
depressed, the coils of relay R4 and relay R4A OFF/RESET position, the operator must manually
are energized. The contacts of relay R4 keeps open the air shutoff valves before starting the engine.
the coils of relay R4 and relay R4A energized
until the Engine Control Switch (ECS) is cycled to
the OFF/RESET position. The contacts of relay
R4A energizes the coils of relays R2 and R2A.
When relays R2 and R2A are energized, power is
removed from the engine's primary Electronic Control
Module (ECM) and the engine's secondary ECM.
The primary ECM and the secondary ECM will power
down. The injection signals to the injector solenoids
will stop. The emergency stop lamp on the instrument
panel will illuminate.
RENR5009-07 149
Troubleshooting Section
g01029797
Illustration 30
Typical example
150 RENR5009-07
Troubleshooting Section
G. Check the harness and the wiring for abrasion C. Monitor the voltage on wire G708 on pin I at
and for pinch points. connector P-C1 of the rigid harness.
B. Turn the ECS to the STOP position. C. Monitor the voltage on wire 354 on pin B at
connector P-C2 of the rigid harness.
C. Activate the customer's remote emergency stop
switch. D. Deactivate the remote emergency stop switch.
E. Deactivate the remote emergency stop switch. The voltage measures 24 3 VDC.
Expected Result:
OK The voltage measures 24 3 VDC. The The voltage measures 24 3 VDC for approximately
circuit is operating correctly to this point. Proceed 2.5 seconds.
to Test Step 5.
Results:
Not OK No voltage was measured. Proceed to
Test Step 11. OK The voltage measures 24 3 VDC for
approximately 2.5 seconds. The circuit is operating
Test Step 5. Test for Voltage at the Coil of correctly to this point.
the ASOS Switch.
Repair: Repair the wire G708 between the ASOS
A. Turn the ECS to the OFF/RESET position. switch and wire G708 on pin I at connector P-C1 of
the rigid harness.
B. The input to the coil of the ASOS switch is
wire T708 from terminal 4 of the timer. Connect STOP.
a voltmeter between wire T708 on the ASOS
switch and the engine ground. Not OK The voltage did not measure 24 3 VDC
for approximately 2.5 seconds.
C. Turn the ECS to the STOP position.
Repair: Verify that 24 3 VDC is present on wire
D. Activate the remote emergency stop switch. K708 at the normally open contacts of the ASOS
switch. If voltage is not present on wire K708,
E. Monitor the voltage on the voltmeter. check the wire K708 and the circuit breaker for the
air shutoff for problems.
F. Deactivate the remote emergency stop switch.
If voltage is present on the wire K708, check wire
Expected Result: 220 on the coil of the ASOS switch for continuity
to the Battery. If necessary, repair the wire or
The voltage measures 24 3 VDC for approximately replace the wire. If wire 220 is okay and voltage is
2.5 seconds. present on wire K708, replace the ASOS switch.
Results: STOP.
OK The voltage measures 24 3 VDC for Test Step 7. Check the Voltage at the
approximately 2.5 seconds. The circuit is operating Connector for the Air Shutoff Solenoids.
correctly to this point. Proceed to Test Step 6.
A. Turn the ECS to the OFF/RESET position.
Not OK The voltage did not measure 24 3
VDC. Proceed to Test Step 8. B. Disconnect the connector for the air shutoff
solenoids. Disconnect the connector for the right
Test Step 6. Check for Voltage from and left sides of the engine.
the ASOS Switch to the Air Shutoff
Solenoids. C. Connect a voltmeter between wire G708 on the
connector for the air shutoff solenoid and the
A. Turn the ECS to the OFF/RESET position. engine ground.
B. Disconnect wire G708 from the ASOS switch. D. Turn the ECS to the STOP position.
C. Connect a voltmeter to the empty terminal on the E. Activate the remote emergency stop switch.
ASOS switch. Connect the other lead from the
voltmeter to engine ground. F. Monitor the voltage on the voltmeter.
D. Turn the ECS to the STOP position. G. Deactivate the remote emergency stop switch.
E. Activate the remote emergency stop switch. H. Reconnect the connectors for the air shutoff
solenoids.
F. Monitor the voltage on the voltmeter.
Expected Result:
G. Deactivate the remote emergency stop switch.
The voltage measures 24 3 VDC for approximately
H. Reconnect wire G708 to the ASOS switch. 2.5 seconds.
152 RENR5009-07
Troubleshooting Section
Results: Results:
OK The voltage measures 24 3 VDC for OK The voltage measures 24 3 VDC. Proceed
approximately 2.5 seconds. The circuit is operating to Test Step 9.
correctly to this point.
Not OK The voltage did not measure 24 3
Repair: Check the wire H708 from terminal A of the VDC. Proceed to Test Step 10.
connector for continuity to the Battery. If the wire
H708 does not have continuity to the Battery from Test Step 9. Check the Voltage at Terminal
terminal A of the connector, check for continuity 4 of the Connector for the Timer.
on wire H708 on pin H at connector P-C1 of the
rigid harness to Battery. If the wire H708 does A. Connect a voltmeter between terminal 4 of the
not have continuity to the Battery from pin H at connector for the timer and engine ground.
connector P-C1 of the rigid harness, verify that
the breaker for the prelube and air shutoff is not B. Turn the ECS to the STOP position.
tripped. If the wire H708 to the Battery terminal is
okay, replace the air shutoff solenoid. Verify that C. Activate the remote emergency stop switch.
the circuit operates correctly.
D. Monitor the voltage on the voltmeter.
STOP.
E. Deactivate the remote emergency stop switch.
Not OK The voltage did not measure 24 3 VDC
for approximately 2.5 seconds. System voltage Expected Result:
was not available at the solenoid connector.
The voltage measures 24 3 VDC for approximately
Repair: There is a problem in the wiring between 2.5 seconds.
the connector for the air shutoff solenoids and
wire G708 on pin I at connector P-C1 of the rigid Results:
harness. Repair the connectors or wiring and/or
replace the connectors or wiring. OK The voltage measures 24 3 VDC for
approximately 2.5 seconds.
STOP.
Repair: Repair wire T708 between the ASOS
Test Step 8. Check the Voltage at the switch and terminal 4 of the timer.
Contact of Relay R4A.
STOP.
A. Turn the ECS to the OFF/RESET position.
Not OK The voltage did not measure 24 3 VDC
B. Disconnect wire T120 from terminal 87 of relay for approximately 2.5 seconds.
R4A.
Repair: Check for 24 3 VDC on terminal 1 of the
C. Connect a voltmeter between terminal 87 of relay connector for the timer.
R4A and the engine ground.
If voltage is not present on terminal 1, repair the
D. Turn the ECS to the STOP position. wire T120 between terminal 87 of relay R4A and
terminal 1 of the connector for the timer.
E. Activate the remote emergency stop switch.
If voltage is present on terminal 1 of the connector
F. Monitor the voltage on the voltmeter. for the timer, verify that wire 220 on terminal 2 of
the connector for the timer has continuity to the
G. Deactivate the remote emergency stop switch. Battery. If wire 220 does not have continuity to the
Battery, repair the wire.
H. Turn the ECS to the OFF/RESET position.
Expected Result:
Verify that 24 3 VDC is present on terminal 3 of Test Step 11. Check the Voltage from
the connector for the timer. If 24 3 VDC is not the Customer Connector for the Remote
present on terminal 3 of the connector for the timer, Emergency Stop to Relay R4A.
verify that the ECS is not in the OFF/RESET
position. Verify that the MPD breaker is not A. Turn the ECS to the OFF/RESET position.
tripped. Check the normally closed contact of relay
R1 for proper operation. Check the wire 120 B. Disconnect wire 354 from the terminal AS of the
between terminal 3 of the connector for the timer customer connector.
and relay R1 for damage. Check the wire A120
between relay R1 and the MPD breaker for C. Connect a voltmeter to terminal AS on the
damage. If necessary, repair the wires. customer connector. Connect the other lead from
the voltmeter to engine ground.
If the voltage is present on terminal 1 and 3 of the
timer and wire 220 is okay, replace the timer. D. Turn the ECS to the STOP position.
Test Step 10. Check the Voltage at the F. Monitor the voltage on the voltmeter.
Coil of Relay R4A.
G. Deactivate the remote emergency stop switch.
A. Connect a voltmeter between wire 354 on terminal
86 of relay R4A and the engine ground. H. Reconnect wire 354.
C. Activate the remote emergency stop switch. The voltage measures 24 3 VDC.
E. Deactivate the remote emergency stop switch. OK The voltage measures 24 3 VDC.
Expected Result: Repair: Repair the wire 354 between terminal AS
on the customer connector and the wire 354 on pin
The voltage measures 24 3 VDC. B at connector P-C2 of the rigid harness.
Results: STOP.
OK The voltage measures 24 3 VDC. Not OK The voltage did not measure 24 3
VDC.
Repair: Check wire 220 on the coil of the R4A
relay for continuity to the Battery. If necessary, Repair: Troubleshoot the customer's connection to
repair the wire or replace the wire. the remote emergency stop input on terminal AS of
the customer connector.
Check for 24 3 VDC on wire 120 on terminal 30
of relay R4A. If 24 3 VDC is not present on wire STOP.
120, verify that the ECS is not in the OFF/RESET
position. Verify that the MPD breaker is not
i01900704
tripped. Check the normally closed contact of relay
R1 for proper operation. Check the wire 120
between terminal 30 of the relay R4A and relay
Engine Control Switch (ECS)
R1 for damage. Check the wire A120 between SMCS Code: 1901-038
relay R1 and the MPD breaker for damage. If
necessary, repair the wires. System Operation Description:
If wire 220 is okay and voltage is present on wire The Engine Control Switch (ECS) can operate in four
120 on terminal 30, replace relay R4A. modes: OFF/RESET, START, STOP, and REMOTE.
STOP.
C remote start 2
D remote start 1
E remote stop 1
F remote stop 2
S remote input
-C keyswitch
When the ECS is in the REMOTE position, the
Remote Start relay and the Remote Stop relay are
energized. When the remote start inputs C and D go
low, the following relays energize: Run 1 relay, Run
2 relay, Reset 1 relay, and Reset 2 relay. The
start/run/stop inputs P1-21 and P1-22 will be pulled
low. The engine will begin the start cycle. When the
customer's remote stop inputs F and E are low, the
following relays energize: Stop 1 relay and Stop
2 relay. The start/run/stop inputs P1-21 and P1-22
will be high. The engine will begin the stop function.
When the ECS is in the REMOTE position, the ECS
in Remote relay energizes. The ECS in Remote
relay sends a signal to the customer connector that
allows the customer to determine the position of the
ECS.
g00991229
Illustration 31
Typical example
156 RENR5009-07
Troubleshooting Section
C. Thoroughly inspect the ECM connectors J1/P1 and Test Step 3. Check the Status of the ECS
J2/P2. Inspect all of the other connectors. Refer in the START Position.
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors for details. A. Turn the ECS on the instrument panel to the
START position.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated B. Observe the status for the ECS on Cat ET.
with the circuit.
Expected Result:
E. Check the ECM connector (allen head screw) for
the proper torque of 6 1 Nm (53 9 lb in). The status for the ECS is RUN.
All connectors, pins, and sockets are completely Not OK The status of the ECS is not RUN.
coupled and/or inserted. The harness and wiring are Proceed to Test Step 5.
free of corrosion, of abrasion or of pinch points.
Test Step 4. Check the Status of the ECS
Results: in the REMOTE Position.
OK The connectors and wiring are okay. Proceed A. Turn the ECS on the instrument panel to the
to Test Step 2. REMOTE position.
Not OK The connectors and/or wiring need B. Observe the status for the ECS on Cat ET.
repair.
Expected Result:
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. The status for the ECS is AUTO.
STOP. Results:
Test Step 2. Check the Status of the ECS OK The ECS is working correctly.
in the STOP Position.
Repair: The problem may be intermittent. If the
A. Turn the circuit breaker for the battery to the ON problem is intermittent, perform the diagnostic
position. functional test Troubleshooting, Inspecting
Electrical Connectors.
B. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. STOP.
C. Turn the ECS on the instrument panel to the ECS Not OK The status for the ECS is not
STOP position. AUTO. Proceed to Test Step 6.
D. Observe the status for the ECS on Cat ET. Test Step 5. Install a Wire Jumper at the
ECM in order to Simulate a START/STOP
Expected Result: Function.
The status for the ECS is STOP. A. Turn the ECS to the OFF/RESET position.
C. Remove wire F716 from P1-21. Install a wire E. Fabricate a wire jumper.
jumper into the socket P1-21.
F. Install the wire jumper between terminal 11 of the
D. Remove wire F717 from P1-22. Install a wire ECS and the wire jumper in P1-68.
jumper into the socket P1-22.
G. Turn the ECS to the STOP position.
E. Reconnect the ECM connector P1.
H. Observe the status for the ECS on Cat ET.
F. Fabricate a wire jumper.
I. Remove the wire jumper between terminal 11 of
G. Install the wire jumper between terminal 11 of the the ECS and the wire jumper in P1-68.
ECS and the wire jumpers in P1-21 and P1-22.
J. Observe the status for the ECS on Cat ET.
H. Turn the ECS to the STOP position.
K. Turn the ECS to the OFF/RESET position.
I. Observe the status for the ECS on Cat ET. Remove the wire jumpers and replace all wires.
Reconnect the ECM connector P1.
J. Remove the wire jumper between terminal 11 of
the ECS and the wire jumpers in P1-21 and P1-22. Expected Result:
K. Observe the status for the ECS on Cat ET. The status for the ECS displays AUTO while the
wire jumper is installed. The status for the ECS
L. Turn the ECS to the OFF/RESET position. displays OFF when the wire jumper is removed.
Remove the wire jumpers and replace all wires.
Reconnect the ECM connector P1. Results:
Not OK The status for the ECS does not display Test Step 7. Check for Voltage on Wire
the correct state. F716 at the Normally Closed Contacts of
the Stop 1 Relay.
Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, Replacing the ECM. A. Turn the remote start switch to the OFF position.
Not OK The voltage is not 6.5 0.5 VDC. The voltage is 6.5 0.5 VDC.
Test Step 8. Check for Voltage on Wire Not OK The voltage is not 6.5 0.5 VDC.
DM775 at the Normally Closed Contacts
of the Stop 1 Relay. Repair: There is a problem with the wire DM775
between the Stop 1 relay and the Run 1 relay.
A. Turn the ECS on the instrument panel to the Repair the wire DM775.
START position.
STOP.
B. Measure the voltage between wire DM775 at the
normally closed contacts of the Stop 1 relay and Test Step 10. Check for Voltage on Wire
engine ground. BM775 at the Normally Open Contacts of
the Run 1 Relay.
C. Turn the ECS that is on the instrument panel to
the STOP position. A. Turn the ECS on the instrument panel to the
START position.
Expected Result:
B. Measure the voltage between wire BM775 at the
The voltage is 6.5 0.5 VDC. normally open contacts of the Run 1 relay and
engine ground.
Results:
C. Turn the ECS that is on the instrument panel to
OK The voltage is 6.5 0.5 VDC. Proceed to the STOP position.
Test Step 9.
Expected Result:
Not OK The voltage is not 6.5 0.5 VDC. The
Stop 1 relay's normally closed contacts are faulty The voltage is 6.5 0.5 VDC.
or the Stop 1 relay is energized.
Results:
Repair: Check the voltage across the coil of the
Stop 1 relay. If voltage is present across the coil OK The voltage is 6.5 0.5 VDC. Proceed to
of the Stop 1 relay, ensure that the ECS is not in Test Step 11.
the STOP position.
Not OK The voltage is not 6.5 0.5 VDC. The
If no voltage is measured across the coil of Run 1 relay is not energized or there is a problem
the Stop 1 relay, the normally closed contacts with the normally open contacts between wire
between wire F716 and wire DM775 are faulty. DM775 and wire BM775.
Replace the Stop 1 relay and check for diagnostic
codes. Repair: Check the voltage across the coil of the
Run 1 relay. The voltage should measure 24 3
STOP. VDC. If the voltage is not 24 3 VDC, verify that 24
3 VDC is present between wire 120 at the coil of
Test Step 9. Check for Voltage on Wire the Run 1 relay and engine ground. If the voltage
DM775 at the Normally Open Contacts of is present, verify that wire DM775 has continuity
the Run 1 Relay. between the coil of the Run 1 relay and the ECM.
If wire DM775 is okay, replace the Run 1 relay. If
A. Turn the ECS on the instrument panel to the wire DM775 is not okay, repair the wire.
START position.
STOP.
B. Measure the voltage between wire DM775 at the
normally open contacts of the Run 1 relay and
engine ground.
RENR5009-07 159
Troubleshooting Section
Test Step 11. Check for Voltage on Wire Repair: Check the voltage across the coil of the
BM775 at the Normally Closed Contacts Stop 1 relay. The voltage should not measure 24
of the Stop 1 Relay. 3 VDC. If the voltage is 24 3 VDC, the wire
SM775 is shorted to ground or the ECS is in the
A. Turn the ECS on the instrument panel to the STOP position. Repair the wire SM775 or repair
START position. the ECS. If voltage is not present across the coil of
the Stop 1 relay, replace the stop 1 relay.
B. Measure the voltage between wire BM775 at the
normally closed contacts of the Stop 1 relay and STOP.
engine ground.
Test Step 13. Check for Voltage on Wire
C. Turn the ECS that is on the instrument panel to F717 at the Normally Closed Contacts of
the STOP position. the Stop 2 Relay.
Expected Result: A. Turn the remote start switch to the OFF position.
The voltage is 6.5 0.5 VDC. B. Turn the ECS on the instrument panel to the
START position.
Results:
C. Measure the voltage between wire F717 at the
OK The voltage is 6.5 0.5 VDC. Proceed to normally closed contacts of the Stop 2 relay and
Test Step 12. engine ground.
Not OK The voltage is not 6.5 0.5 VDC. D. Turn the ECS that is on the instrument panel to
the STOP position.
Repair: There is a problem with the wire BM775
between the Stop 1 relay and the Run 1 relay. Expected Result:
Repair the wire BM775.
The voltage is 6.5 0.5 VDC.
STOP.
Results:
Test Step 12. Check for Voltage on Wire
D998 at the Normally Closed Contacts of OK The voltage is 6.5 0.5 VDC. Proceed to
the Stop 1 Relay. Test Step 14.
A. Turn the ECS on the instrument panel to the Not OK The voltage is not 6.5 0.5 VDC.
START position.
Repair: Repair the wire F717 between the normally
B. Measure the voltage between wire D998 at the closed contacts on the Stop 2 relay and the ECM.
normally closed contacts of the Stop 1 relay and
engine ground. STOP.
C. Turn the ECS to the STOP position. Test Step 14. Check for Voltage on Wire
DM776 at the Normally Closed Contacts
Expected Result: of the Stop 2 Relay.
The voltage is 6.5 0.5 VDC. A. Turn the ECS on the instrument panel to the
START position.
Results:
B. Measure the voltage between wire DM776 at the
OK The voltage is 6.5 0.5 VDC. The digital normally closed contacts of the Stop 2 relay and
return wire is open between the Stop 1 relay and engine ground.
the ECM.
C. Turn the ECS that is on the instrument panel to
Repair: Repair the wire D998. the STOP position.
Not OK The voltage is not 6.5 0.5 VDC. The The voltage is 6.5 0.5 VDC.
normally closed contacts between wire BM775 and
wire D998 are open.
160 RENR5009-07
Troubleshooting Section
Not OK The voltage is not 6.5 0.5 VDC. There The voltage is 6.5 0.5 VDC.
is a problem with the normally closed contacts of
the Stop 2 relay or the Stop 2 relay is energized. Results:
Repair: Check the voltage across the coil of the OK The voltage is 6.5 0.5 VDC. Proceed to
Stop 2 relay. If voltage is present across the coil Test Step 17.
of the Stop 2 relay, ensure that the ECS is not in
the STOP position. Not OK The voltage is not 6.5 0.5 VDC. The
Run 2 relay is not energized or there is a problem
If no voltage is measured across the coil of the with the normally open contacts between wire
Stop 2 relay, there is a problem with the normally DM776 and wire BM776.
closed contacts between wire F717 and wire
DM776. Replace the Stop 2 relay and check for Repair: Check the voltage across the coil of the
diagnostic codes. Run 2 relay. The correct voltage is 24 3 VDC.
If the voltage is not 24 3 VDC, verify that 24
STOP. 3 VDC is present between wire 120 at the coil of
the Run 2 relay and engine ground. If the voltage
Test Step 15. Check for Voltage on Wire is present, verify that wire DM776 has continuity
DM776 at the Normally Open Contacts of between the coil of the run 2 relay and the ECM.
the Run 2 Relay. If wire DM776 is okay, replace the Run 2 relay.
If wire DM776 is not okay, repair the wire or the
A. Turn the ECS on the instrument panel to the component.
START position.
STOP.
B. Measure the voltage between wire DM776 at the
normally open contacts of the Run 2 relay and Test Step 17. Check for Voltage on Wire
engine ground. BM776 at the Normally Closed Contacts
of the Stop 2 Relay.
C. Turn the ECS that is on the instrument panel to
the STOP position. A. Turn the ECS on the instrument panel to the
START position.
Expected Result:
B. Measure the voltage between wire BM776 at the
The voltage is 6.5 0.5 VDC. normally closed contacts of the Stop 2 relay and
engine ground.
Results:
C. Turn the ECS that is on the instrument panel to
OK The voltage is 6.5 0.5 VDC. Proceed to the STOP position.
Test Step 16.
Expected Result:
Not OK The voltage is not 6.5 0.5 VDC.
The voltage is 6.5 0.5 VDC.
Repair: There is a problem with the wire DM776
between the Stop 2 relay and the Run 2 relay. Results:
Repair the wire DM776.
OK The voltage is 6.5 0.5 VDC. Proceed to
STOP. Test Step 18.
Test Step 16. Check for Voltage on Wire Not OK The voltage is not 6.5 0.5 VDC.
BM776 at the Normally Open Contacts of
the Run 2 Relay. Repair: There is a problem with the wire BM776
between the Stop 2 relay and the run 2 relay.
A. Turn the ECS on the instrument panel to the Repair the wire BM776.
START position.
STOP.
B. Measure the voltage between wire BM776 at the
normally open contacts of the Run 2 relay and
engine ground.
RENR5009-07 161
Troubleshooting Section
Test Step 18. Check for Voltage on Wire The primary ECM performs an automatic calibration
D998 at the Normally Closed Contacts of of these sensors whenever power is rst applied to
the Stop 2 Relay. the engine ECM and the engine has been off for at
least ve seconds. During an automatic calibration,
A. Turn the ECS on the instrument panel to the the primary ECM calibrates pressure sensors against
START position. the atmospheric pressure sensor and an acceptable
offset pressure range.
B. Measure the voltage between wire D998 at the
normally closed contacts of the Stop 2 relay and
engine ground.
Expected Result:
Results:
STOP.
STOP.
i01905746
g00992368
Illustration 32
Typical example
Test Step 1. Check for Connector D. Perform a 45 N (10 lb) pull test on each of the
Damage. wires in the ECM connector that are associated
with the circuit.
A. Turn the ECS to the OFF/RESET position.
E. Check the ECM connector (allen head screw) for
B. Turn the battery disconnect switch to the OFF the proper torque of 6 1 Nm (53 9 lb in).
position.
F. Check the harness and the wiring for abrasion
C. Thoroughly inspect the ECM connectors J1/P1 and and for pinch points.
J2/P2. Inspect all of the other connectors. Refer
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors for details.
RENR5009-07 163
Troubleshooting Section
Results: STOP.
OK The connectors and wiring are okay. Proceed Test Step 3. Check the Sensor Supply
to Test Step 2. Voltage at the Sensor Connector if the
Diagnostic Code FMI-03 is Present.
Not OK The connectors and/or wiring are not
okay. A. Turn the ECS to the OFF/RESET position.
Repair: Repair the connectors or wiring and/or B. Disconnect the suspect sensor.
replace the connectors or wiring.
Note: Disconnecting the sensor will generate an
STOP. open circuit diagnostic code for any sensor that is
disconnected. Troubleshoot the original diagnostic
Test Step 2. Check for Active Diagnostic code. Reset the system. Delete the logged diagnostic
Codes. codes when you are nished.
A. Connect the Caterpillar Electronic Technician (ET) C. Turn the ECS to the STOP position. The engine
to the ECM through the service tool connector. should be off.
B. Turn the battery disconnect switch to the ON D. Measure the voltage on the ECM side of the
position. sensor connector between pin A and pin B for the
suspect sensor.
C. Turn the ECS to the STOP position. The engine
should be off. Expected Result:
D. Wait for 15 seconds for the CID-FMI. The supply voltage is 5.0 0.2 VDC for all analog
sensors and 8.0 0.4 VDC for all digital sensors.
Expected Result:
Results:
Determine the failure mode identier (FMI).
Determine if the diagnostic codes 262-03 5 Volt OK The voltage is 5.0 0.2 VDC for all analog
Sensor DC Power Supply short to +batt or 262-04 5 sensors and 8.0 0.4 VDC for all digital sensors.
Volt Sensor DC Power Supply short to ground are Proceed to Test Step 5.
present. Determine if the diagnostic codes 263-03
Digital Sensor Supply short to +batt or 263-04 Digital Not OK The voltage is not 5.0 0.2 VDC for all
Sensor Supply short to ground are present. analog sensors and 8.0 0.4 VDC for all digital
sensors. Proceed to Test Step 7.
Results:
Test Step 4. Check the Sensor Supply
FMI 03 A diagnostic code with a FMI of 03 is Voltage at the Sensor Connector if the
present. Proceed to Test Step 3. Diagnostic Code FMI-04 is Present.
FMI 04 A diagnostic code with a FMI of 04 is A. Turn the ECS to the OFF/RESET position.
present. Proceed to Test Step 4.
B. Disconnect the suspect sensor.
FMI 00 or 08 A diagnostic code with a FMI of 00
or of 08 is present. Proceed to Test Step 11. Note: Disconnecting the sensor will generate an
open circuit diagnostic code for any sensor that is
262-03 or 262-04 Active Code A diagnostic code disconnected. Troubleshoot the original diagnostic
of 262-03 or of 262-04 is present. code. Reset the system. Delete the logged diagnostic
codes when you are nished.
Repair: Perform the diagnostic functional test
Troubleshooting, Analog Sensor Supply. C. Turn the ECS to the STOP position. The engine
should be off.
STOP.
164 RENR5009-07
Troubleshooting Section
D. Measure the voltage on the ECM side of the Not OK The voltage on pin B should measure
sensor connector between pin A and pin B for the 0 VDC. The voltage on pin C may measure
suspect sensor. approximately 6.5 VDC. The voltage on pin C
is a pull up voltage. The ECM provides the pull
Expected Result: up voltage to the signal input when the ECM
senses an open circuit in the incoming input
The supply voltage is 5.0 0.2 VDC for all analog signal. Frequency sensors do not receive a pull up
sensors and 8.0 0.4 VDC for all digital sensors. voltage. The sensor common and signal wire are
not shorted to the +Battery. Proceed to Test Step 6.
Results:
Test Step 6. Create a Short at the Sensor
OK The voltage is 5.0 0.2 VDC for all analog Connector.
sensors and 8.0 0.4 VDC for all digital sensors.
Proceed to Test Step 8. A. Turn the ECS to the OFF/RESET position.
Not OK The voltage is not 5.0 0.2 VDC for all B. Use a wire jumper to connect pin B and pin C
analog sensors and 8.0 0.4 VDC for all digital together on the sensor connector.
sensors. Proceed to Test Step 7.
C. Turn the ECS to the STOP position. The engine
Test Step 5. Check for a Short to the should be off.
+Battery.
D. Check if the CID-FMI has changed from 03 to 04.
A. Turn the ECS to the OFF/RESET position.
E. Turn the ECS to the OFF/RESET position.
B. Disconnect the suspect sensor.
F. Remove the wire jumper.
Note: Disconnecting the sensor will generate an
open circuit diagnostic code for any sensor that is Expected Result:
disconnected. Troubleshoot the original diagnostic
code. Reset the system. Delete the logged diagnostic The CID-FMI changes from 03 to 04.
codes when you are nished.
Results:
C. Turn the ECS to the STOP position. The engine
should be off. OK The CID-FMI changed from 03 to 04. The
circuit now indicates a short circuit diagnostic code.
D. Measure the voltage on the ECM side of the
sensor connector between pin B and the engine Repair: Temporarily connect a new sensor. Verify
ground. that the new sensor solves the problem before you
permanently install the new sensor. Calibrate the
E. Measure the voltage on the ECM side of the sensor.
sensor connector between pin C and the engine
ground. STOP.
F. Turn the ECS to the OFF/RESET position. Not OK The CID-FMI did not change from 03 to
04. The circuit indicates an open circuit diagnostic
Expected Result: code. Proceed to Test Step 9.
The voltage measures 24 3 VDC when a short to Test Step 7. Check the Sensor Supply
the +Battery is present. Voltage at the ECM.
Results: A. Turn the ECS to the OFF/RESET position.
OK The voltage measures 24 3 VDC. A short B. Check the analog supply voltage.
to the +Battery is present.
a. Check the left analog supply voltage by
Repair: Repair the connectors or wiring and/or removing wire 997 in P1-02 and wire 993
replace the connectors or wiring. in P1-03 from ECM connector P1. Install a
wire jumper into the sockets for P1-02 and for
STOP. P1-03.
RENR5009-07 165
Troubleshooting Section
b. Check the right analog supply voltage by Repair: Repair the connectors or wiring and/or
removing wire A997 in P1-18 and wire A993 replace the connectors or wiring.
in P1-35 from ECM connector P1. Install a
wire jumper into the sockets for P1-35 and for STOP.
P1-18.
Not OK - Analog or Digital The supply voltage is
Note: If you remove the sensor common from not 5.0 0.2 VDC for all analog sensors and 8.0
the ECM, an open circuit diagnostic code will 0.4 for all digital sensors. The voltage at the ECM
be generated for all sensors that use the sensor is not correct.
common. Troubleshoot the original code. Delete the
logged diagnostic codes when you are nished. Repair: Perform the diagnostic functional test
Troubleshooting, Electrical Power Supply.
C. Check the digital supply voltage.
STOP.
a. Check the left digital supply voltage by
removing wire 700 in P1-04 and wire D998 Test Step 8. Create an Open Circuit at the
in P1-05 from ECM connector P1. Install a Sensor Connector.
wire jumper into the sockets for P1-04 and for
P1-05. A. Turn the ECS to the OFF/RESET position.
b. Check the right digital supply voltage by B. Leave the sensor disconnected.
removing wire A700 in P2-56 and wire F998
in P2-66 from ECM connector P2. Install a C. Wait for a period of 15 seconds.
wire jumper into the sockets for P2-56 and for
P2-66. D. Turn the ECS to the STOP position. The engine
should be off.
Note: If you remove the sensor common from
the ECM, an open circuit diagnostic code will E. The CID-FMI should change from 04 to 03.
be generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the Note: Disconnecting the atmospheric pressure
logged diagnostic codes when you are nished. sensor will cause several sensor diagnostic codes
to become active. Troubleshoot the original code.
D. Reconnect ECM connector J1/P1 and J2/P2. Delete the logged diagnostic codes when you are
nished.
E. Turn the ECS to the STOP position. The engine
should be off. F. Turn the ECS to the OFF/RESET position.
F. Measure the analog voltage between the wire G. Reconnect the suspect sensor.
jumpers.
Expected Result:
G. Measure the digital voltage between the wire
jumpers. The CID-FMI changes from 04 to 03 when the sensor
is disconnected.
H. Turn the ECS to the OFF/RESET position.
Results:
I. Turn the keyswitch for the ECM to the OFF
position. OK The CID-FMI changed from 04 to 03 when
the sensor was disconnected. The open circuit was
J. Remove the wire jumpers and replace all wires. seen by the ECM. The wiring between the ECM
Reconnect ECM connector J1/P1. and the sensor is good.
Test Step 9. Create a Short at the ECM Note: Disconnecting the atmospheric pressure
Connector. sensor will cause several sensor diagnostic codes
to become active. Troubleshoot the original code.
A. Connect the suspect sensor. Delete the logged diagnostic codes when you are
nished.
B. Remove the suspect sensor's signal wire from
ECM connector P1 or P2. Install a wire jumper E. Turn the ECS to the OFF/RESET position.
into the socket for the signal wire.
F. Replace the signal wire and reconnect ECM
C. Use a jumper to create a short between the wire connector J1/P1 or J2/P2.
jumper and the sensor's common wire.
Expected Result:
D. Turn the ECS to the STOP position. The engine
should be off. The CID-FMI changes from 04 to 03 when the sensor
signal wire is disconnected.
E. The CID-FMI should change from 03 to 04 when
the jumper is in place. Results:
F. Turn the ECS to the OFF/RESET position. OK The CID-FMI changed from 04 to 03 when
the sensor signal wire was disconnected. The ECM
G. Remove the wire jumper and replace the signal recognized the open at the ECM.
wire. Reconnect ECM connector J1/P1 and/or
J2/P2. Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
Expected Result:
STOP.
The CID-FMI changes from 03 to 04 when the jumper
is in place. Not OK The CID-FMI did not change from 04 to
03 when the sensor signal wire was disconnected.
Results: The ECM did not recognize the open at the ECM.
OK The CID-FMI changed from 03 to 04 when Repair: Refer to the diagnostic procedure
the jumper was put in place. The ECM recognized Troubleshooting, Replacing the ECM.
the short at the ECM. There is a problem with the
wiring between the ECM and the suspect sensor. STOP.
Repair: Repair the connectors or wiring and/or Test Step 11. Check the Fluid Level.
replace the connectors or wiring.
A. Check the fuel level.
STOP.
B. Check the engine oil level.
Not OK The CID-FMI did not change from 03 to
04 when the jumper was put in place. The ECM did C. Check for any leaks.
not see the short at the ECM. Replace the ECM.
Expected Result:
Repair: Refer to the diagnostic procedure
Troubleshooting, Replacing the ECM. The fuel and oil level are okay. There are not any
leaks.
STOP.
Results:
Test Step 10. Create an Open at the ECM.
OK The fuel and oil levels are correct. Proceed
A. Turn the ECS to the OFF/RESET position. to Test Step 12.
B. Remove the suspect sensor signal wire from Not OK The fuel and/or oil levels are not correct.
J1/P1 or J2/P2.
Repair: If the oil level is low, add oil. If the fuel level
C. Turn the ECS to the STOP position. The engine is low, add fuel. Repair the leaks. Reset the system
should be off. and note any active diagnostic codes.
Test Step 12. Compare the Pressure or Repair: Reset the system and note any active
Temperature to the Actual Pressure or diagnostic codes.
Temperature.
STOP.
A. Turn the ECS to the OFF/RESET position.
Not OK - Analog A constant pressure is not
B. If you are troubleshooting a temperature sensor, shown on the Cat ET. A 5 2 kPa (0.7 0.3 psi)
install a 6V-9130 Temperature Adapter near the drop in pressure is not shown on the Cat ET while
sensor. the vacuum is being applied. An analog sensor is
not producing the correct reading. Proceed to Test
C. Turn the ECS to the STOP position. The engine Step 13.
should be off.
Not OK - Digital The correct temperature is
D. Observe the temperature reading for the suspect not shown on the Cat ET. A digital sensor is not
sensor. The Cat ET screen should display the producing the correct reading. Proceed to Test
same temperature as the 6V-9130 Temperature Step 14.
Adapter.
Vacuum Leak A vacuum leak is suspected.
E. If you are troubleshooting a pressure sensor,
disconnect the sensor. Repair: Check for leaks. If no leaks are found,
there is an internal leak in the suspect pressure
F. Remove the suspect sensor from the engine. sensor. Replace the sensor and calibrate the
sensor. Reset the system and note any active
G. Reconnect the suspect sensor. diagnostic codes.
F. Turn the keyswitch for the ECM to the OFF B. Use a suitable piece of wire to connect pin A to
position. pin C.
G. Replace the sensor's signal wire and reconnect C. Measure the resistance between the sensor signal
the sensor. wire and the sensor voltage supply at the ECM
connector P1 or P2.
Expected Result:
D. Use a suitable piece of wire to connect pin B to
The frequency reading is approximately 500 Hz. pin C.
When the temperature is below 49 C (120 F), the E. Measure the resistance between the sensor signal
duty cycle is between 16 percent to 21 percent. and the sensor common at the ECM connector
P1 or P2.
When the temperature is between 49 C (120 F)
and 851 C (1564 F), the duty cycle is between 22 F. Use a suitable piece of wire to connect pin A to
percent to 88 percent. pin B.
B. Measure the resistance between the sensor signal OK - Analog The resistance is less than 5 Ohms.
wire and engine ground. Proceed to Test Step 17.
C. Measure the resistance between the sensor OK - Digital The resistance is less than 5 Ohms.
common and engine ground. Proceed to Test Step 18.
D. Measure the resistance between the sensor Not OK The resistance is greater than 5 Ohms.
supply and engine ground at the ECM connector.
Repair: Repair the connectors or wiring and/or
E. Reconnect all connectors and all sensors. replace the connectors or wiring.
Test Step 17. Check the Analog Sensor's Test Step 18. Check the Digital Sensor's
Signal Voltage at the ECM. Signal Frequency and the Duty Cycle at
the ECM.
A. Turn the ECS to the STOP position. The engine
should be off. A. Turn the ECS to the STOP position.
B. Measure the sensor signal voltage between pin C B. Measure the frequency and the duty cycle
and pin B at the ECM connector P1 or P2. between pin C and pin B at the ECM connector
P1 or P2.
C. Observe the sensor reading on the status screen
on the Cat ET. C. Start the engine.
Note: The status screen on the Cat ET displays D. Observe the sensor reading on the status screen
ABNORMAL SIGNAL when the ECM reads a signal on the Cat ET.
that is out of the normal range.
Note: The status screen on the Cat ET displays
D. Turn the ECS to the OFF/RESET position. ABNORMAL SIGNAL when the ECM reads a signal
that is out of normal range.
Expected Result:
E. Turn the ECS to the OFF/RESET position.
The signal voltage for the analog sensors is between
0.2 VDC and 4.8 VDC for the suspect analog sensor. Expected Result:
OK The signal voltage for the analog sensors When the temperature is below 49 C (120 F),
is between 0.2 VDC and 4.8 VDC for the suspect the duty cycle should be between 16 percent to 21
analog sensor. The sensor voltage at the ECM is percent.
correct. The Cat ET screen displays the correct
information. When the temperature is between 49 C (120 F)
and 851 C (1564 F), the duty cycle is between 22
Repair: There may be an intermittent problem. If percent to 88 percent.
the problem is intermittent, perform the diagnostic
functional test Troubleshooting, Inspecting While the engine is cold, the Cat ET should read
Electrical Connectors. 30 C (86 F). As the engine warms up the exhaust
temperature increases.
STOP.
Results:
Not OK The signal voltage for the analog
sensors is not between 0.2 VDC and 4.8 VDC for OK The digital sensor voltage at the ECM is
the suspect analog sensor. The sensor voltage at correct.
the ECM is not correct.
Repair: There may be an intermittent problem. If
Repair: Repair the connectors and/or wiring the problem is intermittent, perform the diagnostic
between the ECM connector and the sensor. functional test Troubleshooting, Inspecting
Electrical Connectors.
STOP.
STOP.
ABNORMAL SIGNAL The status screen on the
Cat ET displays ABNORMAL SIGNAL. The signal Not OK The digital sensor voltage at the ECM
voltage for the analog sensors is between 0.2 VDC is not correct.
and 4.8 VDC for the suspect analog sensor. The
sensor voltage at the ECM is correct. Repair: Repair the connectors and/or wiring
between the ECM and the sensor.
Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, Replacing the ECM. STOP.
STOP.
i01900706
g01012369
Illustration 33
Typical example
C. Thoroughly inspect the ECM connectors J1/P1 and Repair: Repair the connectors or wiring and/or
J2/P2. Inspect all of the other connectors. Refer replace the connectors or wiring.
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors for details. STOP.
D. Perform a 45 N (10 lb) pull test on each of the Test Step 2. Check for a CID-FMI.
wires in the ECM connector that are associated
with the circuit. A. Connect the Caterpillar Electronic Technician (ET).
E. Check the ECM connector (allen head screw) for B. Turn the circuit breaker for the battery to the ON
the proper torque of 6 1 Nm (53 9 lb in). position.
F. Check the harness and the wiring for abrasion C. Turn the ECS to the STOP position.
and for pinch points.
D. Observe logged diagnostic codes on Cat ET.
Expected Result:
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Cat ET indicates a CID-FMI 190-03 or 342-03.
are free of corrosion, of abrasion or of pinch points.
Results:
Test Step 3. Check for Shorts in Wiring Not OK The resistance is less than 20,000
Harness. Ohms. There is a short circuit in the harness wiring.
A. Turn the ECS to the OFF/RESET position. Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
B. Disconnect J1/P1 from the primary ECM.
Disconnect J1/P1 from the secondary ECM. STOP.
Disconnect the primary engine speed/timing
sensor J401/P401. Disconnect the secondary Test Step 4. Check the Engine
engine speed/timing sensor J402/P402. Speed/Timing Sensor.
C. To test the primary engine speed/timing sensor, Note: An active CID-FMI 190-07 or an active
measure the resistance at the primary ECM CID-FMI 342-07 indicates that the connectors
connector P1: for the primary engine speed/timing sensor and
the secondary engine speed/timing sensor have
Measure the resistance between P1-33 and been installed incorrectly. The connector for the
P1-51. primary engine speed/timing sensor has been
installed on the secondary engine speed/timing
Measure the resistance between P1-33 and sensor and the connector for the secondary engine
P1-43. speed/timing sensor has been installed on the
primary engine speed/timing sensor. Turn the ECS to
Measure the resistance between P1-43 and the OFF/RESET position and switch the connectors.
P1-51. Turn the ECS to the STOP position and verify that
the diagnostic codes are no longer active.
Measure the resistance between P1-33 and
engine ground. NOTICE
Be sure to extend the sliphead before installing the
Measure the resistance between P1-43 and Speed/Timing Sensor and also check that the Timing
engine ground. Gear is in a position that will not allow the sliphead of
the Speed/Timing Sensor to protrude into the slot of
Measure the resistance between P1-51 and the Timing Gear before the sensor is installed (visually
engine ground. inspect with a ashlight). Turn the crankshaft to rotate
the Timing Gear, if necessary, to position the gear in a
D. To test the secondary engine speed/timing sensor, place that will not allow the sliphead to protrude into a
measure the resistance at the secondary ECM slot. If the sensor sliphead does protrude into one of
connector P1: the slots, the sliphead will be broken off as the gear
begins to rotate.
Measure the resistance between P1-13 and
P1-51.
A. Turn the ECS to the OFF/RESET position.
Measure the resistance between P1-13 and
P1-43. B. Disconnect the sensor and remove the sensor.
Measure the resistance between P1-43 and C. Inspect the plastic sliphead for damage.
P1-51.
D. Check the tension. Gently extend the sliphead
Measure the resistance between P1-13 and 3.5 mm (0.14 inch). Return the sliphead to the
engine ground. original position.
Measure the resistance between P1-43 and E. Extend the sliphead and reinstall the sensor.
engine ground.
Note: If you are troubleshooting the primary engine
Measure the resistance between P1-51 and speed/timing sensor, disconnect the secondary
engine ground. sensor for the remainder of the test. If you are
troubleshooting the secondary engine speed/timing
Expected Result: sensor, disconnect the primary sensor for the
remainder of the test.
The resistance is greater than 20,000 Ohms.
RENR5009-07 173
Troubleshooting Section
b. Measure the resistance between P1-43 Test Step 6. Check the Engine Speed.
and P1-51. Wiggle the harness during the
measurement in order to reveal an intermittent A. Turn the ECS to the OFF/RESET position.
condition.
B. Connect Cat ET.
c. Use a suitable piece of wire to short J401-A
and J401-C. C. Crank the engine.
d. Measure the resistance between P1-43 D. Observe the engine speed on the Cat ET screen.
and P1-33. Wiggle the harness during the
measurement in order to reveal an intermittent Expected Result:
condition.
Cat ET displays a steady reading between 100 and
C. For the secondary engine speed/timing sensor, 250 rpm. The engine starts.
perform the following steps.
Results:
a. Use a suitable piece of wire to short J402-A
and J402-B. OK The engine speed/timing sensor is operating
correctly at this time.
b. Measure the resistance between P1-43
and P1-51. Wiggle the harness during the Repair: The problem may be intermittent. If the
measurement in order to reveal an intermittent problem is intermittent, perform the diagnostic
condition. functional test Troubleshooting, Inspecting
Electrical Connectors.
c. Use a suitable piece of wire to short J402-A
and J402-C together. STOP.
174 RENR5009-07
Troubleshooting Section
Test Step 7. Check the Supply Voltage on Repair: Replace the sensor. Calibrate the
the Sensor Side of the Sensor Connector. sensor. Perform the diagnostic functional test
Troubleshooting, Engine Speed/Timing Sensor -
A. Turn the ECS to the STOP position. Calibrate.
A. Remove pin-C from the sensor connector. Not OK The voltage is not 12 1.0 VDC.
Proceed to Test Step 10.
B. Turn the ECS to the STOP position.
Test Step 10. Check the Supply Voltage
C. Measure the voltage between pin-C and pin-B. at the ECM.
Perform this step before you crank the engine.
Perform this step while you are cranking the A. Measure the voltage at the primary ECM
engine. connector between P1-43 and P1-51. Measure
the voltage at the secondary ECM connector
D. Turn the ECS to the OFF/RESET position. between P1-43 and P1-51.
C. Measure the voltage between P1-13 and P1-51 Repair: Replace the ECM. Refer to the diagnostic
for the secondary engine speed/timing sensor. procedure Troubleshooting, Replacing the ECM.
Measure the voltage before you crank the engine
and while you crank the engine. STOP.
g00992542
Illustration 34
Typical example
RENR5009-07 177
Troubleshooting Section
Not OK The connectors and/or wiring need H. Use diagnostic tests on Cat ET in order to initiate
repair. the injector solenoid test.
Repair: Repair the connectors or wiring and/or As each solenoid is energized by the ECM an
replace the connectors or wiring. audible click can be heard at the valve cover.
Listen for a click at each valve cover. A black
STOP. square will appear over the cylinder number when
the cylinder is being red.
Test Step 2. Check for Logged Diagnostic
Codes. Note: A false reading may result from the initial test.
By the fourth consecutive test, the readings should
A. Connect the Caterpillar Electronic Technician (ET). become valid.
B. Turn the circuit breaker for the battery to the ON Expected Result:
position.
As each solenoid is energized by the ECM, an
C. Turn the ECS to the STOP position. audible click of the solenoid is heard. The solenoids
are energized one at a time in the following numerical
D. Observe the diagnostic codes on Cat ET. order: 1-16. There will be momentary delay between
each one.
Expected Result:
Results:
A CID-FMI from 1-05 to 16-05 or from 1-06 to 16-06
is not logged. OK As each solenoid is energized an audible
click is heard. Proceed to Test Step 4.
Repair: Perform the diagnostic functional test Not OK There was no change in the sound, feel,
Troubleshooting, Electrical Power Supply. or power of the engine as one of the cylinder's was
cut out. Proceed to Test Step 5.
STOP.
Test Step 5. Check for a Short between
Test Step 4. Perform the Cylinder Cutout Wires in the Harness.
Test.
NOTICE
Engine power is reduced when a properly functioning This engine uses high voltage to control the fuel
cylinder is cut out. Make sure that you will not damage injectors.
auxiliary or driven equipment if the engine power is
suddenly reduced. Disconnect the fuel enable circuit connector to
prevent personal injury.
A. Turn the circuit breaker for the battery to the OFF
position. Do not come in contact with the fuel injector ter-
minals while the engine is running.
B. Turn the ECS to the OFF/RESET position.
A. Turn the circuit breaker for the battery to the OFF
C. Verify that the ECM connector J2/P2 and the position.
injector connectors J301/P301 through J316/P316
are properly connected. B. Turn the ECS to the OFF/RESET position.
D. Turn the circuit breaker for the battery to the ON C. Disconnect J2/P2 and J301/P301 through
position. J316/P316.
E. Connect Cat ET. D. Measure the resistance between the solenoid wire
pairs at the ECM connector P2.
F. Start the engine.
Measure the resistance for SOLENOID 1 at
G. Apply a load to the engine. P2-1 and P2-2.
H. Use the diagnostic tests on Cat ET to initiate the Measure the resistance for SOLENOID 2 at
injector solenoid test. P2-3 and P2-4.
I. Check for a difference in the sound, feel, or power Measure the resistance for SOLENOID 3 at
of the engine as each cylinder is cut out. The P2-40 and P2-41.
amount of change should be similar for all of the
good cylinders. The amount of change should be Measure the resistance for SOLENOID 4 at
minimal for a weak cylinder or a bad cylinder. P2-42 and P2-43.
J. Disable the override. Repeat above steps for each Measure the resistance for SOLENOID 5 at
cylinder (solenoid). P2-14 and P2-15.
Repair: The test indicates that all of the cylinders Measure the resistance for SOLENOID 10 at
are operating correctly. P2-34 and P2-35.
Measure the resistance for SOLENOID 12 at Measure the resistance between P2-5 and
P2-52 and P2-62. engine ground.
Measure the resistance for SOLENOID 13 at Measure the resistance between P2-14 and
P2-32 and P2-33. engine ground.
Measure the resistance for SOLENOID 14 at Measure the resistance between P2-15 and
P2-60 and P2-61. engine ground.
Measure the resistance for SOLENOID 15 at Measure the resistance between P2-16 and
P2-5 and P2-18. engine ground.
Measure the resistance for SOLENOID 16 at Measure the resistance between P2-17 and
P2-26 and P2-27. engine ground.
OK The resistance is greater than 20000 Ohms. Measure the resistance between P2-25 and
Proceed to Test Step 6. engine ground.
Not OK The resistance is less than 20000 Ohms. Measure the resistance between P2-26 and
There is a problem in the wiring harness. engine ground.
Repair: Repair the connectors or wiring and/or Measure the resistance between P2-27 and
replace the connectors or wiring. engine ground.
Measure the resistance between P2-1 and Measure the resistance between P2-43 and
engine ground. engine ground.
Measure the resistance between P2-2 and Measure the resistance between P2-48 and
engine ground. engine ground.
Measure the resistance between P2-3 and Measure the resistance between P2-49 and
engine ground. engine ground.
Measure the resistance between P2-4 and Measure the resistance between P2-50 and
engine ground. engine ground.
180 RENR5009-07
Troubleshooting Section
Measure the resistance between P2-51 and Measure the resistance for SOLENOID 6 at
engine ground. P2-16 and P2-17.
Measure the resistance between P2-52 and Measure the resistance for SOLENOID 7 at
engine ground. P2-48 and P2-49.
Measure the resistance between P2-58 and Measure the resistance for SOLENOID 8 at
engine ground. P2-50 and P2-51.
Measure the resistance between P2-59 and Measure the resistance for SOLENOID 9 at
engine ground. P2-24 and P2-25.
Measure the resistance between P2-60 and Measure the resistance for SOLENOID 10 at
engine ground. P2-34 and P2-35.
Measure the resistance between P2-61 and Measure the resistance for SOLENOID 11 at
engine ground. P2-58 and P2-59.
Measure the resistance between P2-62 and Measure the resistance for SOLENOID 12 at
engine ground. P2-52 and P2-62.
OK The resistance is greater than 20000 Ohms. Measure the resistance for SOLENOID 15 at
Proceed to Test Step 7. P2-5 and P2-18.
Not OK The resistance is less than 20000 Ohms. Measure the resistance for SOLENOID 16 at
There is a short in the wiring harness. P2-26 and P2-27.
Repair: Repair the connectors or wiring and/or Note: Repeat this test step for the secondary ECM.
replace the connectors or wiring.
Expected Result:
STOP.
The resistance is less than 5 Ohms.
Test Step 7. Check for an Open in the
Harness. Results:
A. Use a suitable piece of wire to short socket-1 to OK The resistance is less than 5 Ohms. Proceed
socket-2 at each solenoid connector. to Test Step 8.
B. Measure the resistance between the following Not OK The resistance is greater than 5 Ohms.
solenoid wire pairs in connector P2: There is a problem in the wiring harness.
Measure the resistance for SOLENOID 1 at Repair: Repair the connectors or wiring and/or
P2-1 and P2-2. replace the connectors or wiring.
Test Step 8. Measure the Resistance Test Step 9. Check the Resistance of the
of the Injector Solenoids through the Injector Solenoids and Check for Shorts.
Harness Yoke.
STOP.
182 RENR5009-07
Troubleshooting Section
B. Ensure that the sealing plugs are in place. If If moisture or corrosion is evident in the connector,
any of the plugs are missing, replace the plug. the source of the moisture entry must be found and
Ensure that the plugs are inserted correctly into the source of the moisture entry must be repaired.
the connector. Refer to Illustration 36. If the source of the moisture entry is not repaired,
the problem will recur. Simply drying the connector
will not x the problem. Check the following items
for the possible moisture entry path:
Missing seals
Improperly installed seals
Nicks in exposed insulation
Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in a
g01131019
connector, thoroughly check the connector's
Illustration 37 harness for damage. Also check other connectors
Seal for a three-pin connector (typical example) that share the harness for moisture.
Expected Result:
Results:
STOP.
184 RENR5009-07
Troubleshooting Section
Test Step 2. Check the Wires for Damage Repair: Repair the terminals and/or replace the
to the Insulation terminals, as required.
A. Carefully inspect each wire for signs of abrasion, Verify that the repair eliminates the problem.
of nicks, and of cuts.
STOP.
Inspect the wires for the following conditions:
Test Step 4. Perform a Pull Test on Each
Exposed insulation Wire Terminal Connection
Rubbing of a wire against the engine
Rubbing of a wire against a sharp point
B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a attened portion
of wire. A fastener that has been overtightened
attens the harness. This damages the wires that
are inside the harness.
Not OK There is damage to the harness. B. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily
Repair: Repair the wires or replace the wires, withstand 45 N (10 lb) of tension and each wire
as required. Verify that the repair eliminates the should remain in the connector body. This test
problem. checks whether the wire was properly crimped
in the terminal and whether the terminal was
STOP. properly inserted into the connector.
The terminals are properly aligned and the terminals Not OK A wire has been pulled from a terminal
appear undamaged. or a terminal has been pulled from the connector.
Test Step 5. Check Individual Pin Not OK The connector's locking mechanism is
Retention into the Socket damaged or missing.
STOP.
g01131604
A. Connect the ECM connectors.
Illustration 40
Diagram for testing pin retention (typical example)
Expected Result:
Results:
STOP.
The connector will securely lock. The connector and b. Torque the allen head screw for the 70
the locking mechanism are without cracks or breaks. pin ECM connector to 6.0 + 1.5 - 0.5 Nm
(55 + 13 - 4 lb in).
Results:
STOP.
c. Torque the allen head screw for the 40 pin ECM If an intermittent problem exists, the status will be
connector to 2.25 0.25 Nm (20 2 lb in). highlighted and an audible beep will be heard.
Expected Result:
Results:
Expected Result:
Results:
i02384273
Prelubrication System
SMCS Code: 1319-038
g01193921
Illustration 45
C. Thoroughly inspect the ECM connectors J1/P1 and Repair: Repair the connectors or wiring and/or
J2/P2. Inspect all of the other connectors. Refer replace the connectors or wiring.
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors for details. STOP.
D. Check the allen head screw on each ECM Test Step 2. Check the Resistance of the
connector for the proper torque. Refer Prelube Pressure Switch at the ECM.
to Troubleshooting, Inspecting Electrical
Connectors for the correct torque values. A. Turn the ECS to the OFF/RESET position.
E. Check the ECM connector (allen head screw) for B. Disconnect ECM connector J1/P1.
the proper torque of 6 1 Nm (53 9 lb in).
C. Ensure that the prelube override switch is not
F. Check the harness and the wiring for abrasion activated.
and for pinch points.
D. Measure the resistance between the prelube
Expected Result: pressure switch P1-66 and the digital return P1-5.
All connectors, pins, and sockets are completely E. Reconnect the ECM connector P1.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion, and of pinch points. Expected Result:
Note: If the engine has been running, the residual oil B. Turn the ECS to the STOP position.
pressure may be high enough to activate the prelube
pressure switch. If the residual oil pressure is high, C. Use Cat ET and view the following parameters:
the resistance would be less than 5 Ohms. Engine Prelube and Ignition Switch.
F. Monitor the voltage on the voltmeter. E. Go to the diagnostic test in the diagnostic section
on CAT ET. Activate the override for the engine
G. Disable the override for the engine prelube. prelube.
The voltage is 24 3 VDC. G. Disable the override for the engine prelube.
B. Connect one end of the voltmeter to the Battery Not OK The voltage is not 24 3 VDC. Proceed
terminal. to Test Step 8.
C. Connect the other end of the voltmeter on wire Test Step 8. Check for Output Voltage to
F705 on pin c at connector P-C1 of the rigid the PPR1 Relay from the ECM.
harness.
A. Leave one end of the voltmeter on the Battery
D. Turn the ECS to the STOP position. terminal.
E. Go to the diagnostic test in the diagnostic section B. Connect the other lead of the voltmeter to wire
on CAT ET. Activate the override for the engine F705 on terminal 3 of the PPR1 relay.
prelube.
C. Turn the ECS to the STOP position.
F. Monitor the voltage on the voltmeter.
D. Go to the diagnostic test in the diagnostic section
G. Disable the override for the engine prelube. on CAT ET. Activate the override for the engine
prelube.
Expected Result:
E. Monitor the voltage on the voltmeter.
The voltage is 24 3 VDC.
F. Disable the override for the engine prelube.
Results:
Expected Result:
OK The voltage is 24 3 VDC. Proceed to Test
Step 7. The voltage is 24 3 VDC.
Test Step 9. Check the Voltage across the F. Go to the diagnostic test in the diagnostic section
Coil of the PPR1 Relay. on CAT ET. Activate the override for the engine
prelube.
A. Connect one lead of the voltmeter to wire D229 on
terminal 4 of the PPR1 relay. G. Monitor the voltage on the voltmeter.
B. Connect the other lead of the voltmeter to wire H. Disable the override for the engine prelube.
F705 on terminal 3 of the PPR1 relay.
I. Turn the ECS to the OFF/RESET position.
C. Turn the ECS to the STOP position.
J. Remove all jumpers and replace all wires.
D. Go to the diagnostic test in the diagnostic section
on CAT ET. Activate the override for the engine Expected Result:
prelube.
The voltage is 24 3 VDC.
E. Monitor the voltage on the voltmeter.
Results:
F. Disable the override for the engine prelube.
OK The voltage is 24 3 VDC. There is a
Expected Result: problem in the wire F705 between the ECM and
terminal c at the connector P-C1 of the rigid
The voltage is 24 3 VDC. harness.
A. Turn the ECS to the OFF/RESET position. E. Monitor the voltage on the voltmeter.
B. Disconnect ECM connector J2/P2. F. Disable the override for the engine prelube.
Results: i01988356
g01029811
Illustration 46
Typical example
194 RENR5009-07
Troubleshooting Section
Test Step 1. Check for Connector Repair: The secondary ECM reads the primary
Damage. ECM heartbeat signal. Active injector codes are
not present. If the problem is intermittent, perform
A. Turn the ECS to the OFF/RESET position. the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors.
B. Disconnect the main power.
STOP.
C. Thoroughly inspect the ECM connectors J1/P1 and
J2/P2. Inspect all of the other connectors. Refer Not OK The Secondary ECM Ready lamp is
to the diagnostic functional test Troubleshooting, not illuminated. Proceed to Test Step 6.
Inspecting Electrical Connectors for details.
Secondary ECM Active Lamp ON Both lamps
D. Perform a 45 N (10 lb) pull test on each of the illuminated for ve seconds. The Secondary ECM
wires in the ECM connector that are associated Active lamp remained illuminated. The secondary
with the circuit. ECM has assumed control of the engine. Proceed
to Test Step 3.
E. Check the ECM connector (allen head screw) for
the proper torque of 6 1 Nm (53 9 lb in). Test Step 3. Check for Logged Diagnostic
Codes.
F. Check the harness and the wiring for abrasion
and for pinch points. A. Turn the ECS to the OFF/RESET position.
All connectors, pins, and sockets are completely C. Turn the ECS to the STOP position.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points. D. Observe the diagnostic codes on the Cat ET.
STOP. Results:
Test Step 2. Check the Secondary ECM OK A diagnostic code of CID 0579 - FMI 05 or a
Active Lamp and the Secondary ECM diagnostic code of CID 0579 - FMI 06 is present.
Ready Lamp. Proceed to Test Step 8.
A. Observe the Secondary ECM Active lamp OK An error code for the fuel injectors is present.
and the Secondary ECM Ready lamp on the
instrument panel when the ECS is turned to the Repair: Perform the diagnostic functional test
STOP position. Troubleshooting, Injector Solenoids.
Both lamps illuminate for ve seconds. The Not OK No logged diagnostic codes are present.
Secondary ECM Ready lamp stays illuminated. The Proceed to Test Step 4.
Secondary ECM Active lamp turns off after ve
seconds. Test Step 4. Check the Primary ECM
Heartbeat Signal at the Primary ECM.
Results:
A. Turn the ECS to the OFF/RESET position.
OK Both lamps illuminated for ve seconds.
The Secondary ECM Ready lamp remained B. Disconnect the primary ECM connector J2/P2.
illuminated. The Secondary ECM Active lamp is
off. The problem is no longer present.
RENR5009-07 195
Troubleshooting Section
C. Remove wire C401 from the primary ECM G. Observe the frequency of the primary ECM
connector P2-28. Install a wire jumper with heartbeat signal on the multimeter display. If
sockets on both ends into ECM connector P2-28. a number does not appear on the multimeter
display, verify the connections. Measure the
D. Connect a multimeter that is capable of reading frequency from another digital sensor. Verify that
frequency between the wire jumper in P2-28 and the multimeter is operating correctly.
the engine ground.
H. Turn the ECS to the OFF/RESET position.
E. Reconnect the primary ECM connector J2/P2.
I. Reconnect all wires and connectors.
F. Turn the ECS to the STOP position.
Expected Result:
G. Observe the frequency of the primary ECM
heartbeat signal on the multimeter display. If The frequency is between 15.67 and 16.33 Hz.
a number does not appear on the multimeter
display, verify the connections. Measure the Results:
frequency from another digital sensor. Verify that
the multimeter is operating correctly. OK The frequency is between 15.67 and 16.33
Hz. Proceed to Test Step 6.
H. Turn the ECS to the OFF/RESET position.
Not OK The frequency is not between 15.67 and
I. Remove the wire jumper. Reconnect all wires and 16.33 Hz. The signal is not within the frequency
connectors. range.
Expected Result: Repair: Repair the wire C401 between the primary
ECM connector P2-28 and the secondary ECM
The frequency is between 15.67 and 16.33 Hz. connector P1-21.
Results: STOP.
OK The frequency is between 15.67 and 16.33 Test Step 6. Test the Secondary ECM
Hz. Proceed to Test Step 5. Ready Lamp.
Not OK The frequency is not between 15.67 and A. Turn the ECS to the OFF/RESET position.
16.33 Hz. The primary ECM heartbeat signal is not
within the frequency range. B. Disconnect the secondary ECM connector J2/P2.
Repair: Verify that the proper software has been C. Remove the wire 675 from the secondary ECM
installed. Verify that the primary ECM is receiving connector J2-31.
the correct voltage. Perform the diagnostic
functional test Troubleshooting, Electrical Power D. Connect a wire jumper between wire 675 and the
Supply. engine ground.
Test Step 5. Check the Primary ECM F. Turn the ECS to the STOP position.
Heartbeat Signal at the Secondary ECM.
G. Observe the Secondary ECM Ready lamp.
A. Turn the ECS to the OFF/RESET position.
H. Turn the ECS to the OFF/RESET position.
B. Disconnect the secondary ECM connector J1/P1.
I. Remove the wire jumper. Reconnect all wires and
C. Remove the wire C401 from the secondary ECM connectors.
connector P1-21.
Expected Result:
D. Connect a multimeter that is capable of reading
frequency between wire C401 and engine ground. The lamp illuminates while the jumper is connected.
The lamp does not illuminate when the jumper is
E. Reconnect the secondary ECM connector J1/P1. removed.
Not OK The lamp circuit is not functioning Not OK The lamp circuit is not functioning
properly. properly.
Repair: Verify that wire 675 is not open between Repair: Verify that wire 676 is not open between
the Secondary ECM Ready lamp and the ECM. the Secondary ECM Active lamp and the ECM.
Verify that voltage is present at wire 120 on Verify that voltage is present on wire 120 at
terminal X1 of the Secondary ECM Ready lamp. terminal X1 of the Secondary ECM Active lamp.
If voltage is present on terminal X1, replace the If voltage is present on terminal X1, replace the
Secondary ECM Ready lamp. Secondary ECM Active lamp.
If voltage is not present on terminal X1, verify that If voltage is not present on terminal X1, verify
the engine control switch is not in the OFF/RESET that the engine control switch is not in the OFF
position. Verify that the MPD breaker is not position. Verify that the MPD breaker is not
tripped. Check the normally closed contact of tripped. Check the normally closed contact of
relay R1 for proper operation. Check the wire relay R1 for proper operation. Check the wire
120 between the Secondary ECM Ready lamp 120 between the Secondary ECM Ready lamp
and relay R1 for damage. Check the wire A120 and relay R1 for damage. Check the wire A120
between relay R1 and the MPD breaker for between relay R1 and the MPD breaker for
damage. If necessary, repair the wires. damage. If necessary, repair the wires.
STOP. STOP.
Test Step 7. Test the Secondary ECM Test Step 8. Check for Shorts in the
Active lamp. Wiring Harness.
A. Turn the ECS to the OFF/RESET position. A. Turn the ECS to the OFF/RESET position.
B. Disconnect the secondary ECM connector J2/P2. B. Disconnect the primary ECM J2/P2 and the
secondary ECM connector J1/P1.
C. Remove the wire 676 from the secondary ECM
connector J2-29. C. Measure the resistance at the primary ECM
between P2-28 and engine ground.
D. Connect a wire jumper between wire 676 and the
engine ground. D. Reconnect all wires and connectors.
F. Turn the ECS to the STOP position. The resistance is greater than 20,000 Ohms.
H. Turn the ECS to the OFF/RESET position. OK The resistance is greater than 20,000 Ohms.
Proceed to Test Step 9.
I. Remove the wire jumper. Reconnect all wires and
connectors. Not OK There is a problem in the wiring harness.
Expected Result: Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
The lamp illuminates while the jumper is connected.
The lamp does not illuminate when the jumper is STOP.
removed.
Test Step 9. Check for Opens in the
Results: Wiring Harness.
OK The Secondary ECM Active lamp circuit A. Measure the resistance of the wire C401 between
is okay. the secondary ECM P1-21 and the primary ECM
P2-28.
RENR5009-07 197
Troubleshooting Section
OK The resistance is less than 5 Ohms. Proceed The Electronic Control Module (ECM) has the ability
to Test Step 10. to crank the engine when the Engine Control Switch
(ECS) is placed in the START position. The engine
Not OK There is a problem in the wiring harness. control will start the rst crank cycle, when the ECS
is placed in the START position. The crank cycle
Repair: Repair the connectors or wiring and/or will continue for the time that is equal to the cycle
replace the connectors or wiring. crank time that has been programmed or the crank
cycle will continue until the engine speed reaches the
STOP. crank terminate speed. If crank terminate speed is
not reached before the crank cycle time, the starting
Test Step 10. Check the Personality motor will deactivate at the end of the crank cycle
Module. time.
A. Determine if new software has recently been This process will repeat for a programmed amount of
installed. times Total Number of Crank Cycles. If the engine
does not start, Caterpillar Electronic Technician (ET)
Note: If the secondary ECM does not see a primary will display OVERCRANK. The engine control will
ECM Heartbeat Signal, the secondary ECM will be in an idle state. The process can be restarted by
assume engine control. The power must be reset. turning the ECS to the OFF/RESET position. Next,
After the power has been reset the primary ECM will turn the ECS to the STOP position. Then turn the
take control of the engine. ECS to the START position.
B. Turn the ECS to the OFF/RESET Position. After the ECS is placed in the START position, the
ECM will begin the prelube cycle. The ECM will send
C. Connect the Cat ET. a signal to terminal BH of the customer connector
after the prelube cycle is complete. The engine start
D. Wait for 70 seconds. signal will return on terminal BJ of the customer
connector to the starting motor relays SMMS1 and
E. Verify that the correct personality module SMMS2. The starting motor relays will energize
(software) is installed in the primary ECM. closing the normally open contacts of the relays.
Current will ow to the starting motors. The starting
F. Turn the ECS to the STOP position. motors will begin to crank the engine.
Results:
STOP.
STOP.
198 RENR5009-07
Troubleshooting Section
g01009170
Illustration 47
Typical example
Test Step 1. Check for Connector F. Check the harness and the wiring for abrasion
Damage. and for pinch points.
B. Turn the circuit breaker for the battery to the OFF All connectors, pins, and sockets are completely
position. coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
C. Thoroughly inspect the ECM connectors J1/P1 and
J2/P2. Inspect all of the other connectors. Refer Results:
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors for details. OK The connectors and wiring are okay. Proceed
to Test Step 2.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated Not OK The connectors and/or wiring need
with the circuit. repair.
Repair: Repair the connectors or wiring and/or Repair: Perform the diagnostic functional test
replace the connectors or wiring. Troubleshooting, Engine Control Switch (ECS).
STOP. STOP.
Test Step 2. Attempt to Start the Engine. Test Step 3. Check the Start Signal at the
Customer Connector.
Note: After the ECS is placed in the START position,
the ECM will begin the prelube cycle. The ECM A. Connect one end of a voltmeter to the Battery
will send a signal to terminal BH of the customer terminal. Connect the other end of the voltmeter
connector after the prelube cycle is complete. The to wire F701 on terminal BJ of the customer
engine start signal will return on terminal BJ of the connector.
customer connector to the starting motor relays
SMMS1 and SMMS2. The prelube cycle can be B. Turn the ECS to the START position.
disabled by setting the duration of the prelube cycle
to 0. C. Monitor the voltage on the voltmeter.
A. Turn the circuit breaker for the battery to the ON D. Turn the ECS to the OFF/RESET position.
position.
Expected Result:
B. Turn the ECS to the STOP position.
The voltage is 24 3 VDC.
C. Connect Cat ET to the service tool connector.
Results:
D. Observe the startup mode parameter on the Cat
ET status screen. OK The voltage is 24 3 VDC. Proceed to Test
Step 5.
E. Turn the ECS to the START position. Continue
monitoring engine parameters as the engine Not OK The voltage is not 24 3 VDC. Proceed
cranks. to Test Step 4.
The crank cycle will continue for the time that Test Step 4. Check the Start Signal at the
is equal to the cycle crank time that has been Primary ECM.
programmed or the crank cycle will continue until
the engine speed reaches the crank terminate A. Disconnect the primary ECM connector J2/P2.
speed.
B. Remove wire G701 from the primary ECM
Expected Result: connector P2-6. Install a wire jumper into P2-6.
The status screen for the startup mode parameter C. Reconnect the primary ECM connector J2/P2.
displays CRANK. The engine cranks.
D. Connect one end of a voltmeter to the Battery
Results: terminal. Connect the other end of the voltmeter
to the wire jumper in P2-6.
OK The startup mode parameter on the status
screen on Cat ET displays CRANK. The engine E. Turn the ECS to the START position.
cranks.
F. Monitor the voltage on the voltmeter.
Repair: The problem may be intermittent. If the
problem is intermittent, perform the diagnostic G. Turn the ECS to the OFF/RESET position.
functional test Troubleshooting, Inspecting
Electrical Connectors. H. Remove the wire jumper and replace all wires.
Repair: Check wire G701 for continuity between E. Connect one end of a voltmeter to the Battery
ECM connector P2-6 and terminal BH of the terminal. Connect the other end of the voltmeter
customer connector. If necessary, repair the wire. to wire 314 on terminal R of connector P-C2 of
If wire G701 is okay, repair the wiring or devices on the rigid harness.
the customer's side of the customer connector.
F. Turn the ECS to the START position.
STOP.
G. Monitor the voltage on the voltmeter.
Not OK The voltage is not 24 3 VDC.
H. Turn the ECS to the OFF/RESET position.
Repair: The problem may be in the ECM.
Check the electrical power to the ECM. Refer to Expected Result:
the diagnostic functional test Troubleshooting,
Electrical Power Supply. The voltage is 24 3 VDC.
STOP. Results:
Test Step 5. Check the Start Signal to OK The voltage is 24 3 VDC. Proceed to Test
SMMS1 and SMMS2 at the Rigid Step 10.
Harness.
Not OK The voltage is not 24 3 VDC. Proceed
A. Connect one end of a voltmeter to the Battery to Test Step 7.
terminal. Connect the other end of the voltmeter
to wire F701 on terminal _F of connector P-C2 of Test Step 7. Check the Voltage at the Coil
the rigid harness. of SMMS1 and the Coil of SMMS2.
B. Turn the ECS to the START position. A. Turn the ECS to the OFF/RESET position.
C. Monitor the voltage on the voltmeter. B. Connect a voltmeter at the coil of SMMS1.
Connect the voltmeter between terminal 3 of
D. Turn the ECS to the OFF/RESET position. SMMS1 and engine ground.
OK The voltage is 24 3 VDC. Proceed to Test F. Turn the ECS to the STOP position.
Step 6.
Expected Result:
Not OK The voltage is not 24 3 VDC.
The voltage is 24 3 VDC.
Repair: Repair the wire F701 between terminal
BJ of the customer connector and terminal _F of Results:
connector P-C2 of the rigid harness.
OK The voltage is 24 3 VDC. Proceed to Test
STOP. Step 8.
Test Step 6. Check the Voltage from Not OK The voltage is not 24 3 VDC.
SMMS1 and SMMS2 at the Rigid
Harness. Repair: Repair the wire F701 between the diode
and terminal _F of connector P-C2 of the rigid
A. Connect one end of a voltmeter to the Battery harness or repair the wire G701 between the diode
terminal. Connect the other end of the voltmeter and terminal 3 of SMM2. Verify that the diode is
to wire 304 on terminal O of connector P-C2 of working properly.
the rigid harness.
STOP.
B. Turn the ECS to the START position.
Test Step 8. Check the Voltage across E. Connect one end of a voltmeter to the Battery
the Coil of SMMS1 and across the Coil terminal. Connect the other end of the voltmeter
of SMMS2. to wire 304 on terminal 2 of SMMS1.
A. Turn the ECS to the OFF/RESET position. F. Turn the ECS to the START position.
B. Connect a voltmeter across the coil of SMMS1. G. Monitor the voltage on the voltmeter.
Connect the voltmeter between terminal 4 and
terminal 3 of SMMS1. H. Turn the ECS to the STOP position.
Repair: Verify that 24 3 VDC is present on Not OK The voltage is not 24 3 VDC.
terminal 1 of SMMS1 or on terminal 1 of
SMMS2. If voltage is not present on terminal 1 Repair: Replace either relay SMM2 or relay
of SMMS1 or on terminal 1 of SMMS2, check SMM2.
the wire A291 between terminal 1 of the starter
magnetic switches and the Starter and Alternator STOP.
breaker. Verify that the Starter and Alternator
breaker is functioning properly. Test Step 10. Check the Voltage at the
Starting Motor.
If voltage is present on terminal 1, proceed to Test
Step 9. A. Turn the ECS to the OFF/RESET position.
Not OK The voltage is not 24 3 VDC. B. Connect one end of a voltmeter to the Battery
terminal. Connect the other end of the voltmeter
Repair: The problem is in the wire G229 between to wire 314 on terminal S of the starting motor.
terminal 4 of SMMS1 or SMMS2 and the ECM.
Check the wire G229 for continuity between C. Turn the ECS to the START position.
terminal 4 of SMMS1 or SMMS2 and the ECM
connector P2-7. Repair the wire or replace the wire. D. Monitor the voltage on the voltmeter.
Test Step 9. Check the Voltage to the F. Connect one end of a voltmeter to the Battery
Rigid Harness from the Starter Motor terminal. Connect the other end of the voltmeter
Magnetic Switches. to wire 304 on terminal S of the starting motor.
A. Connect one end of a voltmeter to the Battery G. Turn the ECS to the START position.
terminal. Connect the other end of the voltmeter
to wire 314 on terminal 2 of SMMS2. H. Monitor the voltage on the voltmeter.
B. Turn the ECS to the START position. I. Turn the ECS to the STOP position.
STOP.
STOP.
i02659958
g01012536
Illustration 48
Typical example
Expected Result: B. Remove the wire for the throttle signal from the
customer's connector. Refer to Illustration 48 for
All connectors, pins, and sockets are completely the schematic of the circuit.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points. C. Set the multimeter to VDC. Press the Hz button
twice so that the % symbol is displayed.
Results:
D. Place the red probe of the digital multimeter on
OK The connectors and wiring are OK. If you are the terminal for the throttle signal on the customer
troubleshooting either the primary speed control or connector. Place the black probe of the multimeter
the secondary speed control from the customer, on the Battery terminal.
proceed to Test Step 2. If you are troubleshooting
the local speed control on the instrument panel, E. Turn the ECS to the STOP position.
proceed to Test Step 5.
F. Measure the percent duty cycle of the throttle
Not OK The connectors and/or wiring need signal. Adjust the throttle from the lowest position
repair. to the highest position.
Repair: Repair the connectors or wiring and/or G. Turn the ECS to the OFF/RESET position.
replace the connectors or wiring.
H. Replace all connectors and wires.
STOP.
Expected Result:
Test Step 2. Check the Throttle Position
on the Caterpillar Electronic Technician The duty cycle is 5 to 10 percent at the lowest setting.
(ET). The duty cycle is 90 to 95 percent at the highest
setting.
A. Connect Cat ET to the service tool connector.
Results:
B. Turn the ECS to the STOP position.
OK The duty cycle and throttle position readings
C. Observe the position of the throttle on Cat ET. are correct. Proceed to Test Step 4.
D. Adjust the customer's throttle to the lowest setting. Not OK The duty cycle reading is not correct.
The throttle position signal is not reaching the
E. Start at the lowest position. Slowly adjust the ECM.
customer's throttle to the highest setting. Monitor
the position of the throttle on Cat ET. Repair: Check the signal from the customer's
connector to the customer's speed control.
Expected Result:
STOP.
The throttle position on Cat ET is 0 percent at the
lowest setting and 0 to 100 percent as the throttle is Test Step 4. Check the Duty Cycle at the
adjusted to the highest setting. ECM Connector.
Results: A. Turn the ECS to the OFF/RESET position.
OK The throttle is operating correctly. B. Remove the ECM connector P1 from the ECM.
Remove the throttle signal wire from the ECM
Repair: There may be an intermittent problem. If connector P1. Refer to Illustration 48 for the
the problem is intermittent, refer to Troubleshooting, schematic of the circuit.
Inspecting Electrical Connectors for details on
inspecting wiring and connectors. C. Reconnect the ECM connector J1/P1.
A. Turn the ECS to the OFF/RESET position. F. Turn the ECS to the STOP position.
RENR5009-07 205
Troubleshooting Section
G. Measure the percent duty cycle of the throttle Repair: There may be an intermittent problem. If
signal. Move the throttle from the lowest setting to the problem is intermittent, refer to Troubleshooting,
the highest setting. Inspecting Electrical Connectors for details on
inspecting wiring and connectors.
H. Turn the ECS to the OFF/RESET position.
STOP.
I. Replace all connectors and wires.
Not OK The throttle position on Cat ET does not
Expected Result: change correctly. Proceed to Test Step 6.
The duty cycle is 5 to 10 percent at the lowest setting. Test Step 6. Check the Supply Voltage to
The duty cycle is 90 to 95 percent at the highest the Local Speed Control.
setting.
A. Turn the ECS to the STOP position.
Results:
B. Connect the red probe of the digital multimeter to
OK The duty cycle and the throttle signal are the +B terminal of the local speed control. Connect
correct. the black probe of the digital multimeter to the B
terminal of the local speed control.
Repair: Temporarily replace the ECM and perform
the test again. If the problem is resolved, the C. Measure the voltage across the terminals of the
ECM is faulty. Permanently replace the ECM. local speed control.
Refer to the diagnostic procedure Troubleshooting,
Replacing the ECM. Expected Result:
STOP. Results:
Not OK The voltage does not measure 24 3 OK The local speed control is supplying the
VDC. correct signal. Proceed to Test Step 9.
Repair: Verify that the breaker for the primary ECM Not OK The duty cycle is not correct on the
is not tripped. Check for 24 3 VDC on terminal multimeter.
87A at the normally closed contact of relay R2A.
Relay R2A is located in the power distribution Repair: Verify that the local speed control on the
panel. Verify that the normally closed contact of instrument panel is operating correctly. Temporarily
relay R2A is operating correctly. install another speed control. Verify that the
problem is no longer present. Reinstall the old
If voltage is present on terminal 87A at the normally speed control. If the problem returns, replace the
closed contact of relay R2A, repair the wire C150 local speed control.
between the contacts of relay R2A and terminal L
of connector P-C2 of the rigid harness. STOP.
If 24 3 VDC is present on wire C150 at diode D9, Test Step 9. Check the Duty Cycle at the
verify that voltage is present on wire M150 at diode ECM Connector.
D9. If 24 3 VDC is not present on wire M150 at
diode D9, replace the diode D9. A. Turn the ECS to the OFF/RESET position.
If 24 3 VDC is present at the diode D9 on wire B. Remove the ECM connector P2 from the primary
M150, repair the wire M150 between the diode D9 ECM. Remove the wire 389 from ECM connector
and the local speed control. P2-68.
Test Step 8. Check the Local Speed D. Place the red probe on wire 389. Place the black
Control. probe on the Battery terminal.
A. Remove the wire 389 from the S terminal at the E. Turn the ECS to the STOP position.
local speed control.
F. Measure the percent duty cycle of the speed
B. Set the multimeter to VDC. Press the Hz button control. Turn the potentiometer from the low
twice so that the % symbol is displayed. setting to the high setting.
C. Place one probe of the multimeter on the S G. Turn the ECS to the OFF/RESET position.
terminal of the local speed control. Place the other
probe on the Battery terminal of the local speed H. Replace all connectors and wires.
control.
Expected Result:
D. Turn the ECS to the STOP position.
The duty cycle is 5 to 10 percent at the low idle stop.
E. Measure the percent duty cycle from the speed The duty cycle is 90 to 95 percent at the high idle
control on the multimeter. Turn the potentiometer stop.
from the low setting to the high setting.
Results:
Note: The throttle position on the Cat ET will not
match the percent duty cycle on the multimeter. OK The duty cycle and throttle position readings
are correct.
F. Reconnect the wire 389 to the S terminal at the
local speed control.
RENR5009-07 207
Troubleshooting Section
STOP.
STOP.
208 RENR5009-07
Troubleshooting Section
Results:
Turbocharger compressor inlet pressure is
atmospheric pressure 8 kPa (1.2 psi).
OK There are no active diagnostics. Proceed Turbocharger compressor outlet pressure is
to Test Step 2. atmospheric pressure 15 kPa (2.2 psi).
Not OK A pressure sensor with an active Fuel pressure is atmospheric pressure 27 kPa
diagnostic code cannot be calibrated. (3.9 psi).
Repair: Perform the appropriate troubleshooting
procedure.
Engine oil pressure is atmospheric pressure
27 kPa (3.9 psi).
STOP.
RENR5009-07 209
Troubleshooting Section
Results:
STOP.
STOP.
i01900713
g00992448
Illustration 50
Typical example
Test Step 1. Check for Active Engine B. Remove the timing calibration plug from the
Diagnostics. ywheel housing.
A. Start the Caterpillar Electronic Technician (ET). C. Examine the ywheel through the timing calibration
hole. Ensure that the probe is not inserted into the
B. Start the engine. timing pin hole. If necessary, turn the engine.
C. Operate the engine until normal operating D. Install the 6V-3093 Transducer Adapter into the
temperatures are obtained. hole for the timing calibration at the ywheel.
Expected Result: If all of the problems have been corrected but the
timing can not be calibrated, check the cable of the
Only CID-FMI 261-13 should be active. 189-5746 Speed Sensor. Check the 189-5746
Speed Sensor in order to verify that the probe is
Results: not bent. Verify that the probe is installed correctly
before restarting this procedure.
OK CID-FMI 261-13 is the only active code at
this time. Proceed to Test Step 3. STOP.
A. Select Calibrations from the Service menu on The throttle linkage should operate without binding
the Cat ET. Select the Timing Calibration from or without excessive drag. When the throttle position
the Calibrations menu. sensor is not connected to the throttle, the throttle
should return to low idle within one second. The
Note: Engine speed will be set to 800 rpm by the calibration of the throttle position sensor requires the
ECM during the calibration. use of Caterpillar Electronic Technician (ET).
Expected Result:
Results:
STOP.
Expected Result:
Results:
STOP.
Expected Result:
g00726080
Illustration 51
When the throttle is in high idle, the duty cycle is 90
Test Step 1. Check and Adjust the to 95 percent.
Throttle Linkage.
Note: When the adjustment of the high idle is made
A. Inspect the throttle linkage for components with on some types of linkage, the adjustment may
the following conditions: change the low idle position. Repeat the adjustment
for low idle in order to verify that the low idle is
Loose correctly adjusted.
Bent Results:
STOP.
214 RENR5009-07
Index Section
Index
A ECM Will Not Accept Factory Passwords.............. 35
Probable Causes ............................................... 35
Air Shutoff System................................................ 118 Recommended Actions...................................... 35
Air Starting Motor................................................... 31 ECM Will Not Communicate with Other Systems or
Alternator ............................................................... 32 Display Modules .................................................. 35
Analog Sensor - Calibrate ................................... 208 Probable Causes ............................................... 35
Analog Sensor Supply ......................................... 125 Recommended Actions...................................... 35
Electrical Power Supply....................................... 136
Electronic Display Module ..................................... 14
C Control Panel ..................................................... 15
Power Distribution Panel.................................... 15
Calibration Procedures ........................................ 208 Electronic Service Tool Will Not Communicate with
CAN Data Link..................................................... 128 ECM..................................................................... 35
Can Not Reach Top Engine RPM .......................... 32 Probable Causes ............................................... 35
Probable Causes ............................................... 32 Recommended Actions...................................... 36
Recommended Actions...................................... 32 Electronic Service Tools ......................................... 11
Cat Data Link....................................................... 131 Caterpillar Electronic Technician (ET)................ 12
Coolant in Engine Oil............................................. 33 Optional Service Tools ....................................... 12
Probable Causes ............................................... 33 PL1000E Communication ECM (If Equipped).... 14
Recommended Actions...................................... 33 Service Tools....................................................... 11
Coolant Temperature Is Too High .......................... 34 Electronic Troubleshooting ...................................... 6
Probable Causes ............................................... 34 Emergency Stop Switch ...................................... 142
Recommended Actions...................................... 34 Emergency Stop Switch (Remote) ...................... 148
Customer Parameters Worksheet ......................... 27 Engine Control Switch (ECS) .............................. 153
Engine Cranks but Will Not Start ........................... 36
Engine Has Early Wear ......................................... 38
D Probable Causes ............................................... 38
Recommended Actions...................................... 38
Diagnostic Codes .................................................. 63 Engine Misres, Runs Rough or Is Unstable......... 38
Diagnostic Functional Tests.................................. 118 Probable Causes ............................................... 39
Digital Sensor Supply .......................................... 133 Recommended Actions...................................... 39
Engine Monitoring System..................................... 16
Oil Pressure Map ............................................... 20
E Engine Oil in Cooling System ................................ 40
Probable Causes ............................................... 40
E007 High Aftercooler Temperature Derate .......... 99 Recommended Actions...................................... 40
E008 High Aftercooler Temperature Shutdown ... 100 Engine Sensor Open/Short Test .......................... 161
E009 High Altitude Derate ................................... 101 Engine Speed/Timing Sensor .............................. 170
E012 High Crankcase Pressure Derate .............. 101 Engine Speed/Timing Sensor - Calibrate ............ 209
E013 High Crankcase Pressure Shutdown ......... 102 Engine Stalls at Low RPM ..................................... 40
E015 High Engine Coolant Temperature Derate.. 103 Probable Causes ............................................... 40
E016 High Engine Coolant Temperature Recommended Actions...................................... 40
Shutdown........................................................... 104 Engine Will Not Crank ........................................... 41
E017 High Engine Coolant Temperature Probable Causes ............................................... 41
Warning ............................................................. 104 Recommended Actions...................................... 41
E021 High Exhaust Temperature Derate............. 105 Event Codes .......................................................... 98
E031 Air Inlet Restriction Derate ......................... 106 Programmable Engine Parameters.................... 98
E038 Low Engine Coolant Temperature Excessive Black Smoke ........................................ 43
Warning ............................................................. 107 Probable Causes ............................................... 43
E040 Low Engine Oil Pressure Shutdown........... 108 Recommended Actions...................................... 43
E043 Low System Voltage Warning .................... 109 Excessive Engine Oil Consumption....................... 42
E048 Backup ECM Took Control .......................... 110 Probable Causes ............................................... 42
E095 Fuel Filter Restriction Warning .................... 111 Recommended Actions...................................... 42
E099 Engine Oil Filter Restriction Warning .......... 112 Excessive White Smoke ........................................ 44
E100 Low Engine Oil Pressure Warning .............. 112 Probable Causes ............................................... 44
E101 High Crankcase Pressure Warning............. 113 Recommended Actions...................................... 44
E173 High Exhaust Temperature Warning ........... 114 Exhaust Temperature Is Too High ......................... 45
E190 Engine Overspeed Warning ........................ 115 Probable Causes ............................................... 45
E272 Inlet Air Restriction Warning........................ 116 Recommended Actions...................................... 45
E279 High Aftercooler Temperature Warning....... 116
RENR5009-07 215
Index Section
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Temperature short to ground ............................... 74 inputs ................................................................... 83
MID 036 - CID 0168 - FMI 00 System Voltage MID 036 - CID 0337 - FMI 02 Incorrect Remote
High ..................................................................... 75 E-Stop Switch inputs............................................ 83
MID 036 - CID 0168 - FMI 01 System Voltage MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
Low ...................................................................... 75 circuit ................................................................... 83
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short
intermittent/erratic ................................................ 75 to ground.............................................................. 84
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed MID 036 - CID 0342 - FMI 02 Loss of Secondary
signal ................................................................... 75 Engine Speed signal............................................ 84
MID 036 - CID 0190 - FMI 03 Engine Speed MID 036 - CID 0342 - FMI 03 Secondary Engine
open/short to +batt............................................... 76 Speed open/short to +batt ................................... 84
MID 036 - CID 0190 - FMI 07 Primary Speed Sensor MID 036 - CID 0342 - FMI 07 Secondary Speed
misinstalled .......................................................... 76 Sensor misinstalled.............................................. 84
MID 036 - CID 0190 - FMI 08 Engine Speed signal MID 036 - CID 0342 - FMI 08 Secondary Engine
abnormal.............................................................. 76 Speed signal abnormal ........................................ 85
MID 036 - CID 0248 - FMI 09 Cat Data Link not MID 036 - CID 0444 - FMI 05 Start Relay open
communicating..................................................... 76 circuit ................................................................... 85
MID 036 - CID 0253 - FMI 02 Personality Module MID 036 - CID 0444 - FMI 06 Start Relay short to
mismatch ............................................................. 77 ground.................................................................. 85
MID 036 - CID 0254 - FMI 12 Electronic Control MID 036 - CID 0446 - FMI 05 Air Shutoff Relay
Module Error ........................................................ 77 open..................................................................... 85
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0446 - FMI 06 Air Shutoff Relay
calibration required .............................................. 77 short..................................................................... 86
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC MID 036 - CID 0542 - FMI 03 Unltered Engine Oil
Power Supply short to +batt ................................ 78 Pressure open/short to +batt ............................... 86
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC MID 036 - CID 0542 - FMI 04 Unltered Engine Oil
Power Supply short to ground ............................. 78 Pressure short to ground ..................................... 86
MID 036 - CID 0263 - FMI 03 Digital Sensor Supply MID 036 - CID 0827 - FMI 08 Left Exhaust
short to +batt........................................................ 78 Temperature signal abnormal .............................. 86
MID 036 - CID 0263 - FMI 04 Digital Sensor Supply MID 036 - CID 0828 - FMI 08 Right Exhaust
short to ground..................................................... 78 Temperature signal abnormal .............................. 87
MID 036 - CID 0268 - FMI 02 Check Programmable MID 036 - CID 1249 - FMI 08 Secondary Throttle
Parameters .......................................................... 79 Position signal abnormal...................................... 87
MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure MID 036 - CID 1249 - FMI 13 Secondary Throttle
above normal ....................................................... 79 Position calibration required ................................ 87
MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure MID 036 - CID 1495 - FMI 02 Injector Trim Codes Not
open/short to +batt............................................... 79 Programmed ........................................................ 88
MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure MID 047 - CID 0001 - FMI 05 Injector Cylinder 1 open
short to ground..................................................... 80 circuit ................................................................... 88
MID 036 - CID 0274 - FMI 03 Atmospheric Pressure MID 047 - CID 0001 - FMI 06 Injector Cylinder 1
open/short to +batt............................................... 80 short..................................................................... 88
MID 036 - CID 0274 - FMI 04 Atmospheric Pressure MID 047 - CID 0002 - FMI 05 Injector Cylinder 2 open
short to ground..................................................... 80 circuit ................................................................... 88
MID 036 - CID 0275 - FMI 03 Right Turbo Inlet MID 047 - CID 0002 - FMI 06 Injector Cylinder 2
Pressure open/short to +batt ............................... 80 short..................................................................... 89
MID 036 - CID 0275 - FMI 04 Right Turbo Inlet MID 047 - CID 0003 - FMI 05 Injector Cylinder 3 open
Pressure short to ground ..................................... 81 circuit ................................................................... 89
MID 036 - CID 0276 - FMI 03 Left Turbo Inlet MID 047 - CID 0003 - FMI 06 Injector Cylinder 3
Pressure open/short to +batt ............................... 81 short..................................................................... 89
MID 036 - CID 0276 - FMI 04 Left Turbo Inlet MID 047 - CID 0004 - FMI 05 Injector Cylinder 4 open
Pressure short to ground ..................................... 81 circuit ................................................................... 89
MID 036 - CID 0277 - FMI 08 Timing Calibration MID 047 - CID 0004 - FMI 06 Injector Cylinder 4
signal abnormal ................................................... 81 short..................................................................... 90
MID 036 - CID 0279 - FMI 03 Aftercooler Temperature MID 047 - CID 0005 - FMI 05 Injector Cylinder 5 open
open/short to +batt............................................... 82 circuit ................................................................... 90
MID 036 - CID 0279 - FMI 04 Aftercooler Temperature MID 047 - CID 0005 - FMI 06 Injector Cylinder 5
short to ground..................................................... 82 short..................................................................... 90
MID 036 - CID 0289 - FMI 03 Unltered Fuel Pressure MID 047 - CID 0006 - FMI 05 Injector Cylinder 6 open
open/short to +batt............................................... 82 circuit ................................................................... 90
MID 036 - CID 0289 - FMI 04 Unltered Fuel Pressure MID 047 - CID 0006 - FMI 06 Injector Cylinder 6
short to ground..................................................... 83 short..................................................................... 91
RENR5009-07 217
Index Section
MID 047 - CID 0007 - FMI 05 Injector Cylinder 7 open Programming Parameters ..................................... 21
circuit ................................................................... 91
MID 047 - CID 0007 - FMI 06 Injector Cylinder 7
short..................................................................... 91 R
MID 047 - CID 0008 - FMI 05 Injector Cylinder 8 open
circuit ................................................................... 91 Replacing the ECM................................................ 29
MID 047 - CID 0008 - FMI 06 Injector Cylinder 8
short..................................................................... 92
MID 047 - CID 0009 - FMI 05 Injector Cylinder 9 open S
circuit ................................................................... 92
MID 047 - CID 0009 - FMI 06 Injector Cylinder 9 Secondary ECM Assumes Control ........................ 52
short..................................................................... 92 Secondary ECM Indicator Fault............................. 53
MID 047 - CID 0010 - FMI 05 Injector Cylinder 10 Secondary ECM/Personality Module................... 192
open circuit .......................................................... 92 Self-Diagnostics..................................................... 10
MID 047 - CID 0010 - FMI 06 Injector Cylinder 10 Starting Motor System ......................................... 197
short..................................................................... 93 Symptoms.............................................................. 31
MID 047 - CID 0011 - FMI 05 Injector Cylinder 11 Synchronizing Switch Not Functioning Properly.... 53
open circuit .......................................................... 93 System Conguration Parameters......................... 23
MID 047 - CID 0011 - FMI 06 Injector Cylinder 11 Customer Parameters........................................ 24
short..................................................................... 93 Parameter Descriptions ..................................... 23
MID 047 - CID 0012 - FMI 05 Injector Cylinder 12 Parameter Table........................................... 24, 26
open circuit .......................................................... 93 System Overview..................................................... 6
MID 047 - CID 0012 - FMI 06 Injector Cylinder 12 Electronic Controls............................................... 6
short..................................................................... 94 Location of the Engine Components.............. 810
MID 047 - CID 0013 - FMI 05 Injector Cylinder 13
open circuit .......................................................... 94
MID 047 - CID 0013 - FMI 06 Injector Cylinder 13 T
short..................................................................... 94
MID 047 - CID 0014 - FMI 05 Injector Cylinder 14 Table of Contents..................................................... 3
open circuit .......................................................... 94 Throttle Position Sensor ...................................... 202
MID 047 - CID 0014 - FMI 06 Injector Cylinder 14 Throttle Position Sensor - Calibrate...................... 211
short..................................................................... 95 Too Much Valve Lash ............................................ 61
MID 047 - CID 0015 - FMI 05 Injector Cylinder 15 Probable Causes ............................................... 61
open circuit .......................................................... 95 Recommended Actions...................................... 61
MID 047 - CID 0015 - FMI 06 Injector Cylinder 15 Too Much Vibration................................................ 61
short..................................................................... 95 Probable Causes ............................................... 61
MID 047 - CID 0016 - FMI 05 Injector Cylinder 16 Recommended Actions...................................... 62
open circuit .......................................................... 95 Troubleshooting Section.......................................... 6
MID 047 - CID 0016 - FMI 06 Injector Cylinder 16 Troubleshooting with a Diagnostic Code ............... 63
short..................................................................... 96 Troubleshooting with an Event Code..................... 98
MID 047 - CID 0190 - FMI 02 Loss of Engine Speed Troubleshooting without a Diagnostic Code .......... 31
signal ................................................................... 96
MID 047 - CID 0190 - FMI 08 Engine Speed signal
abnormal.............................................................. 96 V
MID 047 - CID 0342 - FMI 02 Loss of Secondary
Engine Speed signal............................................ 96 Valve Rotocoil or Spring Lock Is Free ................... 62
MID 047 - CID 0342 - FMI 08 Secondary Engine Probable Causes ............................................... 62
Speed signal abnormal ........................................ 97 Recommended Actions...................................... 62