SENR1003-07

November 2003

Troubleshooting
3500B Generator Set Engines
3DM1-Up (Engine) 5AW1-Up (Engine)
4GM1-Up (Engine)
5XM1-Up (Engine)
6PM1-Up (Engine)
7KM1-Up (Engine)
8EM1-Up (Engine)
8RM1-Up (Engine)
6HN1-Up (Engine)
6PN1-Up (Engine)
6WN1-Up (Engine)
7RN1-Up (Engine)
9AN1-Up (Engine)
3LS1-Up (Engine)
3MS1-Up (Engine)
3NS1-Up (Engine)
3TS1-Up (Engine)
3WS1-Up (Engine)
3XS1-Up (Engine)
1NW1-Up (Engine)
1PW1-Up (Engine)
2FW1-Up (Engine)
2HW1-Up (Engine)
2JW1-Up (Engine)
3DW1-Up (Engine)
4AW1-Up (Engine)

Prime Power, Standby and Marine Auxiliary Generator Set Engines

 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 open
circuit ................................................................... 56
MID 036 - CID 0002 - FMI 06 Injector Cylinder 2
short .................................................................... 57
Troubleshooting Section MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 open
circuit ................................................................... 57
Electronic Troubleshooting
MID 036 - CID 0003 - FMI 06 Injector Cylinder 3
System Overview .................................................... 6
short .................................................................... 57
Self-Diagnostics .................................................... 14
MID 036 - CID 0004 - FMI 05 Injector Cylinder 4 open
Electronic Service Tools ........................................ 15
circuit ................................................................... 57
Electronic Display Module ..................................... 18
MID 036 - CID 0004 - FMI 06 Injector Cylinder 4
Engine Monitoring System .................................... 21
short .................................................................... 58
MID 036 - CID 0005 - FMI 05 Injector Cylinder 5 open
Programming Parameters
circuit ................................................................... 58
Programming Parameters ..................................... 25
MID 036 - CID 0005 - FMI 06 Injector Cylinder 5
Factory Passwords ................................................ 25
short .................................................................... 58
Factory Passwords Worksheet ............................. 25
MID 036 - CID 0006 - FMI 05 Injector Cylinder 6 open
Flash Programming .............................................. 26
circuit ................................................................... 58
System Configuration Parameters ........................ 28
MID 036 - CID 0006 - FMI 06 Injector Cylinder 6
Customer Parameters Worksheet ......................... 30
short .................................................................... 59
Replacing the ECM ............................................... 32
MID 036 - CID 0007 - FMI 05 Injector Cylinder 7 open
circuit ................................................................... 59
Troubleshooting without a Diagnostic Code
MID 036 - CID 0007 - FMI 06 Injector Cylinder 7
Symptoms ............................................................. 34
short .................................................................... 59
Alternator .............................................................. 34
MID 036 - CID 0008 - FMI 05 Injector Cylinder 8 open
Can Not Reach Top Engine RPM ......................... 35
circuit ................................................................... 59
Coolant in Engine Oil ............................................ 36
MID 036 - CID 0008 - FMI 06 Injector Cylinder 8
Coolant Temperature Is Too High ......................... 36
short .................................................................... 60
ECM Will Not Accept Factory Passwords ............. 37
MID 036 - CID 0009 - FMI 05 Injector Cylinder 9 open
ECM Will Not Communicate with Other Systems or
circuit ................................................................... 60
Display Modules .................................................. 37
MID 036 - CID 0009 - FMI 06 Injector Cylinder 9
Electronic Service Tool Will Not Communicate with
short .................................................................... 60
ECM .................................................................... 37
MID 036 - CID 0010 - FMI 05 Injector Cylinder 10
Engine Cranks but Will Not Start .......................... 38
open circuit .......................................................... 60
Engine Has Early Wear ........................................ 39
MID 036 - CID 0010 - FMI 06 Injector Cylinder 10
Engine Misfires, Runs Rough or Is Unstable ........ 40
short .................................................................... 61
Engine Oil in Cooling System ............................... 41
MID 036 - CID 0011 - FMI 05 Injector Cylinder 11
Engine Stalls at Low RPM .................................... 41
open circuit .......................................................... 61
Engine Will Not Crank ........................................... 42
MID 036 - CID 0011 - FMI 06 Injector Cylinder 11
Excessive Engine Oil Consumption ...................... 43
short .................................................................... 61
Excessive Black Smoke ........................................ 43
MID 036 - CID 0012 - FMI 05 Injector Cylinder 12
Excessive White Smoke ....................................... 44
open circuit .......................................................... 61
Exhaust Temperature Is Too High ......................... 45
MID 036 - CID 0012 - FMI 06 Injector Cylinder 12
Fuel Dilution of Engine Oil .................................... 46
short .................................................................... 62
Fuel in Cooling System ......................................... 46
MID 036 - CID 0013 - FMI 05 Injector Cylinder 13
Intermittent Engine Shutdown ............................... 46
open circuit .......................................................... 62
Intermittent Low Power or Power Cutout ............... 47
MID 036 - CID 0013 - FMI 06 Injector Cylinder 13
Low Engine Oil Pressure ...................................... 49
short .................................................................... 62
Low Power/Poor or No Response to Throttle ........ 49
MID 036 - CID 0014 - FMI 05 Injector Cylinder 14
Mechanical Noise (Knock) in Engine .................... 51
open circuit .......................................................... 62
Noise Coming from Cylinder ................................. 51
MID 036 - CID 0014 - FMI 06 Injector Cylinder 14
Poor Fuel Consumption ........................................ 52
short .................................................................... 63
Too Much Valve Lash ............................................ 53
MID 036 - CID 0015 - FMI 05 Injector Cylinder 15
Too Much Vibration ............................................... 53
open circuit .......................................................... 63
Valve Rotocoil or Spring Lock Is Free ................... 54
MID 036 - CID 0015 - FMI 06 Injector Cylinder 15
short .................................................................... 63
Troubleshooting with a Diagnostic Code
MID 036 - CID 0016 - FMI 05 Injector Cylinder 16
Diagnostic Codes .................................................. 55
open circuit .......................................................... 63
MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open
MID 036 - CID 0016 - FMI 06 Injector Cylinder 16
circuit ................................................................... 56
short .................................................................... 64
MID 036 - CID 0001 - FMI 06 Injector Cylinder 1
MID 036 - CID 0091 - FMI 08 Throttle Position signal
short .................................................................... 56
abnormal ............................................................. 64
4
Table of Contents

MID 036 - CID 0094 - FMI 02 Fuel Pressure MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure
misinstalled ......................................................... 64 short to ground .................................................... 73
MID 036 - CID 0094 - FMI 03 Fuel Pressure MID 036 - CID 0273 - FMI 13 Turbo Outlet Pressure
open/short to +batt .............................................. 65 calibration required ............................................. 73
MID 036 - CID 0094 - FMI 04 Fuel Pressure short to MID 036 - CID 0274 - FMI 03 Atmospheric Pressure
ground ................................................................. 65 open/short to +batt .............................................. 73
MID 036 - CID 0094 - FMI 13 Fuel Pressure MID 036 - CID 0274 - FMI 04 Atmospheric Pressure
calibration required ............................................. 65 short to ground .................................................... 73
MID 036 - CID 0100 - FMI 02 Engine Oil Pressure out MID 036 - CID 0274 - FMI 13 Atmospheric Pressure
of range ............................................................... 65 calibration required ............................................. 74
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0275 - FMI 03 Right Turbo Inlet
open/short to +batt .............................................. 66 Pressure open/short to +batt .............................. 74
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0275 - FMI 04 Right Turbo Inlet
short to ground .................................................... 66 Pressure short to ground .................................... 74
MID 036 - CID 0100 - FMI 13 Engine Oil Pressure MID 036 - CID 0275 - FMI 13 Right Turbo Inlet
calibration required ............................................. 66 Pressure calibration required .............................. 75
MID 036 - CID 0101 - FMI 03 Crankcase Pressure MID 036 - CID 0276 - FMI 03 Left Turbo Inlet
open/short to +batt .............................................. 66 Pressure open/short to +batt .............................. 75
MID 036 - CID 0101 - FMI 04 Crankcase Pressure MID 036 - CID 0276 - FMI 04 Left Turbo Inlet
short to ground .................................................... 67 Pressure short to ground .................................... 75
MID 036 - CID 0101 - FMI 13 Crankcase Pressure MID 036 - CID 0276 - FMI 13 Left Turbo Inlet
calibration required ............................................. 67 Pressure calibration required .............................. 75
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0279 - FMI 03 Aftercooler Temperature
Temperature open/short to +batt ......................... 67 open/short to +batt .............................................. 76
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0279 - FMI 04 Aftercooler Temperature
Temperature short to ground ............................... 68 short to ground .................................................... 76
MID 036 - CID 0168 - FMI 00 System Voltage MID 036 - CID 0289 - FMI 02 Unfiltered Fuel Pressure
High ..................................................................... 68 misinstalled ......................................................... 76
MID 036 - CID 0168 - FMI 01 System Voltage MID 036 - CID 0289 - FMI 03 Unfiltered Fuel Pressure
Low ..................................................................... 68 open/short to +batt .............................................. 77
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0289 - FMI 04 Unfiltered Fuel Pressure
intermittent/erratic ............................................... 68 short to ground .................................................... 77
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed MID 036 - CID 0289 - FMI 13 Unfiltered Fuel Pressure
signal ................................................................... 69 calibration required ............................................. 77
MID 036 - CID 0190 - FMI 03 Engine Speed MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
open/short to +batt .............................................. 69 inputs .................................................................. 77
MID 036 - CID 0190 - FMI 08 Engine Speed signal MID 036 - CID 0337 - FMI 02 Incorrect Remote
abnormal ............................................................. 69 E-Stop Switch inputs ........................................... 78
MID 036 - CID 0248 - FMI 09 CAT Data Link not MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
communicating .................................................... 69 circuit ................................................................... 78
MID 036 - CID 0253 - FMI 02 Personality Module MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short
mismatch ............................................................. 70 to ground ............................................................. 78
MID 036 - CID 0254 - FMI 12 Electronic Control MID 036 - CID 0444 - FMI 05 Start Relay open
Module Error ....................................................... 70 circuit ................................................................... 78
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0444 - FMI 06 Start Relay short to
calibration required ............................................. 70 ground ................................................................. 79
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power MID 036 - CID 0446 - FMI 05 Air Shutoff Relay
Supply short to +batt ........................................... 70 open .................................................................... 79
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power MID 036 - CID 0446 - FMI 06 Air Shutoff Relay
Supply short to ground ........................................ 71 short .................................................................... 79
MID 036 - CID 0263 - FMI 03 Digital Sensor Supply MID 036 - CID 0542 - FMI 02 Unfiltered Engine Oil
short to +batt ....................................................... 71 Pressure misinstalled .......................................... 79
MID 036 - CID 0263 - FMI 04 Digital Sensor Supply MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
short to ground .................................................... 71 Pressure open/short to +batt .............................. 80
MID 036 - CID 0268 - FMI 02 Check Programmable MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
Parameters .......................................................... 72 Pressure short to ground .................................... 80
MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure MID 036 - CID 0542 - FMI 13 Unfiltered Engine Oil
above normal ...................................................... 72 Pressure cal required ......................................... 80
MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure MID 036 - CID 0545 - FMI 05 Ether Start Relay
open/short to +batt .............................................. 72 open/short to +batt .............................................. 80
 5
Table of Contents

MID 036 - CID 0545 - FMI 06 Ether Start Relay short

to ground ............................................................. 81
MID 036 - CID 0546 - FMI 05 Ether Hold Relay
open/short to ground ........................................... 81
MID 036 - CID 0546 - FMI 06 Ether Hold Relay short
to +batt ................................................................ 81
MID 036 - CID 0827 - FMI 08 Left Exhaust
Temperature signal abnormal ............................. 81
MID 036 - CID 0828 - FMI 08 Right Exhaust
Temperature signal abnormal ............................. 82

Troubleshooting with an Event Code

Event Codes ........................................................ 83
E017 High Engine Coolant Temperature
Warning ............................................................... 84
E100 Low Engine Oil Pressure Warning ............... 84
E190 Engine Overspeed Warning ........................ 85
E272 Inlet Air Restriction Warning ........................ 86

Diagnostic Functional Tests

Air Shutoff System ................................................ 87
Analog Sensor Supply .......................................... 91
CAT Data Link ....................................................... 96
Digital Sensor Supply ........................................... 99
Direct Fuel Control Mode .................................... 103
ECM/Personality Module .................................... 106
Electrical Power Supply ...................................... 108
Emergency Stop Switch ...................................... 112
Engine Control Switch (ECS) .............................. 115
Engine Sensor Open/Short Test ......................... 119
Engine Speed/Timing Sensor ............................. 128
Ether Injection System ........................................ 132
Injector Solenoids ............................................... 139
Inspecting Electrical Connectors ........................ 145
Prelubrication System ......................................... 151
Speed Control ..................................................... 155
Starting Motor System ....................................... 159

Calibration Procedures
Analog Sensor - Calibrate ................................... 163
Engine Speed/Timing Sensor - Calibrate ........... 164

Index Section
Index ................................................................... 166
6
Troubleshooting Section

Troubleshooting Section Fuel Injection

The ECM controls the amount of fuel that is injected
by varying the signals to the injector solenoids. The
Electronic Troubleshooting injectors will pump fuel only if the injector solenoid
is energized. The ECM sends a 105 volt signal to
the injector solenoid. By controlling the timing and
i01961129 the duration of the high voltage signal, the ECM can
control injection timing and the ECM can control the
System Overview amount of fuel that is injected.
SMCS Code: 1901-038; 1924 The ECM limits engine power during “Cold Mode”
operation and the ECM modifies injection timing
System Operation during “Cold Mode” operation. “Cold Mode”
operation provides the following benefits:
This engine was designed for electronic control.
The injection pump, the fuel lines and the nozzles • Increased cold weather starting capability
that are used in mechanical engines have been
replaced with an electronic unit injector in each • Reduced warm-up time
cylinder. A solenoid on each injector controls the
amount of fuel that is delivered by the injector. The • Reduced white smoke
Electronic Control Module (ECM) sends a signal to
each injector solenoid in order to provide complete “Cold Mode” is activated whenever the engine’s
control over the operation of the fuel injection coolant temperature falls below a predetermined
system. value. “Cold Mode” remains active until the engine’s
coolant temperature rises above a predetermined
Electronic Controls value.

The electronic system consists of the following The personality module inside the ECM sets certain
components: the ECM, the electronic unit injectors limits on the amount of fuel that can be injected.
(EUI), the wiring harnesses, the switches, and the The Fuel Ratio Control (FRC) is used to control
sensors. The ECM is the computer. The personality the air/fuel ratio for control of emissions. The FRC
module is the software for the computer. The is a limit that is based on the turbocharger outlet
personality module contains the operating mapsthat pressure. A higher turbocharger outlet pressure
define the following characteristics of the engine: indicates that there is more air in the cylinder.
When the ECM senses a higher turbocharger outlet
pressure, the ECM increases the FRC. When the
• Horsepower ECM increases the FRC, the ECM allows more fuel
into the cylinder. The FRC is programmed into the
• Torque curves personality module at the factory. The FRC cannot
The ECM determines the timing and the amount be changed.
of fuel that is delivered to the cylinders. These
decisions are based on the actual conditions and/or The rated fuel position is a limit that is based on the
on the desired conditions at any given time. power rating of the engine. The rated fuel position
is similar to the rack stops and to the torque spring
The ECM compares the desired engine speed to on a mechanically governed engine. The rated fuel
the actual engine speed. The actual engine speed position limits the power curves and the torque
is determined through the engine speed/timing curves for a specific engine family and for a specific
sensor. The desired engine speed is determined engine rating. The rated fuel limit is programmed
through the following items: into the personality module at the factory. The rated
fuel limit cannot be changed.
• Throttle signal
• Other input signals from sensors
• Certain diagnostic codes
If the desired engine speed is greater than the
actual engine speed, the ECM injects more fuel in
order to increase the actual engine speed.
 7
Troubleshooting Section

Once the ECM determines the amount of fuel that

is required, the ECM must determine the timing
of the fuel injection. The ECM determines the top
center position of each cylinder from the engine
speed/timing sensor’s signal. The ECM decides
when fuel injection should occur relative to the top
center position and the ECM provides the signal to
the injector solenoid at the desired time. The ECM
adjusts timing for optimum engine performance, for
optimum fuel economy, and for optimum control of
white smoke.
8
Troubleshooting Section

Engine Wiring Diagram for the 3500B

Engine with CMS and Without 2301A
Loadshare

g00638234
Illustration 1
 9
Troubleshooting Section

Engine Wiring Diagram for the 3500B

Engine with EMCP II and 2301A
Loadshare

g00638235
Illustration 2
10
Troubleshooting Section

Location Of The Engine Components

g01019347
Illustration 3
Typical left side view
(1) Connector for the electronic unit injector (4) Left turbocharger compressor inlet (6) Electric starting motor
(2) Left exhaust temperature sensor pressure sensor (7) Engine speed/timing sensor
(3) Air shutoff (5) Ether starting aid
 11
Troubleshooting Section

Location Of The Engine Components

g01019348
Illustration 4
Typical left side view of section A
(8) Unfiltered fuel pressure sensor (10) Filtered engine oil pressure sensor (12) Atmospheric pressure sensor
(9) Filtered fuel pressure sensor (11) Coolant temperature sensor (13) Aftercooler temperature sensor
12
Troubleshooting Section

Location Of The Engine Components

g01019349
Illustration 5
Typical right side view
(14) Right turbocharger compressor inlet (17) Crankcase pressure sensor (21) Alternator
pressure sensor (18) Instrument panel connector
(3) Air shutoff (19) Electronic service tool connector
(15) Right exhaust temperature sensor J60/P60
(16) Air start solenoid (20) Prelube pump
 13
Troubleshooting Section

Location Of The Engine Components

g01019352
Illustration 6
Typical front view
(14) Right turbocharger compressor inlet (4) Left turbocharger compressor inlet (24) Turbocharger compressor outlet
pressure sensor pressure sensor pressure sensor
(10) Filtered engine oil pressure sensor (22) Unfiltered engine oil pressure sensor (25) ECM
(3) Air shutoff (23) Instrument panel (13) Aftercooler temperature sensor
14
Troubleshooting Section

Location Of The Engine Components

g01019353
Illustration 7
Typical rear view
(7) Engine speed/timing sensor (23) Instrument panel (26) Emergency stop push button

i01977688 Event Code – An event code is generated by

the detection of an abnormal engine operating
Self-Diagnostics condition. For example, an event code will be
generated if the oil pressure is too low. In this case,
SMCS Code: 1901-038 the event code indicates the symptom of a problem.
The Electronic Control Module (ECM) has the ability The codes can have two different states:
to detect problems with the electronic system
and with engine operation. When a problem is • Active
detected, a code is generated. An alarm may also
be generated. There are two types of codes: • Logged
• Diagnostic Active Code – An active diagnostic code or an
active event code indicates that an active problem
• Event has been detected. Active codes require immediate
attention. Always service active codes prior to
Diagnostic Code – When a problem with the servicing logged codes.
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the electronic control system.
 15
Troubleshooting Section

Logged Code – Every generated code is stored in Table 1

the permanent memory of the ECM. The codes are Required Service Tools
logged.
Part Number Description
Logged codes may not indicate that a repair is N/A 4 mm Allen Wrench
needed. The problem may have been temporary.
The problem may have been resolved since the N/A Vacuum Pump Test Unit
logging of the code. If the system is powered, it
1U-5805 Wire Removal Tool (14
is possible to generate an active diagnostic code AWG)
whenever a component is disconnected. When
the component is reconnected, the code is no 151-6320 Wire Removal Tool (16/18
longer active. Logged codes may be useful to help AWG)
troubleshoot intermittent problems. Logged codes 9U-7330 Digital Multimeter
can also be used to review the performance of the
engine and of the electronic system. 7X-1710 Multimeter Probe
175-3700 Connector Repair Kit
i01966901 1U-5804 Crimp Tool
Electronic Service Tools 7X-1695 Cable
6V-3093 Transducer Adapter
SMCS Code: 1901-038
6V-2197 Magnetic Transducer
The Caterpillar Electronic Service Tools are
147-6456 (Wedge Removal Tool)
designed to perform the following functions:

• Obtain data from the engine. Optional Service Tools

• Display the diagnostic codes or display the event Two short jumper wires are needed to check
codes on the Caterpillar Electronic Technician
continuity of some wiring harness circuits. The
(ET).
jumper wires are used to short two adjacent pins or
sockets together in a connector.
• Perform sensor calibrations.
A long extension wire may be needed to check
• Read the programmable parameters. continuity of some wiring harness circuits.
• Change the programmable parameters. The following list contains service tools that are not
required. These tools may be helpful to service the
The use of a communication adapter must be used
engine. The following optional tools are used to
in order for the Cat ET to communicate with the
measure voltage, pressures and/or temperatures.
Electronic Control Module (ECM).

There are several service tools that are required in

order to allow a service technician to perform the
procedures. These tools are listed in the following
tables.
16
Troubleshooting Section

Table 2 Electronic Technician

Optional Service Tools
The Caterpillar Electronic Technician (ET) is
Part Number Description designed to run on a personal computer. The Cat
1U-5470 Engine Pressure Group
ET can display the status of a group of parameters.
The Cat ET can display the following information:
4C-4071 Contact Removal Tool
4C-4072 Contact Removal Tool • Sensor values
4C-4073 Contact Removal Tool • Diagnostic codes
4C-4074 Contact Removal Tool
• Engine configuration
4C-4075 Crimp Tool
The Cat ET can perform the following functions:
146-4080 Digital Multimeter
4C-4911(1) Battery Load Tester • Diagnostic tests
6V-9130(2) Temperature Adapter
• Sensor calibration
7X-6370 Adapter Cable
151-6320 Wire Removal Tool
• Flash downloading
8T-5319 Connector Tool Group • Set programmable parameters
8T-8726 Adapter Cable The following components are required to use the
9S-9082 Engine Turning Tool Cat ET to service the engine.
9S-9150 Clip
5P-7277 Voltage Tester
(1) Refer to Special Instruction, SEHS9249, “Use of the 4C-4911
Battery Load Tester for 6, 8, and 12 Volt Lead”. Also, refer to
Special Instruction, SEHS7633, “Battery Test Procedure”.
(2) Refer to Special Instructions, SEHS8382, “Use of 6V-9130
Temperature Adapter Group”.

g00728634
Illustration 8
Vacuum pump test unit
(1) 4C-3973 Connector
(2) Pressure sensor
(3) Tee
(4) 9X-0263 Adapter
(5) 1U-5718 Vacuum Pump
(6) 169-7372 Fluid Sampling Bottle

Note: Similar parts may be used to build the vacuum

pump test unit. The vacuum pump test unit can be
used with the 1U-5470 Engine Pressure Group.
 17
Troubleshooting Section

Table 3 Connecting Cat ET and the

Required Electronic Service Tools for Communication Adapter II
the Use of Cat ET
Part Description
Number
Requirements
IBM PC compatible 100 MHz processor
32 megabyte of RAM
10 megabyte of available hard drive
space
N/A
CD-ROM drive
3.5" 1.44-MB floppy disk drive
Windows NT or Windows 95
RS232 port with “16550AF UART”
VGA monitor or display
Recommended
Intel Pentium II 333 mHz processor
N/A 64 megabyte of RAM
4.3 gigabyte hard drive
CD-ROM drive 14X speed

JERD2124 License for Cat ET

Data Subscription for all engines and

JERD2129
machines
Service Program Module for the
NEHS0758(1)
171-4401 Communication Adapter II
160-0141(2) Data Link Cable
207-6845(2) Data Link Cable
g00647144
Illustration 9
Communication Adapter II for use
171-4401(2) (1) Personal computer
between Cat ET and the ECM
(2) 160-0141 Data Link Cable
237-7547(3) Adapter Cable As (3) 171-4401 Communication Adapter II
(4) 207-6845 Data Link Cable
(1) The subscription will be updated at regular intervals.
(2) This part number is part of the 171-4400 Communication The service tool connector provides the
Adapter II Group.
(3) The 237-7547 Adapter Cable As is required to connect to the
Communication Adapter II with 24 VDC. Use the
USB port on computers that are not equipped with a RS232 following procedure to connect the Cat ET and the
serial port. Communication Adapter II to the engine.

1. Turn the engine control to the OFF position.

2. Turn the Battery disconnect switch to the OFF

position.

3. Connect the 207-6845 Data Link Cable between

the J42 service tool connector and the control
connector on the 171-4401 Communication
Adapter II.

4. Connect the 160-0141 Data Link Cable

between the laptop computer’s RS232 serial
port and the serial connector on the 171-4401
Communication Adapter II.

5. Turn the battery disconnect switch to the ON

position.
18
Troubleshooting Section

6. Start the program for the Cat ET on the personal

computer. Establish communication with the
Engine’s Electronic Control Module (ECM). If
the Cat ET and the communication adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Will Not
Communicate With ECM”.
Table 4
Specifications for the Communication Adapter II
Operating Voltage 7 VDC to 40 VDC at 1.0
amp
Operating Temperature −18 C to +65 C
(0 F to 149 F)
Storage Temperature − 40 C to +80 C (-40 F
to 176 F)
Dimensions 180 mm X 85 mm X 44.5
mm (7.085 inch X 3.343
inch X 1.75 inch)
Weight 454 g (1 lb)

i01961142

Electronic Display Module

SMCS Code: 1901-038

The instrument panel contains the following controls:

Caterpillar monitoring system, control switches
for the Caterpillar monitoring system, gauges,
emergency stop switch, and Engine Control
Switch (ECS). The Caterpillar monitoring system
can display diagnostic code information from the
engine’s Electronic Control Module (ECM). Three
switches are used to select various operating
modes and display modes. Refer to the System
Operation manual for more information.
 19
Troubleshooting Section

g01018744
Illustration 10
Instrument panel
(1) Gauge cluster (5) “LH/RH select switch”
(2) Ether control switch (6) Emergency stop switch
(3) Scroll switch (7) Alarm silence switch
(4) Clear mode switch (8) Engine control switch (ECS)
20
Troubleshooting Section

g01018755
Illustration 11
Electronic monitoring system and gauge clusters
(9) Shutdown (17) Oil pressure (25) Aftercooler temperature
(10) System voltage (18) Coolant temperature (26) Fuel filter restriction
(11) Overspeed (19) Low oil pressure (27) Air inlet restriction
(12) Low coolant level (20) High coolant temperature (38) Oil filter restriction
(13) Overcrank (21) Low coolant temperature (29) Inlet air pressure
(14) Not in AUTO (22) Fuel pressure (30) Inlet air temperature
(15) Low fuel level (23) LED display (31) Oil temperature
(16) System voltage (24) Exhaust temperature
 21
Troubleshooting Section

i02006662 Table 5

Engine Monitoring System Parameter Hysteresis

ECM Voltage 3 VDC
SMCS Code: 1901-038
Oil Pressure 25 kPa (4 psi)
The Electronic Control Module (ECM) monitors High Coolant Temperature 5 C (9 F)
engine operating parameters. If a parameter
exceeds the acceptable range, the ECM will initiate Low Coolant Temperature N/A
action. The ECM can cause a warning to occur. The Overspeed 100 rpm
ECM can derate engine power. The ECM can cause
an engine shutdown to occur. Not all of the actions Air Inlet Restriction N/A
are available for all parameters. Altitude N/A

The Caterpillar Electronic Technician (ET) can be High Exhaust Temperature 10 C (18 F)
used to select the ECM response. Cat ET can be Oil Filter Differential 10 kPa (1.5 psi)
used to program the level of engine monitoring and Pressure
the delay times.
Fuel Filter Differential 10 kPa (1.5 psi)
Separate timers are used in the ECM for each Pressure
response that is associated with a parameter. Once Crankcase Pressure N/A
the trip point is exceeded for an action, the timer
for that action is started. Aftercooler Water 3 C (5 F)
Temperature
For example, if the high coolant temperature
warning is set to 102 C (216 F) with a five seconds Note: The following tables are examples. The values
delay, the delay timer starts counting once the may have changed. Use Cat ET to determine the
coolant temperature exceeds 102 C (216 F). If the actual defaults and the specific configuration.
coolant remained above 102 C (216 F) for five
seconds, a warning would be issued.

Use care when you program the trip point and the
delay times. The resulting ECM response must be
correct for the application. If the acceptable range
is not exceeded, the engine monitoring system will
accept any setting.

If the trip point for a shutdown is lower than the trip

point for a warning, the engine will shut down. The
warning will not be activated.

Once a parameter has exceeded the trip point the

parameter must drop a certain amount below the
trip point before the ECM response will end.

If a warning is programmed to 102 C (216 F), the

temperature must exceed the range in order for the
warning to activate. The temperature must decrease
below 99 C (210 F) for the warning to stop. The
variance is the hysteresis. The following table gives
the hysteresis for each parameter.
22
Troubleshooting Section

Table 6
Engine Monitoring System
Parameter ECM Default Default Limits
Response Trip Point Delay
Time Range for Trip Point Delay
Time
Low High
Low System Voltage Off
Warning 20 VDC 10 20 VDC 22 VDC 1 to 30
Seconds seconds
Low Oil Pressure Off
(1)
Warning 4 N/A 1 to 15
Seconds seconds
(1)
Shutdown 9 N/A 1 to 15
Seconds seconds
High Coolant Temperature Off
Warning 102 C 5 90 C (194 F) 102 C (216 F) 1 to 60
(216 F) Seconds Seconds
Derate 107 C 30 90 C (194 F) 107 C (225 F) 1 to 60
(225 F) Seconds Seconds
Shutdown 107 C 5 90 C (194 F) 107 C (225 F) 1 to 60
(225 F) Seconds Seconds
Low Coolant Temperature Off
Warning 80 C 5 63 C (145 F) 85 C (185 F) 1 to 60
(176 F) Seconds Seconds
Engine Overspeed Off
Warning 1.18 × 0 1200 rpm 2400 rpm 0 to 5
Rated Seconds Seconds
Speed
Shutdown 1.18 × 0 1200 rpm 2400 rpm 0 to 5
(50 Hz) Rated Seconds Seconds
Speed
Shutdown 1.18 × 0 1200 rpm 2400 rpm 0 to 5
(60 Hz) Rated Seconds Seconds
Speed
Air Filter Restriction Off
Pressure
Warning 7 kPa 5 3 kPa (0.4 psi) 7 kPa (1 psi) 1 to 60
(1 psi) Seconds Seconds
Derate 7 kPa 5 1 kPa (0.14 psi) 7 kPa (1 psi) 1 to 60
(1 psi) Seconds Seconds
Altitude Off
(2)
Derate N/A 250 m (820 ft) 3658 m N/A
(12001 ft)
High Exhaust Temperature Off
Warning (2)
5 500 C (932 F) 800 C 1 to 60
Seconds (1472 F) Seconds
(2)
Derate 5 1 to 60
Seconds Seconds
(continued)
 23
Troubleshooting Section

(Table 6, contd)
Engine Monitoring System
Parameter ECM Default Default Limits
Response Trip Point Delay
Time Range for Trip Point Delay
Time
Low High
Oil Filter Differential Off
Pressure
Warning 105 kPa 5 70 kPa (10 psi) 105 kPa (15 psi) 1 to 60
(15 psi) Seconds Seconds
Fuel Filter Differential Off
Pressure
Warning 105 kPa 5 70 kPa (10 psi) 105 kPa (15 psi) 1 to 60
(15 psi) Seconds Seconds
Crankcase Pressure Off
Warning 2 kPa 3 0.5 kPa (0.1 psi) 6 kPa (0.9 psi) 1 to 30
(0.3 psi) Seconds Seconds
Derate 6 kPa 10 0.5 kPa (0.1 psi) 6 kPa (0.9 psi) 1 to 60
(0.9 psi) Seconds Seconds
Shutdown 3.5 kPa 3 0.5 kPa (0.1 psi) 6 kPa (0.9 psi) 1 to 60
(0.5 psi) Seconds Seconds
Aftercooler Water Off
Temperature
Warning 102 C 5 40 C (104 F) 102 C (216 F) 1 to 60
(216 F) Seconds Seconds
Derate 107 C 5 40 C (104 F) 107C (225 F) 1 to 60
(225 F) Seconds Seconds
Shutdown 107 C 5 40 C (104 F) 107 C (225 F) 1 to 60
(225 F) Seconds Seconds
(1) Refer to the oil pressure map.
(2) Refer to the Performance and Ratings Specifications in the TMI (Technical Marketing Information).

Active engine derates that occur are activated when

the associated parameter is out of the specified
range. When the parameter returns to a value within
the specified range, the active engine derate is
automatically removed for most of the parameters.

Some derates remain locked even after the

parameters return to values within the specified
ranges. After the problem is resolved for the
following derates, power must be cycled to the
engine’s ECM in order to remove the derate:

• High exhaust temperature

• High air filter restriction
• Crankcase pressure
24
Troubleshooting Section

Oil Pressure Map

g00775727
Illustration 12
Oil pressure map
 25
Troubleshooting Section

Programming Parameters Note: The old interlock code and the new interlock
code are required to change the interlock code on
a used Electronic Control Module (ECM).
i01951720
The Cat ET screen for factory passwords will display
Programming Parameters the following parameters:
SMCS Code: 1901-038 • Serial number of the ECM
The Caterpillar Electronic Technician (ET) can be • Engine serial number
used to view certain parameters that can affect
the operation of the engine. The Cat ET can also • Serial number for Cat ET
be used to change certain parameters. Some of
the parameters are protected from unauthorized • Reason code
changes by passwords. Parameters that can be
changed have a tattletale number. The tattletale • Interlock code
number shows if a parameter has been changed.
• Total tattletale
i01961377
Note: Factory passwords are only valid for the
Factory Passwords current Cat ET screen. A different set of factory
passwords will be required if you exit the current
SMCS Code: 1901-038 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 Customer Passwords
helps to prevent unauthorized changing of certain
parameters. Passwords prevent unauthorized Customer passwords allow the customer to restrict
erasing of logged events. Passwords allow the access to parameters that can be changed by
factory to control access to engine calibration the customer. The customer passwords cannot
parameters. Passwords allow the customer to be longer than eight characters. The customer
control access to certain engine parameters. passwords may 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 limits and the power rating within an engine family.
have been entered, the changes can then be made. Refer to the diagnostic procedure Troubleshooting,
“System Configuration 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 customer passwords are lost, the
parameters that are protected by customer
In order to obtain the proper factory passwords, passwords cannot be changed. You must use
certain information must be given to an authorized factory passwords in order to read the customer
Caterpillar dealer. Since the factory passwords passwords. You may then use those customer
contain alphabetic characters, the Caterpillar passwords to change parameters that have been
Electronic Technician (ET) can be used to perform 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 i01961508
passwords are actually needed, Cat ET will request
the factory passwords and Cat ET will display the Factory Passwords Worksheet
information that is required to obtain the factory
passwords. SMCS Code: 1901-038

Note: A mistake in recording these parameters will

result in incorrect passwords.
26
Troubleshooting Section

The following information is required to obtain The Caterpillar Electronic Technician (ET) can be
factory passwords: utilized to flash new software into the personality
module in the ECM. This is the preferred method for
Table 7 updating the software. This procedure eliminates
Dealer Code the need to physically remove the personality
module from the ECM. This procedure eliminates
Customer’s Name the risk of moisture entry into the ECM due to
Address improper seal installation. The flash is accomplished
by transferring the data from the personal computer
(PC) to the ECM.

Note: If the PC and Cat ET are not available, the

Telephone Number
personality module can be physically removed and
Information From Engine Information Plate replaced.
Engine Serial Number
Full Load Setting
Programming a Personality Module
with Flash Programming
Full Torque Setting
Information From Engine Hour Meter Note: After you program the personality module, the
operation of the engine is identical to the operation
Engine Hours after you replace the personality module chip. The
Information From Factory Password Entry only difference is the software. The software was
Screen on ET already programmed in the chip when you replaced
the chip. Now, you are actually performing the
Electronic Service Tool programming function.
Serial Number
Engine Serial Number For example, if you are rerating an engine, you will
still need factory passwords to change the interlock
ECM Serial Number
code for the personality module.
Total Tattletale
Reason Code
From Interlock(1)
To Interlock(1)
Factory Passwords
Factory Password (No. 1)
Factory Password (No. 2)
(1) This parameter is required when the engine is being rerated.
This parameter is displayed only when the engine is being
rerated.

i01961516

Flash Programming
SMCS Code: 1901-038

Flash Programming – This is a method of

programming or updating the personality module in
an Electronic Control Module (ECM).
 27
Troubleshooting Section

6. Select the correct file from the list of flash files.

Read the “Description” and the “File Info” in
order to verify that the correct file is selected.
Select “OK”.

7. Select the “Begin Flash” button in order to

program the personality module.

When the flash is completed, this message will

appear: “Flash Completed Successfully”.

8. Check all programmable parameters for correct

settings.

a. Access the “Configuration” screen under

the “Service” menu in order to determine if
any of the parameters require programming.
Look under the “Tattletale” column. All of the
parameters should have a tattletale of 1 or
more. If a parameter has a tattletale of 0,
program that parameter.

b. If a diagnostic code of 268-02 “Check

Programmable Parameters” is generated,
program any parameters that were not in the
old personality module.

9. Start the engine and check for proper operation.

g00647144
Illustration 13
(1) Personal computer “Winflash” Error Messages
(2) 160-0141 Data Link Cable
(3) 171-4401 Communication Adapter II
(4) 160-0133 Data Link Cable “The engine ID in the flash file does not match
the engine ID in the ECM.”
Flash Programming a Personality This message means that the ECM has a personality
Module module for a different engine. For example, the
ECM has a personality module for a 3512B Marine
1. Start the Cat ET. Engine and you are attempting to program another
personality module into the ECM.
2. When possible, write down all of the current
engine parameters. If you receive this message, stop the transfer.
Access the information about the ECM summary
3. Select “WinFlash” from the “Utilities” menu on under the “Information Menu”. Be certain that you
the Cat ET. are transferring the correct file for your engine.

“WinFlash” will try to detect an ECM. “The application ID in the flash file does not
match the application ID in the ECM.”
4. When an ECM has been detected, the “ECM
Selector” window will appear. Select the This message means that the ECM has a personality
appropriate ECM and then select “OK”. module for a different application.

The “Flash File Selection” window will appear. If you receive this message, stop the transfer.
Access the information about the ECM summary
5. The flash files are located on a disk drive and under the “Information Menu”. Be certain that you
in a directory. Select the correct disk drive and are transferring the correct file for your engine.
the directory from “Drives” and “Directories” on
the Cat ET. “The ECM ID in the flash file does not match the
ECM ID in the ECM.”
A list of flash files will appear.
This message means that the ECM is not the correct
ECM for the engine.
28
Troubleshooting Section

If you receive this message, stop the transfer. Acceleration Delay

Access the information about the ECM summary
under the “Information Menu”. Be certain that you When the engine is started, the ECM will limit the
are using the correct ECM for your engine. engine to low idle. The ECM will no longer limit the
engine rpm when the following conditions exist:
Note: If a problem occurs, refer to the documentation
that accompanies Cat ET. • The engine oil pressure is above 70 kPa (10 psi).

i01961525
• The acceleration delay is reached.

System Configuration Programming this parameter to 0 will disable this

function.
Parameters
Note: If the engine is configured to operate in direct
SMCS Code: 1901-038 fuel control mode, this parameter is disabled.

System configuration parameters are parameters Table 9

that affect emissions, power of the engine, and Minimum Default Maximum
other features. The parameters are programmed
at the factory. In most cases, the parameters do 0 seconds 0 seconds 60 seconds
not need to be changed. You must reprogram the
system configuration parameters if the Electronic
Control Module (ECM) is replaced and/or if you Acceleration Ramp Rate
reprogram the engine rating. You do not need to
reprogram the system configuration parameters The acceleration ramp rate is the maximum ramp
if you replace the personality module. Proper rate of the desired engine rpm. The desired engine
values for these parameters are available on the rpm will be set to low idle until the engine rpm
Caterpillar Electronic Technician (ET). Certain reaches 400. When the engine rpm becomes
system configuration parameters are also stamped greater than 400 rpm, desired engine rpm will start
on the engine information plate. increasing until the required desired engine rpm
is reached.
The following functions will be performed with an
engine that has EMCP II: Note: If the engine is configured to operate in “Direct
Fuel Control Mode”, this parameter is disabled.
• Automatic Start/Stop Table 10

• Air shutoff Minimum rpm Default rpm per Maximum rpm

per second second per second
• Cooldown 1 rpm/sec 250 rpm/sec 750 rpm/sec

Note: Changing the parameters that are protected

by factory passwords may cause your Caterpillar Low Idle
warranty to be voided.
The parameter defines the low idle rpm.
Engine Serial Number
Note: If the engine is configured to operate in direct
Program the engine serial number to match the fuel control mode, this parameter is disabled.
engine information plate. The serial number is not
Table 11
programmed on a new ECM.
Minimum Default Maximum
Rated Fuel Position 810 rpm 1000 rpm 1000 rpm

This parameter is used to set engine power. A

factory password is required to change this setting. Cooldown Speed
Table 8 This parameter defines the engine rpm during the
Minimum Default Maximum cooldown period.

Minimum Rack Engine Engine

Dependent Dependent
 29
Troubleshooting Section

Table 12 Crank Terminate Speed

Minimum Default Maximum
This parameter determines the engine rpm that the
810 rpm 1000 rpm 1800 rpm starting motors will disengage.
Table 17
Cooldown Period
Minimum Default Maximum
This parameter defines the duration of engine 100 rpm 400 rpm 500 rpm
operation at the cooldown speed. Programming this
parameter to 0 will disable this function.
Air Shutoff
Note: Program this parameter to 0 if EMCP II is
connected to this system. Problems may result if Programming the parameter to “OFF” will disable
both controls try to perform this function. the air shutoff. Program this parameter to “OFF” if
the function is not being used or installed on this
Table 13 engine. This will prevent diagnostics from being
Minimum Default Maximum
logged.

0 minutes 0 minutes 30 minutes Table 18

Minimum Default Maximum
Prelube Time OFF OFF ON

The parameter sets the amount of time for

prelubrication. Programming this parameter to 0 will Ether Control
disable this function.
Programming this parameter to “OFF” will disable
Table 14 the function. Program this parameter to “OFF” if
Minimum Default Maximum the function is not being used or installed on this
engine. This will prevent diagnostics from being
0 seconds 0 seconds 210 seconds logged.
Table 19
Crank Duration
Minimum Default Maximum
The crank duration determines the amount of OFF OFF ON
time that the starting motors will be engaged.
Programming this parameter to 0 will prevent the
ECM from engaging the starting motors. Engine Cooling System
Note: Program this parameter to 0 if EMCP II is This parameter determines the configuration of the
connected to this system. Problems may result if cooling system. This parameter requires a factory
both controls try to perform this function. password to change.

Table 15 Table 20

Minimum Default Maximum Minimum Default Maximum

0 seconds 0 seconds 60 seconds SCAC SCAC JWAC

Cranking Cycles Fuel Correction Factor

This parameter is the total number of crank cycles The parameter is programmed to a numerical value.
that can be performed. The calculations will be adjusted in accordance
with the numerical value. The parameter requires a
Table 16 factory password to change.
Minimum Default Maximum
CAT Data Link
0 0 10
This parameter determines the engine identification
for the secondary CAT Data Link.
30
Troubleshooting Section

Table 21 Table 24
Minimum Default Maximum Engine Serial Number
Engine Control 1 Engine Control 1 Engine Control 8 ECM Serial Number
Rated Fuel Position
Cold Mode Cylinder Cutout Low Idle Speed

This parameter provides the ability to enable the Acceleration Delay Time
cold mode cylinder cutout. Acceleration Ramp Rate
Table 22 Cooldown Period
Minimum Default Maximum Cooldown Speed
Disabled Disabled Enabled Prelube Time
Crank Duration
Direct Fuel Control Mode Total Number of Crank
Cycles
If you program the parameter to “ON”, you will
enable the direct fuel control mode. The parameter Air Shutoff
requires a factory password to change. This feature Fuel Control
requires special hardware in order to operate
properly. Direct Fuel Control Mode

Table 23 Table 25
Minimum Default Maximum Injector Codes
OFF OFF ON Injector Code (1)
Injector Code (2)
i01961565 Injector Code (3)
Customer Parameters Injector Code (4)
Worksheet Injector Code (5)
Injector Code (6)
SMCS Code: 1901-038
Injector Code (7)
Record the following information before you change
any programmable parameter: Injector Code (8)
Injector Code (9)
Injector Code (10)
Injector Code (11)
Injector Code (12)
Injector Code (13)
Injector Code (14)
Injector Code (15)
Injector Code (16)

Record the following information from the engine

monitoring system.
 31
Troubleshooting Section

ECM Voltage High Exhaust Temperature

Table 26 Table 33
Warning Trip Point Warning Trip Point
Warning Delay Time Warning Delay Time
Derate Trip Point
Engine Oil Pressure
Dlay Time
Table 27
Warning Trip Point Engine Oil Filter Differential Pressure
Warning Delay Time Table 34
Shutdown Trip Point Warning Trip Point
Shutdown Delay Time Warning Delay Time

High Coolant Temperature Fuel Filter Differential Pressure

Table 28 Table 35
Warning Trip Point Warning Trip Point
Warning Delay Time Warning Delay Time
Derate Trip Point
Crankcase Pressure
Derate Delay Time
Shutdown Trip Point Table 36

Shutdown Delay Time Warning Trip Point

Warning Delay Time
Low Coolant Temperature Shutdown Trip Point
Table 29 Shutdown Delay Time
Warning Trip Point
Aftercooler Temperature
Warning Delay Time
Table 37
Engine Overspeed Warning Trip Point
Table 30 Warning Delay Time
Warning Trip Point Derate Trip Point
Warning Delay Time Derate Delay Time
Shutdown Trip Point Shutdown Trip Point
Shutdown Delay Time Shutdown Delay Time

Air Inlet Restriction

Table 31
Warning Trip Point
Warning Delay Time
Derate Trip Point
Derate Delay Time

Altitude
Table 32
Derate Trip Point
32
Troubleshooting Section

i01961571
NOTICE
Replacing the ECM If the personality module and engine application are
not matched, engine damage may result.
SMCS Code: 1901-038

NOTICE Perform the following procedure in order to replace

Care must be taken to ensure that fluids are contained the ECM.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 1. Start the Cat ET.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 2. Print the parameters from the “Configuration”
nent containing fluids. screen on the Cat ET. If a printer is unavailable,
record all of the parameters. Record any logged
Refer to Special Publication, NENG2500, “Caterpillar diagnostic codes and logged event codes for
Tools and Shop Products Guide” for tools and supplies your records.
suitable to collect and contain fluids on Caterpillar
products. 3. Use the “Copy Configuration/ECM Replacement”
feature that is found under the “Service” menu
Dispose of all fluids according to local regulations and on the Cat ET. Select “Load from ECM” in order
mandates. to copy the configuration from the suspect ECM.

Note: If the “Copy Configuration” process fails and

NOTICE the parameters were not obtained in Step 2, the
Keep all parts clean from contaminants. parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
Contaminants may cause rapid wear and shortened plate, but most parameters must be obtained from
component life. the Service Center at the Caterpillar Large Engine
Center.
The Electronic Control Module (ECM) contains no
moving parts. Follow the troubleshooting procedures 4. Remove the ECM.
in this manual in order to be sure that replacing
the ECM will correct the problem. Verify that the a. Turn the keyswitch to the OFF/RESET position.
suspect ECM is the cause of the problem.
b. Disconnect the ECM connectors J1/P1 and
Note: Ensure that the ECM is receiving power J2/P2.
and that the ECM is properly grounded before
a replacement of the ECM is attempted. Refer NOTICE
to the diagnostic functional test Troubleshooting, Use a suitable container to catch any fuel that might
“Electrical Power Supply”. spill. Clean up any spilled fuel immediately.

A spare ECM can be used to determine if the

ECM is faulty. Install a spare ECM in place of the NOTICE
suspect ECM. Transfer the personality module from Do not allow dirt to enter the fuel system. Thoroughly
the suspect ECM to the spare ECM. Program the clean the area around a fuel system component that
parameters for normal operation. The parameters will be disconnected. Fit a suitable cover over discon-
must match the parameters in the suspect ECM. nected fuel system component.
Refer to the following test steps for details. If the
spare ECM resolves the problem, reconnect the c. Remove the fuel lines from the ECM.
suspect ECM. Verify that the problem returns. If the
problem returns, replace the ECM. d. Remove the mounting bolts from the ECM.
Note: The replacement or the spare ECM must e. Disconnect the ECM ground strap from the
have the same serial number suffix as the suspect engine.
ECM. Ensure that the replacement ECM and the
Interlock code for the personality module match the f. If you are flash programming, go to Step 7. If
suspect ECM. Be sure to record the parameters you are physically replacing the personality
from the replacement ECM. Use the “Copy module, proceed to Step 5.
Configuration/ECM Replacement” feature that is
found under the “Service” menu on the Caterpillar
Electronic Technician (ET).
 33
Troubleshooting Section

Note: Flash programming is the preferred method c. Ensure that the ECM mounting hardware is
for replacing the personality module. The personality installed correctly. The fuel lines should not
module can be physically removed, if flash be pulling the ECM. The rubber grommets
programming is unsuccessful. are used to protect the ECM from excessive
vibration. The ECM should be able to drift in
NOTICE the rubber grommets. If the ECM cannot be
Moisture entry into the ECM from improper servicing moved slightly in the grommets, check that
can result in ECM failure. the fuel lines are not pulling the ECM against
one side of the grommets.

5. Remove the personality module from the old d. Install the ECM ground strap on the engine.
ECM.
e. Reconnect ECM connectors J1/P1 and
a. Remove the tag wire from the back cover of J2/P2. Tighten the allen head screws on the
the ECM. connectors to a torque of 2.25 N·m (20 lb in).

b. Remove the bolts from the back cover of the f. If the personality module has been physically
ECM. replaced, go to Step 9. If you are flash
programming, continue to Step 8.
c. Remove the O-ring seal from the cover.
8. Flash program the personality module into
d. Remove the personality module by squeezing the ECM. Refer to the diagnostic procedure
the tabs on the ends of the blue plastic case. Troubleshooting, “Flash Programming” for the
Pull the module straight out of the ECM. correct procedure.

NOTICE 9. Use the Cat ET to match the engine application

Improper O-ring placement could result in moisture and the Interlock code for the personality module
damage from improper sealing. Do not over tighten if the replacement ECM was used for a different
bolts! This could result in damaged threads and mois- application.
ture damage from improper sealing.
10. Configure the ECM.

6. Install the personality module into the a. If the “Copy Configuration” process from
replacement ECM. Step 3 was successful, return to the “Copy
Configuration/ECM Replacement” screen on
a. Carefully seat the personality module in the the Cat ET and select “Program ECM”. Go
EPROM carrier socket. to Step 12.

Note: Do not use excessive force to insert the b. If the “Copy Configuration” process was
module into the socket. The socket will accept the unsuccessful, program the ECM parameters.
personality module in only one position. A click is The parameters should match the parameters
audible when the personality module is inserted from Step 2.
correctly.
Note: If the “Copy Configuration” process fails and
b. Install the O-ring seal for the cover of the the parameters were not obtained in Step 2, the
personality module. parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
c. Install the access cover for the personality plate, but most parameters must be obtained from
module on the ECM. Tighten the cover bolts the Service Center at the Caterpillar Large Engine
for the personality module to a torque of Center.
1.36 N·m (12 lb in).
c. If necessary, program the engine monitoring
7. Install the replacement ECM. system.

a. Use the old mounting hardware to install 11. Calibrate the injection timing. Refer to the
the replacement ECM. Make sure that the calibration procedure Troubleshooting, “Engine
mounting hardware is free of damage. Speed/Timing Sensor - Calibrate”.

b. Reconnect the fuel lines. 12. Check for diagnostic codes and event codes.
34
Troubleshooting Section

Troubleshooting without a • Determine if the “LOGGED” diagnostic codes

correlate to probable causes.
Diagnostic Code
• Determine if the “LOGGED” diagnostic codes
occur at the same time as the symptoms.
i01953471

Symptoms • Determine if the“LOGGED” diagnostic codes

are logged repeatedly.
SMCS Code: 1000-038; 1901-038 If these inspections do not reveal any problems, use
the procedure that best describes the symptoms.
Some engine symptoms can be unrelated to the
electronic control system. Gather information about
the complaint that describes the symptoms. Verify i01953472
that the complaint is not due to normal engine
operation. Repair all “ACTIVE” diagnostic codes. Alternator
Perform the following steps in order to determine SMCS Code: 1405-035
the problem.
The probable root causes are listed below:
1. Gather operator information.
• The alternator is not charging the battery.
2. Verify that the complaint is not due to normal
engine operation. • The battery charge is low.
3. Perform a visual inspection of the engine. Inspect • The battery charge is high.
the following items:
• Noisy operation
• Wiring
Perform the following checks:
• Connectors
1. Loosen the drive belts on the alternator. Adjust
• Fuel level the drive belt tension. Inspect all of the cables
and the connections. Clean the connections and
• Fuel supply tighten the connections. Replace faulty parts.
Inspect the rotor. Install a new rotor.
• Engine oil level
2. Inspect the rectifier diodes. Replace the diode.
• Engine oil supply
3. Inspect the alternator for loose connections.
• Coolant level Tighten all connections to the alternator. Inspect
the regulator. If a replacement is required, the
• Intake air system alternator must be disassembled.

• Air shutoff valves 4. Inspect the drive belts. Install new drive belts.
Loosen the drive pulley. Tighten the pulley. Refer
• Air exhaust system to the Specifications manual. If the belt and the
pulley are misaligned, adjust the belt and the
4. Check the wiring and the connectors for the pulley. If the alternator bearings are worn, install
following problems: new bearings.

• Damage 5. If the problem is still present, refer to Special

Instruction, REHS0354, “Charging System
• Abrasion Troubleshooting”.

• Corrosion
• Incorrect attachment
5. Check for any “LOGGED” diagnostic codes.
 35
Troubleshooting Section

i01953473 4. Check fuel lines for the following problems:

restrictions, collapse, and pinched line. Repair
Can Not Reach Top Engine the lines and/or replace the lines.
RPM
a. Check the fuel tank for foreign objects which
SMCS Code: 1000-038; 1901-038 may block the fuel supply. Check for air leaks
in the suction line of the fuel pump. Check
Note: If this problem occurs under load, refer to for air in the low pressure fuel supply system
the diagnostic procedure Troubleshooting, “Low after you perform the following procedures:
Power/Poor Or No Response To Throttle”.
• Replacing the fuel filters
The probable root causes are listed below:
• Working on the low pressure fuel supply
• Derated engine circuit

• Personality module • Replacing fuel injectors

• Throttle signal b. Purge air from the low pressure fuel supply
circuit with the hand priming pump and by
• Fuel supply cranking the engine in 30 second cycles.
After you crank the engine, stop for two
• Air inlet restriction minutes. This will allow the starting motor to
cool. Loosen the vent plug on the fuel return.
• Exhaust restriction The plug is located on the rear upper left side
of the engine block. Hand prime the engine
• Leaks in air system again if air in fuel continues. A sight glass
in the low pressure supply line is helpful in
• Valve adjustment diagnosing air in the fuel.

• Injectors c. Check fuel quality. In temperatures below 0 C

(32 F), check for solidified fuel (wax). Refer
• Faulty accessory equipment to Special Publication, SEBD0717, “Diesel
Fuels And Your Engine”.
Perform the following checks:
d. Check the fuel pressure with the engine
1. Connect the Caterpillar Electronic Technician cranking. Check the fuel pressure at the filter.
(ET) and check for an active derate event. A If the pressure is low, check for plugged fuel
derate status flag will appear on Cat ET if an filters. If the fuel pressure is still low, check
active engine derate is occurring. In order to the following items: fuel transfer pump, fuel
view active events, go to the “Events” menu transfer pump coupling, and fuel pressure
under “Diagnostics”. The engine speed might regulating valve. Check for a combustion
be limited due to one of the following possible problem.
causes: altitude, exhaust temperatures that are
high, high coolant temperature, air filter restriction 5. Check the air inlet system for restrictions and/or
pressure, aftercooler water temperature, and for leaks.
crankcase pressure.
6. Leaks in the air inlet manifold system can lower
2. Verify that the correct personality module is Inlet manifold pressure.
installed. Refer to the diagnostic procedure
Troubleshooting, “System Configuration 7. Check the exhaust system for restrictions and/or
Parameters”. for leaks.

3. Use Cat ET in order to monitor the status of the 8. Check the air filter restriction indicator. Replace
throttle. Observe the throttle position. The throttle plugged air filters and/or clean the filters.
position should be stable. The throttle position
should reach 100 percent. Perform one of the 9. Check the valve lash setting.
following applicable diagnostic functional test:

• Troubleshooting, “Throttle Position Sensor”

• Troubleshooting, “Speed Control”
• Troubleshooting, “Throttle Switch”
36
Troubleshooting Section

10. Use Cat ET to determine if any active diagnostic i01953489

codes are present for the injector solenoids.
Perform the “Injector Solenoid Test”. Observe Coolant Temperature Is Too
that the injector solenoids are being energized High
on Cat ET. Perform the “Cylinder Cutout Test”.
Locate the misfiring cylinder. Refer to the SMCS Code: 1350-038; 1901-038
diagnostic functional test Troubleshooting,
“Injector Solenoids”. The probable root causes are listed below:
11. Check attached accessory equipment. Ensure • Radiator
that the accessory equipment is not lugging
down the engine. • Low coolant level

i01941409 • Coolant leak

Coolant in Engine Oil • Faulty engine cooling fan (if equipped)
SMCS Code: 1300-038; 1901-038 • Faulty pressure relief valve
The probable root causes are listed below: • Cooling system
• Failure of any of the oil cooler cores • Faulty temperature gauge
• Failure of cylinder head gasket • Faulty jacket water coolant pump
• Crack in cylinder head • Too much load on the system
• Cracked cylinder liner Perform the following checks:

• Cylinder liner seals 1. Check the cooling fins on the radiator for dirt
and/or for debris. Remove the dirt and/or debris.
• Water pump
a. Check the cooling fins on the radiator for
Perform the following checks: damage. Refer to the Testing and Adjusting
manual for instructions for testing and
1. Inspect the oil cooler for leaks. Drain the inspecting the cooling system.
crankcase. Refill the crankcase with clean
lubricant. Install new oil filters. b. Check the radiator for internal blockage.
Check the temperature difference between
2. Check the cylinder head gasket. the top and the bottom of the radiator.

3. Check for cracks in the cylinder head. Repair 2. Inspect the coolant level. If necessary, add
the cylinder head and/or replace the cylinder coolant.
head. Repair the cylinder block and/or replace
the cylinder block. 3. Check the cooling system for leaks.

4. Check the cylinder liner for cracks. Use a a. Inspect the coolant for presence of bubbles.
borescope to check the cylinder liner. Tighten
the bolts that hold the cylinder head according b. Check the cooling system for combustion
to the Specifications Manual. gases. Inspect the cylinder liners for cracks.

5. Check the liner water seals in the spacer plate. 4. Check for proper operation of the cooling fan.
Check the bottom seals on the liner for damage. Check the fan drive belts for correct tension.
Check applicable drive belts, pumps, speed
6. Check the weep hole in the water pump for sensors and/or control solenoids for proper
blockage. Check the water pump seals for operation.
leakage.
5. Connect the Caterpillar Electronic Technician
(ET) and monitor the cooling fan.
 37
Troubleshooting Section

6. Check operation of the pressure relief valve and 3. Verify that the following items are correct
the radiator cap. If necessary, clean the pressure and that the items are entered correctly: total
relief valve and/or the radiator cap. Check that tattletale, reason code, serial number for Cat
the seating surface of the valve is clean and ET, serial number for the ECM , and engine
undamaged. If necessary, install new parts. serial number. Refer to the diagnostic procedure
Troubleshooting, “Factory Passwords” for more
7. Pressure test the cooling system. details.

a. Check the radiator for contaminants. Clean

i01708891
the radiator and flush the radiator.

8. Check the water temperature regulators for

ECM Will Not Communicate
correct operation. with Other Systems or Display
a. Check the temperature gauge for correct
Modules
operation. If necessary, install new parts.
SMCS Code: 1901-038
9. Inspect the impeller vanes at the jacket water
The probable root causes are listed below:
pump for damage and/or for erosion. Repair
impeller vanes and/or replace the impeller vanes.
• Electronic Control Module (ECM)
10. Check that the engine is not loaded beyond
design. • Connector or wiring problem
• CAT Data Link
i01953492
Perform the following checks:
ECM Will Not Accept Factory
1. Connect the Caterpillar Electronic Technician
Passwords (ET). If the ECM does not communicate with the
Cat ET, perform the diagnostic functional test
SMCS Code: 1901-038
Troubleshooting, “Electronic Service Tool Will Not
Communicate With ECM”.
The probable root causes are listed below:
2. Check for correct installation of the ECM
• Incorrect password connectors J1/P1, J2/P2 and J3A/P3A,
J3B/P3B. Refer to the diagnostic functional
• Incorrect engine serial number test Troubleshooting, “Inspecting Electrical
Connectors”.
• Incorrect serial number for the Electronic Control
Module (ECM)
3. Refer to the diagnostic functional test
Troubleshooting, “CAT Data Link”.
• Incorrect serial number for the Caterpillar
Electronic Technician (ET)
i01953493
• Total tattletale
Electronic Service Tool Will
• Reason code Not Communicate with ECM
Perform the following checks:
SMCS Code: 1901-038
1. Check that each password was copied correctly. The probable root causes are listed below:
Verify that the passwords were entered correctly.
Check for proper letters in each password. Cycle
the power. Wait for 30 seconds and then retry. • Connector or wiring problem

2. Verify that the engine serial number that is used to • Communication adapter and/or cable
calculate the password is typed correctly. Refer
to the diagnostic procedure Troubleshooting, • Battery voltage
“Factory Passwords” for more details.
• Service tool connector
• Personality module
• CAT Data Link
38
Troubleshooting Section

• Electrical power supply to the Electronic Control i01953495

Module (ECM)
Engine Cranks but Will Not
Perform the following checks: Start
1. Check for correct installation of the ECM SMCS Code: 1000-038; 1901-038
connector(s) J1/P1 and/or J2/P2 and service
tool connector J60/P60 or J31/P31. Refer to The probable root causes are listed below:
the diagnostic functional test Troubleshooting,
“Inspecting Electrical Connectors”. • Electrical power supply
2. Disconnect the communication adapter from the • Low fuel level
ECM. Reconnect the communication adapter to
the ECM. • Fuel supply
a. Verify that the correct cable from the • Starting aids (if applicable)
communication adapter to the ECM is being
used. Refer to the diagnostic procedure • Cranking speed
Troubleshooting, “Electronic Service Tools”.
• Shutdown switch
3. Verify that battery voltage is present at pin-A
and pin-B of the service tool connector. If the • Active engine shutdown
communication adapter tool is not receiving
power, the display will be blank. • Electrical connectors
4. In order to eliminate the service tool as the • Circuit breakers
problem, verify if the problem can be repeated
with another engine. If the problem can be • Personality module
repeated with another engine, check the
communication adapter and cable. Refer to • Engine speed/timing sensor
Operating Manual, SEHS9264. If the problem
can not be repeated with another engine, refer • Injector solenoid
to the diagnostic functional test Troubleshooting,
“CAT Data Link”. • Air shutoff (if applicable)
5. Check for correct installation of the ECM Perform the following checks:
personality module.
1. Measure the voltage at the connector of the
Note: If the personality module has not been Electronic Control Module (ECM). If the ECM is
installed or the personality module is a blank, new not receiving battery voltage, the ECM will not
personality module, the engine will not start. The power up. Refer to the diagnostic functional test
ECM will not communicate with the Caterpillar Troubleshooting, “Electrical Power Supply”.
Electronic Technician (ET). Refer to the diagnostic
procedure Troubleshooting, “Programming 2. Visually check the fuel level. If necessary, add
Parameters”. fuel. Ensure the proper operation of the jacket
water heater. Repair the jacket water heater
6. Check power to the ECM. Refer to the diagnostic and/or replace the jacket water heater. Check for
functional test Troubleshooting, “Electrical Power the presence of solidified fuel (wax).
Supply”.
3. Check the fuel system. Check fuel lines for
Note: If the ECM is not receiving 24 VDC, the ECM the following problems: restrictions, collapse,
will not communicate. pinched line, and loose fittings. Repair the lines
and/or replace the lines.

a. Check the fuel tank for foreign objects which

may block the fuel supply. Check for air in
the low pressure fuel supply system after you
perform the following procedures:

• Replacing the fuel filters

 39
Troubleshooting Section

• Working on the low pressure fuel supply 9. The circuit breakers may exceed the trip point
circuit due to overheating. Check the circuit breakers
on the machine. Reset the circuit breakers if the
• Replacing fuel injectors circuit breakers are tripped.

b. Purge air from the low pressure fuel supply 10. If the diagnostic code 253-02 is present, refer
circuit with the hand priming pump and by to the diagnostic procedure Troubleshooting,
cranking the engine in 30 second cycles. “ECM/Personality Module”.
After you crank the engine, stop for two
minutes. This will allow the starting motor to 11. Crank the engine and observe the engine
cool. Loosen the vent plug for the fuel return rpm on Cat ET. If engine rpm is 0, refer to
line. The plug is located on the rear upper the diagnostic functional test Troubleshooting,
left side of the engine block. Hand prime the “Engine Speed/Timing Sensor”.
engine again if air in fuel continues. A sight
glass in the low pressure supply line is helpful a. Ensure that the timing reference gear is
in diagnosing air in the fuel. installed correctly. The engine will not start if
the gear was installed backward. Check for
c. Check fuel quality. In temperatures below 0 C proper orientation between the crankshaft and
(32 F), check for solidified fuel (wax). Refer camshaft drive gears. Correct the orientation
to Special Publication, SEBD0717, “Diesel and/or replace the drive gear. Refer to
Fuels And Your Engine”. Check the fuel Disassembly and Assembly Manual.
pressure while the engine is cranking. Check
the fuel pressure at the filter. If the pressure 12. Perform the “Injector Solenoid Test”. Verify
is low, check for plugged fuel filters. If the that the ECM is energizing all the injector
fuel pressure is still low, check the following solenoids. Refer to the diagnostic functional test
items: fuel transfer pump, fuel transfer pump Troubleshooting, “Injector Solenoids”.
coupling, and fuel pressure regulating valve.
13. Verify that both of the air shutoff valves are
4. If equipped, check the operation of the ether open and that both of the air shutoffs are in the
starting aids. Replace the ether canister if the starting position.
ether is low. Refer to the diagnostic functional
test Troubleshooting, “Ether Injection System”. 14. Check for a problem with the combustion
system.
5. Check the cranking speed of the starter.
i01953502
6. The shutdown switch should be in the OFF
position. Connect the Caterpillar Electronic
Technician (ET). Use Cat ET in order to verify
Engine Has Early Wear
the status of the shutdown switch. If the Cat SMCS Code: 1000-038; 1901-038
ET will not communicate with the ECM, refer
to the diagnostic procedure Troubleshooting, The probable root causes are listed below:
“Electronic Service Tool Will Not Communicate
with ECM”. When a shutdown occurs, the
keyswitch must be turned to the OFF position.
• Dirt in lubrication oil
The keyswitch must then be turned to the ON
position before the engine will start.
• Leaks in air inlet system

7. Use Cat ET to determine if any active shutdowns

• Fuel dilution
are present. If a Shutdown is “ACTIVE”,
determine the reason. After you correct the
• Low oil pressure
problem, turn the keyswitch to the OFF position Perform the following checks:
for at least 15 seconds before you try to restart
the engine. 1. Determine the cause of the oil contamination and
eliminate the cause of the oil contamination.
8. Check for correct installation of the following
components: ECM connectors J1/P1 and a. Remove dirty lubrication oil.
J2/P2, customer connector, connector for the
engine speed/timing sensor, and fuel injector b. Install new oil filters.
connectors. Refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical c. Put clean oil in the engine.
Connectors”.
40
Troubleshooting Section

2. Check for leaks in the air inlet system. Eliminate a. Use Cat ET in order to monitor the temperature
any air leaks that bypass the filters of the air of the coolant. If the reading is incorrect,
inlet. Repair the leaks. refer to the diagnostic functional test
Troubleshooting, “Engine Sensor Open/Short
3. Check the bypass valve spring at the oil filter. Test”.
Ensure that the bypass valve is operating
correctly. Ensure that the bypass valve is not 2. Use Cat ET in order to monitor the status of
stuck in the open position. the throttle. Observe the throttle position. The
throttle position should be stable. The throttle
4. Inspect the quality of the fuel that is being used. position should reach 100 percent. Perform the
Ensure that all fuel filters are operating correctly. appropriate diagnostic functional test for your
application:
5. Inspect all gaskets and connections. Repair any
leaks. • Troubleshooting, “Throttle Position Sensor”

i01953503
• Troubleshooting, “Speed Control”

Engine Misfires, Runs Rough • Troubleshooting, “Throttle Switch”

or Is Unstable 3. Check for correct installation of the connector(s)
for the Electronic Control Module (ECM)
SMCS Code: 1000-038; 1901-038 J2/P2 and/or J1/P1 and electronic fuel injector
connectors. Refer to the diagnostic functional
Note: If the symptom cannot be repeated, refer to test Troubleshooting, “Inspecting Electrical
the diagnostic procedure Troubleshooting, “Low Connectors”.
Power/Poor or No Response to Throttle”. If the
symptom can be repeated, continue with this 4. Use Cat ET to determine if any active diagnostic
procedure. codes are present for the injector solenoids.
Check that the injector trim codes have been
The probable root causes are listed below: entered. Use Cat ET to determine if any logged
diagnostic codes are present for the injector
• Cold mode operation solenoids. Perform the “Injector Solenoid Test”.
Observe that the injector solenoids are being
• Throttle input signal energized on Cat ET. Perform the “Cylinder
Cutout Test”. Locate the misfiring cylinder. Refer
• Electrical connector to the diagnostic functional test Troubleshooting,
“Injector Solenoids”.
• Injector
5. Check fuel lines for the following problems:
• Fuel supply restrictions, collapse, pinched line, and loose
fittings. Repair the lines and/or replace the lines.
• Air inlet restrictions
a. Check the fuel tank for foreign objects which
• Exhaust restrictions may block the fuel supply. Check for air in
the low pressure fuel supply system after you
• Air shutoff (if applicable) perform the following procedures:

• Valve adjustment • Replacing the fuel filters

Note the conditions that caused the problem. • Working on the low pressure fuel supply
Troubleshooting the symptoms under other circuit
conditions can give misleading results.
• Replacing fuel injectors
Perform the following checks:

1. Use the Caterpillar Electronic Technician (ET) in

order to verify that the engine has exited cold
mode. During cold mode, fuel injection timing is
modified. The cylinders may cut out. Cold mode
cylinder cutouts may cause variations in vibration
and available power. This is normal operation.
 41
Troubleshooting Section

b. Purge air from the low pressure fuel supply i01953515

circuit with the hand priming pump and by
cranking the engine in 30 second cycles. Engine Stalls at Low RPM
After you crank the engine, stop for two
minutes. This will allow the starting motor to SMCS Code: 1000-038; 1901-038
cool. Loosen the vent plug at the fuel return.
The plug is located on the rear upper left side The probable root causes are listed below:
of the engine block. Hand prime the engine
again if air in fuel continues. A sight glass • Faulty fuel injector(s)
in the low pressure supply line is helpful in
diagnosing air in the fuel. • Low fuel pressure
c. Check fuel quality. In temperatures below 0 C • Air shutoffs (if applicable) or blocked air supply
(32 F), check for solidified fuel (wax). Refer
to Special Publication, SEBD0717, “Diesel • Low engine idle
Fuels And Your Engine”. Check the fuel
pressure with engine cranking. Check the fuel • Faulty engine accessories
pressure at the filter. If pressure is low, check
for plugged fuel filters. If the fuel pressure Perform the following checks:
is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, 1. Check for correct installation of the connector(s)
and fuel pressure regulating valve. Check for of the Electronic Control Module (ECM) J1/P1
a problem with the combustion system. and/or J2/P2 and fuel injector connectors. Repair
the connector and/or replace the connector. Refer
6. Check for restrictions in the air inlet system. to the diagnostic functional test Troubleshooting,
Refer to the Testing and Adjusting manual for “Inspecting Electrical Connectors”.
information on the air inlet and exhaust systems.
2. Check for active diagnostic codes. Check
7. Check for restrictions in the exhaust system. for logged diagnostic codes. Perform the
“Injector Solenoid Test”. Verify that the ECM is
8. Check that both air shutoff valves are open. energizing all the injector solenoids. Refer to
the diagnostic functional test Troubleshooting,
9. Check the valve lash adjustment. “Injector Solenoids”.

3. Check fuel lines for the following problems:

i01953514 restrictions, collapse, pinched line, and loose
fittings. Repair the lines and/or replace the lines.
Engine Oil in Cooling System
4. Check the fuel tank for foreign objects which may
SMCS Code: 1350-038; 1901-038 block the fuel supply. Check for air in the low
pressure fuel supply system after you perform
The probable root causes are listed below: the following procedures:
• Faulty engine oil cooler core • Replacing the fuel filters
• Failure of cylinder head gasket or water seals • Working on the low pressure fuel supply circuit
• Water pump • Replacing fuel injectors
Perform the following checks: 5. Purge air from the low pressure fuel supply circuit
with the hand priming pump and by cranking the
1. Inspect each engine oil cooler core. Replace the engine in 30 second cycles. After you crank the
engine oil cooler or repair the engine oil cooler. engine, stop for two minutes. This will allow the
starting motor to cool. Loosen the fuel return vent
2. Check the cylinder liner projection. Install a new plug. The plug is located on the rear upper left
cylinder head gasket and new water seals in the side of the engine block. Hand prime the engine
spacer plate. Tighten the cylinder head bolts again if air in fuel continues. A sight glass in the
according to the Specifications manual. low pressure supply line is helpful in diagnosing
air in the fuel.
3. Check the weep hole in the water pump for
blockage. Check the water pump seals for
leakage.
42
Troubleshooting Section

6. Check fuel quality. In temperatures below 0 C 1. Ensure that the ground level shutdown switch is
(32 F), check for solidified fuel (wax). Refer to in the OFF position. Ensure that the user defined
Special Publication, SEBD0717, “Diesel Fuels shutdown switch is in the OFF position. Use the
And Your Engine”. Check the fuel pressure with Caterpillar Electronic Technician (ET) to monitor
engine cranking. Check the fuel pressure at the the status of the switches for proper operation.
filter. If pressure is low, check for plugged fuel
filters. If the fuel pressure is still low, check the 2. Use Cat ET to monitor the status of the engine.
following items: fuel transfer pump, fuel transfer Check for “ACTIVE” shutdowns due to shutdown
pump coupling, and fuel pressure regulating switches. Determine the cause for the “ACTIVE”
valve. Check for a combustion problem. shutdown and make any repairs necessary.

7. Check for restrictions in the air inlet system. 3. Test the operation of the switch that indicates that
Refer to the Testing and Adjusting manual for the transmission is in neutral gear. Ensure that
information on the air inlet and exhaust systems the machine is in neutral gear before attempting
for your engine. to start the engine.

8. Check that both air shutoff valves are in the 4. Ensure that the crank enable switch is not
OPEN position. faulty. Measure the voltage across the 9X-8124
Magnetic Switch between pin 3 and pin 4. The
9. Check the setting for the low engine idle. voltage should be 24 ± 3 VDC. If the voltage is
not within this range, something is wrong with the
10. Check all flywheel and damper driven accessory circuit. Check the wiring.
equipment for proper operation. Ensure that the
accessory equipment is not lugging down the 5. Check the following items for loose connections
engine. and for corrosion: master disconnect switch,
battery posts, battery, and battery cables. Clean
the cables and/or connections if corrosion is
i01953516
found. Load test the battery. Refer to Special
Engine Will Not Crank Instruction, SEHS9249, “Use Of 4C4911 Battery
Load Tester” for more information. If necessary,
SMCS Code: 1000-038; 1901-038 charge the batteries. Refer to Special Instruction,
SEHS7633, “Battery Test Procedure”.
The probable root causes are listed below:
6. Check the operation of the engine start switch.
Monitor the engine start switch on Cat ET. The
• Ground level shutdown switch or user defined engine start switch may be one of the following
shutdown switch (if applicable)
types:
• Shutdown switch
• Engine Control Switch (ECS)
• The machine is in gear (if applicable).
• Start/Run/Stop switch
• Faulty crank enable switch (if applicable)
• Keyswitch
• Battery cables and/or batteries Refer to the appropriate troubleshooting test
that is applicable to your engine if repairs are
• Engine start switch required.
• Prelubrication system (if applicable) 7. If equipped, inspect the prelubrication system for
proper operation.
• Starting motor
8. If equipped, test the operation of the air starting
• Flywheel ring gear motor. Check the system wiring to the air starting
motor.
• Engine accessories
a. If equipped, test the operation of the electric
• Hydraulic cylinder lock starting motor. Check the system wiring to the
electric starting motor.
• Internal engine problem
Perform the following checks:
 43
Troubleshooting Section

Refer to the appropriate troubleshooting test 2. Check the crankcase breather(s) for restrictions
for the starting system that is installed on your and/or for debris. If necessary, clean the
engine. Refer to the service manual Testing crankcase breather.
and Adjusting for more information on your
starting system. 3. Inspect the engine oil level. Remove any extra
oil from the engine. Verify that there is a correct
9. Ensure that the timing pin is not left in the amount of oil in engine.
flywheel housing after you set the valve lash. Use
the 9S-9082 Engine Turning Tool and attempt to 4. Check for leaks in the engine oil cooler. Check
manually turn the engine. for oil in the engine coolant. If necessary, repair
the engine oil cooler.
10. Inspect the engine accessories if the engine will
not turn. Remove the engine accessories and 5. Check for oil leakage past the seal rings in
inspect the engine accessories that can lock the impeller end of the turbocharger shaft. If
up the engine. Repair the engine accessories necessary, repair the turbocharger.
and/or replace the engine accessories.
6. Reconditioning of the cylinder head may be
11. Remove injectors and check for fluid in the required. If necessary, install new parts.
cylinders.
7. Inspect the valve guides and valve stems for
12. Disassemble the engine. Inspect the engine wear. If necessary, install new parts.
for internal component damage. Refer to
Disassembly and Assembly Manual. 8. Inspect the pistons and piston rings for wear
or for damage. If necessary, install new parts.
Inspect the oil return holes in the piston for
i01953560
blockage.
Excessive Engine Oil 9. Check the installation of the compression ring
Consumption and the intermediate ring. If necessary, install
new parts.
SMCS Code: 1300-038; 1901-038

The probable root causes are listed below: i01953561

• Leaking engine oil

Excessive Black Smoke
SMCS Code: 1000-038; 1901-038
• Crankcase breather
The probable root causes are listed below:
• Engine oil level
• Air shutoff (if applicable)
• Engine oil cooler
• Leaking fuel injector
• Air breather
• Air inlet restriction
• Turbocharger
• Cylinder head • Exhaust restriction
• Turbocharger
• Valve guides and valve stems
• Incorrect calibration of the engine speed/timing
• Pistons, piston rings, or dirty oil return holes in sensor
the piston
• Personality module
• Incorrect installation of the compression ring
and/or the intermediate ring
• Rated fuel position
Perform the following checks:
• Fuel Ratio Control (FRC)
1. Inspect the engine for oil leaks. Repair all leaks
that were found. • Atmospheric pressure sensor
• Fuel supply
Perform the following checks:
44
Troubleshooting Section

1. Check that both the air shutoffs are open. 9. Check the atmospheric pressure sensor for dirt
and/or for debris. Remove the dirt and/or the
2. Check that the injector trim codes have been debris. The atmospheric pressure should be
entered. Perform the “Cylinder Cutout Test”. between 50 kPa (7.2 psi) and 100 kPa (14.5 psi).
Use similar conditions for the test that were The atmospheric pressure will vary depending
experienced during operation. Refer to the on your altitude. If there is an active diagnostic
diagnostic functional test Troubleshooting, code, perform the diagnostic functional test
“Injector Solenoids”. Troubleshooting, “Engine Sensor Open/Short
Test”.
a. Cut out the individual cylinder for 30 seconds
to 1 minute. Verify that the smoke decreases. 10. Check fuel lines for the following problems:
restrictions, collapse, pinched line, and loose
3. Connect the Caterpillar Electronic Technician fittings. Repair the lines and/or replace the lines.
(ET). Check the atmospheric pressure reading.
Check the turbocharger inlet pressure. a. Check the fuel tank for foreign objects which
may block the fuel supply. Check for air in
a. Check the air inlet system for restrictions the low pressure fuel supply system after you
and/or for leaks. Remove any restrictions. perform the following procedures:
Repair any leaks that are found.
• Replacing the fuel filters
b. Replace plugged air filters and/or clean the
filters. • Working on the low pressure fuel supply
circuit
4. Check for restrictions in the exhaust system.
• Replacing fuel injectors
5. Verify that the turbocharger has not
failed. Periodic inspection and cleaning is b. Purge air from the low pressure fuel supply
recommended for the turbocharger compressor circuit with the hand priming pump and by
housing (inlet side). cranking the engine in 30 second cycles.
After you crank the engine, stop for two
6. Check the calibration of the engine speed/timing minutes. This will allow the starting motor to
sensor. If there is an active diagnostic cool. Loosen the vent plug at the fuel return.
code, then refer to the calibration procedure The plug is located on the rear upper left side
Troubleshooting, “Engine Speed/Timing Sensor - of the engine block. Hand prime the engine
Calibrate”. again if air in fuel continues. A sight glass
in the low pressure supply line is helpful in
7. Verify that the correct personality module is diagnosing air in the fuel.
installed. Refer to the diagnostic procedure
Troubleshooting, “System Configuration c. Check fuel quality. In temperatures below 0 C
Parameters”. (32 F), check for solidified fuel (wax). Refer to
Special Publication, SEBD0717, “Diesel Fuels
8. Monitor the turbocharger compressor outlet And Your Engine”. Check the fuel pressure
pressure and the atmospheric pressure with Cat with engine cranking. Check the fuel pressure
ET. If there is an active diagnostic code, perform at the filter. If the fuel pressure is low, check
the diagnostic functional test Troubleshooting, for plugged fuel filters. If the fuel pressure
“Engine Sensor Open/Short Test”. Operate the is still low, check the following items: fuel
engine under full load. Use Cat ET in order transfer pump, fuel transfer pump coupling,
to monitor the following values: turbocharger and fuel pressure regulating valve. Check for
compressor outlet pressure, fuel position, rated a combustion problem.
fuel position, and Fuel Ratio Control (FRC). The
fuel position should equal the rated fuel position.
i01953562
The FRC fuel position should be greater than the
rated fuel position. Excessive White Smoke
Note: A problem with the FRC will only cause black SMCS Code: 1000-038; 1901-038
smoke during acceleration. A problem with the FRC
will not cause black smoke during steady state Note: Some white smoke may be present during
operation. cold start-up conditions when the engine is
operating normally.
 45
Troubleshooting Section

The probable root causes are listed below: 5. Perform the “Cylinder Cutout Test”. Use similar
conditions for the test that were experienced
• Starting aids (if applicable) during operation. Refer to the diagnostic
functional test Troubleshooting, “Injector
• Coolant temperature sensor Solenoids”.

• Coolant temperature regulator a. Cut out the individual cylinder for 30

seconds to one minute. Verify that the smoke
• Engine speed/timing sensor decreases.

• Fuel injector 6. Verify that the correct personality module is

installed. Refer to the diagnostic procedure
• Personality module Troubleshooting, “System Configuration
Parameters”.
• Fuel supply
7. Inspect the fuel system components. Check for
• Component wear correct fuel pressure. Check fuel quality. Low
cetane fuel can create white smoke. Replace the
• Cooling system fuel with a higher cetane fuel. In temperatures
below 0 C (32 F), check for solidified fuel (wax).
Perform the following checks: Refer to Special Publication, SEBD0717, “Diesel
Fuels And Your Engine”.
1. If equipped, check for proper operation of
installed starting aids. Check for proper operation 8. Check the engine for the following problems:
of the jacket water heater. Repair the jacket water excessive valve wear, piston wear, ring wear,
heater or replace the jacket water heater. liner wear, low cranking speed, and reduced
compression pressure.
a. Ensure that the ether canister is not empty
and/or low. Replace the ether canister if the 9. Check for a coolant leak. Check the cooling
ether canister is empty and/or low. system for coolant in the cylinders and for
coolant in the exhaust system.
b. Actuate the system manually after start-up
and observe results. The ether system will
i01953572
not operate if the coolant temperature is too
high. Refer to the diagnostic functional test
Troubleshooting, “Ether Injection System”.
Exhaust Temperature Is Too
High
2. Use the Caterpillar Electronic Technician (ET) in
order to verify that the engine has exited cold SMCS Code: 1050-038; 1901-038
mode. Use Cat ET in order to monitor the coolant
temperature. If the reading is incorrect, refer to The probable root causes are listed below:
the diagnostic functional test Troubleshooting,
“Engine Sensor Open/Short Test”. • Exhaust restriction
3. Verify that the engine reaches full operating • Engine speed/timing sensor
temperature. If the engine does not reach full
operating temperature, a water temperature • Electrical connectors
regulator may be stuck open. Remove the water
temperature regulator and inspect the water • Injector
temperature regulator. If necessary, repair the
water temperature regulator and/or replace the • Air leak
coolant temperature regulator.
• Aftercooler
4. Check the calibration of the engine speed/timing
sensor. Refer to the calibration procedure • Accessory equipment
Troubleshooting, “Engine Speed/Timing Sensor -
Calibrate”. Perform the following checks:

a. Verify that the crankshaft and camshaft drive 1. Check for exhaust restrictions.
gears are set with the proper orientation.
Refer to Disassembly and Assembly Manual.
46
Troubleshooting Section

2. Check the Caterpillar Electronic Technician (ET) 2. Inspect the fuel injector for damage. If necessary,
for the following logged Diagnostic Codes: replace the fuel injector.
190-02 and 190-08. Refer to the diagnostic
functional test Troubleshooting, “Engine 3. Inspect the fuel supply manifold for damage.
Speed/Timing Sensor”. Replace the fuel supply manifold, if necessary.

3. Check for correct installation of the connector(s) 4. Repair the fuel transfer pump and/or replace the
of the Electronic Control Module (ECM) J1/P1 fuel transfer pump.
and/or J2/P2 and fuel injector connectors. Repair
the connector and/or replace the connector. Refer
i01700530
to the diagnostic functional test Troubleshooting,
“Inspecting Electrical Connectors”. Fuel in Cooling System
4. Use Cat ET to determine if any diagnostic SMCS Code: 1350-038; 1901-038
codes for the injector solenoids are present.
Check that the injector trim codes have been The probable root cause is listed below:
entered. Perform the “Injector Solenoid Test”.
Observe that the injector solenoids are being
energized on Cat ET. Perform the “Cylinder
• Internal cylinder head
Cutout Test”. Locate the misfiring cylinder. Refer Perform the following check:
to the diagnostic functional test Troubleshooting,
“Injector Solenoids”. 1. Remove the valve cover. Remove the fuel supply.
Remove the fuel return line from the cylinder
5. Check the air pressure in the air inlet manifold. head. Cap the fuel return connector and apply
Check for air inlet leaks. Look for restrictions 700 kPa (102 psi) maximum air pressure to the
at the air cleaner. Check for leaks between the fuel supply connector. Check for fuel leakage
exhaust manifold and the turbocharger. around the fuel injector. If leakage is present,
remove the fuel injector. Install a new O-ring seal.
6. Check the aftercooler for correct operation.
Check for blockage in the cores of the aftercooler.
i01953583
7. Check all flywheel and damper driven equipment
for proper operation. Ensure that the accessory Intermittent Engine Shutdown
equipment is not lugging down the engine.
SMCS Code: 1000-038; 1901-038

i01700527 The probable root causes are listed below:

Fuel Dilution of Engine Oil • Crank without injection input (if applicable)
SMCS Code: 1300-038; 1901-038
• Engine shutdown (if applicable)
The probable root causes are listed below:
• Faulty engine start switch
• Leaking fuel seals • Faulty electrical connections
• Leaking fuel injector • Electrical power supply to the Electronic Control
Module (ECM)
• Leaking fuel transfer pump seal
• Circuit breakers
• Cracked fuel passage in the cylinder head
Perform the following checks:
• Engine speed/timing sensor(s)

1. Inspect the fuel seals on the fuel injector for

• Fuel supply
damage. If necessary, replace the fuel seals. Perform the following checks:
a. Inspect the fuel seals on the cylinder head for
damage. If necessary, replace the fuel seals.
 47
Troubleshooting Section

1. If equipped, verify that the plug is installed for the b. Purge air from the low pressure fuel supply
crank without injection input. Ensure that the plug circuit with the hand priming pump and by
for the crank without injection input is installed cranking the engine in 30 second cycles.
securely. Refer to the diagnostic functional test After you crank the engine, stop for two
Troubleshooting, “Crank without Injection Input”. minutes. This will allow the starting motor to
cool. Loosen the vent plug at the fuel return.
2. Connect the Caterpillar Electronic Technician The plug is located on the rear upper left side
(ET) and check for engine shutdowns. Determine of the engine block. Hand prime the engine
the reason for the shutdown. After correcting the again if air in fuel continues. A sight glass
problem, cycle power to the ECM for at least 15 in the low pressure supply line is helpful in
seconds before you try to restart the engine. diagnosing air in the fuel.

3. Check the engine start switch on Cat ET. Look c. Check fuel quality. In temperatures below 0 C
for an intermittent problem in the wiring for the (32 F), check for solidified fuel (wax). Refer
engine start switch. to Special Publication, SEBD0717, “Diesel
Fuels And Your Engine”. Check the fuel
4. Check for correct installation of the connector(s) pressure while the engine is cranking. Check
for the ECM J2/P2 and/or J1/P1 and electronic the fuel pressure at the filter. If the pressure
fuel injector connectors. Refer to the diagnostic is low, check for plugged fuel filters. If the
functional test Troubleshooting, “Inspecting fuel pressure is still low, check the following
Electrical Connectors”. items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve.
5. Check Cat ET for the following logged diagnostic Check for a combustion problem.
codes: 168-01 and 168-02. Follow the battery
wires from the ECM back to the battery
i01953585
compartment. Refer to the electrical system
schematic. Inspect the wires and the power relay.
Check the power to the ECM and to the ground
Intermittent Low Power or
connections. Refer to the diagnostic functional Power Cutout
test Troubleshooting, “Electrical Power Supply”.
SMCS Code: 1000-038; 1901-038
6. The circuit breakers may have exceeded the
trip point due to overheating. Check the circuit The probable root causes are listed below:
breakers. Reset the circuit breakers if the circuit
breakers are tripped. • Fuel position multiplier (if applicable)
7. Check Cat ET for any of the following logged • Engine start switch
diagnostic codes for the primary engine
speed/timing sensor: 190-02, 190-03, and • Engine speed/timing sensor
190-08. If the engine is equipped with a
secondary engine speed/timing sensor, check • Turbocharger
for any of the following logged diagnostic
codes: 342-02, 342-03, and 342-08. Refer to • Rated Fuel Position
the diagnostic functional test Troubleshooting,
“Engine Speed/Timing Sensor”. • Air inlet restrictions
8. Check fuel lines for the following problems: • Exhaust restrictions
restrictions, collapse, and pinched line Repair
the lines and/or replace the lines. • Fuel level
a. Check the fuel tank for foreign objects which • Derate mode
may block the fuel supply. Check for air in
the low pressure fuel supply system after • Throttle signal
performing the following procedures:
• Electrical power supply to the Electronic Control
• Replacing the fuel filters Module (ECM)

• Working on the low pressure fuel supply • Fuel supply

circuit
• Accessory equipment
• Replacing fuel injectors
Perform the following checks:
48
Troubleshooting Section

1. If equipped, refer to the diagnostic procedure 8. Monitor fuel level during engine operation. If a
Troubleshooting, “Fuel Position Multiplier”. low fuel level causes the problem, maintain a
higher fuel level.
2. Check the operation of the engine start switch.
Monitor the engine start switch on the Caterpillar 9. Connect Cat ET and check for logged derate
Electronic Technician (ET). The engine start events. A derate status flag will appear on Cat
switch may be one of the following types: ET if an active engine derate is occurring. The
engine speed might be limited due to one of
• Engine Control Switch (ECS) the following possible causes: altitude, high
exhaust temperatures, high coolant temperature,
• Start/Run/Stop switch aftercooler water temperature, air filter restriction,
and crankcase pressure.
• Keyswitch
10. Use Cat ET in order to monitor the status of the
Refer to the appropriate troubleshooting test throttle. Observe the throttle position. The throttle
that is applicable to your engine if repairs are position should be stable. The throttle position
required. should reach 100 percent. Perform one of the
following applicable diagnostic functional test:
3. Check Cat ET for any of the following logged
diagnostic codes for the primary engine • Troubleshooting, “Throttle Position Sensor”
speed/timing sensor: 190-02, 190-03, and
190-08. If the engine is equipped with a • Troubleshooting, “Speed Control”
secondary engine speed/timing sensor, check
for any of the following logged diagnostic • Troubleshooting, “Throttle Switch”
codes: 342-02, 342-03, and 342-08. Refer to
the diagnostic functional test Troubleshooting, 11. Check Cat ET for the following logged diagnostic
“Engine Speed/Timing Sensor”. codes: 168-01 and 168-02. Follow battery wires
from the ECM back to the battery compartment.
4. Ensure that the turbocharger is operating Refer to Electrical System Schematic. Inspect
correctly. Periodic inspection and cleaning is the wires and the power relay. Check the power
recommended for the turbocharger compressor to the ECM and to the ground connections. Refer
housing (inlet side). to the diagnostic functional test Troubleshooting,
“Electrical Power Supply”.
5. Operate the engine under full load. Use Cat
ET in order to monitor the following values: 12. Check fuel lines for the following problems:
turbocharger compressor outlet pressure, fuel restrictions, collapse, and pinched line Repair
position, rated fuel position, and Fuel Ratio the lines and/or replace the lines.
Control (FRC). The fuel position should equal the
rated fuel position. The FRC fuel position should a. Check the fuel tank for foreign objects which
be greater than the rated fuel position. may block the fuel supply. Check for air in
the low pressure fuel supply system after you
If any of the above values are changing rapidly perform the following procedures:
for no apparent reason, there may be an
intermittent problem with the wiring. Refer to • Replacing the fuel filters
the diagnostic functional test Troubleshooting,
“Inspecting Electrical Connectors”. • Working on the low pressure fuel supply
circuit
6. Check the air inlet system for the following
problems: restrictions, collapse, and pinched • Replacing fuel injectors
line. Repair the lines and/or replace the lines.
b. Purge air from the low pressure fuel supply
a. Check for an air filter restriction indicator. circuit with the hand priming pump and by
Replace plugged air filters and/or clean filters. cranking the engine in 30 second cycles.
Repair any leaks. After you crank the engine, stop for two
minutes. This will allow the starting motor to
7. Check the exhaust system for the following cool. Loosen the vent plug at the fuel return.
problems: restrictions, collapse, and pinched The plug is located on the rear upper left side
line. Repair the lines and/or replace the lines. of the engine block. Hand prime the engine
again if air in fuel continues. A sight glass
in the low pressure supply line is helpful in
diagnosing air in the fuel.
 49
Troubleshooting Section

c. Check fuel quality. In temperatures below 4. Check for presence of fuel in lubricating oil. Refer
0 C (32 F), check for solidified fuel (wax). to the diagnostic procedure Troubleshooting,
Refer to Special Publication, SEBD0717, “Fuel Dilution of Engine Oil” .
“Diesel Fuels And Your Engine”. Check the
fuel pressure with engine cranking. Check 5. Check the engine oil pressure gauge on another
the fuel pressure at the filter. If the pressure engine.
is low, check for plugged fuel filters. If the
fuel pressure is still low, check the following 6. Clean the bypass valve and the housing. If
items: fuel transfer pump, fuel transfer pump necessary, install new parts.
coupling, and fuel pressure regulating valve.
Check for a combustion problem. 7. Check for blockage of the inlet screen in the
engine oil pump. Check for air leakage into the
13. Check attached accessory equipment. Ensure supply to the engine oil pump. Examine the
that the accessory equipment is not lugging engine oil pump for excessive wear.
down the engine.
8. Inspect the camshaft and/or camshaft bearings.
Check the components for excessive wear.
i01953586
Excessive wear is an indication of a blocked oil
Low Engine Oil Pressure passage.

SMCS Code: 1300-038; 1901-038 9. Inspect the crankshaft and/or crankshaft

bearings. Check the components for excessive
wear.
NOTICE
Do not operate engine with low oil pressure. Engine
damage will result. If measured engine oil pressure is i01953587
low, discontinue engine operation until the problem is
corrected. Low Power/Poor or No
Response to Throttle
The probable root causes are listed below:
SMCS Code: 1000-038; 1901-038
• Low engine oil level
The probable root causes are listed below:
• Dirty engine oil filters
• Cold mode operation
• Restriction in engine oil cooler(s)
• Coolant temperature sensor
• Fuel dilution of engine oil
• Derate mode
• Faulty engine oil pressure gauge
• Fuel position multiplier (if applicable)
• Faulty pressure relief valve for the engine oil
• Throttle signal
• Restriction at engine oil pump
• Electrical connectors
• Camshaft and/or camshaft bearings
• Injector
• Crankshaft bearings
• Fuel Ratio Control Limit (FRC)
Perform the following checks:
• Air inlet restriction
1. Inspect the engine oil level. If engine oil is low
add engine oil. • Exhaust restrictions
2. Check the operation of bypass valve for the filter. • Electronic Control Module (ECM)
Inspect the engine oil filter. If the engine oil filter
is dirty, install a new engine oil filter. • Fuel supply
3. Clean the engine oil cooler core(s) and/or install • Air shutoff valve (if applicable)
new engine oil cooler core(s).
Perform the following checks:
a. Remove dirty oil from the engine. Put clean
oil in the engine.
50
Troubleshooting Section

1. Use the Caterpillar Electronic Technician (ET) in If any of the above values are changing rapidly
order to verify that the engine has exited cold for no apparent reason, there may be an
mode. During cold mode, injection timing is intermittent problem with the wiring. Refer to
modified. The cylinders may cut out. Cold mode the diagnostic functional test Troubleshooting,
cylinder cutouts may cause variations in vibration “Inspecting Electrical Connectors”.
and in available power. This is normal operation.
9. Check the air inlet system for the following
2. Use Cat ET in order to monitor the temperature problems: restrictions, collapse, pinched line,
of the coolant. If the reading is incorrect, perform and loose fittings. Repair the lines and/or replace
the diagnostic functional test Troubleshooting, the lines.
“Engine Sensor Open/Short Test”.
a. Observe the service engine lamp. Check
3. Connect Cat ET and check for logged derate for an air filter restriction indicator. Replace
events. A derate status flag will appear on Cat plugged air filters and/or clean the filters.
ET if an active engine derate is occurring. The Repair any leaks.
engine speed might be limited due to one of the
following possible causes: altitude, high exhaust 10. Check the exhaust system for the following
temperatures, air filter restriction, high coolant problems: restrictions, collapse, pinched line,
temperature, aftercooler water temperature, and and loose fittings. Repair the lines and/or replace
crankcase pressure. the lines.

4. If equipped, refer to the diagnostic functional test 11. If you have replaced the ECM, check the
Troubleshooting, “Fuel Position Multiplier”. read/change system configuration parameters.
Verify that the parameters match the information
5. Use Cat ET in order to monitor the status of the on the engine information plate. Verify that the
throttle. Observe the throttle position. The throttle correct personality module has been installed.
position should be stable. The throttle position
should reach 100 percent. Perform one of the 12. Monitor fuel level during engine operation. If a
following applicable diagnostic functional test: low fuel level causes the problem, maintain a
higher fuel level. Check fuel lines for the following
• Troubleshooting, “Throttle Position Sensor” problems: restrictions, collapse, and pinched
line. Repair the lines and/or replace the lines.
• Troubleshooting, “Speed Control”
a. Check the fuel tank for foreign objects which
• Troubleshooting, “Throttle Switch” may block the fuel supply. Check for air in
the low pressure fuel supply system after you
6. Check for the correct installation of the ECM perform the following procedures:
connector(s) J1/P1 and/or J2/P2. Check for
correct installation of the applicable fuel Injector • Replacing the filters
connectors. Refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical • Working on the low pressure fuel supply
Connectors”. circuit

7. Use Cat ET to determine if any active diagnostic • Replacing fuel injectors

codes are present. Check that the injector
trim codes have been entered. Use Cat ET to b. Purge air from the low pressure fuel supply
determine if any logged diagnostic codes are circuit with the hand priming pump and by
present. Perform the “Injector Solenoid Test”. cranking the engine in 30 second cycles.
Observe that the solenoids for the injectors are After you crank the engine, stop for two
being energized on Cat ET. Perform the “Cylinder minutes. This will allow the starting motor to
Cutout Test”. Locate the misfiring cylinder. Refer cool. Loosen the vent plug at the fuel return.
to the diagnostic functional test Troubleshooting, The plug is located on the rear upper left side
“Injector Solenoids”. of the engine block. Hand prime the engine
again if air in fuel continues. A sight glass
8. Operate the engine under full load. Use Cat in the low pressure supply line is helpful in
ET in order to monitor the following values: diagnosing air in the fuel.
turbocharger compressor outlet pressure, fuel
position, rated fuel position, and Fuel Ratio
Control (FRC). The fuel position should equal the
rated fuel position. The FRC fuel position should
be greater than the rated fuel position.
 51
Troubleshooting Section

c. Check fuel quality. In temperatures below 0 C i01953600

(32 F), check for solidified fuel (wax). Refer
to Special Publication, SEBD0717, “Diesel Noise Coming from Cylinder
Fuels And Your Engine”. Check the fuel
pressure while the engine is cranking. Check SMCS Code: 1000-038; 1290-038
the fuel pressure at the filter. If the pressure
is low, check for plugged fuel filters. If the The probable root causes are listed below:
fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump • Low quality fuel
coupling, and fuel pressure regulating valve.
Check for a problem with the combustion • Engine speed/timing sensor
system.
• Electrical connectors
13. Check that both of the air shutoffs are open.
• Injector
i01953598 • Not enough lubrication
Mechanical Noise (Knock) in • Too much valve lash
Engine
• Damage to valve train components
SMCS Code: 1000-038; 1901-038
• Failure of connecting rod bearing
The probable root causes are listed below:
Perform the following checks:
• Faulty accessory
1. Check fuel quality. Refer to Special Publication,
• Damage to valve train components SEBD0717, “Diesel Fuels And Your Engine”.
Remove unsatisfactory fuel from the fuel tank.
• Failure of connecting rod bearing Install new fuel filters. Use the proper grade of
clean fuel in the fuel tank.
• Crankshaft bearings
2. Calibrate the engine speed/timing sensor if
Perform the following checks: a CID-FMI 261-13 Engine Timing calibration
required diagnostic code is active. Refer to the
1. Isolate the source of the noise. Remove calibration procedure Troubleshooting, “Engine
the suspect engine accessories. Inspect Speed/Timing Sensor - Calibrate”.
the suspect engine accessories. Repair the
engine accessories and/or replace the engine 3. Check for the correct installation of the
accessories. connector(s) for the Electronic Control Module
(ECM) J1/P1 and/or J2/P2. Check for correct
2. Remove the valve cover from the suspect installation of the applicable fuel injector
cylinder(s). Check the following items for connectors. Repair the connector and/or replace
damage: camshaft, valve rotocoil, valve springs, the connector. Refer to the diagnostic functional
lifters, pushrods, bridges, and injectors. Check test Troubleshooting, “Inspecting Electrical
for valves that do not move freely. Remove the Connectors”.
cylinder head and inspect the valves. Replace
any damaged parts. If damage has occurred, 4. Use Caterpillar Electronic Technician (ET) to
clean the following components: cylinder liner, determine if any diagnostic codes for the
piston, and exhaust system. Replace any injector solenoids are present. Perform the
damaged parts. “Injector Solenoid Test”. Observe that the injector
solenoids are being energized on Cat ET. Perform
3. Inspect the connecting rod bearings and the the “Cylinder Cutout Test”. Locate the misfiring
bearing surfaces (journals) on the crankshaft. cylinder. Refer to the diagnostic functional test
Check the piston pin for excessive wear. Replace Troubleshooting, “Injector Solenoids”.
any damaged parts.
5. Check the lubrication in the valve compartment.
4. Check the crankshaft and/or crankshaft bearings. Check for sufficient lubrication between the
Check the components for excessive wear. injector tappet and the rocker arm buttons.
Check for blocked oil passages. Oil passages
must be clean. Ensure that the oil passages that
send oil to the cylinder heads are clean.
52
Troubleshooting Section

6. Check the valve lash. Refer to the diagnostic 3. Check for the correct installation of the
procedure Troubleshooting, “Too Much Valve connectors for the Electronic Control Module
Lash”. (ECM) J1/P1 and/or J2/P2. Check for the
correct installation of the applicable fuel injector
7. Remove the valve cover from the suspect connectors. Repair the connector and/or replace
cylinder(s). Check the following items for the connector. Refer to the diagnostic functional
damage: camshaft, valve rotocoil, valve springs, test Troubleshooting, “Inspecting Electrical
lifters, pushrods, and bridges. Check for valves Connectors”.
that do not move freely. Remove the cylinder
head. Inspect the valves. Replace any damaged 4. Check for active diagnostic codes that are
parts. associated with the circuits for the fuel injector.
Check that the injector trim codes have been
8. Inspect the connecting rod bearings and the entered. Perform the “Injector Solenoid Test”.
bearing surfaces (journals) on the crankshaft. Verify that the ECM is energizing all the injector
Check the piston pin for excessive wear. Replace solenoids. Refer to the diagnostic functional test
any damaged parts. Troubleshooting, “Injector Solenoids”.

5. Check fuel lines for the following problems:

i01953602
restrictions, collapse, pinched line, and loose
Poor Fuel Consumption fittings. Repair the lines and/or replace the lines.

SMCS Code: 1000-038; 1901-038 a. Check the fuel tank for foreign objects which
may block the fuel supply. Check for air in
The probable root causes are listed below: the low pressure fuel supply system after you
perform the following procedures:
• Improper machine operation (if applicable)
• Replacing the fuel filters
• Engine speed/timing sensor
• Working on the low pressure fuel supply
circuit
• Electrical connectors
• Injector • Replacing fuel injectors
b. Purge air from the low pressure fuel supply
• Fuel supply circuit with the hand priming pump and by
cranking the engine in 30 second cycles.
• Air inlet restrictions After you crank the engine, stop for two
minutes. This will allow the starting motor to
• Exhaust restrictions cool. Loosen the vent plug on the fuel return.
The plug is located on the rear upper left side
• Leaks in air system of the engine block. Hand prime the engine
again if air in fuel continues. A sight glass
• Accessory equipment in the low pressure supply line is helpful in
Perform the following checks: diagnosing air in the fuel.

1. Use Caterpillar Electronic Technician (ET) to c. Check fuel quality. In temperatures below 0 C
check the Trip Totals. Use Cat ET to check the (32 F), check for solidified fuel (wax). Refer
Job Totals. Check the totals for the following to Special Publication, SEBD0717, “Diesel
data: idle time, poor operating habits, and high Fuels And Your Engine”. Check the fuel
load factor. pressure with engine cranking. Check the fuel
pressure at the filter. If pressure is low, check
Note: Engine operation can be affected by for plugged fuel filters. If the fuel pressure
environmental conditions. is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling,
2. Check the calibration of the engine speed/timing and fuel pressure regulating valve. Check for
sensor if a CID-FMI 261-13 Engine Timing a combustion problem.
calibration required diagnostic code is
active. Refer to the calibration procedure 6. Verify that the crankshaft and camshaft drive
Troubleshooting, “Engine Speed/Timing Sensor - gears are set with the proper orientation.
Calibrate”.
 53
Troubleshooting Section

7. Check the air inlet systems for restrictions and 4. Check the bridges for signs of wear. Adjust the
for leaks. bridges and/or replace the bridges. If there is
too much wear, install new parts. Adjust the
8. Check the exhaust systems for restrictions and valve lash.
for leaks.
5. Inspect the pushrods for signs of wear. If there
9. Check the service indicator for the engine air is too much wear, install new pushrods. Adjust
cleaner. Replace plugged air filters and/or clean the valve lash.
filters.
6. Clean the valve train. Install new valve lifters.
10. Check attached accessory equipment. Ensure
that the accessory equipment is not lugging 7. Check the camshaft for wear.
down the engine.
8. Check the valve stem for signs of wear. Check
for free movement of valves. Check for a bent
i01953618
valve stem. Adjust the valve lash.
Too Much Valve Lash 9. Check the valve lash.
SMCS Code: 1000-038; 1901-038
10. Repair the retaining bolt for the rocker shaft
The probable root causes are listed below: and/or replace the retaining bolt.

11. Check the valve springs for damage or for signs

• Rocker arm of wear. If there is too much wear, install new
springs. Adjust the valve lash.
• Not enough lubrication
12. Check the valve seats for signs of wear. If there
• Worn rocker arm is too much wear, install new valve seats. Adjust
the valve lash.
• Worn bridges for valves
• Worn pushrods i01953619

• Worn valve lifters Too Much Vibration

• Worn camshaft SMCS Code: 1000-038; 1901-038

• Worn valve stem The probable root causes are listed below:

• Incorrect valve lash • Vibration damper

• Loose retaining bolt(s) for rocker shaft • Loose engine supports
• Worn valve springs • Fan blade
• Valve seats • Misfiring cylinder
Perform the following checks: • Alignment and balance
1. Check for proper installation of the rocker arm Perform the following checks:
adjustment screw locknut. If the rocker arm
adjustment screw locknut is loose, adjust the 1. Check the vibration damper for damage. Tighten
valve lash. the bolts. Check the vibration damper bolt holes
for damage and/or wear.
2. Check the lubrication in the valve compartment.
Check for sufficient lubrication between the 2. Run the engine. Check the engine for the
injector tappet and the rocker arm buttons. following problems: loose mounts, broken
mounts, loose brackets, and broken brackets.
3. Check the rocker arms for signs of wear. If there Tighten all mounting bolts.
is too much wear, install new parts or rocker
arms. Adjust the valve lash. 3. Check the fan blade for damage. Ensure that the
fan blade is balanced.
54
Troubleshooting Section

4. Check for a misfiring cylinder. Perform the

Cylinder Cutout Test. Refer to the diagnostic
functional test Troubleshooting, “Injector
Solenoids”.

5. Check alignment and the balance. If the

symptom remains refer to the diagnostic
procedure Troubleshooting, “Engine Misfires,
Runs Rough or Is Unstable”.

i01953620

Valve Rotocoil or Spring Lock

Is Free
SMCS Code: 1109-038

The probable root causes are listed below:

• Cracked inlet valve rotocoil

• Broken spring locks
• Broken valve spring(s)
Perform the following checks:

1. Determine the cause of the cracked rotocoil.

a. If necessary, install new parts.

2. Check the locks. A broken lock can cause the

valve to fall into the cylinder.

3. Install the new valve spring(s). Replace the valve

and/or other damaged parts.
 55
Troubleshooting Section

Troubleshooting with a
Diagnostic Code
i01922972

Diagnostic Codes
SMCS Code: 1901-038

Diagnostic codes alert the operator that a problem

exists. Diagnostic codes indicate the nature of the
problem to the service technician. Diagnostic codes
consist of the following identifiers: module identifier
(MID), component identifier (CID), and failure mode
identifier (FMI). The MID indicates the electronic
module that generated the diagnostic code. The
MID for the engine’s Electronic Control Module
(ECM) is 36. The CID indicates the component in
the system. The FMI indicates the failure mode that
is present. Diagnostic codes may be viewed on
the Caterpillar Electronic Technician (ET). Do not
confuse diagnostic codes with diagnostic events. If
a diagnostic event is active, refer to the diagnostic
section Troubleshooting, “Event Codes”.

Active Diagnostic Codes

An active diagnostic code represents a problem
with the electronic control system. Correct any
active diagnostic codes as soon as possible. When
an active diagnostic code is generated, a display
module such as the Electronic Monitoring System
(EMS) may produce a warning.

g00740986
Illustration 14

Illustration 14 indicates a typical output voltage

from the coolant temperature sensor. Cat ET can be
used to monitor the output voltage and temperature
of any sensor. Cat ET will display diagnostic codes
that are associated with a sensor. As you look
at Illustration 14, notice the output voltage of the
sensor. A diagnostic code is generated when the
ECM detects an abnormal output voltage from the
sensor.

Note: Always clear logged diagnostic codes after

investigating and correcting the problem which
generated the code.
56
Troubleshooting Section

Logged Diagnostic Codes i01954439

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 following information: the hour of the first SMCS Code: 1290-038
occurrence of the diagnostic code, the hour of the
last occurrence of the diagnostic code, and the Conditions Which Generate This Code:
number of occurrences of the code. This information
is a valuable indicator for troubleshooting The Electronic Control Module (ECM) detects a
intermittent problems. Some diagnostic codes may short circuit or short to ground in the No. 1 cylinder
log occurrences that did not result in complaints. injector solenoid.
The most likely cause of an intermittent problem is
a faulty connection or damaged wiring. The next System Response:
likely cause is a component failure. The least likely
cause is the failure of the ECM. Diagnostic codes The CID-FMI is logged in memory. The ECM will
that are logged repeatedly may indicate a problem continue to operate all injectors.
that needs special investigation.
Perform the following diagnostic procedure:
If the symptoms continue, use the proper procedure “Injector 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:
• OK – STOP. “Injector Solenoids”

• REPAIRED, OK – STOP. Results:

• OK – STOP.
• REPAIRED, OK – STOP.
 57
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 The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 2 cylinder short circuit or short to ground in the No. 3 cylinder
injector solenoid. injector solenoid.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector 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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector Solenoids”

Results: Results:

• OK – STOP. • OK – STOP.
• REPAIRED, OK – STOP. • REPAIRED, OK – STOP.
58
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 The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 4 cylinder short circuit or short to ground in the No. 5 cylinder
injector solenoid. injector solenoid.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector 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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector Solenoids”

Results: Results:

• OK – STOP. • OK – STOP.
• REPAIRED, OK – STOP. • REPAIRED, OK – STOP.
 59
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 The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 6 cylinder short circuit or short to ground in the No. 7 cylinder
injector solenoid. injector solenoid.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector 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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector Solenoids”

Results: Results:

• OK – STOP. • OK – STOP.
• REPAIRED, OK – STOP. • REPAIRED, OK – STOP.
60
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 The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 8 cylinder short circuit or short to ground in the No. 9 cylinder
injector solenoid. injector solenoid.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector 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
System Response: cylinder injector solenoid.

The CID-FMI is logged in memory. The ECM will System Response:

continue to operate all injectors.
The CID-FMI is logged in memory. The ECM will
Perform the following diagnostic procedure: continue to operate all injectors.
“Injector Solenoids”
Perform the following diagnostic procedure:
Results: “Injector Solenoids”

Results:
• OK – STOP.
• REPAIRED, OK – STOP. • OK – STOP.
• REPAIRED, OK – STOP.
 61
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 The Electronic Control Module (ECM) detects a
short circuit or a short to ground in the No. 10 short circuit or short to ground in the No. 11 cylinder
cylinder injector solenoid. injector solenoid.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector 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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector Solenoids”

Results: Results:

• OK – STOP. • OK – STOP.
• REPAIRED, OK – STOP. • REPAIRED, OK – STOP.
62
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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector 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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector Solenoids”

Results: Results:

• OK – STOP. • OK – STOP.
• REPAIRED, OK – STOP. • REPAIRED, OK – STOP.
 63
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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector 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.

System Response: System Response:

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: Perform the following diagnostic procedure:
“Injector Solenoids” “Injector Solenoids”

Results: Results:

• OK – STOP. • OK – STOP.
• REPAIRED, OK – STOP. • REPAIRED, OK – STOP.
64
Troubleshooting Section

i01954525 Expected Result:

MID 036 - CID 0016 - FMI 06 Results:
Injector Cylinder 16 short
• OFF – The “Direct Fuel Control Mode” is OFF or
SMCS Code: 1290-038 N/A. Proceed to Test Step 2.

Conditions Which Generate This Code: • ON – The “Direct Fuel Control Mode” is ON.
Proceed to Test Step 3.
The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 16 cylinder Test Step 2.
injector solenoid.
Perform the following diagnostic procedure: “Speed
System Response: Control”

The CID-FMI is logged in memory. The ECM will Results:

continue to operate all injectors.
• OK – STOP.
Perform the following diagnostic procedure:
“Injector Solenoids” • REPAIRED, OK – STOP.
Results: Test Step 3.
• OK – STOP. Perform the following diagnostic procedure: “Direct
Fuel Control Mode”
• REPAIRED, OK – STOP.
Results:
i01923025
• OK – STOP.
MID 036 - CID 0091 - FMI
08 Throttle Position signal • REPAIRED, OK – STOP.
abnormal i01961640

SMCS Code: 1913-038 MID 036 - CID 0094 - FMI 02

Conditions Which Generate This Code: Fuel Pressure misinstalled
The Electronic Control Module (ECM) has been SMCS Code: 1901-038
powered up for three seconds. The diagnostic
codes 263-03 and 263-04 are not active. The sensor Conditions Which Generate This Code:
frequency is greater than 1000 Hz or less than 150
Hz for two seconds. The duty cycle is greater than The Electronic Control Module (ECM) reads a
95 percent or less than 5 percent for one second. negative differential pressure between the unfiltered
fuel pressure sensor and the filtered fuel pressure
System Response: sensor. The sensors may be installed incorrectly.

The throttle position is set to a default value of 0 System Response:

percent (low idle) by the ECM. The code is logged.
The CID-FMI is logged in memory. The ECM flags
filtered fuel pressure as invalid data. The engine
Test Step 1. monitoring system is disabled for filtered fuel
pressure.
A. Determine if the “Direct Fuel Control Mode” is ON
or OFF. View the configuration screen in order to
Correctly install the sensor.
find the status of the “Direct Fuel Control Mode”.
Results:

• REPAIRED, OK – STOP.
 65
Troubleshooting Section

i01936028 i01961641

MID 036 - CID 0094 - FMI 03 MID 036 - CID 0094 - FMI 13 Fuel
Fuel Pressure open/short to Pressure calibration required
+batt SMCS Code: 1901-038
SMCS Code: 1901-038
Conditions Which Generate This Code:
Conditions Which Generate This Code: The Electronic Control Module (ECM) records one
of the following conditions. The filtered fuel pressure
The Electronic Control Module (ECM) reads signal sensor never calibrated. The ECM reads filtered
voltage that is greater than 4.8 VDC for one second. fuel pressure less than 35 kPa (5 psi). The ECM
The ECM has been powered for three seconds. The
reads filtered fuel pressure more than 130 kPa
diagnostic codes 262-03 and 262-04 are not active. (19 psi). The filtered fuel pressure changes more
than 25 kPa (3.6 psi) during a calibration attempt.
System Response:
The diagnostic codes 94-03 or 94-04 are active.
The diagnostic codes 274-03 or 274-04 are active.
The code is logged. The ECM flags filtered fuel
pressure as invalid data and a default value of
System Response:
500 kPa (73 psi) is used.
The diagnostic code is active. The diagnostic code
Perform the following diagnostic procedure: “Engine
is not logged in memory. The ECM will use the data
Sensor Open/Short Test”
from the previous calibration.
Results:
Perform the following diagnostic procedure: “Analog
Sensor - Calibrate”
• OK – STOP.
Results:
• REPAIRED, OK – STOP.
• OK – STOP.
i01936029
• REPAIRED, OK – STOP.
MID 036 - CID 0094 - FMI 04
Fuel Pressure short to ground i01961657

SMCS Code: 1901-038 MID 036 - CID 0100 - FMI 02

Conditions Which Generate This Code:
Engine Oil Pressure out of
range
The Electronic Control Module (ECM) reads signal
voltage that is below 0.2 VDC for one second. The SMCS Code: 1924-038
ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. Conditions Which Generate This Code:

System Response: The Electronic Control Module (ECM) reads a

negative differential pressure between the unfiltered
The code is logged. The ECM flags filtered fuel engine oil pressure sensor and the filtered engine
pressure as invalid data and a default value of oil pressure sensor. The sensors are installed
500 kPa (73 psi) is used. incorrectly.

Perform the following diagnostic procedure: “Engine System Response:

Sensor Open/Short Test”
The CID-FMI is logged in memory. The ECM flags
Results: the filtered engine oil pressure as invalid data. The
engine monitoring system is disabled for filtered
• OK – STOP. engine oil pressure.

• REPAIRED, OK – STOP. Correctly install the sensor.

66
Troubleshooting Section

Results: Results:

• REPAIRED, OK – STOP. • OK – STOP.

i01954600
• REPAIRED, OK – STOP.

MID 036 - CID 0100 - FMI i01961659

03 Engine Oil Pressure MID 036 - CID 0100 - FMI 13
open/short to +batt Engine Oil Pressure calibration
SMCS Code: 1924-038 required
Conditions Which Generate This Code: SMCS Code: 1924-038

The Electronic Control Module (ECM) reads signal Conditions Which Generate This Code:
voltage that is greater than 4.8 VDC for one second.
The ECM has been powered for three seconds. The The Electronic Control Module (ECM) records one
diagnostic codes 262-03 and 262-04 are not active. of the following conditions. The filtered engine oil
pressure sensor never calibrated. The ECM reads
System Response: engine oil pressure less than 35 kPa (5 psi). The
engine oil pressure is greater than 130 kPa (19 psi).
The CID-FMI is logged in memory. The ECM flags The engine oil pressure changes more than 25 kPa
engine oil pressure as invalid data and a default (3.6 psi) during a calibration attempt. The diagnostic
value of 500 kPa (73 psi) is used. codes 100-03 or 100-04 are active. The diagnostic
codes 274-03 or 274-04 are active.
Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test” System Response:

Results: The diagnostic code is not logged in memory. The

ECM will use the data from the previous calibration.
• OK – STOP.
Perform the following diagnostic procedure: “Analog
• REPAIRED, OK – STOP. Sensor - Calibrate”

Results:
i01954601

MID 036 - CID 0100 - FMI 04 • OK – STOP.

Engine Oil Pressure short to • REPAIRED, OK – STOP.
ground
i01954609
SMCS Code: 1924-038
MID 036 - CID 0101 - FMI
Conditions Which Generate This Code: 03 Crankcase Pressure
The Electronic Control Module (ECM) reads signal open/short to +batt
voltage that is below 0.2 VDC for one second. The
ECM has been powered for three seconds. The SMCS Code: 1916-038
diagnostic codes 262-03 and 262-04 are not active.
Conditions Which Generate This Code:
System Response:
The Electronic Control Module (ECM) reads signal
The CID-FMI is logged in memory. The ECM flags voltage that is greater than 4.8 VDC for one second.
engine oil pressure as invalid data and a default The ECM has been powered for three seconds. The
value of 500 kPa (73 psi) is used. diagnostic codes 262-03 and 262-04 are not active.

Perform the following diagnostic procedure: “Engine

Sensor Open/Short Test”
 67
Troubleshooting Section

System Response: i01961662

The CID-FMI is logged in memory. The ECM flags MID 036 - CID 0101 - FMI
crankcase pressure as invalid data. The engine 13 Crankcase Pressure
monitoring system is disabled for crankcase
pressure. calibration required
Perform the following diagnostic procedure: “Engine SMCS Code: 1916-038
Sensor Open/Short Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) records one
• OK – STOP. of the following conditions. The crankcase pressure
sensor never calibrated. The crankcase pressure is
• REPAIRED, OK – STOP. less than 45 kPa (6.5 psi). The crankcase pressure
is greater than 111 kPa (16 psi). The crankcase
pressure changes more than 5 kPa (0.7 psi) during
i01954610 a calibration attempt. The diagnostic codes 101-03
or 101-04 are active.
MID 036 - CID 0101 - FMI 04
Crankcase Pressure short to System Response:
ground The diagnostic codes are active. The diagnostic
codes are not logged in memory.
SMCS Code: 1916-038
Perform the following diagnostic procedure: “Analog
Conditions Which Generate This Code: Sensor - Calibrate”
The Electronic Control Module (ECM) reads signal Results:
voltage that is less than 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.
• OK – STOP.

System Response:
• REPAIRED, OK – STOP.

The CID-FMI is logged in memory. The ECM flags i01954615

crankcase pressure as invalid data. The engine
monitoring system is disabled for crankcase MID 036 - CID 0110 - FMI 03
pressure. Engine Coolant Temperature
Perform the following diagnostic procedure: “Engine open/short to +batt
Sensor Open/Short Test”
SMCS Code: 1906-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) reads signal
• REPAIRED, OK – STOP. voltage that is greater than 4.8 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:

The CID-FMI is logged in memory. The ECM flags

coolant temperature as invalid data and a default
value of −40 C (−40 F) is used.

Perform the following diagnostic procedure: “Engine

Sensor Open/Short Test”

Results:

• OK – STOP.
68
Troubleshooting Section

• REPAIRED, OK – STOP. i01954670

MID 036 - CID 0168 - FMI 01

i01954616
System Voltage Low
MID 036 - CID 0110 - FMI 04
SMCS Code: 1401-038
Engine Coolant Temperature
short to ground Conditions Which Generate This Code:

SMCS Code: 1906-038 The Electronic Control Module (ECM) has been
powered for three seconds. The engine is not
Conditions Which Generate This Code: cranking. The battery voltage is less than 9 VDC for
two seconds.
The Electronic Control Module (ECM) reads signal
voltage that is less than 0.2 VDC for one second. System Response:
The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. The CID-FMI is logged in memory.

System Response: Perform the following diagnostic procedure:

“Electrical Power Supply”
The CID-FMI is logged in memory. The ECM flags
coolant temperature as invalid data and a default Results:
value of −40 C (−40 F) is used.
• OK – STOP.
Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test” • REPAIRED, OK – STOP.
Results: i01954671

• OK – STOP. MID 036 - CID 0168 -

• REPAIRED, OK – STOP. FMI 02 System Voltage
intermittent/erratic
i01954667
SMCS Code: 1401-038
MID 036 - CID 0168 - FMI 00
Conditions Which Generate This Code:
System Voltage High
The engine is running but not cranking. One of the
SMCS Code: 1401-038 following conditions exist. The battery voltage is
less than 9 VDC for at least 0.06 seconds. Three
Conditions Which Generate This Code: times in the last seven seconds, the battery voltage
was less than 9 VDC.
The Electronic Control Module (ECM) has been
powered for three seconds. The engine is not System Response:
cranking. The battery voltage is greater than 32
VDC for two seconds. The CID-FMI is logged in memory.
System Response: Perform the following diagnostic procedure:
“Electrical Power Supply”
The CID-FMI is logged in memory.
Results:
Perform the following diagnostic procedure:
“Electrical Power Supply”
• OK – STOP.
Results:
• REPAIRED, OK – STOP.
• OK – STOP.
• REPAIRED, OK – STOP.
 69
Troubleshooting Section

i01935913 Results:
MID 036 - CID 0190 - FMI 02 • OK – STOP.
Loss of Engine Speed signal
• REPAIRED, OK – STOP.
SMCS Code: 1912-038
i01954685
Conditions Which Generate This Code:
MID 036 - CID 0190 - FMI 08
The primary engine speed signal cannot be
detected. The timing gear pattern returns within one Engine Speed signal abnormal
second before being lost and the battery voltage
is greater than 9 VDC for the last two seconds. SMCS Code: 1912-038
The code is logged only if the engine has been
running for three seconds. The code will be active Conditions Which Generate This Code:
and logged if the Electronic Control Module (ECM)
detects an incorrect signal for one second. The The diagnostic code will become active if the
battery voltage is greater than 9 VDC for the last following conditions exist. The engine speed
two seconds. is greater than 0 rpm. The primary engine
speed/timing signal is incorrect.
System Response:
System Response:
The code is logged. On engines with a secondary
engine speed/timing sensor, the secondary engine The code will become logged if the following
speed/timing signal will be used if the primary conditions exist. The engine speed is greater than
engine speed/timing signal is lost. 0 rpm. The engine speed/timing signal is incorrect
for five seconds. The engine speed/timing signal
Perform the following diagnostic procedure: “Engine returns for five seconds.
Speed/Timing Sensor”
On engines with a secondary engine speed/timing
Results: sensor, the secondary engine speed/timing signal
will be used if the primary engine speed/timing
signal is abnormal.
• OK – STOP.
Perform the following diagnostic procedure: “Engine
• REPAIRED, OK – STOP. Speed/Timing Sensor”

i01954681 Results:
MID 036 - CID 0190 - FMI 03 • OK – STOP.
Engine Speed open/short to
• REPAIRED, OK – STOP.
+batt
SMCS Code: 1912-038 i01954686

Conditions Which Generate This Code:

MID 036 - CID 0248 - FMI 09 CAT
Data Link not communicating
A wire on the primary engine speed/timing sensor is
disconnected and/or broken. There is a short circuit SMCS Code: 1901-038
to the +Battery terminal.
Conditions Which Generate This Code:
System Response:
The battery voltage to the Electronic Control
The CID-FMI is logged in memory. On engines Module (ECM) has been above 9 VDC for the
with a secondary engine speed/timing sensor, the last two seconds. The engine is not cranking.
secondary engine speed/timing signal will be used Communication was lost for two or more seconds.
if the primary engine speed/timing signal is lost.

Perform the following diagnostic procedure: “Engine

Speed/Timing Sensor”
70
Troubleshooting Section

System Response: System Response:

The CID-FMI is logged in memory. The CID-FMI is logged in memory. Engine power
and performance may be affected. All normal
Perform the following diagnostic procedure: “CAT functions of the ECM may be affected.
Data Link”
Perform the following diagnostic procedure:
Results: “ECM/Personality Module”

• OK – STOP. Results:

• REPAIRED, OK – STOP. • OK – STOP.

i01961720
• REPAIRED, OK – STOP.

MID 036 - CID 0253 - FMI 02 i01935923

Personality Module mismatch MID 036 - CID 0261 - FMI 13
SMCS Code: 1901-038 Engine Timing calibration
Conditions Which Generate This Code: required
SMCS Code: 1905-038
The personality module is for a different engine.

System Response: Conditions Which Generate This Code:

The CID-FMI is not logged in memory. The fuel The engine speed/timing sensor has not been
injection is disabled. If a personality module from calibrated.
another engine family is installed, the mismatch can
Note: This will not keep the engine from running.
be programmed to allow the engine to start.
The fuel injection timing may be out of adjustment.
Perform the following diagnostic procedure:
System Response:
“ECM/Personality Module”
The code is logged.
Results:
Perform the following diagnostic procedure: “Engine
• OK – STOP. Speed/Timing Sensor - Calibrate”
• REPAIRED, OK – STOP. Results:

i01961664 • OK – STOP.
MID 036 - CID 0254 - FMI 12 • REPAIRED, OK – STOP.
Electronic Control Module
Error i01954690

SMCS Code: 1901-038

MID 036 - CID 0262 - FMI 03 5
Volt Sensor DC Power Supply
Conditions Which Generate This Code:
short to +batt
The Electronic Control Module (ECM) has detected
SMCS Code: 1408-038-NS
an internal fault.
Conditions Which Generate This Code:

The Electronic Control Module (ECM) reads an

analog sensor supply voltage above 5.2 VDC for
two or more seconds. The ECM has been powered
for three seconds.
 71
Troubleshooting Section

Note: Normal voltage is 5.0 ± 0.2 VDC. i01954692

System Response: MID 036 - CID 0263 - FMI 03

Digital Sensor Supply short to
The CID-FMI is logged in memory. Analog sensors
are set to the default values. +batt
Perform the following diagnostic procedure: “Analog SMCS Code: 1408-038-NS
Sensor Supply”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) reads a digital
• OK – STOP. sensor supply voltage above 8.5 VDC for two
seconds. The ECM has been powered for three
• REPAIRED, OK – STOP. seconds.

Note: Normal voltage is 8.0 ± 0.4 VDC.

i01954691
System Response:
MID 036 - CID 0262 - FMI 04 5
Volt Sensor DC Power Supply The CID-FMI is logged in memory.
short to ground Perform the following diagnostic procedure: “Digital
Sensor Supply”
SMCS Code: 1408-038-NS
Results:
Conditions Which Generate This Code:

The Electronic Control Module (ECM) reads an

• OK – STOP.
analog sensor supply voltage below 4.8 VDC for
two seconds. The ECM has been powered for three
• REPAIRED, OK – STOP.
seconds.
i01954694
Note: Normal voltage is 5.0 ± 0.2 VDC.
MID 036 - CID 0263 - FMI 04
System Response: Digital Sensor Supply short to
The CID-FMI is logged in memory. The analog ground
sensors are set to the default values.
SMCS Code: 1408-038-NS
Perform the following diagnostic procedure: “Analog
Sensor Supply” Conditions Which Generate This Code:

Results: The Electronic Control Module (ECM) reads a digital

sensor supply voltage below 7.5 VDC for two
• OK – STOP. seconds. The ECM has been powered for three
seconds.
• REPAIRED, OK – STOP.
Note: Normal voltage is 8.0 ± 0.4 VDC.

System Response:

The CID-FMI is logged in memory.

Perform the following diagnostic procedure: “Digital

Sensor Supply”

Results:

• OK – STOP.
• REPAIRED, OK – STOP.
72
Troubleshooting Section

i01961665 System Response:

MID 036 - CID 0268 - FMI The CID-FMI is logged in memory. The ECM flags
02 Check Programmable turbocharger compressor outlet pressure as invalid
data and a default value of 0 kPa (0 psi) is used.
Parameters
Perform the following diagnostic procedure: “Engine
SMCS Code: 1901-038 Sensor Open/Short Test”
Conditions Which Generate This Code: Results:

One or more of the following programmable • OK – STOP.

parameters have not been programmed:
• REPAIRED, OK – STOP.
• Engine serial number
• Full Load Setting (FLS) i01936079

• Full Torque Setting (FTS)

MID 036 - CID 0273 - FMI
03 Turbo Outlet Pressure
• Rated fuel position open/short to +batt
System Response:
SMCS Code: 1052-038
The code is logged. The engine performance
and/or system operation may be affected. Conditions Which Generate This Code:

A. Check for parameters that have not been The Electronic Control Module (ECM) reads signal
programmed. voltage that is greater than 4.8 VDC for one second.
The ECM has been powered for three seconds. The
Results: diagnostic codes 262-03 and 262-04 are not active.

System Response:
• OK – A parameter has not been programmed.
Repair: Program the missing parameter. Refer The code is logged. The ECM flags turbocharger
to the diagnostic procedure Troubleshooting, compressor outlet pressure as invalid data and a
“System Configuration Parameters”. default value of 0 kPa (0 psi) is used.

STOP. Perform the following diagnostic procedure: “Engine

Sensor Open/Short Test”

i01954757 Results:
MID 036 - CID 0273 - FMI 00 • OK – STOP.
Turbo Outlet Pressure above
• REPAIRED, OK – STOP.
normal
SMCS Code: 1052-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) reads

turbocharger compressor outlet pressure above
200 kPa (29 psi). The engine speed is within 50
rpm of low idle for 5 seconds. The diagnostic codes
262-03, 262-04, 273-03, and 273-04 are not active.
 73
Troubleshooting Section

i01936089 Results:
MID 036 - CID 0273 - FMI 04 • OK – STOP.
Turbo Outlet Pressure short to
• REPAIRED, OK – STOP.
ground
SMCS Code: 1052-038 i01954758

Conditions Which Generate This Code:

MID 036 - CID 0274 - FMI
03 Atmospheric Pressure
The Electronic Control Module (ECM) reads signal
voltage that is less than 0.2 VDC for one second. open/short to +batt
The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. SMCS Code: 1923-038

System Response: Conditions Which Generate This Code:

The code is logged. The ECM flags turbocharger The Electronic Control Module (ECM) reads signal
compressor outlet pressure as invalid data and a voltage that is greater than 4.8 VDC for one second.
default value of 0 kPa (0 psi) is used. The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active.
Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test” System Response:

Results: The CID-FMI is logged in memory. The turbocharger

compressor inlet pressure sensor (if equipped) is
used as a backup for atmospheric pressure.
• OK – STOP.
Perform the following diagnostic procedure: “Engine
• REPAIRED, OK – STOP. Sensor Open/Short Test”

i01961666 Results:
MID 036 - CID 0273 - FMI • OK – STOP.
13 Turbo Outlet Pressure
• REPAIRED, OK – STOP.
calibration required
SMCS Code: 1052-038 i01954760

Conditions Which Generate This Code: MID 036 - CID 0274 - FMI 04
Atmospheric Pressure short to
The Electronic Control Module (ECM) detects
one of the following conditions. The turbocharger ground
compressor outlet pressure is ± 15 kPa (2.1 psi)
from the atmospheric pressure. The turbocharger SMCS Code: 1923-038
outlet pressure is less than 35 kPa (5 psi). The
turbocharger outlet pressure is greater than 122 kPa Conditions Which Generate This Code:
(17 psi). The turbocharger outlet pressure changed
more than 10 kPa (1.4 psi) during a calibration The Electronic Control Module (ECM) reads an
attempt. A pressure calibration has not been atmospheric pressure signal voltage below 1.7 VDC
performed on a new ECM. The diagnostics 273-03 for one second. The ECM has been powered for
or 273-04 are active. three seconds. The diagnostic codes 262-03 and
262-04 are not active.
System Response:

The diagnostic codes are not logged in memory.

The ECM will use data from the previous calibration.

Perform the following diagnostic procedure: “Analog

Sensor - Calibrate”
74
Troubleshooting Section

System Response: i01935990

The CID-FMI is logged in memory. The turbocharger MID 036 - CID 0275 - FMI 03
compressor inlet pressure sensor (if equipped) is Right Turbo Inlet Pressure
used as a backup for atmospheric pressure. The
atmospheric pressure is set to a default value of open/short to +batt
45 kPa (7 psi).
SMCS Code: 1052-038
Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test” Conditions Which Generate This Code:

Results: The Electronic Control Module (ECM) reads signal

voltage that is greater than 4.8 VDC for one second.
• OK – STOP. The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active.
• REPAIRED, OK – STOP.
System Response:
i01961668 The code is logged. The right turbocharger
compressor inlet pressure is set to a default value
MID 036 - CID 0274 - FMI of 45 kPa (7 psi).
13 Atmospheric Pressure
Perform the following diagnostic procedure: “Engine
calibration required Sensor Open/Short Test”
SMCS Code: 1923-038 Results:
Conditions Which Generate This Code:
• OK – STOP.
Any one of the following conditions is present:
• REPAIRED, OK – STOP.
• A pressure calibration has not been performed
on a new sensor. i01954762

• The Electronic Control Module (ECM) reads an MID 036 - CID 0275 - FMI 04
atmospheric pressure signal that is less than
45 kPa (6.5 psi) absolute or greater than 111 kPa
Right Turbo Inlet Pressure
(16 psi) absolute pressure. short to ground
• The diagnostics 274-03 or 274-04 are active. SMCS Code: 1052-038

• The atmospheric pressure changes more than Conditions Which Generate This Code:
5 kPa (0.7 psi).
The Electronic Control Module (ECM) reads signal
System Response: voltage that is less than 0.2 VDC for one second.
The ECM has been powered for three seconds. The
When this CID-FMI is active, all offsets for pressure diagnostic codes 262-03 and 262-04 are not active.
calibration will default to 0 kPa (0 psi). The
diagnostic codes are active. The diagnostic code System Response:
is not logged in memory.
The CID-FMI is logged in memory. The turbocharger
Perform the following diagnostic procedure: “Analog compressor inlet pressure is set to a default value
Sensor - Calibrate” of 45 kPa (7 psi).

Results: Perform the following diagnostic procedure: “Engine

Sensor Open/Short Test”
• OK – STOP.
Results:
• REPAIRED, OK – STOP.
• OK – STOP.
• REPAIRED, OK – STOP.
 75
Troubleshooting Section

i01961671 Results:
MID 036 - CID 0275 - FMI 13 • OK – STOP.
Right Turbo Inlet Pressure
• REPAIRED, OK – STOP.
calibration required
SMCS Code: 1052-038 i01936097

Conditions Which Generate This Code:

MID 036 - CID 0276 - FMI 04
Left Turbo Inlet Pressure short
The Electronic Control Module (ECM) detects
one of the following conditions. The turbocharger to ground
compressor inlet pressure is ± 8 kPa (1.2 psi)
from the atmospheric pressure. The turbocharger SMCS Code: 1052-038
compressor inlet pressure is less than 45 kPa
(6.6 psi). The turbocharger compressor inlet Conditions Which Generate This Code:
pressure is greater than 111 kPa (16 psi). The
turbocharger compressor inlet pressure changed The Electronic Control Module (ECM) reads signal
more than 5 kPa (0.7 psi) during a calibration voltage that is less than 0.2 VDC for one second.
attempt. The diagnostic codes 275-03 and 275-04 The ECM has been powered for three seconds. The
are active. diagnostic codes 262-03 and 262-04 are not active.

System Response: System Response:

The diagnostic codes are not logged in memory. The code is logged. The turbocharger compressor
The ECM will use the data from the previous inlet pressure is set to a default value of 45 kPa
calibration. (7 psi).

Perform the following diagnostic procedure: “Analog Perform the following diagnostic procedure: “Engine
Sensor - Calibrate” Sensor Open/Short Test”

Results: Results:

• OK – STOP. • OK – STOP.

• REPAIRED, OK – STOP. • REPAIRED, OK – STOP.

i01961673
i01935998

MID 036 - CID 0276 - FMI MID 036 - CID 0276 - FMI
03 Left Turbo Inlet Pressure 13 Left Turbo Inlet Pressure
open/short to +batt calibration required
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) detects
voltage that is greater than 4.8 VDC for one second. one of the following conditions. The turbocharger
The ECM has been powered for three seconds. The compressor inlet pressure is ± 8 kPa (1.2 psi)
diagnostic codes 262-03 and 262-04 are not active. from the atmospheric pressure. The turbocharger
compressor inlet pressure is less than 45 kPa
System Response: (6.5 psi). The turbocharger compressor inlet
pressure is greater than 111 kPa (16 psi). The
The code is logged. The left turbocharger turbocharger compressor inlet pressure changed
compressor inlet pressure is set to a default value more than 5 kPa (0.7 psi) during a calibration
of 45 kPa (7 psi). attempt. The diagnostic codes 276-03 and 276-04
are active.
Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test”
76
Troubleshooting Section

System Response: i01954877

The diagnostic codes are not logged in memory. MID 036 - CID 0279 - FMI 04
The ECM will use the data from the previous Aftercooler Temperature short
calibration.
to ground
Perform the following diagnostic procedure: “Analog
Sensor - Calibrate” SMCS Code: 1063-038

Results: Conditions Which Generate This Code:

• OK – STOP. The Electronic Control Module (ECM) reads an

output voltage that is 0.2 VDC or less for one
• REPAIRED, OK – STOP. second. The ECM has been powered for three
seconds. The CID-FMI 262-03 and/or the CID-FMI
262-04 are not active.
i01954871
System Response:
MID 036 - CID 0279 - FMI
03 Aftercooler Temperature The CID-FMI is logged in memory. The ECM no
longer optimizes engine operation according to
open/short to +batt aftercooler temperature. The ECM flags aftercooler
temperature as invalid data. The engine monitoring
SMCS Code: 1063-038 system is disabled for aftercooler temperature.
Conditions Which Generate This Code: Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test”
The Electronic Control Module (ECM) reads an
output voltage that is 4.8 VDC or more for one Results:
second. The ECM has been powered for three
seconds. The CID-FMI 262-03 and/or the CID-FMI
262-04 are not active.
• OK – STOP.

System Response:
• REPAIRED, OK – STOP.

The CID-FMI is logged in memory. The ECM no i01961675

longer optimizes engine operation according to
aftercooler temperature. The ECM flags aftercooler MID 036 - CID 0289 - FMI
temperature as invalid data. The engine monitoring
system is disabled for aftercooler temperature.
02 Unfiltered Fuel Pressure
misinstalled
Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test” SMCS Code: 1261-038-NS

Results: Conditions Which Generate This Code:

• OK – STOP. The Electronic Control Module (ECM) reads a

negative differential pressure between the unfiltered
• REPAIRED, OK – STOP. fuel pressure sensor and the filtered fuel pressure
sensor. The sensors may be installed incorrectly.

System Response:

The CID-FMI is logged in memory. The ECM flags

unfiltered fuel pressure as invalid data. The engine
monitoring system is disabled for unfiltered fuel
pressure.

Correctly install the sensor.

 77
Troubleshooting Section

Results: Results:

• REPAIRED, OK – STOP. • OK – STOP.

i01954880
• REPAIRED, OK – STOP.

MID 036 - CID 0289 - FMI i01961676

03 Unfiltered Fuel Pressure MID 036 - CID 0289 - FMI
open/short to +batt 13 Unfiltered Fuel Pressure
SMCS Code: 1261-038-NS calibration required
Conditions Which Generate This Code: SMCS Code: 1261-038-NS

The Electronic Control Module (ECM) reads signal Conditions Which Generate This Code:
voltage that is greater than 4.8 VDC for one second.
The ECM has been powered for three seconds. The The Electronic Control Module (ECM) records one
diagnostic codes 262-03 and 262-04 are not active. of the following conditions. The Unfiltered Fuel
Pressure Sensor never calibrated. The ECM reads
System Response: unfiltered fuel pressure less than 35 kPa (5 psi). The
ECM reads filtered fuel pressure more than 130 kPa
The CID-FMI is logged in memory. The ECM flags (19 psi). The unfiltered fuel pressure is more than
fuel pressure as invalid data. The engine monitoring ± 27 kPa (4 psi) from the atmospheric pressure.
system for this feature will be disabled. The unfiltered fuel pressure changes more than
25 kPa (3.6 psi) during a calibration attempt. The
Perform the following diagnostic procedure: “Engine diagnostic codes 289-03 and 289-04 are active. The
Sensor Open/Short Test” diagnostic codes 274-03 and 274-04 are active.

Results: System Response:

• OK – STOP. The diagnostic codes are not logged in memory.

The ECM will use the data from the previous
• REPAIRED, OK – STOP. calibration.

Perform the following diagnostic procedure: “Analog

i01954883
Sensor - Calibrate”
MID 036 - CID 0289 - FMI 04 Results:
Unfiltered Fuel Pressure short
to ground • OK – STOP.

SMCS Code: 1261-038-NS • REPAIRED, OK – STOP.

Conditions Which Generate This Code: i01961678

The Electronic Control Module (ECM) reads signal MID 036 - CID 0336 - FMI 02
voltage that is below 0.2 VDC for one second. The Incorrect ECS Switch inputs
ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active.
SMCS Code: 1901-038
System Response:
Conditions Which Generate This Code:
The CID-FMI is logged in memory. The ECM flags One line for the Engine Control Switch (ECS) is
unfiltered fuel pressure as invalid data. The engine
open and one line is low.
monitoring system is disabled for unfiltered fuel
pressure.

Perform the following diagnostic procedure: “Engine

Sensor Open/Short Test”
78
Troubleshooting Section

System Response: System Response:

The CID-FMI is logged in memory. The Electronic The CID-FMI is logged in memory.
Control Module (ECM) will flag the ignition switch
as invalid data. Perform the following diagnostic procedure:
“Prelubrication System”
Perform the following diagnostic procedure: “Engine
Control Switch (ECS)” Results:

Results: • OK – STOP.
• OK – STOP. • REPAIRED, OK – STOP.
• REPAIRED, OK – STOP. i01954893

i01961679 MID 036 - CID 0338 - FMI

MID 036 - CID 0337 - FMI 06 Pre-Lube Relay short to
02 Incorrect Remote E-Stop ground
Switch inputs SMCS Code: 1319-038

SMCS Code: 1901-038 Conditions Which Generate This Code:

Conditions Which Generate This Code: The Electronic Control Module (ECM) detects a
short circuit at the prelube relay.
One line for the customer shutdown switch is open
and one line is low. 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:
“Emergency Stop Switch” Results:

Results: • OK – STOP.
• OK – STOP. • REPAIRED, OK – STOP.
• REPAIRED, OK – STOP. i01954916

i01954889 MID 036 - CID 0444 - FMI 05

MID 036 - CID 0338 - FMI 05 Start Relay open circuit
Pre-Lube Relay open circuit SMCS Code: 1426-038

SMCS Code: 1319-038 Conditions Which Generate This Code:

Conditions Which Generate This Code: The Electronic Control Module (ECM) detects
an open circuit and/or a short circuit to battery
The Electronic Control Module (ECM) detects an condition.
open circuit at the prelube relay. The ECM detects
a short to battery voltage at the prelube relay. System Response:

The CID-FMI is logged in memory.

Perform the following diagnostic procedure:

“Starting Motor System”
 79
Troubleshooting Section

Results: i01954913

• OK – STOP. MID 036 - CID 0446 - FMI 06 Air

Shutoff Relay short
• REPAIRED, OK – STOP.
SMCS Code: 1078-038
i01954914
Conditions Which Generate This Code:
MID 036 - CID 0444 - FMI 06
The Electronic Control Module (ECM) detects a
Start Relay short to ground short circuit to ground. The ECM can only detect this
condition when the air shutoff relay is not energized.
SMCS Code: 1426-038
System Response:
Conditions Which Generate This Code:
The CID-FMI is logged in memory.
The Electronic Control Module (ECM) detects a
short circuit to ground condition. Perform the following diagnostic procedure: “Air
Shutoff System”
System Response:
Results:
The CID-FMI is logged in memory.

Perform the following diagnostic procedure:

• OK – STOP.
“Starting Motor System”
• REPAIRED, OK – STOP.
Results:
i01961681
• OK – STOP.
MID 036 - CID 0542 - FMI 02
• REPAIRED, OK – STOP. Unfiltered Engine Oil Pressure
misinstalled
i01954915
SMCS Code: 1924-038
MID 036 - CID 0446 - FMI 05 Air
Shutoff Relay open Conditions Which Generate This Code:

SMCS Code: 1078-038 The Electronic Control Module (ECM) reads a

negative differential pressure between the unfiltered
Conditions Which Generate This Code: engine oil pressure sensor and the filtered engine
oil pressure sensor. The sensors may be installed
The Electronic Control Module (ECM) detects incorrectly.
an open circuit and/or a short circuit to battery
condition. The ECM can only detect this condition System Response:
when the air shutoff relay is not energized.
The CID-FMI is logged in memory. The ECM flags
System Response: the unfiltered engine oil pressure as invalid data.
The engine monitoring system is disabled for
The CID-FMI is logged in memory. unfiltered engine oil pressure.

Perform the following diagnostic procedure: “Air Correctly install the sensor.
Shutoff System”
Results:
Results:
• REPAIRED, OK – STOP.
• OK – STOP.
• REPAIRED, OK – STOP.
80
Troubleshooting Section

i01954911 i01961682

MID 036 - CID 0542 - FMI 03 MID 036 - CID 0542 - FMI 13
Unfiltered Engine Oil Pressure Unfiltered Engine Oil Pressure
open/short to +batt cal required
SMCS Code: 1924-038 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) records one
voltage that is greater than 4.8 VDC for one second. of the following conditions. The oil pressure sensor
The ECM has been powered for three seconds. The never calibrated. The oil pressure is greater than ±
diagnostic codes 262-03 and 262-04 are not active. 27 kPa (4 psi) from the atmospheric pressure. The
ECM reads oil pressure less than 35 kPa (5 psi).
System Response: The oil pressure is greater than 130 kPa (19 psi).
The oil pressure changes more than 25 kPa (3.6 psi)
The CID-FMI is logged in memory. The ECM flags during a calibration attempt. The diagnostics 274-03
oil pressure as invalid data and a default value of or 274-04 are active.
500 kPa (73 psi) is used.
System Response:
Perform the following diagnostic procedure: “Engine
Sensor Open/Short Test” The diagnostic codes are not logged in memory.

Results: Perform the following diagnostic procedure: “Analog

Sensor - Calibrate”
• OK – STOP.
Results:
• REPAIRED, OK – STOP.
• OK – STOP.
i01954910
• REPAIRED, OK – STOP.
MID 036 - CID 0542 - FMI 04
Unfiltered Engine Oil Pressure i01961686

short to ground MID 036 - CID 0545 - FMI 05

SMCS Code: 1924-038
Ether Start Relay open/short
to +batt
Conditions Which Generate This Code:
SMCS Code: 1456-038
The Electronic Control Module (ECM) reads signal
voltage that is below 0.2 VDC for one second. The Conditions Which Generate This Code:
ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. The Electronic Control Module (ECM) has been
powered up for two seconds. The ECM detects an
System Response: open circuit and/or a short circuit to the +Battery
terminal at the output to the ether start relay.
The CID-FMI is logged in memory. The ECM flags
oil pressure as invalid data and a default value of System Response:
500 kPa (73 psi) is used.
The CID-FMI is logged in memory. Ether injection
Perform the following diagnostic procedure: “Engine is disabled.
Sensor Open/Short Test”
Perform the following diagnostic procedure: “Ether
Results: Injection System”

• OK – STOP. Results:

• REPAIRED, OK – STOP. • OK – STOP.

 81
Troubleshooting Section

• REPAIRED, OK – STOP. i01961692

MID 036 - CID 0546 - FMI 06

i01961687
Ether Hold Relay short to +batt
MID 036 - CID 0545 - FMI 06
SMCS Code: 1456-038
Ether Start Relay short to
ground Conditions Which Generate This Code:

SMCS Code: 1456-038 The ECM has been powered up for two seconds.
The Electronic Control Module (ECM) detects a
Conditions Which Generate This Code: short circuit to the +Battery at the output to the
ether hold relay.
The Electronic Control Module (ECM) has been
powered up for two seconds. The ECM detects a System Response:
short circuit to ground at the output to the ether
start relay. The CID-FMI is logged in memory. Ether injection
is disabled.
System Response:
Perform the following diagnostic procedure: “Ether
The CID-FMI is logged in memory. Ether injection Injection System”
is disabled.
Results:
Perform the following diagnostic procedure: “Ether
Injection System” • OK – STOP.
Results: • REPAIRED, OK – STOP.
• OK – STOP. i01954909

• REPAIRED, OK – STOP. MID 036 - CID 0827 - FMI 08 Left

Exhaust Temperature signal
i01961690
abnormal
MID 036 - CID 0546 - FMI 05
SMCS Code: 1919-038
Ether Hold Relay open/short to
ground Conditions Which Generate This Code:

SMCS Code: 1456-038 The Electronic Control Module (ECM) has been
powered for three seconds. The diagnostic codes
Conditions Which Generate This Code: 263-03 and 263-04 are not active. The sensor
frequency is greater than 1000 Hz or less than 150
The Electronic Control Module (ECM) has been Hz. The duty cycle is greater than 90 percent or
powered up for two seconds. The ECM detects an less than 10 percent.
open circuit and/or a short circuit to ground at the
output to the ether hold relay. System Response:

System Response: The CID-FMI is logged in memory. The status

screen on Caterpillar Electronic Technician (ET) will
The CID-FMI is logged in memory. Ether injection show the parameter as invalid data.
is disabled.
Perform the following diagnostic procedure: “Engine
Perform the following diagnostic procedure: “Ether Sensor Open/Short Test”
Injection System”
Results:
Results:
• OK – STOP.
• OK – STOP.
• REPAIRED, OK – STOP.
• REPAIRED, OK – STOP.
82
Troubleshooting Section

i01936099

MID 036 - CID 0828 - FMI 08

Right Exhaust Temperature
signal abnormal
SMCS Code: 1919-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) has been

powered for three seconds. The diagnostic codes
262-03 and 262-04 are not active. The sensor
frequency is greater than 1000 Hz or less than 150
Hz. The duty cycle is greater than 95 percent or
less than 5 percent.

System Response:

The code is logged. The status screen on the

Caterpillar Electronic Technician (ET) will show the
parameter as invalid data.

Perform the following diagnostic procedure: “Engine

Sensor Open/Short Test”

Results:

• OK – STOP.
• REPAIRED, OK – STOP.
 83
Troubleshooting Section

Troubleshooting with an
Event Code
i01962208

Event Codes
SMCS Code: 1901-038

Use this section for the troubleshooting of problems

that have generated event codes but do not have
active diagnostic codes. When the event code is
generated, the event is active. Any generated code
becomes logged in the permanent memory of the
Electronic Control Module (ECM).

Event codes alert the operator that an abnormal

engine operating condition such as low oil pressure
or high coolant temperature has been detected.
Events do not indicate problems with the electronic
system. Event codes also indicate the nature of the
problem. Event codes may be viewed on a personal
computer that has the software for the Caterpillar
Electronic Technician (ET).

g00740986
Illustration 15
Typical example

Illustration 15 indicates output voltage from

the coolant temperature sensor. As you look at
Illustration 15, notice the output voltage of the
sensor. An event code is generated when the ECM
detects an output voltage from the sensor which
indicates an above normal operating temperature.

Programmable Engine Parameters

You can program the engine to perform the following
actions for some applications:

• Engine shutdown
• Engine alarm
• Engine derate
84
Troubleshooting Section

Table 38 Expected Result:

3500B System Event Codes
No diagnostic codes are present.
Event Code Description
Results:
E017 High Engine Coolant
Temperature Warning
• OK – No diagnostic codes are present. Proceed
E100 Low Engine Oil Pressure to Test Step 2.
Warning
E190 Engine Overspeed • Not OK – Diagnostic codes are present.
Warning
Repair: Repair the diagnostic codes that are
E272 Inlet Air Restriction present. Refer to the appropriate topic in the
Warning “Troubleshooting With a Diagnostic Code” section
of this manual. Ensure that the repair eliminates
the problem.
i01909401
STOP.
E017 High Engine Coolant
Temperature Warning Test Step 2. Perform a Check of the
Cooling System.
SMCS Code: 1901-038
A. Perform a check of the cooling system. Refer
Conditions Which Generate This Code: to the diagnostic procedure Troubleshooting,
“Coolant Temperature is Too High” for possible
The Electronic Control Module (ECM) detects the causes.
following condition:
Expected Result:
• Engine coolant temperature that is greater

than
the default temperature of 102 C (216 F) for There are no problems with the cooling system.
five seconds
Results:
System Response:
• OK – There may be an intermittent problem.
The event is logged. After the temperature returns
below 97 C (207 F) the warning due to high Repair: Monitor the operation of the engine.
coolant temperature will be turned off. Repair the problem. Ensure that the repair
eliminates the problem.
Possible Performance Effect:
STOP.
• None
• Not OK – There is a problem with the cooling
Troubleshooting: 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.

Test Step 1. Check for “ACTIVE”

i01962213
Diagnostic Codes.
A. Start the Caterpillar Electronic Technician (ET).
E100 Low Engine Oil Pressure
Warning
B. Turn the main power to the ON position.
SMCS Code: 1901-038
C. Check for any active diagnostic codes or for
logged diagnostic codes. Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects all of

the following conditions:
 85
Troubleshooting Section

• The engine has been running for at least ten Test Step 2. Perform a Check of the
seconds after engine speed is within 50 rpm of Engine Lubrication System.
low idle.
A. Perform a check of the engine lubrication
• Engine oil pressure is low for four seconds. system. Refer to the diagnostic procedure
Troubleshooting, “Low Engine Oil Pressure”.
• 100-03 “Engine Oil Pressure open/short to +batt”
is not active. Expected Result:

• 100-04 “Engine Oil Pressure short to ground” is There are problems with engine oil pressure.
not active.
Results:
System Response:
• OK – There are problems with engine oil pressure.
The ECM will log the event.
Repair: Repair the problem. Ensure that the repair
Possible Performance Effect: eliminates the problem.

• None STOP.

Troubleshooting: • Not OK – There are no problems with engine oil

pressure. There may be an intermittent problem.
• There may be a problem with the engine
lubrication system. Repair: Monitor the operation of the engine.
Repair the problem. Ensure that the repair
• There may be a problem with the engine oil eliminates the problem.
pressure sensor.
STOP.
Test Step 1. Check for “ACTIVE”
Diagnostic Codes.
i01962210

A. Start the Caterpillar Electronic Technician (ET). E190 Engine Overspeed

B. Turn the main power to the ON position. Warning
C. Check for any active diagnostic codes or logged SMCS Code: 1901-038
diagnostic codes.
Conditions Which Generate This Code:
Expected Result:
Engine speed is above the setpoint for engine
There are no diagnostic codes that are present. overspeed. The default value for engine overspeed
is dependent on the application. Use the Caterpillar
Results: Electronic Technician (ET) in order to monitor the
system parameter for engine overspeed.
• OK – There are no diagnostic codes that are
present. Proceed to Test Step 2. System Response:

• Not OK – There are diagnostic codes that are The event is logged in memory. If the engine speed
present. decreases 100 rpm below the default setpoint, the
warning will become inactive.
Repair: Repair the diagnostic codes that are
present. Refer to the appropriate topic in the Possible Performance Effect:
“Troubleshooting With a Diagnostic Code” section
of this manual. Ensure that the repair eliminates None
the problem.
Troubleshooting:
STOP.
This event indicates excessive engine speed. This
does not represent a problem with the Electronic
Control Module (ECM). This event does not
represent a problem with the engine speed/timing
sensor.
86
Troubleshooting Section

Engine Overspeed Warning Results:

This event records the engine overspeed warning. • OK – There are no diagnostic codes that are
No troubleshooting is required. present. Proceed to Test Step 2.

Expected Result: • Not OK – There are diagnostic codes that are

present.
Results:
Repair: Repair the diagnostic codes that are
• OK – STOP. present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section
of this manual.
i01962209

E272 Inlet Air Restriction Ensure that the repair eliminates the problem.

Warning STOP.

SMCS Code: 1901-038 Test Step 2. Perform a Check of the Air

Inlet System.
Conditions Which Generate This Code:
A. Perform a check of the air inlet system. Refer to
The Electronic Control Module (ECM) detects one the Testing and Adjusting manual for information
of the following conditions: on inspecting the air inlet and exhaust system.

• The air inlet pressure for the left turbocharger is Expected Result:
above the default value of 7 kPa (28 inches of H2O)
for five seconds. There are no problems with the air inlet system.

• The air inlet pressure for the right turbocharger is Results:

above the default value of 7 kPa (28 inches of H2O)
for five seconds. • OK – There may be an intermittent problem.
System Response: Repair: Monitor the operation of the engine.
Repair the problem. Ensure that the repair
The ECM will log the event. eliminates the problem.

Possible Performance Effect: STOP.

• None • Not OK – There is a problem with the air inlet

system.
Troubleshooting:
Repair: Repair the problem. Ensure that the repair
• There may be a problem with the air inlet system. eliminates the problem.

• There may be a problem with one of the air inlet STOP.

pressure sensors.

Test Step 1. Check for “ACTIVE”

Diagnostic Codes.
A. Start the Caterpillar Electronic Technician (ET).

B. Turn the main power to the ON position. The

engine should be OFF.

C. Check for any active diagnostic codes or logged

diagnostic codes.

Expected Result:

There are no diagnostic codes that are present.

 87
Troubleshooting Section

Diagnostic Functional
Tests
i01962786

Air Shutoff System

SMCS Code: 1078-038

System Operation Description:

The Electronic Control Module (ECM) has the ability

to stop the engine in an emergency situation by
shutting off the intake air supply. The ECM activates
two relays which energize the two air shutoff
solenoids. The solenoids trip the air shutoff valves.
The presence of a switch at each air shutoff valve
informs the ECM that the air shutoff solenoids have
activated. Unless the air shutoff valves are manually
opened, the ECM will not attempt to restart the
engine.

There are two conditions which cause the engine

control to activate the air shutoff relay. The first
condition occurs when the operator initiates a
remote shutdown. If the customer’s emergency stop
is activated, the shutdown inputs to the ECM are
open. This signals the ECM to turn on the output
for the air shutoff relays. The ECM will hold the air
shutoff relays active for 1.5 seconds. The second
condition occurs for an engine overspeed. The
engine overspeed could be an actual overspeed or
a simulated overspeed. The simulated overspeed
can be obtained by using the overspeed verify
switch. When the overspeed verify switch is
activated, the ECM will activate the output for the
air shutoff relays at 75 percent of the overspeed
setpoint.

The air shutoff relays can also be activated without

the aid of the ECM. When the emergency stop on
the instrument panel is depressed, the air shutoff
relays are activated. The air shutoff timer will allow
the air shutoff relays to deactivate after 2.5 seconds
in order to prevent damage to the air shutoff
solenoids.

Regardless of the reason for activation, the Engine

Control Switch (ECS) must be turned to the
OFF/RESET position for three seconds in order to
reset the ECM and the air shutoff timer. The operator
must manually open the air shutoff valves in order
to reset the switches at the air shutoff valves.
88
Troubleshooting Section

g01019840
Illustration 16
Typical example

Test Step 1. Check for Connector E. Check the ECM connector (allen head screw) for
Damage. the proper torque of 6.0 N·m (55 lb in).

A. Turn the circuit breaker for the battery to the OFF F. Check the customer connector (allen head
position. screw) for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in).
B. Turn the ECS to the OFF/RESET position.
G. Check the harness and the wiring for abrasion
C. Thoroughly inspect the ECM connectors and for pinch points.
J1/P1 and J2/P2. Inspect all of the other
connectors. Refer to the diagnostic functional Expected Result:
test Troubleshooting, “Inspecting Electrical
Connectors” for details. All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring
D. Perform a 45 N (10 lb) pull test on each of the are free of corrosion, of abrasion or of pinch points.
wires in the ECM connector that are associated
with the circuit.
 89
Troubleshooting Section

Results: C. Turn the ECS to the ON position. The engine

should be off.
• OK – The connectors and wiring are okay.
Proceed to Test Step 2. D. Access the override on Cat ET. Activate the
override for the air shutoff.
• Not OK – The connectors and/or wiring are not
okay. E. Disable the override for the air shutoff.

Repair: Repair the connectors or wiring and/or F. If a second air shutoff relay is installed, repeat
replace the connectors or wiring. the above steps for the other air shutoff relay.

STOP. Expected Result:

Test Step 2. Test the Air Shutoff System. The voltage measures 24 ± 3 VDC.

A. Turn the circuit breaker for the battery to the ON Results:

position.
• OK – The voltage measures 24 ± 3 VDC for 1.5
B. Turn the ECS to the OFF/RESET position. seconds. The relay is operating correctly. Proceed
to Test Step 4.
C. Connect the Caterpillar Electronic Technician
(ET). • Not OK – The voltage did not measure 24 ± 3
VDC for 1.5 seconds. Proceed to Test Step 5.
D. Turn the ECS to the ON position. The engine
should be off. Test Step 4. Test for Voltage at the Air
Shutoff Solenoids.
E. Access the override on Cat ET. Activate the
override for the air shutoff. A. Turn the ECS to the OFF/RESET position.

F. Disable the override for the air shutoff. B. At the air shutoff solenoid, disconnect the wires
that go to the air shutoff solenoid.
Expected Result:
C. Use a voltmeter to measure the voltage at the air
The air shutoff relay activates. The air shutoff relay shutoff solenoid. Connect the voltmeter across
deactivates after 1.5 seconds. While the air shutoff the wires that were removed from the solenoid in
relay was active, the air shutoff solenoid activated. the previous step.

Results: D. Turn the ECS to the ON position. The engine

should be off.
• OK – The air shutoff solenoid activated correctly.
E. Access the override on Cat ET. Activate the
Repair: The problem may be intermittent. If the override for the air shutoff.
problem is intermittent, refer to the diagnostic
functional test Troubleshooting, “Inspecting F. Disable the override for the air shutoff.
Electrical Connectors”.
G. If a second air shutoff solenoid is installed, repeat
STOP. the above steps for the other air shutoff solenoid.

• Not OK – The air shutoff solenoid failed to Expected Result:

activate. Proceed to Test Step 3.
The voltage measures 24 ± 3 VDC.
Test Step 3. Test for Voltage from the Air
Shutoff Relay. Results:

A. Turn the ECS to the OFF/RESET position. • OK – The voltage measures 24 ± 3 VDC for 1.5
seconds. The circuit is operating correctly to this
B. The output to the air shutoff solenoids is terminal point.
30 on the air shutoff relays. The wires to the
solenoids are 395-BR and 394-GR. Connect a
voltmeter between terminal 30 on the air shutoff
relay and the −Battery terminal.
90
Troubleshooting Section

Repair: Temporarily install a new air shutoff Test Step 6. Check the Resistance at the
solenoid. Ensure that the problem is no longer Connector of the Air Shutoff Timer.
present. Reinstall the old solenoid. If the problem
returns, replace the air shutoff solenoid. A. Turn the ECS to the OFF/RESET position.

STOP. B. Disconnect the connector to the air shutoff timer.

• Not OK – The voltage did not measure 24 ± 3 C. Check the resistance at the connector of the air
VDC for 1.5 seconds. System voltage was not shutoff timer. Check the resistance between wire
available at the air shutoff solenoid. There is a 200-BK on pin 1 and the −Battery terminal.
problem in the wiring between the air shutoff
solenoid and the air shutoff relay. D. Check the resistance at the connector of the air
shutoff timer. Check the resistance between wire
Repair: Repair the connectors or wiring and/or F708-YL on pin 2 and wire 055-WH on pin 3.
replace the connectors or wiring.
Expected Result:
STOP.
The resistance of the wire on pin 1 is less than 10
Test Step 5. Test for Voltage at the Coil of Ohms. The resistance between the wires on pin 2
the Air Shutoff Relay. and pin 3 is approximately 260 Ohms if one relay is
present. The resistance between the wires on pin
A. Turn the ECS to the OFF/RESET position. 2 and pin 3 is approximately 130 Ohms when two
relays are present.
B. Remove wire F708-YL from the coil of the air
shutoff relay. If two air shutoff relays are present Results:
disconnect wire F708-YL from both coils of
the relays. Connect a voltmeter between wire • OK – The resistance on the wires meets the
F708-YL of the air shutoff relay and the −Battery above requirements. The relay coils are okay. The
terminal. relay’s NORMALLY OPEN contacts may be faulty.

C. Turn the ECS to the ON position. The engine Repair: Temporarily install a new air shutoff
should be off. solenoid. Ensure that the problem is no longer
present. If the problem still exists, the air shutoff
D. Access the override on Cat ET. Activate the relay is okay. Replace the air shutoff timer. Verify
override for the air shutoff. that this solves the problem.

This test will cause a 446-05 CID-FMI to be STOP.

logged. Be sure to delete this CID-FMI when this
test is completed. • Not OK – The resistance does not meet the
above requirements. Check the coil of the air
E. Disable the override for the air shutoff. shutoff relay for an open. The coil resistance
should be approximately 260 Ohms.
F. If a second air shutoff relay is installed, repeat
the above steps for the other air shutoff relay. Repair: Replace the air shutoff relay if the coil of
the relay is bad. Repair the connectors or wiring
G. Reconnect all wires. and/or replace the connectors or wiring.

Expected Result: STOP.

The voltage measures 24 ± 3 VDC. Test Step 7. Test the Output Voltage from
the ECM.
Results:
A. Turn the ECS to the OFF/RESET position.
• OK – The voltage measures 24 ± 3 VDC for 1.5
seconds. Voltage from the ECM was present. B. Disconnect P1 from the ECM. Remove the wire
Proceed to Test Step 6. F708-YL from P1-28.

• Not OK – The voltage did not measure 24 ± 3 C. Install a jumper wire at P1-28. Reconnect ECM
VDC. The voltage from the ECM was not present. connector P1.
Proceed to Test Step 7.
 91
Troubleshooting Section

D. Connect the voltmeter between the wire jumper Note: The analog sensors are not protected from
in P1-28 and the −Battery terminal. overvoltage. A short from the analog supply line to
the +Battery supply may damage the sensors. If
E. Turn the ECS to the ON position. The engine CID-FMI 262-03 is logged, it is possible that all of
should be off. the analog sensors have been damaged. Repair the
analog sensor supply and check for any “ACTIVE”
F. Access the override on Cat ET. Activate the sensor diagnostic codes in order to determine if a
override for the air shutoff. sensor has failed.

Note: This test will cause a 446-05 CID-FMI to be Note: The engine monitoring system may be
logged. Be sure to delete this CID-FMI when this programmed by dealers and/or customers in some
test is completed. instances. Dealers and/or customers can monitor
customized warnings, derates, shutdown override
G. Disable the override for the air shutoff. setpoints, and delay times using the Caterpillar
Electronic Technician (ET). Customized parameters
H. Turn the ECS to the OFF/RESET position. Remove may affect the behavior of the ECM. The behavior of
the wire jumper. the ECM may vary from the description that is given
in this system operation section. You may refer to
Expected Result: Troubleshooting, “Engine Monitoring System” in
order to determine if there are any parameters that
The voltage measures 24 ± 3 VDC for 1.5 seconds. are affecting engine operation.

Results: The following list contains a description of the

analog sensors that are found on the engine.
• OK – The voltage measures 24 ± 3 VDC for 1.5
seconds. Voltage from the ECM was present. Aftercooler Temperature Sensor – The ECM uses the
There is a problem in the wiring between the ECM signal from the sensor to monitor changes in system
and the air shutoff relay. temperature. The ECM makes adjustments to the
system’s operating parameters as the temperature
Repair: Repair the connectors or wiring and/or changes. This allows the engine to operate at
replace the connectors or wiring. optimal performance through a wide range of
operating temperatures. The operating range of the
STOP. sensor is −40 C to 120 C (−40 F to 248 F). If the
value is not in this range, the previous calibration
• Not OK – The voltage did not measure 24 ± 3 will be used. Refer to the diagnostic calibration
VDC for 1.5 seconds. The voltage from the ECM procedure Troubleshooting, “Anolog Sensor -
was not present. Calibrate”.

Repair: Replace the ECM. Refer to the diagnostic Coolant Temperature Sensor – The operating range
procedure Troubleshooting, “Replacing the ECM”. of the sensor is −40 C to 120 C (−40 F to 248 F).
The ECM calibrates the sensor within the first
STOP. five seconds after power is applied to the ECM.
The ECM checks the sensor value against an
acceptable pressure range. If the value is not in
i01963497
this range, the previous calibration will be used.
Analog Sensor Supply Refer to the diagnostic calibration procedure
Troubleshooting, “Anolog Sensor - Calibrate”.
SMCS Code: 1901-038
Filtered Fuel Pressure Sensor – The sensor is used
System Operation Description: in conjunction with the unfiltered fuel pressure
sensor to determine the restriction across the fuel
The analog sensor supply provides power to all filters. The sensor output is a DC voltage that varies
analog sensors. The Electronic Control Module with filtered fuel pressure between 0.2 VDC and 4.8
(ECM) supplies 5.0 ± 0.2 VDC from the ECM VDC. The sensor is located on the end cap of the
connector J1/P1 to each analog sensor connector. fuel filter housing. The operating range of the sensor
The sensor return line connects to the ECM is 0.0 kPa to 1090 kPa (0.0 psi to 158 psi). The ECM
connector J1/P1. The analog sensor supply is calibrates the sensor within the first five seconds
output short circuit protected. A short circuit to the after power is applied to the ECM. The ECM checks
battery will not damage the circuit inside the ECM. the sensor value against an acceptable pressure
range. If the pressure value is not in this range,
the previous calibration will be used. Refer to the
diagnostic calibration procedure Troubleshooting,
“Anolog Sensor - Calibrate”.
92
Troubleshooting Section

Unfiltered Fuel Pressure Sensor – The sensor is Left Turbocharger Compressor Inlet Pressure
used in conjunction with the filtered fuel pressure Sensor – The sensor is used in conjunction with
sensor to determine the restriction across the fuel the atmospheric pressure sensor to determine if the
filters. The sensor output is a DC voltage that varies engine air filter is plugged. The sensor indicates
with unfiltered fuel pressure between 0.2 VDC and if the left turbocharger compressor inlet has a
4.8 VDC. The sensor is located on the end cap of restriction. The sensor output is a DC voltage
the fuel filter housing. The operating range of the between 0.2 VDC and 4.8 VDC that varies with
sensor is 0.0 kPa to 1090 kPa (0.0 psi to 158 psi). left turbocharger compressor inlet pressure. The
The ECM calibrates the sensor within the first operating range of the sensor is 0.0 kPa to 111 kPa
five seconds after power is applied to the ECM. (0.0 psi to 16 psi). The ECM calibrates the sensor
The ECM checks the sensor value against an within the first five seconds after power is applied to
acceptable pressure range. If the pressure value is the ECM. The ECM checks the sensor value against
not in this range, the previous calibration will be an acceptable pressure range. If the pressure value
used. Refer to the diagnostic calibration procedure is not in this range, the previous calibration will be
Troubleshooting, “Anolog Sensor - Calibrate”. used. Refer to the diagnostic calibration procedure
Troubleshooting, “Anolog Sensor - Calibrate”.
Filtered Engine Oil Pressure Sensor – The sensor
is used in conjunction with the unfiltered engine Right Turbocharger Compressor Inlet Pressure
oil pressure sensor in order to determine the Sensor – The sensor is used in conjunction with
restriction across the engine oil filters. The ECM the atmospheric pressure sensor to determine if the
uses this sensor to detect low engine oil pressure engine air filter is plugged. The sensor indicates
which may indicate a failed engine oil pump or low if the right turbocharger compressor inlet has
engine oil pressure. The signal is compared with a restriction. The sensor output is a DC voltage
a map of engine oil pressure versus engine rpm between 0.2 VDC and 4.8 VDC that varies with
which is stored in the ECM. The sensor output is right turbocharger compressor inlet pressure. The
a DC voltage that varies with engine oil pressure operating range of the sensor is 0.0 kPa to 111 kPa
between 0.2 VDC and 4.8 VDC. The sensor is (0.0 psi to 16 psi). The ECM calibrates the sensor
located downstream of the engine oil filter. The within the first five seconds after power is applied to
operating range of the sensor is 0.0 kPa to 1090 kPa the ECM. The ECM checks the sensor value against
(0.0 psi to 158 psi). The ECM calibrates the sensor an acceptable pressure range. If the pressure value
within the first five seconds after power is applied to is not in this range, the previous calibration will be
the ECM. The ECM checks the sensor value against used. Refer to the diagnostic calibration procedure
an acceptable pressure range. If the pressure value Troubleshooting, “Anolog Sensor - Calibrate”.
is not in this range, the previous calibration will be
used. Refer to the diagnostic calibration procedure Turbocharger Compressor Outlet Pressure Sensor –
Troubleshooting, “Anolog Sensor - Calibrate”. The sensor is used to obtain boost pressure. Boost
pressure is used to control the ratio of fuel to air
Unfiltered Engine Oil Pressure Sensor – The sensor during acceleration. The ECM limits the amount
is used in conjunction with the filtered engine of fuel that is injected, based upon inlet manifold
oil pressure sensor to determine the restriction pressure. Information in the ECM defines the
across the engine oil filters. The sensor output is relationship between the manifold pressure and
a DC voltage that varies with unfiltered engine the fuel ratio control limit (FRC). The operation
oil pressure between 0.2 VDC and 4.8 VDC. The is similar to the fuel ratio control on an engine
sensor is located before the engine oil filters in the with a mechanical governor. The sensor output
oil passage of the engine oil filter housing. The is a DC voltage between 0.2 VDC and 4.8 VDC
operating range of the sensor is 0.0 kPa to 1090 kPa that varies with turbocharger outlet pressure. The
(0.0 psi to 158 psi). The ECM calibrates the sensor operating range of the sensor is 0.0 kPa to 452 kPa
within the first five seconds after power is applied to (0.0 psi to 65 psi). The ECM calibrates the sensor
the ECM. The ECM checks the sensor value against within the first five seconds after power is applied to
an acceptable pressure range. If the pressure value the ECM. The ECM checks the sensor value against
is not in this range, the previous calibration will be an acceptable pressure range. If the pressure value
used. Refer to the diagnostic calibration procedure is not in this range, the previous calibration will be
Troubleshooting, “Anolog Sensor - Calibrate”. used. Refer to the diagnostic calibration procedure
Troubleshooting, “Anolog Sensor - Calibrate”.
 93
Troubleshooting Section

Atmospheric Pressure Sensor – The sensor is

used to provide an atmospheric pressure signal
to the ECM. If the atmospheric pressure sensor
should fail, the right turbocharger compressor inlet
pressure sensor is used as a substitute. If the right
turbocharger compressor inlet pressure sensor
should fail, the left turbocharger compressor inlet
pressure sensor is used as a substitute. The sensor
output is a DC voltage between 0.2 VDC and 4.8
VDC that varies with atmospheric pressure. The
operating range of the sensor is 0.0 kPa to 111 kPa
(0.0 psi to 16 psi). The sensor is used to calibrate
the other pressure sensors within the first five
seconds after power is applied to the ECM. The
ECM checks the sensor value against an acceptable
pressure range. If the pressure value is not in this
range, a diagnostic message will be generated and
the engine may be derated. Refer to the diagnostic
calibration procedure Troubleshooting, “Anolog
Sensor - Calibrate”.

Crankcase Pressure Sensor – The sensor is used in

conjunction with the atmospheric pressure sensor to
determine if the engine crankcase pressure is too
high. The atmospheric pressure is subtracted from
the absolute crankcase pressure. The difference
between the atmospheric pressure and the absolute
crankcase pressure is the differential crankcase
pressure. The sensor output is a DC voltage
between 0.2 VDC and 4.8 VDC that varies with
crankcase pressure. The operating range of the
sensor is 0.0 kPa to 111 kPa (0.0 psi to 16 psi).
The ECM calibrates the sensor within the first
five seconds after power is applied to the ECM.
The ECM checks the sensor value against an
acceptable pressure range. If the pressure value is
not in this range, the previous calibration will be
used. Refer to the diagnostic calibration procedure
Troubleshooting, “Anolog Sensor - Calibrate”.
94
Troubleshooting Section

g00599048
Illustration 17
 95
Troubleshooting Section

Typical example

Test Step 1. Check for Connector Expected Result:

Damage.
The resistance is more than 20,000 Ohms for each
A. Turn the circuit breaker for the battery to the OFF measurement.
position.
Results:
B. Turn the ECS to the OFF/RESET position.
• OK – The resistance is greater than 20,000
C. Thoroughly inspect the ECM connectors Ohms. Proceed to Test Step 3.
J1/P1 and J2/P2. Inspect all of the other
connectors. Refer to the diagnostic functional • Not OK – The resistance is less than 20,000
test Troubleshooting, “Inspecting Electrical Ohms.
Connectors” for details.
Repair: Repair the connectors and/or wiring or
D. Perform a 45 N (10 lb) pull test on each of the replace the connectors and/or wiring.
wires in the ECM connector that are associated
with the circuit. STOP.

E. Check the ECM connector (allen head screw) for Test Step 3. Check the Analog Sensor
the proper torque of 6.0 N·m (55 lb in). Supply Voltage at the ECM.
F. Check the customer connector (allen head A. Remove wire 997-OR from P1-36. Install a wire
screw) for the proper torque of 2.25 ± 0.25 N·m jumper into P1-36.
(20 ± 2 lb in).
B. Remove wire 993-BR from P1-30. Install a wire
G. Check the harness and the wiring for abrasion jumper into P1-30.
and for pinch points.
Note: If you remove the sensor common from
Expected Result: the ECM, an open circuit diagnostic code will
be generated for all sensors that use the sensor
All connectors, pins, and sockets are completely common. Troubleshoot the original code. Delete the
coupled and/or inserted, and the harness and wiring logged diagnostic codes when you are finished.
are free of corrosion, of abrasion or of pinch points.
C. Turn the circuit breaker for the battery to the ON
Results: position.

• OK – The connectors and wiring are okay. D. Turn the ECS to the STOP position. The engine
Proceed to Test Step 2. should be off.

• Not OK – The connectors and/or wiring are not E. Measure the voltage between the analog sensor
okay. supply P1-36 and the analog sensor return
P1-30.
Repair: Repair the connectors and/or wiring or
replace the connectors and/or wiring. F. Turn the ECS to the OFF/RESET position.

STOP. G. Remove the wire jumpers. Reinstall wires 997-OR

and 993-BR. Reconnect ECM connector J1/P1.
Test Step 2. Check for a Short Circuit in
the Harness. Expected Result:

A. Disconnect ECM connector J1/P1. Disconnect all The supply voltage is 5.0 ± 0.2 VDC.
of the analog sensors.
Results:
B. Measure the resistance between the analog
supply P1-36 and the analog return P1-30. • OK – The supply voltage is 5.0 ± 0.2 VDC.
Proceed to Test Step 4.
C. Measure the resistance between the analog
supply P1-36 and the engine ground. • Not OK – The supply voltage is not 5.0 ± 0.2
VDC.
D. Measure the resistance between the analog
return P1-30 and the engine ground.
96
Troubleshooting Section

Repair: The supply voltage is not correct at the Expected Result:

ECM. Perform the following diagnostic functional
test Troubleshooting, “Electrical Power Supply”. The supply voltage is 5.0 ± 0.2 VDC after each
analog sensor is connected.
STOP.
Results:
Test Step 4. Check the Analog Sensor
Supply Voltage at the Sensor Connector. • OK – The analog supply voltage is 5.0 ± 0.2
VDC when all of the sensors are connected. The
A. Turn the ECS to the STOP position. The engine analog sensor supply and the harness are okay.
should be off.
Repair: The problem may be intermittent. If the
B. Measure the voltage between socket A and problem is intermittent, perform the diagnostic
socket B on the harness side of all analog sensor functional test Troubleshooting, “Inspecting
connectors. Ensure that you are measuring on Electrical Connectors”.
the harness side of the connector since the
sensors are disconnected. STOP.

C. Turn the ECS to the OFF/RESET position. • Not OK – The supply voltage is not 5.0 ± 0.2
VDC after a sensor is connected. The sensor may
Expected Result: be internally shorted.

The supply voltage is 5.0 ± 0.2 VDC. Repair: Temporarily install a new sensor. Ensure
that the problem is no longer present. Reinstall
Results: the old sensor. If the problem returns, replace the
sensor.
• OK – The supply voltage is 5.0 ± 0.2 VDC.
Proceed to Test Step 5. STOP.

• Not OK – The supply voltage is not 5.0 ± 0.2 i01963559

VDC. There is an open circuit in the harness or
connectors. CAT Data Link
Repair: Repair the connectors and/or wiring or SMCS Code: 1901-038
replace the connectors and/or wiring.
System Operation Description:
STOP.
The CAT Data Link is a pair of twisted wires that
Test Step 5. Check the Analog Sensors are used for communication between electronic
for Short Circuits. modules. The engine’s Electronic Control Module
(ECM) communicates with the electronic monitoring
A. Turn the ECS to the STOP position. The engine system over the CAT Data Link. The CAT Data Link
should be off. is used to share status and diagnostic information
with the Caterpillar Electronic Technician (ET). The
B. Connect one analog sensor at a time. CAT Data Link is used to program the ECM. The
CAT Data Link is used to troubleshoot the ECM.
Note: If the sensor is disconnected from the
harness, an open circuit diagnostic code will be
generated for that sensor. Troubleshoot the original
code. Delete the logged diagnostic codes when
you are finished.

C. Measure the analog sensor supply voltage at a

sensor connector between socket A and socket
B on the harness side of the connector. Repeat
this step with all of the analog sensors.

D. Turn the ECS to the OFF/RESET position.

 97
Troubleshooting Section

g00756646
Illustration 18
Typical example

Test Step 1. Check for Connector • Not OK – The connectors and/or wiring are not
Damage. okay.

A. Turn the circuit breaker for the battery to the OFF Repair: Repair the connector and/or wiring or
position. replace the connector and/or wiring.

B. Turn the ECS to the OFF/RESET position. STOP.

C. Thoroughly inspect the ECM connectors Test Step 2. Check the CAT Data Link.
J1/P1 and J2/P2. Inspect all of the other
connectors. Refer to the diagnostic functional A. Turn the ECS to the OFF/RESET position.
test Troubleshooting, “Inspecting Electrical
Connectors” for details. B. Connect CAT ET.

D. Perform a 45 N (10 lb) pull test on each of the C. Turn the circuit breaker for the battery to the ON
wires in the ECM connector that are associated position.
with the circuit.
D. Turn the ECS to the STOP position.
E. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in). E. Check for any logged diagnostic codes.

F. Check the customer connector (allen head F. Start the engine and read the status information
screw) for the proper torque of 2.25 ± 0.25 N·m on CAT ET.
(20 ± 2 lb in).
G. Observe the engine oil pressure and the coolant
G. Check the harness and the wiring for abrasion temperature on the electronic monitoring system.
and for pinch points.
Note: If some of the parameters, but not all of the
Expected Result: parameters were displayed, the CAT Data Link is
okay. Check the component that is associated with
All connectors, pins, and sockets are completely any missing parameter.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points. Expected Result:

Results: CAT ET displays the status information. The

electronic monitoring system displays engine
• OK – The connectors and wiring are okay. parameters.
Proceed to Test Step 2.
98
Troubleshooting Section

Results: Results:

• OK – The CAT Data Link is operating correctly • OK – The voltage is 24 ± 3 VDC.

at this time.
Repair: Repair the service tool connector and/or
Repair: The problem may be intermittent. If the wiring or replace the service tool connector
problem is intermittent, refer to the diagnostic and/or wiring.
functional test Troubleshooting, “Inspecting
Electrical Connectors”. STOP.

STOP. • Not OK – The voltage is not 24 ± 3 VDC. There

is a problem in the harness or in the electrical
• No Parameter Displayed. – There is a problem power supply.
with communications between the ECM and the
CAT ET. Proceed to Test Step 3. Repair: Check the voltage from terminal 3 of the
Engine Control Switch (ECS). Verify that voltage is
• Service Tool Did Not Power Up. – The CAT ET or present at terminal 1 of the ECS. Verify that the
the communication adapter did not power up. “battery breaker” is not tripped.
Proceed to Test Step 4.
STOP.
Test Step 3. Check the Operation of the
CAT ET. Test Step 5. Check for Shorts in the
Harness
Verify proper operation of CAT ET on another
engine. A. Turn the ECS to the OFF/RESET position.

Expected Result: B. Disconnect the ECM connectors J1/P1 and

J2/P2. Disconnect the service tool connector
CAT ET and the communications adapter worked J60/P60. Disconnect the connector J99/P99 of
on another engine. the electronic monitoring system . Disconnect
any other devices that are attached to the CAT
Results: Data Link.

• OK – CAT ET and the communications adapter C. Ensure that the customer connector J3A/P3A is
worked on another engine. Proceed to Test Step connected.
5.
D. Measure resistance from P1-3 to P1-9.
• Not OK – CAT ET and the communications
adapter did not work on another engine. There E. Check the resistance at the following points:
is a problem with CAT ET, cables, or the
communication adapter. • P1-3 to P1-5
Repair: Repair the connector and/or wiring or • P1-9 to P1-5
replace the connector and/or wiring.
• P1-3 to P1-6
STOP.
• P1-3 to P1-4
Test Step 4. Check for the Battery Voltage.
• P1-9 to P1-4
A. Turn the ECS to the OFF/RESET position.
• P1-3 to P1-11
B. Ensure that all connectors are connected.
• P1-9 to P1-11
C. Turn the ECS to the STOP position.
F. Measure the resistance from P99-5 to P99-14.
D. Measure the voltage between pin A and pin B
at J60. Expected Result:

Expected Result: Resistance is more than 20,000 Ohms for each

measurement.
The voltage is 24 ± 3 VDC.
 99
Troubleshooting Section

Results: D. Observe the parameters on the monitoring

system.
• OK – The resistance is greater than 20,000
Ohms. The harness is free of shorts. Proceed to Note: The CAT Data Link is operating correctly at
Test Step 6. this time. If some of the parameters, but not all of
the parameters were displayed, the CAT Data Link
• Not OK – The resistance is less than 20,000 is okay. Check the component that is associated
Ohms. with any missing parameter.

Repair: Repair the connector and/or wiring or Note: The monitoring system can display a message
replace the connector and/or wiring. that indicates a fault with communications between
the monitoring system and the ECM. The message
STOP. is displayed when the system no longer receives
any engine related parameters.
Test Step 6. Check the Resistance
through the Harness. Expected Result:

A. Turn the ECS to the OFF/RESET position. The parameters appear on the electronic monitoring
system.
B. Disconnect the ECM connectors J1/P1 and
J2/P2. Disconnect the service tool connector Results:
J60/P60 and the connector for the monitoring
system J99/P99. Disconnect any other devices • OK – The parameters are available for viewing
that are attached to the CAT Data Link. on the CAT ET.

C. Ensure that the customer connector J3A/P3A is Repair: The problem may be intermittent. If the
connected. problem is intermittent, refer to the diagnostic
functional test Troubleshooting, “Inspecting
D. Use a suitable piece of wire to short P1-9 to P1-3. Electrical Connectors”.

E. Measure the resistance between P99-14 to STOP.

P99-5.
• Not OK – The parameters are not available for
F. Measure the resistance between pin D and pin E viewing on CAT ET.
of the service tool connector J60.
Repair: There is a problem with the electronic
Expected Result: monitoring system and/or the data link cable.
Check that the cable is not too long. Refer to
The resistance is less than 5 Ohms through the Service Manual, SENR6587.
wires.
STOP.
Results:
i01963793
• OK – Resistance is less than 5 Ohms through the
harness and connectors. Proceed to Test Step 7. Digital Sensor Supply
• Not OK – Resistance is greater than 5 Ohms. SMCS Code: 1901-038
There is an open circuit in the harness or
connectors. System Operation Description:
Repair: Repair the connector and/or wiring or The digital sensor supply provides power to all
replace the connector and/or wiring. digital sensors. The Electronic Control Module
(ECM) supplies 8.0 ± 0.4 VDC from the ECM
STOP. connector J1/P1 to each digital sensor connector
pin “A”. The digital sensor return is used as the
Test Step 7. Verify the CAT Data Link. return line for the digital sensors, speed/timing
sensors, and the switch inputs to the ECM. The
A. Turn the ECS to the OFF/RESET position. digital return line is from the ECM connector J1/P1
to each digital sensor connector pin “B”. The digital
B. Reconnect all of the connectors. sensor supply is output short circuit protected.
A short circuit to the battery will not damage the
C. Turn the ECS to the STOP position. circuit inside the ECM. The digital sensors are not
protected from overvoltage.
100
Troubleshooting Section

The following list contains a description of the digital

sensors that are found on the engine.

Left Exhaust Temperature Sensor – The ECM uses

the signal from the sensor to monitor left exhaust
temperature. The sensor is mounted in the left
exhaust manifold before the turbocharger. The
sensor output is a constant frequency signal with a
pulse width that varies with the exhaust temperature.
The output signal is referred to as a duty cycle
or as a pulse width modulated signal. The output
signal is expressed as a percentage between 0 and
100 percent. The Caterpillar Electronic Technician
(ET) will display the exhaust temperature as a value
between 49 C to 850 C (120 F to 1562 F). If
the actual temperature is between −40 C to 49 C
(−40 F to 120 F), the display will read 30 C (86 F).
If the temperature is above 851 C (1564 F), the
display will read 851 C (1564 F).

Right Exhaust Temperature Sensor – The ECM uses

the signal from the sensor to monitor right exhaust
temperature. The sensor is mounted in the right
exhaust manifold before the turbocharger. The
sensor output is a constant frequency signal with a
pulse width that varies with the exhaust temperature.
The output signal is referred to as a duty cycle
or as a pulse width modulated signal. The output
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
(120 F to 1562 F). If the actual temperature is
between −40 C to 49 C (−40 F to 120 F), the
display will read 30 C (86 F). If the temperature
is above 851 C (1564 F), the display will read
851 C (1564 F).

Note: The engine monitoring system may be

programmed by dealers and/or customers. Dealers
and/or customers can monitor customized warnings,
derates, shutdown override setpoints, and delay
times using Cat ET. Customized parameters may
affect the behavior of the ECM. The behavior of the
ECM may vary from the description that is given
in this system operation section. You may refer to
the diagnostic procedure Troubleshooting, “Engine
Monitoring System” in order to determine if there are
any parameters that are affecting engine operation.
 101
Troubleshooting Section

g01020181
Illustration 19
Typical example

Test Step 1. Check for Connector • Not OK – The connectors and/or wiring are not
Damage. okay.

A. Turn the breaker for the battery to the OFF Repair: Repair the connectors or wiring and/or
position. replace the connectors or wiring.

B. Turn the ECS to the OFF/RESET position. STOP.

C. Thoroughly inspect the ECM connectors Test Step 2. Check for a Short Circuit in
J1/P1 and J2/P2. Inspect all of the other the Wiring Harness.
connectors. Refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical A. Disconnect ECM connector J1/P1 and all of the
Connectors” for details. digital sensors.

D. Perform a 45 N (10 lb) pull test on each of the B. Measure the resistance between the digital
wires in the ECM connector that are associated supply P1-35 (A700-OR) and the digital return
with the circuit. P1-29 (998-BR) on connector P1.

E. Check the ECM connector (allen head screw) for C. Measure the resistance between the digital
the proper torque of 6.0 N·m (55 lb in). supply P1-35 (A700-OR) and engine ground.

F. Check the customer connector (allen head D. Measure the resistance between the digital return
screw) for the proper torque of 2.25 ± 0.25 N·m P1-29 (998-BR) and engine ground.
(20 ± 2 lb in).
Expected Result:
G. Check the harness and the wiring for abrasion
and for pinch points. The resistance is greater than 20,000 Ohms for
each measurement.
Expected Result:
Results:
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring • OK – The resistance is greater than 20,000
are free of corrosion, of abrasion or of pinch points. Ohms. Proceed to Test Step 3.

Results: • Not OK – The resistance is less than 20,000

Ohms.
• OK – The connectors and wiring are okay.
Proceed to Test Step 2.
102
Troubleshooting Section

Repair: Repair the connectors or wiring and/or B. Measure the digital sensor supply voltage
replace the connectors or wiring. between the digital supply terminal-A (A700-OR)
and the digital return terminal-B (998-BR) of all
STOP. the digital sensors.

Test Step 3. Check the Digital Supply Note: If the sensor is disconnected from the
Voltage at the ECM. harness, an open circuit diagnostic code will be
generated for that sensor. Troubleshoot the original
A. Remove the wire A700-OR from ECM connector code. Delete the logged diagnostic codes when
P1-35. Install a wire jumper into the socket for you are finished.
wire A700-OR.
C. Turn the ECS to the OFF/RESET position.
B. Remove the wire 998-BR from ECM connector
P1-29. Install a wire jumper into the socket for Expected Result:
wire 998-BR.
The supply voltage is 8.0 ± 0.4 VDC.
Note: If you remove the sensor common from
the ECM an open circuit diagnostic code will be Results:
generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the • OK – The supply voltage is 8.0 ± 0.4 VDC at all
logged diagnostic codes when you are finished. of the digital sensor connectors. Proceed to Test
Step 5.
C. Turn the breaker for the battery to the ON
position. • Not OK – The supply voltage is not 8.0 ± 0.4
VDC. There is an open circuit in the harness or
D. Turn the ECS to the STOP position. The engine connectors.
should be off.
Repair: Repair the connectors or wiring and/or
E. Measure the voltage between the wire jumper in replace the connectors or wiring.
P1-35 and the wire jumper in P1-29.
STOP.
F. Turn the ECS to the OFF/RESET position.
Test Step 5. Check the Digital Sensors for
G. Remove the wire jumpers and reconnect all Short Circuits.
wires. Reconnect ECM connector J1/P1.
A. Disconnect all of the digital sensors.
Expected Result:
B. Turn the ECS to the STOP position. The engine
The supply voltage is 8.0 ± 0.4 VDC. should be off.

Results: Note: If the sensor is disconnected from the

harness, an open circuit diagnostic code will be
• OK – The supply voltage is 8.0 ± 0.4 VDC. The generated for that sensor. Troubleshoot the original
digital sensor supply is producing the correct code. Delete the logged diagnostic codes when
voltage. Proceed to Test Step 4. you are finished.

• Not OK – The supply voltage is not 8.0 ± 0.4 C. Connect one digital sensor at a time.
VDC. The digital sensor is not producing the
correct voltage. D. Measure the digital sensor supply voltage
between the digital supply terminal-A (A700-OR)
Repair: Perform the diagnostic functional test and the digital return terminal-B (998-BR) at a
Troubleshooting, “Electrical Power Supply”. different sensor connector. Repeat these steps
with all of the digital sensors.
STOP.
E. Turn the ECS to the OFF/RESET position.
Test Step 4. Check the Digital Sensor
Supply Voltage at the Sensor Connector. Expected Result:

A. Turn the ECS to the STOP position. The engine The supply voltage is 8.0 ± 0.4 VDC.
should be off.
 103
Troubleshooting Section

Results:

• OK – The supply voltage is 8.0 ± 0.4 VDC. The

digital sensor supply is correct. The harness and
sensors are okay.

Repair: The problem may be intermittent. If the

problem is intermittent, perform the diagnostic
functional test Troubleshooting, “Inspecting
Electrical Connectors”.

STOP.

• Not OK – The supply voltage is not 8.0 ± 0.4

VDC when a sensor is reconnected. The sensor
may be internally shorted.

Repair: Temporarily install a new sensor. Ensure

that the problem is no longer present. Reinstall
the old sensor. If the problem returns, replace the
sensor.

STOP.

i01963840

Direct Fuel Control Mode

SMCS Code: 1901-038

System Operation Description:

The direct fuel control mode enables the engine

to be controlled by an external governor. You must
install the components of the signal converter for
the direct fuel control mode in order to operate
in direct fuel control mode. The configuration
parameter must be programmed to “ON” in order
for the Electronic Control Module (ECM) to respond
properly to the external governor.

The input to the signal converter is a 0 to 200 mA

signal. The signal is received from the external
governor. The output signal from the signal
converter is a pulse width modulated signal (PWM).

The output signal varies with the current to the

signal converter. The ECM calculates the desired
fuel from the PWM signal.

You have a valid signal when the duty cycle is

between 2 and 95 percent. If an invalid signal is
received, the engine will automatically be set to a
minimum fuel setting and the engine will shut down.

The droop is not used for the direct fuel control

mode. Disconnecting the droop at the ECM will not
affect engine operation.
104
Troubleshooting Section

g00836404
Illustration 20
Typical example

Test Step 1. Check for Connector Results:

Damage.
• OK – The connectors and wiring are okay.
A. Turn the Engine Control Switch (ECS) to the Proceed to Test Step 2.
OFF/RESET position.
• Not OK – The connectors and/or wiring are not
B. Turn the battery disconnect switch to the OFF okay.
position.
Repair: Repair the connectors or wiring and/or
C. Thoroughly inspect the ECM connectors replace the connectors or wiring.
J1/P1 and J2/P2. Inspect all of the other
connectors. Refer to the diagnostic functional STOP.
test Troubleshooting, “Inspecting Electrical
Connectors” for details. Test Step 2. Check the Current Input.
D. Perform a 45 N (10 lb) pull test on each of the A. Measure the current to the signal converter.
wires in the ECM connector that are associated
with the circuit. Note: Some external governors may only be able to
output approximately 150 mA. This should not be
E. Check the ECM connector (allen head screw) for seen as a problem with the external governor.
the proper torque of 6.0 N·m (55 lb in).
Expected Result:
F. Check the customer connector (allen head
screw) for the proper torque of 2.25 ± 0.25 N·m The current range is between 0 and 200 mA.
(20 ± 2 lb in).
Results:
G. Check the harness and the wiring for abrasion
and for pinch points. • OK – The current is within the correct range.
Proceed to Test Step 3.
Expected Result:
• Not OK – The current is not within the correct
All connectors, pins, and sockets are completely range.
coupled and/or inserted. The harness and wiring
are free of corrosion, of abrasion or of pinch points.
 105
Troubleshooting Section

Repair: Replace the external governor that is Test Step 5. Check the Desired Fuel
supplying the controlling current. Position.
STOP. A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector J60. Start Cat
Test Step 3. Check the Voltage at the ET.
Battery.
B. Turn the ECS to the STOP position.
A. Turn the circuit breaker for the battery to the ON
position. C. Observe the throttle position reading on Cat ET.

B. Connect one probe of the voltmeter to +Battery D. Vary the current to the signal converter.
terminal.
Expected Result:
C. Connect one probe of the voltmeter to −Battery
terminal. The throttle position on Cat ET varies from 5 percent
to 85 percent as the current input is adjusted from 0
Expected Result: mA to 200 mA.

The voltage measures 24 ± 3 VDC. Results:

Results: • OK – The throttle position on Cat ET corresponds

with the current input.
• OK – The voltage measures 24 ± 3 VDC. Proceed
to Test Step 4. Repair: Check the system for any diagnostic
codes.
• Not OK – The voltage does not measure 24 ±
3 VDC. STOP.

Repair: There is a problem with the battery or • Not OK – The throttle position does not
with the connections at the battery. Repair the correspond to the current input. Proceed to Test
connections or the battery. Step 6.

STOP. Test Step 6. Check the Hardware.

Test Step 4. Check the Voltage at the A. Remove the signal wire from the signal converter.
Signal Converter.
B. Set the multimeter to “VDC”.
A. Connect one probe of the voltmeter to the
+Battery terminal at the signal converter. C. Press the “Hz” button twice so that the “%”
symbol is displayed.
B. Connect one probe of the voltmeter to the
−Battery terminal at the signal converter. D. Place one probe on the signal terminal of the
signal converter.
Expected Result:
E. Place the other probe on the −Battery terminal
The voltage measures 24 ± 3 VDC. of the signal converter.

Results: F. Monitor the output of the percent duty cycle from

the signal converter.
• OK – The voltage measures 24 ± 3 VDC. Proceed
to Test Step 5. G. Adjust the current input from a low current setting
to a high current setting.
• Not OK – The voltage does not measure 24 ±
3 VDC. Note: The throttle position on Cat ET will not match
the percent duty cycle on the multimeter.
Repair: Check the wiring and/or the connectors
that are between the battery and the signal Expected Result:
converter. Repair the wiring and/or connectors.
The duty cycle is between 3 and 5 percent at the
STOP. low setting and above 60 percent at the high setting.
106
Troubleshooting Section

Results: • Not OK-Throttle Position – The duty cycle is okay.

The throttle position on Cat ET is incorrect.
• OK – The correct signal is being supplied.
Proceed to Test Step 7. Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, “Replacing the ECM”.
• Not OK – The duty cycle is not correct on the
multimeter. STOP.

Repair: Temporarily install another signal

i01963859
converter. Verify that the problem is no longer
present. Reinstall the old signal converter. If the
problem returns, replace the signal converter.
ECM/Personality Module
SMCS Code: 1901-038
STOP.
System Operation Description:
Test Step 7. Check the ECM.
The Electronic Control Module (ECM) is the
A. Turn the ECS to the STOP position. computer which controls the engine. The personality
module contains the software that determines the
B. Replace the wire of the desired fuel output on function of the ECM. The two must be used together.
the signal converter.
The ECM consists of the following items:
C. Set the multimeter to “VDC”.

D. Press the “Hz” button twice so that the “%”

• A microprocessor that will execute the following
ECM functions: governing, injection timing control,
symbol is displayed. system diagnostics, and data link communication
E. Measure the voltage between the ECM connector
P2-24 and ECM connector P1-29.
• A permanent memory that stores programmable
parameters and diagnostic codes
F. Monitor the output of the percent duty cycle on
the multimeter.
• Input circuits that filter electrical noise from
sensor signals
G. Monitor the percent throttle position on Cat ET.
• Input circuits that protect internal circuits in the
ECM from potentially damaging voltage levels
H. Vary the input current to the signal converter.

Expected Result:
• Output circuits that provide high voltage for the
injector solenoids and relays
The duty cycle is between 3 and 5 percent at
the low setting and above 60 percent at the high
• Power circuits that provide a clean, stable,
electrical power for the injector solenoids, internal
setting. The percent throttle position is between 5 circuits, and external sensors
and 85 percent.
The personality module consists of the following
Results: items:
• OK – The duty cycle and the throttle position are • The personality module contains all of the
correct. software for the ECM. Updating the personality
module to a different version may cause some
Repair: Check the system for any diagnostic engine features to behave differently.
codes.

STOP.
• Control maps define such operating conditions
as timing and fuel rates. These maps help to
achieve optimum engine performance and fuel
• Not OK-Duty Cycle – The duty cycle is not consumption. The maps are programmed into the
correct. personality module at the factory.
Repair: There is a problem in the wiring between
P2-24 and the signal converter.

STOP.
 107
Troubleshooting Section

The personality module on earlier engines could E. Turn the ECS to the STOP position. The engine
be updated only by the removal of the module should be off.
from the ECM. A module that contained a different
program would then be installed. A new type of F. Check for active diagnostic codes.
memory chip which can be programmed through
the use of the Caterpillar Electronic Technician Results:
(ET) is now used. This is called “FLASH” memory.
“FLASH” memory has the advantage of retaining • 253-02 Present – Proceed to Test Step 2.
programmed information indefinitely and “FLASH”
memory can be reprogrammed without opening the • 254-12 Present – If an internal problem develops,
case of the ECM. This process of flash programming the diagnostic code 254-12 becomes active. This
is accomplished through the use of Cat ET. Refer indicates that the ECM has detected an internal
to the diagnostic procedure Troubleshooting, “Flash problem that cannot be fixed.
Programming”.
Repair: Replace the ECM. Ensure that the new
Note: The personality module can still be removed ECM serial number ends in CD. Refer to the
and replaced. Flash programming is the preferred diagnostic procedure Troubleshooting, “Replacing
method for reprogramming a personality module. the ECM” before replacing the ECM.

STOP.

• 268-02 Present
Repair: Reprogram the system configuration
parameters. Refer to the diagnostic procedure
Troubleshooting, “Programming Parameters” for
additional information.

STOP.

Test Step 2. Check for a Personality

Module Mismatch.
A. Verify that the correct ECM has been installed.

B. Check the ECM part number. Check the last two

characters of the ECM serial number.

Expected Result:

The ECM serial number ends with a CD.

Results:

• OK – The serial number of the ECM ends with

a CD. Verify that the correct personality module
g00589030 is installed.
Illustration 21
Personality Module
Repair: Connect Cat ET and reprogram the
Test Step 1. Check for “ACTIVE” interlock code.
Diagnostic Codes.
STOP.
A. Turn the ECS to the OFF/RESET position.
• Not OK – The serial number of the ECM does
B. Turn the battery disconnect switch to the OFF not end in a CD.
position.
Repair: Replace the ECM. Ensure that the new
C. Connect Cat ET to the service tool connector ECM serial number ends in CD. Refer to the
J60. Start Cat ET. diagnostic procedure Troubleshooting, “Replacing
the ECM” before replacing the ECM.
D. Turn the battery disconnect switch to the ON
position. STOP.
108
Troubleshooting Section

i01963905

Electrical Power Supply

SMCS Code: 1401-038

System Operation Description:

The electrical power for the engine comes through

a 16 amp circuit breaker, the Engine Control Switch
(ECS), and the Electronic Control Module (ECM).
The system receives battery voltage when the ECS
is in the AUTO, START or STOP positions. A signal
is provided to the ECM that senses the position of
the ECS. When the ECM senses battery voltage on
this input, the ECM will power up. If the voltage is
removed from the input, the ECM will power down.

An emergency stop for engine operation is provided

in the starting system. Power to the ECM flows
through the breaker for the ECM and the ECM relay.
The ECM relay is energized when the ECS is in the
AUTO, START or STOP positions and the emergency
stop button is not activated. When the emergency
stop button is activated, power is removed from the
coil of the ECM relay. The contacts of the ECM relay
open removing the power to the ECM.

The presence of two +Battery connections and

two −Battery connections to the ECM reduce
harness resistance. All of these connections must
be complete in order to ensure proper engine
operation.

With intermittent faults, you may want to bypass the

engine wiring. Bypassing the wiring helps to locate
the problem. If the problem is no longer present
with the bypass in place, the engine wiring is faulty.
 109
Troubleshooting Section

g01020990
Illustration 22
Typical example

Test Step 1. Check for Connector G. Check the harness and the wiring for abrasion
Damage. and for pinch points.

A. Turn the circuit breaker for the battery to the OFF Expected Result:
position.
All connectors, pins, and sockets are completely
B. Turn the ECS to the OFF/RESET 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 Results:
connectors. Refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical • OK – The connectors and wiring are okay.
Connectors” for details. Proceed to Test Step 2.

D. Perform a 45 N (10 lb) pull test on each of the • Not OK – The connectors and/or wiring are not
wires in the ECM connector that are associated okay.
with the circuit.
Repair: Repair the connectors and/or wiring or
E. Check the ECM connector (allen head screw) for replace the connectors and/or wiring.
the proper torque of 6.0 N·m (55 lb in).
STOP.
F. Check the customer connector (allen head
screw) for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in).
110
Troubleshooting Section

Test Step 2. Check the Voltage to the Repair: The batteries or the alternator are causing
ECM. the problem. Recharge the batteries or replace
the batteries. Verify that the original condition
A. Disconnect ECM connector J1/P1. is resolved. Refer to Testing and Adjusting,
“Electrical System”.
B. Turn the circuit breaker for the battery to the ON
position. STOP.

C. Turn the ECS to the STOP position. Test Step 4. Check the Voltage at the
Emergency Stop Relay.
D. Measure the voltage between P1-6 and P1-5.
A. Reconnect ECM connector J1/P1.
E. Measure the voltage between P1-4 and P1-11.
B. Turn the circuit breaker for the battery to the ON
F. Measure the voltage between P1-23 and P1-11. position.

Expected Result: C. Turn the ECS to the STOP position.

The voltage is ± 1 VDC from the voltage at the D. Measure the voltage from wire 103-RD on
battery terminals. The voltage is 24 ± 3 VDC. terminal 30 of the emergency stop relay to the
−Battery terminal.
Results:
Expected Result:
• OK – The ECM is receiving the correct voltage.
Proceed to Test Step 8. The voltage is 24 ± 3 VDC.

• Not OK – The voltage is incorrect. The battery Results:

or the alternator may be causing the problem.
Proceed to Test Step 3. • OK – The voltage is 24 ± 3 VDC. Proceed to Test
Step 5.
Test Step 3. Check the Battery Voltage.
• Not OK – The voltage is not 24 ± 3 VDC. Proceed
A. Turn the circuit breaker for the battery to the OFF to Test Step 7.
position.
Test Step 5. Check the Voltage at the ECM
B. Turn the ECS to the OFF/RESET position. Relay.
C. Measure no-load voltage at the battery terminals. A. Measure the voltage from wire 103-RD on
Refer to Testing and Adjusting, “Test Tools for terminal 86 of the ECM relay to the −Battery
the Electrical System” for the proper procedures terminal.
to check the batteries.
Expected Result:
D. Load test the batteries. Use the 4C-4911
Battery Load Tester. Refer to the Operating The voltage is 24 ± 3 VDC.
Manual, SEHS9249. Refer to Special Instruction,
SEHS7633. Results:

Expected Result: • OK – The voltage is 24 ± 3 VDC. Proceed to Test

Step 6.
The no-load voltage at the batteries is at least 23.5
VDC, and the batteries pass the load test. • Not OK – The voltage is not 24 ± 3 VDC.
Results: Repair: Check for 24 ± 3 VDC on terminal 87 on
the emergency stop relay. If the voltage is 24 ± 3
• OK – The battery voltage is okay and the battery VDC, the wire from the emergency stop relay to
passes the load test. Proceed to Test Step 4. the ECM relay may be the problem. If the voltage
is incorrect, replace the emergency stop relay.
• Not OK – The battery voltage is incorrect and/or
the battery fails the load test. STOP.
 111
Troubleshooting Section

Test Step 6. Check the Voltage at the Table 39

Output of the ECM Relay. Engine Control Switch
A. Measure the voltage from wire 102-RD on Switch Position Terminal Voltage
terminal 87 of the ECM relay to the −Battery STOP 1, 3, 4, 5, 16, 19, 24 ± 3 VDC
terminal. 20

B. Measure the voltage from wire 150-OR on START 1, 3, 4, 5, 16, 19, 24 ± 3 VDC
terminal 30 of the ECM relay to the −Battery 20
terminal. AUTO 1, 3, 4, 5, 16, 18, 24 ± 3 VDC(1).
19, 20
Expected Result:
OFF/RESET 3, 4, 5, 16, 18, 0.0 VDC
19, 20
The voltage is 24 ± 3 VDC on both terminals.
(1) The remote START/STOP switch is in the START or in the
Results: COOL/STOP position

• OK – The voltage is 24 ± 3 VDC on both Expected Result:

terminals.
The measured voltage at the ECS agrees with the
Repair: The wire from the ECM relay to the ECM voltage that is listed in Table 39.
is bad. Repair the connectors and/or wiring or
replace the connectors and/or wiring. Results:

STOP. • OK – The correct voltage appears at the ECS.

• Not OK - Terminal 87 – The voltage is incorrect Repair: Verify that the emergency stop is working
on terminal 87. correctly. The problem could be in two places.
Check the wire 103-RD between the ECS and the
Repair: Verify that the circuit breakers for the emergency stop switch. Check the wire 103-RD
battery and for the ECM are not tripped. Repair between the emergency stop switch and the
the connectors and/or wiring or replace the emergency stop relay. Repair the connectors
connectors and/or wiring. and/or wiring or replace the connectors and/or
wiring.
STOP.
STOP.
• Not OK - Terminal 30 – The voltage is incorrect
on terminal 30. • Not OK - Terminal 1 – The correct voltage does
not appear on terminal 1 of the ECS.
Repair: Verify that wire 200-BK on terminal 85 of
the ECM relay is not damaged. Replace the ECM Repair: Check the harness between the ECS and
relay. Verify that the original condition is resolved. the battery. Verify that the circuit breakers for the
battery and the control switch are not tripped.
STOP. The problem is in the wiring and/or connectors.
Repair the connectors and/or wiring or replace
Test Step 7. Check the Voltage at the ECS. the connectors and/or wiring.

A. Measure the voltage at the ECS when the switch STOP.

is in the positions that are listed in Table 39.
• Not OK - Other Terminals – The correct voltage
appears on terminal 1 on the ECS. The voltage is
incorrect at other terminals on the ECS.

Repair: Replace the ECS. If the problem is no

longer present, reinstall the old ECS. If the
problem returns, replace the ECS.

STOP.

Test Step 8. Check the Voltage at the

Sensor Power Supplies.
A. Turn the ECS to the STOP position.
112
Troubleshooting Section

B. Measure the voltage from the analog sensor If the ECM is powering up and one of the signals
supply P1-36 to the analog sensor return P1-30. from the emergency stop switch is in a different
state from the other signal, the ECM knows that one
C. Measure the voltage from digital sensor supply of the signals is faulty. If one of the signals from the
P1-35 to the digital sensor return P1-29. emergency stop switch is in a different state from
the other signal, the ECM will generate a diagnostic
Expected Result: code that remains active until power to the ECM is
cycled. The ECM will not allow the crank cycle to
The voltage is 5 ± 0.2 VDC between P1-36 and begin if the signals are opposite of each other. The
P1-30. The voltage is 8 ± 0.4 VDC between P1-35 ECM will allow the engine to be started manually
and P1-29. in this state.

Results: The ECM monitors the emergency stop signals at

all times. If the engine is running and one of the
• OK – The sensor power supplies are functioning signals from the emergency stop switch changes
properly. The ECM is powered up. states, the engine will continue to run. The ECM
initiates an emergency stop shutdown only when
Repair: The problem may be intermittent. If the both signals are high during engine operation.
problem is intermittent, perform the diagnostic
functional test Troubleshooting, “Inspecting When a signal from the emergency stop switch
Electrical Connectors”. is received, the ECM will activate the air shutoff
solenoid.
STOP.
For safety, the ECM will not allow the starting
• Not OK – If the ECM is getting the correct voltage sequence to begin when the emergency stop switch
at the +Battery terminal, but the ECM does is activated. The engine will not be able to restart
not supply the correct voltages to the sensors, until the following conditions are met:
replace the ECM.
• The engine rpm must equal zero.
Repair: Refer to the diagnostic procedure
Troubleshooting, “Replacing the ECM”. • The emergency stop inputs must go low.
STOP. • The ECM has been reset.
Note: If one of the signals from the emergency stop
i01966253
switch is in a different state from the other signal,
Emergency Stop Switch the Caterpillar Electronic Technician (ET) will display
the warning “INVALID DATA”.
SMCS Code: 1901-038

System Operation Description:

The customer’s emergency stop switch sends two

signals to the Electronic Control Module (ECM). The
signals are used to determine if the emergency
stop switch is active. The emergency stop switch is
active when the switch is in the open state and the
two signals are high. The emergency stop switch is
inactive when the switch is in the closed state and
the two signals are held low.
 113
Troubleshooting Section

g00728931
Illustration 23
Typical example

Test Step 1. Check for Connector Repair: Repair the connectors or wiring and/or
Damage. replace the connectors or wiring.

A. Turn the circuit breaker for the battery to the OFF STOP.
position.
Test Step 2. Check the ON Status of the
B. Turn the ECS to the OFF/RESET position. Emergency Stop Switch.
C. Thoroughly inspect the ECM connectors A. Turn the circuit breaker for the battery to the ON
J1/P1 and J2/P2. Inspect all of the other position.
connectors. Refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical B. Connect Cat ET.
Connectors” for details.
C. Turn the ECS to the STOP position.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated D. Activate the emergency stop switch.
with the circuit.
E. Observe the status of the emergency stop switch
E. Check the ECM connector (allen head screw) for on Cat ET.
the proper torque of 6.0 N·m (55 lb in).
Expected Result:
F. Check the customer connector (allen head
screw) for the proper torque of 2.25 ± 0.25 N·m The parameter for the emergency stop switch reads
(20 ± 2 lb in). “ON”.

G. Check the harness and the wiring for abrasion Results:

and for pinch points.
• OK – The emergency stop switch is working
Expected Result: correctly. Proceed to Test Step 3.

All connectors, pins, and sockets are completely • Not OK – The parameter for the emergency stop
coupled and/or inserted, and the harness and wiring switch does not display “ON”. Proceed to Test
are free of corrosion, of abrasion or of pinch points. Step 4.

Results: Test Step 3. Check the OFF Status of the

Emergency Stop Switch.
• OK – The connectors and wiring are okay.
Proceed to Test Step 2. A. Deactivate the emergency stop switch.

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

okay.
The parameter for the emergency stop switch reads
“OFF”.
114
Troubleshooting Section

Results: Results:

• OK – The emergency stop switch is functioning • OK – The problem is not with the ECM. Proceed
correctly. to Test Step 5.

Repair: The problem may be intermittent. If the • Not OK – The parameter on the ECM is incorrect.
problem is intermittent, refer to the diagnostic
functional test Troubleshooting, “Inspecting Repair: Replace the ECM. Refer to the diagnostic
Electrical Connectors”. procedure Troubleshooting, “Replacing the ECM”.

STOP. STOP.

• Not OK – The parameter for the emergency stop Test Step 5. Check the Emergency Stop
switch does not display “OFF”. Proceed to Test Switch and the Wiring.
Step 4.
A. Turn the ECS to the OFF/RESET position.
Test Step 4. Test the ECM.
B. Disconnect connector P1 from ECM connector
A. Turn the ECS to the OFF/RESET position. J1.

B. Disconnect ECM connector P1 from the ECM. C. Activate the emergency stop switch.
Remove wire 998-BR from P1-29. Insert a wire
jumper into P1-29. D. Measure the resistance between P1-29 and
P1-02.
Note: The digital return will no longer be connected
to the other sensors and switches. Additional E. Measure the resistance between P1-29 and
diagnostic codes will be generated from the ECM. P1-24.
Clear the codes after you complete this test.
Expected Result:
C. Remove wire F715-PU from P1-02. Insert a wire
jumper into P1-02. The resistance is greater than 20,000 Ohms.

D. Remove wire F719-BR from P1-24. Insert a wire Results:

jumper into P1-29.
• OK – The resistance is greater than 20,000
E. Reconnect connector P1 to ECM connector J1. Ohms. Proceed to Test Step 6.

F. Use a wire jumper to connect the jumper wire in • Not OK – The resistance is less than 20,000
P1-29 to the jumper wires in P1-02 and P1-24. Ohms. There is a short in the circuit.

G. Turn the ECS to the STOP position. Repair: Repair the switch or wiring and/or replace
the switch or wiring.
H. Observe the parameters for the emergency stop
on Cat ET. STOP.

I. Remove the wire jumper that is connecting the Test Step 6. Deactivate the Emergency
three wires together. Stop Switch.
J. Observe the parameters for the emergency stop A. Deactivate the emergency stop switch.
on Cat ET.
B. Measure the resistance between P1-29 and
K. Turn the ECS to the OFF/RESET position. Remove P1-02.
the wire jumpers and reinstall all wires.
C. Measure the resistance between P1-29 and
Expected Result: P1-24.

The parameter for the emergency stop switch Expected Result:

displays “OFF” when the jumper is installed. The
parameter for the emergency stop switch displays The resistance is less than 5 Ohms.
“ON” when the jumper is removed.
 115
Troubleshooting Section

Results: If the signals from the start/run/stop input to the

ECM are in opposite states, the ECM determines
• OK – The resistance is less than 5 Ohms. The that one of the signals is faulty. The ECM ignores
emergency stop switch is okay. the signals until power is cycled to the ECM. If
this occurs, the engine must be cranked manually.
Repair: The problem may be intermittent. If the Use the “Manual Crank Switch” which is located
problem is intermittent, refer to the diagnostic inside the electronic instrument panel. When the
functional test Troubleshooting, “Inspecting engine is shutdown, the ECS must be placed in the
Electrical Connectors”. OFF/RESET position. This will disconnect power to
the ECM. A CID-FMI will be active until the ECM is
STOP. powered down. The status for the ignition switch
will display “ABNORMAL DATA” until power to the
• Not OK – The resistance is greater than 5 ECM is cycled.
Ohms. There is an open circuit in the emergency
shutdown switch. If the engine is running and the signals from the
start/run/stop input to the ECM change to opposite
Repair: Repair the switch or wiring and/or replace states, the engine will continue to run. The ECM
the switch or wiring. generates a diagnostic code that will remain active
until power to the ECM is cycled. When the engine
STOP. is shutdown, the ECS must be placed in the
OFF/RESET position. This will disconnect power to
the ECM.
i01966118

Engine Control Switch (ECS) If you close the remote start/stop switch, and
the ECS is in the AUTO position, the engine will
SMCS Code: 1901-038 start. The status for the switch will display “ON” or
“OFF”. This status of the remote start/stop switch is
System Operation Description: available on the Caterpillar Electronic Technician
(ET) when the ECS is in the AUTO position.
The Electronic Control Module (ECM) receives
four input signals from the Engine Control Switch
(ECS). The input signals allow the control to
determine the mode of operation. The ECS can
operate in four modes: OFF/RESET, MAN/START,
COOLDOWN/STOP, and AUTO.

When the ECS is set to the OFF/RESET position, the

start/run/stop input to the ECM and the auto input to
the ECM are open. The ECM is not powered. Engine
operation will stop when the ECS is switched to this
position.

When the ECS is set to the AUTO position, the

start/run/stop input to the ECM is open and the auto
input to the ECM is low. The ECM is powered. If the
remote start/run/stop switch is closed, the engine
start sequence will begin.

When the ECS is set to the MAN/START position,

the start/run/stop input to the ECM is low and the
ECS in auto input to the ECM is open. The ECM will
begin the engine start sequence.

When the ECS is set to the COOLDOWN/STOP

position, the start/run/stop input to the ECM is open
and the ECS in auto input is open. After the engine
cooldown, the ECM will shut down the engine.
116
Troubleshooting Section

g01021043
Illustration 24
Typical example

Test Step 1. Check for Connector F. Check the harness and the wiring for abrasion
Damage. and for pinch points.

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

B. Thoroughly inspect the ECM connector J1/P1 The connectors and wiring are free of the following
and the machine connector J2/P2. Inspect all problems: damage, corrosion, abrasion, and
of the other connectors. Refer to the diagnostic incorrect attachment.
functional test Troubleshooting, “Inspecting
Electrical Connectors” for details. Results:

C. Perform a 45 N (10 lb) pull test on each of the • OK – The connectors and wiring are okay.
wires in the ECM connector that are associated Proceed to Test Step 2.
with the circuit.
• Not OK – The connectors and/or wiring are not
D. Check the ECM connector (allen head screw) okay.
for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in). Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. If necessary,
E. Check the machine connector (allen head replace the ECS.
screw) for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in). STOP.
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Troubleshooting Section

Test Step 2. Check the Status of the ECS C. Remove wire F716-WH from P1-08. Insert a wire
on Cat ET. jumper into P1-08.

A. Turn the circuit breaker for the battery to the ON D. Remove wire F717-YL from P1-14. Insert a wire
position. jumper into P1-14.

B. Turn the circuit breaker for the mag relay of the E. Reconnect connector P1 to ECM connector J1.
starting motor system to the OFF position.
F. Use a wire jumper to connect the jumper wire in
C. Turn the ECS to the STOP position. P1-29 to the jumper wires in P1-08 and P1-14.

D. Connect Cat ET to the service tool connector. G. Turn the ECS to the STOP position.

E. Observe the status for the ignition switch on Cat H. Observe the status for the ignition switch on Cat
ET. ET.

Expected Result: I. Turn the ECS to the OFF/RESET position and

remove the jumper wire.
The status for the ignition switch reads “STOP”.
Expected Result:
Results:
The status for the ignition switch displays “RUN”
• OK – The status does display “STOP”. The ECS while the jumper wire is installed. The status for the
is functioning correctly. Proceed to Test Step 3. ignition switch displays “STOP” when the jumper
wire is removed.
• Not OK – The status does not display “STOP”.
Proceed to Test Step 4. Results:

Test Step 3. Check the Status of the ECS • OK – The status for the ignition switch displays
in the START Position. the proper states. The problem is not with the
ECM.
A. Turn the ECS to the START position.
Repair: The problem is in the wiring and/or the
B. Observe the status for the ignition switch on Cat ECS. Check continuity of the wiring between
ET. the ECM and ECS. Check continuity across the
contacts of the ECS.
Expected Result:
STOP.
The status for the ignition switch reads “RUN”.
• Not OK – The status for the ignition switch does
Results: not show the correct states.

• OK – The status for the ignition switch does Repair: Replace the ECM. Refer to the diagnostic
display “RUN”. The ECS is working correctly. procedure Troubleshooting, “Replacing the ECM”.
Proceed to Test Step 5.
STOP.
• Not OK – The status for the ignition switch does
not display “RUN”. Proceed to Test Step 4. Test Step 5. Check the Status of the ECS
in the AUTO Position.
Test Step 4. Simulate the RUN Position
at the ECM. A. Turn the ECS to the AUTO position. Place the
remote start/stop switch in the START position.
A. Turn the ECS to the OFF/RESET position.
B. Observe the status for the ignition switch on Cat
B. Disconnect ECM connector P1 from the ECM. ET. Observe the status for the remote start on
Remove wire 998-BR from P1-29. Insert a wire Cat ET.
jumper into P1-29.
Expected Result:
Note: The digital return will no longer be connected
to the other sensors and switches. Additional The status for the ignition switch reads “AUTO”. The
diagnostic codes will be generated from the ECM. status for the remote start reads “ON”.
Clear the codes after you complete this test.
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Troubleshooting Section

Results: Results:

• OK – The status for the ignition switch does • OK – The status for the ignition switch displays
display “AUTO”. The status for the remote start the proper state. The ECM is functioning properly.
does read “ON”. The ECS and the remote
start/stop switch are working correctly. Repair: The problem is in the wiring and/or the
ECS. Check continuity of the wiring between
Repair: The problem may be intermittent. If the the ECM and ECS. Check continuity across the
problem is intermittent, refer to the diagnostic contacts of the ECS.
functional test Troubleshooting, “Inspecting
Electrical Connectors”. STOP.

STOP. • Not OK – The status for the ignition switch does

not display the correct states.
• Not OK - Remote Start – The status for the remote
start does not display “ON”. There is a problem Repair: Replace the ECM. Refer to the diagnostic
with the wiring between the remote start/stop procedure Troubleshooting, “Replacing the ECM”.
switch and the ECS. Proceed to Test Step 7.
STOP.
• Not OK - Ignition Switch – The status for the
ignition switch does not display “AUTO”. Proceed Test Step 7. Check the Wiring to the ECS
to Test Step 6. from the Remote Start/Run/Stop Switch.
Test Step 6. Simulate the AUTO Position A. Ensure that the remote start/run/stop switch is in
at the ECM. the START/RUN position.

A. Turn the ECS to the OFF/RESET position. B. Disconnect wire 998-BR from terminal 14 of the
ECS.
B. Disconnect ECM connector P1 from the ECM.
Remove wire 998-BR from P1-29. Insert a wire C. Measure the resistance betweenwire 998-BR and
jumper into P1-29. terminal 13 of the ECS.

Note: The digital return will no longer be connected D. Measure the resistance between wire 998-BR
to the other sensors and switches. Additional and terminal 8 of the ECS.
diagnostic codes will be generated from the ECM.
Clear the codes after you complete this test. Expected Result:

C. Remove wire F721-GY from P1-19. Insert a wire The resistance reads less than 5 Ohms.
jumper into P1-19.
Results:
D. Use a wire jumper to connect the jumper wire in
P1-29 to the jumper wire in P1-19. • OK – The resistance is less than 5 Ohms.
E. Reconnect ECM connector P1 to the ECM. Repair: The problem may be intermittent. If the
problem is intermittent, refer to the diagnostic
F. Turn the ECS to the STOP position. functional test Troubleshooting, “Inspecting
Electrical Connectors”.
G. Observe the status for the ignition switch on Cat
ET. STOP.

H. Turn the ECS to the OFF/RESET position. • Not OK – The resistance is greater than 5 Ohms.
There is an open circuit or excessive resistance
I. Remove the jumper wire. in the wiring between the remote start/run/stop
switch and the ECS.
Expected Result:
Repair: Repair the connectors or wiring and/or
The status for the ignition switch reads “AUTO” replace the connectors or wiring. Check the
while the jumper wire is installed. The status for remote start/stop switch for proper operation.
the ignition switch does not read “AUTO” when the
jumper wire is removed. STOP.
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Troubleshooting Section

i01967127

Engine Sensor Open/Short

Test
SMCS Code: 1901-038

System Operation Description:

Engine sensors provide various signals to the

engine’s Electronic Control Module (ECM). These
sensors receive a regulated voltage from the ECM.
Analog sensors receive 5.0 ± 0.2 VDC and digital
sensors receive 8.0 ± 0.4 VDC.

The ECM performs an automatic calibration of these

sensors whenever the ECM is powered and the
engine is off for at least five seconds. During an
automatic calibration, the ECM calibrates pressure
sensors against the atmospheric pressure sensor
and an acceptable offset pressure range.
120
Troubleshooting Section

g01023566
Illustration 25
Typical example

Test Step 1. Check for Connector B. Turn the battery disconnect switch to the OFF
Damage. position.

A. Turn the ECS to the OFF/RESET position.

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Troubleshooting Section

C. Thoroughly inspect the ECM connectors Results:

J1/P1 and J2/P2. Inspect all of the other
connectors. Refer to the diagnostic functional • FMI 03 – A diagnostic code with a FMI of 03 is
test Troubleshooting, “Inspecting Electrical present. Proceed to Test Step 3.
Connectors” for details.
• FMI 04 – A diagnostic code with a FMI of 04 is
D. Perform a 45 N (10 lb) pull test on each of the present. Proceed to Test Step 4.
wires in the ECM connector that are associated
with the circuit. • FMI 00 or 08 – A diagnostic code with a FMI of
00 or of 08 is present. Proceed to Test Step 11.
E. Check the ECM connector (allen head screw)
for the proper torque of 2.25 ± 0.25 N·m • 262-03 or 262-04 Active Code – A diagnostic
(20 ± 2 lb in). code of 262-03 or of 262-04 is present.

F. Check the customer connector (allen head Repair: Perform the diagnostic functional test
screw) for the proper torque of 2.25 ± 0.25 N·m Troubleshooting, “Analog Sensor Supply”.
(20 ± 2 lb in).
STOP.
G. Check the harness and the wiring for abrasion
and for pinch points. • 263-03 or 263-04 Active Code – A diagnostic
code of 263-03 or 263-04 is present.
Expected Result:
Repair: Perform the diagnostic functional test
All connectors, pins, and sockets are completely Troubleshooting, “Digital Sensor Supply”.
coupled and/or inserted. The harness and wiring
are free of corrosion, of abrasion or of pinch points. STOP.

Results: Test Step 3. Check the Sensor Supply

Voltage at the Sensor Connector if the
• OK – The connectors and wiring are okay. Diagnostic Code FMI-03 is Present.
Proceed to Test Step 2.
A. Turn the ECS to the OFF/RESET position.
• Not OK – The connectors and/or wiring are not
okay. B. Disconnect the suspect sensor.

Repair: Repair the connectors or wiring and/or Note: Disconnecting the sensor will generate
replace the connectors or wiring. an open circuit diagnostic code for any sensor
that is disconnected. Troubleshoot the original
STOP. diagnostic code. Reset the system. Delete the
logged diagnostic codes when you are finished.
Test Step 2. Check for “ACTIVE”
Diagnostic Codes. C. Turn the ECS to the STOP position. The engine
should be off.
A. Connect the Caterpillar Electronic Technician (ET)
to the ECM through the service tool connector. D. Measure the voltage on the ECM side of the
sensor connector between pin A and pin B for
B. Turn the battery disconnect switch to the ON the suspect sensor.
position.
Expected Result:
C. Turn the ECS to the STOP position. The engine
should be off. The supply voltage is 5.0 ± 0.2 VDC for all analog
sensors and 8.0 ± 0.4 VDC for all digital sensors.
D. Wait for 15 seconds for the CID-FMI.
Results:
Expected Result:
• OK – The voltage is 5.0 ± 0.2 VDC for all analog
Determine the failure mode identifier (FMI). sensors and 8.0 ± 0.4 VDC for all digital sensors.
Determine if the diagnostic codes 262-03 5 Volt Proceed to Test Step 5.
Sensor DC Power Supply short to +batt or 262-04 5
Volt Sensor DC Power Supply short to ground are • Not OK – The voltage is not 5.0 ± 0.2 VDC for all
present. Determine if the diagnostic codes 263-03 analog sensors and 8.0 ± 0.4 VDC for all digital
Digital Sensor Supply short to +batt or 263-04 sensors. Proceed to Test Step 7.
Digital Sensor Supply short to ground are present.
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Troubleshooting Section

Test Step 4. Check the Sensor Supply Expected Result:

Voltage at the Sensor Connector if the
Diagnostic Code FMI-04 is Present. The voltage will measure 24 ± 3 VDC when a short
to the +Battery is present.
A. Turn the ECS to the OFF/RESET position.
Results:
B. Disconnect the suspect sensor.
• OK – The voltage measures 24 ± 3 VDC. A short
Note: Disconnecting the sensor will generate to the +Battery is present.
an open circuit diagnostic code for any sensor
that is disconnected. Troubleshoot the original Repair: Repair the connectors or wiring and/or
diagnostic code. Reset the system. Delete the replace the connectors or wiring.
logged diagnostic codes when you are finished.
STOP.
C. Turn the ECS to the STOP position. The engine
should be off. • Not OK – The voltage on pin B should measure
0 VDC. The voltage on pin C may measure
D. Measure the voltage on the ECM side of the approximately 6.5 VDC. The voltage on pin C
sensor connector between pin A and pin B for is a pull up voltage. The ECM provides the pull
the suspect sensor. up voltage to the signal input when the ECM
senses an open circuit in the incoming input
Expected Result: signal. Frequency sensors do not receive a pull
up voltage. The sensor common and signal wire
The supply voltage is 5.0 ± 0.2 VDC for all analog are not shorted to the +Battery. Proceed to Test
sensors and 8.0 ± 0.4 VDC for all digital sensors. Step 6.

Results: Test Step 6. Create a Short at the Sensor

Connector.
• OK – The voltage is 5.0 ± 0.2 VDC for all analog
sensors and 8.0 ± 0.4 VDC for all digital sensors. A. Turn the ECS to the OFF/RESET position.
Proceed to Test Step 8.
B. Use a wire jumper to connect pin B and pin C
• Not OK – The voltage is not 5.0 ± 0.2 VDC for all together on the sensor connector.
analog sensors and 8.0 ± 0.4 VDC for all digital
sensors. Proceed to Test Step 7. C. Turn the ECS to the STOP position. The engine
should be off.
Test Step 5. Check for a Short to the
+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 Expected Result:

an open circuit diagnostic code for any sensor
that is disconnected. Troubleshoot the original The CID-FMI changes from 03 to 04.
diagnostic code. Reset the system. Delete the
logged diagnostic codes when you are finished. Results:

C. Turn the ECS to the STOP position. The engine • OK – The CID-FMI changed from 03 to 04. The
should be off. 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
E. Measure the voltage on the ECM side of the the sensor.
sensor connector between pin C and the engine
ground. STOP.

F. Turn the ECS to the OFF/RESET position.

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Troubleshooting Section

• Not OK – The CID-FMI did not change from • Not OK - Analog or Digital – The supply voltage
03 to 04. The circuit indicates an open circuit is not 5.0 ± 0.2 VDC for all analog sensors and
diagnostic code. Proceed to Test Step 9. 8.0 ± 0.4 for all digital sensors. The voltage at
the ECM is not correct.
Test Step 7. Check the Sensor Supply
Voltage at the ECM. Repair: Perform the diagnostic functional test
Troubleshooting, “Electrical Power Supply”.
A. Turn the ECS to the OFF/RESET position.
STOP.
B. Check the analog supply voltage by removing
wires P1-36 (997-OR) and P1-30 (993-BR) from Test Step 8. Create an Open Circuit at the
ECM connector P1. Install a wire jumper into the Sensor Connector.
sockets for P1-36 and for P1-30.
A. Turn the ECS to the OFF/RESET position.
Check the digital supply voltage by removing
wires P1-35 (A700-OR) and P1-29 (998-BR) from B. Leave the sensor disconnected.
ECM connector P1. Install a wire jumper into the
sockets for P1-35 and for P1-29. C. Wait for a period of 15 seconds.

Note: If you remove the sensor common from D. Turn the ECS to the STOP position. The engine
the ECM, an open circuit diagnostic code will should be off.
be generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the E. The CID-FMI should change from 04 to 03.
logged diagnostic codes when you are finished.
Note: Disconnecting the atmospheric pressure
C. Reconnect ECM connector J1/P1. sensor will cause several sensor diagnostic codes
to become active. Troubleshoot the original code.
D. Turn the ECS to the STOP position. The engine Delete the logged diagnostic codes when you are
should be off. finished.

E. Measure the analog voltage between P1-36 and F. Turn the ECS to the OFF/RESET position.
P1-30 at the wire jumpers.
G. Reconnect the suspect sensor.
F. Measure the digital voltage between P1-35 and
P1-29 at the wire jumpers. Expected Result:

G. Turn the ECS to the OFF/RESET position. The CID-FMI changes from 04 to 03 when the
sensor is disconnected.
H. Turn the keyswitch for the ECM to the OFF
position. Results:

I. Remove the wire jumpers and replace all wires. • OK – The CID-FMI changed from 04 to 03 when
Reconnect ECM connector J1/P1. the sensor was disconnected. The open circuit
was seen by the ECM. The wiring between the
Expected Result: ECM and the sensor is good.

The supply voltage is 5.0 ± 0.2 VDC for all analog Repair: Replace the suspect sensor. Verify that
sensors and 8.0 ± 0.4 for all digital sensors. the repair eliminates the problem.

Results: STOP.

• OK - Analog or Digital – The supply voltage is 5.0 • Not OK – The CID-FMI did not change from 04
± 0.2 VDC for all analog sensors and 8.0 ± 0.4 to 03 when the sensor was disconnected. The
for all digital sensors. The supply voltage at the open circuit was not seen at the ECM. Proceed to
ECM is correct. There is a problem in the wiring Test Step 10.
between the ECM and the suspect sensor.
Test Step 9. Create a Short at the ECM
Repair: Repair the connectors or wiring and/or Connector.
replace the connectors or wiring.
A. Connect the suspect sensor.
STOP.
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Troubleshooting Section

B. Remove the suspect sensor’s signal wire from Note: Disconnecting the atmospheric pressure
ECM connector P1 or P2. Install a wire jumper sensor will cause several sensor diagnostic codes
into the socket for the signal wire. to become active. Troubleshoot the original code.
Delete the logged diagnostic codes when you are
C. Use a jumper to create a short between the wire finished.
jumper and the sensor’s common wire.
E. Turn the ECS to the OFF/RESET position.
D. Turn the ECS to the STOP position. The engine
should be off. F. Replace the signal wire and reconnect ECM
connector J1/P1 or J2/P2.
E. The CID-FMI should change from 03 to 04 when
the jumper is in place. Expected Result:

F. Turn the ECS to the OFF/RESET position. The The CID-FMI changes from 04 to 03 when the
engine should be off. sensor signal wire is disconnected.

G. Remove the wire jumper and replace the signal Results:

wire. Reconnect ECM connector J1/P1 and/or
J2/P2. • OK – The CID-FMI changed from 04 to 03 when
the sensor signal wire was disconnected. The
Expected Result: ECM recognized the open at the ECM.

The CID-FMI changes from 03 to 04 when the Repair: Repair the connectors or wiring and/or
jumper is in place. replace the connectors or wiring.

Results: STOP.

• OK – The CID-FMI changed from 03 to 04 when • Not OK – The CID-FMI did not change from 04 to
the jumper was put in place. The ECM recognized 03 when the sensor signal wire was disconnected.
the short at the ECM. There is a problem with the The ECM did not recognize the open at the ECM.
wiring between the ECM and the suspect sensor.
Repair: Refer to the diagnostic procedure
Repair: Repair the connectors or wiring and/or Troubleshooting, “Replacing the ECM”.
replace the connectors or wiring.
STOP.
STOP.
Test Step 11. Check the Fluid Level.
• Not OK – The CID-FMI did not change from 03 to
04 when the jumper was put in place. The ECM A. Check the fuel level.
did not see the short at the ECM. Replace the
ECM. B. Check the engine oil level.

Repair: Refer to the diagnostic procedure C. Check for any leaks.

Troubleshooting, “Replacing the ECM”.
Expected Result:
STOP.
The fuel and oil level are okay. There are not any
Test Step 10. Create an Open at the ECM. leaks.

A. Turn the ECS to the OFF/RESET position. Results:

B. Remove the suspect sensor signal wire from • OK – The fuel and oil levels are correct. Proceed
J1/P1 or J2/P2. to Test Step 12.

C. Turn the ECS to the STOP position. The engine • Not OK – The fuel and/or oil levels are not correct.
should be off.
Repair: If the oil level is low, add oil. If the fuel
D. Check if the CID-FMI has changed from 04 to 03. level is low, add fuel. Repair the leaks. Reset the
system and note any active diagnostic codes.

STOP.
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Troubleshooting Section

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
C. Turn the ECS to the STOP position. The engine Test 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.

H. Connect the vacuum pump test unit to the STOP.

suspect sensor.
Test Step 13. Check the Analog Sensor’s
I. Connect the vacuum pump to the differential Signal Voltage at the Sensor Connector.
pressure gauge.
A. Turn the ECS to the OFF/RESET position.
J. Turn the ECS to the STOP position. The engine
should be off. B. Remove the sensor’s signal wire from pin C of
the sensor connector.
K. Observe the pressure reading for the suspect
sensor. The Cat ET should display the barometric C. Turn the ECS to the STOP position. The engine
pressure in your area. should be off.

L. Use the vacuum pump to pull 5 kPa (0.7 psi) of D. Measure the sensor signal voltage between the
vacuum on the differential pressure gauge. sensor’s signal wire and pin B at the sensor
connector.
Note: The pressure gauge reading should remain
constant until the vacuum is released. E. Turn the ECS to the OFF/RESET position.

M. Compare the readings on the Cat ET and the F. Replace the sensor signal wire and reconnect
pressure test kit. the sensor.

Expected Result: Expected Result:

The Cat ET shows the correct temperature. The Cat The signal voltage is between 0.2 VDC and 4.8
ET shows constant pressure. The Cat ET shows a VDC for analog sensors.
5 ± 2 kPa (0.7 ± 0.3 psi) drop in pressure when
the vacuum is applied. Results:

Results: • OK – The signal voltage is between 0.2 VDC and

4.8 VDC for analog sensors. Proceed to Test Step
• OK – The correct temperature is shown on the 17.
Cat ET. A constant pressure is shown on the Cat
ET. A 5 ± 2 kPa (0.7 ± 0.3 psi) drop in pressure is • Not OK – The signal voltage is not between 0.2
shown on the Cat ET when the vacuum is applied. VDC and 4.8 VDC for analog sensors. Proceed to
The sensor is working correctly. Test Step 15.
126
Troubleshooting Section

Test Step 14. Check the Digital Sensor’s Expected Result:

Signal Frequency and the Duty Cycle at
the Sensor Connector. The resistance is greater than 20,000 Ohms.

A. Turn the ECS to the OFF/RESET position. Results:

B. Remove the sensor’s signal wire from pin C of • OK – The resistance is greater than 20,000
the sensor connector. Ohms. Proceed to Test Step 16.

C. Turn the ECS to the STOP position. The engine • Not OK – The resistance is less than 20,000
should be off. Ohms.

D. Measure the frequency and the duty cycle Repair: Repair the connectors or wiring and/or
between the sensor’s signal wire and pin B of the replace the connectors or wiring.
suspect digital sensor at the sensor connector.
STOP.
E. Turn the ECS to the OFF/RESET position.
Test Step 16. Check the Resistance
F. Turn the keyswitch for the ECM to the OFF through the Harness.
position.
A. Disconnect the suspect sensor connector.
G. Replace the sensor’s signal wire and reconnect
the sensor. B. Use a suitable piece of wire to connect pin A
to pin C.
Expected Result:
C. Measure the resistance between the sensor
The frequency reading is approximately 500 Hz. signal wire and the sensor voltage supply at the
ECM connector P1 or P2.
When the temperature is below 49 C (120 F), the
duty cycle is between 16 percent to 21 percent. D. Use a suitable piece of wire to connect pin B
to pin C.
When the temperature is between 49 C (120 F)
and 851 C (1564 F), the duty cycle is between E. Measure the resistance between the sensor
22 percent to 88 percent. signal and the sensor common at the ECM
connector P1 or P2.
Results:
F. Use a suitable piece of wire to connect pin A
• OK – The frequency and the duty cycle are to pin B.
correct. Proceed to Test Step 18.
G. Measure the resistance between the sensor
• Not OK – The frequency and the duty cycle are supply and the sensor common at the ECM
not correct. Proceed to Test Step 15. connector P1 or P2.

Test Step 15. Check for Shorts in the H. Remove all wire shorts.
Wiring Harness.
I. Reconnect all connectors and all sensors.
A. Disconnect the ECM connectors J1/P1 and
J2/P2. Disconnect the suspect sensor. Expected Result:

B. Measure the resistance between the sensor The resistance is less than 5 Ohms.
signal wire and engine ground.
Results:
C. Measure the resistance between the sensor
common and engine ground. • OK - Analog – The resistance is less than 5
Ohms. Proceed to Test Step 17.
D. Measure the resistance between the sensor
supply and engine ground at the ECM connector. • OK - Digital – The resistance is less than 5 Ohms.
Proceed to Test Step 18.
E. Reconnect all connectors and all sensors.
• Not OK – The resistance is greater than 5 Ohms.
 127
Troubleshooting Section

Repair: Repair the connectors or wiring and/or Test Step 18. Check the Digital Sensor’s
replace the connectors or wiring. Signal Frequency and the Duty Cycle at
the ECM.
STOP.
A. Turn the ECS to the STOP position. The engine
Test Step 17. Check the Analog Sensor’s should be off.
Signal Voltage at the ECM.
B. Measure the frequency and the duty cycle
A. Turn the ECS to the STOP position. The engine between pin C and pin B at the ECM connector
should be off. P1 or P2.

B. Measure the sensor signal voltage between pin C. Start the engine.
C and pin B at the ECM connector P1 or P2.
D. Observe the sensor reading on the status screen
C. Observe the sensor reading on the status screen on the Cat ET.
on the Cat ET.
Note: The status screen on the Cat ET displays
Note: The status screen on the Cat ET displays “ABNORMAL SIGNAL” when the ECM reads a
“ABNORMAL SIGNAL” when the ECM reads a signal that is out of normal range.
signal that is out of the normal range.
E. Turn the ECS to the OFF/RESET position.
D. Turn the ECS to the OFF/RESET position.
Expected Result:
Expected Result:
The frequency reading is approximately 500 Hz.
The signal voltage for the analog sensors is between
0.2 VDC and 4.8 VDC for the suspect analog sensor. When the temperature is below 49 C (120 F), the
duty cycle is between 16 percent to 21 percent.
Results:
When the temperature is between 49 C (120 F)
• OK – The signal voltage for the analog sensors and 851 C (1564 F), the duty cycle is between
is between 0.2 VDC and 4.8 VDC for the suspect 22 percent to 88 percent.
analog sensor. The sensor voltage at the ECM is
correct. The Cat ET screen displays the correct While the engine is cold, the Cat ET reads 30 C
information. (86 F). As the engine warms up the exhaust
temperature increases.
Repair: There may be an intermittent problem. If
the problem is intermittent, perform the diagnostic Results:
functional test Troubleshooting, “Inspecting
Electrical Connectors”. • OK – The digital sensor voltage at the ECM is
correct.
STOP.
Repair: There may be an intermittent problem. If
• Not OK – The signal voltage for the analog the problem is intermittent, perform the diagnostic
sensors is not between 0.2 VDC and 4.8 VDC for functional test Troubleshooting, “Inspecting
the suspect analog sensor. The sensor voltage at Electrical Connectors”.
the ECM is not correct.
STOP.
Repair: Repair the connectors and/or wiring
between the ECM connector and the sensor. • Not OK – The digital sensor voltage at the ECM
is not correct.
STOP.
Repair: Repair the connectors and/or wiring
• ABNORMAL SIGNAL – The status screen on between the ECM and the sensor.
the Cat ET displays “ABNORMAL SIGNAL”. The
signal voltage for the analog sensors is between STOP.
0.2 VDC and 4.8 VDC for the suspect analog
sensor. The sensor voltage at the ECM is correct. • ABNORMAL SIGNAL – The digital sensor voltage
at the ECM is correct. The status screen on the
Repair: Replace the ECM. Refer to the diagnostic Cat ET displays “ABNORMAL SIGNAL”. The
procedure Troubleshooting, “Replacing the ECM”. signal is out of normal range.

STOP.
128
Troubleshooting Section

Repair: Replace the ECM. Refer to the diagnostic

procedure Troubleshooting, “Replacing the ECM”.

STOP.

i01967237

Engine Speed/Timing Sensor

SMCS Code: 1912-038

System Operation Description:

The Electronic Control Module (ECM) provides the

engine speed/timing sensor with 12.5 ± 1.0 VDC.
The engine speed/timing sensor provides a pulse
signal to the ECM. The signal is created as the
timing reference gear rotates past the pickup of the
engine speed/timing sensor. The timing reference
gear is mounted on the rear of the left camshaft.
A unique tooth pattern on the timing reference
gear allows the ECM to determine the crankshaft
position, rotation, and rpm.

The engine speed/timing sensor generates a pulse

signal to the ECM as each tooth passes the sensor.
The ECM counts the pulses in order to determine
the engine rpm. The ECM memorizes the pattern
of the pulses. The ECM compares that pattern
to a standard pattern in order to determine the
crankshaft position. The ECM uses this information
to determine the No. 1 cylinder. The ECM then
triggers each unit injector to fire in the correct firing
order and at the correct time. The actual timing
and duration of each injection is determined by the
ECM. The ECM uses engine rpm and engine load
to determine the timing and duration of injection.
The loss of the signal from the engine speed/timing
sensor generates an alert on the Caterpillar
Electronic Technician (ET). The loss of the signal
from the engine speed/timing sensor triggers the
termination of the signals to the fuel injectors by
the ECM.

Note: If the engine timing gear is installed backward,

the diagnostic code 190-08 will be generated.
If this code is active, the ECM will not fire the
injectors. You may refer to the diagnostic procedure
Troubleshooting, “Engine Monitoring System” in
order to determine if there are any parameters that
are affecting engine operation.
 129
Troubleshooting Section

g00594171
Illustration 26
Typical example

Test Step 1. Check for Connector Test Step 2. Check for an “ACTIVE”
Damage. Diagnostic Code.
A. Turn the Engine Control Switch (ECS) to the A. Connect Cat ET to the service tool connector.
OFF/RESET position. Start Cat ET.

B. Thoroughly inspect the ECM connector J1/P1 B. Turn the ECS to the STOP position. The engine
and the machine connector J2/P2. Inspect all should be off.
of the other connectors. Refer to the diagnostic
functional test Troubleshooting, “Inspecting C. Access the logged diagnostic codes on Cat ET.
Electrical Connectors” for details.
Expected Result:
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated The Cat ET screen indicates one of the following
with the circuit. diagnostic codes: CID-FMI 190-02, CID-FMI 190-03,
and CID-FMI 190-08.
D. Check the ECM connector (allen head screw)
for the proper torque of 2.25 ± 0.25 N·m Results:
(20 ± 2 lb in).
• OK – A diagnostic code for the engine
E. Check the machine connector (allen head speed/timing sensor is present. Proceed to Test
screw) for the proper torque of 2.25 ± 0.25 N·m Step 3.
(20 ± 2 lb in).
Test Step 3. Check the Engine
F. Check the harness and the wiring for abrasion Speed/Timing Sensor.
and for pinch points.

Expected Result: NOTICE

Be sure to extend the sliphead before you install the
The connectors and wiring are free of the following Engine Speed/Timing Sensor. Also check that the
problems: damage, corrosion, abrasion, and Timing Gear is in a position that will not allow the slip-
head of the Engine Speed/Timing Sensor to protrude
incorrect attachment.
into one of the slots of the Timing Gear. This is done
Results: visually with a flashlight prior to the installation of the
Engine Speed/Timing Sensor. Turn the crankshaft to
rotate the Timing Gear, if necessary, to position the
• OK – The connectors and wiring are okay. gear in a place that will not allow the sliphead to pro-
Proceed to Test Step 2.
trude into a slot. If the sensor sliphead does protrude
into one of the slots, the sliphead wll be broken off as
• Not OK – The connectors and/or wiring are not the gear begins to rotate.
okay.

Repair: Repair the connectors and/or wiring or A. Turn the ECS to the OFF/RESET position.
replace the connectors and/or wiring.
B. Disconnect connector J20/P20 and remove the
STOP. engine speed/timing sensor.
130
Troubleshooting Section

C. Inspect the plastic sliphead for damage. • Not OK – The Cat ET screen does not display a
steady engine speed between 100 and 250 rpm
D. Check the tension. Gently extend the sliphead while the engine is cranking. The Cat ET screen
3.5 mm (0.14 inch). Return the sliphead to the does not display the correct engine rpm signal.
original position. Proceed to Test Step 5.

E. Extend the sliphead. Test Step 5. Check the Supply Voltage to

the Sensor.
F. Install the engine speed/timing sensor.
A. Disconnect the engine speed/timing connector
Expected Result: J20/P20.

The sliphead requires at least 22 N (5 lb) of force B. Turn the ECS to the STOP position. The engine
in order to push in the sliphead from the extended should be off.
position.
C. Measure the voltage at the connector for the
Results: engine speed/timing sensor between J20-A and
J20-B.
• OK – The sensor and the sliphead are
undamaged. The tension on the sliphead is Expected Result:
normal. Reinstall the sensor. Proceed to Test Step
4. The supply voltage is 12.5 ± 1.0 VDC.

• Not OK – The engine speed/timing sensor or the Results:

sliphead is damaged and/or the sliphead has
insufficient tension. • OK – The supply voltage is 12.5 ± 1.0 VDC. The
sensor is receiving the correct supply voltage.
Repair: Replace the engine speed/timing Proceed to Test Step 6.
sensor. Calibrate the sensor. Perform the
calibration procedure Troubleshooting, “Engine • Not OK – The supply voltage is not 12.5 ± 1.0
Speed/Timing Sensor - Calibrate”. VDC. The supply voltage is incorrect. Proceed
to Test Step 8.
STOP.
Test Step 6. Check the Signal Voltage at
Test Step 4. Check the Engine RPM on the Sensor.
the Cat ET.
A. Remove the signal wire 999-WH from the sensor
A. Turn the ECS to the START position. Start the connector P20-C.
engine.
B. Reconnect connector J20/P20.
B. Observe the engine speed on Cat ET.
C. Turn the ECS to the STOP position. The engine
Expected Result: should be off.

Cat ET displays a steady engine speed between D. Measure the voltage between the signal wire
100 and 250 rpm while the engine is cranking. 999-WH from the sensor connector P20-C and
the engine ground.
Results:
E. Crank the engine. Measure the voltage between
• OK – The Cat ET screen displays a steady the signal wire 999-WH from the sensor
engine speed between 100 and 250 rpm while connector P20-C and the engine ground.
the engine is cranking. The engine speed/timing
sensor is operating normally at this time. F. Turn the ECS to the OFF/RESET position.

Repair: There may be an intermittent problem. If G. Reinsert the sensor signal wire back into P20-C.
the problem is intermittent, perform the diagnostic
functional test Troubleshooting, “Inspecting
Electrical Connectors”.

STOP.
 131
Troubleshooting Section

Expected Result: Results:

The voltage measures less than 3 VDC or more • OK – A correct signal voltage appears at the
than 9 VDC when the engine is not cranking. While ECM connector P1 but the ECM is not reading
the engine is cranking, the voltage is between 2.0 the signal.
VDC and 7.0 VDC.
Repair: Replace the ECM. Refer to the diagnostic
Note: The voltage output is determined by the procedure Troubleshooting, “Replacing the ECM”.
presence or the absence of a tooth on the timing
gear. STOP.

Results: • Not OK – The correct signal voltage does not

appear at the ECM. There is a problem in the
• OK – The engine speed/timing sensor is wiring between the ECM and the sensor. Proceed
producing the correct output signal. Proceed to to Test Step 9.
Test Step 7.
Test Step 8. Check the Supply Voltage at
• Not OK – The engine speed/timing sensor is not the ECM.
producing the correct output signal.
A. Turn the ECS to the OFF/RESET position.
Repair: Replace the engine speed/timing
sensor. Calibrate the sensor. Perform the B. Reconnect the connector for the engine
calibration procedure Troubleshooting, “Engine speed/timing sensor J20/P20.
Speed/Timing Sensor - Calibrate”.
C. Disconnect ECM connector J1/P1.
STOP.
D. Remove wire 996-GN from the ECM connector
Test Step 7. Check the Signal Voltage at P1-32. Install a jumper wire into the socket for
the ECM. P1-32.

A. Turn the ECS to the OFF/RESET position. E. Remove wire 998-BR from the ECM connector
P1-29. Install a jumper wire into the socket for
B. Remove the signal wire 999-WH from ECM P1-29.
connector P1-38.
Note: If you remove the sensor common from
C. Turn the ECS to the STOP position. The engine the ECM, an open circuit diagnostic code will
should be off. be generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the
D. Measure the voltage between the signal wire logged diagnostic codes when you are finished.
999-WH from ECM connector P1-38 and the
engine ground. F. Turn the ECS to the STOP position. The engine
should be off.
E. Crank the engine. Measure the voltage between
wire 999-WH and the engine ground. G. Measure the voltage between the jumper wire at
ECM connector P1-32 and the jumper wire at
F. Turn the ECS to the OFF/RESET position. ECM connector P1-29.

G. Reconnect all wires and connectors. H. Turn the ECS to the OFF/RESET position.

Expected Result: I. Reconnect all wires and connectors.

The voltage measures less than 3 VDC or more Expected Result:

than 9 VDC when the engine is not cranking. While
the engine is cranking, the voltage is between 2.0 The voltage is 12.5 ± 1.0 VDC.
VDC and 7.0 VDC.
Results:
Note: The voltage output is determined by the
presence or the absence of a tooth on the timing • OK – The voltage is 12.5 ± 1.0 VDC. There is a
gear. problem in the wiring between the ECM and the
sensor. Proceed to Test Step 9.

• Not OK – The voltage is not 12.5 ± 1.0 VDC. The

voltage from the ECM is incorrect.
132
Troubleshooting Section

Repair: Perform the diagnostic functional test D. Measure the resistance between wire 996-GN at
Troubleshooting, “Electrical Power Supply”. connector P1-32 and wire 999-WH at the ECM
connector P1-38.
STOP.
E. Remove all shorts and reconnect J1/P1 and
Test Step 9. Check for Shorts in the J20/P20.
Wiring Harness.
Expected Result:
A. Turn the ECS to the OFF/RESET position.
The resistance is less than 5 Ohms.
B. Disconnect the ECM connector J1/P1 and the
engine speed/timing connector J20/P20. Results:

C. Measure the resistance between wire 996-GN at • OK – The resistance is less than 5 Ohms. The
connector J20-A and wire 998-BR at connector wiring is okay.
J20-B.
Repair: There may be an intermittent problem. If
D. Measure the resistance between wire 996-GN at the problem is intermittent, perform the diagnostic
connector J20-A and wire 999-WH at connector functional test Troubleshooting, “Inspecting
J20-C. Electrical Connectors”.

E. Measure the resistance between wire 998-BR at STOP.

connector J20-B and wire 999-WH at connector
J20-C. • Not OK – The resistance is greater than 5 Ohms.
There is an open circuit or excessive resistance
F. Measure the resistance of the following wires to in the harness or in the connectors.
engine ground: J20-A, J20-B, and J20-C.
Repair: Repair the connectors and/or wiring or
Expected Result: replace the connectors and/or the wiring.

The resistance is more than 20,000 Ohms. STOP.

Results:
i01967398

• OK – The resistance is greater than 20,000

Ohms. Proceed to Test Step 10.
Ether Injection System
SMCS Code: 1456-038
• Not OK – The resistance is less than 20,000
Ohms. There is a short circuit in the harness or System Operation Description:
in the connectors.
The engine uses an ether system to improve starting
Repair: Repair the connectors and/or wiring or in cold temperatures. The duration of the ether cycle
replace the connectors and/or the wiring. is based on the engine coolant temperature. The
Electronic Control Module (ECM), which controls the
STOP. ether system, uses the engine coolant temperature
sensor to detect engine temperature. The ECM
Test Step 10. Check for an Open Circuit determines if ether should be injected by monitoring
in the Harness. actual engine rpm and the engine temperature. The
ECM will activate the ether solenoid if the engine
A. Use a suitable piece of wire to short wire 996-GN coolant temperature is below a set temperature and
at connector J20-A to wire 998-BR at connector the engine rpm is below a certain level. The ether
J20-B. will activate for a minimum of 15 seconds at 30 C
(86 F) up to a maximum of 130 seconds at −50 C
B. Measure the resistance from wire 996-GN at (−58 F). The automatic ether injection system is
ECM connector P1-32 and wire 998-BR at ECM disabled whenever engine rpm exceeds 400 rpm
connector P1-29. or the engine coolant temperature exceeds 30 C
(86 F).
C. Use a suitable piece of wire to short wire 996-GN
at connector J20-A to wire 999-WH at connector
J20-C.
 133
Troubleshooting Section

The ether injection system can also be operated in

manual mode. The ether system is switched into
manual mode whenever the starting aid switch is
depressed. Manual mode also allows ether to be
injected whenever the coolant temperature is less
than 30 C (86 F) and engine rpm is greater than
50 rpm. Ether is injected in manual mode if the
starting aid switch is depressed and the coolant
temperature is below the maximum limit. The manual
mode will allow ether to be injected for a maximum
of 130 seconds when the switch is toggled.

Two driver outputs from the ECM are usedto activate

the ether injection system. One driver provides the
voltage to the coil of the ether start relay. The other
terminal of the ether start relay is connected to the
digital return. A sinking driver connects to the coil
of the ether hold relay. The drivers and the relays
are used to provide a high initial voltage signal that
will actuate the ether solenoids. The resistor and
diode assembly provides a lower voltage signal
in order to keep the ether solenoid activated. The
solenoids will be damaged if battery voltage is
applied continuously.

g01021529
Illustration 27
Typical example
134
Troubleshooting Section

Test Step 1. Check for Connector E. Determine if CID-FMI 545-05, 545-06, 546-05 or
Damage. 546-06 is active or logged.

A. Turn the circuit breaker for the battery to the OFF F. Toggle the starting aid switch. Observe the
position. parameter for the ether switch on Cat ET.

B. Turn the ECS to the OFF/RESET position. Expected Result:

C. Thoroughly inspect the ECM connectors The parameter for the ether switch displays “ON”
J1/P1 and J2/P2. Inspect all of the other while the starting aid switch is toggled. The
connectors. Refer to the diagnostic functional parameter for the ether switch displays “OFF” when
test Troubleshooting, “Inspecting Electrical the switch is released.
Connectors” for details.
Results:
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated • OK – No active codes or logged codes are
with the circuit. present. The ether injection system does not
inject ether. Proceed to Test Step 3.
E. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in). • Active Code – Active diagnostics are displayed.
Proceed to Test Step 4.
F. Check the customer connector (allen head
screw) for the proper torque of 2.25 ± 0.25 N·m • Logged Code – Logged diagnostics are
(20 ± 2 lb in). displayed. Check for an intermittent short or for
an open in the wiring or in the connectors
G. Check the harness and the wiring for abrasion
and for pinch points. Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
Expected Result:
STOP.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring • Not OK – The starting aid switch is not functioning
are free of corrosion, of abrasion or of pinch points. correctly. Proceed to Test Step 15.

Results: Test Step 3. Check the Ether Canisters.

• OK – The connectors and wiring are okay. A. Turn the circuit breaker for the battery to the OFF
Proceed to Test Step 2. position.

• Not OK – The connectors and/or wiring are not B. Turn the ECS to the OFF/RESET position.
okay.
C. Remove the ether canister(s) from the ether
Repair: Repair the connectors or wiring and/or solenoid(s). Determine if the canister contains
replace the connectors or wiring. any ether. Ether can not be injected if the
canister is empty.
STOP.
Expected Result:
Test Step 2. Check for Diagnostics on the
Caterpillar Electronic Technician (ET). The ether canister is not empty.

A. Remove the ether canister(s) from the ether Results:

solenoid(s).
• OK – The ether canister is not empty. Proceed
B. Turn the circuit breaker for the battery to the ON to Test Step 4.
position.
• Not OK – The ether canister is empty.
C. Turn the ECS to the STOP position.
Repair: Replace the empty ether canister with a
D. Connect Cat ET. full ether canister.

STOP.
 135
Troubleshooting Section

Test Step 4. Check the Voltage from the C. Connect a voltmeter to pin 1 and pin 2 of the
Ether Start Relay. ether solenoid connector.

A. Turn the circuit breaker for the battery to the OFF D. Turn the ECS to the STOP position.
position.
E. Activate the ether override and observe the
B. Turn the ECS to the OFF/RESET position. voltmeter while ether injection is on. Disable
the ether override. This procedure must be
C. Remove the ether canister(s) from the ether performed on both solenoids if two solenoids
solenoid(s). are present. Do not allow the ether to be on for
more than two minutes. Damage to the solenoid
D. Connect Cat ET. may occur.

E. Turn the circuit breaker to the battery to the ON F. Reconnect all connectors.
position.
Expected Result:
F. Connect a voltmeter between wire 382-PK on
terminal 30 of the ether start relay and ground. The voltage at the ether solenoid is 24 ± 3 VDC
during the first two seconds of injection. The voltage
G. Turn the ECS to the STOP position. then decreases to 3 ± 1 VDC for the remainder of
the injection duration.
H. Select the “Diagnostic Tests” on Cat ET.
Results:
I. Select the “Override Parameters” screen on Cat
ET. • OK – The voltage at the ether solenoid is 24 ± 3
VDC during the first two seconds of injection. The
J. Activate the ether override and observe the voltage then decreases to approximately 3 ± 1
voltmeter while ether injection is “ON”. Disable VDC for the remainder of injection duration.
the ether override. Do not allow the ether to be
“ON” for more than two minutes. Damage to the Repair: If ether is not being injected, temporarily
solenoid may occur. replace the ether solenoid. If the problem is no
longer present, reinstall the old solenoid. If the
Expected Result: problem returns, replace the solenoid.

The voltage at the ether start relay is 24 ± 3 VDC STOP.

during the first two seconds of injection. The voltage
then decreases to 3 ± 1 VDC for the remainder of • Not OK - 24 VDC – The voltage at the ether
the injection duration. solenoid is not 24 ± 3 VDC during the first two
seconds of injection.
Results:
Repair: Inspect the wiring and connectors
• OK – The voltage at the ether start relay is 24 ± between the ether start relay and the connectors
3 VDC during the first two seconds of injection. at the ether solenoids. Repair the connectors or
The voltage then decreases to approximately 3 wiring and/or replace the connectors or wiring.
± 1 VDC for the remainder of injection duration.
Proceed to Test Step 5. STOP.

• Not OK - 24 VDC – The voltage at the ether • Not OK - 3 VDC – The voltage did not decrease
start relay is not 24 ± 3 VDC during the first two to 3 ± 1 VDC for the remainder of the injection
seconds of injection. Proceed to Test Step 6. duration. Proceed to Test Step 9.

• Not OK - 3 VDC – The voltage did not decrease Test Step 6. Check ECM Voltage at the
to approximately 3 ± 1 VDC for the remainder of Ether Start Relay.
the injection duration. Proceed to Test Step 9.
A. Turn the ECS to the OFF/RESET position.
Test Step 5. Check the Voltage at the
Ether Solenoids. B. Connect a voltmeter between wire F710-BR on
terminal 85 of the ether start relay to ground.
A. Turn the ECS to the OFF/RESET position.
C. Turn the ECS to the STOP position.
B. Disconnect the ether solenoid connector at the
solenoid.
136
Troubleshooting Section

D. Activate the ether override and observe the D. Connect a voltmeter between the jumper wire
voltmeter while ether injection is on. Disable in P1-40 and ground.
the ether override. Do not allow the ether to be
on for more than two minutes. Damage to the E. Turn the ECS to the STOP position.
solenoid may occur.
F. Activate the ether override and observe the
Expected Result: voltmeter while ether injection is on. Disable
the ether override. Do not allow the ether to be
The voltage measures 24 ± 3 VDC for two seconds. on for more than two minutes. Damage to the
solenoid may occur.
Results:
G. Remove all wire jumpers and reconnect all
• OK – The voltage was 24 ± 3 VDC. Proceed to connectors.
Test Step 7.
Expected Result:
• Not OK – The voltage was not 24 ± 3 VDC.
Proceed to Test Step 8. The voltage at the ECM is 24 ± 3 VDC for two
seconds.
Test Step 7. Check the Battery Voltage to
the Ether Start Relay. Results:

A. Measure the voltage between wire 104-RD on • OK – The voltage at the ECM is 24 ± 3 VDC for
terminal 87 of the ether start relay and ground. two seconds.

Expected Result: Repair: The wire F710-BR and/or the connectors

between the ECM and the ether start relay need
The voltage is 24 ± 3 VDC. repair. Inspect the wiring and connectors between
the ether start relay and the connector at the
Results: ECM. Repair the connectors or wiring and/or
replace the connectors or wiring.
• OK – The voltage is 24 ± 3 VDC.
STOP.
Repair: Disconnect wire 998-BR on terminal 86 of
the ether start relay. Check this wire for continuity • Not OK – The voltage at the ECM is not 24 ± 3
to ground. If the wire is okay, replace the ether VDC for two seconds.
start relay. If the wire is not okay, repair the wire.
Verify that the system is operating correctly. Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, “Replacing the ECM”.
STOP.
STOP.
• Not OK – The voltage is not 24 ± 3 VDC.
Test Step 9. Check the Voltage from the
Repair: Verify that the breakers for the battery Ether Hold Relay.
and/or the relay are not tripped. Disconnect wire
104-RD on terminal 87 of the ether start relay. A. Turn the ECS to the OFF/RESET position.
Check wire 104-RD for continuity to the +Battery.
If the wire is not okay, repair the wire. Verify that B. Connect a voltmeter between wire 926-RD on
the system is operating correctly. terminal 30 of the ether hold relay and ground.

STOP. C. Turn the ECS to the STOP position.

Test Step 8. Check the Voltage from the D. Activate the ether override and observe the
ECM to the Ether Start Relay. voltmeter while ether injection is on. Disable
the ether override. Do not allow the ether to be
A. Turn the ECS to the OFF/RESET position. on for more than two minutes. Damage to the
solenoid may occur.
B. Disconnect connector P1 from the ECM.
Expected Result:
C. Remove wire F710-BR from connector P1-40.
Install a jumper wire that has a socket on one end The voltage at terminal 30 is 24 ± 3 VDC during
into P1-40. Reconnect connector P1 to the ECM. injection.
 137
Troubleshooting Section

Results: D. Connect the positive lead of the multimeter to

pin 1 and the negative lead to pin 2 of the
• OK – The voltage at terminal 30 is 24 ± 3 VDC resistor and the diode assembly and observe
during injection. Proceed to Test Step 10. the multimeter.

• Not OK – The voltage at terminal 30 is not 24 ± 3 E. Repeat the measurements for all of the resistor
VDC during injection. Proceed to Test Step 12. and the diode assemblies if more than one
resistor and diode assembly is present.
Test Step 10. Check the Voltage at the
Resistor and the Diode Assembly. Expected Result:

A. Turn the ECS to the OFF/RESET position. When the positive lead of the multimeter is
connected to pin 2 and the negative lead to pin 1,
B. Disconnect the connector at the resistor and the the multimeter displays an overload “(OL)”.
diode assembly.
When the positive lead of the multimeter is
C. Connect a voltmeter to pin 1 of the resistor and connected to pin 1 and the negative lead to pin 2,
the diode assembly and ground. the multimeter displays a number less than one.

D. Turn the ECS to the STOP position. Results:

E. Activate the ether override and observe the • OK – The resistor and the diode assembly is
voltmeter while ether injection is on. Disable operating correctly.
the ether override. This procedure must be
performed on all of the resistor and diode Repair: There is a problem in the harness
assemblies, if more than one resistor and diode between the resistor and diode assembly and the
assembly is present. Do not allow the ether to be ether solenoids. Repair the connectors or wiring
on for more than two minutes. Damage to the and/or replace the connectors or wiring.
solenoid may occur.
STOP.
Expected Result:
• Not OK – The resistor and the diode assembly is
The voltage is 24 ± 3 VDC. not operating correctly.

Results: Repair: The resistor and the diode assembly is

causing the problem. Temporarily replace the
• OK – The voltage is 24 ± 3 VDC. Proceed to Test resistor and the diode assembly. If the problem
Step 11. is no longer present, reinstall the resistor and the
diode assembly. If the problem returns replace
• Not OK – The voltage is not 24 ± 3 VDC. the resistor and the diode assembly.

Repair: There is a problem in the harness STOP.

between the ether hold relay and the resistor and
diode assembly. Repair the connectors or wiring Test Step 12. Check the Battery Voltage
and/or replace the connectors or wiring. to the Ether Hold Relay.
STOP. A. Measure the voltage between wire 104-RD on
terminal 87 and on terminal 86 of the ether hold
Test Step 11. Check the Resistor and relay and ground.
Diode Assembly.
Expected Result:
A. Disconnect the connector at the resistor and the
diode assembly. The voltage is 24 ± 3 VDC.

B. Set the multimeter to the “Check Diode” setting. Results:

C. Connect the positive lead of the multimeter to • OK – The voltage is 24 ± 3 VDC. Proceed to Test
pin 2 and the negative lead to pin 1 of the Step 13.
resistor and the diode assembly and observe
the multimeter. • Not OK – The voltage is not 24 ± 3 VDC.
138
Troubleshooting Section

Repair: Verify that the breakers for the battery G. Activate the ether override and observe the
and/or the relay are not tripped. Disconnect wire voltage on the voltmeter while ether injection
104-RD on terminal 87 of the ether hold relay. is on. Disable the ether override. Do not allow
Check wire 104-RD for continuity to the +Battery. the ether to be on for more than two minutes.
If the wire is not okay, repair the wire. Verify that Damage to the solenoid may occur.
the system is operating correctly.
H. Remove all jumpers and connect all connectors.
STOP.
Expected Result:
Test Step 13. Check the Coil of the Ether
Hold Relay. The voltage is 24 ± 3 VDC.

A. Turn the ECS to the OFF/RESET position. Results:

B. Remove wire F707-WH from terminal 85 of the • OK – The voltage is 24 ± 3 VDC.

ether hold relay. Connect a voltmeter between
terminal 85 of the ether hold relay and −Battery Repair: There is a problem in the wire F707-WH
terminal. between the ECM and the ether hold relay. Repair
the connectors or wiring and/or replace the
C. Turn the ECS to the STOP position. connectors or wiring.

D. Measure the voltage on the voltmeter. STOP.

E. Remove the voltmeter and reconnect all wires. • Not OK – The voltage is not 24 ± 3 VDC.
Expected Result: Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, “Replacing the ECM”.
The voltage is 24 ± 3 VDC.
STOP.
Results:
Test Step 15. Check the Wires of the
• OK – The voltage is 24 ± 3 VDC. Proceed to Test Starting Aid Switch at the Harness.
Step 14.
A. Turn the circuit breaker to the battery to the OFF
• Not OK – The voltage is not 24 ± 3 VDC. The position.
problem is the ether hold relay.
B. Turn the ECS to the OFF/RESET position.
Repair: Temporarily replace the ether hold relay.
If the problem is no longer present, reinstall the C. Disconnect J1/P1 and the starting aid switch.
ether hold relay. If the problem returns replace
the ether hold relay. D. Obtain a suitable piece of wire. Connect the
wires at the starting aid switch together.
STOP.
E. Measure the resistance between the ether switch
Test Step 14. Check the Wire from the P1-25 and the digital return P1-29.
Coil of the Ether Hold Relay to the ECM.
Expected Result:
A. Turn the ECS to the OFF/RESET position.
The resistanceis less than 5 Ohms.
B. Disconnect ECM connector P1.
Results:
C. Remove wire F707-WH from ECM connector
P1-22. Install a jumper wire that has a socket • OK – The resistance is less than 5 Ohms. The
on one end into P1-22. switch wiring is not the problem. Proceed to Test
Step 16.
D. Reconnect ECM connector P1.
• Not OK – The resistance is greater than 5 Ohms.
E. Connect one end of a voltmeter to the jumper There is a problem with the switch wiring in the
wire and the other end to the +Battery. harness.

F. Turn the ECS to the STOP position.

 139
Troubleshooting Section

Repair: Repair the connectors or wiring and/or i01967487

replace the connectors or wiring.
Injector Solenoids
STOP.
SMCS Code: 1290-038-JV
Test Step 16. Check the Starting Aid
Switch. System Operation Description:

A. Turn the circuit breaker for the battery to the OFF The engine uses electronic unit injectors that are
position. mechanically actuated and electronically energized.
The Electronic Control Module (ECM) sends a 105
B. Turn the ECS to the OFF/RESET position. volt pulse to each injector solenoid. The pulse is
sent at the proper time and at the correct duration
C. Disconnect the starting aid switch. for a given engine load and speed. If a diagnostic
is detected in the solenoid circuit, the ECM will
D. Toggle the starting aid switch. disable that solenoid circuit. The ECM keeps
the solenoid circuit disabled for ten revolutions
E. Measure the resistance between pin 1 and pin 2 of the crankshaft. The ECM then tries to fire the
of the starting aid switch. injector. If the diagnostic is still present, the ECM
will disable the circuit for another ten revolutions
F. Release the starting aid switch and repeat the of the crankshaft. This sequence of events will be
previous measurement. repeated indefinitely until the problem is corrected.

Expected Result: The 105 volt pulse can be individually cut out to aid
in troubleshooting misfire problems by using the
The resistance is less than 5 Ohms with the switch Caterpillar Electronic Technician (ET). The solenoid
toggled. The resistance is greater than 20,000 is mounted on top of the fuel injector body.
Ohms when the switch is released.

Results:

• OK – The resistance is less than 5 Ohms with

the switch toggled. The resistance is greater than
20,000 Ohms when the switch is released.

Repair: The switch is operating correctly but the

ECM is not reading the switch correctly. Replace
the ECM. Refer to the diagnostic procedure
Troubleshooting, “Replacing the ECM”.

STOP.

• Not OK – The resistance is greater than 5 Ohms

when the switch is toggled. The resistance is less
than 20,000 Ohms when the switch is released.

Repair: There is a problem with the starting aid

switch. Temporarily replace the starting aid switch
with a new switch. If the problem is no longer
present, reinstall the old switch. If the problem
returns, replace the switch.

STOP.
140
Troubleshooting Section

g00795019
Illustration 28
Typical of 8 cylinder engine
 141
Troubleshooting Section

g00761831
Illustration 29
Typical of 12 or 16 cylinder engine

Test Step 1. Check for Connector C. Thoroughly inspect the ECM connectors
Damage. J1/P1 and J2/P2. Inspect all of the other
connectors. Refer to the diagnostic functional
A. Turn the ECS to the OFF/RESET position. test Troubleshooting, “Inspecting Electrical
Connectors” for details.
B. Turn the battery disconnect switch to the OFF
position. D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with the circuit.

E. Check the ECM connector (allen head screw) for

the proper torque of 6.0 N·m (55 lb in).
142
Troubleshooting Section

F. Check the customer connector (allen head A. Turn the ECS to the OFF/RESET position.
screw) for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in). B. Turn the battery disconnect switch to the OFF
position.
G. Check the harness and the wiring for abrasion
and for pinch points. C. Verify that the ECM connector J2/P2 and the
injector connectors J4/P4 through J19/P19 are
Expected Result: properly connected.

All connectors, pins, and sockets are completely D. Install Cat ET.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points. E. Turn the battery disconnect switch to the ON
position.
Results:
F. Turn the ECS to the START position.
• OK – The connectors and wiring are okay.
Proceed to Test Step 2. G. Start the engine.

• Not OK – The connectors and/or wiring are not H. Apply a load to the engine.
okay.
I. Perform the following steps on all suspect
Repair: Repair the connectors or wiring and/or cylinders (solenoids).
replace the connectors or wiring.
J. Use the diagnostic tests on Cat ET to initiate the
STOP. “Cylinder Cutout Test”.

Test Step 2. Check for LOGGED K. Check for a difference in the sound, in the feel,
Diagnostic Codes. or in the power of the engine as each cylinder
is cut out. The amount of change should be
A. Connect the Cat ET to the service tool connector. similar for all of the good cylinders. The amount
of change should be minimal for a weak cylinder
B. Turn the battery disconnect switch to the ON or for a malfunctioning cylinder.
position.
L. Disable the override.
C. Turn the ECS to the STOP position.
Expected Result:
D. Observe the diagnostic codes on Cat ET.
The amount of change was similar for all of the
Expected Result: good cylinders. The amount of change was minimal
for a weak cylinder or for a bad cylinder.
A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 is not
logged. Results:

Results: • OK – There was a noticeable change in engine

performance during the “Cylinder Cutout Test”.
• OK – A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 is
not logged. Proceed to Test Step 3. Repair: The change in engine performance
indicates that the cylinder was firing correctly.
• Not OK – A CID-FMI 1-05 to 16-05 or 1-06 to The problem may be intermittent. If the problem
16-06 is logged. Proceed to Test Step 5. is intermittent, refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical
Test Step 3. Perform the “Cylinder Cutout Connectors”.
Test”.
STOP.
NOTICE
Engine power is reduced when a properly functioning • Not OK – There was no noticeable change in
cylinder is cut out. Make sure that you will not damage engine performance during the “Cylinder Cutout
auxiliary or driven equipment if the engine power is Test”. Proceed to Test Step 4.
suddenly reduced.
 143
Troubleshooting Section

Test Step 4. Check the Injector Lash and D. Measure the resistance at ECM connector P2
the Engine Valve Lash Setting. between the sockets for power output and the
solenoid return for the individual solenoid. For
A. Turn the ECS to the OFF/RESET position. the eight cylinder engine, refer to Illustration 29.
For the twelve and sixteen cylinder engines, refer
B. Turn the battery disconnect switch to the OFF to Illustration 28.
position.
Expected Result:
C. Check the injector and the engine valve lash
setting. Refer to the Systems Operation, “Testing The resistance is greater than 20,000 Ohms.
and Adjusting”.
Results:
Expected Result:
• OK – The resistance is greater than 20,000
The engine valve lash setting is correct. The Ohms. Proceed to Test Step 6.
injectors are okay.
• Not OK – The resistance is less than 20,000
Results: Ohms.

• OK – The injector is okay. Proceed to Test Step 5. Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
• Not OK – The injector is not okay. A problem is
found with the injector. STOP.

Repair: Repair the injector. If the problem is still Test Step 6. Check for Shorts in the
present, replace the injector. If the new injector Harness to Engine Ground.
has an injector code that is different from the old
injector, change the code in the ECM.

STOP.
This engine uses high voltage to control the fuel
Test Step 5. Check the Resistance of the injectors.
Harness from the Solenoid to the ECM
Connector. Disconnect electronic fuel injector enable circuit
connector to prevent personal injury.

Do not come in contact with the fuel injector ter-

minals while the engine is running.
This engine uses high voltage to control the fuel
injectors.
A. For the 3508B engine, measure the resistance at
Disconnect electronic fuel injector enable circuit the ECM connector between the following points
connector to prevent personal injury. and engine ground: P2-5, P2-16, P2-17, P2-26,
P2-27, P2-30, P2-31, P2-32, P2-36, P2-37, P2-38,
Do not come in contact with the fuel injector ter- and P2-39. For the 3512B engine, measure
minals while the engine is running. the resistance at the ECM connector between
the following points and engine ground: P2-5,
P2-11, P2-12, P2-16, P2-17, P2-18, P2-21, P2-22,
A. Turn the ECS to the OFF/RESET position. P2-26, P2-27, P2-28, P2-31, P2-32, P2-33, P2-34,
P2-37, P2-38, and P2-40. For the 3516B engine,
B. Turn the battery disconnect switch to the OFF measure the resistance at the ECM connector
position. between the following points and engine ground:
P2-4, P2-5, P2-6, P2-10, P2-11, P2-12, P2-16,
C. Disconnect ECM connector J2/P2 and injector P2-17, P2-18, P2-21, P2-22, P2-26, P2-27, P2-28,
connectors J4/P4 through J11/P11 for the eight P2-30, P2-31, P2-32, P2-33, P2-34, P2-36, P2-37,
cylinder engine. Disconnect ECM connector P2-38, P2-39, and P2-40.
J2/P2 and injector connectors J4/P4 through
J15/P15 for the twelve cylinder engine. Expected Result:
Disconnect ECM connector J2/P2 and injector
connectors J4/P4 through J19/P19 for the sixteen The resistance is greater than 20,000 Ohms.
cylinder engine.
144
Troubleshooting Section

Results: A. Measure the solenoid resistance between pin

1 and pin 2 at J4 through J11 for the eight
• OK – The resistance is greater than 20,000 cylinder engine. Measure the solenoid resistance
Ohms. Proceed to Test Step 7. between pin 1 and pin 2 at J4 through J15 for
the twelve cylinder engine. Measure the solenoid
• Not OK – The resistance is less than 20,000 resistance between pin 1 and pin 2 at J4 through
Ohms. J19 for the sixteen cylinder engine.

Repair: Repair the connectors or wiring and/or B. Record the measured resistance for each
replace the connectors or wiring. solenoid.

STOP. Expected Result:

Test Step 7. Check for Open Circuits in The resistance is between 0.5 and 1.5 Ohms.
the Harness.
Results:
A. Use a suitable piece of wire to short socket 1 to
socket 2 at each injector connector. • OK – The resistance is between 0.5 and 1.5
Ohms. Proceed to Test Step 9.
B. Measure the resistance at ECM connector P2
between the sockets for power output and the • Not OK – The resistance is not between 0.5 and
solenoid return for the individual solenoid. For 1.5 Ohms. Proceed to Test Step 10.
the eight cylinder engine, refer to Illustration 29.
For the twelve and sixteen cylinder engines, refer Test Step 9. Perform the “Injector
to Illustration 28. Solenoid Test”.
Expected Result: Note: This test will help the service technician verify
that the ECM can fire the solenoids. DO NOT try
The resistance is less than 5 Ohms. to manually crank the engine during this test. The
ECM will terminate the “Injector Solenoid Test”.
Results:
A. Ensure that the ECM connector J2/P2 is
• OK – The resistance is less than 5 Ohms. connected. Ensure that the injector connectors
Proceed to Test Step 8. J4/P4 through J19/P19 are connected.

• Not OK – The resistance is greater than 5 Ohms. B. Connect Cat ET.

Repair: Repair the connectors or wiring and/or C. Turn the battery disconnect switch to the ON
replace the connectors or wiring. position.

STOP. D. Turn the ECS to the STOP position.

Test Step 8. Measure the Resistance at E. Use the diagnostic tests on Cat ET to initiate the
the Valve Cover Base. “Injector Solenoid Test”.

F. As each solenoid is energized by the ECM, an

audible click can be heard at the valve cover.
Personal injury can result from high voltage. Listen for a click at each valve cover. A black
square will appear over the cylinder number
The Electronic Control Module produces high volt- when the cylinder is being fired.
age.
Expected Result:
Make sure the Electronic Control Module is not
powered and the fuel injector solenoids are dis- As each solenoid is energized by the ECM, an
connected before proceeding. audible click of the solenoid is heard. The solenoids
will be energized one at a time in the following
numerical order: 1 to 16. There will be a momentary
delay between each one.
 145
Troubleshooting Section

Results: Results:

• OK – The audible click is heard for each solenoid. • OK – All resistance readings are within limits.
Proceed to Test Step 3. There is a problem in the valve cover base
harness.
• Not OK – The audible click is not heard for each
solenoid. Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
Repair: Perform a diagnostic functional test. Refer
to the diagnostic functional test Troubleshooting, STOP.
“Electrical Power Supply”.
• Not OK – The injector has failed.
STOP.
Repair: Repair the injector. If the problem is still
Test Step 10. Check the Resistance of the present, replace the injector. If the new injector
Injector Solenoid. has an injector code that is different from the old
injector, change the code in the ECM.

STOP.
This engine uses high voltage to control the fuel
injectors. i01967507

Disconnect the fuel enable circuit connector to Inspecting Electrical

prevent personal injury. Connectors
Do not come in contact with the fuel injector ter- SMCS Code: 1901-038
minals while the engine is running.
System Operation Description:
A. Turn the ECS to the OFF/RESET position.
Most electrical problems are caused by poor
B. Turn the battery disconnect switch to the OFF connections. The following procedure will assist
position. in detecting problems due to connectors. If a
problem is found in an electrical connector, repair
C. Remove the valve cover of the suspected the connector. Do not cut connector wires unless
cylinder. terminals are being replaced. Repair the connectors
with a 1U-5804 Crimp Tool.
D. Remove the harness yoke from the solenoid
terminals. Intermittent electrical problems often disappear
by disconnecting and reconnecting connectors.
E. Measure the resistance between the two solenoid Check for diagnostic codes before disconnecting
terminals on top of the injector. Record the and connecting a connector. If a diagnostic code is
resistance. generated due to disconnecting and reconnecting
a connector, there are several possible reasons.
F. Measure the resistance from either solenoid The likely problems are loose or improperly crimped
terminal to the fuel injector body (metal). terminals, moisture, corrosion, or connectors not
mated securely.
G. Record the resistance.
The following procedure will ensure the correct
H. Reconnect the harness yoke and install the valve installation of pins and sockets in connectors:
cover.
• Do not solder the sockets and pins to the wires.
Expected Result:
• Do not crimp any more than one wire into a
Resistance between the two solenoid terminals is socket or into a pin. Refer to Illustration 32.
between 0.5 and 1.5 Ohms. Resistance from either
solenoid terminal to the fuel injector body (metal) is • Sockets and pins should be crimped on the
greater than 20,000 Ohms. wires. Use the 1U-5804 Crimp Tool for 12 - 18
gauge wire.

• Unused slots for sockets and pins must be filled

with sealing plugs in order to ensure that the
connector is sealed.
146
Troubleshooting Section

• Sealing plugs should be installed on the back

side of the connector. Wires are inserted into the
connector from the back side.

• The sealing plugs that are installed in unused

slots must seal correctly. The plug rests against
the seal face. Do not permit the large end of the
plug to go past the seal face. Refer to Illustration
33 for correct installation of plugs.

g00889323
Illustration 30
 147
Troubleshooting Section

g00720332 g00690572
Illustration 31 Illustration 34
Harness Deutsch Contact Terminals

Test Step 1. Check the Locking of the

DT Connector (Deutsch) and Check the
Lock Ring of the HD Style Connector
(Deutsch).
A. Ensure that the connector is properly locked.
Also ensure that the two halves of the connector
can not be pulled apart.

B. Verify that the latch tab of the connector is

properly latched.

Expected Result:
g00721340
Illustration 32
The connector will securely lock. The connector
and the locking mechanism are without cracks or
without breaks.

Results:

• OK – The connector will lock securely. The

connector and the locking mechanism are without
cracks or without breaks. The connector is okay.
Proceed to Test Step 2.

• Not OK – The connector will not securely lock or

the connector and the locking mechanism have
cracks or breaks. The connector needs repair.

Repair: Repair the connector or replace the

connector, as required. Refer to Special
Instruction, SEHS9615, “Servicing DT
Connectors”. Refer to Special Instruction,
SEHS9065, “Use of CE/VE Connector Tools”.

Verify that the repair eliminates the problem.

g00690571
Illustration 33
Deutsch Sealing Plug STOP.
148
Troubleshooting Section

Test Step 2. Check the Allen Head Screw Results:

on the Connector for the Electronic
Control Module (ECM). • OK – The connector and the terminals withstand
the pull test. Proceed to Test Step 4.
A. Ensure that the allen head screw is properly
tightened. Be careful not to overtighten the screw • Not OK – The connectors and/or the terminals
and break the screw. fail the pull test. The connectors and/or terminals
need repair.
B. Do not exceed 2.25 N·m (20 lb in) of torque on
the allen head screw. Repair: Repair the terminals and/or replace the
terminals, as required. Refer to Special Instruction,
Expected Result: SEHS9615, “Servicing DT Connectors”. Refer to
Special Instruction, SEHS9065, “Use of CE/VE
The ECM connector is secure and the allen head Connector Tools”.
screw is properly torqued.
Verify that the repair eliminates the problem.
Results:
STOP.
• OK – The ECM connector is secure and the allen
head screw is properly torqued. Proceed to Test Test Step 4. Monitor the Caterpillar
Step 3. Electronic Technician (ET) while the
Wiring and the Connectors are Being
• Not OK – The ECM connector or allen head Pulled.
screw need repair.
A. If there is an active diagnostic code that pertains
Repair: Repair the connector or replace the to the circuit, perform the following test:
connector, as required. Refer to Special
Instruction, SEHS9615, “Servicing DT Monitor the active diagnostic code screen on
Connectors”. Refer to Special Instruction, the Cat ET while all the harnesses and the
SEHS9065, “Use of CE/VE Connector Tools”. connectors that connect to the component with
the active diagnostic code are pulled. If the
Verify that the repair eliminates the problem. harness is being pulled and the active diagnostic
code disappears, there is a problem in the wiring
STOP. or the connector.

Test Step 3. Perform a Pull Test on each B. If there are no active diagnostic codes that
Wire Terminal Connection. pertain to the circuit, perform the following test:

A. Each terminal and each connector should easily Monitor the status screen on Cat ET for the
withstand 45 N (10 lb) of pull and each wire suspect component while the harnesses are
should remain in the connector body. This test being pulled. If the harness is being pulled
checks whether the wire was properly crimped and the reading changes erratically, there is a
in the terminal and whether the terminal was problem in the wiring or the connector.
properly inserted into the connector.
C. If there are no active diagnostic codes and the
B. The “DT” connectors use an orange wedge operator is complaining about speed burps or
to lock the terminals in place. Ensure that the power cutouts, perform the following test:
orange wedge is not missing and that the
orange wedge is installed properly on the “DT” Run the engine. Listen for speed burps or power
connectors. cutouts while the wiring or the connectors are
pulled. If the harness is being pulled and the
Note: Terminals should always be crimped onto the engine has a speed burp or a power cutout,
wires through the use of a crimp tool. Do not solder there could be a problem in the wiring or in the
terminals. Use the 1U-5804 Crimp Tool. connector.

Expected Result:

Each terminal and each connector easily withstands

45 N (10 lb) of pull and each wire remains in the
connector body.
 149
Troubleshooting Section

Expected Result: • Not OK – An inspection of the wiring found a

problem. The wires are not free of abrasion,
The problem appears to be external to the of nicks, or of cuts and/or the harness is not
harnesses and to the connectors. Pulling on the properly clamped.
harness and the connectors has no effect on the
active diagnostic code, on the component status, or Repair: Repair the wires or replace the wires, as
on the engine performance. required.

Results: Verify that the repair eliminates the problem.

• OK – There was no change in the active STOP.

diagnostic code, in the component status, or in
the engine performance. Proceed to Test Step 5. Test Step 6. Check the Connectors for
Moisture or Corrosion.
• Not OK – There was a change in the active
diagnostic code, in the component status, or in A. Ensure that the connector seals and the white
the engine performance. sealing plugs are in place. If any of the seals or
plugs are missing, replace the seal or the plug.
Repair: Repair the terminals and/or replace the If necessary, replace the connector.
terminals, as required. Refer to Special Instruction,
SEHS9615, “Servicing DT Connectors”. Refer to B. Check all of the wiring harnesses in order to
Special Instruction, SEHS9065, “Use of CE/VE verify that the harness does not make a sharp
Connector Tools”. bend out of a connector. This will deform the
connector seal and this will create a path for the
Verify that the repair eliminates the problem. entrance of moisture.

STOP. Thoroughly inspect ECM Connectors J1/P1 and

J2/P2 for evidence of moisture entry.
Test Step 5. Check the Wires for Nicks in
the Insulation or Abrasion. Note: It is normal to see some minor seal abrasion
on the ECM connector seals. Minor seal abrasion
A. Carefully inspect each wire for signs of abrasion, will not allow the entry of moisture.
nicks, or cuts.
C. If moisture or corrosion is evident in the
The following areas are locations that should connector, the source of the moisture entry must
be checked: be found. The source of the moisture entry must
be repaired. If the source of the moisture entry
• Exposed insulation is not repaired, the problem will reoccur. Simply
drying the connector will not fix the problem.
• Points of rubbing wire against the engine Likely paths for the entrance of moisture are
illustrated in the following list:
• Points of rubbing wire against a sharp point
• Missing seals
B. Check all of the hold down clamps for the
harness in order to verify that the harness is • Improperly installed seals
properly clamped. Also check all of the hold
down clamps for the harness in order to verify • Nicks in exposed insulation
that the harness is not compressed by the
clamp. Pull back the harness sleeves in order • Improperly mated connectors
to check for a flattened portion of wire. The
flattened portion of wire is caused by the clamp Moisture can also travel from one connector
that holds the harness. through the inside of a wire to the ECM connector.
If moisture is found in the ECM connector,
Expected Result: thoroughly check all connectors and wires on the
harness that connect to the ECM. The ECM is
The wires are free of abrasion, of nicks, or of cuts not the source of the moisture. Do not replace an
and the harness is properly clamped. ECM if moisture is found in either ECM connector.

Results:

• OK – The wires are free of abrasion, of nicks,

or of cuts and the harness is properly clamped.
Proceed to Test Step 6.
150
Troubleshooting Section

Note: If corrosion is evident on the pins, sockets or Results:

the connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush • OK – The terminals are properly aligned and the
to remove the corrosion. Do not use any cleaners terminals appear undamaged. The terminals were
that contain 1,1,1 trichloro-ethylene because 1,1,1 okay. Proceed to Test Step 8.
trichloro-ethylene may damage the connector.
• Not OK – A problem was found with the terminals.
Expected Result: The terminals are not properly aligned and/or the
terminals appear damaged.
All of the connectors are completely coupled and
all of the seals are completely inserted. The harness Repair: Repair the terminals and/or replace the
and the wiring are free of corrosion, of abrasion or terminals, as required. Refer to Special Instruction,
of pinch points. SEHS9615, “Servicing DT Connectors”. Refer to
Special Instruction, SEHS9065, “Use of CE/VE
Results: Connector Tools”.

• OK – All of the connectors are completely Verify that the repair eliminates the problem.
coupled and all of the seals are completely
inserted. The harness and the wiring are free of STOP.
corrosion, of abrasion or of pinch points. The
connectors and wiring were okay. Proceed to Test Test Step 8. Check the Individual Pin
Step 7. Retention into the Socket.
• Not OK – All of the connectors are not completely Note: This is especially important for intermittent
coupled and all of the seals are not completely problems.
inserted. The harness and the wiring are not free
of corrosion, of abrasion or of pinch points. The A. Use a new pin. Insert the pin into each socket
connectors and/or wiring were not okay. one at a time in order to check for a good grip
on the pin by the socket.
Repair: Repair the circuit. Ensure that all of the
seals are properly in place and ensure that the B. Use a new socket. Insert the socket over each
connectors are completely coupled. pin one at a time in order to check for a good
grip on the pin by the socket. The pins are
Verify that the repair eliminates the problem located on the mating side of the connector.
by running the engine for several minutes and
by checking again for moisture. If moisture C. The contact terminal should stay connected
reappears, the moisture is wicking into the when the connector is held in the position shown
connector. Even if the moisture entry path is in Illustration 34. The contact terminal is the pin
repaired, it may be necessary to replace the or the socket.
wires that have moisture. These wires may have
moisture that is trapped inside the insulation. Expected Result:
Verify that the repair eliminates the problem.
The pins and the sockets appear to be okay.
STOP.
Results:
Test Step 7. Inspect the Connector
Terminals. • OK – The pins and the sockets are okay.
A. Verify that the terminals are not damaged. Verify Repair: Recheck the system for diagnostic codes.
that the terminals are properly aligned in the
connector. Verify that the terminals are properly STOP.
located in the connector.
• Not OK – A problem was found in the pins or
Expected Result: sockets.

The terminals are properly aligned and the terminals Repair: Repair the terminals and/or replace the
appear undamaged. terminals. Refer to Special Instruction, SEHS9615,
“Servicing DT Connectors”. Refer to Special
Instruction, SEHS9065, “Use of CE/VE Connector
Tools”.
 151
Troubleshooting Section

Verify that the repair eliminates the problem.

STOP.

i01967610

Prelubrication System
SMCS Code: 1319-038

System Operation Description:

The Electronic Control Module (ECM) has the ability

to automatically prelube the engine before cranking.
This prelubrication may increase the life of certain
engine parts. The ECM will prelube the engine,
when the Engine Control Switch (ECS) is placed in
the START position or the AUTO position and the
remote start/run/stop switch is closed. The length of
time for the prelube cycle can be programmed by
the customer. The prelube cycle will end when the
prelube pressure switch closes or if the customer
programmed time ends. The engine speed must
equal zero rpm before the prelube will begin.

The prelube cycle has the following status codes.

“OFF” – The ECM is powered and the ECS is in

the STOP position.

“ON” – The ECM is powered and the ECS is in the

START position.

“COMPLETED” – The prelube has timed out or the

prelube pressure switch has activated.

“DISABLED” – The engine prelube duration is

programmed to 0.
152
Troubleshooting Section

g01021696
Illustration 35
Typical example

Test Step 1. Check for Connector F. Check the customer connector (allen head
Damage. screw) for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in).
A. Turn the circuit breaker for the battery to the OFF
position. G. Check the harness and the wiring for abrasion
and for pinch points.
B. Turn the ECS to the OFF/RESET position.
Expected Result:
C. Thoroughly inspect the ECM connectors
J1/P1 and J2/P2. Inspect all of the other All connectors, pins, and sockets are completely
connectors. Refer to the diagnostic functional coupled and/or inserted, and the harness and wiring
test Troubleshooting, “Inspecting Electrical are free of corrosion, of abrasion or of pinch points.
Connectors” for details.
Results:
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated • OK – The connectors and wiring are okay.
with the circuit. Proceed to Test Step 2.

E. Check the ECM connector (allen head screw) for • Not OK – The connectors and/or wiring are not
the proper torque of 6.0 N·m (55 lb in). okay.
 153
Troubleshooting Section

Repair: Repair the connectors or wiring and/or Repair: Verify that 24 ± 3 VDC is present on
replace the connectors or wiring. terminal 1 of the prelube switch. If 24 ± 3 VDC is
not present on terminal 1, check the wiring and
STOP. breakers between the battery and the prelube
switch. Refer to Illustration 35 as a reference.
Test Step 2. Check for Output Voltage to
the Prelube Motor. Verify that wire 200-BK has continuity to the
−Battery terminal. If wire 200-BK is okay and
A. Turn the circuit breaker for the battery to the ON voltage is present on terminal 4, replace the
position. prelube switch.

B. Turn the ECS to the OFF/RESET position. STOP.

C. Connect one lead of a voltmeter to the −Battery • Not OK – The voltage is not 24 ± 3 VDC. Proceed
terminal. to Test Step 4.

D. Connect the other lead of the voltmeter to wire Test Step 4. Check the Voltage from the
C465-OR on terminal 2 of the prelube switch. Prelube Relay.
E. Turn the ECS to the START position. A. Leave one lead of the voltmeter on the −Battery
terminal.
F. Monitor the voltage on the voltmeter.
B. Connect the other lead of the voltmeter to wire
G. Turn the ECS to the STOP position. 118-GN on terminal 30 of the prelube relay.

Expected Result: C. Turn the ECS to the START position.

The voltage is 24 ± 3 VDC. D. Monitor the voltage on the voltmeter.

Results: E. Turn the ECS to the STOP position.

• OK – The voltage is 24 ± 3 VDC. Proceed to Test Expected Result:

Step 7.
The voltage is 24 ± 3 VDC.
• Not OK – The voltage is not 24 ± 3 VDC. Proceed
to Test Step 3. Results:

Test Step 3. Check for Output Voltage to • OK – The voltage is 24 ± 3 VDC.

the Prelube Switch.
Repair: Repair the wire 118-GN between the
A. Leave one lead of the voltmeter on the −Battery prelube switch and terminal 30 of the prelube
terminal. relay.

B. Connect the other lead of the voltmeter to wire STOP.

118-GN on terminal 4 of the prelube switch.
• Not OK – The voltage is not 24 ± 3 VDC. Proceed
C. Turn the ECS to the START position. to Test Step 5.

D. Monitor the voltage on the voltmeter. Test Step 5. Check the Voltage to the
ECM from the Coil of the Prelube Relay.
E. Turn the ECS to the STOP position.
A. Turn the ECS in the OFF/RESET position.
Expected Result:
B. Remove wire F705-PK from terminal 86 of the
The voltage is 24 ± 3 VDC. prelube relay.

Results: C. Connect one lead of the voltmeter on terminal

86 of the prelube relay.
• OK – The voltage is 24 ± 3 VDC.
D. Connect the other lead of the voltmeter to wire
F705-PK that was removed from terminal 86 of
the prelube relay.
154
Troubleshooting Section

E. Turn the ECS in the START position. Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, “Replacing the ECM”.
F. Monitor the voltage on the voltmeter.
STOP.
Expected Result:
Test Step 7. Check the Operation of the
The voltage is 24 ± 3 VDC. Prelube Motor.
Results: A. Turn the circuit breaker for the battery to the OFF
position.
• OK – The voltage is 24 ± 3 VDC.
B. Turn the ECS to the OFF/RESET position.
Repair: Verify that 24 ± 3 VDC is present on
terminal 87 of the prelube relay. If 24 ± 3 VDC is C. Connect one side of a suitable piece of 10 AWG
present on terminal 87, replace the prelube relay. wire to the +Battery terminal.

STOP. D. For one second, connect the other end of the

wire to the positive terminal of the prelube motor.
• Not OK – The voltage is not 24 ± 3 VDC. Proceed
to Test Step 6. Expected Result:

Test Step 6. Check the Sinking Driver for The prelube motor starts while the wire is connected
the Prelube Relay. to the positive terminal.

A. Turn the ECS to the OFF/RESET position. Results:

B. Disconnect ECM connector J1/P1. • OK – The prelube motor starts. There is a

problem in the wiring harness.
C. Remove wire F705-PK from ECM connector
P1-21. Install a jumper wire that has a pin on one Repair: Inspect the connectors and the wiring
end into P1-21. between the positive terminal of the prelube
motor and pin 2 of the prelube switch.
D. Reconnect ECM connector J1/P1.
STOP.
E. Connect one lead of a voltmeter to the jumper
wire in P1-21 and the other lead to +Battery. • Not OK – The prelube motor did not start. The
problem appears to be in the prelube motor.
F. Turn the ECS to the START position.
Repair: Temporarily replace the prelube motor
G. Monitor the voltage on the voltmeter. with a new prelube motor. If the problem is no
longer present, reinstall the old prelube motor. If
H. Turn the ECS to the OFF/RESET position. the problem returns, replace the prelube motor.

I. Remove all jumpers and replace all wires. STOP.

Expected Result:

The voltage is 24 ± 3 VDC.

Results:

• OK – The voltage is 24 ± 3 VDC.

Repair: Repair the wire F705-Pk between the
prelube relay and ECM connector P1-21.

STOP.

• Not OK – The voltage is not 24 ± 3 VDC.

 155
Troubleshooting Section

i01968325

Speed Control
SMCS Code: 1901-038

System Operation Description:

The speed control provides a throttle signal and

a droop signal to the engine’s Electronic Control
Module (ECM). The output for rated speed is a
pulse width modulated signal (PWM) at a constant
frequency. The speed signal varies with the position
of the speed adjust potentiometer. The output for
droop is a PWM signal at a constant frequency. The
droop signal varies with the position of the droop
adjust potentiometer. The output signal is referred
to as a duty cycle or as a PWM signal. The output
signal is expressed as a percentage between 0 and
100 percent for the speed adjust and a percentage
between 0 and 10 percent for the droop adjust.

The ECM calculates the desired engine rpm from

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

Note: Desired speed can be adjusted from 1369

to 1945 rpm for a 60 Hz system and from 1141 to
1621 rpm for a 50 Hz system.

The droop signal is valid when the duty cycle

is in the range of 15 to 85 percent. If the ECM
determines that the droop signal is invalid, the
engine will run with no droop which is referred to as
isochronous mode.

Some applications may choose not to use the speed

control. Some applications may use a load sharing
module. The load sharing module is configured
to provide the engine control with a rated speed
signal. The signal has the same characteristics
as the above defined signal. Some of these load
sharing modules can not provide a signal until the
engine is running. In these cases, troubleshooting
should be performed while the engine is running.
156
Troubleshooting Section

g01022000
Illustration 36
Typical example

Test Step 1. Check for Connector F. Check the harness and the wiring for abrasion
Damage. and for pinch points.

A. Turn the ECS to the OFF/RESET position. Expected Result:

B. Thoroughly inspect the ECM connectors All connectors, pins, and sockets are completely
J1/P1 and J2/P2. Inspect all of the other coupled and/or inserted, and the harness and wiring
connectors. Refer to the diagnostic functional are free of corrosion, of abrasion or of pinch points.
test Troubleshooting, “Inspecting Electrical
Connectors” for details. Results:

C. Perform a 45 N (10 lb) pull test on each of the • OK – The connectors and wiring are okay.
wires in the ECM connector that are associated Proceed to Test Step 2.
with the circuit.
• Not OK – The connectors and/or wiring are not
D. Check the ECM connector (allen head screw) for okay.
the proper torque of 6.0 N·m (55 lb in).
Repair: Repair the connectors or wiring and/or
E. Check the customer connector (allen head replace the connectors or wiring.
screw) for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in). STOP.
 157
Troubleshooting Section

Test Step 2. Check the Supply Voltage to Results:

the Speed Control.
• RATED SPEED – The throttle position on Cat ET
A. Turn the circuit breaker at the battery to the ON does not vary with the turning of the speed adjust
position. potentiometer. Proceed to Test Step 4.

B. Turn the ECS to the STOP position. • DROOP SPEED – The droop on Cat ET does
not vary with the turning of the droop adjust
C. Connect one probe of a voltmeter to the +Battery potentiometer. Proceed to Test Step 5.
terminal of the speed control. Connect one probe
of the voltmeter to the −Battery terminal of the • Unsure – The problem is not apparent. Proceed
speed control. to Test Step 4.

Expected Result: Test Step 4. Check the Throttle Position.

The voltage is 24 ± 3 VDC. A. Turn the ECS to the STOP position.

Results: B. Observe the position of the throttle on Cat ET.

• OK – The voltage is 24 ± 3 VDC. The voltage C. Turn the speed adjust potentiometer to the lowest
supply to the speed control is correct. Proceed setting.
to Test Step 3.
• 60 Hz equals 1369 rpm
• Not OK – The voltage is not 24 ± 3 VDC.
• 50 Hz equals 1141 rpm
Repair: Check wire 998-BR for continuity to the
ECM connector P1-29. Check wire 104-RD for D. Start at the low idle position. Slowly turn the
continuity to the breaker for the “relay breaker”. speed adjust potentiometer in the other direction.
Check the “relay breaker” and the “battery Monitor the position of the throttle on Cat ET.
breaker” in order to ensure that the breakers are
not tripped. Expected Result:

STOP. The throttle position on Cat ET reads 0 percent

at the lowest setting and 0 to 100 percent as the
Test Step 3. Determine the Component speed adjust potentiometer is adjusted.
that has Failed.
Results:
A. Determine if the problem is with the input for the
throttle or the droop. • OK – The speed control is operating correctly.
B. Turn the ECS to the STOP position. Repair: The problem may be intermittent. If the
problem is intermittent, perform the diagnostic
C. Observe the position of the throttle on the functional test Troubleshooting, “Inspecting
Caterpillar Electronic Technician (ET) as you turn Electrical Connectors”.
the speed adjust potentiometer.
STOP.
D. Observe the droop on Cat ET as you turn the
droop adjust potentiometer. • Not OK – The throttle position on Cat ET does
not vary as the speed adjust potentiometer is
E. Select “UNSURE” if the source of the problem is adjusted. Proceed to Test Step 6.
unknown.
Test Step 5. Check the Droop Signal on
Expected Result: Cat ET.
The throttle position on Cat ET varies with the A. Turn the ECS to the STOP position.
turning of the speed adjust potentiometer. The
droop on Cat ET varies with the turning of the droop B. Observe the droop on Cat ET.
adjust potentiometer.
C. Turn the droop adjust potentiometer in a
counterclockwise direction.

D. Slowly turn the droop adjust potentiometer in a

clockwise direction. Monitor the droop on Cat ET.
158
Troubleshooting Section

Note: Do not overturn the droop adjust potentiometer Repair: Temporarily install another speed control.
in the clockwise direction. The signal will become Verify that the problem is no longer present.
erratic. Reinstall the old speed control. If the problem
returns, replace the speed control.
Expected Result:
STOP.
The droop on Cat ET reads 0 percent at the lowest
setting and 0 to 10 percent as the droop adjust Test Step 7. Check the Droop Signal at
potentiometer is adjusted. the Speed Control.
Results: A. Remove the wire from the D terminal of the
speed control.
• OK – The droop is operating correctly.
B. Set the multimeter to “VDC”. Press the “Hz”
Repair: The problem may be intermittent. If the button twice so that the % symbol is displayed.
problem is intermittent, perform the diagnostic
functional test Troubleshooting, “Inspecting C. Place one probe of the multimeter on the D
Electrical Connectors”. terminal of the speed control. Place the other
probe on the −Battery terminal of the speed
STOP. control.

• Not OK – The droop on Cat ET does not vary D. Monitor the output of the percent duty cycle from
as the droop adjust potentiometer is adjusted. the speed control on the multimeter. Turn the
Proceed to Test Step 7. droop adjust potentiometer from the low setting
to the high setting.
Test Step 6. Check the Speed Control.
Note: The droop on Cat ET will not match the
A. Remove the wire from the S terminal at the speed percent duty cycle on the multimeter.
control.
Expected Result:
B. Set the multimeter to “VDC”. Press the “Hz”
button twice so that the % symbol is displayed. The duty cycle is between 15 and 85 percent. This
range should be attainable.
C. Place one probe of the multimeter on the S
terminal of the speed control. Place the other Results:
probe on the −Battery terminal of the speed
control. • OK – The speed control is providing the correct
droop signal. Proceed to Test Step 9.
D. Monitor the output of the percent duty cycle from
the speed control on the multimeter. Turn the • Not OK – The problem appears to be in the
speed adjust potentiometer from the low setting speed control.
to the high setting.
Repair: Temporarily install another speed control.
Note: The throttle position on Cat ET will not match Verify that the problem is no longer present.
the percent duty cycle on the multimeter. Reinstall the old speed control. If the problem
returns, replace the speed control.
Expected Result:
STOP.
The duty cycle is between 4 and 10 percent at the
low setting and between 90 and 95 percent at the Test Step 8. Check the Speed Signal at
high setting. the ECM Input.
Results: A. Turn the ECS to the STOP position.

• OK – The speed control is supplying the correct B. Set the multimeter to “VDC”. Press the “Hz”
duty cycle. Proceed to Test Step 8. button twice so that the % symbol is displayed.

• Not OK – The duty cycle is not correct on the C. Measure the voltage between pins P2-24 and
multimeter. P1-29 on the ECM connectors.
 159
Troubleshooting Section

D. Monitor the output of the percent duty cycle from Expected Result:
the speed control on the multimeter. Monitor
the percent throttle position on Cat ET. Turn the The duty cycle is between 1 and 15 percent at the
speed adjust potentiometer from the low setting clockwise setting and between 85 and 99 percent at
to the high setting. the counterclockwise setting. The droop is between
0 and 100 percent for the above settings of the
Expected Result: droop adjust potentiometer.

The duty cycle is between 4 and 10 percent at Results:

the low setting and between 90 and 95 percent
at the high setting. The percent throttle position is • OK – The duty cycle is correct.
between 0 and 100 percent for the above settings
of the speed adjust potentiometer. Repair:

Results: STOP.

• OK – The duty cycle is correct. Proceed to Test • Not OK - Duty Cycle – The duty cycle is not
Step 5. correct.

• Not OK - Duty Cycle – The duty cycle is not Repair: There is a problem in the wiring between
correct. P1-13 and the D terminal of the speed control.

Repair: There is a problem in the wiring between STOP.

P2-24 and the S terminal of the speed control.
Verify that the low idle switch is functioning • Not OK - Droop – The duty cycle is correct but the
properly. droop is not correct. The ECM is not processing
the correct signal.
STOP.
Repair: Replace the ECM. Refer to the diagnostic
• Not OK - Throttle Position – The duty cycle is procedure Troubleshooting, “Replacing the ECM”.
correct but the throttle position is not correct. The
ECM is not processing the correct signal. STOP.

Repair: Replace the ECM. Refer to the diagnostic

i01968458
procedure Troubleshooting, “Replacing the ECM”.

STOP.
Starting Motor System
SMCS Code: 1901-038
Test Step 9. Check the Droop Signal at
the ECM Input. System Operation Description:
A. Turn the ECS to the STOP position. The Electronic Control Module (ECM) has the ability
to crank the engine when the Engine Control Switch
B. Measure the voltage between pins P1-13 and (ECS) is placed in the START position. The engine
P1-29 on the ECM connector. control will start the first crank cycle, when the ECS
is placed in the START position. The crank cycle
C. Set the multimeter to “VDC”. Press the “Hz” will continue for the time that is equal to the cycle
button twice so that the % symbol is displayed. crank time that has been programmed or the crank
cycle will continue until the engine speed reaches
D. Monitor the output of the percent duty cycle of the crank terminate speed. If crank terminate speed
the droop signal at the speed control with the is not reached before the crank cycle time, the
multimeter. Monitor the droop on Cat ET. Turn the starting motor will deactivate at the end of the crank
droop adjust potentiometer from the low setting cycle time.
to the high setting.
This process will repeat for a programmed amount
Note: Do not overturn the droop adjust potentiometer of times (Total Number of Crank Cycles). If the
in the clockwise direction. The signal will become engine does not start, the Caterpillar Electronic
erratic. Technician (ET) will display “OVERCRANK”. The
engine control will be in an idle state. The process
can be restarted by turning the ECS to the
OFF/RESET position. Next turn the ECS to the STOP
position. Then turn the ECS to the START position.
160
Troubleshooting Section

After the ECS is placed in the START position, the

ECM will begin the prelube cycle. The ECM will
send a signal to the starting motor relays after the
prelube cycle is complete. The starting motor relays
will energize closing the normally open contacts of
the relays. Current will flow to the starting motors
from the “mag relay breaker”. The starting motors
will begin to crank the engine.

The engine can be manually started by using the

manual crank switch.

g00722490
Illustration 37
Typical example

Test Step 1. Check for Connector C. 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. Disconnect the main power.
D. Check the ECM connector (allen head screw)
B. Thoroughly inspect the ECM connectors for the proper torque of 2.25 ± 0.25 N·m
J1/P1 and J2/P2. Inspect all of the other (20 ± 2 lb in).
connectors. Refer to the diagnostic functional
test Troubleshooting, “Inspecting Electrical E. Check the customer connector (allen head
Connectors” for details. screw) for the proper torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in).
 161
Troubleshooting Section

F. Check the harness and the wiring for abrasion • Not OK - Engine Doesn’t Crank – The “startup
and for pinch points. mode” parameter on the status screen on the Cat
ET displays “CRANK”. The engine will not crank.
Expected Result: Proceed to Test Step 3.

All connectors, pins, and sockets are completely • Not OK - Status Screen – The “startup mode”
coupled and/or inserted, and the harness and wiring parameter on the status screen on the Cat ET
are free of corrosion, of abrasion or of pinch points. does not display “CRANK”.

Results: Repair: Perform the diagnostic functional test

Troubleshooting, “Engine Control Switch (ECS)”.
• OK – The connectors and wiring are okay.
Proceed to Test Step 2. STOP.

• Not OK – The connectors and/or wiring need Test Step 3. Manually Crank the Engine.
repair.
A. Turn the ECS to the STOP position.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. B. Open the electronic instrument panel.

STOP. C. Connect one lead of a voltmeter to the −Battery

terminal. Connect the other lead of the voltmeter
Test Step 2. Attempt to Start the Engine. to wire 314-PU on terminal 2 of the mag relay.

A. Turn the circuit breaker for the battery to the ON D. Activate the manual crank switch.
position.
E. Monitor the voltage on the voltmeter.
B. Turn the ECS to the STOP position.
Expected Result:
C. Connect the Cat ET to the service tool connector.
The voltage measures 24 ± 3 VDC.
D. Observe the “startup mode” parameter on the
Cat ET status screen. Results:

E. Turn the ECS to the START position. Continue • OK – The voltage measures 24 ± 3 VDC. Proceed
monitoring engine parameters as the engine to Test Step 6.
cranks.
• Not OK – The voltage does not measure 24 ± 3
F. The crank cycle will continue for the time that VDC. Proceed to Test Step 4.
is equal to the cycle crank time that has been
programmed or the crank cycle will continue until Test Step 4. Check the Voltage at the Coil
the engine speed reaches the crank terminate of the Mag Relay.
speed.
A. Turn the ECS to the OFF/RESET position.
Expected Result:
B. Connect a voltmeter across the coil of the mag
The status screen for the “startup mode” parameter relay. Connect the voltmeter between terminal 4
displays “CRANK”. The engine cranks. and terminal 3 of the mag relay.

Results: C. Turn the ECS to the STOP position.

• OK – The “startup mode” parameter on the status D. Activate the override for the starting motor relay.
screen on the Cat ET displays “CRANK”. The
engine cranks. E. Monitor the voltage on the voltmeter.

Repair: The problem may be intermittent. If the F. Turn off the override for the starting motor relay.
problem is intermittent, perform the diagnostic
functional test Troubleshooting, “Inspecting G. Replace all wires.
Electrical Connectors”.
Expected Result:
STOP.
The voltage measures 24 ± 3 VDC.
162
Troubleshooting Section

Results: Repair: The problem is not with the ECM. The

problem is most likely in the wiring between
• OK – The voltage measures 24 ± 3 VDC. ECM connector P2 and the mag relay. Repair
the connectors or wiring and/or replace the
Repair: Verify that 24 ± 3 VDC is present connectors or wiring.
on terminal 1 of the mag relay. If voltage is
not present on terminal 1 of the mag relay, STOP.
troubleshoot the wiring to the breaker for the mag
relay. If voltage is present on terminal 1 of the • Not OK – The voltage does not measure 24 ±
mag relay, install a new mag relay. Verify that the 3 VDC.
problem is no longer present.
Repair: Replace the ECM. Refer to the diagnostic
STOP. procedure Troubleshooting, “Replacing the ECM”.

• Not OK – The voltage does not measure 24 ± 3 STOP.

VDC. Proceed to Test Step 5.
Test Step 6. Check the Solenoid.
Test Step 5. Check the ECM Signal at the
ECM. A. Turn the ECS to the OFF/RESET position.

A. Turn the ECS to the OFF/RESET position. B. Connect one end of a suitable piece of 10 AWG
wire to the +Battery terminal. Connect the other
B. Disconnect ECM connector P2 from the ECM. end to the S terminal of the starting solenoid for
Remove the wire from P2-7 and P2-13 from ECM one second.
connector P2.
Expected Result:
C. Obtain two suitable pieces of 18 AWG wire with
socket pins on one end. The starting solenoid activates while the wire is
connected to the S terminal.
D. Install one wire at P2-7. Install the second wire at
P2-13. Reconnect ECM connector P2. Results:

E. Connect one lead of the voltmeter to the wire at • OK – The starting solenoid activated. The
P2-7. Connect the other lead of the voltmeter to problem appears to be in the system wiring.
the wire at P2-13.
Repair: Check and repair the wiring between the
F. Turn the ECS to the STOP position. S terminal of the starting solenoid and terminal
2 of the mag relay. Verify repairs by checking
G. Activate the override for the starting motor relay. starting solenoid operation.

Note: This test will cause a 444-05 CID-FMI to be STOP.

Logged. Delete this CID-FMI when you are finished
with this test. • Not OK – The starting solenoid did not activate.
The problem appears to be in the starting
H. Monitor the voltage on the voltmeter. solenoid.

I. Turn off the override for the starting motor relay. Repair: Temporarily install a new starting solenoid.
Verify that the problem is no longer present.
J. Turn the ECS to the OFF/RESET position. Remove Reinstall the old starting solenoid. If the problem
all jumpers and replace all wires. returns, replace the starting solenoid.

Expected Result: STOP.

The voltage measures 24 ± 3 VDC.

Results:

• OK – The voltage measures 24 ± 3 VDC.

 163
Troubleshooting Section

Calibration Procedures Repair: Perform the appropriate troubleshooting

procedure.

i01937941 STOP.
Analog Sensor - Calibrate Test Step 2. Perform a Calibration of the
Sensors.
SMCS Code: 1901-524
A. Select “Calibrations” from the “Service” menu on
System Operation Description: Cat ET. Select the “Pressure Sensor Calibration”
from the “Calibrations” menu. The ECM will
The Electronic Control Module (ECM) attempts to perform a pressure sensor calibration when this
perform an automatic calibration of all pressure screen is entered.
sensors whenever the ECM is powered and the
engine has been off for at least ten seconds. Expected Result:
Cranking the engine during the first ten seconds
causes the ECM to abort the calibration attempt. The Cat ET screen indicates that the calibration
was completed.
During an automatic pressure sensor calibration,
the ECM checks all pressure sensors against an Results:
acceptable range. If any pressure sensor reading
is outside the acceptable range, the previous
calibration value is used. The ECM then calibrates
• OK – The Cat ET screen indicates that the
calibration was completed.
all pressure sensors against the atmospheric
pressure sensor. Repair: Reset the system and check for active
diagnostic codes.
A pressure sensor calibration will not be successful
if there are active sensor diagnostic codes with an STOP.
FMI of 03 and/or 04. A pressure sensor calibration
will not be successful if one of the following
conditions exist:
• Not OK – All pressure sensors could not be
calibrated. Proceed to Test Step 3.
• The pressure reading is outside of an acceptable Test Step 3. Determine the Cause of
range. Failed Calibration.
• The pressure reading varies significantly during A. Check if any pressure sensors have an active
calibration. diagnostic code. A pressure sensor calibration
will not be successful if there are active
Test Step 1. Check for “ACTIVE” diagnostic codes with an FMI of 03 and/or 04.
Diagnostic Codes.
B. Verify that the correct sensor has been installed.
A. Disconnect the main power.
C. Check the display status screen on Cat ET for
B. Start the Caterpillar Electronic Technician (ET). the pressure sensor reading.
C. Connect the main power. D. The atmospheric pressure must be greater than
111 kPa (16 psi) for a successful calibration.
D. Check for active diagnostics.
Expected Result:
Expected Result:
Cat ET displays the following pressures:
There are no active diagnostics.

Results:
• Crankcase pressure is atmospheric pressure ±
8 kPa (1.2 psi).
• OK – There are no active diagnostics. Proceed • Turbocharger compressor inlet pressure is
to Test Step 2. atmospheric pressure ± 8 kPa (1.2 psi).
• Not OK – A pressure sensor with an active • Turbocharger compressor outlet pressure is
diagnostic code cannot be calibrated. atmospheric pressure ± 15 kPa (2.2 psi).

• Fuel pressure is atmospheric pressure ± 25 kPa

(3.6 psi).
164
Troubleshooting Section

• Engine oil pressure is atmospheric pressure ±

27 kPa (3.9 psi).

Results:

• OK – Repeat calibration of the sensors.

Repair: Repeat the calibration. Verify that no
active diagnostic codes are present.

STOP.

• Not OK – There is a problem with the wiring

harness and/or the sensor. Inspect the
components for damage, for corrosion or for
abrasion. Repair the components and/or replace
the components.

Repair: Perform the appropriate troubleshooting

procedure.

STOP.

i01968506

Engine Speed/Timing Sensor -

Calibrate
SMCS Code: 1912-524

System Operation Description:

The engine speed/timing sensor provides engine

information to the engine’s Electronic Control
Module (ECM). The sensor generates a pulse signal.
A loss of the engine speed/timing signal causes the
ECM to stop sending power to the fuel injectors.

The ECM provides the engine speed/timing sensor

with 12.5 ± 1.0 VDC. A unique tooth on the timing
reference gear generates a unique duty cycle. The
signal provides the ECM with information on the
engine position.

g00594171
Illustration 38
Typical example
 165
Troubleshooting Section

Test Step 1. Check for Active Diagnostic If all of the problems have been corrected but the
Codes. timing can not be calibrated, check the cable of
the 6V-2197 Timing Calibration Probe and check
A. Start the Caterpillar Electronic Technician (ET). the 6V-2197 Timing Calibration Probe in order to
verify that the probe is not bent. Verify that the
B. Start the engine. probe is installed correctly before restarting this
procedure.
C. Operate the engine until normal operating
temperatures are obtained. STOP.

Expected Result:

There is one active diagnostic code 261-13.

Results:

• OK – The active diagnostic code is 261-13.

Proceed to Test Step 2.

• Not OK – There is more than one active

diagnostic code.

Repair: Repair any active diagnostic codes.

STOP.

Test Step 2. Calibrate the Fuel Injection

Timing.
A. Select “Calibrations” from the “Service” menu on
the Cat ET. Select the “Timing Calibration” from
the “Calibrations” menu.

B. Follow the instructions on the Cat ET screen.

Note: If the Cat ET screen reads “COULD NOT

CALIBRATE”, the timing has not been set.

Expected Result:

The timing calibration procedure was successful.

Results:

• OK – The timing calibration procedure was

completed successfully.

Repair: Disconnect the timing calibration probe

before you exit the “Timing Calibration” screen on
the Cat ET. Reset the system and check for any
diagnostic codes.

STOP.

• Not OK – The timing could not be calibrated.

Repair: Verify that the engine speed was stable
during the testing (± 50 rpm). If the engine speed
was unstable or the engine speed could not be
controlled within ± 50 rpm because of mechanical
factors or electrical factors, refer to the diagnostic
procedure Troubleshooting, “Engine Misfires,
Runs Rough or Is Unstable”.
166
Index Section

Index
A Event Codes .......................................................... 83
Programmable Engine Parameters.................... 83
Air Shutoff System................................................. 87 Excessive Black Smoke......................................... 43
Alternator............................................................... 34 Excessive Engine Oil Consumption....................... 43
Analog Sensor - Calibrate ................................... 163 Excessive White Smoke ........................................ 44
Analog Sensor Supply........................................... 91 Exhaust Temperature Is Too High ......................... 45

C F

Calibration Procedures ........................................ 163 Factory Passwords ................................................ 25

Can Not Reach Top Engine RPM .......................... 35 Customer Passwords ......................................... 25
CAT Data Link........................................................ 96 Factory Passwords............................................. 25
Coolant in Engine Oil............................................. 36 Passwords.......................................................... 25
Coolant Temperature Is Too High .......................... 36 Factory Passwords Worksheet .............................. 25
Customer Parameters Worksheet ................... 30–31 Flash Programming ............................................... 26
Flash Programming a Personality Module ......... 27
Programming a Personality Module with Flash
D Programming.................................................... 26
Fuel Dilution of Engine Oil ..................................... 46
Diagnostic Codes .................................................. 55 Fuel in Cooling System.......................................... 46
Diagnostic Functional Tests................................... 87
Digital Sensor Supply ............................................ 99
Direct Fuel Control Mode..................................... 103 I

Important Safety Information ................................... 2

E Injector Solenoids ................................................ 139
Inspecting Electrical Connectors ......................... 145
E017 High Engine Coolant Temperature Warning.. 84 Intermittent Engine Shutdown ............................... 46
E100 Low Engine Oil Pressure Warning ............... 84 Intermittent Low Power or Power Cutout ............... 47
E190 Engine Overspeed Warning ......................... 85
E272 Inlet Air Restriction Warning......................... 86
ECM Will Not Accept Factory Passwords .............. 37 L
ECM Will Not Communicate with Other Systems or
Display Modules .................................................. 37 Low Engine Oil Pressure ....................................... 49
ECM/Personality Module ..................................... 106 Low Power/Poor or No Response to Throttle ........ 49
Electrical Power Supply ....................................... 108
Electronic Display Module ..................................... 18
Electronic Service Tool Will Not Communicate with M
ECM..................................................................... 37
Electronic Service Tools ........................................ 15 Mechanical Noise (Knock) in Engine..................... 51
Electronic Technician ......................................... 16 MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open
Optional Service Tools ....................................... 15 circuit ................................................................... 56
Electronic Troubleshooting ...................................... 6 MID 036 - CID 0001 - FMI 06 Injector Cylinder 1
Emergency Stop Switch ...................................... 112 short..................................................................... 56
Engine Control Switch (ECS) .............................. 115 MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 open
Engine Cranks but Will Not Start ........................... 38 circuit ................................................................... 56
Engine Has Early Wear ......................................... 39 MID 036 - CID 0002 - FMI 06 Injector Cylinder 2
Engine Misfires, Runs Rough or Is Unstable......... 40 short..................................................................... 57
Engine Monitoring System .................................... 21 MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 open
Oil Pressure Map ............................................... 24 circuit ................................................................... 57
Engine Oil in Cooling System ................................ 41 MID 036 - CID 0003 - FMI 06 Injector Cylinder 3
Engine Sensor Open/Short Test.......................... 119 short..................................................................... 57
Engine Speed/Timing Sensor.............................. 128 MID 036 - CID 0004 - FMI 05 Injector Cylinder 4 open
Engine Speed/Timing Sensor - Calibrate ............ 164 circuit ................................................................... 57
Engine Stalls at Low RPM ..................................... 41 MID 036 - CID 0004 - FMI 06 Injector Cylinder 4
Engine Will Not Crank ........................................... 42 short..................................................................... 58
Ether Injection System......................................... 132
 167
Index Section

MID 036 - CID 0005 - FMI 05 Injector Cylinder 5 open MID 036 - CID 0100 - FMI 04 Engine Oil Pressure
circuit ................................................................... 58 short to ground .................................................... 66
MID 036 - CID 0005 - FMI 06 Injector Cylinder 5 MID 036 - CID 0100 - FMI 13 Engine Oil Pressure
short..................................................................... 58 calibration required .............................................. 66
MID 036 - CID 0006 - FMI 05 Injector Cylinder 6 open MID 036 - CID 0101 - FMI 03 Crankcase Pressure
circuit ................................................................... 58 open/short to +batt .............................................. 66
MID 036 - CID 0006 - FMI 06 Injector Cylinder 6 MID 036 - CID 0101 - FMI 04 Crankcase Pressure
short..................................................................... 59 short to ground .................................................... 67
MID 036 - CID 0007 - FMI 05 Injector Cylinder 7 open MID 036 - CID 0101 - FMI 13 Crankcase Pressure
circuit ................................................................... 59 calibration required .............................................. 67
MID 036 - CID 0007 - FMI 06 Injector Cylinder 7 MID 036 - CID 0110 - FMI 03 Engine Coolant
short..................................................................... 59 Temperature open/short to +batt ......................... 67
MID 036 - CID 0008 - FMI 05 Injector Cylinder 8 open MID 036 - CID 0110 - FMI 04 Engine Coolant
circuit ................................................................... 59 Temperature short to ground ............................... 68
MID 036 - CID 0008 - FMI 06 Injector Cylinder 8 MID 036 - CID 0168 - FMI 00 System Voltage
short..................................................................... 60 High ..................................................................... 68
MID 036 - CID 0009 - FMI 05 Injector Cylinder 9 open MID 036 - CID 0168 - FMI 01 System Voltage
circuit ................................................................... 60 Low ...................................................................... 68
MID 036 - CID 0009 - FMI 06 Injector Cylinder 9 MID 036 - CID 0168 - FMI 02 System Voltage
short..................................................................... 60 intermittent/erratic ................................................ 68
MID 036 - CID 0010 - FMI 05 Injector Cylinder 10 MID 036 - CID 0190 - FMI 02 Loss of Engine Speed
open circuit .......................................................... 60 signal ................................................................... 69
MID 036 - CID 0010 - FMI 06 Injector Cylinder 10 MID 036 - CID 0190 - FMI 03 Engine Speed
short..................................................................... 61 open/short to +batt .............................................. 69
MID 036 - CID 0011 - FMI 05 Injector Cylinder 11 MID 036 - CID 0190 - FMI 08 Engine Speed signal
open circuit .......................................................... 61 abnormal.............................................................. 69
MID 036 - CID 0011 - FMI 06 Injector Cylinder 11 MID 036 - CID 0248 - FMI 09 CAT Data Link not
short..................................................................... 61 communicating..................................................... 69
MID 036 - CID 0012 - FMI 05 Injector Cylinder 12 MID 036 - CID 0253 - FMI 02 Personality Module
open circuit .......................................................... 61 mismatch ............................................................. 70
MID 036 - CID 0012 - FMI 06 Injector Cylinder 12 MID 036 - CID 0254 - FMI 12 Electronic Control
short..................................................................... 62 Module Error ........................................................ 70
MID 036 - CID 0013 - FMI 05 Injector Cylinder 13 MID 036 - CID 0261 - FMI 13 Engine Timing
open circuit .......................................................... 62 calibration required .............................................. 70
MID 036 - CID 0013 - FMI 06 Injector Cylinder 13 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power
short..................................................................... 62 Supply short to +batt ........................................... 70
MID 036 - CID 0014 - FMI 05 Injector Cylinder 14 MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power
open circuit .......................................................... 62 Supply short to ground ........................................ 71
MID 036 - CID 0014 - FMI 06 Injector Cylinder 14 MID 036 - CID 0263 - FMI 03 Digital Sensor Supply
short..................................................................... 63 short to +batt ....................................................... 71
MID 036 - CID 0015 - FMI 05 Injector Cylinder 15 MID 036 - CID 0263 - FMI 04 Digital Sensor Supply
open circuit .......................................................... 63 short to ground .................................................... 71
MID 036 - CID 0015 - FMI 06 Injector Cylinder 15 MID 036 - CID 0268 - FMI 02 Check Programmable
short..................................................................... 63 Parameters .......................................................... 72
MID 036 - CID 0016 - FMI 05 Injector Cylinder 16 MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure
open circuit .......................................................... 63 above normal ....................................................... 72
MID 036 - CID 0016 - FMI 06 Injector Cylinder 16 MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure
short..................................................................... 64 open/short to +batt .............................................. 72
MID 036 - CID 0091 - FMI 08 Throttle Position signal MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure
abnormal.............................................................. 64 short to ground .................................................... 73
MID 036 - CID 0094 - FMI 02 Fuel Pressure MID 036 - CID 0273 - FMI 13 Turbo Outlet Pressure
misinstalled .......................................................... 64 calibration required .............................................. 73
MID 036 - CID 0094 - FMI 03 Fuel Pressure MID 036 - CID 0274 - FMI 03 Atmospheric Pressure
open/short to +batt .............................................. 65 open/short to +batt .............................................. 73
MID 036 - CID 0094 - FMI 04 Fuel Pressure short to MID 036 - CID 0274 - FMI 04 Atmospheric Pressure
ground.................................................................. 65 short to ground .................................................... 73
MID 036 - CID 0094 - FMI 13 Fuel Pressure MID 036 - CID 0274 - FMI 13 Atmospheric Pressure
calibration required .............................................. 65 calibration required .............................................. 74
MID 036 - CID 0100 - FMI 02 Engine Oil Pressure out MID 036 - CID 0275 - FMI 03 Right Turbo Inlet
of range................................................................ 65 Pressure open/short to +batt ............................... 74
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0275 - FMI 04 Right Turbo Inlet
open/short to +batt .............................................. 66 Pressure short to ground ..................................... 74
MID 036 - CID 0275 - FMI 13 Right Turbo Inlet P
Pressure calibration required............................... 75
MID 036 - CID 0276 - FMI 03 Left Turbo Inlet Poor Fuel Consumption ......................................... 52
Pressure open/short to +batt ............................... 75 Prelubrication System ......................................... 151
MID 036 - CID 0276 - FMI 04 Left Turbo Inlet Programming Parameters...................................... 25
Pressure short to ground ..................................... 75
MID 036 - CID 0276 - FMI 13 Left Turbo Inlet
Pressure calibration required............................... 75 R
MID 036 - CID 0279 - FMI 03 Aftercooler Temperature
open/short to +batt .............................................. 76 Replacing the ECM................................................ 32
MID 036 - CID 0279 - FMI 04 Aftercooler Temperature
short to ground .................................................... 76
MID 036 - CID 0289 - FMI 02 Unfiltered Fuel Pressure S
misinstalled .......................................................... 76
MID 036 - CID 0289 - FMI 03 Unfiltered Fuel Pressure Self-Diagnostics..................................................... 14
open/short to +batt .............................................. 77 Speed Control...................................................... 155
MID 036 - CID 0289 - FMI 04 Unfiltered Fuel Pressure Starting Motor System......................................... 159
short to ground .................................................... 77 Symptoms.............................................................. 34
MID 036 - CID 0289 - FMI 13 Unfiltered Fuel Pressure System Configuration Parameters......................... 28
calibration required .............................................. 77 System Overview..................................................... 6
MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch System Operation ................................................ 6
inputs ................................................................... 77
MID 036 - CID 0337 - FMI 02 Incorrect Remote
E-Stop Switch inputs............................................ 78 T
MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
circuit ................................................................... 78 Table of Contents..................................................... 3
MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short Too Much Valve Lash ............................................ 53
to ground.............................................................. 78 Too Much Vibration................................................ 53
MID 036 - CID 0444 - FMI 05 Start Relay open Troubleshooting Section .......................................... 6
circuit ................................................................... 78 Troubleshooting with a Diagnostic Code ............... 55
MID 036 - CID 0444 - FMI 06 Start Relay short to Troubleshooting with an Event Code ..................... 83
ground.................................................................. 79 Troubleshooting without a Diagnostic Code .......... 34
MID 036 - CID 0446 - FMI 05 Air Shutoff Relay
open..................................................................... 79
MID 036 - CID 0446 - FMI 06 Air Shutoff Relay V
short..................................................................... 79
MID 036 - CID 0542 - FMI 02 Unfiltered Engine Oil Valve Rotocoil or Spring Lock Is Free.................... 54
Pressure misinstalled........................................... 79
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
Pressure open/short to +batt ............................... 80
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
Pressure short to ground ..................................... 80
MID 036 - CID 0542 - FMI 13 Unfiltered Engine Oil
Pressure cal required........................................... 80
MID 036 - CID 0545 - FMI 05 Ether Start Relay
open/short to +batt .............................................. 80
MID 036 - CID 0545 - FMI 06 Ether Start Relay short
to ground.............................................................. 81
MID 036 - CID 0546 - FMI 05 Ether Hold Relay
open/short to ground ........................................... 81
MID 036 - CID 0546 - FMI 06 Ether Hold Relay short
to +batt................................................................. 81
MID 036 - CID 0827 - FMI 08 Left Exhaust
Temperature signal abnormal .............................. 81
MID 036 - CID 0828 - FMI 08 Right Exhaust
Temperature signal abnormal .............................. 82

Noise Coming from Cylinder.................................. 51

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