Trouble Shooting G3516C

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RENR5944

March 2004

Troubleshooting
G3516C and G3516E Engines
RWA1-Up (Engine)
GHP1-Up (Engine)
DKR1-Up (Engine)
i01658146

Important Safety Information


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

The meaning of this safety alert symbol is as follows:


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

When replacement parts are required for this


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

Failure to heed this warning can lead to prema-


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

Table of Contents Inlet Air Temperature (High) .................................. 57


Intermittent Engine Shutdown ............................... 58
Jacket Water Inlet Pressure (High) ....................... 59
Jacket Water Pressure (Low) ................................ 59
Troubleshooting Section Jacket Water to Engine Oil Differential Temperature
(Low) ................................................................... 60
Electronic Troubleshooting
System Voltage ..................................................... 60
System Overview .................................................... 9
Turbocharger Turbine Temperature (High) ........... 60
Self-Diagnostics .................................................... 10
Turbocharger Turbine Temperature (Low) ............ 61
Location of Components ........................................ 11
Electrical Connectors and Functions .................... 15
Troubleshooting with a Diagnostic Code
Electronic Service Tools ........................................ 17
Diagnostic Codes .................................................. 63
Engine Monitoring System .................................... 19
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open
circuit ................................................................... 64
Programming Parameters
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short
Programming Parameters ..................................... 26
to ground ............................................................. 65
Customer Passwords ............................................ 26
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve
Factory Passwords ............................................... 27
malfunction .......................................................... 65
Factory Passwords Worksheet ............................. 27
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short
Flash Programming .............................................. 27
to +batt ................................................................ 65
System Configuration Parameters ........................ 28
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short
Replacing the ECM ............................................... 29
to ground ............................................................. 66
Replacing the ITSM .............................................. 31
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure
Troubleshooting Data Sheet ................................. 33
open/short to +batt .............................................. 66
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure
Troubleshooting without a Diagnostic Code
short to ground .................................................... 67
Symptoms ............................................................. 35
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure
Detonation ............................................................ 35
Sensor short to +batt .......................................... 67
Driven Equipment ................................................. 37
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure
ECM Will Not Accept Factory Passwords ............. 37
Sensor noisy signal ............................................. 67
Electronic Service Tool Will Not Communicate with
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure
ECM (The Caterpillar Electronic Technician (ET)
open/short to +batt .............................................. 68
Will Not Communicate With an Electronic Control
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet
Module (ECM) and/or the Integrated Temperature
Pressure Sensor noisy signal ............................. 68
Sensing Module (ITSM)) ..................................... 37
MID 036 - CID 0110 - FMI 03 Engine Coolant
Engine Coolant Temperature (High) ..................... 38
Temperature open/short to +batt ......................... 68
Engine Coolant Temperature (Low) ...................... 39
MID 036 - CID 0110 - FMI 04 Engine Coolant
Engine Cranks but Will Not Start .......................... 40
Temperature short to ground ............................... 69
Engine Misfires, Runs Rough or Is Unstable ........ 41
MID 036 - CID 0145 - FMI 03 12 Volt DC Power
Engine Oil Filter Differential Pressure ................... 42
Supply short to +batt ........................................... 69
Engine Oil Pressure (Low) .................................... 43
MID 036 - CID 0145 - FMI 04 12 Volt DC Power
Engine Oil Temperature (High) ............................. 44
Supply short to ground ........................................ 69
Engine Overcrank ................................................. 44
MID 036 - CID 0168 - FMI 02 System Voltage
Engine Overload ................................................... 45
intermittent/erratic ............................................... 70
Engine Overspeed ................................................ 46
MID 036 - CID 0172 - FMI 03 Intake Manifold Air
Engine Shutdown .................................................. 46
Temp open/short to +batt .................................... 70
Engine Shutdown (Unexpected) ........................... 47
MID 036 - CID 0172 - FMI 04 Intake Manifold Air
Engine Shutdown without a Diagnostic Code ....... 48
Temp short to ground .......................................... 71
Engine Starts but Stalls Immediately .................... 49
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature
Engine Timing Does Not Match Programmed
open/short to +batt .............................................. 71
Timing ................................................................. 50
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature
Engine Will Not Crank ........................................... 50
short to ground .................................................... 71
Exhaust Port Temperature (High) ......................... 51
MID 036 - CID 0261 - FMI 13 Engine Timing
Exhaust Port Temperature (Low) .......................... 52
calibration required ............................................. 72
Fuel Energy Content ............................................. 53
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC
Fuel Metering Valve .............................................. 53
Power Supply short to +batt ................................ 72
Fuel Pressure ....................................................... 53
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC
Gas Fuel Differential Pressure (High) ................... 54
Power Supply short to ground ............................. 73
Gas Fuel Differential Pressure (Low) .................... 54
MID 036 - CID 0301 - FMI 05 Ignition Transformer
Gas Fuel Flow Rate (Low) .................................... 54
Primary #1 open circuit ....................................... 73
Gas Temperature (High) ....................................... 55
MID 036 - CID 0301 - FMI 06 Ignition Transformer
Generator Output Power Readings Do Not
Primary #1 short .................................................. 73
Match .................................................................. 56
4
Table of Contents

MID 036 - CID 0302 - FMI 05 Ignition Transformer MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor
Primary #2 open circuit ....................................... 74 short to +batt ....................................................... 85
MID 036 - CID 0302 - FMI 06 Ignition Transformer MID 036 - CID 0320 - FMI 08 Engine Speed/Timing
Primary #2 short .................................................. 74 signal abnormal ................................................... 85
MID 036 - CID 0303 - FMI 05 Ignition Transformer MID 036 - CID 0323 - FMI 03 Shutdown Lamp short
Primary #3 open circuit ....................................... 74 to +batt ................................................................ 85
MID 036 - CID 0303 - FMI 06 Ignition Transformer MID 036 - CID 0324 - FMI 03 Warning Lamp short to
Primary #3 short .................................................. 75 +batt .................................................................... 86
MID 036 - CID 0304 - FMI 05 Ignition Transformer MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Primary #4 open circuit ....................................... 75 inputs .................................................................. 86
MID 036 - CID 0304 - FMI 06 Ignition Transformer MID 036 - CID 0401 - FMI 05 Ignition Transformer
Primary #4 short .................................................. 76 Secondary #1 open circuit .................................. 86
MID 036 - CID 0305 - FMI 05 Ignition Transformer MID 036 - CID 0401 - FMI 06 Ignition Transformer
Primary #5 open circuit ....................................... 76 Secondary #1 short to ground ............................. 87
MID 036 - CID 0305 - FMI 06 Ignition Transformer MID 036 - CID 0402 - FMI 05 Ignition Transformer
Primary #5 short .................................................. 76 Secondary #2 open circuit .................................. 87
MID 036 - CID 0306 - FMI 05 Ignition Transformer MID 036 - CID 0402 - FMI 06 Ignition Transformer
Primary #6 open circuit ....................................... 77 Secondary #2 short to ground ............................. 87
MID 036 - CID 0306 - FMI 06 Ignition Transformer MID 036 - CID 0403 - FMI 05 Ignition Transformer
Primary #6 short .................................................. 77 Secondary #3 open circuit .................................. 88
MID 036 - CID 0307 - FMI 05 Ignition Transformer MID 036 - CID 0403 - FMI 06 Ignition Transformer
Primary #7 open circuit ....................................... 77 Secondary #3 short to ground ............................. 88
MID 036 - CID 0307 - FMI 06 Ignition Transformer MID 036 - CID 0404 - FMI 05 Ignition Transformer
Primary #7 short .................................................. 78 Secondary #4 open circuit .................................. 89
MID 036 - CID 0308 - FMI 05 Ignition Transformer MID 036 - CID 0404 - FMI 06 Ignition Transformer
Primary #8 open circuit ....................................... 78 Secondary #4 short to ground ............................. 89
MID 036 - CID 0308 - FMI 06 Ignition Transformer MID 036 - CID 0405 - FMI 05 Ignition Transformer
Primary #8 short .................................................. 78 Secondary #5 open circuit .................................. 89
MID 036 - CID 0309 - FMI 05 Ignition Transformer MID 036 - CID 0405 - FMI 06 Ignition Transformer
Primary #9 open circuit ....................................... 79 Secondary #5 short to ground ............................. 90
MID 036 - CID 0309 - FMI 06 Ignition Transformer MID 036 - CID 0406 - FMI 05 Ignition Transformer
Primary #9 short .................................................. 79 Secondary #6 open circuit .................................. 90
MID 036 - CID 0310 - FMI 05 Ignition Transformer MID 036 - CID 0406 - FMI 06 Ignition Transformer
Primary #10 open circuit ..................................... 80 Secondary #6 short to ground ............................. 91
MID 036 - CID 0310 - FMI 06 Ignition Transformer MID 036 - CID 0407 - FMI 05 Ignition Transformer
Primary #10 short ................................................ 80 Secondary #7 open circuit .................................. 91
MID 036 - CID 0311 - FMI 05 Ignition Transformer MID 036 - CID 0407 - FMI 06 Ignition Transformer
Primary #11 open circuit ..................................... 80 Secondary #7 short to ground ............................. 91
MID 036 - CID 0311 - FMI 06 Ignition Transformer MID 036 - CID 0408 - FMI 05 Ignition Transformer
Primary #11 short ................................................ 81 Secondary #8 open circuit .................................. 92
MID 036 - CID 0312 - FMI 05 Ignition Transformer MID 036 - CID 0408 - FMI 06 Ignition Transformer
Primary #12 open circuit ..................................... 81 Secondary #8 short to ground ............................. 92
MID 036 - CID 0312 - FMI 06 Ignition Transformer MID 036 - CID 0409 - FMI 05 Ignition Transformer
Primary #12 short ................................................ 81 Secondary #9 open circuit .................................. 92
MID 036 - CID 0313 - FMI 05 Ignition Transformer MID 036 - CID 0409 - FMI 06 Ignition Transformer
Primary #13 open circuit ..................................... 82 Secondary #9 short to ground ............................. 93
MID 036 - CID 0313 - FMI 06 Ignition Transformer MID 036 - CID 0410 - FMI 05 Ignition Transformer
Primary #13 short ................................................ 82 Secondary #10 open circuit ................................ 93
MID 036 - CID 0314 - FMI 05 Ignition Transformer MID 036 - CID 0410 - FMI 06 Ignition Transformer
Primary #14 open circuit ..................................... 82 Secondary #10 short to ground ........................... 94
MID 036 - CID 0314 - FMI 06 Ignition Transformer MID 036 - CID 0411 - FMI 05 Ignition Transformer
Primary #14 short ................................................ 83 Secondary #11 open circuit ................................. 94
MID 036 - CID 0315 - FMI 05 Ignition Transformer MID 036 - CID 0411 - FMI 06 Ignition Transformer
Primary #15 open circuit ..................................... 83 Secondary #11 short to ground ........................... 95
MID 036 - CID 0315 - FMI 06 Ignition Transformer MID 036 - CID 0412 - FMI 05 Ignition Transformer
Primary #15 short ................................................ 84 Secondary #12 open circuit ................................ 95
MID 036 - CID 0316 - FMI 05 Ignition Transformer MID 036 - CID 0412 - FMI 06 Ignition Transformer
Primary #16 open circuit ..................................... 84 Secondary #12 short to ground ........................... 95
MID 036 - CID 0316 - FMI 06 Ignition Transformer MID 036 - CID 0413 - FMI 05 Ignition Transformer
Primary #16 short ................................................ 84 Secondary #13 open circuit ................................ 96
5
Table of Contents

MID 036 - CID 0413 - FMI 06 Ignition Transformer MID 036 - CID 1509 - FMI 04 Cylinder #9 Detonation
Secondary #13 short to ground ........................... 96 Sensor short to ground ..................................... 107
MID 036 - CID 0414 - FMI 05 Ignition Transformer MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation
Secondary #14 open circuit ................................ 96 Sensor open/short to +batt ............................... 107
MID 036 - CID 0414 - FMI 06 Ignition Transformer MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation
Secondary #14 short to ground ........................... 97 Sensor short to ground ..................................... 108
MID 036 - CID 0415 - FMI 05 Ignition Transformer MID 036 - CID 1513 - FMI 03 Cylinder #13 Detonation
Secondary #15 open circuit ................................ 97 Sensor open/short to +batt ............................... 108
MID 036 - CID 0415 - FMI 06 Ignition Transformer MID 036 - CID 1513 - FMI 04 Cylinder #13 Detonation
Secondary #15 short to ground ........................... 98 Sensor short to ground ..................................... 108
MID 036 - CID 0416 - FMI 05 Ignition Transformer MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation
Secondary #16 open circuit ................................ 98 Sensor open/short to +batt ............................... 109
MID 036 - CID 0416 - FMI 06 Ignition Transformer MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation
Secondary #16 short to ground ........................... 99 Sensor short to ground ..................................... 109
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay MID 036 - CID 1719 - FMI 03 Generator Output
short to +batt ....................................................... 99 Power Sensor open/short to +batt .................... 109
MID 036 - CID 0444 - FMI 05 Start Relay open MID 036 - CID 1719 - FMI 04 Generator Output
circuit ................................................................... 99 Power Sensor short to ground ........................... 110
MID 036 - CID 0444 - FMI 06 Start Relay short to MID 036 - CID 1719 - FMI 12 Generator Output
ground ............................................................... 100 Power Sensor malfunction ................................. 110
MID 036 - CID 0445 - FMI 03 Run Relay short to MID 036 - CID 1720 - FMI 09 Turbocharger
+batt .................................................................. 100 Compressor Bypass Valve Actuator not
MID 036 - CID 0524 - FMI 03 Desired Engine Speed communicating on link ....................................... 110
Sensor short to +batt ........................................ 100 MID 111 - CID 0591 - FMI 12 EEPROM checksum
MID 036 - CID 0524 - FMI 04 Desired Engine Speed fault or ECM not programmed ............................ 110
Sensor short to ground ..................................... 101 MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Temp Sens short to +batt ................................... 111
Pressure open/short to +batt ............................ 101 MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Temp Sens short to ground ................................ 111
Pressure short to ground .................................. 101 MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out
MID 036 - CID 1042 - FMI 09 Unable to communicate Temp Sens open circuit ...................................... 111
with ITSM .......................................................... 102 MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out
MID 036 - CID 1440 - FMI 09 Unable to communicate Temp Sens short to +batt ................................... 112
with Throttle Actuator Drv ................................. 102 MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out
MID 036 - CID 1446 - FMI 05 Fuel Metering Module Temp Sens short to ground ................................ 112
open circuit ........................................................ 102 MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out
MID 036 - CID 1446 - FMI 09 Unable to communicate Temp Sens open circuit ...................................... 112
with Fuel Metering Module ................................ 103 MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In
MID 036 - CID 1446 - FMI 12 Fuel Metering Module Temp Sens short to +batt ................................... 113
malfunction ........................................................ 103 MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In
MID 036 - CID 1446 - FMI 13 Fuel Metering Module Temp Sens short to ground ................................ 113
calibration required ........................................... 103 MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In
MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Temp Sens open circuit ...................................... 113
Module malfunction ........................................... 104 MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In
MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation Temp Sens short to +batt ................................... 114
Sensor open/short to +batt ............................... 104 MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In
MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation Temp Sens short to ground ................................ 114
Sensor short to ground ..................................... 104 MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In
MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Temp Sens open circuit ...................................... 114
Sensor open/short to +batt ............................... 105 MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port
MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Temp Sensor short to +batt ................................ 115
Sensor short to ground ..................................... 105 MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port
MID 036 - CID 1505 - FMI 03 Cylinder #5 Detonation Temp Sensor short to ground ............................. 115
Sensor open/short to +batt ............................... 105 MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port
MID 036 - CID 1505 - FMI 04 Cylinder #5 Detonation Temp Sensor open circuit .................................. 116
Sensor short to ground ..................................... 106 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port
MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Temp Sensor short to +batt ................................ 116
Sensor open/short to +batt ............................... 106 MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port
MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Temp Sensor short to ground ............................. 116
Sensor short to ground ..................................... 106 MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port
MID 036 - CID 1509 - FMI 03 Cylinder #9 Detonation Temp Sensor open circuit .................................. 117
Sensor open/short to +batt ............................... 107 MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port
Temp Sensor short to +batt ................................ 117
6
Table of Contents

MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port
Temp Sensor short to ground ............................. 117 Temp Sensor short to ground ............................ 129
MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port
Temp Sensor open circuit .................................. 118 Temp Sensor open circuit ................................. 129
MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port
Temp Sensor short to +batt ................................ 118 Temp Sensor short to +batt ............................... 129
MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port
Temp Sensor short to ground ............................. 119 Temp Sensor short to ground ............................ 130
MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port
Temp Sensor open circuit .................................. 119 Temp Sensor open circuit ................................. 130
MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port
Temp Sensor short to +batt ................................ 119 Temp Sensor short to +batt ............................... 131
MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port
Temp Sensor short to ground ............................ 120 Temp Sensor short to ground ............................ 131
MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port
Temp Sensor open circuit ................................. 120 Temp Sensor open circuit ................................. 131
MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port
Temp Sensor short to +batt ............................... 120 Temp Sensor short to +batt ............................... 132
MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port
Temp Sensor short to ground ............................ 121 Temp Sensor short to ground ............................ 132
MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port
Temp Sensor open circuit ................................. 121 Temp Sensor open circuit ................................. 132
MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port
Temp Sensor short to +batt ............................... 122 Troubleshooting with an Event Code
MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Event Codes ...................................................... 134
Temp Sensor short to ground ............................ 122 E004 Engine Overspeed Shutdown .................... 136
MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port E016 High Engine Coolant Temperature
Temp Sensor open circuit ................................. 122 Shutdown .......................................................... 136
MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port E017 High Engine Coolant Temperature
Temp Sensor short to +batt ............................... 123 Warning ............................................................. 137
MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port E019 High Engine Oil Temperature Shutdown ... 137
Temp Sensor short to ground ............................ 123 E020 High Engine Oil Temperature Warning ...... 137
MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port E026 High Inlet Air Temperature Shutdown ........ 137
Temp Sensor open circuit ................................. 123 E027 High Inlet Air Temperature Warning .......... 138
MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port E038 Low Engine Coolant Temperature
Temp Sensor short to +batt ............................... 124 Warning ............................................................. 138
MID 111 - CID 1539 - FMI 04 Cyl #9 Exhaust Port E040 Low Engine Oil Pressure Shutdown .......... 138
Temp Sensor short to ground ............................ 124 E042 Low System Voltage Shutdown ................. 139
MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port E043 Low System Voltage Warning .................... 139
Temp Sensor open circuit ................................. 125 E050 High System Voltage Warning ................... 139
MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port E053 Low Fuel Pressure Warning ...................... 139
Temp Sensor short to +batt ............................... 125 E096 High Fuel Pressure .................................... 140
MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port E100 Low Engine Oil Pressure Warning ............. 140
Temp Sensor short to ground ............................ 125 E127 Engine Oil Filter Diff Pressure Low
MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Warning ............................................................. 140
Temp Sensor open circuit ................................. 126 E128 Engine Oil Filter Diff Pressure Low
MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Shutdown .......................................................... 140
Temp Sensor short to +batt ............................... 126 E129 Engine Oil Filter Diff Pressure High
MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Warning ............................................................. 141
Temp Sensor short to ground ............................ 126 E130 Engine Oil Filter Diff Pressure High
MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Shutdown .......................................................... 141
Temp Sensor open circuit ................................. 127 E135 Low Jacket Water Pressure Shutdown ...... 141
MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port E223 High Gas Temperature .............................. 142
Temp Sensor short to +batt ............................... 127 E224 High Jacket Water Inlet Pressure .............. 142
MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port E225 Engine Overcrank ...................................... 142
Temp Sensor short to ground ............................ 128 E226 Driven Equipment Not Ready .................... 142
MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port E229 Fuel Energy Content Setting Low .............. 143
Temp Sensor open circuit ................................. 128 E230 Fuel Energy Content Setting High ............. 143
MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port E231 Fuel Quality Out of Range ......................... 143
Temp Sensor short to +batt ............................... 128 E243 High Left Turbo Turbine Outlet
Temperature ...................................................... 143
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Table of Contents

E244 High Right Turbo Turbine Outlet E824 Cyl #4 Exhaust Port Temp Deviating High .. 162
Temperature ...................................................... 144 E825 Cyl #5 Exhaust Port Temp Deviating High .. 163
E245 High Right Turbo Turbine Inlet E826 Cyl #6 Exhaust Port Temp Deviating High .. 163
Temperature ...................................................... 144 E827 Cyl #7 Exhaust Port Temp Deviating High .. 163
E246 High Left Turbo Turbine Inlet E828 Cyl #8 Exhaust Port Temp Deviating High .. 164
Temperature ...................................................... 145 E829 Cyl #9 Exhaust Port Temp Deviating High .. 164
E264 Emergency Stop Activated ........................ 145 E830 Cyl #10 Exhaust Port Temp Deviating
E268 Unexpected Engine Shutdown .................. 145 High ................................................................... 165
E269 Customer Shutdown Requested ............... 145 E831 Cyl #11 Exhaust Port Temp Deviating
E270 Driven Equipment Shutdown Requested .. 146 High ................................................................... 165
E337 High Engine Oil to Engine Coolant Diff E832 Cyl #12 Exhaust Port Temp Deviating
Temp ................................................................. 146 High ................................................................... 165
E401 Cylinder #1 Detonation .............................. 147 E833 Cyl #13 Exhaust Port Temp Deviating
E402 Cylinder #2 Detonation .............................. 147 High ................................................................... 166
E403 Cylinder #3 Detonation .............................. 147 E834 Cyl #14 Exhaust Port Temp Deviating
E404 Cylinder #4 Detonation .............................. 147 High ................................................................... 166
E405 Cylinder #5 Detonation .............................. 148 E835 Cyl #15 Exhaust Port Temp Deviating
E406 Cylinder #6 Detonation .............................. 148 High ................................................................... 167
E407 Cylinder #7 Detonation .............................. 148 E836 Cyl #16 Exhaust Port Temp Deviating
E408 Cylinder #8 Detonation .............................. 148 High ................................................................... 167
E409 Cylinder #9 Detonation .............................. 149 E841 Cyl #1 Exhaust Port Temp Deviating Low .. 167
E410 Cylinder #10 Detonation ............................ 149 E842 Cyl #2 Exhaust Port Temp Deviating Low .. 168
E411 Cylinder #11 Detonation ............................ 149 E843 Cyl #3 Exhaust Port Temp Deviating Low .. 168
E412 Cylinder #12 Detonation ............................ 149 E844 Cyl #4 Exhaust Port Temp Deviating Low .. 169
E413 Cylinder #13 Detonation ............................ 150 E845 Cyl #5 Exhaust Port Temp Deviating Low .. 169
E414 Cylinder #14 Detonation ............................ 150 E846 Cyl #6 Exhaust Port Temp Deviating Low .. 169
E415 Cylinder #15 Detonation ............................ 150 E847 Cyl #7 Exhaust Port Temp Deviating Low .. 170
E416 Cylinder #16 Detonation ............................ 150 E848 Cyl #8 Exhaust Port Temp Deviating Low .. 170
E421 Cylinder #1 Detonation Shutdown ............. 151 E849 Cyl #9 Exhaust Port Temp Deviating Low .. 171
E422 Cylinder #2 Detonation Shutdown ............. 151 E850 Cyl #10 Exhaust Port Temp Deviating
E423 Cylinder #3 Detonation Shutdown ............. 151 Low ................................................................... 171
E424 Cylinder #4 Detonation Shutdown ............. 151 E851 Cyl #11 Exhaust Port Temp Deviating
E425 Cylinder #5 Detonation Shutdown ............. 152 Low ................................................................... 171
E426 Cylinder #6 Detonation Shutdown ............. 152 E852 Cyl #12 Exhaust Port Temp Deviating
E427 Cylinder #7 Detonation Shutdown ............. 152 Low ................................................................... 172
E428 Cylinder #8 Detonation Shutdown ............. 152 E853 Cyl #13 Exhaust Port Temp Deviating
E429 Cylinder #9 Detonation Shutdown ............. 153 Low ................................................................... 172
E430 Cylinder #10 Detonation Shutdown ........... 153 E854 Cyl #14 Exhaust Port Temp Deviating
E431 Cylinder #11 Detonation Shutdown ........... 153 Low ................................................................... 173
E432 Cylinder #12 Detonation Shutdown ........... 154 E855 Cyl #15 Exhaust Port Temp Deviating
E433 Cylinder #13 Detonation Shutdown ........... 154 Low ................................................................... 173
E434 Cylinder #14 Detonation Shutdown ........... 154 E856 Cyl #16 Exhaust Port Temp Deviating
E435 Cylinder #15 Detonation Shutdown ........... 154 Low ................................................................... 173
E436 Cylinder #16 Detonation Shutdown ........... 155 E864 Low Gas Fuel Differential Pressure ........... 174
E801 Cylinder #1 High Exhaust Port Temp ........ 155 E865 High Gas Fuel Differential Pressure .......... 174
E802 Cylinder #2 High Exhaust Port Temp ........ 155 E866 Low Gas Fuel Flow Rate ........................... 174
E803 Cylinder #3 High Exhaust Port Temp ........ 156 E867 Improper Gas Flow Control Valve
E804 Cylinder #4 High Exhaust Port Temp ........ 156 Response .......................................................... 175
E805 Cylinder #5 High Exhaust Port Temp ........ 156 E868 Gas Flow Control Valve Malfunction ......... 175
E806 Cylinder #6 High Exhaust Port Temp ........ 157
E807 Cylinder #7 High Exhaust Port Temp ........ 157 Diagnostic Functional Tests
E808 Cylinder #8 High Exhaust Port Temp ........ 158 +5V Sensor Voltage Supply ................................ 176
E809 Cylinder #9 High Exhaust Port Temp ........ 158 +8V Sensor Voltage Supply ................................ 184
E810 Cylinder #10 High Exhaust Port Temp ...... 158 Analog Sensor Signal ......................................... 191
E811 Cylinder #11 High Exhaust Port Temp ....... 159 CAT Data Link ..................................................... 199
E812 Cylinder #12 High Exhaust Port Temp ...... 159 Compressor Bypass ........................................... 203
E813 Cylinder #13 High Exhaust Port Temp ...... 159 Desired Speed Input (4 - 20 mA) ........................ 210
E814 Cylinder #14 High Exhaust Port Temp ...... 160 Detonation Sensors ............................................ 214
E815 Cylinder #15 High Exhaust Port Temp ...... 160 ECM Output Circuit (Fuel Control) ...................... 222
E816 Cylinder #16 High Exhaust Port Temp ...... 161 ECM Output Circuit (Starting Motor) ................... 230
E821 Cyl #1 Exhaust Port Temp Deviating High .. 161 ECM Status Indicator Output .............................. 241
E822 Cyl #2 Exhaust Port Temp Deviating High .. 161 Electrical Power Supply ...................................... 247
E823 Cyl #3 Exhaust Port Temp Deviating High .. 162 Engine Speed/Timing Sensor ............................. 254
8
Table of Contents

Fuel Metering Valve ............................................ 261


Generator Output Power Sensor ........................ 268
Ignition Transformers Primary Circuit ................. 275
Ignition Transformers Secondary Circuit and Spark
Plugs ................................................................. 284
Inspecting Electrical Connectors ........................ 290
Integrated Temperature Sensing Module
(ITSM) ............................................................... 295
PWM Sensor ....................................................... 301
Throttle Actuator ................................................. 308

Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 314
Generator Output Power Sensor - Calibrate ....... 316

Index Section
Index ................................................................... 320
9
Troubleshooting Section

Troubleshooting Section Air/Fuel Ratio Control


The ECM provides control of the air/fuel mixture for
performance and for efficiency at low emission levels.
Electronic Troubleshooting The system consists of an electronic fuel metering
valve, output drivers in the ECM, and maps in the
ECM. The control compensates for changes in the
i02051481 BTU of the fuel in order to maintain desired emission
levels.
System Overview
The following steps describe the basic operation:
SMCS Code: 1900
1. The ECM determines the desired flow rates for the
Introduction air and for the fuel. The flow rates are determined
by these factors:
The Electronic Control Module (ECM) controls
most of the functions of the engine. The ECM is • Desired engine speed
an environmentally sealed unit that is mounted in
a terminal box on the engine. The ECM monitors • Actual engine speed
various inputs from sensors in order to activate
relays, solenoids, etc at the appropriate levels. The • Calculated engine load
ECM supports the following five primary functions:
2. The command for the flow of the fuel is sent to
• Engine speed governing the electronic fuel metering valve via the CAN
data link.
• Air/fuel ratio control
This process is repeated continuously during engine
• Start/stop sequencing operation.

• Engine monitoring and protection Start/Stop Sequencing


• Ignition control The ECM contains the logic and the outputs for
control of starting and of shutdown. The customer
Engine Speed Governing programmable logic responds to signals from the
following components: engine control, emergency
The ECM maintains the desired engine speed by stop switch, remote start switch, data link, and other
controlling the actuator for the throttle. The actuator inputs.
is located at the inlet to the aftercooler. The actuator
is electrically controlled and electrically actuated. When the programmable logic determines that
it is necessary to crank the engine, the ECM
The ECM issues a throttle command that represents supplies +Battery voltage to the relay for the starting
a percent of the level of electrical current. The motor. The ECM removes the voltage when the
output can be viewed on the Caterpillar Electronic programmable crank terminate speed is reached or
Technician (ET). when a programmable cycle crank time has expired.

Desired engine speed is determined by the status The engine must be equipped with an energize-to-run
of the idle/rated switch, the desired speed input type of gas shutoff valve (GSOV). The source of
(analog voltage or 4 to 20 mA), and parameters the voltage to the GSOV depends on the engine’s
such as maximum engine high idle speed that configuration. The GSOV may be energized by the
are programmed into the software. Actual engine customer’s equipment or by the engine’s control
speed is detected via a signal from the speed/timing system.
sensor. Parameters such as governor gain can be
programmed with Cat ET. If the engine’s control system controls the GSOV,
the ECM supplies +Battery voltage to the GSOV
whenever the programmable logic determines that
fuel is required to operate the engine.

For more information on programmable parameters,


see Troubleshooting, “Programming Parameters”.
10
Troubleshooting Section

Engine Monitoring and Protection • Diagnostic


The ECM monitors both the engine operation and the • Event
electronic system.
Diagnostic Code – When a problem with the
Problems with engine operation such as low oil electronic system or a component is detected,
pressure produce an event code. The ECM can the ECM generates a diagnostic code. The code
issue a warning, a derating, or a shutdown. This indicates the specific problem with the circuitry.
depends on the severity of the condition. For more
information, see Troubleshooting, “Troubleshooting Diagnostic codes can have two different states:
With An Event Code”.
• Active
Problems with the electronic system such as an
open circuit produce a diagnostic code. For more • Logged
information, see Troubleshooting, “Troubleshooting
With A Diagnostic Code”. Active Code – An active diagnostic code indicates
that an active problem has been detected. Active
codes require immediate attention. Always service
Ignition Control active codes prior to servicing logged codes.
The ECM provides variable ignition timing that is
Logged Code – Every generated code is stored in
sensitive to detonation.
the memory of the ECM. The code is logged. The
ECM can store a maximum of ten different codes at
Each cylinder has an ignition transformer that is
one time. Logged codes remain in the memory of the
located under the valve cover for the cylinder. To
ECM even if the power is removed from the ECM.
initiate combustion, the ECM sends a pulse of
Logged codes may be useful to help troubleshoot
approximately 100 volts to the primary coil of an
intermittent problems. Logged codes can also be
ignition transformer at the appropriate time and for
used to review the performance of the engine and the
the appropriate duration. The transformer steps up
electronic system.
the voltage in order to create a spark across the
spark plug electrode.
Logged codes may not indicate that a repair is
needed. The problem may have been temporary. The
Detonation sensors monitor the engine for excessive
problem may have been resolved since the logging of
detonation. The G3516C Engine has eight
the code. For example, if the system is powered and
detonation sensors. Each sensor monitors two
a sensor is disconnected, the ECM will detect the
adjacent cylinders. The sensors generate data on
problem. The ECM will generate an active diagnostic
vibration that is processed by the ECM in order to
code for the problem. The ECM will also log the
determine detonation levels. If detonation reaches
code. When the sensor is connected, the active code
an unacceptable level, the ECM retards the ignition
will disappear. The logged code will remain in the
timing of the affected cylinder or cylinders. If retarding
memory of the ECM until the code is cleared.
the timing does not limit detonation to an acceptable
level, the ECM shuts down the engine.
A code is cleared from memory when one of the
following conditions occur:
The ECM provides extensive diagnostics for the
ignition system. The ECM also provides a switch
for ignition timing in order to allow operation with • The service technician manually clears the code.
alternate fuels such as propane that require a timing
offset. • The code does not recur for 1000 hours.
• A new code is logged and there are already ten
i02051566 codes in memory. In this case, the oldest code is
cleared.
Self-Diagnostics
Event Code – An event code is generated when
SMCS Code: 1901 the ECM detects an abnormal engine operating
condition. For example, an event code will be
The Electronic Control Module (ECM) has the ability generated if the oil pressure is too low. In this case,
to detect problems with the electronic system and the event code indicates the symptom of a problem.
with engine operation. When the ECM detects a
problem, the ECM generates a code. An alarm may
also be generated. There are two types of codes:
11
Troubleshooting Section

i02051602 Actuators
Location of Components
SMCS Code: 1900

Fuel Metering Valve

g01012402
Illustration 2
Right side view
(1) Throttle actuator
(2) Actuator for the compressor bypass valve

Throttle actuator (1) and the actuator for the


compressor bypass valve (2) are electrically
controlled and electrically actuated. The ECM issues
commands to the actuators via the CAN data link.

Sensors
Illustration 1
g01016786 Sensors provide information to the electronic control
modules. The information enables the modules to
Top view
control the engine as efficiently as possible over a
wide range of operating conditions. The information
The fuel metering valve is electrically controlled and
is used for monitoring engine operation.
electrically actuated. The fuel metering valve and the
Electronic Control Module (ECM) communicate via The sensors also enable the activation of alarms
the CAN data link.
and of shutoffs in response to abnormal operation.
Illustrations 3, 4, and 5 show the locations of the
sensors. Refer to Systems Operation/Testing and
Adjusting, “Engine Sensors” for the descriptions of
the sensors.
12
Troubleshooting Section

g01052257
Illustration 3
Right side view
(1) Engine oil temperature sensor (3) Detonation sensors (5) Pressure switch for the coolant pump
(2) Pressure sensor for unfiltered oil (4) Pressure sensor for filtered oil (inlet)

g01052265
Illustration 4
Top view
(6) Engine coolant temperature sensor (8) Engine coolant pressure sensor (outlet)
(7) Inlet air pressure sensor (9) Inlet air temperature sensor
13
Troubleshooting Section

g01052273
Illustration 5
Left side view
(3) Detonation sensors (10) Speed/timing sensor

Thermocouples
Thermocouples provide information to the Integrated
Temperature Sensing Module (ITSM). The
information is used to monitor engine operation. The
thermocouples also enable alarms and shutoffs to
be activated.

Illustration 6 shows the locations of the


thermocouples. Refer to Systems Operation/Testing
and Adjusting, “Integrated Temperature Sensing
Module” for the descriptions of the thermocouples.
14
Troubleshooting Section

g01057880
Illustration 6
(1) Thermocouple for the temperature of a (2) Thermocouple for the temperature of an (3) Thermocouples for the temperature of
cylinder exhaust port exhaust inlet to a turbocharger turbine the turbocharger exhaust outlets

Integrated Temperature Sensing


Module
The Integrated Temperature Sensing Module
(ITSM) monitors all of the thermocouples. The
ITSM broadcasts the temperature readings of the
thermocouples over the CAT data link for use by
other modules.

Illustration 7 shows the location of the ITSM. Refer to


Systems Operation/Testing and Adjusting, “Integrated
Temperature Sensing Module” for the description of
the ITSM.

g01052274
Illustration 7
Integrated temperature sensing module
15
Troubleshooting Section

i02051630 Terminal Box


Electrical Connectors and
Functions
SMCS Code: 7553-WW

Harness Wire Identification


Caterpillar identifies different wires with eleven
different solid colors. Table 1 lists the color codes of
the wiring.

Table 1
Color Codes for Wiring
Code Color
BK Black
BR Brown
BU Blue
GN Green
GY Gray
OR Orange
PK Pink
PU Purple Illustration 8
g00927440

RD Red Rear view

WH White (1) Terminal box


(2) Emergency stop button
YL Yellow
The terminal box contains the Electronic Control
Module (ECM). The electrical connectors for the
In addition to the color, the entire length of each
terminal box are located between the terminal box
wire is stamped with a specific circuit number that is
and the engine.
repeated on every 25 mm (1 inch) of the wire. The
actual wires are identified on the schematic.

For example, a code of J011-RD on the schematic


identifies a red wire that is stamped with the circuit
number J011. This particular wire is the engine
harness wire for the primary signal of the transformer
in the number one cylinder. For all Caterpillar engine
harnesses with electronic ignition systems, the code
of J011-RD identifies the wire for the primary signal
of the transformer in the number one cylinder.

The schematic also identifies the size of the wire.


The size or gauge of the wire is called the American
Wire Gauge (AWG). Unless the schematic specifies
a different size, you may assume that the wire is 16
AWG.
16
Troubleshooting Section

g01052301
Illustration 9
Components inside the terminal box
(3) ECM (8) J10/P10 connector for the terminating (11) J9 connector
(4) Ground strap for the ECM resistor for the CAN data link (12) J7 connector
(5) P2 connector (9) Service tool connector J5 for the (13) J8 connector for the detonation sensors
(6) P1 connector Caterpillar Electronic Technician (ET)
(7) Ignition harness (10) J6 connector for the customer
17
Troubleshooting Section

Junction Box

g00927512
Illustration 10
The junction box is located on left side of the engine.
(1) Junction box (4) 35 amp circuit breaker for the engine (6) Positive terminal for the connection of
(2) 2.5 amp circuit breaker for the engine (5) 2.5 amp circuit breaker for the start the engine’s power supply
control command from the ECM (7) Negative terminal for the connection of
(3) 10 amp circuit breaker for the customer the engine’s power supply

The junction box contains all of the circuit breakers


for the engine. The junction box also contains the
magnetic switches for the electric starting motors.

i02051687

Electronic Service Tools


SMCS Code: 0785

Caterpillar Electronic Service Tools are designed to


help the service technician perform the following
functions:

• Obtain data.
• Diagnose problems.
• Read parameters.
• Program parameters.
• Calibrate sensors.
The tools that are listed in Table 2 are required in
order to enable a service technician to perform the
procedures.
18
Troubleshooting Section

Table 2
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) The PC is required for the use of Cat ET.
“JERD2124” Software Single user license for Caterpillar Electronic Technician (ET)
Use the most recent version of the software.
“JERD2129” Software Data subscription for all engines
171-4400 (1) Communication Adapter Gp This group provides the communication between the PC and the
engine.
7X-1414 Data Link Cable As This cable connects the communication adapter to the service tool
connector on the engine.
237-7547 Adapter Cable As This cable connects to the USB port on computers that are not
equipped with a serial port.
8T-8726 Adapter Cable As This breakout harness is for use between the jacks and the plugs
of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch
connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.
146-4080 Digital Multimeter The multimeter is used for the testing and for the adjusting of
electronic circuits.
7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage in
wiring harnesses without disconnecting the harnesses.
(1) The 7X-1700 Communication Adapter Gp may also be used.

Note: For more information regarding the use of Cat • Set parameters
ET and of the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET Connecting Cat ET with the 171-4401
software.
Communication Adapter II
Caterpillar Electronic Technician The engine’s power supply supplies the
(ET) communication adapter with 24 VDC. Use the
following procedure to connect Cat ET and the
The Caterpillar Electronic Technician (ET) is designed communication adapter to the engine.
to run on a personal computer. Cat ET can display
the following information: 1. Set the engine control to the OFF/RESET mode.

• Parameters
• Diagnostic codes
• Event codes
• Engine configuration
• Status of the monitoring system
Cat ET can perform the following functions:

• Diagnostic tests
• Sensor calibration
• Flash downloading
19
Troubleshooting Section

7. Set the engine control to the STOP mode.


The engine should be OFF. If Cat ET and the
communication adapter do not communicate with
the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate With ECM”.

i02051696

Engine Monitoring System


SMCS Code: 7490

The Electronic Control Module (ECM) monitors


the operating parameters of the engine. The
ECM can initiate responses if a specific engine
parameter exceeds an acceptable range. Two
possible responses may be available for each
parameter: “WARNING” and “SHUTDOWN”. Some
of the responses are not available for some of the
parameters. Use the Caterpillar Electronic Technician
(ET) to perform the following activities:

• Select the available responses.


• Program the level for monitoring.
• Program delay times for each response.
The default settings for the parameters are
programmed at the factory. To accommodate unique
applications and sites, the parameters may be
reprogrammed with Cat ET. The screens of Cat ET
provide guidance for the changing of trip points.
g00927657
Illustration 11 Note: Some of the parameters are protected
(1) PC by factory passwords. Other parameters can be
(2) 196-0055 Serial Cable changed with customer passwords.
(3) 171-4401 Communication Adapter II
(4) 207-6845 Adapter Cable
(5) 7X-1414 Data Link Cable Changing the Settings of the
Note: Items (2), (3), and (4) are part of the 171-4400
Monitoring System
Communication Adapter Gp. Use the following procedure to change settings of
the parameters:
2. Connect cable (2) to the RS232 serial port of PC
(1). 1. Use Cat ET and select the “Service/Monitoring
System” screen.
Note: If your PC is not equipped with a serial port,
use the 237-7547 Adapter Cable As in order to 2. Highlight the desired parameter. Then click on the
connect to the USB port. Connect one end of the “Change” button in the lower left corner of the
adapter to the end of cable (2). Connect the other screen.
end of the adapter to a USB port on the PC.
The “Change Monitor System” screen will appear.
3. Connect cable (2) to communication adapter (3).
3. Change the “State” to “On” or “Off”.
4. Connect cable (4) to communication adapter (3).
4. Set the “Trip Point” and the “Delay Time” according
5. Connect cable (4) to cable (5). to the “Allowed Values” in the lower half of the
screen.
6. Connect cable (5) to the service tool connector of
the terminal box. 5. Click the “OK” button.
20
Troubleshooting Section

If a password is required, the “Enter Passwords” “High Oil Filter Differential Pressure”
screen will appear. Enter the correct passwords
and then click the “OK” button. The trip point for a warning for this parameter can
be programmed by the customer. The trip point for
The new settings will be effective immediately. a shutdown is set at the factory. This parameter is
always ON. This parameter cannot be turned off. If
the engine oil filter differential pressure increases
Monitoring Parameters to the trip point or if the engine oil filter differential
pressure exceeds the trip point, the ECM will
“Low System Voltage” generate a warning or a shutdown.
The trip point for this parameter is set at the factory.
The trip point cannot be changed. This parameter
“Low Oil Filter Differential Pressure”
is always ON. This parameter cannot be turned off.
If the system voltage decreases to the trip point or The trip point for a warning for this parameter can
be programmed by the customer. The trip point for a
if the system voltage goes below the trip point, the
shutdown for this parameter is set at the factory. This
ECM will generate a warning or a shutdown.
parameter is always ON. This parameter cannot be
turned off. If the engine oil filter differential pressure
“High Engine Coolant Temperature” decreases to the trip point or if the engine oil filter
differential pressure goes below the trip point, the
The trip points for this parameter can be programmed ECM will generate a warning or a shutdown.
by the customer. The shutdown response is always
ON. The shutdown response cannot be turned off. If
the engine coolant temperature increases to the trip “High Fuel Temperature”
point or if the engine coolant temperature exceeds
The trip point for this parameter can be programmed
the trip point, the ECM will generate a warning or a
shutdown. by the customer. If the fuel temperature increases to
the trip point or if the fuel temperature exceeds the
trip point, the ECM will generate a warning.
“Low Engine Coolant Temperature”
The trip point for this parameter can be programmed
“Low Fuel Pressure”
by the customer. If the engine coolant temperature
decreases to the trip point or if the engine coolant The trip point for this parameter can be programmed
by the customer. If the fuel pressure decreases to the
temperature goes below the trip point, the ECM will
trip point or if the fuel pressure goes below the trip
generate a warning.
point, the ECM will generate a warning.
“Engine Overspeed”
“High Engine Oil to Engine Coolant
The trip point for this parameter is set at the factory. Differential Temperature”
This parameter is always ON. This parameter cannot
be turned off. If the engine speed increases to the trip The trip point for a warning for this parameter can
point or if the engine speed exceeds the trip point, be programmed by the customer. The trip point for a
the ECM will activate an engine shutdown. A typical shutdown for this parameter is set at the factory. The
trip point is 118 percent of the engine’s rated speed shutdown response is always ON. The shutdown
for generator set applications. response cannot be turned off. If the differential
temperature of the jacket water and the engine
oil increases to the trip point or if the differential
“High Engine Oil Temperature”
temperature of the jacket water and the engine oil
exceeds the trip point, the ECM will generate a
The trip point for a warning for this parameter can
warning or a shutdown.
be programmed by the customer. The trip point for
a shutdown is set at the factory. This parameter is
always ON. This parameter cannot be turned off. If “Low Gas Fuel Differential Pressure”
the engine oil temperature increases to the trip point
or if the engine oil temperature exceeds the trip point, The trip point for this parameter can be programmed
the ECM will generate a warning or a shutdown. by the customer. If the fuel differential pressure
decreases to the trip point or if the fuel differential
pressure goes below the trip point, the ECM will
generate a warning.
21
Troubleshooting Section

“High Gas Fuel Differential Pressure” “High Fuel Pressure”


The trip point for this parameter can be programmed The trip point for this parameter can be programmed
by the customer. If the fuel differential pressure by the customer. The ECM will activate a warning if
increases to the trip point or if the fuel differential the fuel pressure increases to the trip point or if the
pressure exceeds the trip point, the ECM will fuel pressure exceeds the trip point.
generate a warning.
Default Settings of the Monitoring
“High System Voltage”
System
The trip point for this parameter is set at the factory.
The trip point cannot be changed. This parameter is Examples of the default settings for the parameters
always ON. This parameter cannot be turned off. If are listed in Table 3. The values may have changed.
the system voltage increases to the trip point or if Use the Cat ET to determine the programming for
the system voltage exceeds the trip point, the ECM your engine. Many of the items can be reprogrammed
will generate a warning. in order to accommodate the requirements of
individual sites.
Trip Points of the Engine Load for High
Inlet Air Temperature
The trip points for these parameters can be
programmed by the customer. The shutdown
response is always ON. The shutdown response
cannot be turned off. This feature provides a trip point
between high engine load and low engine load. The
trip point is used for events that involve high inlet air
temperature. The trip point for the events is based
on the engine load. The possible responses of the
system include a warning or a shutdown.

If the load is greater than the trip point, the trip point
for the “High Inlet Air Temperature at High Engine
Load” event is used for the logging of the high inlet
air temperature.

If the load is less than the trip point, the trip point
for the “High Inlet Air Temperature at Low Engine
Load” event is used for the logging of the high inlet
air temperature.

“High Inlet Air Temperature at Low


Engine Load”
The “Service/Configuration” screen of Cat ET defines
the “High Inlet Air Temp Engine Load Set Point”. The
ECM can activate a warning or a shutdown if the inlet
air temperature increases to the trip point or if the
inlet air temperature exceeds the trip point during the
low load operation that is defined.

“High Inlet Air Temperature at High


Engine Load”
The “Service/Configuration” screen of Cat ET defines
the “High Inlet Air Temp Engine Load Set Point”. The
ECM can activate a warning or a shutdown if the inlet
air temperature increases to the trip point or if the
inlet air temperature exceeds the trip point during the
high load operation that is defined.
22
Troubleshooting Section

Table 3
Default Settings of the Programmable Monitoring System
Security Range of
System Trip Delay in
Parameter Event Code State Level Range the Delay
Response Point Seconds
Password in Seconds

“Low System E043 (1) Warning 20 volts 20


On (1) This item cannot be programmed.
Voltage” E042 (3) Shutdown 18 volts 10
“E017 (1)” Warning On 109 °C
“High Engine
Coolant 80 to 129 °C
Temperature” “E016 (3)” Shutdown On (1) 113 °C
20 Customer 1 to 60
“Low Engine
Coolant E038 (1) Warning On 5 °C 5 to 80 °C
Temperature”
“Engine 1770 1200 to
E004 (3) Shutdown 0 Factory 0
Overspeed” rpm 2125 rpm

“High Engine Oil E020 (1) Warning 102 °C Customer 85 to 102 °C


20
Temperature” E019 (3) Shutdown 104 °C Factory 85 to 104 °C
103
“High Oil Filter E129 (1) Warning On (1) Customer
kPa 80 to 138
Differential
138 kPa
Pressure” E130 (3) Shutdown Factory
kPa 10
“Low Oil Filter E127 (1) Warning 35 kPa Customer
Differential 5 to 80 kPa
Pressure” E128 (3) Shutdown 5 kPa Factory

“High Fuel
E223 (1) 60 °C 20 0 to 60 °C
Temperature”
On 1 to 60
“Low Fuel Warning 105 Customer 100 to 135
E053 (1) 10
Pressure” kPa kPa
“High Engine Oil E337 (1) 14 °C
to Engine Coolant
On (1) 20 0 to 20 °C
Differential E337 (3) Shutdown 20 °C Factory
Temperature”
“Low Gas Fuel
Differential E864 (1) 5 kPa
Pressure”
On 10 Customer 0 to 35 kPa
“High Gas Fuel
Differential E865 (1) Warning 35 kPa
Pressure”
“High System
E050 (1) On (1) 34 volts 20 This item cannot be programmed.
Voltage”
“High Inlet Air E027 (1) On 69 °C 32 to 85 °C
Temperature
at Low Engine E026 (3) Shutdown On (1) 73 °C
Load”
20
“High Inlet Air E027 (1) Warning On 53 °C 32 to 100 °C
Customer 1 to 60
Temperature
at High Engine E026 (3) Shutdown On (1) 57 °C
Load”
“High Fuel 135 100 to 135
E096 (1) Warning On 10
Pressure” kPa kPa
(1) This parameter is permanently active. The parameter cannot be turned off.
23
Troubleshooting Section

Separate timers are used in the ECM for each


response that is associated with a parameter. If a trip
point is exceeded, the timer for that event is started.

For example, the warning for “High Engine Coolant


Temperature E017 (1)” can be set to 95 °C with a five
second delay. The timer starts counting if the coolant
temperature exceeds 95 °C. If the temperature is not
reduced to less than 95 °C within five seconds, the
event becomes active and the event is logged.

Conditions for Parameters


Some of the programmable parameters are
dependent on the status of an ECM output before
the parameters are allowed to function. Some of the
parameters are allowed to function after the crank
terminate relay has been energized for more than 30
seconds. Other parameters are allowed to function
after the output for the fuel control relay is energized.
Some parameters are not dependent upon any
conditions.

The conditions are designed to eliminate false events


during start-up if the customer has programmed a
delay time to zero. The conditions are listed in Table
4.

Table 4
Conditions for Activation for Monitoring the Parameters
Parameter Condition
“Low System Voltage” None
“High Engine Coolant Temperature” The crank terminate relay is energized for more than 30 seconds.
“Low Engine Coolant Temperature” None
“Engine Overspeed” None
“High Engine Oil Temperature” The crank terminate relay is energized for more than 30 seconds.
“High Oil Filter Differential Pressure”
“Low Oil Filter Differential Pressure”
“High Fuel Temperature”
“Low Fuel Pressure” The fuel control relay is energized.
“High Engine Oil to Engine Coolant Differential The crank terminate relay is energized for more than 30 seconds.
Temperature”
“Low Gas Fuel Differential Pressure” The fuel control relay is energized.
“High Gas Fuel Differential Pressure”
“High System Voltage” None
“High Inlet Air Temperature at Low Engine Load” The crank terminate relay is energized for more than 30 seconds.
“High Inlet Air Temperature at High Engine Load”
“High Fuel Pressure” The fuel control relay is energized.

Use care when you program the trip points and the If the trip point for a shutdown is programmed to
delay times. Ensure that the response of the ECM is activate before the trip point for a warning, the engine
correct for the application. The monitoring system will will shut down and the warning will not be activated.
accept any settings within the ranges.
24
Troubleshooting Section

Programmable Parameters of the


Integrated Temperature Sensing
Module
The Integrated Temperature Sensing Module (ITSM)
monitors the temperatures of the cylinder exhaust
ports, of the inlets of the turbocharger turbine, and of
the outlets of the turbocharger turbines.

If a temperature exceeds an acceptable range, the


ITSM can initiate a “WARNING” or “SHUTDOWN”.
Both of the responses are available for all of the
parameters. Use Cat ET to perform the following
activities:

• Select the available responses.


• Program the level for monitoring.
• Program delay times for each response.
Note: To initiate the responses, the ITSM sends
commands to the ECM via the Cat Data Link. If the
connection between the ITSM and the ECM is not
correct, the ITSM cannot initiate any response.

The default settings for the parameters are


programmed at the factory. To accommodate unique
applications and sites, the parameters may be
reprogrammed with Cat ET. The screens of Cat ET
provide guidance for changing trip points.

Table 5 lists default examples of the values for the


parameters. However, the values may have changed.
Use Cat ET to determine the programming for your
engine. The items can be reprogrammed in order to
accommodate the requirements of individual sites.

Use care when you program the trip points and the
delay times. Ensure that the response of the ITSM is
correct for the application. The monitoring system will
accept any setting within the ranges.

If the trip point for a shutdown is programmed to


activate before the trip point for a warning, the engine
will shut down and the warning will not be activated.
25
Troubleshooting Section

Table 5
Default Settings for the Integrated Temperature Sensing Module
Parameter Event Code System State Trip Delay in Security Range Range
Response Point Seconds Level of the
Password Delay in
Seconds
“High Exhaust E801 (1)
Temperature” through E820 Warning 655 °C
(1) 100 to 665
30 1 to 60
E801 (3) °C
through E820 Shutdown 665 °C
(3)
“Exhaust Port E821 (1)
Temperature through E840 Warning 50 °C 60 10 to 50 °C 1 to 60
High Deviation” (1)
E821 (3)
100 to 200
through E840 Shutdown 200 °C 10 1 to 10
°C
(3)
“Exhaust Port E841 (1)
Temperature through E860 Warning On 50 °C 60 Customer 10 to 50 °C 1 to 60
Low Deviation” (1)
E841 (3)
10 to 200
through E860 Shutdown 200 °C 10 1 to 10
°C
(3)
“High Turbo E245 (1) 100 to 710
Warning 710 °C
Turbine Inlet E246 (1) °C
Temperature” 30 1 to 60
E245 (3) 100 to 730
Shutdown 730 °C
E246 (3) °C
“High Turbo E243 (1)
Warning 615 °C
Turbine Outlet E244 (1) 100 to 625
Temperature” 60 1 to 60
E243 (3) °C
Shutdown 625 °C
E244 (3)

Separate timers are used in the ITSM for each


response that is associated with a parameter. If a trip
point is exceeded, the timer for that event is started.

For example, the warning for the “High Exhaust


Temperature” (E801 (1)) can be set to 655 °C with
a 30 second delay. The timer starts counting if the
exhaust port temperature of the number 1 cylinder
reaches 655 °C. If the temperature is not reduced
to less than 655 °C within 30 seconds, the event
becomes active and the event is logged.
26
Troubleshooting Section

Programming Parameters The customer passwords can be changed, if


necessary. The customer passwords or a factory
password is needed in order to change the customer
i01829539 passwords. If the customer passwords are forgotten,
factory passwords can be acquired from Caterpillar.
Programming Parameters
After the customer passwords are entered, the
SMCS Code: 1901 passwords are required in order to change certain
parameters. Once the passwords are entered
Programmable parameters enable the engine to be successfully, the passwords are not requested again
configured in order to meet the requirements of the until another screen is accessed or the data link is
application. The system configuration parameters interrupted.
must be programmed when the application is
installed. Perform this programming before the initial This feature is enabled by programming two customer
engine start-up. passwords. Use the following procedure to program
the passwords. The same procedure is used to
Data from a gas analysis and data on engine change the passwords:
performance are required in order to determine the
correct settings for the ignition timing and the fuel 1. Access the “Service/Configuration” screen of the
control. Incorrect programming of parameters may Caterpillar Electronic Technician (ET).
lead to complaints about performance and/or to
engine damage. 2. Highlight the “Customer Password #1” parameter.
Click on the “Change” button in the lower right
Programmable parameters can be classified into the corner of the screen.
following types: engine identification, timing control,
air/fuel ratio control, speed control, and start/stop Note: Be sure to record the customer passwords.
control. Store the passwords securely. The passwords can
have a maximum of eight characters. Alphanumeric
If an Electronic Control Module (ECM) is replaced, the characters may be used. The passwords are case
appropriate parameters must be copied from the old sensitive.
ECM. This can be done with the “Copy Configuration”
feature of the Caterpillar Electronic Technician (ET). 3. Enter the password in the “Change Parameter
Alternatively, the settings can be recorded on paper Value” dialog box and click on the “OK” button.
and then programmed into the new module.
4. Highlight the “Customer Password #2” parameter.
NOTICE Click on the “Change” button in the lower right
Changing the parameters during engine operation can corner of the screen.
cause the engine to operate erratically. This can cause
engine damage. 5. Enter the password in the “Change Parameter
Value” dialog box and click on the “OK” button.
Only change the settings of the parameters when the
engine is STOPPED. The passwords are now programmed into the
memory of the Electronic Control Module (ECM).

Make a copy of Illustration 12 and record your


i02051703
passwords. Store the passwords securely.
Customer Passwords
SMCS Code: 0785

Certain monitoring system parameters and system


configuration parameters may be protected with
customer passwords. Use of the passwords helps
to prevent free access to the modification of the
parameters. If the customer passwords are not Illustration 12
g01052323
programmed, all of the parameters are unprotected.
27
Troubleshooting Section

i01727009 i01932222

Factory Passwords Factory Passwords Worksheet


SMCS Code: 0785 SMCS Code: 0785

Factory level security passwords are required for Note: A mistake in recording this information will
clearing certain logged events and for changing result in incorrect passwords.
certain programmable parameters. Because of the
passwords, only authorized personnel can make Table 6
changes to some of the programmable items in Factory Passwords Worksheet
the Electronic Control Module (ECM). When the
correct passwords are entered, the changes are Dealer Code
programmed into the ECM. Customer’s Name

Factory passwords are required to program the Address


following shutdowns:

• “Engine Overspeed”
Telephone Number
• “High Engine Oil Temperature” Information from the “Enter Factory Passwords”
Screen on the Caterpillar Electronic
• “High Oil Filter Differential Pressure” Technician (Cat ET)

• “Low Oil Filter Differential” Serial Number for Cat ET


Engine Serial Number
• “High Jacket Water to Engine Oil Temperature
Differential” ECM Serial Number
Total Tattletale
The “Enter Factory Passwords” screen on Cat ET
will display the following parameters. To obtain the Reason Code
proper passwords, the information must be given to Factory Passwords
an authorized Caterpillar dealer:
Factory Password (No. 1)
• Current ECM Factory Password (No. 2)

• Serial number of the service tool


i01726985
• Serial number of the engine
Flash Programming
• Serial number of the ECM
SMCS Code: 1901-591
• Diagnostic clock
Software is located in the flash memory of the
• Total Tattletale Electronic Control Module (ECM) and the Integrated
Temperature Sensing Module (ITSM). The Caterpillar
• Reason Electronic Technician (ET) can be used to flash new
software into the ECM or the ITSM. This is the only
The old interlock code is required to change the method for updating the software. The module that
interlock code on a used ECM. The passwords are contains the software cannot be physically removed
controlled by Caterpillar. The passwords may only be from the ECM. This eliminates the risk of moisture
obtained by an authorized Caterpillar dealer. entry into the ECM due to improper seal installation.
The flash is accomplished by transferring the data
The passwords may only be used for one from Cat ET to the module via data link wiring. The
programming session. After you exit the “Enter Software, JERD2124 or Software, JERD2129 is
Factory Passwords” screen on Cat ET, a different used.
set of passwords will be required before you can
program the ECM.
Flash Programming
Factory passwords are not required for the first hour
of operation for a new ECM. After the hour expires, If the slowest baud rate of Cat ET is selected, flash
factory passwords are required for some of the programming can last up to 15 minutes. Be sure to
programming. set the baud rate to the fastest rate for your PC.
28
Troubleshooting Section

To select the baud rate, use the “Utilities/Preferences” 9. Start the engine and check for proper operation.
option on the Cat ET. Select the “Communications”
tab and click on “Advanced...”. Then select the baud a. If a diagnostic code of 268-02 “Check
rate from the “Advanced Communication Settings” Programmable Parameters” is generated,
menu and click the “OK” button. program any parameters that were not in the
original software.
If a communication error occurs, select a slower baud
rate in order to improve the reliability. b. Access the “Configuration” screen under
the “Service” menu in order to determine
Note: The 141-1957 Electronic Control (ITSM) the parameters that require programming.
will not function properly with the Software, Look under the “Tattletale” column. All of the
“190036601.fls”. Do not use any subsequent version parameters should have a tattletale of 1 or
such as Software, “190036602.fls” and Software, more. If a parameter has a tattletale of 0,
“190036603.fls”, etc. Do not flash this software into program that parameter.
the 141-1957 Electronic Control.
“WinFlash” Error Messages
1. Connect Cat ET to the service tool connector.
If you receive any error messages during flash
2. Turn the engine control switch to the STOP programming, click on the “Cancel” button in order
position. to stop the process. Access the information about
the “ECM Summary” under the “Information” menu.
Cat ET will not flash if the engine control switch is Make sure that you are flashing the correct file for
in the OFF or START position. your engine.
3. Select “WinFlash” from the “Utilities” menu on the
Cat ET. i02051715

“WinFlash” will try to detect an ECM. System Configuration


Parameters
4. When an ECM has been detected, the “ECM
Selector” window will appear. Select the SMCS Code: 1901
appropriate ECM and then select “OK”.
Certain parameters are unique for each engine
The “Flash File Selection” window will appear. application. Table 7 is a list of the parameters that can
be configured for G3516C Engines. The parameters
5. The flash files are located on a disk drive and in are programmed into the Electronic Control Module
a directory. Select the correct disk drive and the (ECM) via the Caterpillar Electronic Technician (Cat
directory from “Drives” and “Directories” on Cat ET). The values of the parameters can be viewed on
ET. the “Configuration” screen of Cat ET.
A list of flash files will appear. Refer to Systems Operation/Testing and Adjusting,
“Electronic Control System Parameters” for the
6. Select the correct file from the list of flash files. descriptions of the parameters.
Read the “Description” and the “File Info” in order
to verify that the correct file is selected. Select Table 7
“Open”. Configuration Parameters for G3516C Engines
7. Select the “Begin Flash” button in order to program Timing Control
the personality module.
“First Desired Timing”
When the flash is completed, this message will “Second Desired Timing”
appear: “Flash Completed Successfully”.
Air/Fuel Ratio Control
8. Program the configuration parameters and the “Fuel Quality”
monitoring system parameters.
“Gas Specific Gravity”
The parameters must be programmed in order “Fuel Specific Heat Ratio”
to ensure proper engine operation. Refer to
“Desired Emission Gain Adjustment”
Troubleshooting, “Engine Monitoring System”
and Troubleshooting, “System Configuration “Air/Fuel Proportional Gain”
Parameters”. (continued)
29
Troubleshooting Section

(Table 7, contd) i02051719

Configuration Parameters for G3516C Engines Replacing the ECM


“Air/Fuel Integral Gain”
SMCS Code: 1901-510
Speed Control
“Low Idle Speed” Electronic control modules contain no moving parts.
Replacement of an Electronic Control Module (ECM)
“Minimum High Idle Speed” can consume much time. Before you replace an
“Maximum High Idle Speed” ECM, follow the troubleshooting procedures in this
manual in order to be sure that replacement of the
“Engine Accel. Rate” ECM will correct the problem.
“Desired Speed Input Configuration”
Verify that the suspect ECM is the cause of the
“Governor Type Setting” problem. Install a test ECM in place of the suspect
“Engine Speed Droop” ECM. Transfer the software from the suspect ECM
to the test ECM. Program all the parameters for the
“Governor Proportional Gain” test ECM in order to match the parameters of the
“Governor Integral Gain” suspect ECM. The parameters must match. Refer
to the following test steps for details on programming
“Governor Derivative Gain” the parameters.
“Auxiliary Proportional Governor Gain 1”
If the test ECM resolves the problem, reconnect the
“Auxiliary Integral Governor Gain 1” suspect ECM. Verify that the problem recurs. If the
“Auxiliary Derivative Governor Gain 1” problem recurs, replace the suspect ECM with the
test ECM.
Start/Stop Control
“Driven Equipment Delay Time” Note: If the parameters cannot be read from the
suspect ECM, the parameters must be obtained from
“Crank Terminate Speed” records or from the factory.
“Engine Purge Cycle Time”
Perform the following procedure to replace the ECM.
“Engine Cooldown Duration”
“Cycle Crank Time”
1. Use the “Service/Copy Configuration/ECM
Replacement” function of the Caterpillar Electronic
“Engine Overcrank Time” Technician (ET).
“Engine Speed Drop Time”
Save the file. You can select “Load from ECM”.
“Engine Pre-lube Time Out Period” You may also select the “Print” function in order to
obtain a paper copy of the parameter settings.
Monitoring and Protection
“High Inlet Air Temp Load Set Point” Note: Before you replace an ECM, record all of the
logged events.
Power Monitoring
“Generator Output Power Sensor Scale Factor” a. Connect the Cat ET with the communications
adapter. Select “Service/Copy
“Generator Output Power Sensor Offset”
Configuration/ECM Replacement” from
“Engine Output Power Configuration” the drop-down menu on Cat ET.
“Engine Driven Accessory Load Configuration”
Cat ET will load the configuration parameters
Information for the ECM and the monitoring system parameters of the
suspect ECM.
“Engine Serial Number”
“Equipment ID” b. Select “Load from ECM” in the lower left corner
of the Cat ET screen. Select the suspect ECM
“Customer Password #1” and select “OK”.
“Customer Password #2”
After the loading is complete, the Cat ET will
“Total Tattletale” display this message: “The data has been
successfully loaded from the ECM”. Select
“OK”.
30
Troubleshooting Section

c. Select “File/Disconnect F8” from the drop-down


menu.

Note: Do not terminate the Cat ET.

2. Replace the ECM.

a. Set the engine control to the OFF/RESET


mode.

g01052348
Illustration 14
Internal view of the terminal box
(2) Mounting nut
(3) P2 connector
(4) P1 connector

c. Use a 4 mm Allen wrench to disconnect


connectors (3) and (4).
g00931487 d. Remove mounting nut (2) in order to disconnect
Illustration 13
Junction box the ground strap. Remove the three remaining
(1) Circuit breaker
mounting nuts.

b. Switch 35 amp circuit breaker (1) to the OFF Note: Rubber grommets behind the ECM are held in
position. place by the mounting studs. The grommets help to
reduce vibration. The grommets may fall when the
ECM is removed. Be sure not to lose the grommets.

e. Remove the ECM from the terminal box.

3. Install the replacement ECM.

a. Use the mounting hardware to install the new


ECM. Use a mounting nut to fasten the ground
strap for the ECM to the upper left mounting
stud. Then install the other three mounting
nuts.

Check the mounting hardware and the ECM for


correct installation. A correctly installed ECM
will move slightly on the rubber grommets.
If the ECM cannot move slightly on the
grommets, check that the washers, spacers,
and grommets are positioned correctly.

b. Use a 4 mm Allen wrench to connect the P1


and P2 connectors to the ECM. Tighten the
screws to a torque of 6 ± 1 N·m (55 ± 9 lb in).
31
Troubleshooting Section

4. Program the configuration parameters and Install a test ITSM in place of the suspect ITSM.
the monitoring system parameters into the Transfer the software from the suspect ITSM to
replacement ECM. the test ITSM. Program all the parameters for the
test ITSM in order to match the parameters of the
a. Switch 35 amp circuit breaker (1) to the ON suspect ITSM. The parameters must match. Refer
position. to the following steps for details on programming the
parameters.
b. Set the engine control to the “STOP” mode.
If the test ITSM resolves the problem, reconnect the
c. Select “File/Select ECM” from the drop-down suspect ITSM. Verify that the problem recurs. If the
menu. problem recurs, replace the suspect ITSM with the
test ITSM.
d. Select the replacement ECM and click “OK”.
Use the following procedure to replace the ITSM:
e. Select “Service/Copy Configuration/ECM
Replacement” from the drop-down menu. Click Note: If the parameters cannot be read from the
“OK” on the window. suspect ITSM, the parameters must be obtained from
records or from the factory.
f. Select “Program ECM” from the lower left
corner of the screen. Select the replacement 1. Use the “Service/Copy Configuration/ECM
ECM and click “OK”. If the correct ECM is Replacement” function of the Caterpillar Electronic
shown, select “Yes”. Technician (ET) in order to transfer the software
from the suspect ITSM.
g. After the loading is complete, a window with
the message “Programming Conflict Warning” You may also select the “Print” function in order to
will appear. Select “OK”. obtain a paper copy of the parameter settings.

h. A window with the message “Program ECM Note: Before you replace an ITSM, record all of the
Results” will appear. Select “OK”. logged events.

Note: When you program a new ECM, factory a. Connect Cat ET with the communications
passwords are not required for the first hour of adapter. Select “Service/Copy
operation. After one hour, factory passwords are Configuration/ECM Replacement” from
required for changing the parameters that are the pull-down menu.
normally protected with factory passwords.
Cat ET will load the configuration parameters
5. Calibrate the speed/timing sensor. and the monitoring parameters from the ECM.

See Troubleshooting, “Engine Speed/Timing b. Select “Load from ECM” in the lower left corner
Sensor - Calibrate”. of the screen. Select the suspect ITSM and
select “OK”.
i01819812
After the loading is complete, Cat ET will
Replacing the ITSM display this message: “The data has been
successfully loaded from the ECM”. Select
SMCS Code: 1901-510 “OK”.

The Integrated Temperature Sensing Module (ITSM) c. Select “File/Disconnect F8” from the pull-down
contains no moving parts. Replacement of the ITSM menu.
can consume much time. Before you replace an
ITSM, follow the troubleshooting procedures in this Note: Do not exit from Cat ET.
manual in order to be sure that replacement of the
ITSM will correct the problem. 2. Replace the ITSM.

Use the following guidelines to verify that the suspect a. Set the engine control to the OFF/RESET
ITSM is the cause of the problem: mode.
32
Troubleshooting Section

g00931487 g00929047
Illustration 15 Illustration 17
Junction box Mounting hardware for the ITSM
(4) Nut
b. Switch 35 amp circuit breaker (1) to the OFF (5) Ground strap
position. (6) Washer
(7) Mounting flange on the ITSM

d. Remove the four mounting nuts (4) and


washers (6) from mounting flanges (7) of the
ITSM. Ground strap (5) must also be lifted from
one of the studs.

e. Remove the ITSM from the engine.

3. Install the replacement ITSM. Orient the 54-pin


connector toward the bottom of the engine.

a. Use the mounting hardware to install the


new ITSM. Be sure to install ground strap (5)
between one of the washers on the mounting
flange and the nut.

Note: One of the washers is a lock washer. Be sure


to install the lock washer between ground strap (5)
and mounting flange (7). The lock washer improves
the electrical conductivity between the ground strap
and the mounting flange.
g00929088
Illustration 16
Connectors for the ITSM Check the mounting hardware and the ITSM for
(2) Connectors for the harness to the thermocouples correct installation. A properly installed ITSM
(3) Connectors for the harness to the terminal box for the master will move slightly on the rubber grommets. If the
ECM ITSM cannot move slightly on the grommets,
check that the mounting hardware is installed
c. Disconnect connectors (2) and (3) from the correctly.
ITSM.
b. Connect connectors (2) and (3) to the ITSM.

4. Program the configuration parameters and


the monitoring system parameters into the
replacement ITSM.
33
Troubleshooting Section

a. Switch 35 amp circuit breaker (1) to the ON


position.

b. Set the engine control to the STOP mode.

c. Select “File/Select ECM” from the pull-down


menu of Cat ET.

d. Select the “Replacement ITSM” and click “OK”.

e. Select “Service/Copy Configuration/ECM


Replacement” from the pull-down menu. Click
“OK” on the window.

f. Select “Program ECM” from the lower left


corner of the screen. Select the replacement
ITSM and click “OK”.

g. After the loading is complete, a window with


the message “Programming Complete” will
appear. Select “OK”.

Note: When you program a new ITSM, factory


passwords are not required. Also, the ITSM does not
require calibration.

i02051773

Troubleshooting Data Sheet


SMCS Code: 0785

To help troubleshoot a gas engine, complete the


information in Illustration 18. Be sure to include the
units of measurement.
34
Troubleshooting Section

g01052399
Illustration 18

Report the Service Information Repair – Explain your repair of the problem. For
example, you may have installed a new wiring
After you have successfully repaired the engine, it harness. You may have replaced the ignition
is important to provide good information about the transformer per instructions from the factory.
repair. The following topics are recommended for
your report: The providing of complete, accurate information will
help Caterpillar to provide better service to you and
Complaint – Include a description of the customer’s to the customer.
complaint in the report.

Cause – Provide a specific description of the cause


of the failure. Include the method that was used in
order to diagnose the problem. If diagnostic codes
or event codes were generated, include all of the
codes and the status of the codes. Indicate your
determination of the problem. For example, if you
performed a diagnostic functional test, identify the
test procedure. For example, a visual inspection
revealed abrasion of a wire in a harness. Be specific:
dynamometer testing of the engine produced power
below specifications at 1800 rpm due to the loss of
an ignition transformer.
35
Troubleshooting Section

Troubleshooting without a Operator Information


Diagnostic Code Obtain the following information from the operator:

• The occurrence and the time of the occurrence


i01970297

Symptoms • Determine the conditions for the occurrence. The


conditions will include the engine rpm and the load.
SMCS Code: 1000-035
• Determine if there are any systems that were
installed by the dealer or by the customer that
Some engine symptoms can be unrelated to could cause the symptom.
the electronic control system. This section is for
troubleshooting problems that have symptoms
without active diagnostic codes. Conditions such as
• Determine whether any other occurrences
happened in addition to the symptom.
poor fuel quality or improperly adjusted valves can
cause some engine symptoms.
Diagnostic Codes and Event Codes
For basic troubleshooting of the engine, perform
the following steps first in order to diagnose a Examine the following information regarding any
malfunction. codes:

1. Gather information about the complaint from the • The probable cause of the symptom is correlated
operator. to the code.

2. Verify that the complaint is not due to normal • The code was generated when the symptom
engine operation. Verify that the complaint is not occurred.
due to error of the operator.
• Codes that are repeatedly logged
3. Perform a visual inspection. Inspect the following
items: • The complaint is not due to normal engine
operation.
• Fuel supply
Other Symptoms
• Oil level
If other occurrences happened in addition to the
• Oil supply symptom, investigate the following conditions:
• Coolant level • The other occurrences are related to the symptom.
• Wiring • The symptoms have a probable cause that is
common.
• Connectors
4. Check the diagnostic codes and event codes. i02064369
Repair any active codes.
Detonation
If these inspections do not reveal any problems,
identify the probable causes with the procedures in SMCS Code: 1000-035
this manual that best describe the symptoms. Refer to
Troubleshooting, “Troubleshooting With A Diagnostic Probable Causes
Code” or refer to Troubleshooting, “Troubleshooting
With an Event Code”. Check each probable cause • Excessive load
according to the tests that are recommended.
• Excessive inlet manifold air pressure
Be sure to check the connectors. This is specially
true for problems that are intermittent. Refer to • High inlet air temperature
Troubleshooting, “Inspecting Electrical Connectors”.
• Incorrect air/fuel ratio
Narrow the probable cause. Consider the operator
information, the conditions of operation, and the • Incorrect base timing
history of the engine.
• Changes in the fuel quality
36
Troubleshooting Section

• The engine speed/timing sensor is not calibrated. Check for Event Codes Regarding the
Fuel
• Faulty circuit for the detonation sensor(s)
Check for the following event codes:
• Excessive deposits in the combustion chamber
• “E229 (1) Fuel Energy Content Setting Low”
Recommended Repairs (warning)

Excessive Load • “E230 (1) Fuel Energy Content Setting High”


(warning)
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment • “E231 (3) Fuel Quality Out Of Range” (shutdown)
and test the engine.
Refer to Troubleshooting, “Fuel Energy Content”.
Check the Inlet Manifold Air Pressure
Calibrate the Engine Speed/Timing
The calculated engine load increases when the inlet Sensor
manifold air pressure increases. Measure the inlet
manifold air pressure during engine operation with Note: Only perform this procedure if work on the
a load. For specific data on the engine, refer to the engine may have affected the engine timing. Also,
engine Technical Marketing Information. perform this procedure if the engine speed/timing
sensor has not been calibrated.
Check the Inlet Air Temperature
Calibrate the engine speed/timing sensor. Refer to
Troubleshooting, “Engine Speed/Timing Sensor -
High inlet air temperature can cause detonation.
Check the inlet air temperature. Look for the following Calibrate”.
event codes:
Check the Detonation Sensors
• “E026 (3) High Inlet Air Temperature” (shutdown)
Troubleshoot the detonation sensors. Refer to
• “E027 (1) High Inlet Air Temperature” (warning) Troubleshooting, “Detonation Sensors”.

Refer to Troubleshooting, “Inlet Air Temperature Check for Deposits in the Cylinders
(High)”.
Overfilling of engine oil can lead to deposits. Make
Air/Fuel Ratio sure that the engine oil level is correct.

An air/fuel mixture that is too rich will cause Note: Excessive deposits contribute to guttering of
detonation. Verify that the exhaust emissions are the valves.
correct. Refer to Systems Operation/Testing and
Adjusting, “Air/Fuel Ratio Control - Adjust”. Use a borescope to inspect the cylinders. Look for
the following conditions:
A change in the fuel energy content will change the
air/fuel ratio. Obtain a fuel analysis. • Deposits on the valve seats
The fuel supply pressure must be adequate and • Deposits on the valve faces
stable.
• Deposits on the cylinder walls that are above the
Make sure that the fuel metering valve is operating upper limit of the piston stroke
correctly.
• Signs of internal leaks
Check the Base Timing
Signs of internal leaks include excessive consumption
of engine oil, blue smoke, and excessive detonation.
Verify that the base timing is correct. Refer to
Systems Operation/Testing and Adjusting, “Ignition
Timing - Adjust”. If excessive deposits and/or signs of internal leaks
are found, investigate the cause of the condition.
Make repairs, as needed.
37
Troubleshooting Section

i02052059 Recommended Repairs


Driven Equipment 1. Verify that the correct passwords were entered.
Check every character in each password. Set the
SMCS Code: 1400-035 engine control to the OFF/RESET mode for 30
seconds and then retry.
Probable Causes
2. Verify that Cat ET is on the “Factory Password”
• The Electronic Control Module (ECM) has received screen.
a “Start Inhibit” or a “Shutdown” signal.
3. Verify that the following information from Cat ET
• The circuit for the signal is faulty. has been recorded correctly:

Recommended Repairs • Serial Number of the engine


• Serial Number of the Electronic Control Module
Check the Driven Equipment (ECM)

Determine whether the driven equipment has • Serial Number of the Cat ET
generated a “Start Inhibit” or “Shutdown” request.
Determine the cause for the request. Service the • Total Tattletale
driven equipment according to the recommendations
of the OEM of the equipment. • Reason Code
Check the Circuit for the Switch • Diagnostic Clock
The circuit for the switch must remain closed in order
i02052113
to allow the engine to run. Check the wiring between
the driven equipment and the ECM connector for Electronic Service Tool Will
damage and/or corrosion. Refer to Troubleshooting,
“Inspecting Electrical Connectors”. Repair the wiring, Not Communicate with ECM
as needed. (The Caterpillar Electronic
Check the resistance of the circuit between terminals Technician (ET) Will Not
P1-21 and P1-31 at the ECM. The correct resistance
of the circuit is 5 Ohms or less. If the resistance
Communicate With an
is greater than 5 Ohms, locate the source of the Electronic Control Module
excessive resistance. Make repairs, as needed.
(ECM) and/or the Integrated
i01804809
Temperature Sensing Module
(ITSM))
ECM Will Not Accept Factory
Passwords SMCS Code: 0785-035

SMCS Code: 1901-035 Probable Causes


Probable Causes • Electrical power supply

One of the following items may not be recorded • Electrical connectors


correctly on the Caterpillar Electronic Technician
(ET): • Communication adapter and/or cables

• Passwords • Electronic service tool

• Serial Numbers Recommended Repairs


• Total Tattletale Electrical Power Supply
• Reason Code Check power to the module. Refer to Troubleshooting,
“Electrical Power Supply”.
38
Troubleshooting Section

Note: If a module is not receiving power, the module • Faulty water temperature regulators
will not communicate.
• Faulty coolant temperature sensor and/or circuit
Electrical Connectors
• Insufficient flow of coolant through the engine
Check the following components:
• Exhaust restriction
• Power supply connections and ground to the
module • Excessive load

• Wiring harnesses and the connectors for the • Incorrect base timing
module
• Incorrect air/fuel ratio
Refer to Troubleshooting, “Inspecting Electrical
Connectors”. Recommended Repairs
Communication Adapter and/or Cables Check for High Ambient Temperature
and/or High Inlet Air Temperature
1. Check the condition of the fuse for the
communication adapter. Determine if the ambient air temperature is within the
design specifications for the cooling system.
2. Disconnect the communication adapter and the
cables from the service tool connector. Then Check for high inlet air temperature. Refer to
reconnect the communication adapter.
Troubleshooting, “Inlet Air Temperature (High)”.
If you are using the 171-4401 Communication Determine the cause of the high air temperature.
Adapter II, refer to Manual, “Communication
Make corrections, when possible.
Adapter II User’s Manual”.

3. Verify that power supply voltage is present Check for a Low Coolant Level and/or
between terminals A and B of the J5 service tool Coolant Leakage
connector. If the communication adapter is not
receiving power, the display will be blank. Note: Low coolant level can be the effect of
overheating rather than the cause.
Electronic Service Tool
Check the coolant level.
In order to eliminate Cat ET as the problem, connect
Cat ET to a different engine. If the same problem Run the engine to operating temperature. Inspect the
occurs with a different engine, check Cat ET and the cooling system for leaks.
related equipment in order to determine the cause
of the problem. Determine whether the leak occurs before the engine
overheats.

i01974132 Add coolant, if necessary. If leaking is found, make


the necessary repairs.
Engine Coolant Temperature
(High) Check for Insufficient Flow of Air and
Coolant Through the Radiator or Heat
SMCS Code: 1395-035
Exchanger
Probable Causes Radiator

• High ambient temperature and/or high inlet air Check the fins of the radiator for obstructions. Check
temperature the fan for proper operation.

• Low coolant level and/or coolant leakage If the radiator fins are obstructed, clean the fins. If the
fan does not operate properly, make the necessary
• Insufficient flow of air or coolant through the repairs.
radiator or heat exchanger
39
Troubleshooting Section

Heat Exchanger Check the Base Timing


Check for sufficient flow and temperature of the Verify that the base timing is correct. Refer to
cooling water through the heat exchanger. If the Systems Operation/Testing and Adjusting, “Ignition
flow of cooling water through the heat exchanger is Timing - Adjust”.
insufficient, determine the location of the obstruction.
If the temperature of the cooling water is too high, Air/Fuel Ratio
determine the cause. Make the necessary repairs.
An air/fuel mixture that is too rich will cause
Check the Water Temperature Regulators overheating. Verify that the exhaust emissions are
correct. Refer to Systems Operation/Testing and
Check the water temperature regulators for proper Adjusting, “Air/Fuel Ratio Control - Adjust”.
operation. Refer to Systems Operation/Testing and
Adjusting, “Testing the Cooling System”. A change in the fuel energy content will change the
air/fuel ratio. Obtain a fuel analysis.
Replace the water temperature regulators, if
necessary. The fuel supply pressure must be adequate and
stable.
Check the Coolant Temperature Sensor
Strike the gas pressure regulator with a soft hammer.
and/or the Circuit If the engine speed changes, inspect the internal
parts of the gas pressure regulator for wear. Inspect
Check the reading of the coolant temperature on
the gas pressure regulator’s diaphragm for leaks.
the Caterpillar Electronic Technician (ET). The Make sure that the valve moves freely. The valve
temperature should rise steadily as the engine is
must seat correctly.
warmed. Ensure that the temperature is reasonable.
Ensure that the fuel metering valve is operating
If the reading on Cat ET for the coolant temperature
correctly.
is not reasonable, troubleshoot the circuit
and the coolant temperature sensor. Refer to
Troubleshooting, “Analog Sensor Signal”. i01727368

Check the Flow of Coolant Through the Engine Coolant Temperature


Engine (Low)
During normal operation, check the status of the SMCS Code: 1395-035
following components:
Probable Causes
• Switch for the inlet pressure of the jacket water
• Faulty jacket water heater
• Sensor for the outlet pressure of the jacket water
• Faulty coolant temperature sensor and/or circuit
If the flow of coolant through the engine is not
sufficient, determine the cause of the obstruction. • Faulty water temperature regulators
Make necessary repairs.

Check the Exhaust Restriction Recommended Repairs


Check the back pressure of the exhaust system. Check the Jacket Water Heater
Refer to Systems Operation/Testing and Adjusting,
“Air Inlet and Exhaust System”. Determine if the jacket water heaters are functioning
properly.
If the back pressure exceeds the specifications for
the engine, determine the cause of the excessive If the jacket water heaters are not functioning
back pressure. Make the necessary repairs. properly, determine the cause of the malfunction of
the heaters. Make the necessary repairs.
Excessive Load
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment
and test the engine.
40
Troubleshooting Section

Check the Coolant Temperature Sensor • Low fuel pressure


and/or the Circuit
• High fuel pressure
Check the reading of the coolant temperature with
the Caterpillar Electronic Technician (ET). The • Poor fuel quality
temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable. Make sure that the fuel pressure is correct. When
possible, interview the operator in order to determine
If the reading on Cat ET for the coolant temperature if fuel quality is in question. Try to determine if the
is not reasonable, troubleshoot the circuit source of the fuel was changed.
and the coolant temperature sensor. Refer to
Troubleshooting, “Analog Sensor Signal”. Inspect the fuel system components: fuel filter,
gas pressure regulator, gas shutoff valve, and fuel
metering valve. Verify that the system’s components
Check the Water Temperature Regulators are operating correctly.
The water temperature regulators should not begin to
Replace the fuel filter, if necessary.
open until jacket water reaches opening temperature
for the regulators. Allow the engine to cool and then
start the engine. Check the hose at the outlet for Electrical Connectors or Power Supply
the jacket water. If the hose is warm and normal
operating temperature is not achieved yet, a regulator There may be an intermittent interruption of power.
may be stuck open. Check the wiring harnesses and the connectors.
Inspect the connectors in the terminal box. Inspect
If the water temperature regulators are the battery connections and the ground.
malfunctioning, check the water temperature
regulators according to Systems Operation/Testing Inspect the wiring from the battery to the Electronic
and Adjusting, “Testing the Cooling System”. Replace Control Module (ECM). Inspect the wires and
the water temperature regulators, if necessary. the power relay. Check the power and ground
connections. Refer to Troubleshooting, “Electrical
Power Supply”.
i01727427

Engine Cranks but Will Not No Signal from the Engine Speed/Timing
Sensor
Start
Make sure that the speed/timing sensor is installed
SMCS Code: 1000-035; 1400-035 correctly. Refer to Troubleshooting, “Speed/Timing
Sensor”.
Probable Causes
Make sure that the timing wheel is correctly installed.
• Fuel supply
Ignition System
• Electrical connectors or power supply
Inspect the ignition transformers for loose
• No signal from the speed/timing sensor connections, moisture, short circuits, and open
circuits. Inspect the primary wiring and the secondary
• Ignition system electrical connections.

• Excessive load Make sure that the correct transformers and spark
plugs are installed. Inspect the extenders for signs
Recommended Repairs or pin holes and arcing.

Maintain the spark plug according to Operation and


Fuel Supply Maintenance Manual, “Ignition System Spark Plugs”.
Make sure that fuel is supplied at a sufficient pressure Make sure that the ignition timing is correct.
that is stable. Make sure that the size of the fuel line
is sufficient. Inspect the fuel system for leaks.

The following conditions can cause the engine to


malfunction:
41
Troubleshooting Section

Excessive Load Cat ET will display a graph of the cylinder’s


exhaust gas temperature. The output voltage of
Make sure that the load is not excessive. Reduce the the transformer’s secondary circuit, the engine
load. If necessary, disengage the driven equipment speed, and the desired engine speed are also
and test the engine. displayed.

i02085470
Cold Cylinder
Engine Misfires, Runs Rough Locate the misfiring cylinder. Check the following
components for failure: spark plug, extender, ignition
or Is Unstable transformer, and primary wiring. Inspect the extender
for signs of pin holes and/or arcing.
SMCS Code: 1000-035
Refer to Troubleshooting, “Ignition Transformers
Probable Causes Secondary Circuit and Spark Plugs”.

• Cold cylinder Electrical Connectors or Power Supply


• Electrical connectors or power supply There may be an intermittent interruption of power.
Check the wiring harnesses and the connectors.
• Ignition system Inspect the connectors in the terminal boxes. Inspect
the power supply connections and the ground.
• Fuel supply
Inspect the wiring from the power supply to the
• Incorrect air/fuel ratio control modules. Refer to Troubleshooting, “Electrical
Power Supply”.
• Incorrect governor adjustment
Ignition System
• Compressor bypass valve
Inspect the ignition transformers for the following
• Air inlet restriction items: loose connections, moisture, short circuits,
and open circuits. Inspect the primary wiring and the
• Exhaust restriction secondary electrical connections.
• Binding of the throttle actuator Make sure that the correct transformers and spark
plugs are installed. Inspect the extenders for signs of
• Incorrect valve lash pin holes and of arcing.
• Cylinder head and related components Maintain the spark plug according to the engine’s
Operation and Maintenance Manual.
• Throttle
Make sure that the ignition timing is correct.
Recommended Repairs
Fuel Supply
Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine Make sure that fuel is supplied at a sufficient pressure
operating temperature, etc), test the engine under that is stable. Make sure that the size of the fuel line
the conditions. Troubleshooting the symptom under is sufficient. Inspect the fuel system for leaks.
other conditions can give misleading results.
The following conditions can cause the engine to
The Caterpillar Electronic Technician (ET) and the malfunction:
Integrated Temperature Sensing Module (ITSM)
can be used to detect a misfiring cylinder. Use the • Low fuel pressure
following procedure:
• High fuel pressure
1. Use the “Data Link/Select ECM” option on the Cat
ET to select the ITSM. • Poor fuel quality
2. Select “Diagnostics/Diagnostic Tests”. Make sure that the fuel pressure is correct. When
possible, interview the operator in order to determine
3. Select the suspect cylinder and click the “Start” if fuel quality is in question. Try to determine if the
button in the lower left corner of the screen. source of the fuel was changed.
42
Troubleshooting Section

Inspect the fuel system components: fuel filter, Check for Binding of the Throttle
gas pressure regulator, gas shutoff valve, and fuel Actuator
metering valve. Verify that the system’s components
are operating correctly. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. Move the
Replace the fuel filter, if necessary. throttle plate while you feel the motion. If the motion
is sticky and/or rough, investigate the cause of the
Air/Fuel Ratio binding. Make the necessary repairs.

An air/fuel mixture that is too rich or too lean will have Incorrect Valve Lash
an adverse effect on engine operation. Verify that
the exhaust emissions are correct. Refer to Systems Check the valve lash. Refer to Systems Operation,
Operation/Testing and Adjusting, “Air/Fuel Ratio Testing And Adjusting, “Valve Lash and Valve Bridge
Control - Adjust”. Adjustment”.
A change in the fuel energy content will change the
air/fuel ratio. Obtain a fuel analysis.
Cylinder Head and Related Components
Measure the cylinder compression. Refer to the
The fuel supply pressure must be adequate and
engine’s Operation and Maintenance Manual,
stable.
“Cylinder Pressure - Measure/Record”.
Governor Adjustment Inspect the components of the valve train for good
condition. Check for signs of damage and/or wear
The governor’s parameters must be programmed to the valves, cylinder head gasket, etc. Inspect the
with the values that provide stable operation. Refer condition of the camshafts. If a camshaft is replaced,
to Systems Operation/Testing and Adjusting, “Engine new valve lifters must be installed.
Governing - Adjust”.
Throttle
Compressor Bypass Valve
Make sure that the throttle actuator is operating
The actuator for the compressor bypass valve must properly. If the motion of the actuator is sticky and/or
be installed properly in order to provide stable rough, service the actuator.
operation. Refer to Disassembly and Assembly,
“Actuator Bypass Valve (Variable) - Install”.
i01727473

Air Inlet Restriction Engine Oil Filter Differential


High inlet air restriction adversely affects engine Pressure
performance. Refer to the applicable Gas Engine
Technical Data Sheet for additional information. SMCS Code: 1308-035

The maximum allowable air inlet restriction is Probable Causes


3.75 kPa (15 inches of H2O). If the indication is higher
than the maximum permissible restriction, clean the
filter element or install a new filter element. Check the
• Plugged oil filter or faulty oil filter
restriction again. If the restriction remains too high,
inspect the air inlet piping for obstructions.
• Faulty oil pressure sensor and/or circuit

For more information, refer to Systems


• Malfunctioning of the oil filter bypass valve
Operation/Testing and Adjusting, “Restriction of Air
Inlet and Exhaust”. Recommended Repairs
Exhaust Restriction Check the Oil Filters

Check for restriction in the exhaust system. Refer Check the oil filter differential pressure. Do not allow
to Systems Operation/Testing and Adjusting, the differential pressure to exceed 103 kPa (15 psi).
“Restriction of Air Inlet and Exhaust”. If the oil filter differential pressure is too high, change
the oil filter elements.
43
Troubleshooting Section

Inspect the oil filters for good condition. Replace any Contaminated Engine Oil
suspect oil filter.
Engine oil that is contaminated with another liquid
Check the Oil Pressure Sensors and/or will cause low engine oil pressure. High engine oil
level can be an indication of contamination. Obtain
Circuits an analysis of the engine oil. Determine the reason
for contamination of the engine oil and make the
Use the Caterpillar Electronic Technician (ET) to
necessary repairs. Change the engine oil and the
compare the readings for the filtered oil pressure and engine oil filter. For the correct engine oil to use, refer
the unfiltered oil pressure while the engine is OFF.
to Operation and Maintenance Manual, “Engine Oil”.
Make sure that the sensors are correctly wired.

If the readings are not approximately zero for both Incorrect Viscosity
of the sensors, the sensors are wired improperly.
Troubleshoot the sensor circuit(s). Refer to Make sure that the engine is supplied with the correct
Troubleshooting, “Analog Sensor Signal”. engine oil. For the correct engine oil to use, refer to
Operation and Maintenance Manual, “Engine Oil”.
Check the Oil Filter Bypass Valve
Faulty Engine Oil Pressure Sensors
An oil filter bypass valve that is stuck in the closed
position can cause a high reading for differential Use the Caterpiller Electronic Technician (ET) to
pressure when the oil is cold. An oil filter bypass compare the readings of the filtered engine oil
valve that is stuck in the open position can cause a pressure and the unfiltered engine oil pressure while
low reading for differential pressure when the oil is the engine is OFF. Both readings should be close to
hot. Check the operation of the oil filter bypass valve. zero pressure.
For more information, see Systems Operation/Testing
and Adjusting, “Measuring Engine Oil Pressure”. If a reading is significantly different from zero, replace
the suspect engine oil pressure sensor.
If the oil filter bypass valve is faulty, repair the valve,
when possible. Replace the valve, if necessary. Improper Circulation of the Engine Oil
Several factors could cause improper circulation of
i01727510
the engine oil:
Engine Oil Pressure (Low)
• The engine oil filter is clogged. Replace the engine
SMCS Code: 1348-035-PX oil filter.

• An engine oil line or a passage for engine oil is


Probable Causes disconnected or broken.

• Low engine oil level • The engine oil cooler is clogged. Thoroughly clean
the engine oil cooler.
• Incorrect viscosity
• There is a problem with a piston cooling jet.
• Contaminated engine oil Breakage, a restriction, or incorrect installation of a
piston cooling jet will cause seizure of the piston.
• Faulty oil pressure sensors
• The inlet screen of the suction tube for the engine
• Improper circulation of the engine oil oil pump can have a restriction. This restriction will
cause cavitation and a loss of engine oil pressure.
• Worn components Check the inlet screen on the suction tube and
remove any material that may be restricting engine
Recommended Repairs oil flow.

Low Engine Oil Level • The suction tube is drawing in air. Check the joints
of the tube for cracks or a damaged O-ring seal.
Check the oil level. Add oil, as needed.
• There is a problem with the engine oil pump. Check
the gears of the engine oil pump for excessive
wear. Engine oil pressure is reduced by gears that
have too much wear.
44
Troubleshooting Section

• The engine oil pump’s pressure regulating valve or Oil Coolers that are Cooled by the Separate
a bypass valve is stuck in the open position. Clean Circuit
the valve. Replace parts, if necessary.
Compare the temperature of the coolant at the inlet
Worn Components of the oil cooler to the regulated temperature. If the
inlet temperature is OK, check the temperature of the
Excessive clearance at the crankshaft or camshaft coolant at the outlet of the oil cooler.
bearings will cause low engine oil pressure. Also,
inspect the clearance between the rocker arm shafts A high temperature difference indicates an insufficient
and the rocker arms. Check the engine components flow rate. Investigate the cause of the obstruction.
for excessive clearance. Make the necessary repairs.

Obtain an analysis of the engine oil. Check the Check the Flow of Oil Through the Oil
analysis for the level of wear metals in the engine oil. Cooler

i01727521
Run the engine at normal operating temperature.
Determine the pressure differential between the inlet
Engine Oil Temperature (High) and the outlet of the oil cooler. For comparative data,
refer to the Technical Marketing Information for the
SMCS Code: 1348-035 engine.

If the pressure differential between the inlet and


Probable Causes the outlet of the oil cooler exceeds the data that is
published for the engine, there is an insufficient flow
• Faulty oil temperature sensor and/or circuit of oil through the oil cooler. Determine the cause of
the obstruction. Make the necessary repairs.
• Insufficient flow of coolant through the oil cooler
• Insufficient flow of oil through the oil cooler i02052131

Recommended Repairs Engine Overcrank


SMCS Code: 1400-035
Check the Oil Temperature Sensor and/or
the Circuit Probable Causes
Check the reading of the oil temperature on • The gas supply to the engine is insufficient.
the Caterpillar Electronic Technician (ET). The
temperature should rise steadily as the engine is • A feature for engine protection prevents the engine
warmed. Ensure that the temperature is reasonable. from starting.
If the reading on Cat ET for the oil temperature • The starting motor circuit is faulty.
is not reasonable, troubleshoot the circuit for the
oil temperature sensor. Refer to Troubleshooting, • There is no engine speed signal to the Electronic
“Analog Sensor Signal”. Control Module (ECM).

Check the Flow of Coolant Through the • The ignition system is not functioning.
Oil Cooler
• The base timing is incorrect.
Oil Coolers that are Cooled with Jacket Water
• The quality of the gas does not match the
Check for “High Engine Coolant Temperature” parameter for “Fuel Quality”.
events. Refer to Troubleshooting, “Engine coolant
Temperature (High)”. Recommended Repairs
Check the Gas Supply to the Engine
Check for low gas pressure. If the gas pressure is
low, refer to Troubleshooting, “Fuel Pressure”.
45
Troubleshooting Section

If the throttle does not open, check for binding of Check the Fuel Quality
the throttle actuator. Move the throttle plate while
you feel the motion. If the motion is sticky and/or Compare the Low Heat Value (LHV) of the gas supply
rough, investigate the cause of the binding. Make the to the “Fuel Quality” parameter that is programmed
necessary repairs. by the customer into the ECM. The ECM uses the
setting for start-up and for air/fuel ratio control at low
Check for Active Shutdowns loads.

Use the Caterpillar Electronic Technician (ET) to If the LHV of the fuel does not match the “Fuel
check for active diagnostic codes or event codes Quality” parameter that is programmed into the ECM,
which may prevent the engine from starting. program the ECM with the correct setting for the
“Fuel Quality” parameter.
Correct the cause of the active code. Before the
engine can be started, you must recycle the power to i02052143
the engine. Set the engine control to the OFF/RESET
mode. Then set the control to the STOP mode. Engine Overload
Check the Status of the Relay for the SMCS Code: 1000-035
Starting Motor
Probable Causes
Attempt to start the engine while you observe the
status of the relay for the starting motor on Cat ET. • Excessive inlet manifold air pressure
If the status of the relay for the starting motor • The Low Heat Value (LHV) of the gas or the
indicates that the engine should crank but no specific gravity of the gas is significantly different
cranking occurs, troubleshoot the starting circuit. from the value that is programmed.
Refer to Systems Operation/Testing and Adjusting,
“Air/Electric Starting System”.
Recommended Repairs
If the engine should crank and cranking occurs,
check the engine rpm. Check the Inlet Manifold Air Pressure
The calculated engine load increases when the inlet
Check the Engine Speed manifold air pressure increases. Measure the inlet
manifold air pressure during engine operation with
The ECM must detect a minimum of 50 rpm before
a load. For specific data on the engine, refer to the
the gas and the ignition are supplied to the engine.
engine Technical Marketing Information.
Use Cat ET to monitor the engine speed while you
crank the engine.
Obtain a Fuel Analysis and Program the
If no engine speed is displayed on Cat ET or if Fuel Energy Content
the engine speed is not stable, troubleshoot the
speed/timing sensor. Refer to Troubleshooting, Obtain an analysis of the gas in order to determine
“Engine Speed/Timing Sensor”. the LHV. Program the correct LHV for the “Fuel
Quality” configuration parameter.
Check for Diagnostic Codes
If the LHV of the gas does not match the “Fuel
Check for active diagnostic codes that relate to Quality” parameter value that is programmed into the
the ignition system. If there is at least one active ECM, program the ECM with the correct value for the
diagnostic code that relates to the ignition system, “Fuel Quality” parameter by selecting the “Change”
troubleshoot the diagnostic code. button in the lower left corner of the screen. Type the
correct value and then select “OK”.
Check the Base Timing If the quality of the gas is not consistent, obtain
several analyses over a period of time. Program the
Verify that the base timing is correct. Refer to
“Fuel Quality” configuration parameter to the average
Systems Operation/Testing and Adjusting, “Ignition
value of the LHV.
Timing - Adjust”.
46
Troubleshooting Section

i02052147 Check for Slow Governor Response


Engine Overspeed Observe the “Speed Governor Adjustment” screen
on the Caterpillar Electronic Technician (ET). Look
SMCS Code: 1000-035 for the engine response to the worst cases for
step-loading and unloading.
Probable Causes
Check for Binding of the Throttle
• Low trip point for engine overspeed Actuator
• Signal from the signal driver in the Electronic Set the engine control to the OFF/RESET mode.
Control Module (ECM) for the actuator of the Switch the 35 amp circuit breaker OFF. Move the
throttle throttle plate while you feel the motion. If the motion
is sticky and/or rough, investigate the cause of the
• Energy of the driven equipment binding. Make the necessary repairs.
• Slow governor response
i02052150
• Binding of the throttle actuator
Engine Shutdown
Recommended Repairs SMCS Code: 1400-035

Check the Trip Point Probable Causes


Note: Do not program the trip point for engine
overspeed higher than the maximum ratings of the • The “Emergency Stop” button is pressed.
driven equipment.
• The circuit for the emergency stop is faulty.
The trip point or engine overspeed may be too low.
Verify that the trip point for the engine overspeed is • The normal stop switch that is installed by the
customer is activated.
properly programmed. Typically, this parameter is set
at 118 percent of rated speed.
• The circuit for the normal stop switch is faulty.
This parameter requires a factory password in order
to change the trip point. Change the trip point to an • Either switch is activated by excessive vibration.
acceptable speed.
Recommended Repairs
Check for Diagnostic Codes that Relate
to the Signal from the Signal Driver in Talk to the operator
the ECM Ask the operator if the stop was intentional. Make
sure that the reason for the stop has been corrected.
Check for diagnostic codes that relate to the actuator Reset the control system. Resume normal operation.
of the throttle.
If the stop was accidental, reset the control system.
Investigate the diagnostic code(s). Make the Resume normal operation.
necessary repairs.
Check the Circuit for the Stop Switches
Check the Driven Equipment
Note: The circuit for the normal stop switch and the
Determine if the driven equipment has additional circuit for the emergency stop switch must remain
inputs of energy that could drive the engine beyond closed in order for the engine to run.
the rated rpm. Make corrections to the installation in
order to prevent the overspeed from recurring. Inspect the wiring between the switches and the
connector of the electronic control module. Look for
damage and/or corrosion. Refer to Troubleshooting,
“Inspecting Electrical Connectors”.
47
Troubleshooting Section

For the emergency stop switch, close the switch and Recommended Repair
check the resistance between terminals 22 and 31
of the P1 connector. Check the Circuit for the GSOV
For the normal stop switch, close the switch and Troubleshoot for the following diagnostic codes:
check the resistance between terminals 23 and 31
of the P1 connector. • 17-05 Fuel Shutoff Valve open circuit
The correct resistance between the terminals is less • 17-06 Fuel Shutoff Valve short to ground
than 5 Ohms. If the resistance is greater than 5
Ohms, locate the source of the excessive resistance. • 17-12 Fuel Shutoff Valve malfunction
Make repairs, as needed.
Refer to Troubleshooting, “ECM Output Circuit (Fuel
Inspect the Stop Switches Control)”. Make repairs, as needed.

Inspect the stop switches for evidence of damage Check the Inputs for the Mode of
that has been caused by vibration. Disassemble the
switches. Inspect the components for looseness, Operation to the ECM
cracks, and abrasion. Use an ohmmeter and toggle
the switches in order to check for proper electrical Troubleshoot for the “336-02 Incorrect ECS Switch
operation. inputs” diagnostic code.

Replace any faulty components. Refer to Troubleshooting, “Electrical Power Supply”.


Make repairs, as needed.

i02052172 Check the “Crank Terminate” Relay


Engine Shutdown Troubleshoot for the “443-03 Crank Terminate Relay
(Unexpected) short to +batt” diagnostic code.

SMCS Code: 1400-035 Refer to Troubleshooting, “ECM Status Indicator


Output”. Make repairs, as needed.
Probable Causes
Check the “Start” Relay
• There is a problem with the Gas Shutoff Valve
(GSOV). Troubleshoot for the following diagnostic codes:

• Incorrect input(s) for the mode of operation to the • 444-05 Start Relay open circuit
Electronic Control Module (ECM)
• 444-06 Start Relay short to ground
• There is a problem with the “Crank Terminate”
relay. Refer to Troubleshooting, “ECM Output Circuit
(Starting Motor)”. Make repairs, as needed.
• There is a problem with the relay for the starting
motor. Check for a Request for a Shutdown by
the Driven Equipment
• A shutdown has been requested by the driven
equipment. Determine whether a shutdown for the driven
equipment has been requested. Refer to
• There is a problem with the “Run” relay. Troubleshooting, “Driven Equipment”. Make
corrections, as needed.
• The “Crank Terminate Speed” is incorrectly
programmed.
Check the “Run” Relay
• The “Cycle Crank Time” is incorrectly programmed. Troubleshoot for the “445-03 Run Relay short to
+batt” diagnostic code.
• The “Engine Overcrank Time” is incorrectly
programmed.
Refer to Troubleshooting, “ECM Status Indicator
Output”. Make repairs, as needed.
• The delay time for the driven equipment is
excessive.
48
Troubleshooting Section

Check the “Crank Terminate Speed” An event code is generated if the “Driven Equipment
Delay Time” elapses without closure of the switch
The “Crank Terminate Speed” is a parameter that can input. To disable this feature, program the delay time
be configured. The Electronic Control Module (ECM) to zero.
disengages the starting motor when the engine
exceeds the programmed “Crank Terminate Speed”. If the programmed delay time is too long, the engine
The default value of 250 rpm should be sufficient for may not start. Use Cat ET to check the “Driven
all applications. Equipment Delay Time”. Use Cat ET to program the
delay time to a reasonable amount of time.
If the “Crank Terminate Speed” is too slow, the
engine will shut down. Use the Caterpillar Electronic
i02052174
Technician (ET) to check the programmed “Crank
Terminate” speed. Use Cat ET to adjust the “Crank
Terminate Speed”, if necessary.
Engine Shutdown without a
Diagnostic Code
Check the “Cycle Crank Time”
SMCS Code: 1400-035
The “Cycle Crank Time” is a parameter that can be
configured. This parameter determines the time for Probable Causes
engagement of the starting motor and the gas shutoff
valve during the crank cycle. If the engine does not • An external shutdown or a customer shutdown
start within the programmed “Cycle Crank Time”, was requested.
the attempt to start is suspended for an equal “Rest”
cycle. • The power supply becomes disconnected from the
engine control system.
If the “Cycle Crank Time” is insufficient, the “Engine
Overcrank Time” can elapse before the engine is • The Electronic Control Module (ECM) has lost the
able to start. supply voltage for the speed/timing sensor.

Use Cat ET to check the “Cycle Crank Time”. Use • There is a problem with the fuel supply.
Cat ET to increase the time, if necessary.
• A cylinder or cylinders are misfiring.
Check the “Engine Overcrank Time”
Recommended Repairs
The “Engine Overcrank Time” is a parameter that
can be configured. This parameter determines the
length of time for the crank cycle. If the engine does External Shutdown or Customer
not start within the programmed “Engine Overcrank Shutdown
time”, the attempt to start is terminated. An “E225 (3)
Engine Overcrank” event is generated. Check the ECM and the Integrated Temperature
Sensing Module (ITSM) for logged codes of events
If the “Cycle Crank Time” is insufficient, the “Engine that are shutdowns.
Overcrank Time” can elapse before the engine is
able to start. Power Supply to the Engine Control
System
Use Cat ET to check the “Engine Overcrank Time”.
Use Cat ET to increase the “Engine Overcrank Time”, 1. Refer to Troubleshooting, “Electrical Power
if necessary. Supply”.

Check the “Driven Equipment Delay 2. Inspect the ground strap and the power supply for
Time” connections that are loose and/or corroded.

The “Driven Equipment Delay Time” is a parameter 3. Inspect the electronic control modules and
that can be configured. The ECM provides a switch the terminal box for proper installation of the
input for the driven equipment in order to delay engine connectors.
start-up until the driven equipment is ready. The ECM
will not attempt to start the engine until the switch 4. Check the 35 amp circuit breaker on the power
input for the driven equipment closes to ground and distribution box. Check the wiring connections to
the prelubrication (if equipped) is complete. the 35 amp circuit breaker for proper installation.
49
Troubleshooting Section

Speed/Timing Sensor • Excessive load


A loss of supply voltage to the speed/timing sensor
will cause a shutdown. Refer to Troubleshooting,
Recommended Repairs
“Engine Speed/Timing Sensor”.
Fuel Supply
Fuel Supply Make sure that fuel is supplied at a sufficient pressure
that is stable. Make sure that the size of the fuel line
• Check the fuel supply pressure. is sufficient. Inspect the fuel system for leaks.
• Inspect the fuel lines for foreign objects and for The following conditions can cause the engine to
obstructions that can block the fuel supply.
malfunction:

Misfiring Cylinders • Low fuel pressure


For a shutdown that is due to misfiring cylinders, the • High fuel pressure
shutdown is likely to occur only when the engine is
operating under a load. • Poor fuel quality
The Caterpillar Electronic Technician (ET) and the Make sure that the fuel pressure is correct. When
ITSM can be used to detect a misfiring cylinder. Use possible, interview the operator in order to determine
the following procedure: if fuel quality is in question. Try to determine if the
source of the fuel was changed.
1. Use the “Data Link/Select ECM” screen on Cat
ET to select the ITSM. Inspect the fuel system components: fuel filter, gas
pressure regulator, gas shutoff valve, fuel metering
2. Select “Diagnostics/Diagnostic Tests”. valve, and actuator for the throttle. Verify that the
system’s components are operating correctly.
3. Select the suspect cylinder and click the “Start”
button in the lower left corner of the screen. Replace the fuel filter, if necessary.

Cat ET will display a graph of the cylinder’s Electrical Connectors or Power Supply
exhaust gas temperature. The transformer’s
secondary circuit, the engine speed, and the
1. Inspect the power supply connections and the
desired engine speed are also displayed. ground. Check the wiring harnesses and the
connectors from the power supply to the power
Locate the misfiring cylinder. Check the following
distribution box. Check the wiring harnesses
components for failure: spark plug, extender, ignition and the connectors from the power distribution
transformer, and primary wiring. Inspect the extender
box to the terminal box. Inspect the connectors
for signs of pin holes and/or arcing.
in the terminal box. Refer to Troubleshooting,
“Inspecting Electrical Connectors”.
Refer to Troubleshooting, “Ignition Transformers
Secondary Circuit and Spark Plugs”.
2. Use the Caterpillar Electronic Technician (ET) to
check for the 168-02 diagnostic code for “System
i01804883 Voltage intermittent/erratic”. If this diagnostic code
is logged, proceed to Troubleshooting, “Electrical
Engine Starts but Stalls Power Supply”.
Immediately
Engine Speed/Timing Sensor
SMCS Code: 1250-035; 1400-035
Make sure that the speed/timing sensor is
installed correctly. See Troubleshooting, “Engine
Probable Causes Speed/Timing Sensor”.
• Fuel supply Make sure that the timing wheel is correctly installed.
• Electrical connectors or power supply
• Engine speed/timing sensor
• Ignition system
50
Troubleshooting Section

Ignition System Map


Inspect the ignition transformers for the following Use the “Service/Configuration” screen of Cat ET
items: loose connections, moisture, short circuits, in order to verify the value that is programmed for
and open circuits. Inspect the primary wiring and the the timing. Check the “First Desired Timing”, the
secondary electrical connections. “Second Desired Timing”, and the “Desired Timing”
parameters. Refer to Troubleshooting, “Programming
Make sure that the correct transformers and spark Parameters”.
plugs are installed. Inspect the extenders for signs of
pin holes and of arcing. Timing Selection
Maintain the spark plug according to the engine’s Verify that the input for the selection of the base
Operation and Maintenance Manual. timing is correct. An open circuit between terminals
J1-20 and J1-31 selects the “First Desired Timing”.
Excessive Load A short circuit between terminals J1-20 and J1-31
selects the “Second Desired Timing”.
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment
i02052177
and test the engine.
Engine Will Not Crank
i01804902
SMCS Code: 1000-035; 1400-035
Engine Timing Does Not Match
Programmed Timing Probable Causes
SMCS Code: 1000-035; 1400-035 • Batteries and/or battery cables

Probable Causes • Starting circuit


• Starter motor pinion or flywheel ring gear
• The timing may be retarded due to detonation.
• Low air pressure
• The timing may be retarded due to the selection of
the map for speed or the map for load.
• Static load
• The input for the selection of the base timing may • Internal mechanical problem
be incorrect.

Recommended Repairs Recommended Repairs

Note: If the symptom only occurs under certain Batteries and/or Battery Cables
operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under 1. Inspect the main power switch, battery posts,
the conditions. Troubleshooting the symptom under and battery cables for loose connections and
other conditions can give misleading results. corrosion. If the battery cables are corroded,
remove the battery cables and clean the battery
cables. Tighten any loose connections.
Detonation
2. Inspect the batteries.
Use the Caterpillar Electronic Technician (ET)
to review the logged codes. Look for codes a. Charge the batteries. Refer to Special
“E401-1” through “E416-1”. Refer to the topic in
Instruction, SEHS7633, “Battery Test
Troubleshooting for the particular event code.
Procedure”.

b. Load test the batteries. Refer to Special


Instruction, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”.
51
Troubleshooting Section

Starting Circuit i02085826

Check the starting circuit. Refer to the schematic Exhaust Port Temperature
diagram in Troubleshooting, “ECM Output Circuit (High)
(Starting Motor)”.
SMCS Code: 1059-035
Starting Motor or Flywheel Ring Gear
If the pinion engages the flywheel but the flywheel
Probable Causes
does not turn, there may be a problem with the
starting motor. If the starting motor turns but the • High inlet air temperature
flywheel does not turn, inspect the gear teeth, the
clutch jaws, or other parts. • Inlet air restriction

Inspect the pinion and the flywheel ring gear for • Air/fuel ratio
damage. If the teeth of the pinion and/or of the
flywheel ring gear are worn or broken, replace the • Excessive load
parts.
• Incorrect base timing
If the pinion does not engage correctly with the
flywheel, the pinion shaft may be stuck. Remove the • Exhaust restriction
pinion. Grease the splines of the drive shaft and the
pinion. • A buildup of deposits in the cylinder or internal oil
leaks
If the pinion does not engage the flywheel, the clutch
jaws may be broken. Recommended Repairs
Before you remove the starting motor, turn the Check the Inlet Air Temperature
crankshaft by hand. Ensure that a mechanical failure
inside the engine is not preventing the crankshaft High inlet air temperature can cause detonation.
from turning. If the crankshaft will turn by hand, try Check the inlet air temperature.
the starting motor again. If the starting motor does not
turn the crankshaft, remove the starting motor. Repair Refer to Troubleshooting, “Inlet Air Temperature
the starting motor or replace the starting motor. (High)”.

Low Air Pressure Inlet Air Restriction


Determine the cause of the low air pressure. Inspect High inlet air restriction adversely affects engine
the air lines for leaks. Repair any leaks in the air lines. performance. Refer to the applicable Gas Engine
Technical Data Sheet for additional information.
Static Load
The maximum allowable inlet air restriction is
Make sure that the driven equipment is not 3.75 kPa (15 inches of H2O). If the indication is higher
preventing the crankshaft from turning. Try to turn than the maximum permissible restriction, clean the
the crankshaft by hand. If necessary, disengage the filter element or install a new filter element. Check
driven equipment and test the engine. the restriction again. If the restriction remains too
high, inspect the air inlet piping before the air cleaner
Internal Mechanical Problem for obstructions.

If the crankshaft will not turn and the driven Air/Fuel Ratio
equipment is disengaged, remove the spark plugs.
Check for fluid in the cylinders. If this is not the An air/fuel mixture that is too rich will increase
problem, the engine must be disassembled in order the exhaust temperature. Verify that the exhaust
to investigate internal mechanical problems. Possible emissions are correct. Refer to Systems
internal problems include the following conditions: Operation/Testing and Adjusting, “Air/Fuel Ratio
Control - Adjust”.
• Bearing seizure
A change in the fuel energy content will change the
• Piston seizure air/fuel ratio. Obtain a fuel analysis.

• Valve and piston contact The fuel supply pressure must be adequate and
stable.
52
Troubleshooting Section

Excessive Load • Active diagnostic code from the Integrated


Temperature Sensing Module (ITSM)
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment • A faulty thermocouple
and test the engine.
• Insufficient ignition
Check the Base Timing
• Low cylinder compression
Verify that the base timing is correct. Refer to
Systems Operation/Testing and Adjusting, “Ignition Recommended Repairs
Timing - Adjust”.
Check for Misfire
Measure the Exhaust Restriction
Operation with a low load can result in low exhaust
Measure the exhaust restriction during engine temperatures. Operate the engine at low idle or near
operation with a load. For data that is specific to the low idle in order to identify a misfire problem.
engine, refer to the Technical Marketing Information.
Troubleshoot the cause of the misfire. Refer to
Investigate the cause of the exhaust restriction. Troubleshooting, “Engine Misfires,Runs Rough or Is
Perform adjustments and/or make repairs, as Unstable”.
needed.
Check for Diagnostic Codes from the
Check for Deposits in the Cylinder and Integrated Temperature Sensing Module
Check for Internal Oil Leaks (ITSM)
Use a borescope to inspect the cylinders. Look for Use the Caterpillar Electronic Technician (ET)
the following conditions:
to check for diagnostic codes that relate to
the thermocouples for exhaust temperatures.
• Deposits on the valve seats Troubleshoot the code.
• Deposits on the valve faces
Check for Suspect Thermocouples
• Deposits on the cylinder walls that are above the
upper limit of the piston stroke Observe the temperatures from the thermocouples
after the engine is shut off.
• Signs of internal oil leaks
When the engine is operating properly, the
Other signs of internal oil leaks include high oil temperatures from similar locations are reduced at
consumption and blue smoke. a similar rate. Also, the temperatures from similar
locations are comparable.
Note: Excessive deposits contribute to guttering of
the valves. If any discrepancies are found, switch the suspect
thermocouple for another thermocouple. If the
If excessive deposits and/or signs of internal oil leaks temperature problem follows the thermocouple,
are found, investigate the cause of the condition. replace the thermocouple.
Make repairs, as needed.
If the temperature problem stays at the original
location of the suspect thermocouple, investigate the
i01727687 cause for the low temperature.
Exhaust Port Temperature Check for Insufficient Ignition
(Low)
Use Cat ET to check for logged diagnostic codes that
SMCS Code: 1059-035 relate to the ignition system. Troubleshoot the code.
Refer to Troubleshooting, “Ignition Transformers
Probable Causes Primary Circuit”.

• Operation with a light load


53
Troubleshooting Section

If no logged diagnostic codes are present for Recommended Repairs


the suspect cylinder, inspect the components
of the ignition system for the cylinder. Refer to Check the Operating Voltage for the Fuel
Troubleshooting, “Ignition Transformers Secondary
Circuit and Spark Plugs”. Metering Valve
Check the operating voltage for the fuel metering
Check the Cylinder Compression valve. Refer to Troubleshooting, “Electrical Power
Supply”.
Measure the cylinder pressures of the suspect bank
in order to check for problems that are related to Make repairs, as needed.
compression.

If low compression is found, investigate the cause of Check the Fuel Metering Valve
the low compression. Make repairs, as needed.
Shut OFF the fuel supply. Disconnect the fuel lines
from the fuel metering valve. Visually inspect the
i01804917 internal mechanism of the valve. Check for binding
due to dirt and/or contamination. Check for binding
Fuel Energy Content due to wear of internal components.

SMCS Code: 1250-035 Clean the valve, if necessary. If the valve is binding
due to wear of internal components, refer to the
Probable Causes literature that is provided by the OEM of the valve.

• The Low Heat Value (LHV) of the gas or the specific i01727704
gravity of the gas is significantly different from the
value that is programmed into the electronic control Fuel Pressure
module.
SMCS Code: 1250-035
• Condensation is forming in the gas.
Probable Causes
Recommended Repairs
• Incorrect setting of the gas pressure regulator
Obtain a Fuel Analysis and Program the
“Fuel Quality” Parameter • Faulty gas pressure regulator

Obtain an analysis of the gas in order to determine Recommended Repairs


the LHV. Program the “Fuel Quality” parameter to the
actual value of the LHV. Check the Gas Pressure Regulator
If the quality of the gas is not consistent, obtain Use the Caterpillar Electronic Technician (ET) to
several analyses over a period of time. Program the observe the absolute fuel pressure and the fuel
“Fuel Quality” parameter to the average value of the differential pressure. The fuel metering valve requires
LHV. a gas supply that is regulated to a pressure between
10 to 35 kPa (1.5 to 5 psi).
Check the Dryer for the Gas
If the fuel pressure is not within the acceptable range,
Check the dryer for the gas for proper operation. adjust the gas pressure regulator in order to achieve
Repair the dryer, if necessary. the correct pressure. Verify that the emissions are
within specifications.
i01804920
If the gas pressure regulator cannot be adjusted to
Fuel Metering Valve the correct setting, repair the regulator or replace the
regulator.
SMCS Code: 1274-035

Probable Causes
• Low operating voltage for the fuel metering valve
• Internal binding of the fuel metering valve
54
Troubleshooting Section

i01369481 Recommended repairs


Gas Fuel Differential Pressure Check the Installation of the Fuel
(High) Metering Valve
SMCS Code: 1250-035 An “E864 Low Gas Fuel Differential Pressure” event
will be generated if the fuel metering valve is installed
Probable Causes backward. Ensure that the fuel metering valve is
installed properly.
• Excessive fuel supply pressure
Check the Gas Pressure Regulator
• Leaks in the piping after the fuel metering valve
The fuel metering valve requires a minimum pressure
Recommended Repairs of 10 kPa (1.5 psi) for the gas supply. Check the
outlet pressure from the gas pressure regulator.
Check the Fuel Supply Pressure Adjust the gas pressure regulator in order to achieve
the correct pressure.
Check the pressure of the fuel supply to the fuel
metering valve for high pressure. The maximum If the gas pressure regulator cannot be adjusted to
allowable pressure to the fuel metering valve is the correct setting, repair the regulator or replace the
35 kPa (5 psi). regulator.
Adjust the gas pressure regulator in order to achieve
the correct pressure. Check the Fuel Supply for Obstructions

If the gas pressure regulator cannot be adjusted to Check the fuel filter for restriction. Replace the fuel
the correct setting, repair the regulator or replace the filter, if necessary.
regulator.
Inspect the screen inside the inlet of the fuel metering
valve for cleanliness. Clean the screen, if necessary.
Check for Leaks
Inspect the fuel supply lines to the fuel metering valve
Use a gas detector to check for leaks in the piping for obstructions. Clean the lines and make repairs,
between the outlet of the fuel metering valve and the as needed.
turbocharger compressor.
Check the Gas Shutoff Valve (GSOV) for proper
Repair the piping, if necessary. operation. Verify that the valve is fully open when the
valve is energized. Verify that the GSOV does not
i01804929 stick in a partially open position. Repair the GSOV.
Replace the GSOV, if necessary.
Gas Fuel Differential Pressure
(Low) Check the Fuel Outlet for Obstructions

SMCS Code: 1250-035 Inspect the piping for obstructions between the fuel
metering valve and the inlet to the turbocharger
compressor.
Probable Causes
Clean the piping and make repairs, as needed.
• Improper installation of the fuel metering valve
• Low fuel supply pressure i01727721

• Obstructed fuel supply Gas Fuel Flow Rate (Low)


SMCS Code: 1250-035
• Obstructed fuel outlet
Probable Causes
• High fuel temperature
55
Troubleshooting Section

• Faulty gas pressure regulator or low fuel supply Check the Gas Shutoff Valve (GSOV) for proper
pressure operation. Verify that the valve is fully open when the
valve is energized. Verify that the GSOV does not
• Obstructions in the fuel supply stick in a partially open position. Repair the GSOV.
Replace the GSOV, if necessary.
• Inadequate fuel energy content or moisture in the
gas Obtain a Fuel Analysis

Recommended Repairs If the fuel energy content is too low, the fuel metering
valve could demand an excessive supply of fuel.
Check the Fuel Temperature
Check Cat ET for a “E230 (1) Fuel Energy Content
Setting High” event code. If the code is present, refer
Measure the temperature of the gas that is entering
the fuel metering valve. Compare the measurement to Troubleshooting, “Fuel Energy Content”.
to the reading for the fuel temperature on the
Obtain an analysis of the gas in order to determine
Caterpillar Electronic Technician (ET). Check Cat ET
for a “E223 High Gas Temperature” event code. the LHV. Program the Fuel Energy Content to the
actual value of the LHV.
If the temperature on Cat ET is different, determine
the reason for the faulty signal from the fuel metering If the quality of the gas is not consistent, obtain
several analyses over a period of time. Program the
valve.
Fuel Energy Content to the average value of the LHV.
If the fuel temperature is high, determine the cause of
the high fuel temperature. Check for proper operation Check the Dryer for the Gas
of the equipment that treats the gas prior to the
engine. Check the dryer for the gas for proper operation.
Repair the dryer, if necessary.
If there is an active “E223 High Gas Temperature”
event code, refer to Troubleshooting, “Gas
i01727732
Temperature (High)”.
Gas Temperature (High)
Make repairs, as needed.
SMCS Code: 1250-035
Check the Gas Pressure Regulator
Check the outlet pressure from the gas pressure
Probable Causes
regulator. The fuel metering valve requires a minimum
pressure of 10 kPa (1.5 psi) for the gas supply.
• The temperature of the gas is too high.

If the pressure of the gas supply is too low, adjust


• The fuel metering valve has sent faulty data to the
electronic control module.
the gas pressure regulator in order to achieve the
correct pressure.
Recommended Repairs
If the gas pressure regulator cannot be adjusted to
the correct setting, repair the regulator or replace the Investigate the Cause of the High
regulator. Temperature
Check the Fuel Supply for Obstructions Check for proper operation of the equipment that
treats the gas prior to the engine.
Check the fuel filter for restriction. Replace the fuel
filter, if necessary. If a problem is found for the equipment that treats
the gas prior to the engine, repair the equipment, as
Inspect the screen inside the inlet of the fuel metering needed.
valve for cleanliness. Clean the screen, if necessary.
Check the Data from the Fuel Metering
Inspect the fuel supply lines to the fuel metering valve
for obstructions. Clean the lines and make repairs, Valve
as needed.
Measure the temperature of the gas that is entering
the fuel metering valve. Compare the measurement
to the reading for the temperature on the Caterpillar
Electronic Technician (ET).
56
Troubleshooting Section

If the measurement for the temperature is significantly • There is a problem with the wiring between the
different from the reading on Cat ET, determine the power sensor and the ECM.
reason for the faulty data from the fuel metering
valve. Make repairs, as needed. • There is an incorrect value for one or more of the
parameters for the fuel.
i02064482
• The offset voltage at the input to the ECM from the
Generator Output Power power sensor is too high.

Readings Do Not Match • There is an incorrect value for one or more of the
“Power Monitoring” parameters.
SMCS Code: 5574-035-PWR
Read the rest of this procedure before you adjust the
The Electronic Control Module (ECM) monitors the “Power Monitoring” parameters.
generator’s output power in order to accurately
control the air/fuel ratio. The ECM uses an output
from one of the following sources in order to monitor
Recommended Repairs
the generator’s output power:
Generators that are Equipped with EMCP
• Electronic Modular Control Panel II+ (EMCP II+) II+
• Programmable Logic Controller (PLC) Verify that the transformers and the ATB+ are
operating correctly. Refer to the appropriate service
• Wattmeter literature for the EMCP II+.

The PLC and the wattmeter are also called power Verify that the values for the “Air/Fuel Ratio Control”
sensors. configuration parameters are correct. Refer to
Troubleshooting, “Electronic Control System
Probable Causes Parameters”.

The following probable causes apply if the generator Verify that the values for the “Power Monitoring”
is equipped with the EMCP II+: configuration parameters are correct. Refer to
Troubleshooting, “Electronic Control System
Parameters”.
• There is an incorrect calibration value for the AC
Transformer Box + (ATB+).
Generators that are Equipped with a
• A potential transformer in the ATB+ is faulty. Power Sensor
• A current transformer in the ATB+ is faulty. Verify that the transformers for the power sensor are
operating correctly. Refer to the service literature for
• The ATB+ is faulty. the power sensor.

• There is an incorrect value for one or more of the Verify that the power sensor is operating correctly.
parameters for the fuel. Refer to the service literature for the power sensor.

• There is an incorrect value for one or more of the Verify that the values for the “Air/Fuel Ratio Control”
“Power Monitoring” parameters. configuration parameters are correct. Refer to
Troubleshooting, “Electronic Control System
The following probable causes apply if the generator Parameters”.
is equipped with a power sensor:
Check the wiring between the power sensor and
• There is a faulty potential transformer for the power the ECM for corrosion and for pinch points. Refer to
sensor. Troubleshooting, “Inspecting Electrical Connectors”.

• There is a faulty current transformer for the power The ECM must receive an accurate voltage from the
sensor. power sensor. If the voltage is not accurate, the ECM
may not accurately control the air/fuel ratio. When the
• The power sensor is faulty. generator’s output is zero, the voltage from the power
sensor must be less than 0.01 VDC. This voltage is
called the offset voltage.
57
Troubleshooting Section

Use the following procedure in order to determine if Determine the cause of the high air temperature.
the offset voltage is too high. Perform this procedure Make corrections, when possible.
before you adjust the “Power Monitoring” parameters.
Coolant Temperature
Note: This measurement must be taken at the ECM
P1 connector. The engine must be stopped. Refer to Troubleshooting, “Engine Coolant
Temperature (High)”.
1. If the engine is running, stop the engine.

2. Insert 7X-1710 Multimeter Probes into terminals


Check for High Inlet Air Restriction
P1-19 and P1-25. Connect a digital voltmeter to and/or High Altitude
the probes. The polarity of the connections is not
important. When inlet air pressure is low, the turbocharger works
harder in order to achieve the desired inlet manifold
3. Verify that the probes are making good contact pressure. This increases inlet air temperature.
with the terminals inside the connector. Measure
the DC voltage at the terminals. Measure the inlet air pressure while the engine is
operating under load. For specific data, refer to the
The voltage is acceptable if the voltage is less Technical Marketing Information for the engine.
than ±0.01 VDC.
Inlet Air Restriction
If the voltage is less than ±0.01 VDC, the values
for the “Power Monitoring” parameters may be Check for plugged air filters. Check for obstructions
incorrect. Refer to Systems Operation/Testing to the air inlet.
and Adjusting, “Electronic Control System
Parameters”. Replace the air filters and/or remove the obstruction
from the air inlet.
If the voltage is greater than ±0.01 VDC, the circuit
between the power sensor and the ECM must be High Altitude
calibrated. Refer to Troubleshooting, “Generator
Output Power Sensor - Calibration”. Make sure that the settings for the engine are correct
for the altitude.

i01623042
Check the Temperature Sensor and/or
Inlet Air Temperature (High) the Circuit
SMCS Code: 1087-035 Allow the sensor to cool and remove the sensor.
Check the reading for the inlet air temperature.
If the sensor is OK, the reading and the ambient
Probable Causes temperature are approximately equal.
• High ambient air temperature If the reading is not correct, switch the sensor with
a sensor that is known to be good. Verify that the
• High coolant temperature problem is solved.
• High inlet air restriction and/or high altitude
Check for Sufficient Flow of Cooling
• Faulty inlet air temperature sensor and/or circuit Water Through the Aftercooler
• Insufficient flow of cooling water through the Check the inlet temperature of the coolant for the
aftercooler aftercooler. Compare the reading to the regulated
temperature. If the temperature is OK, check the
• Insufficient flow of air through the aftercooler outlet temperature of the coolant. A high temperature
differential indicates an insufficient flow rate.
Recommended Repairs If there is a high differential between the inlet
temperature and the outlet temperature of the coolant
High Ambient Air Temperature for the aftercooler, perform the following procedures:
Determine if the ambient air temperature is within the
design specifications for the cooling system.
• Check the water circuit of the aftercooler for
obstructions.

• Check the pump for proper operation.


58
Troubleshooting Section

• Make repairs, if necessary. 2. Use Cat ET to check for the 168-02 diagnostic
code for “System Voltage Intermittent”. If
Check for Sufficient Flow of Air Through this diagnostic code is logged, proceed to
Troubleshooting, “Electrical Power Supply”.
the Aftercooler
3. Inspect the wiring from the power supply to
Determine the pressure differential of the inlet air
the power distribution box. Inspect the wiring
across the aftercooler. For specific data, refer to the
from the power distribution box to the electronic
Technical Marketing Information for the engine. control modules. Check the power and ground
connections at each electronic control module.
If the pressure differential of the air across the
Refer to Troubleshooting, “Electrical Power
aftercooler does not match the specifications, clean Supply” for more information.
the aftercooler.
Circuit Breakers
i01804935
Check the 35 amp circuit breaker on the power
Intermittent Engine Shutdown distribution box. The circuit breaker may exceed
the trip point due to overheating. Reset the circuit
SMCS Code: 1400-035 breaker if the circuit breaker is tripped.
Note: Use this procedure only if the engine shuts
down completely and the engine must be restarted. Engine Speed/Timing Signal
Loss of the signal from the speed/timing sensor will
Probable Causes cause a shutdown. Use Cat ET to check for logged
diagnostic codes. For more information, refer to
• Active engine shutdown Troubleshooting, “Engine Speed/Timing Sensor”.

• Electrical connectors Fuel Supply


• Circuit breaker 1. Check the fuel lines for the following problems:
restrictions, obstructions, collapsed lines, and
• Engine speed/timing signal pinched lines. If problems are found with the fuel
lines, repair the lines and/or replace the lines.
• Fuel supply
2. Check the restriction of the fuel filter. If the fuel
• Spark plug pressure is low, replace the fuel filter.

Recommended Repairs 3. Check the fuel quality.

Active Engine Shutdown 4. Check the fuel pressure. Refer to Systems


Operation/Testing and Adjusting, “Fuel System”
Use the Caterpillar Electronic Technician (ET) to for the correct pressure values. If the fuel pressure
check for any active engine shutdowns and/or logged is still low, check the gas regulator and the fuel
engine shutdowns. Determine the reason for the metering valve.
shutdown. After correcting the problem, set the
engine control to the OFF/RESET mode for at least Spark Plug
15 seconds before you try to restart the engine.
An engine shutdown that is due to a faulty spark
Electrical Connectors plug is likely to occur when the engine is operating
under a load. Refer to Troubleshooting, “Ignition
1. Check the wiring harnesses and the connectors. Transformers Secondary Circuit and Spark Plugs”.
Inspect the connectors in the terminal boxes.
Inspect the power supply connections and the
ground. Refer to Troubleshooting, “Inspecting
Electrical Connectors”.
59
Troubleshooting Section

i01368495 i01727750

Jacket Water Inlet Pressure Jacket Water Pressure (Low)


(High) SMCS Code: 1350-035
SMCS Code: 1350-035
Probable Causes
Probable Causes • Low coolant level
• The circuit for the engine coolant pump pressure • Insufficient flow of coolant
switch (inlet) is OPEN.

• The pressure at the inlet for the jacket water is Recommended Repairs
excessive.
Check the Coolant Level and Inspect the
Recommended Repairs Cooling System for Leaks

Check the Circuit for the Engine Coolant Check coolant level. If the coolant level is low, inspect
the cooling system for leaks.
Pump Pressure Switch (Inlet)
If the coolant level is low, fill the cooling system. If
The circuit for the switch must remain closed in order leaks are found, make the necessary repairs.
to avoid an “E224 High Jacket Water Inlet Pressure”
event. Check wiring for damage or corrosion. Refer to
Troubleshooting, “Inspecting Electrical Connectors”. Check the Flow of Coolant

If a problem with the wiring for the circuit is found, Use the Caterpillar Electronic Technician (ET) to
repair the wiring, as needed. observe the pressure at the jacket water outlet with
the engine OFF. Then observe the reading during
engine operation.
Check the Inlet Pressure of the Jacket
Water If the reading is not reasonable or if the reading is
not within specifications, install a pressure gauge
The engine coolant pump pressure switch (inlet) near the pressure sensor at the jacket water outlet.
is designed to open across pin B and pin C at a Compare the gauge reading with the reading from
pressure of 462 ± 41 kPa (67 ± 6 psi). Use a gauge Cat ET.
to check the pressure at the inlet for the jacket water.
If the readings from the comparative gauge do not
If the pressure is less than 462 ± 41 kPa (67 ± 6 psi) agree approximately with Cat ET, troubleshoot the
but the event code “E224 High Jacket Water Inlet circuit for the pressure sensor at the jacket water
Pressure” is occurring, replace the pressure switch at outlet. Refer to Troubleshooting, “PWM Sensor”.
the inlet for the jacket water.
If the readings from the comparative gauge agree
If a pressure of at least 462 ± 41 kPa (67 ± 6 psi) is approximately with Cat ET, check the following
measured at the inlet for the jacket water, the high components:
pressure may be caused by a restriction in the jacket
water system. Inspect the system for restrictions. • Check the water temperature regulators for proper
Make repairs, as needed. operation.

Note: If the outlet pressure of the coolant is greater • Check for plugging of the radiator or the heat
than approximately 444 kPa (64 psi), a 109-08 exchanger.
diagnostic code will be generated. The “Engine
Coolant Outlet Pressure Sensor noisy signal” • Inspect the jacket water pump for damage to the
diagnostic will be generated although there is no impeller.
malfunction in the electrical circuit. If this code is
generated, verify the actual outlet pressure of the Make the necessary repairs.
coolant with a pressure gauge. If the actual pressure
is greater than approximately 444 kPa (64 psi),
reduce the pressure. This will prevent a false 109-08
from being logged.
60
Troubleshooting Section

i01866678 Check the Temperature Sensors and/or


Jacket Water to Engine Oil Circuits
Differential Temperature (Low) Use a separate device to measure the temperatures
of the engine oil and the engine coolant. Compare the
SMCS Code: 1350-035 measured temperatures to the readings on Cat ET.

Probable Causes If one or both of the readings are incorrect,


troubleshoot the circuit(s). Refer to Troubleshooting,
“Analog Sensor Signal”.
• High engine oil temperature or low engine coolant
temperature
Check the Water Temperature Regulators
• Faulty temperature sensor and/or circuit
The water temperature regulators should not begin to
• Faulty water temperature regulators open until jacket water reaches opening temperature
for the regulators. Allow the engine to cool and then
start the engine. Check the tube at the outlet for the
Recommended Repairs jacket water. If the tube is warm and normal operating
temperature is not achieved yet, a regulator may be
Check for Event Codes for the Engine Oil stuck open.
and for the Engine Coolant
Check the water temperature regulators according to
Use the Caterpillar Electronic Technician (ET) to Systems Operation/Testing and Adjusting, “Testing
check for the following event codes: the Cooling System”. Replace the water temperature
regulators, if necessary.
• E019 (3) High Engine Oil Temperature (shutdown)
i01368006
• E020 (1) High Engine Oil Temperature (warning)
System Voltage
• E038 (1) Low Engine Coolant Temperature
(warning) SMCS Code: 1400-035

• E337 (1) Hign Engine Oil to Engine Coolant Diff Probable Causes
Temp (warning)
There is a problem with the electrical system.
• E337 (3) High Engine Oil to Engine Coolant Diff
Temp (shutdown)
Recommended Repairs
If one or more of the codes is active, troubleshoot
the code. Refer to Troubleshooting, “Troubleshooting Troubleshoot the electrical system. Refer to
with an Event Code”. Troubleshooting, “Electrical Power Supply”.

Check the Engine Oil Temperature and i02064382


the Engine Coolant Temperature
Turbocharger Turbine
Use the Caterpillar Electronic Technician (ET) to
check the temperature of the engine oil and the
Temperature (High)
engine coolant.
SMCS Code: 1052-035
If the engine oil temperature is high, refer to
Troubleshooting, “Engine Oil Temperature (High)”. Probable Causes
If the temperature of the engine coolant is low, refer • High inlet manifold temperature
to Troubleshooting, “Engine Coolant Temperature
(Low)”. • Incorrect base timing
• Exhaust restriction
• A buildup of deposits in the cylinder or internal oil
leaks
61
Troubleshooting Section

Recommended Repairs i01804955

Check for Event Codes for High Inlet


Turbocharger Turbine
Manifold Air Temperature Temperature (Low)
Use the Caterpillar Electronic Technician (ET) to SMCS Code: 1052-035
check for the following event codes:
Probable Causes
• E026 (3) High Inlet Air Temperature (shutdown)
• Operation with a light load
• E027 (1) High Inlet Air Temperature (warning)
• Diagnostic code from the Integrated Temperature
If one or more of the codes is active, refer to Sensing Module (ITSM)
Troubleshooting, “Inlet Air Temperature (High)”.
• Low temperature from the cylinder exhaust ports
Check the Base Timing
• A faulty temperature sensor
Verify that the base timing is correct. Refer to
Systems Operation/Testing and Adjusting, “Ignition • Faulty ignition
Timing - Adjust”.
• Low cylinder compression
Measure the Exhaust Restriction
Recommended Repairs
Measure the exhaust restriction during engine
operation with a load. For data that is specific to the Check for Misfire
engine, refer to the Technical Marketing Information.
Operation with a low load can result in low exhaust
Investigate the cause of the exhaust restriction. temperatures. Operate the engine at low idle or near
Perform adjustments and/or make repairs, as low idle in order to identify a misfire problem.
needed.
Troubleshoot the cause of the misfire. Refer to
Check for Deposits in the Cylinder and Troubleshooting, “Engine Misfires, Runs Rough or
Check for Internal Oil Leaks Is Unstable”.

Use a borescope to inspect the cylinders. Look for Check for Diagnostic Codes from the
the following conditions: Integrated Temperature Sensing Module
• Deposits on the valve seats (ITSM)
Use the Caterpillar Electronic Technician (ET)
• Deposits on the valve faces to check for diagnostic codes that relate to the
thermocouples. Troubleshoot the code.
• Deposits on the cylinder walls that are above the
upper limit of the piston stroke
Check the Temperatures of the Cylinder
• Signs of internal oil leaks Exhaust Ports
Other signs of internal oil leaks include high oil Observe the temperatures for the exhaust ports of
consumption and blue smoke. the cylinders in the suspect bank.

Note: Excessive deposits contribute to guttering of If any of the temperatures for the exhaust ports are
the valves. significantly different, determine the reason for the
difference in the exhaust port temperatures. Make
If excessive deposits and/or signs of internal oil leaks repairs, as needed.
are found, investigate the cause of the condition.
Make repairs, as needed. Check for Suspect Thermocouples
Observe the temperatures from the thermocouples
for the turbocharger(s) after the engine is shut off.
62
Troubleshooting Section

When the engine is operating properly, the


temperatures from similar locations are reduced at
a similar rate. Also, the temperatures from similar
locations are comparable.

If any discrepancies are found, switch the suspect


thermocouple for another thermocouple. If the
temperature problem follows the thermocouple,
replace the thermocouple.

If the temperature problem stays at the original


location of the thermocouple, investigate the cause
for the low temperature.

Check for Diagnostic Codes that Relate


to Ignition
Use Cat ET to check for diagnostic codes that relate
to the ignition system. Troubleshoot the code.

Check the Ignition System


Inspect the components of the ignition system for
the suspect cylinder bank. Refer to Troubleshooting,
“Ignition Transformers Secondary Circuit and Spark
Plugs”.

Make repairs, as needed.

Check the Cylinder Compression


Measure the cylinder pressures of the suspect bank
in order to check for problems that are related to
compression.

If low compression is found, investigate the cause of


the low compression. Make repairs, as needed.
63
Troubleshooting Section

Troubleshooting with a Table 8

Diagnostic Code Failure Mode Identifiers


FMI Description of Failure
00 “Data valid but above normal operating
i02053325
range”
Diagnostic Codes 01 “Data valid but below normal operating
range”
SMCS Code: 1901-038
02 “Data erratic, intermittent or incorrect”
Diagnostic codes alert the operator that a problem in 03 “Voltage above normal or shorted high”
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to 04 “Voltage below normal or shorted low”
the service technician. The Caterpillar Electronic 05 “Current below normal or open circuit”
Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic 06 “Current above normal or grounded
codes may be viewed on a personal computer that circuit”
has Cat ET software. Diagnostic codes consist of 07 “Mechanical system not responding
the module identifier (MID), the component identifier properly”
(CID), and the failure mode identifier (FMI).
08 “Abnormal frequency, pulse, or period”
Module Identifier (MID) – The MID is a code with 09 “Abnormal update”
two or three digits that indicates the electronic module
which generated the diagnostic code. The MID for the 10 “Abnormal rate of change”
Electronic Control Module (ECM) is 36. The MID for 11 “Failure mode not identifiable”
the Integrated Temperature Sensing Module (ITSM)
is 111. Some electronic displays do not display the 12 “Bad device or component”
MID because the module which generates the code 13 “Out of calibration”
is obvious.
14 “Not used”
Component Identifier (CID) – The CID is a number 15 “Not used”
with three or four digits. The CID indicates the
component that generated the code. For example, 16 “Parameter not available”
the CID number 0017 identifies the fuel shutoff valve. 17 “Module not responding”

Failure Mode Identifier (FMI) – The FMI is a two 18 “Sensor supply fault”
digit code that indicates the type of failure. Table 8 is 19 “Condition not met”
a list of the failure mode identifiers that are adapted
from the “SAE J1587” standard. 20 “Not used”

Note: Do not confuse diagnostic codes with


event codes. For information on event codes, see
Troubleshooting, “Troubleshooting with an Event
Code”.

Illustration 19 represents the operating range of an


oil temperature sensor. The diagram is a reference.
Do not use the diagram to troubleshoot the oil
temperature sensor.
64
Troubleshooting Section

This information is a valuable indicator for


troubleshooting intermittent problems.

A code is cleared from memory when one of the


following conditions occur:

• The service technician manually clears the code.


• The code does not recur for 1000 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.

Some diagnostic codes may be easily triggered.


Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the failure
of an electronic module. Diagnostic codes that are
Illustration 19
g00791619 logged repeatedly may indicate a problem that needs
Typical operating range of an oil temperature sensor
special investigation.
(1) In these areas, the output voltage of the sensor is too high
or too low. The output is outside of the normal range. The
Note: Always clear logged diagnostic codes after
electronic problem will generate a diagnostic code. investigating and correcting the problem which
(2) In this area, the oil temperature above 102 °C (216 °F) is generated the code.
higher than the normal range. The output voltage of the sensor
will generate an event code for a warning, a derating, or a
shutdown for high oil temperature. The sensor does not have i02053694
an electronic problem.
(3) This area represents the normal operating temperature for the
engine oil. The normal output voltage of the sensor is between
MID 036 - CID 0017 - FMI 05
0.2 and 4.1 volts. Fuel Shutoff Valve open circuit
Active Diagnostic Codes SMCS Code: 1259-038

An active diagnostic code represents a problem with Conditions Which Generate This Code:
the electronic control system. Correct the problem
as soon as possible. The Electronic Control Module (ECM) has detected
a positive voltage source on the output for the fuel
When an active diagnostic code is generated, the shutoff valve. The most likely cause is one of the
“Active Alarm” indicator (“Engine Control Alarm following conditions:
Status” on Cat ET) is activated in order to alert the
operator. If the condition that generated the code • The wiring harness has an open circuit.
is momentary, the message disappears from the
list of active diagnostic codes. The diagnostic code • The fuel control relay has an open coil.
becomes logged.
• There is a short circuit to the +Battery in the wiring
for the fuel control relay.
Logged Diagnostic Codes
Note: This code cannot be detected by the ECM
When an ECM generates a diagnostic code, the ECM when the output for the fuel control relay is ON.
logs the code in permanent memory. Each ECM has The output is normally ON when the engine control
an internal diagnostic clock. Each ECM will record switch is in the START position and the engine rpm
the following information when a code is generated: is greater than zero.

• The hour of the first occurrence of the code System Response:

• The hour of the last occurrence of the code No fuel is provided to the engine. The alarm output is
activated. The code is logged.
• The number of occurrences of the code
65
Troubleshooting Section

Possible Performance Effect: i01741131

The engine will not start due to the lack of fuel. MID 036 - CID 0017 - FMI 12
Fuel Shutoff Valve malfunction
Troubleshooting:
SMCS Code: 1259-038
Perform the following diagnostic procedure: “ECM
Output Circuit (Fuel Control)” Conditions Which Generate This Code:
Results: The driver in the Electronic Control Module (ECM) for
the gas shutoff valve is OFF but the engine still runs.
• OK – STOP.
System Response:
i01727848
The ECM will disable the ignition system and the gas
MID 036 - CID 0017 - FMI 06 shutoff valve in order to shut down the engine. The
shutdown output is activated. The code is logged.
Fuel Shutoff Valve short to
ground Possible Performance Effect:

SMCS Code: 1259-038 The engine is shut down.

Conditions Which Generate This Code: Troubleshooting:

• The output for the fuel control relay is ON. Perform the following diagnostic procedure: “ECM
Output Circuit (Fuel Control)”
• The Electronic Control Module (ECM) detects
excessive current on the output for the fuel control Results:
relay.
• OK – STOP.
Note: This condition cannot be detected by the ECM
when the output for the fuel control relay is OFF.
i01727944
The output is normally OFF when the engine control
switch is in the OFF/RESET position. MID 036 - CID 0041 - FMI 03 8
System Response: Volt DC Supply short to +batt
The ECM will continue attempting to energize the SMCS Code: 5574-038
relay. The engine may shut down due to a lack of fuel.
The alarm output is activated. The code is logged. Conditions Which Generate This Code:

Possible Performance Effect: The voltage supply from the Electronic Control
Module (ECM) to one of the following sensors has
The engine will not start due to the lack of fuel. exceeded the normal range.

Troubleshooting: • Detonation sensors

The condition is probably caused by a short circuit in • Sensor for inlet manifold air pressure
the harness or by an internal short circuit in the fuel
control relay. • Sensor for engine coolant pressure

Perform the following diagnostic procedure: “ECM System Response:


Output Circuit (Fuel Control)”
Default values are assumed for the inputs to the
Results: ECM from all of the 8 volt analog sensors. All of the
diagnostic codes for the 8 volt analog sensors to the
• OK – STOP. ECM are disabled while this code is active.

The fuel is shut off. The shutdown output is activated.


The code is logged.
66
Troubleshooting Section

Possible Performance Effect: i01728439

Since the engine protection is disabled, the engine is MID 036 - CID 0100 - FMI
shut down. 03 Engine Oil Pressure
Troubleshooting: open/short to +batt
Perform the following diagnostic procedure: “+8V SMCS Code: 1924-038
Sensor Voltage Supply”
Conditions Which Generate This Code:
Results:
The signal from the filtered oil pressure sensor to the
• OK – STOP. Electronic Control Module (ECM) is greater than 4.8
VDC for at least five seconds.

i01727976 Additionally, neither of the following diagnostic codes


are active:
MID 036 - CID 0041 - FMI 04 8
Volt DC Supply short to ground • 262 - 03 5 Volt Sensor DC Power Supply short to
+batt
SMCS Code: 5574-038
• 262 - 04 5 Volt Sensor DC Power Supply short to
Conditions Which Generate This Code: ground

The voltage supply from the Electronic Control System Response:


Module (ECM) to one of the following sensors is
below the normal range. The ECM assumes the last valid value for the engine
oil pressure. The monitoring of the oil pressure is
• Detonation sensors disabled. This disables the engine protection for low
oil pressure and excessive oil pressure.
• Sensor for inlet manifold air pressure
The fuel is shut off. The shutdown output is activated.
• Sensor for engine coolant pressure The code is logged.

System Response: Possible Performance Effect:

Default values are assumed for the inputs to the Since the engine protection is disabled, the engine is
ECM from all of the 8 volt analog sensors. All of the shut down.
diagnostic codes for the 8 volt analog sensors to the
ECM are disabled while this code is active. Troubleshooting:

The fuel is shut off. The shutdown output is activated. This condition indicates an open circuit or a short
The code is logged. circuit to a positive voltage source.

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


Sensor Signal”
Since the engine protection is disabled,the engine is
shut down. Results:

Troubleshooting: • OK – STOP.
Perform the following diagnostic procedure: “+8V
Sensor Voltage Supply”

Results:

• OK – STOP.
67
Troubleshooting Section

i01728444 Additionally, neither of the following diagnostic codes


are active:
MID 036 - CID 0100 - FMI 04
Engine Oil Pressure short to • 41 - 03 8 Volt DC Supply short to +batt
ground • 41 - 04 8 Volt DC Supply short to ground
SMCS Code: 1924-038 System Response:
Conditions Which Generate This Code: The fuel is shut off. The shutdown output is activated.
The code is logged.
The signal from the filtered oil pressure sensor to the
Electronic Control Module (ECM) is less than 0.2 Possible Performance Effect:
VDC for at least five seconds.
The engine is shut down.
Additionally, neither of the following diagnostic codes
are active: Troubleshooting:

• 262 - 03 5 Volt Sensor DC Power Supply short to This condition indicates a possible open circuit or a
+batt possible short circuit.

• 262 - 04 5 Volt Sensor DC Power Supply short to Perform the following diagnostic procedure: “PWM
ground Sensor”
System Response: Results:

The ECM assumes the last valid value for the engine • OK – STOP.
oil pressure. The monitoring of the oil pressure is
disabled. This disables the engine protection for low
oil pressure and excessive oil pressure. i01636377

The fuel is shut off. The shutdown output is activated.


MID 036 - CID 0106 - FMI 08 Air
The code is logged. Inlet Pressure Sensor noisy
Possible Performance Effect: signal
Since the engine protection is disabled, the engine is SMCS Code: 5574-038-PX
shut down.
Conditions Which Generate This Code:
Troubleshooting:
The duty cycle or the frequency for the inlet manifold
Perform the following diagnostic procedure: “Analog pressure sensor is out of range.
Sensor Signal”
Additionally, neither of the following diagnostic codes
Results: are active:

• OK – STOP. • 41 - 03 8 Volt DC Supply short to +batt


• 41 - 04 8 Volt DC Supply short to ground
i01780399
System Response:
MID 036 - CID 0106 - FMI 03 Air
Inlet Pressure Sensor short to The fuel is shut off. The shutdown output is activated.
The code is logged.
+batt
Possible Performance Effect:
SMCS Code: 5574-038-PX
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting:
The duty cycle for the inlet manifold pressure sensor
is greater than the maximum value. Perform the following diagnostic procedure: “PWM
Sensor”
68
Troubleshooting Section

Results: Additionally, neither of the following diagnostic codes


are active:
• OK – STOP.
• 41 - 03 8 Volt DC Supply short to +batt
i01793903
• 41 - 04 8 Volt DC Supply short to ground
MID 036 - CID 0109 - FMI System Response:
03 Coolant Outlet Pressure
open/short to +batt The alarm output is activated. The code is logged.

Possible Performance Effect:


SMCS Code: 5574-038-PX

Conditions Which Generate This Code: The engine performance is not affected.

Troubleshooting:
The duty cycle of the pressure sensor for the outlet of
the engine coolant is greater than the maximum limit.
Perform the following diagnostic procedure: “PWM
Sensor”
Additionally, neither of the following diagnostic codes
are active:
Results:
• 41 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 41 - 04 8 Volt DC Supply short to ground
i01728446
System Response:
MID 036 - CID 0110 - FMI 03
The alarm output is activated. The code is logged. Engine Coolant Temperature
Possible Performance Effect: open/short to +batt
The engine performance is not affected. SMCS Code: 1906-038

Troubleshooting: Conditions Which Generate This Code:

The condition indicates a possible open circuit or a The signal from the engine coolant temperature
short circuit. sensor to the Electronic Control Module (ECM) is
greater than 4.8 VDC for at least five seconds.
Perform the following diagnostic procedure: “PWM
Sensor” System Response:

Results: The ECM assumes the last valid value for engine
coolant temperature. The monitoring of the coolant
• OK – STOP. temperature is disabled. This disables the engine
protection for low coolant temperature and high
coolant temperature.
i01691110

MID 036 - CID 0109 - FMI The fuel is shut off. The shutdown output is activated.
The code is logged.
08 Engine Coolant Outlet
Pressure Sensor noisy signal Possible Performance Effect:

Since the engine protection is disabled, the engine is


SMCS Code: 5574-038-PX
shut down.
Conditions Which Generate This Code:

The duty cycle or the frequency of the signal from the


pressure sensor for the outlet of the engine coolant
is out of range.
69
Troubleshooting Section

Troubleshooting: i02053738

This condition indicates the possibility of an open MID 036 - CID 0145 - FMI 03 12
circuit or a short circuit. Volt DC Power Supply short to
Perform the following diagnostic procedure: “Analog +batt
Sensor Signal”
SMCS Code: 5574-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) has been
powered for at least five seconds. The 12 volt sensor
i01728447 supply voltage becomes greater than 14.2 V for at
least one second.
MID 036 - CID 0110 - FMI 04
Engine Coolant Temperature System Response:
short to ground If the engine is running, the fuel is shut off. The
shutdown output is activated. The code is logged.
SMCS Code: 1906-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down or the engine will not start.
The signal from the engine coolant temperature
sensor to the Electronic Control Module (ECM) is Troubleshooting:
less than 0.2 VDC for at least five seconds.
Perform the following diagnostic procedure: “Engine
System Response: Speed/Timing Sensor”
The ECM assumes the last valid value for the engine Results:
coolant temperature. The monitoring of the coolant
temperature is disabled. This disables the engine
protection for low coolant temperature and high
• OK – STOP.
coolant temperature.
i02053745
The fuel is shut off. The shutdown output is activated.
The code is logged. MID 036 - CID 0145 - FMI 04 12
Volt DC Power Supply short to
Possible Performance Effect:
ground
Since the engine protection is disabled, the engine is
shut down. SMCS Code: 5574-038

Troubleshooting: Conditions Which Generate This Code:

Perform the following diagnostic procedure: “Analog The Electronic Control Module (ECM) has been
Sensor Signal” powered for at least five seconds. The 12 volt sensor
supply voltage becomes less than 11 VDC for at least
Results: one second.

• OK – STOP. System Response:

If the engine is running, the fuel is shut off. The


shutdown output is activated. The code is logged.

Possible Performance Effect:

The engine is shut down or the engine will not start.

Troubleshooting:

Perform the following diagnostic procedure: “Engine


Speed/Timing Sensor”
70
Troubleshooting Section

Results: i01728451

• OK – STOP. MID 036 - CID 0172 - FMI 03


Intake Manifold Air Temp
i01728450 open/short to +batt
MID 036 - CID 0168 - SMCS Code: 5574-038-TA
FMI 02 System Voltage
Conditions Which Generate This Code:
intermittent/erratic
The Electronic Control Module (ECM) has been
SMCS Code: 1408-038 powered for at least five seconds. The signal from
the inlet manifold temperature sensor to the ECM
Conditions Which Generate This Code: is greater than 4.8 VDC for at least five seconds.
Additionally, neither of the following diagnostic codes
The Electronic Control Module (ECM) has been are active:
powered for at least 5 seconds. The engine is
running. Either of the two following conditions occur:
• 262 - 03 5 Volt Sensor DC Power Supply short to
+batt
• The battery voltage is less than 6 VDC for a
minimum of 0.060 seconds. The voltage returns to
the normal range within 0.015 seconds.
• 262 -04 5 Volt Sensor DC Power Supply short to
ground
• There are three voltage readings of less than 6 System Response:
VDC within 7 seconds.
The ECM assumes the last valid value for the
System Response: inlet manifold air temperature. The monitoring of
the inlet manifold air temperature is disabled. This
The alarm output is activated. The code is logged. disables the engine protection for high inlet manifold
air temperature. The air/fuel ratio control cannot
Note: If battery voltage is lost and the voltage does compensate for the inlet air temperature.
not return, the ECM will not log this diagnostic code.
The engine will shut down. The fuel is shut off. The shutdown output is activated.
The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The intermittent problem may not affect engine
operation. However, the engine may experience The engine is shut down.
speed burps, intermittent shutdowns, and/or
complete shutdowns. Troubleshooting:
Troubleshooting: The condition indicates a possible open circuit or a
short circuit to a positive voltage source.
Perform the following diagnostic procedure: “Electrial
Power Supply” Perform the following diagnostic procedure: “Analog
Sensor Signal”
Results:
Results:
• OK – STOP.
• OK – STOP.
71
Troubleshooting Section

i01728453 Additionally, neither of the following diagnostic codes


are active:
MID 036 - CID 0172 - FMI 04
Intake Manifold Air Temp short • 262 - 03 5 Volt Sensor DC Power Supply short to
+batt
to ground
• 262 - 04 5 Volt Sensor DC Power Supply short to
SMCS Code: 5574-038-TA ground

Conditions Which Generate This Code: System Response:

The signal from the inlet manifold temperature sensor The ECM assumes the last valid value for the engine
to the Electronic Control Module (ECM) is less than oil temperature. The monitoring of the engine oil
0.2 VDC for at least five seconds. temperature is disabled. Also, the monitoring for a
high difference in temperature between the engine oil
Additionally, neither of the following diagnostic codes and the engine coolant is disabled. This disables the
are active: engine protection for both parameters.

• 262 - 03 5 Volt Sensor DC Power Supply short to The shutdown output is activated. The code is logged.
+batt
Possible Performance Effect:
• 262 - 04 5 Volt Sensor DC Power Supply short to
ground Since engine protection is disabled, the engine is
shut down.
System Response:
Troubleshooting:
The ECM assumes the last valid value for the
inlet manifold air temperature. The monitoring of The condition indicates a possible open circuit or a
the inlet manifold air temperature is disabled. This short circuit to a positive voltage source.
disables the engine protection for high inlet manifold
air temperature. The air/fuel ratio control cannot Perform the following diagnostic procedure: “Analog
compensate for the inlet air temperature. Sensor Signal”

The fuel is shut off. The shutdown output is activated. Results:


The code is logged.
• OK – STOP.
Possible Performance Effect:

The engine is shut down. i01728458

Troubleshooting:
MID 036 - CID 0175 - FMI 04
Engine Oil Temperature short
Perform the following diagnostic procedure: “Analog
Sensor Signal” to ground
Results: SMCS Code: 5574-038-TA

Conditions Which Generate This Code:


• OK – STOP.
The signal from the engine oil temperature sensor to
i01728456 the Electronic Control Module (ECM) is less than 0.2
VDC for at least five seconds.
MID 036 - CID 0175 - FMI
03 Engine Oil Temperature Additionally, neither of the following diagnostic codes
are active:
open/short to +batt
• 262 - 03 5 Volt Sensor DC Power Supply short to
SMCS Code: 5574-038-TA +batt

Conditions Which Generate This Code: • 262 - 04 5 Volt Sensor DC Power Supply short to
ground
The signal from the engine oil temperature sensor to
the Electronic Control Module (ECM) is greater than
4.8 VDC for at least five seconds.
72
Troubleshooting Section

System Response: i02053761

The ECM assumes the last valid value for the engine MID 036 - CID 0262 - FMI 03 5
oil temperature. The monitoring of the engine oil Volt Sensor DC Power Supply
temperature is disabled. Also, monitoring for a high
difference in temperature between the engine oil and short to +batt
the engine coolant is disabled. This disables the
engine protection for both parameters. SMCS Code: 5574-038

The shutdown output is activated. The code is logged. Conditions Which Generate This Code:

Possible Performance Effect: The supply voltage from the Electronic Control
Module (ECM) to the sensors for the following
Since engine protection is disabled, the engine is parameters is exceeding the normal level:
shut down.
• Inlet manifold air temperature
Troubleshooting:
• Engine oil temperature
Perform the following diagnostic procedure: “Analog
Sensor Signal” • Filtered engine oil pressure
Results: • Unfiltered engine oil pressure

• OK – STOP. If the engine is equipped with a desired speed


potentiometer, a short circuit in the signal wire for the
desired speed potentiometer can generate this code.
i01636386
System Response:
MID 036 - CID 0261 - FMI 13
Engine Timing calibration All of the inputs to the ECM for the 5 volt analog
sensors assume default values. All other diagnostic
required codes for the 5 volt analog sensors are disabled while
this diagnostic code is active. The “Status” screen
SMCS Code: 1905-038 of Caterpillar Electronic Technician (ET) indicates a
“Sensor Supply Fault” for each sensor. This indicates
Conditions Which Generate This Code: that the sensors are not operating due to an active
diagnostic code.
The timing calibration has not been performed.
The shutdown indicator is activated. The code is
System Response: logged.
The alarm output is activated. The code is logged. Possible Performance Effect:
Possible Performance Effect: Since engine protection is disabled, the engine is
shut down.
The timing will be advanced or the timing will be
retarded. Either condition will result in reduced Troubleshooting:
engine performance. If the condition is not corrected,
engine damage will result. Perform the following diagnostic procedure: “+5V
Sensor Voltage Supply”
Troubleshooting:
Results:
Calibrate the engine speed/timing sensor.

Perform the following diagnostic procedure: “Engine


• OK – STOP.
Speed/Timing Sensor - Calibrate”

Results:

• OK – STOP.
73
Troubleshooting Section

i02053769 i01762729

MID 036 - CID 0262 - FMI 04 5 MID 036 - CID 0301 - FMI 05
Volt Sensor DC Power Supply Ignition Transformer Primary
short to ground #1 open circuit
SMCS Code: 5574-038 SMCS Code: 1561-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The supply voltage from the Electronic Control The primary circuit of the transformer is diagnosed
Module (ECM) to the sensors for the following with an open circuit.
parameters is less than the normal level:
System Response:
• Inlet manifold air temperature
The alarm output is activated. The code is logged.
• Engine oil temperature
Possible Performance Effect:
• Filtered engine oil pressure
The cylinder will misfire.
• Unfiltered engine oil pressure
Troubleshooting:
If the engine is equipped with a desired speed
potentiometer, a short circuit in the signal wire for the One of the following conditions is the source of the
desired speed potentiometer can generate this code. diagnostic code:

System Response: • An open circuit in the wiring between the Electronic


Control Module (ECM) and the transformer
All of the inputs to the ECM for the 5 volt analog
sensors assume default values. All other diagnostic • An open circuit within the primary winding of the
codes for the 5 volt analog sensors are disabled transformer
while this diagnostic code is active. The “Status”
screen of the Caterpillar Electronic Technician (ET) • An internal failure of the ECM
indicates a “Sensor Supply Fault” for each sensor.
This indicates that the sensors are not operating due Perform the following diagnostic procedure: “Ignition
to an active diagnostic code. Transformers Primary Circuit”

The shutdown output is activated. The code is logged. Results:

Possible Performance Effect: • OK – STOP.


Since engine protection is disabled, the engine is
i01763010
shut down.

Troubleshooting:
MID 036 - CID 0301 - FMI 06
Ignition Transformer Primary
The condition indicates a possible short circuit to
ground or a short circuit between the sensor supply
#1 short
and the return.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “+5V
Conditions Which Generate This Code:
Sensor Voltage Supply”
The path for the circuit driver of the transformer is
Results:
diagnosed with a short circuit.
• OK – STOP. System Response:

The alarm output is activated. The code is logged.

Possible Performance Effect:

The cylinder will misfire.


74
Troubleshooting Section

Troubleshooting: Results:

One of the following conditions is the source of the • OK – STOP.


diagnostic code:
i01763021
• A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer MID 036 - CID 0302 - FMI 06
• A short circuit within the primary winding of the Ignition Transformer Primary
transformer
#2 short
• An internal failure of the ECM SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Transformers Primary Circuit”
The path for the circuit driver of the transformer is
Results: diagnosed with a short circuit.
• OK – STOP. System Response:

i01762758 The alarm output is activated. The code is logged.

MID 036 - CID 0302 - FMI 05 Possible Performance Effect:


Ignition Transformer Primary The cylinder will misfire.
#2 open circuit
Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the
Conditions Which Generate This Code: diagnostic code:

The primary circuit of the transformer is diagnosed • A short circuit in the wiring between the Electronic
with an open circuit. Control Module (ECM) and the transformer

System Response: • A short circuit within the primary winding of the


transformer
The alarm output is activated. The code is logged.
• An internal failure of the ECM
Possible Performance Effect:
Perform the following diagnostic procedure: “Ignition
The cylinder will misfire. Transformers Primary Circuit”

Troubleshooting: Results:

One of the following conditions is the source of the • OK – STOP.


diagnostic code:
i01762766
• An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer MID 036 - CID 0303 - FMI 05
• An open circuit within the primary winding of the Ignition Transformer Primary
transformer #3 open circuit
• An internal failure of the ECM SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition
Conditions Which Generate This Code:
Transformers Primary Circuit”
The primary circuit of the transformer is diagnosed
with an open circuit.
75
Troubleshooting Section

System Response: • An internal failure of the ECM


The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting:
i01762778
One of the following conditions is the source of the
diagnostic code: MID 036 - CID 0304 - FMI 05
• An open circuit in the wiring between the Electronic Ignition Transformer Primary
Control Module (ECM) and the transformer
#4 open circuit
• An open circuit within the primary winding of the SMCS Code: 1561-038
transformer
Conditions Which Generate This Code:
• An internal failure of the ECM
The primary circuit of the transformer is diagnosed
Perform the following diagnostic procedure: “Ignition
with an open circuit.
Transformers Primary Circuit”
System Response:
Results:
The alarm output is activated. The code is logged.
• OK – STOP.
Possible Performance Effect:
i01763029
The cylinder will misfire.
MID 036 - CID 0303 - FMI 06
Ignition Transformer Primary Troubleshooting:

#3 short One of the following conditions is the source of the


diagnostic code:
SMCS Code: 1561-038
• An open circuit in the wiring between the Electronic
Conditions Which Generate This Code: Control Module (ECM) and the transformer

The path for the circuit driver of the transformer is • An open circuit within the primary winding of the
diagnosed with a short circuit. transformer

System Response: • An internal failure of the ECM


The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting:

One of the following conditions is the source of the


diagnostic code:

• A short circuit in the wiring between the Electronic


Control Module (ECM) and the transformer

• A short circuit within the primary winding of the


transformer
76
Troubleshooting Section

i01763033 Possible Performance Effect:


MID 036 - CID 0304 - FMI 06 The cylinder will misfire.
Ignition Transformer Primary
Troubleshooting:
#4 short
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:
Conditions Which Generate This Code: • An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The path for the circuit driver of the transformer is
diagnosed with a short circuit. • An open circuit within the primary winding of the
transformer
System Response:
• An internal failure of the ECM
The alarm output is activated. The code is logged.
Perform the following diagnostic procedure: “Ignition
Possible Performance Effect: Transformers Primary Circuit”

The cylinder will misfire. Results:

Troubleshooting: • OK – STOP.
One of the following conditions is the source of the
diagnostic code: i01763043

• A short circuit in the wiring between the Electronic


MID 036 - CID 0305 - FMI 06
Control Module (ECM) and the transformer Ignition Transformer Primary
• A short circuit within the primary winding of the #5 short
transformer
SMCS Code: 1561-038
• An internal failure of the ECM Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit” The path for the circuit driver of the transformer is
diagnosed with a short circuit.
Results:
System Response:
• OK – STOP. The alarm output is activated. The code is logged.

i01762805 Possible Performance Effect:


MID 036 - CID 0305 - FMI 05 The cylinder will misfire.
Ignition Transformer Primary
Troubleshooting:
#5 open circuit
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:

Conditions Which Generate This Code: • A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The primary circuit of the transformer is diagnosed
with an open circuit. • A short circuit within the primary winding of the
transformer
System Response:

The alarm output is activated. The code is logged.


77
Troubleshooting Section

• An internal failure of the ECM i01763045

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0306 - FMI 06
Transformers Primary Circuit” Ignition Transformer Primary
Results: #6 short
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:


i01762875
The path for the circuit driver of the transformer is
MID 036 - CID 0306 - FMI 05 diagnosed with a short circuit.
Ignition Transformer Primary
System Response:
#6 open circuit
The alarm output is activated. The code is logged.
SMCS Code: 1561-038
Possible Performance Effect:
Conditions Which Generate This Code:
The cylinder will misfire.
The primary circuit of the transformer is diagnosed
with an open circuit. Troubleshooting:
System Response: One of the following conditions is the source of the
diagnostic code:
The alarm output is activated. The code is logged.

Possible Performance Effect:


• A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The cylinder will misfire.
• A short circuit within the primary winding of the
transformer
Troubleshooting:

One of the following conditions is the source of the


• An internal failure of the ECM
diagnostic code: Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
• An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer Results:
• An open circuit within the primary winding of the • OK – STOP.
transformer

• An internal failure of the ECM i01762944

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0307 - FMI 05
Transformers Primary Circuit” Ignition Transformer Primary
Results: #7 open circuit
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:

The primary circuit of the transformer is diagnosed


with an open circuit.

System Response:

The alarm output is activated. The code is logged.

Possible Performance Effect:

The cylinder will misfire.


78
Troubleshooting Section

Troubleshooting: Results:

One of the following conditions is the source of the • OK – STOP.


diagnostic code:
i01762969
• An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer MID 036 - CID 0308 - FMI 05
• An open circuit within the primary winding of the Ignition Transformer Primary
transformer
#8 open circuit
• An internal failure of the ECM SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Transformers Primary Circuit”
The primary circuit of the transformer is diagnosed
Results: with an open circuit.
• OK – STOP. System Response:

i01763068 The alarm output is activated. The code is logged.

MID 036 - CID 0307 - FMI 06 Possible Performance Effect:


Ignition Transformer Primary The cylinder will misfire.
#7 short
Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the
Conditions Which Generate This Code: diagnostic code:

The path for the circuit driver of the transformer is • An open circuit in the wiring between the Electronic
diagnosed with a short circuit. Control Module (ECM) and the transformer

System Response: • An open circuit within the primary winding of the


transformer
The alarm output is activated. The code is logged.
• An internal failure of the ECM
Possible Performance Effect:
Perform the following diagnostic procedure: “Ignition
The cylinder will misfire. Transformers Primary Circuit”

Troubleshooting: Results:

One of the following conditions is the source of the • OK – STOP.


diagnostic code:
i01763077
• A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer MID 036 - CID 0308 - FMI 06
• A short circuit within the primary winding of the Ignition Transformer Primary
transformer #8 short
• An internal failure of the ECM SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition
Conditions Which Generate This Code:
Transformers Primary Circuit”
The path for the circuit driver of the transformer is
diagnosed with a short circuit.
79
Troubleshooting Section

System Response: • An internal failure of the ECM


The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting:
i01763090
One of the following conditions is the source of the
diagnostic code: MID 036 - CID 0309 - FMI 06
• A short circuit in the wiring between the Electronic Ignition Transformer Primary
Control Module (ECM) and the transformer
#9 short
• A short circuit within the primary winding of the SMCS Code: 1561-038
transformer
Conditions Which Generate This Code:
• An internal failure of the ECM
The path for the circuit driver of the transformer is
Perform the following diagnostic procedure: “Ignition
diagnosed with a short circuit.
Transformers Primary Circuit”
System Response:
Results:
The alarm output is activated. The code is logged.
• OK – STOP.
Possible Performance Effect:
i01762971
The cylinder will misfire.
MID 036 - CID 0309 - FMI 05
Ignition Transformer Primary Troubleshooting:

#9 open circuit One of the following conditions is the source of the


diagnostic code:
SMCS Code: 1561-038
• A short circuit in the wiring between the Electronic
Conditions Which Generate This Code: Control Module (ECM) and the transformer

The primary circuit of the transformer is diagnosed • A short circuit within the primary winding of the
with an open circuit. transformer

System Response: • An internal failure of the ECM


The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting:

One of the following conditions is the source of the


diagnostic code:

• An open circuit in the wiring between the Electronic


Control Module (ECM) and the transformer

• An open circuit within the primary winding of the


transformer
80
Troubleshooting Section

i01762975 Possible Performance Effect:


MID 036 - CID 0310 - FMI 05 The cylinder will misfire.
Ignition Transformer Primary
Troubleshooting:
#10 open circuit
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:
Conditions Which Generate This Code: • A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The primary circuit of the transformer is diagnosed
with an open circuit. • A short circuit within the primary winding of the
transformer
System Response:
• An internal failure of the ECM
The alarm output is activated. The code is logged.
Perform the following diagnostic procedure: “Ignition
Possible Performance Effect: Transformers Primary Circuit”

The cylinder will misfire. Results:

Troubleshooting: • OK – STOP.
One of the following conditions is the source of the
diagnostic code: i01762978

• An open circuit in the wiring between the Electronic


MID 036 - CID 0311 - FMI 05
Control Module (ECM) and the transformer Ignition Transformer Primary
• An open circuit within the primary winding of the #11 open circuit
transformer
SMCS Code: 1561-038
• An internal failure of the ECM Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit” The primary circuit of the transformer is diagnosed
with an open circuit.
Results:
System Response:
• OK – STOP. The alarm output is activated. The code is logged.

i01763093 Possible Performance Effect:


MID 036 - CID 0310 - FMI 06 The cylinder will misfire.
Ignition Transformer Primary
Troubleshooting:
#10 short
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:

Conditions Which Generate This Code: • An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The path for the circuit driver of the transformer is
diagnosed with a short circuit. • An open circuit within the primary winding of the
transformer
System Response:

The alarm output is activated. The code is logged.


81
Troubleshooting Section

• An internal failure of the ECM i01762993

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0312 - FMI 05
Transformers Primary Circuit” Ignition Transformer Primary
Results: #12 open circuit
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:


i01763100
The primary circuit of the transformer is diagnosed
MID 036 - CID 0311 - FMI 06 with an open circuit.
Ignition Transformer Primary
System Response:
#11 short
The alarm output is activated. The code is logged.
SMCS Code: 1561-038
Possible Performance Effect:
Conditions Which Generate This Code:
The cylinder will misfire.
The path for the circuit driver of the transformer is
diagnosed with a short circuit. Troubleshooting:
System Response: One of the following conditions is the source of the
diagnostic code:
The alarm output is activated. The code is logged.

Possible Performance Effect:


• An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The cylinder will misfire.
• An open circuit within the primary winding of the
transformer
Troubleshooting:

One of the following conditions is the source of the


• An internal failure of the ECM
diagnostic code: Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
• A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer Results:
• A short circuit within the primary winding of the • OK – STOP.
transformer

• An internal failure of the ECM i01763119

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0312 - FMI 06
Transformers Primary Circuit” Ignition Transformer Primary
Results: #12 short
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:

The path for the circuit driver of the transformer is


diagnosed with a short circuit.

System Response:

The alarm output is activated. The code is logged.

Possible Performance Effect:

The cylinder will misfire.


82
Troubleshooting Section

Troubleshooting: Results:

One of the following conditions is the source of the • OK – STOP.


diagnostic code:
i01763123
• A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer MID 036 - CID 0313 - FMI 06
• A short circuit within the primary winding of the Ignition Transformer Primary
transformer
#13 short
• An internal failure of the ECM SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Transformers Primary Circuit”
The path for the circuit driver of the transformer is
Results: diagnosed with a short circuit.
• OK – STOP. System Response:

i01762996 The alarm output is activated. The code is logged.

MID 036 - CID 0313 - FMI 05 Possible Performance Effect:


Ignition Transformer Primary The cylinder will misfire.
#13 open circuit
Troubleshooting:
SMCS Code: 1561-038
One of the following conditions is the source of the
Conditions Which Generate This Code: diagnostic code:

The primary circuit of the transformer is diagnosed • A short circuit in the wiring between the Electronic
with an open circuit. Control Module (ECM) and the transformer

System Response: • A short circuit within the primary winding of the


transformer
The alarm output is activated. The code is logged.
• An internal failure of the ECM
Possible Performance Effect:
Perform the following diagnostic procedure: “Ignition
The cylinder will misfire. Transformers Primary Circuit”

Troubleshooting: Results:

One of the following conditions is the source of the • OK – STOP.


diagnostic code:
i01763001
• An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer MID 036 - CID 0314 - FMI 05
• An open circuit within the primary winding of the Ignition Transformer Primary
transformer #14 open circuit
• An internal failure of the ECM SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition
Conditions Which Generate This Code:
Transformers Primary Circuit”
The primary circuit of the transformer is diagnosed
with an open circuit.
83
Troubleshooting Section

System Response: • An internal failure of the ECM


The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting:
i01763004
One of the following conditions is the source of the
diagnostic code: MID 036 - CID 0315 - FMI 05
• An open circuit in the wiring between the Electronic Ignition Transformer Primary
Control Module (ECM) and the transformer
#15 open circuit
• An open circuit within the primary winding of the SMCS Code: 1561-038
transformer
Conditions Which Generate This Code:
• An internal failure of the ECM
The primary circuit of the transformer is diagnosed
Perform the following diagnostic procedure: “Ignition
with an open circuit.
Transformers Primary Circuit”
System Response:
Results:
The alarm output is activated. The code is logged.
• OK – STOP.
Possible Performance Effect:
i01763128
The cylinder will misfire.
MID 036 - CID 0314 - FMI 06
Ignition Transformer Primary Troubleshooting:

#14 short One of the following conditions is the source of the


diagnostic code:
SMCS Code: 1561-038
• An open circuit in the wiring between the Electronic
Conditions Which Generate This Code: Control Module (ECM) and the transformer

The path for the circuit driver of the transformer is • An open circuit within the primary winding of the
diagnosed with a short circuit. transformer

System Response: • An internal failure of the ECM


The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
Possible Performance Effect:
Results:
The cylinder will misfire.
• OK – STOP.
Troubleshooting:

One of the following conditions is the source of the


diagnostic code:

• A short circuit in the wiring between the Electronic


Control Module (ECM) and the transformer

• A short circuit within the primary winding of the


transformer
84
Troubleshooting Section

i01763133 Possible Performance Effect:


MID 036 - CID 0315 - FMI 06 The cylinder will misfire.
Ignition Transformer Primary
Troubleshooting:
#15 short
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:
Conditions Which Generate This Code: • An open circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The path for the circuit driver of the transformer is
diagnosed with a short circuit. • An open circuit within the primary winding of the
transformer
System Response:
• An internal failure of the ECM
The alarm output is activated. The code is logged.
Perform the following diagnostic procedure: “Ignition
Possible Performance Effect: Transformers Primary Circuit”

The cylinder will misfire. Results:

Troubleshooting: • OK – STOP.
One of the following conditions is the source of the
diagnostic code: i01763142

• A short circuit in the wiring between the Electronic


MID 036 - CID 0316 - FMI 06
Control Module (ECM) and the transformer Ignition Transformer Primary
• A short circuit within the primary winding of the #16 short
transformer
SMCS Code: 1561-038
• An internal failure of the ECM Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit” The path for the circuit driver of the transformer is
diagnosed with a short circuit.
Results:
System Response:
• OK – STOP. The alarm output is activated. The code is logged.

i01763008 Possible Performance Effect:


MID 036 - CID 0316 - FMI 05 The cylinder will misfire.
Ignition Transformer Primary
Troubleshooting:
#16 open circuit
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:

Conditions Which Generate This Code: • A short circuit in the wiring between the Electronic
Control Module (ECM) and the transformer
The primary circuit of the transformer is diagnosed
with an open circuit. • A short circuit within the primary winding of the
transformer
System Response:

The alarm output is activated. The code is logged.


85
Troubleshooting Section

• An internal failure of the ECM i01728556

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0320 - FMI 08
Transformers Primary Circuit” Engine Speed/Timing signal
Results: abnormal
• OK – STOP. SMCS Code: 1912-038

Conditions Which Generate This Code:


i01728554
The Electronic Control Module (ECM) must be
MID 036 - CID 0320 - FMI 03 powered for at least one second. The engine speed
Speed/Timing Sensor short to is greater than 150 rpm. One of the following two
conditions occurs:
+batt
SMCS Code: 1912-038
• An invalid pattern for the timing reference gear
is detected. For example, reverse rotation is
detected.
Conditions Which Generate This Code:

To activate this code, all of the following conditions


• The pattern for the timing reference gear is lost for
less than one second.
must occur:
System Response:
The Electronic Control Module (ECM) has been
powered for at least one second. The pattern of If the engine is running, the ignition signals stop. The
the timing reference gear is lost for more than one shutdown output is activated. The code is logged.
second. The engine speed is greater than 150 rpm.
Neither of the following diagnostic codes are active: Possible Performance Effect:
• 145 - 03 12 Volt DC Power Supply short to +batt If the engine is running, the engine will be shut down.
If the engine is not running, the engine will not start.
• 145 - 04 12 Volt DC Power Supply short to ground
Troubleshooting:
Note: The 0320 - 03 code is set after the pattern of
the timing reference gear is lost for more than one Perform the following diagnostic procedure: “Engine
second. However, the logic hesitates for 1.5 seconds Speed/Timing Sensor”
before the code is activated. If a 145 - 03 or 145 - 04
is activated during the 1.5 seconds, then the 0320 - Results:
03 code is deactivated.

System Response:
• OK – STOP.

If the engine is running, the ignition signals stop. The i01728557


shutdown output is activated. The code is logged.
MID 036 - CID 0323 - FMI 03
Possible Performance Effect: Shutdown Lamp short to +batt
If the engine is running, the engine will be shut down. SMCS Code: 7400-038-IND
If the engine is not running, the engine will not start.
Conditions Which Generate This Code:
Troubleshooting:
The Electronic Control Module (ECM) detects
Perform the following diagnostic procedure: “Engine excessive current for the shutdown output.
Speed/Timing Sensor”
Note: This diagnostic condition cannot be detected
Results: when the shutdown output is OFF.

• OK – STOP. System Response:

The ECM limits the current for the shutdown output


to 0.3 amperes. The code is logged.
86
Troubleshooting Section

Possible Performance Effect: System Response:

The engine operation is not affected. The shutdown output is activated. The code is logged.

Troubleshooting: Possible Performance Effect:

Perform the following diagnostic procedure: “ECM If the engine is running, the engine will be shut down.
Status Indicator Output”
Troubleshooting:
Results:
Perform the following diagnostic procedure:
• OK – STOP. “Electrical Power Supply”

Results:
i01728563

MID 036 - CID 0324 - FMI 03 • OK – STOP.


Warning Lamp short to +batt
i02053977

SMCS Code: 7400-038-IND


MID 036 - CID 0401 - FMI
Conditions Which Generate This Code: 05 Ignition Transformer
The Electronic Control Module (ECM) detects
Secondary #1 open circuit
excessive current for the alarm output.
SMCS Code: 1561-038
Note: This diagnostic condition cannot be detected
Conditions Which Generate This Code:
when the alarm output is OFF.
The transformer’s secondary circuit is diagnosed with
System Response:
an open circuit.
The ECM limits the current for the alarm output to 0.3
System Response:
amperes. The code is logged.

Possible Performance Effect: The status of the transformer’s secondary output is


set to 120 percent. The alarm output is activated and
the code is logged.
The engine operation is not affected.
Possible Performance Effect:
Troubleshooting:

Perform the following diagnostic procedure: “ECM The cylinder will misfire.
Status Indicator Output”
Troubleshooting:
Results:
One of the following conditions is the source of the
diagnostic code:
• OK – STOP.
• A problem with the transformer’s ground
i01728570
• An open circuit within the secondary winding of
MID 036 - CID 0336 - FMI 02 the transformer
Incorrect ECS Switch inputs
• A problem with the connection to the spark plug’s
SMCS Code: 7332-038 terminal post

Conditions Which Generate This Code: • The spark plug has internal damage or an open
circuit.
The Electronic Control Module (ECM) detects an
invalid combination on these inputs from the Engine
Control Switch (ECS): “Switched +Battery”, “Start”,
“Stop”, and “Auto”.
87
Troubleshooting Section

• The spark plug gap is too wide. i01864831

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0402 - FMI
Transformers Secondary Circuit and Spark Plugs” 05 Ignition Transformer
Results: Secondary #2 open circuit
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:


i02054359
The transformer’s secondary circuit is diagnosed with
MID 036 - CID 0401 - FMI an open circuit.
06 Ignition Transformer
System Response:
Secondary #1 short to ground
The status of the transformer’s secondary output is
SMCS Code: 1561-038 set to 120 percent. The alarm output is activated and
the code is logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The transformer’s secondary circuit is diagnosed with
a short circuit. The cylinder will misfire.
System Response: Troubleshooting:
The status of the transformer’s secondary output is One of the following conditions is the source of the
set to zero percent. The alarm output is activated and diagnostic code:
the code is logged.

Possible Performance Effect:


• A problem with the transformer’s ground

The cylinder will misfire.


• An open circuit within the secondary winding of
the transformer
Troubleshooting:
• A problem with the connection to the spark plug’s
terminal post
One of the following conditions is the source of the
diagnostic code:
• The spark plug has internal damage or an open
circuit.
• A short circuit within the secondary winding of the
transformer
• The spark plug gap is too wide.
• The spark plug is fouled. Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
• The spark plug gap is closed.
Results:
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
• OK – STOP.
Results:
i01864834
• OK – STOP.
MID 036 - CID 0402 - FMI
06 Ignition Transformer
Secondary #2 short to ground
SMCS Code: 1561-038

Conditions Which Generate This Code:

The transformer’s secondary circuit is diagnosed with


a short circuit.
88
Troubleshooting Section

System Response: • An open circuit within the secondary winding of


the transformer
The status of the transformer’s secondary output is
set to zero percent. The alarm output is activated and • A problem with the connection to the spark plug’s
the code is logged. terminal post

Possible Performance Effect: • The spark plug has internal damage or an open
circuit.
The cylinder will misfire.
• The spark plug gap is too wide.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
diagnostic code:
Results:
• A short circuit within the secondary winding of the
transformer • OK – STOP.
• The spark plug is fouled. i02054361

• The spark plug gap is closed. MID 036 - CID 0403 - FMI
Perform the following diagnostic procedure: “Ignition 06 Ignition Transformer
Transformers Secondary Circuit and Spark Plugs”
Secondary #3 short to ground
Results: SMCS Code: 1561-038
• OK – STOP. Conditions Which Generate This Code:

i02054073 The transformer’s secondary circuit is diagnosed with


a short circuit.
MID 036 - CID 0403 - FMI
05 Ignition Transformer System Response:

Secondary #3 open circuit The status of the transformer’s secondary output is


set to zero percent. The alarm output is activated and
SMCS Code: 1561-038 the code is logged.

Conditions Which Generate This Code: Possible Performance Effect:

The transformer’s secondary circuit is diagnosed with The cylinder will misfire.
an open circuit.
Troubleshooting:
System Response:
One of the following conditions is the source of the
The status of the transformer’s secondary output is diagnostic code:
set to 120 percent. The alarm output is activated and
the code is logged. • A short circuit within the secondary winding of the
transformer
Possible Performance Effect:
• The spark plug is fouled.
The cylinder will misfire.
• The spark plug gap is closed.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
diagnostic code:
Results:
• A problem with the transformer’s ground
• OK – STOP.
89
Troubleshooting Section

i01864835 System Response:


MID 036 - CID 0404 - FMI The status of the transformer’s secondary output is
05 Ignition Transformer set to zero percent. The alarm output is activated and
the code is logged.
Secondary #4 open circuit
Possible Performance Effect:
SMCS Code: 1561-038
The cylinder will misfire.
Conditions Which Generate This Code:
Troubleshooting:
The transformer’s secondary circuit is diagnosed with
an open circuit. One of the following conditions is the source of the
diagnostic code:
System Response:
• A short circuit within the secondary winding of the
The status of the transformer’s secondary output is transformer
set to 120 percent. The alarm output is activated and
the code is logged. • The spark plug is fouled.
Possible Performance Effect: • The spark plug gap is closed.
The cylinder will misfire. Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
Troubleshooting:
Results:
One of the following conditions is the source of the
diagnostic code: • OK – STOP.
• A problem with the transformer’s ground
i02054106

• An open circuit within the secondary winding of MID 036 - CID 0405 - FMI
the transformer
05 Ignition Transformer
• A problem with the connection to the spark plug’s Secondary #5 open circuit
terminal post
SMCS Code: 1561-038
• The spark plug has internal damage or an open
circuit.
Conditions Which Generate This Code:
• The spark plug gap is too wide. The transformer’s secondary circuit is diagnosed with
Perform the following diagnostic procedure: “Ignition an open circuit.
Transformers Secondary Circuit and Spark Plugs”
System Response:
Results:
The status of the transformer’s secondary output is
set to 120 percent. The alarm output is activated and
• OK – STOP. the code is logged.

i01864836 Possible Performance Effect:


MID 036 - CID 0404 - FMI Generation of the diagnostic code does not affect
06 Ignition Transformer engine performance. However, the engine will
probably misfire. This will cause the engine to run
Secondary #4 short to ground rough. The engine may shut down.

SMCS Code: 1561-038 Troubleshooting:

Conditions Which Generate This Code: One of the following conditions is the source of the
diagnostic code:
The transformer’s secondary circuit is diagnosed with
a short circuit. • A problem with the transformer’s ground
90
Troubleshooting Section

• An open circuit within the secondary winding of i01864837


the transformer
MID 036 - CID 0406 - FMI
• A problem with the connection to the spark plug’s 05 Ignition Transformer
terminal post
Secondary #6 open circuit
• The spark plug has internal damage or an open
circuit. SMCS Code: 1561-038

• The spark plug gap is too wide. Conditions Which Generate This Code:

Perform the following diagnostic procedure: “Ignition The transformer’s secondary circuit is diagnosed with
Transformers Secondary Circuit and Spark Plugs” an open circuit.

Results: System Response:

• OK – STOP. The status of the transformer’s secondary output is


set to 120 percent. The alarm output is activated and
the code is logged.
i02054363
Possible Performance Effect:
MID 036 - CID 0405 - FMI
06 Ignition Transformer The cylinder will misfire.
Secondary #5 short to ground Troubleshooting:
SMCS Code: 1561-038 One of the following conditions is the source of the
diagnostic code:
Conditions Which Generate This Code:

The transformer’s secondary circuit is diagnosed with


• A problem with the transformer’s ground
a short circuit.
• An open circuit within the secondary winding of
the transformer
System Response:

The status of the transformer’s secondary output is


• A problem with the connection to the spark plug’s
terminal post
set to zero percent. The alarm output is activated and
the code is logged.
• The spark plug has internal damage or an open
circuit.
Possible Performance Effect:

The cylinder will misfire.


• The spark plug gap is too wide.
Perform the following diagnostic procedure: “Ignition
Troubleshooting: Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the Results:
diagnostic code:
• OK – STOP.
• A short circuit within the secondary winding of the
transformer

• The spark plug is fouled.


• The spark plug gap is closed.
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”

Results:

• OK – STOP.
91
Troubleshooting Section

i01864842 Possible Performance Effect:


MID 036 - CID 0406 - FMI The cylinder will misfire.
06 Ignition Transformer
Troubleshooting:
Secondary #6 short to ground
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:
Conditions Which Generate This Code: • A problem with the transformer’s ground
The transformer’s secondary circuit is diagnosed with • An open circuit within the secondary winding of
a short circuit. the transformer

System Response: • A problem with the connection to the spark plug’s


terminal post
The status of the transformer’s secondary output is
set to zero percent. The alarm output is activated and • The spark plug has internal damage or an open
the code is logged. circuit.

Possible Performance Effect: • The spark plug gap is too wide.


The cylinder will misfire. Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
Troubleshooting:
Results:
One of the following conditions is the source of the
diagnostic code: • OK – STOP.
• A short circuit within the secondary winding of the
transformer i02054366

• The spark plug is fouled.


MID 036 - CID 0407 - FMI
06 Ignition Transformer
• The spark plug gap is closed. Secondary #7 short to ground
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs” SMCS Code: 1561-038

Results: Conditions Which Generate This Code:

The transformer’s secondary circuit is diagnosed with


• OK – STOP. a short circuit.

i02054178 System Response:


MID 036 - CID 0407 - FMI The status of the transformer’s secondary output is
05 Ignition Transformer set to zero percent. The alarm output is activated and
the code is logged.
Secondary #7 open circuit
Possible Performance Effect:
SMCS Code: 1561-038
The cylinder will misfire.
Conditions Which Generate This Code:
Troubleshooting:
The transformer’s secondary circuit is diagnosed with
an open circuit. One of the following conditions is the source of the
diagnostic code:
System Response:
• A short circuit within the secondary winding of the
The status of the transformer’s secondary output is transformer
set to 120 percent. The alarm output is activated and
the code is logged. • The spark plug is fouled.
92
Troubleshooting Section

• The spark plug gap is closed. i01864849

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0408 - FMI
Transformers Secondary Circuit and Spark Plugs” 06 Ignition Transformer
Results: Secondary #8 short to ground
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:


i01864848
The transformer’s secondary circuit is diagnosed with
MID 036 - CID 0408 - FMI a short circuit.
05 Ignition Transformer
System Response:
Secondary #8 open circuit
The status of the transformer’s secondary output is
SMCS Code: 1561-038 set to zero percent. The alarm output is activated and
the code is logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The transformer’s secondary circuit is diagnosed with
an open circuit. The cylinder will misfire.
System Response: Troubleshooting:
The status of the transformer’s secondary output is One of the following conditions is the source of the
set to 120 percent. The alarm output is activated and diagnostic code:
the code is logged.

Possible Performance Effect:


• A short circuit within the secondary winding of the
transformer
The cylinder will misfire.
• The spark plug is fouled.
Troubleshooting:
• The spark plug gap is closed.
One of the following conditions is the source of the Perform the following diagnostic procedure: “Ignition
diagnostic code: Transformers Secondary Circuit and Spark Plugs”
• A problem with the transformer’s ground Results:
• An open circuit within the secondary winding of • OK – STOP.
the transformer

• A problem with the connection to the spark plug’s i02054216


terminal post
MID 036 - CID 0409 - FMI
• The spark plug has internal damage or an open 05 Ignition Transformer
circuit.
Secondary #9 open circuit
• The spark plug gap is too wide.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs” Conditions Which Generate This Code:

Results: The transformer’s secondary circuit is diagnosed with


an open circuit.
• OK – STOP.
93
Troubleshooting Section

System Response: Troubleshooting:

The status of the transformer’s secondary output is One of the following conditions is the source of the
set to 120 percent. The alarm output is activated and diagnostic code:
the code is logged.
• A short circuit within the secondary winding of the
Possible Performance Effect: transformer

The cylinder will misfire. • The spark plug is fouled.


Troubleshooting: • The spark plug gap is closed.
One of the following conditions is the source of the Perform the following diagnostic procedure: “Ignition
diagnostic code: Transformers Secondary Circuit and Spark Plugs”

• A problem with the transformer’s ground Results:

• An open circuit within the secondary winding of • OK – STOP.


the transformer
i01864850
• A problem with the connection to the spark plug’s
terminal post MID 036 - CID 0410 - FMI
• The spark plug has internal damage or an open 05 Ignition Transformer
circuit.
Secondary #10 open circuit
• The spark plug gap is too wide. SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Transformers Secondary Circuit and Spark Plugs”
The transformer’s secondary circuit is diagnosed with
Results: an open circuit.
• OK – STOP. System Response:

i02054371 The status of the transformer’s secondary output is


set to 120 percent. The alarm output is activated and
MID 036 - CID 0409 - FMI the code is logged.
06 Ignition Transformer Possible Performance Effect:
Secondary #9 short to ground
The cylinder will misfire.
SMCS Code: 1561-038
Troubleshooting:
Conditions Which Generate This Code:
One of the following conditions is the source of the
The transformer’s secondary circuit is diagnosed with diagnostic code:
a short circuit.
• A problem with the transformer’s ground
System Response:
• An open circuit within the secondary winding of
The status of the transformer’s secondary output is the transformer
set to zero percent. The alarm output is activated and
the code is logged. • A problem with the connection to the spark plug’s
terminal post
Possible Performance Effect:
• The spark plug has internal damage or an open
The cylinder will misfire. circuit.
94
Troubleshooting Section

• The spark plug gap is too wide. i02054226

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0411 - FMI
Transformers Secondary Circuit and Spark Plugs” 05 Ignition Transformer
Results: Secondary #11 open circuit
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:


i01864851
The transformer’s secondary circuit is diagnosed with
MID 036 - CID 0410 - FMI an open circuit.
06 Ignition Transformer
System Response:
Secondary #10 short to ground
The status of the transformer’s secondary output is
SMCS Code: 1561-038 set to 120 percent. The alarm output is activated and
the code is logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The transformer’s secondary circuit is diagnosed with
a short circuit. The cylinder will misfire.
System Response: Troubleshooting:
The status of the transformer’s secondary output is One of the following conditions is the source of the
set to zero percent. The alarm output is activated and diagnostic code:
the code is logged.

Possible Performance Effect:


• A problem with the transformer’s ground

The cylinder will misfire.


• An open circuit within the secondary winding of
the transformer
Troubleshooting:
• A problem with the connection to the spark plug’s
terminal post
One of the following conditions is the source of the
diagnostic code:
• The spark plug has internal damage or an open
circuit.
• A short circuit within the secondary winding of the
transformer
• The spark plug gap is too wide.
• The spark plug is fouled. Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
• The spark plug gap is closed.
Results:
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
• OK – STOP.
Results:

• OK – STOP.
95
Troubleshooting Section

i02054376 Possible Performance Effect:


MID 036 - CID 0411 - FMI The cylinder will misfire.
06 Ignition Transformer
Troubleshooting:
Secondary #11 short to ground
One of the following conditions is the source of the
SMCS Code: 1561-038 diagnostic code:
Conditions Which Generate This Code: • A problem with the transformer’s ground
The transformer’s secondary circuit is diagnosed with • An open circuit within the secondary winding of
a short circuit. the transformer

System Response: • A problem with the connection to the spark plug’s


terminal post
The status of the transformer’s secondary output is
set to zero percent. The alarm output is activated and • The spark plug has internal damage or an open
the code is logged. circuit.

Possible Performance Effect: • The spark plug gap is too wide.


The cylinder will misfire. Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
Troubleshooting:
Results:
One of the following conditions is the source of the
diagnostic code: • OK – STOP.
• A short circuit within the secondary winding of the
transformer i01864861

• The spark plug is fouled.


MID 036 - CID 0412 - FMI
06 Ignition Transformer
• The spark plug gap is closed. Secondary #12 short to ground
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs” SMCS Code: 1561-038

Results: Conditions Which Generate This Code:

The transformer’s secondary circuit is diagnosed with


• OK – STOP. a short circuit.

i01864860 System Response:


MID 036 - CID 0412 - FMI The status of the transformer’s secondary output is
05 Ignition Transformer set to zero percent. The alarm output is activated and
the code is logged.
Secondary #12 open circuit
Possible Performance Effect:
SMCS Code: 1561-038
The cylinder will misfire.
Conditions Which Generate This Code:
Troubleshooting:
The transformer’s secondary circuit is diagnosed with
an open circuit. One of the following conditions is the source of the
diagnostic code:
System Response:
• A short circuit within the secondary winding of the
The status of the transformer’s secondary output is transformer
set to 120 percent. The alarm output is activated and
the code is logged. • The spark plug is fouled.
96
Troubleshooting Section

• The spark plug gap is closed. i02054383

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0413 - FMI
Transformers Secondary Circuit and Spark Plugs” 06 Ignition Transformer
Results: Secondary #13 short to ground
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:


i02054281
The transformer’s secondary circuit is diagnosed with
MID 036 - CID 0413 - FMI a short circuit.
05 Ignition Transformer
System Response:
Secondary #13 open circuit
The status of the transformer’s secondary output is
SMCS Code: 1561-038 set to zero percent. The alarm output is activated and
the code is logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The transformer’s secondary circuit is diagnosed with
an open circuit. The cylinder will misfire.
System Response: Troubleshooting:
The status of the transformer’s secondary output is One of the following conditions is the source of the
set to 120 percent. The alarm output is activated and diagnostic code:
the code is logged.

Possible Performance Effect:


• A short circuit within the secondary winding of the
transformer
The cylinder will misfire.
• The spark plug is fouled.
Troubleshooting:
• The spark plug gap is closed.
One of the following conditions is the source of the Perform the following diagnostic procedure: “Ignition
diagnostic code: Transformers Secondary Circuit and Spark Plugs”
• A problem with the transformer’s ground Results:
• An open circuit within the secondary winding of • OK – STOP.
the transformer

• A problem with the connection to the spark plug’s i01864862


terminal post
MID 036 - CID 0414 - FMI
• The spark plug has internal damage or an open 05 Ignition Transformer
circuit.
Secondary #14 open circuit
• The spark plug gap is too wide.
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs” Conditions Which Generate This Code:

Results: The transformer’s secondary circuit is diagnosed with


an open circuit.
• OK – STOP.
97
Troubleshooting Section

System Response: Troubleshooting:

The status of the transformer’s secondary output is One of the following conditions is the source of the
set to 120 percent. The alarm output is activated and diagnostic code:
the code is logged.
• A short circuit within the secondary winding of the
Possible Performance Effect: transformer

The cylinder will misfire. • The spark plug is fouled.


Troubleshooting: • The spark plug gap is closed.
One of the following conditions is the source of the Perform the following diagnostic procedure: “Ignition
diagnostic code: Transformers Secondary Circuit and Spark Plugs”

• A problem with the transformer’s ground Results:

• An open circuit within the secondary winding of • OK – STOP.


the transformer
i02054289
• A problem with the connection to the spark plug’s
terminal post MID 036 - CID 0415 - FMI
• The spark plug has internal damage or an open 05 Ignition Transformer
circuit.
Secondary #15 open circuit
• The spark plug gap is too wide. SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Transformers Secondary Circuit and Spark Plugs”
The transformer’s secondary circuit is diagnosed with
Results: an open circuit.
• OK – STOP. System Response:

i01864863 The status of the transformer’s secondary output is


set to 120 percent. The alarm output is activated and
MID 036 - CID 0414 - FMI the code is logged.
06 Ignition Transformer Possible Performance Effect:
Secondary #14 short to ground
The cylinder will misfire.
SMCS Code: 1561-038
Troubleshooting:
Conditions Which Generate This Code:
One of the following conditions is the source of the
The transformer’s secondary circuit is diagnosed with diagnostic code:
a short circuit.
• A problem with the transformer’s ground
System Response:
• An open circuit within the secondary winding of
The status of the transformer’s secondary output is the transformer
set to zero percent. The alarm output is activated and
the code is logged. • A problem with the connection to the spark plug’s
terminal post
Possible Performance Effect:
• The spark plug has internal damage or an open
The cylinder will misfire. circuit.
98
Troubleshooting Section

• The spark plug gap is too wide. i01864864

Perform the following diagnostic procedure: “Ignition MID 036 - CID 0416 - FMI
Transformers Secondary Circuit and Spark Plugs” 05 Ignition Transformer
Results: Secondary #16 open circuit
• OK – STOP. SMCS Code: 1561-038

Conditions Which Generate This Code:


i02054386
The transformer’s secondary circuit is diagnosed with
MID 036 - CID 0415 - FMI an open circuit.
06 Ignition Transformer
System Response:
Secondary #15 short to ground
The status of the transformer’s secondary output is
SMCS Code: 1561-038 set to 120 percent. The alarm output is activated and
the code is logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The transformer’s secondary circuit is diagnosed with
a short circuit. The cylinder will misfire.
System Response: Troubleshooting:
The status of the transformer’s secondary output is One of the following conditions is the source of the
set to zero percent. The alarm output is activated and diagnostic code:
the code is logged.

Possible Performance Effect:


• A problem with the transformer’s ground

The cylinder will misfire.


• An open circuit within the secondary winding of
the transformer
Troubleshooting:
• A problem with the connection to the spark plug’s
terminal post
One of the following conditions is the source of the
diagnostic code:
• The spark plug has internal damage or an open
circuit.
• A short circuit within the secondary winding of the
transformer
• The spark plug gap is too wide.
• The spark plug is fouled. Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
• The spark plug gap is closed.
Results:
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
• OK – STOP.
Results:

• OK – STOP.
99
Troubleshooting Section

i01864865 System Response:


MID 036 - CID 0416 - FMI The ECM will limit the current for the crank terminate
06 Ignition Transformer relay to 0.3 amperes. The alarm output is activated.
The code is logged.
Secondary #16 short to ground
Troubleshooting:
SMCS Code: 1561-038
Perform the following diagnostic procedure: “ECM
Conditions Which Generate This Code: Status Indicator Output”

The transformer’s secondary circuit is diagnosed with Results:


a short circuit.
• OK – STOP.
System Response:

The status of the transformer’s secondary output is i01728639


set to zero percent. The alarm output is activated and
the code is logged. MID 036 - CID 0444 - FMI 05
Start Relay open circuit
Possible Performance Effect:
SMCS Code: 1426-038
The cylinder will misfire.
Conditions Which Generate This Code:
Troubleshooting:
The output from the Electronic Control Module (ECM)
One of the following conditions is the source of the for the starting motor relay is OFF. An open circuit or
diagnostic code: a short circuit to the +Battery is detected.

• A short circuit within the secondary winding of the Note: This diagnostic condition can only be detected
transformer by the ECM when the output for the starting motor
relay is OFF. The output is normally OFF when the
• The spark plug is fouled. engine control switch is in the STOP position or when
the crank terminate relay is energized.
• The spark plug gap is closed.
System Response:
Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs” An internal resistor rises to the +Battery side when
no electrical load is present. The alarm output is
Results: activated. The code is logged.

• OK – STOP. Possible Performance Effect:

The engine will be unable to crank.


i01728635

MID 036 - CID 0443 - FMI 03 Troubleshooting:

Crank Terminate Relay short The harness or the relay probably has an open circuit.
to +batt Perform the following diagnostic procedure: “ECM
SMCS Code: 4493-038 Output Circuit (Starting Motor)”

Conditions Which Generate This Code: Results:

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


excessive current for the crank terminate relay.

Note: This diagnostic condition cannot be detected


when the output for the crank terminate relay is OFF.
The output is normally OFF when the engine control
switch is in the STOP position.
100
Troubleshooting Section

i01728642 System Response:


MID 036 - CID 0444 - FMI 06 The ECM will limit the current to 0.3 amperes.
Start Relay short to ground The “Status” screen of the Caterpillar Electronic
Technician (ET) will display “Relay Fault”. The code
SMCS Code: 1426-038 is logged.

Conditions Which Generate This Code: Troubleshooting:

The Electronic Control Module (ECM) detects Perform the following diagnostic procedure: “ECM
excessive current for the output of the starting motor Status Indicator Output”
relay.
Results:
Note: This diagnostic condition can only be detected
by the ECM when the output for the starting motor • OK – STOP.
relay is ON. The output is normally ON when the
engine control switch is turned from the STOP i01728651
position to the START position. The output is ON until
the crank terminate relay is energized. MID 036 - CID 0524 - FMI 03
System Response: Desired Engine Speed Sensor
short to +batt
The ECM will continue to attempt to energize the
relay. The alarm output is activated. The code is SMCS Code: 5574-038
logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The Electronic Control Module (ECM) has been
The engine will probably be unable to crank. powered up for at least five seconds. The current to
the ECM for the desired speed input is greater than
Troubleshooting: 22 mA for more than five seconds.
This condition indicates an short circuit in the harness System Response:
or the relay.
When the “Idle/Rated” switch is in the “Rated”
Perform the following diagnostic procedure: “ECM position, the ECM assumes a default value for the
Output Circuit (Starting Motor)” desired engine speed.
Results: The alarm output is activated. The code is logged.

• OK – STOP. Possible Performance Effect:

i01728646
The default value for the desired engine speed is
equal to the “Minimum Engine High Idle Speed” that
MID 036 - CID 0445 - FMI 03 is programmed on the “Service/Configuration” screen
of the Caterpillar Electronic Technician (ET).
Run Relay short to +batt
Troubleshooting:
SMCS Code: 4493-038
The diagnostic code is generated by one of the
Conditions Which Generate This Code: following conditions:
The Electronic Control Module (ECM) detects • A short circuit to the +Battery side
excessive current for the run relay.
• A short circuit to ground
Note: This diagnostic condition cannot be detected
when the output for the “Run” relay is OFF. The Perform the following diagnostic procedure: “Desired
output is normally OFF when the engine control Speed Input (4 - 20 mA)”
switch is in the STOP position.
101
Troubleshooting Section

Results: i01728660

• OK – STOP. MID 036 - CID 0542 - FMI 03


Unfiltered Engine Oil Pressure
i01728659 open/short to +batt
MID 036 - CID 0524 - FMI 04 SMCS Code: 1924-038
Desired Engine Speed Sensor
Conditions Which Generate This Code:
short to ground
The signal to the Electronic Control Module (ECM)
SMCS Code: 5574-038 from the sensor for unfiltered engine oil pressure is
greater than 4.8 VDC for at least five seconds. Also,
Conditions Which Generate This Code: neither of the following diagnostic codes are active:
The Electronic Control Module (ECM) has been
powered up for at least five seconds. The current to
• 262 - 03 5 Volt Sensor DC Power Supply short to
+batt
the ECM for the desired speed input is less than 2
mA for more than five seconds.
• 262 - 04 5 Volt Sensor DC Power Supply short to
ground
System Response:
System Response:
When the “Idle/Rated” switch is in the “Rated”
position, the ECM assumes a default value for the The ECM assumes the last valid value for unfiltered
desired engine speed. engine oil pressure. Monitoring for restriction of the
oil filters is disabled.
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The default value for the desired engine speed is
equal to the “Minimum Engine High Idle Speed” that Engine operation is not affected.
is programmed on the “Service/Configuration” screen
of the Caterpillar Electronic Technician (ET). Troubleshooting:
Troubleshooting: Perform the following diagnostic procedure: “Analog
Sensor Signal”
The diagnostic code is generated by one of the
following conditions: Results:
• An open circuit or a short circuit to ground • OK – STOP.
• An open circuit or a short circuit to the +Battery
i01728669
Perform the following diagnostic procedure: “Desired
Speed Input (4 - 20 mA)” MID 036 - CID 0542 - FMI 04
Unfiltered Engine Oil Pressure
Results:
short to ground
• OK – STOP.
SMCS Code: 1924-038

Conditions Which Generate This Code:

The signal to the Electronic Control Module (ECM)


from the sensor for unfiltered engine oil pressure is
less than 0.2 VDC for at least five seconds. Also,
neither of the following diagnostic codes are active:

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


+batt
102
Troubleshooting Section

• 262 - 04 5 Volt Sensor DC Power Supply short to i02054401


ground
MID 036 - CID 1440 - FMI 09
System Response: Unable to communicate with
The ECM assumes the last valid value for unfiltered Throttle Actuator Drv
engine oil pressure. Monitoring for restriction of the
oil filters is disabled. SMCS Code: 1716-038

The alarm output is activated. The code is logged. Conditions Which Generate This Code:

Troubleshooting: The Electronic Control Module (ECM) has been


powered for at least five seconds. Messages on the
Perform the following diagnostic procedure: “Analog CAN data link between the ECM and the throttle
Sensor Signal” actuator have been lost for 0.48 seconds, indicating
a short circuit or an open circuit on one of the wires
Results: or both of the wires for the CAN data link.

• OK – STOP. System Response:

The fuel is shut off. The shutdown output is activated.


i01728675 The code is logged.
MID 036 - CID 1042 - FMI 09 Possible Performance Effect:
Unable to communicate with
If the engine is not running, the engine will not start.
ITSM If the engine is running, the engine is shut down.
SMCS Code: 1901-038 Troubleshooting:
Conditions Which Generate This Code: Perform the following diagnostic procedure: “Throttle
Actuator”
The Electronic Control Module (ECM) has been
powered up for at least five seconds. The Integrated Results:
Temperature Sensing Module (ITSM) has sent ten
consecutive messages to the ECM via the CAT Data
Link. None of the messages have been received by
• OK – STOP.
the ECM.
i02054405
Note: This diagnostic code is logged by the ECM
only. This code is not activated or logged by the MID 036 - CID 1446 - FMI 05
ITSM. Although there is a failure to communicate with Fuel Metering Module open
the ECM, the ITSM may still be able to communicate
with the Caterpillar Electronic Technician (ET). circuit
System Response: SMCS Code: 1741-038

The alarm output is activated. The code is logged. Conditions Which Generate This Code:

Note: If ET cannot communicate with the ITSM, the To generate this diagnostic code, all of the following
values for the ITSM “Status Parameter” will display conditions must occur:
“Unavailable”.
• The Electronic Control Module (ECM) has been
Troubleshooting: powered up for more than 5 seconds.

Perform the following diagnostic procedure: • The battery voltage is greater than 20 VDC.
“Integrated Temperature Sensing Module”
• The flow rate of the fuel is less than 8497 L/min
Results: (300 CFM).

• OK – STOP. • The voltage of the signal is less than “X” for 5


seconds. The calculation for “X” is given in Table 9.
103
Troubleshooting Section

Table 9 Results:
X = 3.0 V − [ ( G · 1.75 V ) ÷ 300 CFM ]
• OK – STOP.
G is the flow of the fuel in CFM.

i01728740
System Response:
MID 036 - CID 1446 - FMI 12 Fuel
The “Status Parameter” for “Fuel Valve Position” will
display “0 %” on the Caterpillar Electronic Technician
Metering Module malfunction
(ET). The alarm output is activated. The code is
SMCS Code: 1741-038
logged.
Conditions Which Generate This Code:
Possible Performance Effect:
The fuel metering valve sends a signal to the
Engine performance is affected.
Electronic Control Module (ECM) via the CAN data
link. The signal indicates that there is a problem with
Troubleshooting:
the fuel metering valve.
Perform the following diagnostic procedure: “Fuel
System Response:
Metering Valve”
The code is logged. The shutdown output is activated.
Results:
Possible Performance Effect:
• OK – STOP.
The engine is shut down.
i01728733
Troubleshooting:
MID 036 - CID 1446 - FMI 09
Unable to communicate with Perform the following diagnostic procedure: “Fuel
Metering Valve”
Fuel Metering Module
Results:
SMCS Code: 1741-038
• OK – STOP.
Conditions Which Generate This Code:

The Electronic Control Module (ECM) has been i01619975

powered up for more than 5 seconds. Ten consecutive


messages have been sent from the fuel metering
MID 036 - CID 1446 - FMI 13 Fuel
valve to the ECM via the CAN Data Link. None of the Metering Module calibration
messages have been received by the ECM.
required
System Response:
SMCS Code: 1741-038
The “Alarm Status” is activated. The “Status
Conditions Which Generate This Code:
Parameter” for “Fuel Valve Position”, “Fuel Pressure
(abs)”, “Fuel Valve Differential Pressure”, and “Fuel
The “Gas Fuel Properties” have not been
Temperature” are frozen on the Caterpillar Electronic
programmed for the fuel metering valve.
Technician (ET). The alarm output is activated. The
code is logged.
System Response:
Possible Performance Effect:
The code is logged. The alarm output is activated.
Engine performance is affected.
Possible Performance Effect:
Troubleshooting:
The fuel metering valve is shutdown. This prevents
the engine from running.
Perform the following diagnostic procedure: “Fuel
Metering Valve”
Troubleshooting:

Perform the following diagnostic procedure: “Fuel


Metering Valve”
104
Troubleshooting Section

Results: System Response:

• OK – STOP. The shutdown output is activated. The code is logged.

Possible Performance Effect:


i01728751

MID 036 - CID 1447 - FMI 12 The engine is shut down.

Fuel Metering Sensor Module Troubleshooting:


malfunction Perform the following diagnostic procedure:
“Detonation Sensors”
SMCS Code: 1741-038

Conditions Which Generate This Code: Results:

The fuel metering valve sends a signal to the • OK – STOP.


Electronic Control Module (ECM) via the CAN data
link. The signal indicates that there is a problem with i01741177
the fuel metering valve’s sensor module.
MID 036 - CID 1501 - FMI 04
System Response:
Cylinder #1 Detonation Sensor
The code is logged. The shutdown output is activated. short to ground
Possible Performance Effect: SMCS Code: 1559-038

The engine is shut down. Conditions Which Generate This Code:

Troubleshooting: The run relay and the crank terminate relay are
energized. The input of the signal from the detonation
Perform the following diagnostic procedure: “Fuel sensor to the Electronic Control Module (ECM) is
Metering Valve” less than 1.0 VDC for ten seconds.

Results: Neither of the following diagnostic codes are active:

• OK – STOP. • 0041 - 03 8 Volt DC Supply short to +batt

i01741170
• 0041 - 04 8 Volt DC Supply short to ground

MID 036 - CID 1501 - FMI 03 System Response:

Cylinder #1 Detonation Sensor The shutdown output is activated. The code is logged.
open/short to +batt Possible Performance Effect:
SMCS Code: 1559-038
The engine is shut down.
Conditions Which Generate This Code:
Troubleshooting:
The run relay and the crank terminate relay are
Perform the following diagnostic procedure:
energized. The input of a signal from a detonation
“Detonation Sensors”
sensor to the Electronic Control Module (ECM) is
greater than 4.8 VDC for ten seconds.
Results:
Neither of the following diagnostic codes are active:
• OK – STOP.
• 0041 - 03 8 Volt DC Supply short to +batt
• 0041 - 04 8 Volt DC Supply short to ground
105
Troubleshooting Section

i01741181 System Response:


MID 036 - CID 1502 - FMI 03 The shutdown output is activated. The code is logged.
Cylinder #2 Detonation Sensor
Possible Performance Effect:
open/short to +batt
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is Results:
greater than 4.8 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt i01741187

• 0041 - 04 8 Volt DC Supply short to ground


MID 036 - CID 1505 - FMI 03
Cylinder #5 Detonation Sensor
System Response:
open/short to +batt
The shutdown output is activated. The code is logged.
SMCS Code: 1559-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The run relay and the crank terminate relay are
Troubleshooting: energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is
Perform the following diagnostic procedure: greater than 4.8 VDC for ten seconds.
“Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground
i01741184 System Response:
MID 036 - CID 1502 - FMI 04 The shutdown output is activated. The code is logged.
Cylinder #2 Detonation Sensor
Possible Performance Effect:
short to ground
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of the signal from the detonation
sensor to the Electronic Control Module (ECM) is Results:
less than 1.0 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt


• 0041 - 04 8 Volt DC Supply short to ground
106
Troubleshooting Section

i01741197 System Response:


MID 036 - CID 1505 - FMI 04 The shutdown output is activated. The code is logged.
Cylinder #5 Detonation Sensor
Possible Performance Effect:
short to ground
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of the signal from the detonation
sensor to the Electronic Control Module (ECM) is Results:
less than 1.0 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt i01741203

• 0041 - 04 8 Volt DC Supply short to ground


MID 036 - CID 1506 - FMI 04
Cylinder #6 Detonation Sensor
System Response:
short to ground
The shutdown output is activated. The code is logged.
SMCS Code: 1559-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The run relay and the crank terminate relay are
Troubleshooting: energized. The input of the signal from the detonation
sensor to the Electronic Control Module (ECM) is
Perform the following diagnostic procedure: less than 1.0 VDC for ten seconds.
“Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground
i01741202 System Response:
MID 036 - CID 1506 - FMI 03 The shutdown output is activated. The code is logged.
Cylinder #6 Detonation Sensor
Possible Performance Effect:
open/short to +batt
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is Results:
greater than 4.8 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt


• 0041 - 04 8 Volt DC Supply short to ground
107
Troubleshooting Section

i01741207 System Response:


MID 036 - CID 1509 - FMI 03 The shutdown output is activated. The code is logged.
Cylinder #9 Detonation Sensor
Possible Performance Effect:
open/short to +batt
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is Results:
greater than 4.8 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt i01741209

• 0041 - 04 8 Volt DC Supply short to ground


MID 036 - CID 1510 - FMI
03 Cylinder #10 Detonation
System Response:
Sensor open/short to +batt
The shutdown output is activated. The code is logged.
SMCS Code: 1559-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The run relay and the crank terminate relay are
Troubleshooting: energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is
Perform the following diagnostic procedure: greater than 4.8 VDC for ten seconds.
“Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground
i01741208 System Response:
MID 036 - CID 1509 - FMI 04 The shutdown output is activated. The code is logged.
Cylinder #9 Detonation Sensor
Possible Performance Effect:
short to ground
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of the signal from the detonation
sensor to the Electronic Control Module (ECM) is Results:
less than 1.0 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt


• 0041 - 04 8 Volt DC Supply short to ground
108
Troubleshooting Section

i01741210 System Response:


MID 036 - CID 1510 - FMI The shutdown output is activated. The code is logged.
04 Cylinder #10 Detonation
Possible Performance Effect:
Sensor short to ground
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of the signal from the detonation
sensor to the Electronic Control Module (ECM) is Results:
less than 1.0 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt i01741219

• 0041 - 04 8 Volt DC Supply short to ground


MID 036 - CID 1513 - FMI
04 Cylinder #13 Detonation
System Response:
Sensor short to ground
The shutdown output is activated. The code is logged.
SMCS Code: 1559-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
The run relay and the crank terminate relay are
Troubleshooting: energized. The input of the signal from the detonation
sensor to the Electronic Control Module (ECM) is
Perform the following diagnostic procedure: less than 1.0 VDC for ten seconds.
“Detonation Sensors”
Neither of the following diagnostic codes are active:
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground
i01741213 System Response:
MID 036 - CID 1513 - FMI The shutdown output is activated. The code is logged.
03 Cylinder #13 Detonation
Possible Performance Effect:
Sensor open/short to +batt
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is Results:
greater than 4.8 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt


• 0041 - 04 8 Volt DC Supply short to ground
109
Troubleshooting Section

i01741222 System Response:


MID 036 - CID 1514 - FMI The shutdown output is activated. The code is logged.
03 Cylinder #14 Detonation
Possible Performance Effect:
Sensor open/short to +batt
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
The run relay and the crank terminate relay are “Detonation Sensors”
energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is Results:
greater than 4.8 VDC for ten seconds.
• OK – STOP.
Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt i02085884

• 0041 - 04 8 Volt DC Supply short to ground


MID 036 - CID 1719 - FMI
03 Generator Output Power
System Response:
Sensor open/short to +batt
The shutdown output is activated. The code is logged.
SMCS Code: 5574-038-PWR
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut down.
One of the following conditions has occurred:
Troubleshooting:
• The load signal from the Electronic Modular Control
Perform the following diagnostic procedure: Panel II+ (EMCP II+) is missing.
“Detonation Sensors”
• The load signal from the power sensor to the
Results: Electronic Control Module (ECM) is missing.

• OK – STOP. • The load signal from the power sensor to the ECM
is greater than 4.8 VDC.

i01741227 System Response:


MID 036 - CID 1514 - FMI The diagnostic code is logged and the engine is shut
04 Cylinder #14 Detonation down.

Sensor short to ground Troubleshooting:

SMCS Code: 1559-038 Perform the following diagnostic procedure:


“Generator Output Power Sensor”
Conditions Which Generate This Code:
Results:
The run relay and the crank terminate relay are
energized. The input of the signal from the detonation • OK – STOP.
sensor to the Electronic Control Module (ECM) is
less than 1.0 VDC for ten seconds.

Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt


• 0041 - 04 8 Volt DC Supply short to ground
110
Troubleshooting Section

i02085887 Troubleshooting:
MID 036 - CID 1719 - FMI Perform the following diagnostic procedure:
04 Generator Output Power “Generator Output Power Sensor”

Sensor short to ground Results:

SMCS Code: 5574-038-PWR • OK – STOP.


Conditions Which Generate This Code:
i02054537
This diagnostic code is not applicable to generators
that are equipped with the Electronic Modular Control MID 036 - CID 1720 - FMI 09
Panel II+ (EMCP II+). Turbocharger Compressor
Both of the following conditions occur: Bypass Valve Actuator not
communicating on link
• The engine load is greater than 20 percent.
SMCS Code: 1052-038-BV
• The signal from the power sensor to the Electronic
Control Module (ECM) is less than 0.2 VDC. Conditions Which Generate This Code:

System Response: The Electronic Control Module (ECM) cannot


communicate with the actuator for the bypass valve.
The diagnostic code is logged and the engine is shut
down. System Response:
Troubleshooting: The fuel is shut off. The shutdown output is activated.
The code is logged.
Perform the following diagnostic procedure:
“Generator Output Power Sensor” Possible Performance Effect:

Results: If the engine is not running, the engine will not start.
If the engine is running, the engine is shut down.
• OK – STOP.
Perform the following diagnostic procedure: “Bypass
Valve”
i02054530

MID 036 - CID 1719 - FMI Results:


12 Generator Output Power • OK – STOP.
Sensor malfunction
i01636449
SMCS Code: 5574-038-PWR
MID 111 - CID 0591 - FMI 12
Conditions Which Generate This Code:
EEPROM checksum fault or
This diagnostic code is applicable to generators that ECM not programmed
are equipped with the Electronic Modular Control
Panel II+ (EMCP II+) only. SMCS Code: 1901-038

The Electronic Control Module (ECM) has determined Conditions Which Generate This Code:
that the load signal from the EMCP II+ may be invalid.
The Integrated Temperature Sensing Module (ITSM)
System Response: detects a problem within the EPROM circuit.

The diagnostic code is logged and the engine is shut System Response:
down.
Monitoring of the exhaust temperature is lost. Also,
protection against high exhaust temperatures is lost.
111
Troubleshooting Section

The alarm output is activated. The code is logged. i01728777

Troubleshooting: MID 111 - CID 1489 - FMI 04 Left


Turbo Turbine Out Temp Sens
There is a problem with the ITSM.
short to ground
Replace the ITSM. Follow the instructions in
Troubleshooting, “Replacing the ITSM”. SMCS Code: 5574-038

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module (ITSM)


detects one of the following conditions for the input
from the thermocouple of the turbocharger:
i01728761

MID 111 - CID 1489 - FMI 03 Left • A short circuit to the −Battery side
Turbo Turbine Out Temp Sens • A short circuit to the ground
short to +batt System Response:
SMCS Code: 5574-038 Monitoring of the temperature for the port of the
turbine is lost. Also, protection for the port is lost. The
Conditions Which Generate This Code: code is logged. The “Status” screen of the Caterpillar
Electronic Technician (ET) displays “Shorted to
The Integrated Temperature Sensing Module (ITSM) Ground” for the port of the turbine.
detects a short circuit to the +Battery side for the
input from the thermocouple of the turbocharger. Possible Performance Effect:
System Response: Engine operation is not affected.
Monitoring of the temperature for the port of the Troubleshooting:
turbine is lost. Also, protection for the port is lost. The
code is logged. The “Status” screen of the Caterpillar Perform the following diagnostic procedure:
Electronic Technician (ET) displays “Open/Shorted “Integrated Temperature Sensing Module (ITSM)”
High” for the port of the turbine.
Results:
This diagnostic code remains active until the
condition that caused the problem is not present for
30 seconds.
• OK – STOP.

Possible Performance Effect: i01728782

Engine operation is not affected. MID 111 - CID 1489 - FMI 05 Left
Turbo Turbine Out Temp Sens
Troubleshooting:
open circuit
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 5574-038

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module


(ITSM) detects an open circuit for the input from the
thermocouple of the turbocharger.

System Response:

Monitoring of the exhaust temperature for the port


of the turbine is lost. Also, protection for the port
is lost. The code is logged. The “Status” screen of
the Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the port of the turbine.
112
Troubleshooting Section

Possible Performance Effect: i01728791

Engine operation is not affected. MID 111 - CID 1490 - FMI 04 Rt


Turbo Turbine Out Temp Sens
Troubleshooting:
short to ground
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 5574-038

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module (ITSM)


detects one of the following conditions for the input
from the thermocouple of the turbocharger:
i01728785

MID 111 - CID 1490 - FMI 03 Rt • A short circuit to the −Battery side
Turbo Turbine Out Temp Sens • A short circuit to the ground
short to +batt System Response:
SMCS Code: 5574-038 Monitoring of the temperature for the port of the
turbine is lost. Also, protection for the port is lost. The
Conditions Which Generate This Code: code is logged. The “Status” screen of the Caterpillar
Electronic Technician (ET) displays “Shorted to
The Integrated Temperature Sensing Module (ITSM) Ground” for the port of the turbine.
detects a short circuit to the +Battery side for the
input from the thermocouple of the turbocharger. Possible Performance Effect:
System Response: Engine operation is not affected.
Monitoring of the temperature for the port of the Troubleshooting:
turbine is lost. Also, protection for the port is lost. The
code is logged. The “Status” screen of the Caterpillar Perform the following diagnostic procedure:
Electronic Technician (ET) displays “Open/Shorted “Integrated Temperature Sensing Module (ITSM)”
High” for the port of the turbine.
Results:
This diagnostic code remains active until the
condition that caused the problem is not present for
30 seconds.
• OK – STOP.

Possible Performance Effect: i01728794

Engine operation is not affected. MID 111 - CID 1490 - FMI 05 Rt


Turbo Turbine Out Temp Sens
Troubleshooting:
open circuit
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 5574-038

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module


(ITSM) detects an open circuit for the input from the
thermocouple of the turbocharger.
113
Troubleshooting Section

System Response: i01728797

Monitoring of the exhaust temperature for the port MID 111 - CID 1491 - FMI 04 Rt
of the turbine is lost. Also, protection for the port Turbo Turbine In Temp Sens
is lost. The code is logged. The “Status” screen of
the Caterpillar Electronic Technician (ET) displays short to ground
“Open/Shorted High” for the port of the turbine.
SMCS Code: 5574-038
Possible Performance Effect:
Conditions Which Generate This Code:
Engine operation is not affected.
The Integrated Temperature Sensing Module (ITSM)
Troubleshooting: detects one of the following conditions for the input
from the thermocouple of the turbocharger:
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” • A short circuit to the −Battery side
Results: • A short circuit to the ground

• OK – STOP. System Response:

Monitoring of the temperature for the port of the


i01728795 turbine is lost. Also, protection for the port is lost. The
code is logged. The “Status” screen of the Caterpillar
MID 111 - CID 1491 - FMI 03 Rt Electronic Technician (ET) displays “Shorted to
Turbo Turbine In Temp Sens Ground” for the port of the turbine.
short to +batt Possible Performance Effect:
SMCS Code: 5574-038 Engine operation is not affected.
Conditions Which Generate This Code: Troubleshooting:
The Integrated Temperature Sensing Module (ITSM) Perform the following diagnostic procedure:
detects a short circuit to the +Battery side for the “Integrated Temperature Sensing Module (ITSM)”
input from the thermocouple of the turbocharger.
Results:
System Response:

Monitoring of the temperature for the port of the


• OK – STOP.
turbine is lost. Also, protection for the port is lost. The
code is logged. The “Status” screen of the Caterpillar i01728800
Electronic Technician (ET) displays “Open/Shorted
High” for the port of the turbine. MID 111 - CID 1491 - FMI 05 Rt
Turbo Turbine In Temp Sens
This diagnostic code remains active until the
condition that caused the problem is not present for open circuit
30 seconds.
SMCS Code: 5574-038
Possible Performance Effect:
Conditions Which Generate This Code:
Engine operation is not affected.
The Integrated Temperature Sensing Module
Troubleshooting: (ITSM) detects an open circuit for the input from the
thermocouple of the turbocharger.
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” System Response:

Results: Monitoring of the exhaust temperature for the port


of the turbine is lost. Also, protection for the port
• OK – STOP. is lost. The code is logged. The “Status” screen of
the Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the port of the turbine.
114
Troubleshooting Section

Possible Performance Effect: i01728806

Engine operation is not affected. MID 111 - CID 1492 - FMI 04 Left
Turbo Turbine In Temp Sens
Troubleshooting:
short to ground
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 5574-038

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module (ITSM)


detects one of the following conditions for the input
from the thermocouple of the turbocharger:
i01728804

MID 111 - CID 1492 - FMI 03 Left • A short circuit to the −Battery side
Turbo Turbine In Temp Sens • A short circuit to the ground
short to +batt System Response:
SMCS Code: 5574-038 Monitoring of the temperature for the port of the
turbine is lost. Also, protection for the port is lost. The
Conditions Which Generate This Code: code is logged. The “Status” screen of the Caterpillar
Electronic Technician (ET) displays “Shorted to
The Integrated Temperature Sensing Module (ITSM) Ground” for the port of the turbine.
detects a short circuit to the +Battery side for the
input from the thermocouple of the turbocharger. Possible Performance Effect:
System Response: Engine operation is not affected.
Monitoring of the temperature for the port of the Troubleshooting:
turbine is lost. Also, protection for the port is lost. The
code is logged. The “Status” screen of the Caterpillar Perform the following diagnostic procedure:
Electronic Technician (ET) displays “Open/Shorted “Integrated Temperature Sensing Module (ITSM)”
High” for the port of the turbine.
Results:
This diagnostic code remains active until the
condition that caused the problem is not present for
30 seconds.
• OK – STOP.

Possible Performance Effect: i01728813

Engine operation is not affected. MID 111 - CID 1492 - FMI 05 Left
Turbo Turbine In Temp Sens
Troubleshooting:
open circuit
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 5574-038

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module


(ITSM) detects an open circuit for the input from the
thermocouple of the turbocharger.
115
Troubleshooting Section

System Response: Results:

Monitoring of the exhaust temperature for the port • OK – STOP.


of the turbine is lost. Also, protection for the port
is lost. The code is logged. The “Status” screen of
i01728826
the Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the port of the turbine. MID 111 - CID 1531 - FMI 04 Cyl
Possible Performance Effect: #1 Exhaust Port Temp Sensor
Engine operation is not affected.
short to ground
SMCS Code: 1919
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input
Results:
from the thermocouple of the cylinder.
• OK – STOP. • A short circuit to the −Battery side
i01728819 • A short circuit to the ground
MID 111 - CID 1531 - FMI 03 Cyl System Response:
#1 Exhaust Port Temp Sensor Monitoring of the exhaust temperature for the cylinder
short to +batt is lost. Also, protection for the cylinder is lost.

SMCS Code: 1919 The thermocouple is removed from the calculation for
the average temperature of the engine.
Conditions Which Generate This Code:
The code is logged. The “Status” screen of the
The Integrated Temperature Sensing Module (ITSM) Caterpillar Electronic Technician (ET) displays
detects a short circuit to the +Battery side for the “Shorted to ground” for the cylinder.
input from the thermocouple of the cylinder.
The diagnostic code remains active until the condition
System Response: that caused the code is not present for 30 seconds.

Monitoring of the exhaust temperature for the cylinder Possible Performance Effect:
is lost. Also, protection for the cylinder is lost.
Engine operation is not affected.
The thermocouple is removed from the calculation for
the average temperature of the engine. Troubleshooting:

The code is logged. The “Status” screen of the Perform the following diagnostic procedure:
Caterpillar Electronic Technician (ET) displays “Integrated Temperature Sensing Module (ITSM)”
“Open/Shorted High” for the cylinder.
Results:
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds. • OK – STOP.
Possible Performance Effect:

Engine operation is not affected.

Troubleshooting:

Perform the following diagnostic procedure:


“Integrated Temperature Sensing Module (ITSM)”
116
Troubleshooting Section

i01728828 System Response:


MID 111 - CID 1531 - FMI 05 Cyl Monitoring of the exhaust temperature for the cylinder
#1 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

open circuit The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module
(ITSM) detects an open circuit for the input from the The diagnostic code remains active until the condition
thermocouple of the cylinder. that caused the code is not present for 30 seconds.

System Response: Possible Performance Effect:

Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for
the average temperature of the engine. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Results:
“Open/Shorted High” for the cylinder.
• OK – STOP.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
i01728835
Possible Performance Effect:
MID 111 - CID 1532 - FMI 04 Cyl
Engine operation is not affected. #2 Exhaust Port Temp Sensor
Troubleshooting: short to ground
Perform the following diagnostic procedure: SMCS Code: 1919
“Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input
• OK – STOP. from the thermocouple of the cylinder.

i01728833 • A short circuit to the −Battery side


MID 111 - CID 1532 - FMI 03 Cyl • A short circuit to the ground
#2 Exhaust Port Temp Sensor
System Response:
short to +batt
Monitoring of the exhaust temperature for the cylinder
SMCS Code: 1919 is lost. Also, protection for the cylinder is lost.

Conditions Which Generate This Code: The thermocouple is removed from the calculation for
the average temperature of the engine.
The Integrated Temperature Sensing Module (ITSM)
detects a short circuit to the +Battery side for the The code is logged. The “Status” screen of the
input from the thermocouple of the cylinder. Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.
117
Troubleshooting Section

The diagnostic code remains active until the condition i01728852


that caused the code is not present for 30 seconds.
MID 111 - CID 1533 - FMI 03 Cyl
Possible Performance Effect: #3 Exhaust Port Temp Sensor
Engine operation is not affected. short to +batt
Troubleshooting: SMCS Code: 1919

Perform the following diagnostic procedure: Conditions Which Generate This Code:
“Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM)
Results: detects a short circuit to the +Battery side for the
input from the thermocouple of the cylinder.
• OK – STOP.
System Response:

i01728837 Monitoring of the exhaust temperature for the cylinder


is lost. Also, protection for the cylinder is lost.
MID 111 - CID 1532 - FMI 05 Cyl
#2 Exhaust Port Temp Sensor The thermocouple is removed from the calculation for
the average temperature of the engine.
open circuit
The code is logged. The “Status” screen of the
SMCS Code: 1919 Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
Conditions Which Generate This Code:
The diagnostic code remains active until the condition
The Integrated Temperature Sensing Module that caused the code is not present for 30 seconds.
(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder. Possible Performance Effect:
System Response: Engine operation is not affected.
Monitoring of the exhaust temperature for the cylinder Troubleshooting:
is lost. Also, protection for the cylinder is lost.
Perform the following diagnostic procedure:
The thermocouple is removed from the calculation for “Integrated Temperature Sensing Module (ITSM)”
the average temperature of the engine.
Results:
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
• OK – STOP.

The diagnostic code remains active until the condition i01728912


that caused the code is not present for 30 seconds.
MID 111 - CID 1533 - FMI 04 Cyl
Possible Performance Effect: #3 Exhaust Port Temp Sensor
Engine operation is not affected. short to ground
Troubleshooting: SMCS Code: 1919

Perform the following diagnostic procedure: Conditions Which Generate This Code:
“Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM)
Results: detects one of the following conditions for the input
from the thermocouple of the cylinder.
• OK – STOP.
• A short circuit to the −Battery side
• A short circuit to the ground
118
Troubleshooting Section

System Response: Possible Performance Effect:

Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for
the average temperature of the engine. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Results:
“Shorted to ground” for the cylinder.
• OK – STOP.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
i01728917

Possible Performance Effect: MID 111 - CID 1534 - FMI 03 Cyl


Engine operation is not affected. #4 Exhaust Port Temp Sensor
Troubleshooting:
short to +batt
SMCS Code: 1919
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module (ITSM)
detects a short circuit to the +Battery side for the
• OK – STOP. input from the thermocouple of the cylinder.

i01728915 System Response:

MID 111 - CID 1533 - FMI 05 Cyl Monitoring of the exhaust temperature for the cylinder
#3 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

open circuit The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module
(ITSM) detects an open circuit for the input from the The diagnostic code remains active until the condition
thermocouple of the cylinder. that caused the code is not present for 30 seconds.

System Response: Possible Performance Effect:

Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for
the average temperature of the engine. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Results:
“Open/Shorted High” for the cylinder.
• OK – STOP.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
119
Troubleshooting Section

i01728923 System Response:


MID 111 - CID 1534 - FMI 04 Cyl Monitoring of the exhaust temperature for the cylinder
#4 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

short to ground The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input The diagnostic code remains active until the condition
from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.

• A short circuit to the −Battery side Possible Performance Effect:

• A short circuit to the ground Engine operation is not affected.

System Response: Troubleshooting:

Monitoring of the exhaust temperature for the cylinder Perform the following diagnostic procedure:
is lost. Also, protection for the cylinder is lost. “Integrated Temperature Sensing Module (ITSM)”

The thermocouple is removed from the calculation for Results:


the average temperature of the engine.
• OK – STOP.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder. i01728934

The diagnostic code remains active until the condition


MID 111 - CID 1535 - FMI 03 Cyl
that caused the code is not present for 30 seconds. #5 Exhaust Port Temp Sensor
Possible Performance Effect: short to +batt
Engine operation is not affected. SMCS Code: 1919

Troubleshooting: Conditions Which Generate This Code:

Perform the following diagnostic procedure: The Integrated Temperature Sensing Module (ITSM)
“Integrated Temperature Sensing Module (ITSM)” detects a short circuit to the +Battery side for the
input from the thermocouple of the cylinder.
Results:
System Response:
• OK – STOP. Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
i01728928
The thermocouple is removed from the calculation for
MID 111 - CID 1534 - FMI 05 Cyl the average temperature of the engine.
#4 Exhaust Port Temp Sensor
The code is logged. The “Status” screen of the
open circuit Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
SMCS Code: 1919
The diagnostic code remains active until the condition
Conditions Which Generate This Code: that caused the code is not present for 30 seconds.

The Integrated Temperature Sensing Module Possible Performance Effect:


(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder. Engine operation is not affected.
120
Troubleshooting Section

Troubleshooting: i01728953

Perform the following diagnostic procedure: MID 111 - CID 1535 - FMI 05 Cyl
“Integrated Temperature Sensing Module (ITSM)” #5 Exhaust Port Temp Sensor
Results: open circuit
• OK – STOP. SMCS Code: 1919

Conditions Which Generate This Code:


i01728940
The Integrated Temperature Sensing Module
MID 111 - CID 1535 - FMI 04 Cyl (ITSM) detects an open circuit for the input from the
#5 Exhaust Port Temp Sensor thermocouple of the cylinder.
short to ground System Response:
SMCS Code: 1919 Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code:
The thermocouple is removed from the calculation for
The Integrated Temperature Sensing Module (ITSM) the average temperature of the engine.
detects one of the following conditions for the input
from the thermocouple of the cylinder. The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
• A short circuit to the −Battery side “Open/Shorted High” for the cylinder.
• A short circuit to the ground The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
System Response:
Possible Performance Effect:
Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost. Engine operation is not affected.
The thermocouple is removed from the calculation for Troubleshooting:
the average temperature of the engine.
Perform the following diagnostic procedure:
The code is logged. The “Status” screen of the “Integrated Temperature Sensing Module (ITSM)”
Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder. Results:
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
• OK – STOP.

Possible Performance Effect: i01728959

Engine operation is not affected. MID 111 - CID 1536 - FMI 03 Cyl
#6 Exhaust Port Temp Sensor
Troubleshooting:
short to +batt
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 1919

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module (ITSM)


detects a short circuit to the +Battery side for the
input from the thermocouple of the cylinder.
121
Troubleshooting Section

System Response: Possible Performance Effect:

Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for
the average temperature of the engine. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Results:
“Open/Shorted High” for the cylinder.
• OK – STOP.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
i01728976

Possible Performance Effect: MID 111 - CID 1536 - FMI 05 Cyl


Engine operation is not affected. #6 Exhaust Port Temp Sensor
Troubleshooting:
open circuit
SMCS Code: 1919
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module
(ITSM) detects an open circuit for the input from the
• OK – STOP. thermocouple of the cylinder.

i01728968 System Response:

MID 111 - CID 1536 - FMI 04 Cyl Monitoring of the exhaust temperature for the cylinder
#6 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

short to ground The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input The diagnostic code remains active until the condition
from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.

• A short circuit to the −Battery side Possible Performance Effect:

• A short circuit to the ground Engine operation is not affected.

System Response: Troubleshooting:

Monitoring of the exhaust temperature for the cylinder Perform the following diagnostic procedure:
is lost. Also, protection for the cylinder is lost. “Integrated Temperature Sensing Module (ITSM)”

The thermocouple is removed from the calculation for Results:


the average temperature of the engine.
• OK – STOP.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.

The diagnostic code remains active until the condition


that caused the code is not present for 30 seconds.
122
Troubleshooting Section

i01728993 System Response:


MID 111 - CID 1537 - FMI 03 Cyl Monitoring of the exhaust temperature for the cylinder
#7 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

short to +batt The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.
The Integrated Temperature Sensing Module (ITSM)
detects a short circuit to the +Battery side for the The diagnostic code remains active until the condition
input from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.

System Response: Possible Performance Effect:

Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for
the average temperature of the engine. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Results:
“Open/Shorted High” for the cylinder.
• OK – STOP.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
i01729006
Possible Performance Effect:
MID 111 - CID 1537 - FMI 05 Cyl
Engine operation is not affected. #7 Exhaust Port Temp Sensor
Troubleshooting: open circuit
Perform the following diagnostic procedure: SMCS Code: 1919
“Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module
(ITSM) detects an open circuit for the input from the
• OK – STOP. thermocouple of the cylinder.

i01728999 System Response:


MID 111 - CID 1537 - FMI 04 Cyl Monitoring of the exhaust temperature for the cylinder
#7 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

short to ground The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input The diagnostic code remains active until the condition
from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.

• A short circuit to the −Battery side


• A short circuit to the ground
123
Troubleshooting Section

Possible Performance Effect: i01729019

Engine operation is not affected. MID 111 - CID 1538 - FMI 04 Cyl
#8 Exhaust Port Temp Sensor
Troubleshooting:
short to ground
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 1919

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module (ITSM)


detects one of the following conditions for the input
from the thermocouple of the cylinder.
i01729015

MID 111 - CID 1538 - FMI 03 Cyl • A short circuit to the −Battery side
#8 Exhaust Port Temp Sensor • A short circuit to the ground
short to +batt System Response:
SMCS Code: 1919 Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code:
The thermocouple is removed from the calculation for
The Integrated Temperature Sensing Module (ITSM) the average temperature of the engine.
detects a short circuit to the +Battery side for the
input from the thermocouple of the cylinder. The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
System Response: “Shorted to ground” for the cylinder.
Monitoring of the exhaust temperature for the cylinder The diagnostic code remains active until the condition
is lost. Also, protection for the cylinder is lost. that caused the code is not present for 30 seconds.
The thermocouple is removed from the calculation for Possible Performance Effect:
the average temperature of the engine.
Engine operation is not affected.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Troubleshooting:
“Open/Shorted High” for the cylinder.
Perform the following diagnostic procedure:
The diagnostic code remains active until the condition “Integrated Temperature Sensing Module (ITSM)”
that caused the code is not present for 30 seconds.
Results:
Possible Performance Effect:

Engine operation is not affected.


• OK – STOP.

Troubleshooting: i01729025

Perform the following diagnostic procedure: MID 111 - CID 1538 - FMI 05 Cyl
“Integrated Temperature Sensing Module (ITSM)” #8 Exhaust Port Temp Sensor
Results: open circuit
• OK – STOP. SMCS Code: 1919

Conditions Which Generate This Code:

The Integrated Temperature Sensing Module


(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder.
124
Troubleshooting Section

System Response: Possible Performance Effect:

Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for
the average temperature of the engine. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Results:
“Open/Shorted High” for the cylinder.
• OK – STOP.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
i01761374

Possible Performance Effect: MID 111 - CID 1539 - FMI 04 Cyl


Engine operation is not affected. #9 Exhaust Port Temp Sensor
Troubleshooting:
short to ground
SMCS Code: 1919
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input
• OK – STOP. from the thermocouple of the cylinder.

i01729257 • A short circuit to the −Battery side


MID 111 - CID 1539 - FMI 03 Cyl • A short circuit to the ground
#9 Exhaust Port Temp Sensor System Response:
short to +batt
Monitoring of the exhaust temperature for the cylinder
SMCS Code: 1919 is lost. Also, protection for the cylinder is lost.

Conditions Which Generate This Code: The thermocouple is removed from the calculation for
the average temperature of the engine.
The Integrated Temperature Sensing Module (ITSM)
detects a short circuit to the +Battery side for the The code is logged. The “Status” screen of the
input from the thermocouple of the cylinder. Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.
System Response:
The diagnostic code remains active until the condition
Monitoring of the exhaust temperature for the cylinder that caused the code is not present for 30 seconds.
is lost. Also, protection for the cylinder is lost.
Possible Performance Effect:
The thermocouple is removed from the calculation for
the average temperature of the engine. Engine operation is not affected.

The code is logged. The “Status” screen of the Troubleshooting:


Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds. Results:

• OK – STOP.
125
Troubleshooting Section

i01729264 The thermocouple is removed from the calculation for


the average temperature of the engine.
MID 111 - CID 1539 - FMI 05 Cyl
#9 Exhaust Port Temp Sensor The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
open circuit “Open/Shorted High” for the cylinder.

SMCS Code: 1919 The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
Conditions Which Generate This Code:
Possible Performance Effect:
The Integrated Temperature Sensing Module
(ITSM) detects an open circuit for the input from the Engine operation is not affected.
thermocouple of the cylinder.
Troubleshooting:
System Response:
Perform the following diagnostic procedure:
Monitoring of the exhaust temperature for the cylinder “Integrated Temperature Sensing Module (ITSM)”
is lost. Also, protection for the cylinder is lost.
Results:
The thermocouple is removed from the calculation for
the average temperature of the engine. • OK – STOP.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays i01729270
“Open/Shorted High” for the cylinder.
MID 111 - CID 1540 - FMI 04 Cyl
The diagnostic code remains active until the condition #10 Exhaust Port Temp Sensor
that caused the code is not present for 30 seconds.
short to ground
Possible Performance Effect:
SMCS Code: 1919
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting:
The Integrated Temperature Sensing Module (ITSM)
Perform the following diagnostic procedure: detects one of the following conditions for the input
“Integrated Temperature Sensing Module (ITSM)” from the thermocouple of the cylinder.

Results: • A short circuit to the −Battery side

• OK – STOP. • A short circuit to the ground


System Response:
i01729267
Monitoring of the exhaust temperature for the cylinder
MID 111 - CID 1540 - FMI 03 Cyl is lost. Also, protection for the cylinder is lost.
#10 Exhaust Port Temp Sensor
The thermocouple is removed from the calculation for
short to +batt the average temperature of the engine.
SMCS Code: 1919 The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
Conditions Which Generate This Code: “Shorted to ground” for the cylinder.

The Integrated Temperature Sensing Module (ITSM) The diagnostic code remains active until the condition
detects a short circuit to the +Battery side for the that caused the code is not present for 30 seconds.
input from the thermocouple of the cylinder.
Possible Performance Effect:
System Response:
Engine operation is not affected.
Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
126
Troubleshooting Section

Troubleshooting: i01729273

Perform the following diagnostic procedure: MID 111 - CID 1541 - FMI 03 Cyl
“Integrated Temperature Sensing Module (ITSM)” #11 Exhaust Port Temp Sensor
Results: short to +batt
• OK – STOP. SMCS Code: 1919

Conditions Which Generate This Code:


i01729271
The Integrated Temperature Sensing Module (ITSM)
MID 111 - CID 1540 - FMI 05 Cyl detects a short circuit to the +Battery side for the
#10 Exhaust Port Temp Sensor input from the thermocouple of the cylinder.
open circuit System Response:
SMCS Code: 1919 Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code:
The thermocouple is removed from the calculation for
The Integrated Temperature Sensing Module the average temperature of the engine.
(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder. The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
System Response: “Open/Shorted High” for the cylinder.
Monitoring of the exhaust temperature for the cylinder The diagnostic code remains active until the condition
is lost. Also, protection for the cylinder is lost. that caused the code is not present for 30 seconds.
The thermocouple is removed from the calculation for Possible Performance Effect:
the average temperature of the engine.
Engine operation is not affected.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Troubleshooting:
“Open/Shorted High” for the cylinder.
Perform the following diagnostic procedure:
The diagnostic code remains active until the condition “Integrated Temperature Sensing Module (ITSM)”
that caused the code is not present for 30 seconds.
Results:
Possible Performance Effect:

Engine operation is not affected.


• OK – STOP.

Troubleshooting: i01729275

Perform the following diagnostic procedure: MID 111 - CID 1541 - FMI 04 Cyl
“Integrated Temperature Sensing Module (ITSM)” #11 Exhaust Port Temp Sensor
Results: short to ground
• OK – STOP. SMCS Code: 1919

Conditions Which Generate This Code:

The Integrated Temperature Sensing Module (ITSM)


detects one of the following conditions for the input
from the thermocouple of the cylinder.

• A short circuit to the −Battery side


• A short circuit to the ground
127
Troubleshooting Section

System Response: Troubleshooting:

Monitoring of the exhaust temperature for the cylinder Perform the following diagnostic procedure:
is lost. Also, protection for the cylinder is lost. “Integrated Temperature Sensing Module (ITSM)”

The thermocouple is removed from the calculation for Results:


the average temperature of the engine.
• OK – STOP.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
i01729278
“Shorted to ground” for the cylinder.

The diagnostic code remains active until the condition


MID 111 - CID 1542 - FMI 03 Cyl
that caused the code is not present for 30 seconds. #12 Exhaust Port Temp Sensor
Possible Performance Effect:
short to +batt
SMCS Code: 1919
Engine operation is not affected.
Conditions Which Generate This Code:
Troubleshooting:
The Integrated Temperature Sensing Module (ITSM)
Perform the following diagnostic procedure:
detects a short circuit to the +Battery side for the
“Integrated Temperature Sensing Module (ITSM)” input from the thermocouple of the cylinder.
Results:
System Response:
• OK – STOP. Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
i01729277
The thermocouple is removed from the calculation for
MID 111 - CID 1541 - FMI 05 Cyl the average temperature of the engine.
#11 Exhaust Port Temp Sensor The code is logged. The “Status” screen of the
open circuit Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
SMCS Code: 1919
The diagnostic code remains active until the condition
Conditions Which Generate This Code: that caused the code is not present for 30 seconds.

The Integrated Temperature Sensing Module Possible Performance Effect:


(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder. Engine operation is not affected.

System Response: Troubleshooting:

Monitoring of the exhaust temperature for the cylinder Perform the following diagnostic procedure:
is lost. Also, protection for the cylinder is lost. “Integrated Temperature Sensing Module (ITSM)”

The thermocouple is removed from the calculation for Results:


the average temperature of the engine.
• OK – STOP.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.

The diagnostic code remains active until the condition


that caused the code is not present for 30 seconds.

Possible Performance Effect:

Engine operation is not affected.


128
Troubleshooting Section

i01729281 System Response:


MID 111 - CID 1542 - FMI 04 Cyl Monitoring of the exhaust temperature for the cylinder
#12 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

short to ground The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input The diagnostic code remains active until the condition
from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.

• A short circuit to the −Battery side Possible Performance Effect:

• A short circuit to the ground Engine operation is not affected.

System Response: Troubleshooting:

Monitoring of the exhaust temperature for the cylinder Perform the following diagnostic procedure:
is lost. Also, protection for the cylinder is lost. “Integrated Temperature Sensing Module (ITSM)”

The thermocouple is removed from the calculation for Results:


the average temperature of the engine.
• OK – STOP.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder. i01729287

The diagnostic code remains active until the condition


MID 111 - CID 1543 - FMI 03 Cyl
that caused the code is not present for 30 seconds. #13 Exhaust Port Temp Sensor
Possible Performance Effect: short to +batt
Engine operation is not affected. SMCS Code: 1919

Troubleshooting: Conditions Which Generate This Code:

Perform the following diagnostic procedure: The Integrated Temperature Sensing Module (ITSM)
“Integrated Temperature Sensing Module (ITSM)” detects a short circuit to the +Battery side for the
input from the thermocouple of the cylinder.
Results:
System Response:
• OK – STOP. Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
i01729284
The thermocouple is removed from the calculation for
MID 111 - CID 1542 - FMI 05 Cyl the average temperature of the engine.
#12 Exhaust Port Temp Sensor
The code is logged. The “Status” screen of the
open circuit Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
SMCS Code: 1919
The diagnostic code remains active until the condition
Conditions Which Generate This Code: that caused the code is not present for 30 seconds.

The Integrated Temperature Sensing Module


(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder.
129
Troubleshooting Section

Possible Performance Effect: i01729294

Engine operation is not affected. MID 111 - CID 1543 - FMI 05 Cyl
#13 Exhaust Port Temp Sensor
Troubleshooting:
open circuit
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 1919

Results: Conditions Which Generate This Code:

• OK – STOP. The Integrated Temperature Sensing Module


(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder.
i01729291
System Response:
MID 111 - CID 1543 - FMI 04 Cyl
#13 Exhaust Port Temp Sensor Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
short to ground
The thermocouple is removed from the calculation for
SMCS Code: 1919 the average temperature of the engine.
Conditions Which Generate This Code: The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
The Integrated Temperature Sensing Module (ITSM) “Open/Shorted High” for the cylinder.
detects one of the following conditions for the input
from the thermocouple of the cylinder. The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side
Possible Performance Effect:
• A short circuit to the ground
Engine operation is not affected.
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for
the average temperature of the engine. Results:
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
• OK – STOP.
“Shorted to ground” for the cylinder.
i01729297
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds. MID 111 - CID 1544 - FMI 03 Cyl
#14 Exhaust Port Temp Sensor
Possible Performance Effect:
short to +batt
Engine operation is not affected.
SMCS Code: 1919
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)” The Integrated Temperature Sensing Module (ITSM)
detects a short circuit to the +Battery side for the
Results: input from the thermocouple of the cylinder.

• OK – STOP. System Response:

Monitoring of the exhaust temperature for the cylinder


is lost. Also, protection for the cylinder is lost.
130
Troubleshooting Section

The thermocouple is removed from the calculation for Troubleshooting:


the average temperature of the engine.
Perform the following diagnostic procedure:
The code is logged. The “Status” screen of the “Integrated Temperature Sensing Module (ITSM)”
Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder. Results:

The diagnostic code remains active until the condition • OK – STOP.


that caused the code is not present for 30 seconds.
i01729306
Possible Performance Effect:

Engine operation is not affected.


MID 111 - CID 1544 - FMI 05 Cyl
#14 Exhaust Port Temp Sensor
Troubleshooting:
open circuit
Perform the following diagnostic procedure: SMCS Code: 1919
“Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module
• OK – STOP. (ITSM) detects an open circuit for the input from the
thermocouple of the cylinder.
i01729303
System Response:
MID 111 - CID 1544 - FMI 04 Cyl
#14 Exhaust Port Temp Sensor Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost.
short to ground
The thermocouple is removed from the calculation for
SMCS Code: 1919 the average temperature of the engine.

Conditions Which Generate This Code: The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
The Integrated Temperature Sensing Module (ITSM) “Open/Shorted High” for the cylinder.
detects one of the following conditions for the input
from the thermocouple of the cylinder. The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side
Possible Performance Effect:
• A short circuit to the ground
Engine operation is not affected.
System Response:
Troubleshooting:
Monitoring of the exhaust temperature for the cylinder
is lost. Also, protection for the cylinder is lost. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for
the average temperature of the engine. Results:

The code is logged. The “Status” screen of the • OK – STOP.


Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.

The diagnostic code remains active until the condition


that caused the code is not present for 30 seconds.

Possible Performance Effect:

Engine operation is not affected.


131
Troubleshooting Section

i01729307 System Response:


MID 111 - CID 1545 - FMI 03 Cyl Monitoring of the exhaust temperature for the cylinder
#15 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

short to +batt The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.
The Integrated Temperature Sensing Module (ITSM)
detects a short circuit to the +Battery side for the The diagnostic code remains active until the condition
input from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.

System Response: Possible Performance Effect:

Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
is lost. Also, protection for the cylinder is lost.
Troubleshooting:
The thermocouple is removed from the calculation for
the average temperature of the engine. Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Results:
“Open/Shorted High” for the cylinder.
• OK – STOP.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
i01729312
Possible Performance Effect:
MID 111 - CID 1545 - FMI 05 Cyl
Engine operation is not affected. #15 Exhaust Port Temp Sensor
Troubleshooting: open circuit
Perform the following diagnostic procedure: SMCS Code: 1919
“Integrated Temperature Sensing Module (ITSM)”
Conditions Which Generate This Code:
Results:
The Integrated Temperature Sensing Module
(ITSM) detects an open circuit for the input from the
• OK – STOP. thermocouple of the cylinder.

i01729310 System Response:


MID 111 - CID 1545 - FMI 04 Cyl Monitoring of the exhaust temperature for the cylinder
#15 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.

short to ground The thermocouple is removed from the calculation for


the average temperature of the engine.
SMCS Code: 1919
The code is logged. The “Status” screen of the
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input The diagnostic code remains active until the condition
from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.

• A short circuit to the −Battery side Possible Performance Effect:

• A short circuit to the ground Engine operation is not affected.


132
Troubleshooting Section

Troubleshooting: i01729316

Perform the following diagnostic procedure: MID 111 - CID 1546 - FMI 04 Cyl
“Integrated Temperature Sensing Module (ITSM)” #16 Exhaust Port Temp Sensor
Results: short to ground
• OK – STOP. SMCS Code: 1919

Conditions Which Generate This Code:


i01729314
The Integrated Temperature Sensing Module (ITSM)
MID 111 - CID 1546 - FMI 03 Cyl detects one of the following conditions for the input
#16 Exhaust Port Temp Sensor from the thermocouple of the cylinder.
short to +batt • A short circuit to the −Battery side
SMCS Code: 1919
• A short circuit to the ground
Conditions Which Generate This Code: System Response:
The Integrated Temperature Sensing Module (ITSM) Monitoring of the exhaust temperature for the cylinder
detects a short circuit to the +Battery side for the is lost. Also, protection for the cylinder is lost.
input from the thermocouple of the cylinder.
The thermocouple is removed from the calculation for
System Response: the average temperature of the engine.
Monitoring of the exhaust temperature for the cylinder The code is logged. The “Status” screen of the
is lost. Also, protection for the cylinder is lost. Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.
The thermocouple is removed from the calculation for
the average temperature of the engine. The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds.
The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays Possible Performance Effect:
“Open/Shorted High” for the cylinder.
Engine operation is not affected.
The diagnostic code remains active until the condition
that caused the code is not present for 30 seconds. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure:
“Integrated Temperature Sensing Module (ITSM)”
Engine operation is not affected.
Results:
Troubleshooting:

Perform the following diagnostic procedure:


• OK – STOP.
“Integrated Temperature Sensing Module (ITSM)”
i01729319
Results:
MID 111 - CID 1546 - FMI 05 Cyl
• OK – STOP. #16 Exhaust Port Temp Sensor
open circuit
SMCS Code: 1919

Conditions Which Generate This Code:

The Integrated Temperature Sensing Module


(ITSM) detects an open circuit for the input from the
thermocouple of the cylinder.
133
Troubleshooting Section

System Response:

Monitoring of the exhaust temperature for the cylinder


is lost. Also, protection for the cylinder is lost.

The thermocouple is removed from the calculation for


the average temperature of the engine.

The code is logged. The “Status” screen of the


Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder.

The diagnostic code remains active until the condition


that caused the code is not present for 30 seconds.

Possible Performance Effect:

Engine operation is not affected.

Troubleshooting:

Perform the following diagnostic procedure:


“Integrated Temperature Sensing Module (ITSM)”

Results:

• OK – STOP.
134
Troubleshooting Section

Troubleshooting with an
Event Code
i02053451

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 g00791619
system. Event codes also indicate the nature of the Illustration 20
problem. The Caterpillar Electronic Technician (ET) Typical operating range of an oil temperature sensor
is designed to run on a personal computer. Event (1) In these areas, the output voltage of the sensor is too high
codes may be viewed on a personal computer that or too low. The output is outside of the normal range. The
has the Cat ET software. electronic problem will generate a diagnostic code.
(2) In this area, the oil temperature above 102 °C (216 °F) is higher
than normal. The output voltage of the sensor will generate an
Illustration 20 represents the operating range of an event code for a warningor a shutdown for high oil temperature.
oil temperature sensor. The diagram is a reference. The sensor does not have an electronic problem.
Do not use the diagram to troubleshoot the oil (3) This area represents the normal operating temperature for the
temperature sensor. engine oil. The normal output voltage of the sensor is between
0.2 and 4.1 volts.

The following format is used for event codes:

• “EXXX (X) Description of the code”


The “E” means that the code is an event code. The
“XXX” represents a numeric identifier for the event
code. The fourth “(X)” represents a numeric identifier
for the severity of the code. This is followed by a
description of the code. See the following example:

• “E004 (3) Engine Overspeed Shutdown”


The numbers that indicate the severity of the event
code are defined below:

Warning (1) – This condition represents a serious


problem with engine operation. However, this
condition does not require a shutdown.

Shutdown (3) – For this condition, the engine is


shut down in order to help prevent possible engine
damage.
135
Troubleshooting Section

These responses to certain events may be Be sure to check the connectors. This is specially
programmed into the ECM. If the responses are true for problems that are intermittent. See
programmed, Cat ET can display the event. If the Troubleshooting, “Inspecting Electrical Connectors”.
responses are not programmed, the display will not
appear. However, the occurrence of any event will Narrow the probable cause. Consider the operator
cause the event code to be logged in the ECM. information, the conditions of operation, and the
history of the engine.
Note: Do not confuse event codes with diagnostic
codes. For information on diagnostic codes, see
Troubleshooting, “Troubleshooting with a Diagnostic
Operator Information
Code”. Obtain the following information from the operator:
Perform the following tasks before you troubleshoot
the event code: • The occurrence and the time of the occurrence
• Determine the conditions for the occurrence. The
• Gather enough information about the complaint in conditions will include the engine rpm and the load.
order to describe the symptom(s) adequately.
• Determine if there are any systems that were
• Verify that the complaint is not due to normal installed by the dealer or the customer that could
engine operation. cause the symptom.
• Repair all active diagnostic codes. See • Determine whether any other occurrences
Troubleshooting, “Troubleshooting With A happened in addition to the symptom.
Diagnostic Code”.

Troubleshooting Diagnostic Codes and Event Codes


Examine the following information regarding any
For basic troubleshooting of the engine, perform codes:
the following steps first in order to diagnose a
malfunction.
• The probable cause of the symptom is correlated
to the code.
1. Gather information about the complaint from the
operator.
• The code was generated when the symptom
occurred.
2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
due to error of the operator. • Codes that are repeatedly logged

3. Perform a visual inspection. Inspect the following • The complaint is not due to normal engine
operation.
items:

• Fuel supply Other Symptoms


• Oil level If other occurrences happened in addition to the
symptom, investigate the following conditions:
• Oil supply
• The other occurrences are related to the symptom.
• Wiring
• The symptoms have a probable cause that is
• Connectors common.

4. Check the diagnostic codes and event codes. Active Event Codes
Repair any active codes.
An active event code represents a problem with
If these inspections do not reveal any problems, engine operation. Correct the problem as soon as
identify the probable causes with the procedures in possible.
this manual that best describe the symptoms. Check
each probable cause according to the tests that are
recommended.
136
Troubleshooting Section

When an event code is active, the “Active Alarm” System Response:


indicator (“Engine Control Alarm Status” on Cat
ET) is activated in order to alert the operator. If the The gas shutoff valve and the ignition are shut off.
condition that generated the code is momentary, the The shutdown output is activated. The code is logged.
message disappears. The event code will be logged
in the ECM memory. Possible Performance Effect:

Active event codes are listed in ascending numerical The engine is shut down.
order. The code with the lowest number is listed first.
Troubleshooting:
Logged Event Codes Refer to Troubleshooting, “Engine Overspeed”.
When the ECM generates an event code the ECM
logs the code in permanent memory. The ECM has Results:
an internal diagnostic clock. The ECM will record the
following information when a code is generated: • OK – STOP.

• The hour of the first occurrence of the code i01633543

• The hour of the last occurrence of the code E016 High Engine Coolant
• The number of occurrences of the code
Temperature Shutdown
SMCS Code: 1395-038
This information can be helpful for troubleshooting
intermittent problems. Logged codes can also be Conditions Which Generate This Code:
used to review the performance of the engine.
The crank terminate relay is set and the engine has
A code is cleared from memory when one of the been running for at least 30 seconds. The engine
following conditions occur:
coolant temperature has exceeded the trip point and
the delay time has expired. No other codes for the
• The service technician manually clears the code. engine coolant are active.
• The code does not recur for 1000 hours. System Response:
• A new code is logged and there are already ten The fuel is shut off. The shutdown output is activated.
codes in memory. In this case, the oldest code is
The code is logged.
cleared.
Possible Performance Effect:
Logged events are listed in chronological order. The
most recent event code is listed first. The engine is shut down.
Note: Always clear logged event codes after
Troubleshooting:
investigating and correcting the problem which
generated the code.
Refer to Troubleshooting, “Engine Coolant
Temperature (High)”.
i01729333
Results:
E004 Engine Overspeed
Shutdown • OK – STOP.

SMCS Code: 1348-038

Conditions Which Generate This Code:

The engine rpm has exceeded the trip point that


is programmed into the Electronic Control Module
(ECM) and the delay time has expired. The ECM has
determined that the detected speed is accurate.
137
Troubleshooting Section

i01633545 Results:
E017 High Engine Coolant • OK – STOP.
Temperature Warning
i01633605
SMCS Code: 1395-038
E020 High Engine Oil
Conditions Which Generate This Code:
Temperature Warning
The crank terminate relay is set and the engine has
been running for at least 30 seconds. The engine SMCS Code: 1348-038
coolant temperature has exceeded the trip point and
the delay time has expired. No other codes for the Conditions Which Generate This Code:
engine coolant are active.
The crank terminate relay is set and the engine has
System Response: been running for at least 30 seconds. The engine
oil temperature has exceeded the trip point and the
The alarm output is activated. The code is logged. delay time has expired. No other codes for the engine
oil temperature are active.
Possible Performance Effect:
System Response:
The engine operation is not immediately affected.
However, if the coolant temperature continues to rise, The alarm output is activated. The code is logged.
the engine will be shut down.
Possible Performance Effect:
Troubleshooting:
The engine operation is not immediately affected.
Refer to Troubleshooting, “Engine Coolant However, if the engine oil temperature continues to
Temperature (High)”. rise, the engine can be shut down.

Results: Troubleshooting:

Refer to Troubleshooting, “Engine Oil Temperature


• OK – STOP. (High)”.

i01633603 Results:
E019 High Engine Oil • OK – STOP.
Temperature Shutdown
i01633755
SMCS Code: 1348-038
E026 High Inlet Air
Conditions Which Generate This Code:
Temperature Shutdown
The crank terminate relay is set and the engine has
been running for at least 30 seconds. The engine SMCS Code: 1050-038
oil temperature has exceeded the trip point and the
delay time has expired. No other codes for the engine Conditions Which Generate This Code:
oil temperature are active.
The crank terminate relay is set and the engine has
System Response: been running for at least 30 seconds. The inlet air
temperature has exceeded the trip point and the
The fuel is shut off. The shutdown output is activated. delay time has expired. No other codes for the inlet
The code is logged. air temperature are active.

Possible Performance Effect: System Response:

The engine is shut off. The fuel is shut off. The shutdown output is activated.
The code is logged.
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Engine Oil Temperature
(High)”. The engine is shut down.
138
Troubleshooting Section

Troubleshooting: System Response:

Refer to Troubleshooting, “Inlet Air Temperature The alarm output is activated. The code is logged.
(High)”.
Possible Performance Effect:
Results:
The engine operation is not immediately affected.
• OK – STOP.
Troubleshooting:
i01633756
Refer to Troubleshooting, “Engine Coolant
E027 High Inlet Air Temperature (Low)”.

Temperature Warning Results:

SMCS Code: 1050-038 • OK – STOP.


Conditions Which Generate This Code:
i01633762

The crank terminate relay is set and the engine has


been running for at least 30 seconds. The inlet air
E040 Low Engine Oil Pressure
temperature has exceeded the trip point and the Shutdown
delay time has expired. No other codes for the inlet
air temperature are active. SMCS Code: 1348-038-PX

System Response: Conditions Which Generate This Code:

The alarm output is activated. The code is logged. The crank terminate relay is set and the engine has
been running for at least 10 seconds. The engine oil
Possible Performance Effect: pressure is less than the trip point and the delay time
has expired. No codes for the engine oil pressure
The engine operation is not immediately affected. sensor are active.
However, if the inlet air temperature continues to rise,
the engine may be shut down. System Response:

Troubleshooting: The fuel is shut off. The shutdown output is activated.


The code is logged.
Refer to Troubleshooting, “Inlet Air Temperature
(High)”. Possible Performance Effect:

Results: The engine is shut down.

• OK – STOP. Troubleshooting:

Refer to Troubleshooting, “Engine Oil Pressure


i01633757
(Low)”.
E038 Low Engine Coolant Results:
Temperature Warning
• OK – STOP.
SMCS Code: 1395-038

Conditions Which Generate This Code:

The crank terminate relay is set and the engine


has been running for at least 30 seconds. The
temperature of the engine coolant is less than the trip
point and the delay time has expired. No other codes
for the coolant temperature are active.
139
Troubleshooting Section

i01633763 i01877738

E042 Low System Voltage E050 High System Voltage


Shutdown Warning
SMCS Code: 1400-038 SMCS Code: 1400-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The voltage is less than the trip point and the delay The voltage is greater than the trip point and the
time has expired. No other codes for the system delay time has expired. No other codes for the
voltage are present. system voltage are present.

System Response: System Response:

The shutdown output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine is shut down. The engine operation is not immediately affected.
However, engine components could be damaged if
Troubleshooting: the system voltage continues to increase.

Refer to Troubleshooting, “System Voltage”. Troubleshooting:

Results: Refer to Troubleshooting, “System Voltage”.

• OK – STOP. Results:

i01633765
• OK – STOP.

E043 Low System Voltage i01637578

Warning E053 Low Fuel Pressure


SMCS Code: 1400-038 Warning
Conditions Which Generate This Code: SMCS Code: 1250-038

The voltage is less than the trip point and the delay Conditions Which Generate This Code:
time has expired. No other codes for the system
voltage are present. The fuel pressure is less than the trip point and the
delay time has expired.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine operation is not immediately affected.
However, if the system voltage continues to be The engine operation is not immediately affected.
reduced, the engine will be shut down. However, if the fuel pressure continues to be
reduced, the supply may become inadequate for the
Troubleshooting: fuel metering valve.

Refer to Troubleshooting, “System Voltage”. Troubleshooting:

Results: Refer to Troubleshooting, “Fuel Pressure”.

• OK – STOP. Results:

• OK – STOP.
140
Troubleshooting Section

i01637590 Results:
E096 High Fuel Pressure • OK – STOP.
SMCS Code: 1250-038
i01633790
Conditions Which Generate This Code:
E127 Engine Oil Filter Diff
The fuel pressure is higher than the trip point and the Pressure Low Warning
delay time has expired.
SMCS Code: 1308-038
System Response:
Conditions Which Generate This Code:
The alarm output is activated. The code is logged.
The crank terminate relay is set and the engine has
Possible Performance Effect: been running for at least 30 seconds. The engine oil
filter differential pressure is less than the trip point
The engine operation is not immediately affected. and the delay time has expired. There are no active
However, if the fuel pressure continues to increase, codes for the oil pressure sensors.
the supply may exceed the maximum limit for the fuel
metering valve. System Response:

Troubleshooting: The alarm output is activated. The code is logged.

Refer to Troubleshooting, “Fuel Pressure”. Possible Performance Effect:


Results: The engine operation is not immediately affected.
However, if the engine oil filter differential pressure
• OK – STOP. continues to be reduced, the engine may be shut
down.
i01633787
Troubleshooting:
E100 Low Engine Oil Pressure
Refer to Troubleshooting, “Engine Oil Filter
Warning Differential Pressure”.
SMCS Code: 1348-038 Results:
Conditions Which Generate This Code: • OK – STOP.
The crank terminate relay is set and the engine has
been running for at least ten seconds. The engine i01633814
oil pressure is less than the trip point and the delay
time has expired. There are no active codes for the E128 Engine Oil Filter Diff
engine oil pressure sensor. Pressure Low Shutdown
System Response: SMCS Code: 1308-038

The alarm output is activated. The code is logged. Conditions Which Generate This Code:

Possible Performance Effect: The crank terminate relay is set and the engine has
been running for at least 30 seconds. The oil filter
The engine operation is not immediately affected. differential pressure is less than the trip point and the
However, if the oil pressure continues to be reduced, delay time has expired. There are no active codes for
the engine may be shut down. the oil pressure sensors.

Troubleshooting: System Response:

Refer to Troubleshooting, “Engine Oil Pressure The fuel is shut off. The shutdown output is activated.
(Low)”. The code is logged.
141
Troubleshooting Section

Possible Performance Effect: System Response:

The engine is shut down. The fuel is shut off. The shutdown output is activated.
The code is logged.
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Engine Oil Filter
Differential Pressure”. The engine is shut down.

Results: Troubleshooting:

• OK – STOP. Refer to Troubleshooting, “Engine Oil Filter


Differential Pressure”.
i01633828
Results:
E129 Engine Oil Filter Diff
• OK – STOP.
Pressure High Warning
SMCS Code: 1308-038 i01633833

Conditions Which Generate This Code:


E135 Low Jacket Water
Pressure Shutdown
The crank terminate relay is set and the engine has
been running for at least 30 seconds. The oil filter SMCS Code: 1350-038
differential pressure is greater than the trip point
and the delay time has expired. There are no active Conditions Which Generate This Code:
codes for the oil pressure sensors.
The crank terminate relay is set and the engine has
System Response: been running for at least ten seconds. The pressure
of the jacket water is less than the trip point and the
The alarm output is activated. The code is logged. delay time has expired. There are no active codes for
the pressure sensor at the outlet for the jacket water.
Possible Performance Effect:
System Response:
The engine operation is not immediately affected.
However, if the oil filter differential pressure continues The fuel is shut off. The shutdown output is activated.
to increase, the engine may be shut down. The code is logged.

Troubleshooting: Possible Performance Effect:

Refer to Troubleshooting, “Engine Oil Filter The engine is shut off.


Differential Pressure”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Jacket Water Pressure
• OK – STOP. (Low)”.

Results:
i01633832

E130 Engine Oil Filter Diff • OK – STOP.


Pressure High Shutdown
SMCS Code: 1308-038

Conditions Which Generate This Code:

The crank terminate relay is set and the engine has


been running for at least 30 seconds. The engine oil
filter differential pressure is greater than the trip point
and the delay time has expired. There are no active
codes for the oil pressure sensors.
142
Troubleshooting Section

i01633954 Results:
E223 High Gas Temperature • OK – STOP.
SMCS Code: 1250-038
i01633959
Conditions Which Generate This Code:
E225 Engine Overcrank
The crank terminate relay is set and the engine
has been running for at least 30 seconds. The SMCS Code: 1400-038
temperature of the gas has exceeded the trip point
and the delay timer has expired. There are no active Conditions Which Generate This Code:
codes for the fuel temperature sensor.
The engine did not start within the programmed
System Response: parameters for starting.

The alarm output is activated. The code is logged. System Response:

Possible Performance Effect: The fuel is shut off. Engine cranking is prevented.
The code is logged.
The engine operation is not immediately affected.
However, if the fuel temperature continues to Possible Performance Effect:
increase, the air/fuel ratio and the inlet manifold air
temperature can be affected. The engine will not start.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Gas Temperature (High)”. Refer to Troubleshooting, “Engine Overcrank”.

Results: Results:

• OK – STOP. • OK – STOP.

i01729345
i01633956

E224 High Jacket Water Inlet E226 Driven Equipment Not


Pressure Ready
SMCS Code: 1350-038 SMCS Code: 1404-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The crank terminate relay is set and the engine has The engine is ready to start. However, the Electronic
been running for at least 10 seconds. The trip point Control Module (ECM) has received a signal which
for high pressure at the inlet for the jacket water has indicates that the driven equipment is not ready for
been exceeded and the delay time has expired. the engine to start.

System Response: System Response:

The fuel is shut off. The shutdown output is activated. The shutdown output is activated. Engine cranking
The code is logged. is prevented. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine is shut down. The engine will not start.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Jacket Water Inlet Refer to Troubleshooting, “Driven Equipment”.


Pressure (High)”.
143
Troubleshooting Section

Results: Results:

• OK – STOP. • OK – STOP.

i01633972 i01746483

E229 Fuel Energy Content E231 Fuel Quality Out of Range


Setting Low SMCS Code: 1250-038
SMCS Code: 1250-038
Conditions Which Generate This Code:
Conditions Which Generate This Code: The crank terminate relay is set and the engine has
been running for at least 30 seconds. The Low Heat
The crank terminate relay is set and the engine
Value (LHV) of the fuel is less than the trip point OR
has been running for at least 30 seconds. The fuel the LHV of the fuel is greater than the trip point for
correction factor is less than the trip point for 20
20 seconds.
seconds.
System Response:
System Response:
The fuel is shut off. The shutdown output is activated.
The alarm output is activated. The code is logged. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance may be erratic.
The engine is shut off.
Troubleshooting: Troubleshooting:
Refer to Troubleshooting, “Fuel Energy Content”.
Refer to Troubleshooting, “Fuel Energy Content”.
Results:
Results:
• OK – STOP. • OK – STOP.
i01633976
i01634015

E230 Fuel Energy Content E243 High Left Turbo Turbine


Setting High Outlet Temperature
SMCS Code: 1250-038 SMCS Code: 1052-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The crank terminate relay is set and the engine
The temperature at the outlet for the left turbocharger
has been running for at least 30 seconds. The fuel
turbine has exceeded the trip point and the delay
correction factor is greater than the trip point for 20 time has expired.
seconds.
System Response:
System Response:
The following event codes are logged according to
The alarm output is activated. The code is logged.
the trip points for the temperature:
Possible Performance Effect:
• E243 (1) High Left Turbo Turbine Outlet
Temperature (warning)
The engine performance may be erratic.

Troubleshooting: • E243 (3) High Left Turbo Turbine Outlet


Temperature (shutdown)
Refer to Troubleshooting, “Fuel Energy Content”.
If a warning is generated, the alarm output is
activated.
144
Troubleshooting Section

If a shutdown is generated, the shutdown output is Troubleshooting:


activated.
Refer to Troubleshooting, “Turbocharger Turbine
Possible Performance Effect: Temperature (High)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
i01634041

Troubleshooting: E245 High Right Turbo Turbine


Refer to Troubleshooting, “Turbocharger Turbine Inlet Temperature
Temperature (High)”.
SMCS Code: 1052-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The temperature at the inlet for the right turbocharger
turbine has exceeded the trip point and the delay
i01634039 time has expired.
E244 High Right Turbo Turbine System Response:
Outlet Temperature
The following event codes are logged according to
SMCS Code: 1052-038 the trip points for the temperature:

Conditions Which Generate This Code: • E245 (1) High Right Turbo Turbine Inlet
Temperature (warning)
The temperature at the outlet for the right
turbocharger turbine has exceeded the trip point and • E245 (3) High Right Turbo Turbine Inlet
the delay time has expired. Temperature (shutdown)

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated.
• E244 (1) High Right Turbo Turbine Outlet
Temperature (warning) Possible Performance Effect:

• E244 (3) High Right Turbo Turbine Outlet If a warning is generated, the engine performance is
Temperature (shutdown) not immediately affected.

If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.

If a shutdown is generated, the shutdown output is Troubleshooting:


activated.
Refer to Troubleshooting, “Turbocharger Turbine
Possible Performance Effect: Temperature (High)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
145
Troubleshooting Section

i01634043 System Response:


E246 High Left Turbo Turbine The gas shutoff valve (GSOV) and the ignition are
Inlet Temperature shut off. The shutdown output is activated. The code
is logged.
SMCS Code: 1052-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine is shut off.
The temperature at the inlet for the left turbocharger
turbine has exceeded the trip point and the delay Troubleshooting:
time has expired.
Refer to Troubleshooting, “Engine Shutdown”.
System Response:
Results:
The following event codes are logged according to
the trip points for the temperature: • OK – STOP.

• E246 (1) High Left Turbo Turbine Inlet Temperature i01634063


(warning)
E268 Unexpected Engine
• E246 (3) High Left Turbo Turbine Inlet Temperature Shutdown
(shutdown)

If a warning is generated, the alarm output is SMCS Code: 1400-038


activated.
Conditions Which Generate This Code:
If a shutdown is generated, the shutdown output is
activated. The crank terminate relay is set and the engine is
running. The engine rpm is less than the programmed
Possible Performance Effect: speed of the postlube cycle for 200 ms.

If a warning is generated, the engine performance is System Response:


not immediately affected.
The fuel is shut off. The shutdown output is activated.
The engine will be shut down if the trip point for the The code is logged.
shutdown is exceeded.
Possible Performance Effect:
Troubleshooting:
The engine is shut down.
Refer to Troubleshooting, “Turbocharger Turbine
Temperature (High)”. Troubleshooting:

Results: Refer to Troubleshooting, “Engine Shutdown


(Unexpected)”.
• OK – STOP. Results:

i01634059 • OK – STOP.
E264 Emergency Stop
Activated i01634093

E269 Customer Shutdown


SMCS Code: 1400-038
Requested
Conditions Which Generate This Code:
SMCS Code: 1400-038
The input for the emergency stop is activated.
Conditions Which Generate This Code:

The engine is either cranking or running. The input


for the stop is set for 200 ms.
146
Troubleshooting Section

System Response: i01864896

The fuel is shut off. The shutdown output is activated. E337 High Engine Oil to Engine
The code is logged. Coolant Diff Temp
Possible Performance Effect: SMCS Code: 1350-038
The engine is shut off. Conditions Which Generate This Code:
Troubleshooting: The crank terminate relay is set and the engine has
been running for at least 30 seconds. The differential
Refer to Troubleshooting, “Engine Shutdown”. between the temperature of the engine oil and the
temperature of the engine coolant has exceeded the
Results: trip point. Also, the delay time has expired. There are
no active codes for the sensors for the engine oil
• OK – STOP. temperature and the engine coolant.

i01634097
System Response:

E270 Driven Equipment The following event codes are logged according to
the trip points for the temperature differential:
Shutdown Requested
SMCS Code: 1400-038
• E337 (1) High Engine Oil to Engine Coolant Diff
Temp (warning)
Conditions Which Generate This Code:
• E337 (3) High Engine Oil to Engine Coolant Diff
Temp (shutdown)
The crank terminate relay is set and the engine is
running. The input requests a shutdown for 200 ms. If a warning is activated, the alarm output is activated.
System Response: If a shutdown is activated, the shutdown output is
activated.
The fuel is shut off. The shutdown output is activated.
The code is logged. Possible Performance Effect:
Possible Performance Effect: If a warning is generated, the engine operation is not
immediately affected.
The engine is shut down.
The engine will be shut down if the trip point for the
Troubleshooting: shutdown is exceeded.
Refer to Troubleshooting, “Driven Equipment”. Troubleshooting:
Results: Refer to Troubleshooting, “Jacket Water to Engine
Oil Differential Temperature (Low)”.
• OK – STOP.
Results:

• OK – STOP.
147
Troubleshooting Section

i01637607 i01637627

E401 Cylinder #1 Detonation E403 Cylinder #3 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.

i01637623 i01637634

E402 Cylinder #2 Detonation E404 Cylinder #4 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.
148
Troubleshooting Section

i01637642 i01637648

E405 Cylinder #5 Detonation E407 Cylinder #7 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.

i01637646 i01637651

E406 Cylinder #6 Detonation E408 Cylinder #8 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.
149
Troubleshooting Section

i01637653 i01637663

E409 Cylinder #9 Detonation E411 Cylinder #11 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.

i01637657 i01637665

E410 Cylinder #10 Detonation E412 Cylinder #12 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.
150
Troubleshooting Section

i01637696 i01637702

E413 Cylinder #13 Detonation E415 Cylinder #15 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.

i01637699 i01637706

E414 Cylinder #14 Detonation E416 Cylinder #16 Detonation


SMCS Code: 1000-038 SMCS Code: 1000-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.

System Response: System Response:

The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.

Possible Performance Effect: Possible Performance Effect:

The engine performance may be affected by an The engine performance may be affected by an
adjustment of the timing in order to reduce detonation. adjustment of the timing in order to reduce detonation.

Troubleshooting: Troubleshooting:

Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

Results: Results:

• OK – STOP. • OK – STOP.
151
Troubleshooting Section

i01634664 Results:
E421 Cylinder #1 Detonation • OK – STOP.
Shutdown
i01634838
SMCS Code: 1000-038
E423 Cylinder #3 Detonation
Conditions Which Generate This Code:
Shutdown
The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to SMCS Code: 1000-038
control the detonation adequately during the number
of ignition sparks that are allowed. There is no active Conditions Which Generate This Code:
diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point.
System Response: Maximum retardation of the timing was unable to
control the detonation adequately during the number
The fuel is shut off. The shutdown output is activated. of ignition sparks that are allowed. There is no active
The code is logged. diagnostic code for the cylinder’s detonation sensor.

Possible Performance Effect: System Response:

The engine is shut down. The fuel is shut off. The shutdown output is activated.
The code is logged.
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
Results:
Troubleshooting:
• OK – STOP. Refer to Troubleshooting, “Detonation”.

i01634746 Results:
E422 Cylinder #2 Detonation • OK – STOP.
Shutdown
i01635415
SMCS Code: 1000-038
E424 Cylinder #4 Detonation
Conditions Which Generate This Code:
Shutdown
The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to SMCS Code: 1000-038
control the detonation adequately during the number
of ignition sparks that are allowed. There is no active Conditions Which Generate This Code:
diagnostic code for the cylinder’s detonation sensor.
The level of detonation has exceeded the trip point.
System Response: Maximum retardation of the timing was unable to
control the detonation adequately during the number
The fuel is shut off. The shutdown output is activated. of ignition sparks that are allowed. There is no active
The code is logged. diagnostic code for the cylinder’s detonation sensor.

Possible Performance Effect: System Response:

The engine is shut down. The fuel is shut off. The shutdown output is activated.
The code is logged.
Troubleshooting:
Possible Performance Effect:
Refer to Troubleshooting, “Detonation”.
The engine is shut down.
152
Troubleshooting Section

Troubleshooting: Possible Performance Effect:

Refer to Troubleshooting, “Detonation”. The engine is shut down.

Results: Troubleshooting:

• OK – STOP. Refer to Troubleshooting, “Detonation”.

Results:
i01635416

E425 Cylinder #5 Detonation • OK – STOP.


Shutdown i01635420

SMCS Code: 1000-038


E427 Cylinder #7 Detonation
Conditions Which Generate This Code: Shutdown
The level of detonation has exceeded the trip point. SMCS Code: 1000-038
Maximum retardation of the timing was unable to
control the detonation adequately during the number Conditions Which Generate This Code:
of ignition sparks that are allowed. There is no active
diagnostic code for the cylinder’s detonation sensor. The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to
System Response: control the detonation adequately during the number
of ignition sparks that are allowed. There is no active
The fuel is shut off. The shutdown output is activated. diagnostic code for the cylinder’s detonation sensor.
The code is logged.
System Response:
Possible Performance Effect:
The fuel is shut off. The shutdown output is activated.
The engine is shut down. The code is logged.

Troubleshooting: Possible Performance Effect:

Refer to Troubleshooting, “Detonation”. The engine is shut down.

Results: Troubleshooting:

• OK – STOP. Refer to Troubleshooting, “Detonation”.

Results:
i01635417

E426 Cylinder #6 Detonation • OK – STOP.


Shutdown
i01635421

SMCS Code: 1000-038 E428 Cylinder #8 Detonation


Conditions Which Generate This Code: Shutdown
The level of detonation has exceeded the trip point. SMCS Code: 1000-038
Maximum retardation of the timing was unable to
control the detonation adequately during the number Conditions Which Generate This Code:
of ignition sparks that are allowed. There is no active
diagnostic code for the cylinder’s detonation sensor. The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to
System Response: control the detonation adequately during the number
of ignition sparks that are allowed. There is no active
The fuel is shut off. The shutdown output is activated. diagnostic code for the cylinder’s detonation sensor.
The code is logged.
153
Troubleshooting Section

System Response: i01635424

The fuel is shut off. The shutdown output is activated. E430 Cylinder #10 Detonation
The code is logged. Shutdown
Possible Performance Effect: SMCS Code: 1000-038
The engine is shut down. Conditions Which Generate This Code:
Troubleshooting: The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to
Refer to Troubleshooting, “Detonation”. control the detonation adequately during the number
of ignition sparks that are allowed. There is no active
Results: diagnostic code for the cylinder’s detonation sensor.

• OK – STOP. System Response:

i01635423
The fuel is shut off. The shutdown output is activated.
The code is logged.
E429 Cylinder #9 Detonation
Possible Performance Effect:
Shutdown
The engine is shut down.
SMCS Code: 1000-038
Troubleshooting:
Conditions Which Generate This Code:
Refer to Troubleshooting, “Detonation”.
The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to Results:
control the detonation adequately during the number
of ignition sparks that are allowed. There is no active
diagnostic code for the cylinder’s detonation sensor.
• OK – STOP.

System Response: i01635428

The fuel is shut off. The shutdown output is activated. E431 Cylinder #11 Detonation
The code is logged. Shutdown
Possible Performance Effect: SMCS Code: 1000-038
The engine is shut down. Conditions Which Generate This Code:
Troubleshooting: The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to
Refer to Troubleshooting, “Detonation”. control the detonation adequately during the number
of ignition sparks that are allowed. There is no active
Results: diagnostic code for the cylinder’s detonation sensor.

• OK – STOP. System Response:

The fuel is shut off. The shutdown output is activated.


The code is logged.

Possible Performance Effect:

The engine is shut down.

Troubleshooting:

Refer to Troubleshooting, “Detonation”.


154
Troubleshooting Section

Results: Troubleshooting:

• OK – STOP. Refer to Troubleshooting, “Detonation”.

Results:
i01635429

E432 Cylinder #12 Detonation • OK – STOP.


Shutdown
i01635433

SMCS Code: 1000-038


E434 Cylinder #14 Detonation
Conditions Which Generate This Code: Shutdown
The level of detonation has exceeded the trip point. SMCS Code: 1000-038
Maximum retardation of the timing was unable to
control the detonation adequately during the number Conditions Which Generate This Code:
of ignition sparks that are allowed. There is no active
diagnostic code for the cylinder’s detonation sensor. The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to
System Response: control the detonation adequately during the number
of ignition sparks that are allowed. There is no active
The fuel is shut off. The shutdown output is activated. diagnostic code for the cylinder’s detonation sensor.
The code is logged.
System Response:
Possible Performance Effect:
The fuel is shut off. The shutdown output is activated.
The engine is shut down. The code is logged.

Troubleshooting: Possible Performance Effect:

Refer to Troubleshooting, “Detonation”. The engine is shut down.

Results: Troubleshooting:

• OK – STOP. Refer to Troubleshooting, “Detonation”.

Results:
i01635431

E433 Cylinder #13 Detonation • OK – STOP.


Shutdown i01635435

SMCS Code: 1000-038


E435 Cylinder #15 Detonation
Conditions Which Generate This Code: Shutdown
The level of detonation has exceeded the trip point. SMCS Code: 1000-038
Maximum retardation of the timing was unable to
control the detonation adequately during the number Conditions Which Generate This Code:
of ignition sparks that are allowed. There is no active
diagnostic code for the cylinder’s detonation sensor. The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to
System Response: control the detonation adequately during the number
of ignition sparks that are allowed. There is no active
The fuel is shut off. The shutdown output is activated. diagnostic code for the cylinder’s detonation sensor.
The code is logged.
System Response:
Possible Performance Effect:
The fuel is shut off. The shutdown output is activated.
The engine is shut down. The code is logged.
155
Troubleshooting Section

Possible Performance Effect: • E801 (1) Cylinder #1 High Exhaust Port Temp
(warning)
The engine is shut down.
• E801 (3) Cylinder #1 High Exhaust Port Temp
Troubleshooting: (shutdown)

Refer to Troubleshooting, “Detonation”. If a warning is generated, the alarm output is


activated.
Results:
If a shutdown is generated, the shutdown output is
• OK – STOP. activated and the fuel is shut off.

Possible Performance Effect:


i01635436

E436 Cylinder #16 Detonation If a warning is generated, the engine performance is


not immediately affected.
Shutdown
The engine will be shut down if the trip point for the
SMCS Code: 1000-038 shutdown is exceeded.

Conditions Which Generate This Code: Troubleshooting:

The level of detonation has exceeded the trip point. Refer to Troubleshooting, “Exhaust Port Temperature
Maximum retardation of the timing was unable to (High)”.
control the detonation adequately during the number
of ignition sparks that are allowed. There is no active Results:
diagnostic code for the cylinder’s detonation sensor.
• OK – STOP.
System Response:

The fuel is shut off. The shutdown output is activated. i01635500

The code is logged.


E802 Cylinder #2 High Exhaust
Possible Performance Effect: Port Temp
The engine is shut down. SMCS Code: 1059-038

Troubleshooting: Conditions Which Generate This Code:

Refer to Troubleshooting, “Detonation”. The cylinder exhaust temperature has exceeded the
trip point and the delay time has expired.
Results:
System Response:
• OK – STOP.
The following event codes are logged according to
the trip points for the temperature:
i01635494

E801 Cylinder #1 High Exhaust • E802 (1) Cylinder #2 High Exhaust Port Temp
(warning)
Port Temp
• E802 (3) Cylinder #2 High Exhaust Port Temp
SMCS Code: 1059-038 (shutdown)

Conditions Which Generate This Code: If a warning is generated, the alarm output is
activated.
The cylinder exhaust temperature has exceeded the
trip point and the delay time has expired. If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
System Response:
Possible Performance Effect:
The following event codes are logged according to
the trip points for the temperature: If a warning is generated, the engine performance is
not immediately affected.
156
Troubleshooting Section

The engine will be shut down if the trip point for the i01635505
shutdown is exceeded.
E804 Cylinder #4 High Exhaust
Troubleshooting: Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature has exceeded the
• OK – STOP. trip point and the delay time has expired.

i01635503
System Response:

E803 Cylinder #3 High Exhaust The following event codes are logged according to
the trip points for the temperature:
Port Temp
SMCS Code: 1059-038
• E804 (1) Cylinder #4 High Exhaust Port Temp
(warning)
Conditions Which Generate This Code:
• E804 (3) Cylinder #4 High Exhaust Port Temp
(shutdown)
The cylinder exhaust temperature has exceeded the
trip point and the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output is
The following event codes are logged according to activated and the fuel is shut off.
the trip points for the temperature:
Possible Performance Effect:
• E803 (1) Cylinder #3 High Exhaust Port Temp
(warning) If a warning is generated, the engine performance is
not immediately affected.
• E803 (3) Cylinder #3 High Exhaust Port Temp
(shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (High)”.
Possible Performance Effect: Results:
If a warning is generated, the engine performance is
not immediately affected.
• OK – STOP.

The engine will be shut down if the trip point for the i01635508
shutdown is exceeded.
E805 Cylinder #5 High Exhaust
Troubleshooting: Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature has exceeded the
• OK – STOP. trip point and the delay time has expired.
157
Troubleshooting Section

System Response: Possible Performance Effect:

The following event codes are logged according to If a warning is generated, the engine performance is
the trip points for the temperature: not immediately affected.

• E805 (1) Cylinder #5 High Exhaust Port Temp The engine will be shut down if the trip point for the
(warning) shutdown is exceeded.

• E805 (3) Cylinder #5 High Exhaust Port Temp Troubleshooting:


(shutdown)
Refer to Troubleshooting, “Exhaust Port Temperature
If a warning is generated, the alarm output is (High)”.
activated.
Results:
If a shutdown is generated, the shutdown output is
activated and the fuel is shut off. • OK – STOP.
Possible Performance Effect:
i01635512

If a warning is generated, the engine performance is


not immediately affected.
E807 Cylinder #7 High Exhaust
Port Temp
The engine will be shut down if the trip point for the
shutdown is exceeded. SMCS Code: 1059-038

Troubleshooting: Conditions Which Generate This Code:

Refer to Troubleshooting, “Exhaust Port Temperature The cylinder exhaust temperature has exceeded the
(High)”. trip point and the delay time has expired.

Results: System Response:

• OK – STOP. The following event codes are logged according to


the trip points for the temperature:
i01635511
• E807 (1) Cylinder #7 High Exhaust Port Temp
E806 Cylinder #6 High Exhaust (warning)

Port Temp • E807 (3) Cylinder #7 High Exhaust Port Temp


(shutdown)
SMCS Code: 1059-038
If a warning is generated, the alarm output is
Conditions Which Generate This Code: activated.

The cylinder exhaust temperature has exceeded the If a shutdown is generated, the shutdown output is
trip point and the delay time has expired. activated and the fuel is shut off.

System Response: Possible Performance Effect:

The following event codes are logged according to If a warning is generated, the engine performance is
the trip points for the temperature: not immediately affected.

• E806 (1) Cylinder #6 High Exhaust Port Temp The engine will be shut down if the trip point for the
(warning) shutdown is exceeded.

• E806 (3) Cylinder #6 High Exhaust Port Temp Troubleshooting:


(shutdown)
Refer to Troubleshooting, “Exhaust Port Temperature
If a warning is generated, the alarm output is (High)”.
activated.
Results:
If a shutdown is generated, the shutdown output is
activated and the fuel is shut off. • OK – STOP.
158
Troubleshooting Section

i01635513 System Response:


E808 Cylinder #8 High Exhaust The following event codes are logged according to
Port Temp the trip points for the temperature:

SMCS Code: 1059-038 • E809 (1) Cylinder #9 High Exhaust Port Temp
(warning)
Conditions Which Generate This Code:
• E809 (3) Cylinder #9 High Exhaust Port Temp
The cylinder exhaust temperature has exceeded the (shutdown)
trip point and the delay time has expired.
If a warning is generated, the alarm output is
System Response: activated.

The following event codes are logged according to If a shutdown is generated, the shutdown output is
the trip points for the temperature: activated and the fuel is shut off.

• E808 (1) Cylinder #8 High Exhaust Port Temp Possible Performance Effect:
(warning)
If a warning is generated, the engine performance is
• E808 (3) Cylinder #8 High Exhaust Port Temp not immediately affected.
(shutdown)
The engine will be shut down if the trip point for the
If a warning is generated, the alarm output is shutdown is exceeded.
activated.
Troubleshooting:
If a shutdown is generated, the shutdown output is
activated and the fuel is shut off. Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
Possible Performance Effect:
Results:
If a warning is generated, the engine performance is
not immediately affected. • OK – STOP.

The engine will be shut down if the trip point for the i01635549
shutdown is exceeded.
E810 Cylinder #10 High
Troubleshooting:
Exhaust Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature
(High)”. SMCS Code: 1059-038

Results: Conditions Which Generate This Code:

The cylinder exhaust temperature has exceeded the


• OK – STOP. trip point and the delay time has expired.

i01635546 System Response:


E809 Cylinder #9 High Exhaust The following event codes are logged according to
Port Temp the trip points for the temperature:

SMCS Code: 1059-038 • E810 (1) Cylinder #10 High Exhaust Port Temp
(warning)
Conditions Which Generate This Code:
• E810 (3) Cylinder #10 High Exhaust Port Temp
The cylinder exhaust temperature has exceeded the (shutdown)
trip point and the delay time has expired.
If a warning is generated, the alarm output is
activated.
159
Troubleshooting Section

If a shutdown is generated, the shutdown output is Results:


activated and the fuel is shut off.
• OK – STOP.
Possible Performance Effect:
i01635568
If a warning is generated, the engine performance is
not immediately affected. E812 Cylinder #12 High
The engine will be shut down if the trip point for the Exhaust Port Temp
shutdown is exceeded.
SMCS Code: 1059-038
Troubleshooting:
Conditions Which Generate This Code:
Refer to Troubleshooting, “Exhaust Port Temperature
(High)”. The cylinder exhaust temperature has exceeded the
trip point and the delay time has expired.
Results:
System Response:
• OK – STOP.
The following event codes are logged according to
the trip points for the temperature:
i01635556

E811 Cylinder #11 High • E812 (1) Cylinder #12 High Exhaust Port Temp
(warning)
Exhaust Port Temp
• E812 (3) Cylinder #12 High Exhaust Port Temp
SMCS Code: 1059-038 (shutdown)

Conditions Which Generate This Code: If a warning is generated, the alarm output is
activated.
The cylinder exhaust temperature has exceeded the
trip point and the delay time has expired. If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
System Response:
Possible Performance Effect:
The following event codes are logged according to
the trip points for the temperature: If a warning is generated, the engine performance is
not immediately affected.
• E811 (1) Cylinder #11 High Exhaust Port Temp
(warning) The engine will be shut down if the trip point for the
shutdown is exceeded.
• E811 (3) Cylinder #11 High Exhaust Port Temp
(shutdown) Troubleshooting:

If a warning is generated, the alarm output is Refer to Troubleshooting, “Exhaust Port Temperature
activated. (High)”.

If a shutdown is generated, the shutdown output is Results:


activated and the fuel is shut off.
• OK – STOP.
Possible Performance Effect:
i01635570
If a warning is generated, the engine performance is
not immediately affected. E813 Cylinder #13 High
The engine will be shut down if the trip point for the Exhaust Port Temp
shutdown is exceeded.
SMCS Code: 1059-038
Troubleshooting:
Conditions Which Generate This Code:
Refer to Troubleshooting, “Exhaust Port Temperature
(High)”. The cylinder exhaust temperature has exceeded the
trip point and the delay time has expired.
160
Troubleshooting Section

System Response: If a shutdown is generated, the shutdown output is


activated and the fuel is shut off.
The following event codes are logged according to
the trip points for the temperature: Possible Performance Effect:

• E813 (1) Cylinder #13 High Exhaust Port Temp If a warning is generated, the engine performance is
(warning) not immediately affected.

• E813 (3) Cylinder #13 High Exhaust Port Temp The engine will be shut down if the trip point for the
(shutdown) shutdown is exceeded.

If a warning is generated, the alarm output is Troubleshooting:


activated.
Refer to Troubleshooting, “Exhaust Port Temperature
If a shutdown is generated, the shutdown output is (High)”.
activated and the fuel is shut off.
Results:
Possible Performance Effect:
• OK – STOP.
If a warning is generated, the engine performance is
not immediately affected.
i01635578

The engine will be shut down if the trip point for the
shutdown is exceeded.
E815 Cylinder #15 High
Exhaust Port Temp
Troubleshooting:
SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature
(High)”. Conditions Which Generate This Code:

Results: The cylinder exhaust temperature has exceeded the


trip point and the delay time has expired.
• OK – STOP.
System Response:
i01635577 The following event codes are logged according to
E814 Cylinder #14 High the trip points for the temperature:

Exhaust Port Temp • E815 (1) Cylinder #15 High Exhaust Port Temp
(warning)
SMCS Code: 1059-038
• E815 (3) Cylinder #15 High Exhaust Port Temp
Conditions Which Generate This Code: (shutdown)

The cylinder exhaust temperature has exceeded the If a warning is generated, the alarm output is
trip point and the delay time has expired. activated.

System Response: If a shutdown is generated, the shutdown output is


activated and the fuel is shut off.
The following event codes are logged according to
the trip points for the temperature: Possible Performance Effect:

• E814 (1) Cylinder #14 High Exhaust Port Temp If a warning is generated, the engine performance is
(warning) not immediately affected.

• E814 (3) Cylinder #14 High Exhaust Port Temp The engine will be shut down if the trip point for the
(shutdown) shutdown is exceeded.

If a warning is generated, the alarm output is


activated.
161
Troubleshooting Section

Troubleshooting: i01635587

Refer to Troubleshooting, “Exhaust Port Temperature E821 Cyl #1 Exhaust Port Temp
(High)”. Deviating High
Results: SMCS Code: 1059-038

• OK – STOP. Conditions Which Generate This Code:

i01635584
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
E816 Cylinder #16 High amount of deviation has exceeded the trip point and
the delay time has expired.
Exhaust Port Temp
System Response:
SMCS Code: 1059-038
The following event codes are logged according to
Conditions Which Generate This Code: the trip points for the temperature:
The cylinder exhaust temperature has exceeded the
trip point and the delay time has expired.
• E821 (1) Cyl #1 Exhaust Port Temp Deviating High
(warning)
System Response:
• E821 (3) Cyl #1 Exhaust Port Temp Deviating High
(shutdown)
The following event codes are logged according to
the trip points for the temperature: If a warning is generated, the alarm output is
activated.
• E816 (1) Cylinder #16 High Exhaust Port Temp
(warning) If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E816 (3) Cylinder #16 High Exhaust Port Temp
(shutdown) Possible Performance Effect:
If a warning is generated, the alarm output is If a warning is generated, the engine performance is
activated. not immediately affected.
If a shutdown is generated, the shutdown output is The engine will be shut down if the trip point for the
activated and the fuel is shut off. shutdown is exceeded.
Possible Performance Effect: Troubleshooting:
If a warning is generated, the engine performance is Refer to Troubleshooting, “Exhaust Port Temperature
not immediately affected. (High)”.
The engine will be shut down if the trip point for the Results:
shutdown is exceeded.

Troubleshooting:
• OK – STOP.

Refer to Troubleshooting, “Exhaust Port Temperature i01635593


(High)”.
E822 Cyl #2 Exhaust Port Temp
Results: Deviating High
• OK – STOP. SMCS Code: 1059-038

Conditions Which Generate This Code:

The cylinder exhaust temperature is higher than the


average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
the delay time has expired.
162
Troubleshooting Section

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E822 (1) Cyl #2 Exhaust Port Temp Deviating High
(warning) Possible Performance Effect:

• E822 (3) Cyl #2 Exhaust Port Temp Deviating High If a warning is generated, the engine performance is
(shutdown) not immediately affected.

If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.

If a shutdown is generated, the shutdown output is Troubleshooting:


activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature
Possible Performance Effect: (High)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
i01635604

Troubleshooting: E824 Cyl #4 Exhaust Port Temp


Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1059-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
i01635600 amount of deviation has exceeded the trip point and
E823 Cyl #3 Exhaust Port Temp the delay time has expired.

Deviating High System Response:

SMCS Code: 1059-038 The following event codes are logged according to
the trip points for the temperature:
Conditions Which Generate This Code:
• E824 (1) Cyl #4 Exhaust Port Temp Deviating High
The cylinder exhaust temperature is higher than the (warning)
average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and • E824 (3) Cyl #4 Exhaust Port Temp Deviating High
the delay time has expired. (shutdown)

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E823 (1) Cyl #3 Exhaust Port Temp Deviating High
(warning) Possible Performance Effect:

• E823 (3) Cyl #3 Exhaust Port Temp Deviating High If a warning is generated, the engine performance is
(shutdown) not immediately affected.
163
Troubleshooting Section

The engine will be shut down if the trip point for the i01635612
shutdown is exceeded.
E826 Cyl #6 Exhaust Port Temp
Troubleshooting: Deviating High
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is higher than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
i01635605
the delay time has expired.

E825 Cyl #5 Exhaust Port Temp System Response:


Deviating High The following event codes are logged according to
the trip points for the temperature:
SMCS Code: 1059-038

Conditions Which Generate This Code:


• E826 (1) Cyl #6 Exhaust Port Temp Deviating High
(warning)
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
• E826 (3) Cyl #6 Exhaust Port Temp Deviating High
(shutdown)
amount of deviation has exceeded the trip point and
the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output is
The following event codes are logged according to activated and the fuel is shut off.
the trip points for the temperature:
Possible Performance Effect:
• E825 (1) Cyl #5 Exhaust Port Temp Deviating High
(warning) If a warning is generated, the engine performance is
not immediately affected.
• E825 (3) Cyl #5 Exhaust Port Temp Deviating High
(shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (High)”.
Possible Performance Effect: Results:
If a warning is generated, the engine performance is
not immediately affected.
• OK – STOP.

The engine will be shut down if the trip point for the i01635614
shutdown is exceeded.
E827 Cyl #7 Exhaust Port Temp
Troubleshooting: Deviating High
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is higher than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
the delay time has expired.
164
Troubleshooting Section

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E827 (1) Cyl #7 Exhaust Port Temp Deviating High
(warning) Possible Performance Effect:

• E827 (3) Cyl #7 Exhaust Port Temp Deviating High If a warning is generated, the engine performance is
(shutdown) not immediately affected.

If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.

If a shutdown is generated, the shutdown output is Troubleshooting:


activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature
Possible Performance Effect: (High)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
i01635618

Troubleshooting: E829 Cyl #9 Exhaust Port Temp


Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1059-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
i01635616 amount of deviation has exceeded the trip point and
E828 Cyl #8 Exhaust Port Temp the delay time has expired.

Deviating High System Response:

SMCS Code: 1059-038 The following event codes are logged according to
the trip points for the temperature:
Conditions Which Generate This Code:
• E829 (1) Cyl #9 Exhaust Port Temp Deviating High
The cylinder exhaust temperature is higher than the (warning)
average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and • E829 (3) Cyl #9 Exhaust Port Temp Deviating High
the delay time has expired. (shutdown)

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E828 (1) Cyl #8 Exhaust Port Temp Deviating High
(warning) Possible Performance Effect:

• E828 (3) Cyl #8 Exhaust Port Temp Deviating High If a warning is generated, the engine performance is
(shutdown) not immediately affected.
165
Troubleshooting Section

The engine will be shut down if the trip point for the i01635641
shutdown is exceeded.
E831 Cyl #11 Exhaust Port
Troubleshooting: Temp Deviating High
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is higher than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
i01635634
the delay time has expired.

E830 Cyl #10 Exhaust Port System Response:


Temp Deviating High The following event codes are logged according to
the trip points for the temperature:
SMCS Code: 1059-038

Conditions Which Generate This Code:


• E831 (1) Cyl #11 Exhaust Port Temp Deviating
High (warning)
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
• E831 (3) Cyl #11 Exhaust Port Temp Deviating
High (shutdown)
amount of deviation has exceeded the trip point and
the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output is
The following event codes are logged according to activated and the fuel is shut off.
the trip points for the temperature:
Possible Performance Effect:
• E830 (1) Cyl #10 Exhaust Port Temp Deviating
High (warning) If a warning is generated, the engine performance is
not immediately affected.
• E830 (3) Cyl #10 Exhaust Port Temp Deviating
High (shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (High)”.
Possible Performance Effect: Results:
If a warning is generated, the engine performance is
not immediately affected.
• OK – STOP.

The engine will be shut down if the trip point for the i01635645
shutdown is exceeded.
E832 Cyl #12 Exhaust Port
Troubleshooting: Temp Deviating High
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is higher than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
the delay time has expired.
166
Troubleshooting Section

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E832 (1) Cyl #12 Exhaust Port Temp Deviating
High (warning) Possible Performance Effect:

• E832 (3) Cyl #12 Exhaust Port Temp Deviating If a warning is generated, the engine performance is
High (shutdown) not immediately affected.

If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.

If a shutdown is generated, the shutdown output is Troubleshooting:


activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature
Possible Performance Effect: (High)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
i01635656

Troubleshooting: E834 Cyl #14 Exhaust Port


Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating High
(High)”.
SMCS Code: 1059-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
i01635653 amount of deviation has exceeded the trip point and
E833 Cyl #13 Exhaust Port the delay time has expired.

Temp Deviating High System Response:

SMCS Code: 1059-038 The following event codes are logged according to
the trip points for the temperature:
Conditions Which Generate This Code:
• E834 (1) Cyl #14 Exhaust Port Temp Deviating
The cylinder exhaust temperature is higher than the High (warning)
average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and • E834 (3) Cyl #14 Exhaust Port Temp Deviating
the delay time has expired. High (shutdown)

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E833 (1) Cyl #13 Exhaust Port Temp Deviating
High (warning) Possible Performance Effect:

• E833 (3) Cyl #13 Exhaust Port Temp Deviating If a warning is generated, the engine performance is
High (shutdown) not immediately affected.
167
Troubleshooting Section

The engine will be shut down if the trip point for the i01635661
shutdown is exceeded.
E836 Cyl #16 Exhaust Port
Troubleshooting: Temp Deviating High
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is higher than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
i01635658
the delay time has expired.

E835 Cyl #15 Exhaust Port System Response:


Temp Deviating High The following event codes are logged according to
the trip points for the temperature:
SMCS Code: 1059-038

Conditions Which Generate This Code:


• E836 (1) Cyl #16 Exhaust Port Temp Deviating
High (warning)
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
• E836 (3) Cyl #16 Exhaust Port Temp Deviating
High (shutdown)
amount of deviation has exceeded the trip point and
the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output is
The following event codes are logged according to activated and the fuel is shut off.
the trip points for the temperature:
Possible Performance Effect:
• E835 (1) Cyl #15 Exhaust Port Temp Deviating
High (warning) If a warning is generated, the engine performance is
not immediately affected.
• E835 (3) Cyl #15 Exhaust Port Temp Deviating
High (shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (High)”.
Possible Performance Effect: Results:
If a warning is generated, the engine performance is
not immediately affected.
• OK – STOP.

The engine will be shut down if the trip point for the i01635664
shutdown is exceeded.
E841 Cyl #1 Exhaust Port Temp
Troubleshooting: Deviating Low
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is less than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
the delay time has expired.
168
Troubleshooting Section

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E841 (1) Cyl #1 Exhaust Port Temp Deviating Low
(warning) Possible Performance Effect:

• E841 (3) Cyl #1 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance is
(shutdown) not immediately affected.

If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.

If a shutdown is generated, the shutdown output is Troubleshooting:


activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature
Possible Performance Effect: (Low)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
i01635668

Troubleshooting: E843 Cyl #3 Exhaust Port Temp


Refer to Troubleshooting, “Exhaust Port Temperature Deviating Low
(Low)”.
SMCS Code: 1059-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The cylinder exhaust temperature is less than the
average temperature for all of the cylinders. The
i01635667 amount of deviation has exceeded the trip point and
E842 Cyl #2 Exhaust Port Temp the delay time has expired.

Deviating Low System Response:

SMCS Code: 1059-038 The following event codes are logged according to
the trip points for the temperature:
Conditions Which Generate This Code:
• E843 (1) Cyl #3 Exhaust Port Temp Deviating Low
The cylinder exhaust temperature is less than the (warning)
average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and • E843 (3) Cyl #3 Exhaust Port Temp Deviating Low
the delay time has expired. (shutdown)

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E842 (1) Cyl #2 Exhaust Port Temp Deviating Low
(warning) Possible Performance Effect:

• E841 (3) Cyl #2 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance is
(shutdown) not immediately affected.
169
Troubleshooting Section

The engine will be shut down if the trip point for the i01635672
shutdown is exceeded.
E845 Cyl #5 Exhaust Port Temp
Troubleshooting: Deviating Low
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(Low)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is less than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
i01635670
the delay time has expired.

E844 Cyl #4 Exhaust Port Temp System Response:


Deviating Low The following event codes are logged according to
the trip points for the temperature:
SMCS Code: 1059-038

Conditions Which Generate This Code:


• E845 (1) Cyl #5 Exhaust Port Temp Deviating Low
(warning)
The cylinder exhaust temperature is less than the
average temperature for all of the cylinders. The
• E845 (3) Cyl #5 Exhaust Port Temp Deviating Low
(shutdown)
amount of deviation has exceeded the trip point and
the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output is
The following event codes are logged according to activated and the fuel is shut off.
the trip points for the temperature:
Possible Performance Effect:
• E844 (1) Cyl #4 Exhaust Port Temp Deviating Low
(warning) If a warning is generated, the engine performance is
not immediately affected.
• E844 (3) Cyl #4 Exhaust Port Temp Deviating Low
(shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (Low)”.
Possible Performance Effect: Results:
If a warning is generated, the engine performance is
not immediately affected.
• OK – STOP.

The engine will be shut down if the trip point for the i01635673
shutdown is exceeded.
E846 Cyl #6 Exhaust Port Temp
Troubleshooting: Deviating Low
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(Low)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is less than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
the delay time has expired.
170
Troubleshooting Section

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E846 (1) Cyl #6 Exhaust Port Temp Deviating Low
(warning) Possible Performance Effect:

• E846 (3) Cyl #6 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance is
(shutdown) not immediately affected.

If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.

If a shutdown is generated, the shutdown output is Troubleshooting:


activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature
Possible Performance Effect: (Low)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
i01635680

Troubleshooting: E848 Cyl #8 Exhaust Port Temp


Refer to Troubleshooting, “Exhaust Port Temperature Deviating Low
(Low)”.
SMCS Code: 1059-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The cylinder exhaust temperature is less than the
average temperature for all of the cylinders. The
i01635677 amount of deviation has exceeded the trip point and
E847 Cyl #7 Exhaust Port Temp the delay time has expired.

Deviating Low System Response:

SMCS Code: 1059-038 The following event codes are logged according to
the trip points for the temperature:
Conditions Which Generate This Code:
• E848 (1) Cyl #8 Exhaust Port Temp Deviating Low
The cylinder exhaust temperature is less than the (warning)
average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and • E848 (3) Cyl #8 Exhaust Port Temp Deviating Low
the delay time has expired. (shutdown)

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E847 (1) Cyl #7 Exhaust Port Temp Deviating Low
(warning) Possible Performance Effect:

• E847 (3) Cyl #7 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance is
(shutdown) not immediately affected.
171
Troubleshooting Section

The engine will be shut down if the trip point for the i01635684
shutdown is exceeded.
E850 Cyl #10 Exhaust Port
Troubleshooting: Temp Deviating Low
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(Low)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is less than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
i01635683
the delay time has expired.

E849 Cyl #9 Exhaust Port Temp System Response:


Deviating Low The following event codes are logged according to
the trip points for the temperature:
SMCS Code: 1059-038

Conditions Which Generate This Code:


• E850 (1) Cyl #10 Exhaust Port Temp Deviating
Low (warning)
The cylinder exhaust temperature is less than the
average temperature for all of the cylinders. The
• E850 (3) Cyl #10 Exhaust Port Temp Deviating
Low (shutdown)
amount of deviation has exceeded the trip point and
the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output is
The following event codes are logged according to activated and the fuel is shut off.
the trip points for the temperature:
Possible Performance Effect:
• E849 (1) Cyl #9 Exhaust Port Temp Deviating Low
(warning) If a warning is generated, the engine performance is
not immediately affected.
• E849 (3) Cyl #9 Exhaust Port Temp Deviating Low
(shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (Low)”.
Possible Performance Effect: Results:
If a warning is generated, the engine performance is
not immediately affected.
• OK – STOP.

The engine will be shut down if the trip point for the i01635685
shutdown is exceeded.
E851 Cyl #11 Exhaust Port
Troubleshooting: Temp Deviating Low
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(Low)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is less than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
the delay time has expired.
172
Troubleshooting Section

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E851 (1) Cyl #11 Exhaust Port Temp Deviating
Low (warning) Possible Performance Effect:

• E851 (3) Cyl #11 Exhaust Port Temp Deviating If a warning is generated, the engine performance is
Low (shutdown) not immediately affected.

If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.

If a shutdown is generated, the shutdown output is Troubleshooting:


activated and the fuel is shut off.
Refer to Troubleshooting, “Exhaust Port Temperature
Possible Performance Effect: (Low)”.

If a warning is generated, the engine performance is Results:


not immediately affected.
• OK – STOP.
The engine will be shut down if the trip point for the
shutdown is exceeded.
i01635691

Troubleshooting: E853 Cyl #13 Exhaust Port


Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating Low
(Low)”.
SMCS Code: 1059-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The cylinder exhaust temperature is less than the
average temperature for all of the cylinders. The
i01635688 amount of deviation has exceeded the trip point and
E852 Cyl #12 Exhaust Port the delay time has expired.

Temp Deviating Low System Response:

SMCS Code: 1059-038 The following event codes are logged according to
the trip points for the temperature:
Conditions Which Generate This Code:
• E853 (1) Cyl #13 Exhaust Port Temp Deviating
The cylinder exhaust temperature is less than the Low (warning)
average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and • E853 (3) Cyl #13 Exhaust Port Temp Deviating
the delay time has expired. Low (shutdown)

System Response: If a warning is generated, the alarm output is


activated.
The following event codes are logged according to
the trip points for the temperature: If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
• E852 (1) Cyl #12 Exhaust Port Temp Deviating
Low (warning) Possible Performance Effect:

• E852 (3) Cyl #12 Exhaust Port Temp Deviating If a warning is generated, the engine performance is
Low (shutdown) not immediately affected.
173
Troubleshooting Section

The engine will be shut down if the trip point for the i01635694
shutdown is exceeded.
E855 Cyl #15 Exhaust Port
Troubleshooting: Temp Deviating Low
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(Low)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is less than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
i01635692
the delay time has expired.

E854 Cyl #14 Exhaust Port System Response:


Temp Deviating Low The following event codes are logged according to
the trip points for the temperature:
SMCS Code: 1059-038

Conditions Which Generate This Code:


• E855 (1) Cyl #15 Exhaust Port Temp Deviating
Low (warning)
The cylinder exhaust temperature is less than the
average temperature for all of the cylinders. The
• E855 (3) Cyl #15 Exhaust Port Temp Deviating
Low (shutdown)
amount of deviation has exceeded the trip point and
the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output is
The following event codes are logged according to activated and the fuel is shut off.
the trip points for the temperature:
Possible Performance Effect:
• E854 (1) Cyl #14 Exhaust Port Temp Deviating
Low (warning) If a warning is generated, the engine performance is
not immediately affected.
• E854 (3) Cyl #14 Exhaust Port Temp Deviating
Low (shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (Low)”.
Possible Performance Effect: Results:
If a warning is generated, the engine performance is
not immediately affected.
• OK – STOP.

The engine will be shut down if the trip point for the i01635695
shutdown is exceeded.
E856 Cyl #16 Exhaust Port
Troubleshooting: Temp Deviating Low
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(Low)”.
Conditions Which Generate This Code:
Results:
The cylinder exhaust temperature is less than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point and
the delay time has expired.
174
Troubleshooting Section

System Response: Results:

The following event codes are logged according to • OK – STOP.


the trip points for the temperature:
i01637716
• E856 (1) Cyl #16 Exhaust Port Temp Deviating
Low (warning) E865 High Gas Fuel Differential
• E856 (3) Cyl #16 Exhaust Port Temp Deviating Pressure
Low (shutdown)
SMCS Code: 1250-038
If a warning is generated, the alarm output is
activated. Conditions Which Generate This Code:

If a shutdown is generated, the shutdown output is The Gas Shutoff Valve (GSOV) is energized. The
activated and the fuel is shut off. difference in fuel pressure between the inlet and the
outlet of the fuel metering valve is greater than the
Possible Performance Effect: trip point. The delay time has expired.

If a warning is generated, the engine performance is System Response:


not immediately affected.
The alarm output is activated. The code is logged.
The engine will be shut down if the trip point for the
shutdown is exceeded. Possible Performance Effect:

Troubleshooting: The engine performance is not immediately affected.

Refer to Troubleshooting, “Exhaust Port Temperature Troubleshooting:


(Low)”.
Refer to Troubleshooting, “Gas Fuel Differential
Results: Pressure (High)”.

• OK – STOP. Results:

• OK – STOP.
i01637712

E864 Low Gas Fuel Differential i01637720

Pressure E866 Low Gas Fuel Flow Rate


SMCS Code: 1250-038 SMCS Code: 1250-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The gas shutoff valve (GSOV) is energized. The The fuel metering valve is fully open. However, the
difference in fuel pressure between the outlet and the flow rate that is computed by the valve does not
inlet of the fuel metering valve is less than the trip match the fuel demand for a delay time of 5 seconds.
point. The delay time has expired.
System Response:
System Response:
The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged.
Possible Performance Effect:
Possible Performance Effect:
The engine performance is not immediately affected.
The engine performance is not immediately affected.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Gas Fuel Flow Rate
Refer to Troubleshooting, “Gas Fuel Differential (Low)”.
Pressure (Low)”.
175
Troubleshooting Section

Results:

• OK – STOP.

i02053631

E867 Improper Gas Flow


Control Valve Response
SMCS Code: 1741-038

Conditions Which Generate This Code:

The fuel metering valve is not responding correctly to


the Electronic Control Module (ECM) and the delay
time has expired.

System Response:

The alarm output is activated. The code is logged.

Possible Performance Effect:

The engine performance is not immediately affected.

Troubleshooting:

Refer to Troubleshooting, “Fuel Metering Valve”.

Results:

• OK – STOP.

i02053641

E868 Gas Flow Control Valve


Malfunction
SMCS Code: 1741-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) has detected a


malfunction for the fuel metering valve and the delay
time has expired.

System Response:

The alarm output is activated. The code is logged.

Possible Performance Effect:

The engine performance is not immediately affected.

Troubleshooting:

Refer to Troubleshooting, “Fuel Metering Valve”.

Results:

• OK – STOP.
176
Troubleshooting Section

Diagnostic Functional A “5 Volt Sensor DC Power Supply short to ground”


diagnostic code will be activated if both of these
Tests conditions occur:

• The desired speed signal wire is shorted to ground.


i02054619

+5V Sensor Voltage Supply • The “DESIRED SPEED” potentiometer is near


the maximum desired speed or at the maximum
desired speed.
SMCS Code: 5574-038

System Operation Description:

The Electronic Control Module (ECM) supplies 5.0 ±


0.5 VDC to the sensors for these parameters:

• Inlet air temperature


• Engine oil temperature
• Unfiltered engine oil pressure
• Filtered engine oil pressure
Terminals J1-2 and J1-18 are connected together
inside the ECM. A short circuit on one of these
terminals will cause a short circuit on the other
terminal.

A “+5 V sensor supply” diagnostic code is probably


caused by a short circuit or an open circuit in a
harness. The next likely cause is a sensor problem.
The least likely cause is a problem with the ECM.

Logged diagnostic codes provide a historical record.


Before you begin this procedure, use the Caterpillar
Electronic Technician (ET) to print the logged codes
to a file.

This troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.

“DESIRED SPEED” Potentiometer (if equipped)

The ECM also provides 5.0 ± 0.5 VDC to the


“DESIRED SPEED” potentiometer (if equipped).

A “5 Volt Sensor DC Power Supply short to +batt”


diagnostic code will be activated if both of these
conditions occur:

• The desired speed signal wire is shorted to a


voltage source that is greater than +5 volts.

• The “DESIRED SPEED” potentiometer is near


the maximum desired speed or at the maximum
desired speed.
177
Troubleshooting Section

g01053662
Illustration 21
Schematic for the 5 V supply
178
Troubleshooting Section

Test Step 1. Inspect the Electrical B. Thoroughly inspect each of the following
Connectors and Wiring connectors:

• J1/P1 connectors
• J6/P6, and J7/P7 connectors on the terminal
box

a. Check the torque of the Allen head screws for


the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054206
Illustration 22
Junction box
(1) 35 amp circuit breaker

A. Set the engine control to the OFF/RESET mode.


Switch 35 amp circuit breaker (1) to the OFF
g01053671
position. Illustration 24
Harness side of the ECM P1 connector
Note: For the following steps, refer to (P1-2) 5 volt supply
Troubleshooting, “Inspecting Electrical Connectors”. (P1-3) Return
(P1-14) Signal for the inlet manifold air temperature
(P1-16) Signal for the desired speed
(P1-17) Signal for the engine oil temperature
(P1-18) 5 volt supply
(P1-24) Signal for the filtered engine oil pressure
(P1-26) Signal for the unfiltered engine oil pressure
(P1-35) Return

g01053664
Illustration 23
Terminal box
(2) J1/P1 connectors for the ECM
(3) J6/P6 connectors for the customer
(4) J7/P7 connectors for the harness from the 5 volt sensors
179
Troubleshooting Section

g01053675
Illustration 25
Harness side of the J6 connector
(J6-5) 5 volt supply
(J6-15) Return
(J6-25) Signal for desired speed
(J6-35) Shield
g01053684
Illustration 26
Harness side of the J7 connector
(J7-3) Signal for the inlet manifold air temperature
(J7-4) Signal for the filtered engine oil pressure
(J7-5) Signal for the engine oil temperature
(J7-6) Signal for the unfiltered engine oil pressure
(J7-17) Return for the inlet manifold air temperature
(J7-18) Return for the filtered engine oil pressure
(J7-19) Return for the engine oil temperature
(J7-20) Return for the unfiltered engine oil pressure
(J7-31) Shield for the inlet manifold air temperature
(J7-32) Shield for the filtered engine oil pressure
(J7-33) Shield for the engine oil temperature
(J7-34) Shield for the unfiltered engine oil pressure
(J7-45) 5 volt supply for the inlet manifold air temperature
(J7-46) 5 volt supply for the filtered engine oil pressure
(J7-47) 5 volt supply for the engine oil temperature
(J7-48) 5 volt supply for the unfiltered engine oil pressure

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


wires that are associated with the circuit for the
5 V sensors.
180
Troubleshooting Section

d. Check the harness and wiring for corrosion,


abrasion and pinch points from the 5 volt
sensors to the ECM.

Expected Result:

All connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.

Results:

• OK – All connectors, pins, and sockets are


connected properly. The connectors and the wiring
do not have corrosion, abrasion, or pinch points.
The components are in good condition with proper
connections. Proceed to Test Step 2.

• Not OK – At least one of the connectors, pins, or


sockets are not connected properly. At least one
of the connectors and the wiring has corrosion,
abrasion, and/or pinch points.

Repair: Perform the necessary repairs and/or


replace parts, if necessary.

STOP.
g01053697
Illustration 27 Test Step 2. Check for Diagnostic Codes
Right side of the engine
(5) Engine oil temperature sensor A. Connect Cat ET to the service tool connector.
(6) Unfiltered oil pressure sensor Refer to Troubleshooting, “Electronic Service
(7) Filtered oil pressure sensor Tools”.

B. Rotate the “DESIRED SPEED” potentiometer


(if equipped) counterclockwise to the minimum
speed position.

C. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.

D. Observe the “Active Diagnostic” screen on Cat ET.


Wait at least 30 seconds so that any codes may
become activated. Look for these codes:

• 262-03 5 Volt Sensor DC Power Supply short


to +batt

• 262-04 5 Volt Sensor DC Power Supply short


to ground

E. Observe the “Logged Diagnostic” screen on Cat


ET. Look for the same codes.

Illustration 28
g01053715 Expected Result:
Top view of the engine
The 262-03 code or the 262-04 code is not active
(8) Inlet air temperature sensor
or logged.
181
Troubleshooting Section

Results: Expected Result:

• No codes – There are no active codes or logged The resistance is greater than 20,000 Ohms.
codes. Proceed to Test Step 3.
Results:
• Active code – The 262-03 code or the 262-04
code is active. Proceed to Test Step 5. • OK – The resistance is greater than 20,000
Ohms. The wiring for the “DESIRED SPEED”
• Logged code – The 262-03 code or the 262-04 potentiometer appears to be OK.
code is not active. However, there is at least one
logged code for the 5 volt sensor supply. Repair: The “DESIRED SPEED” potentiometer
may have a problem. Perform the following
Repair: There may be a problem with the wiring procedure:
and/or a connector. Refer to Troubleshooting,
“Inspecting Electrical Connectors”. 1. Check the “DESIRED SPEED” potentiometer
in order to ensure that the potentiometer does
Verify that the wiring and/or connectors are OK. not have an internal short circuit. Replace the
Check for diagnostic codes again. Proceed to Test “DESIRED SPEED” potentiometer, if necessary.
Step 3, if necessary. Continue with this procedure when the
“DESIRED SPEED” potentiometer is operating
Test Step 3. Check the Analog Speed correctly.
Circuit
2. Reconnect the wiring to the “DESIRED SPEED”
Note: If the engine is not equipped with a “DESIRED potentiometer. Be sure to connect the wires to
SPEED” potentiometer, proceed to Test Step 9. the appropriate terminals.

A. Rotate the “DESIRED SPEED” potentiometer 3. Reconnect the P1 connector to the ECM.
(if equipped) clockwise to the maximum speed
position. 4. Perform this entire procedure again. Verify that
the original problem is resolved.
Expected Result:
STOP.
The 262-03 code or the 262-04 code is not active.
• Not OK – The resistance is less than 20,000
Results: Ohms. There is a problem with the wiring for the
“DESIRED SPEED” potentiometer. The problem
• No codes – Rotating the “DESIRED SPEED” could be between the P1 connector and the J6
potentiometer clockwise to the maximum speed connector. Alternatively, the problem could be in
position did not cause an active code. The +5 V the P6 connector or the wiring that is connected to
sensor voltage supply is operating correctly at this the P6 connector.
time. Resume normal operation. STOP.
Repair: Perform any necessary repairs or replace
• Active code – Rotating the “DESIRED SPEED” parts, if necessary.
potentiometer clockwise to the maximum speed
position caused an active code. There is a problem STOP.
with the analog speed circuit. Proceed to Test Step
4. Test Step 5. Isolate the Wiring Harnesses
from the ECM
Test Step 4. Check the Wiring for the
“DESIRED SPEED” Potentiometer A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. B. Reconnect the P1 connector to the ECM.

B. Label the wiring that is connected to the C. Use a 151-6320 Wire Removal Tool to remove
“DESIRED SPEED” potentiometer. Disconnect the terminals P1-2 and P1-18. This will disconnect all
wiring from the “DESIRED SPEED” potentiometer. of the +5 V wiring from the ECM.

C. Disconnect the P1 connector from the ECM. D. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.
D. Measure the resistance between terminals P1-16
and P1-69. E. Use Cat ET to look for diagnostic codes.
182
Troubleshooting Section

Expected Result: Results:

No active codes • No codes – The 262-03 code or the 262-04 code


is not active. Connecting the wiring for the analog
Results: speed circuit to the ECM did not cause a diagnostic
code. The wiring for the analog speed circuit
• No codes – The 262-03 code or the 262-04 code appears to be OK. Proceed to Test Step 7.
is not active. Disconnecting all of the +5 V wiring
from the ECM eliminated the active “5 Volt Sensor • Active codes – The 262-03 code or the 262-04
Supply” diagnostic code. There is a problem with a code is active. Connecting the wiring for the analog
connector and/or the wiring in a harness. Proceed speed circuit to the ECM caused a diagnostic code.
to Test Step 6. Proceed to Test Step 4.

• Active code – The 262-03 code or the 262-04 Test Step 7. Connect the 5 Volt Wiring for
code is active. Disconnecting all of the 5 volt wiring the Sensors to the ECM
from the ECM did not eliminate the active “5 Volt
Sensor Supply” diagnostic code. There may be a A. Set the engine control to the OFF/RESET mode.
problem with the ECM. Switch the 35 amp circuit breaker OFF.

Repair: It is unlikely that the ECM has failed. Exit B. Insert terminal P1-2 into the P1 connector. Pull on
this procedure and perform this procedure again. If the wire in order to verify that the terminal is fully
the problem is not resolved, perform the following inserted into the connector.
steps:
C. Switch the 35 amp circuit breaker ON. Set the
Temporarily install a new ECM. Refer to engine control to the STOP mode.
Troubleshooting, “Replacing the ECM”.
D. Use Cat ET to look for diagnostic codes.
If the problem is resolved with the new ECM,
install the original ECM and verify that the problem Expected Result:
returns. If the new ECM operates correctly and the
original ECM does not operate correctly, replace No active codes
the original ECM. Refer to Troubleshooting,
“Replacing the ECM”. Results:

STOP. • No codes – The 262-03 code or the 262-04 code


is not active. Connecting the 5 VDC for the sensors
Test Step 6. Connect the 5 Volt Wiring for did not cause a diagnostic code. The problem
the Analog Speed Circuit to the ECM appears to be resolved.

A. Set the engine control to the OFF/RESET mode. Repair: The initial diagnostic code was probably
Switch the 35 amp circuit breaker OFF. caused by a poor electrical connection. Resume
normal operation.
B. Insert terminal P1-18 into the P1 connector. Pull
on the wire in order to verify that the terminal is STOP.
fully inserted into the connector.
• Active code – The 262-03 code or the 262-04 code
C. Rotate the “DESIRED SPEED” potentiometer is active. Connecting the 5 VDC for the sensors
clockwise to the maximum speed position. caused a diagnostic code. Proceed to Test Step 8.

D. Switch the 35 amp circuit breaker ON. Set the Test Step 8. Disconnect the 5 Volt
engine control to the STOP mode. Sensors and Look For Active Diagnostic
Codes.
E. Use Cat ET to look for diagnostic codes.
A. Set the engine control to the OFF/RESET mode.
Expected Result: Switch the 35 amp circuit breaker OFF.

No active codes B. Disconnect the sensors for the following


parameters:

• Inlet air temperature


183
Troubleshooting Section

• Engine oil temperature • No – The original “5 Volt Sensor” diagnostic code


was still active while all of the 5 volt sensors were
• Unfiltered engine oil pressure disconnected. Do not reconnect the sensors.
Proceed to Test Step 9.
• Filtered engine oil pressure
Test Step 9. Check the Harnesses
C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
Note: An “Open Circuit” code will be generated for
each sensor that is disconnected. This is normal. B. Disconnect the P1 connector. Verify that all of
Clear the codes after you complete this procedure. the sensors for the following parameters are
disconnected from the engine harness:
D. Observe the “Active Diagnostic” screen on Cat ET.
Verify that the 262-03 code or the 262-04 code • Inlet air temperature
is not active.
• Engine oil temperature
E. Reconnect the sensors for the following
parameters one at a time. After you reconnect • Unfiltered engine oil pressure
each sensor, wait for at least 30 seconds and then
observe the “Active Diagnostic” screen on Cat ET. • Filtered engine oil pressure
• Inlet air temperature C. Measure the resistance between terminal P1-2
and the points that are listed in Table 10. During
• Engine oil temperature each measurement, wiggle the harnesses in
order to check for an intermittent problem with
• Unfiltered engine oil pressure the harness. Be sure to wiggle the harnesses
near each of the connectors for the disconnected
• Filtered engine oil pressure sensors. Also, wiggle the harness at the P7
connector.
Expected Result:
Table 10
The original “5 Volt Sensor” diagnostic code is Measure the Resistance for the Engine Harness.
activated when a particular sensor is disconnected.
Connector and Connector and Terminal
Results: Terminal
P1-2 P1-14 (inlet air temperature)
• Yes – The original “5 Volt Sensor” diagnostic 5 volt supply
code is activated when a particular sensor is P1-17 (engine oil temperature)
reconnected. The sensor and/or the wiring for the P1-26 (unfiltered engine oil pressure)
sensor has a short circuit.
P1-24 (filtered engine oil pressure)
Repair: Perform the following procedure: P1-3 (analog return)

1. Set the engine control to the OFF/RESET mode. Ground strap for the engine
P1-69 (−Battery terminal)
2. Disconnect the suspect sensor.
P1-57 (unswitched +Battery)
3. Set the engine control to the STOP mode. Use P1-70 (switched +Battery)
Cat ET to clear the logged 262-03 or 262-04
code.
Expected Result:
4. Reconnect the suspect sensor. Verify that the
diagnostic code recurs. Each check of the resistance is greater than 20,000
Ohms.
If these conditions are true, replace the sensor.

5. Clear all of the diagnostic codes. Verify that the


problem is eliminated.

STOP.
184
Troubleshooting Section

Results: Logged diagnostic codes provide a historical record.


Before you begin this procedure, use the Caterpillar
• OK – Each check of the resistance is greater Electronic Technician (ET) to print the logged codes
than 20,000 Ohms. The 5 volt wires in the engine to a file.
harnesses do not have a problem. The problem
appears to be resolved. The initial diagnostic This troubleshooting procedure may generate
code was probably caused by a poor electrical additional diagnostic codes. Keep your mind on
connection. correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
Repair: Reconnect all of the connectors. Resume resolved.
normal operation.

STOP.

• Not OK – At least one check of the resistance is


less than 20,000 Ohms. There is a problem with a
connector and/or at least one of the 5 volt wires
in a harness.

Repair: The problem may be between the P1


connector and the P7 connector. Alternatively,
the problem may be in the engine harness that is
connected to the J7 connector.

Repair the connection and/or the wire, when


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

STOP.

i02055144

+8V Sensor Voltage Supply


SMCS Code: 5574-038

System Operation Description:

The Electronic Control Module (ECM) supplies 8.0 ±


0.8 VDC to these sensors:

• Sensor for engine coolant pressure (outlet)


• Sensor for inlet air pressure
• The detonation sensors
Terminals J1-4, J2-56, and J2-57 are connected
together inside the ECM. A short circuit on one of
these terminals will cause a short circuit on the other
terminal.

A “+8 V sensor supply” diagnostic code is probably


caused by a short circuit or an open circuit in a
harness. The next likely cause is a sensor problem.
The least likely cause is a problem with the ECM.
185
Troubleshooting Section

g01053943
Illustration 29
Schematic for the 8 V supply
186
Troubleshooting Section

Test Step 1. Inspect the Electrical B. Thoroughly inspect each of the following
Connectors and Wiring. connectors:

• J1/P1 and J2/P2 connectors for the ECM


• J7/P7 and J8/P8 connectors on the terminal box
a. Check the torque of the Allen head screws for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054206
Illustration 30
Junction box
(1) 35 amp circuit breaker

A. Set the engine control to the OFF/RESET mode.


g01053945
Switch the 35 amp circuit breaker OFF. Illustration 32
Harness side of the ECM P1 connector
Note: For the following steps, refer to (P1-4) 8 volt supply for the pressure sensors
Troubleshooting, “Inspecting Electrical Connectors”. (P1-5) Return for the pressure sensors
(P1-10) Signal for the inlet air pressure

g01053944
Illustration 31
Terminal box
(2) J2/P2 connectors for the ECM
(3) J1/P1 connectors for the ECM
(4) J7/P7 connectors for the harness from the 8 volt sensors
(5) J8/P8 connectors for the detonation sensors
187
Troubleshooting Section

g01053946
Illustration 33
Harness side of the ECM P2 connector
(P2-36) Detonation sensor signal for cylinders 1 and 3
(P2-37) Detonation sensor signal for cylinders 5 and 7
(P2-38) Detonation sensor signal for cylinders 9 and 11
(P2-39) Detonation sensor signal for cylinders 13 and 15
(P2-44) Detonation sensor signal for cylinders 2 and 4
(P2-45) Detonation sensor signal for cylinders 6 and 8
(P2-46) Detonation sensor signal for cylinders 10 and 12
(P2-47) Detonation sensor signal for cylinders 14 and 16
(P2-54) Return for the detonation sensors
(P2-55) Return for the detonation sensors
(P2-56) 8 volt supply for the detonation sensors
(P2-57) 8 volt supply for the detonation sensors
(P2-68) Signal for the engine coolant pressure
g01053959
Illustration 34
Harness side of the J7 connector
(J7-1) Signal for the inlet air pressure
(J7-2) Signal for the engine coolant pressure
(J7-15) Return for the inlet air pressure
(J7-16) Return for the engine coolant pressure
(J7-29) Shield for the inlet air pressure
(J7-30) Shield for the engine coolant pressure
(J7-43) 8 volt supply for the inlet air pressure
(J7-44) 8 volt supply for the engine coolant pressure
188
Troubleshooting Section

g01053984
Illustration 36
Top view of the engine
(6) Engine coolant pressure sensor
(7) Inlet air pressure sensor

g01053963
Illustration 35
Harness side of the J8 connector
(J8-1) 8 V Supply for the detonation sensor for cylinders 1 and 3
(J8-2) 8 V Supply for the detonation sensor for cylinders 9 and 11
(J8-3) 8 V Supply for the detonation sensor for cylinders 5 and 7
(J8-4) 8 V Supply for the detonation sensor for cylinders 13 and 15
(J8-5) 8 V Supply for the detonation sensor for cylinders 2 and 4
(J8-6) 8 V Supply for the detonation sensor for cylinders 6 and 8
(J8-7) 8 V Supply for the detonation sensor for cylinders 10 and 12
(J8-8) 8 V Supply for the detonation sensor for cylinders 14 and 16
(J8-11) Return for the detonation sensor for cylinders 1 and 3
(J8-12) Return for the detonation sensor for cylinders 5 and 7
(J8-13) Return for the detonation sensor for cylinders 9 and 11
(J8-14) Return for the detonation sensor for cylinders 13 and 15
(J8-15) Return for the detonation sensor for cylinders 2 and 4
(J8-16) Return for the detonation sensor for cylinders 6 and 8
(J8-17) Return for the detonation sensor for cylinders 10 and 12
(J8-18) Return for the detonation sensor for cylinders 14 and 16
(J8-21) Signal from the detonation sensor for cylinders 1 and 3
(J8-22) Signal from the detonation sensor for cylinders 5 and 7
(J8-23) Signal from the detonation sensor for cylinders 9 and 11
(J8-24) Signal from the detonation sensor for cylinders 13 and 15
(J8-25) Signal from the detonation sensor for cylinders 2 and 4
(J8-26) Signal from the detonation sensor for cylinders 6 and 8
(J8-27) Signal from the detonation sensor for cylinders 10 and 12
(J8-28) Signal from the detonation sensor for cylinders 14 and 16
(J8-31) Shield for the detonation sensor for cylinders 1 and 3
(J8-32) Shield for the detonation sensor for cylinders 5 and 7
(J8-33) Shield for the detonation sensor for cylinders 9 and 11
(J8-34) Shield for the detonation sensor for cylinders 13 and 15
(J8-35) Shield for the detonation sensor for cylinders 2 and 4 g01053993
Illustration 37
(J8-36) Shield for the detonation sensor for cylinders 6 and 8
(J8-37) Shield for the detonation sensor for cylinders 10 and 12 Detonation sensors
(J8-38) Shield for the detonation sensor for cylinders 14 and 16
d. Check the harness and wiring for abrasion
c. Perform a 45 N (10 lb) pull test on each of the and pinch points from the 8 volt sensors to
wires that are associated with the circuit for the the ECM.
8 volt sensors.
Expected Result:

All connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
189
Troubleshooting Section

Results: Test Step 3. Disconnect the 8 Volt


Sensors and Look for Active Diagnostic
• OK – All connectors, pins, and sockets are Codes.
connected properly. The connectors and the wiring
do not have corrosion, abrasion, or pinch points. A. Turn on the “Active Diagnostic” screen on Cat ET.
The components are in good condition with proper Verify that the “41-03” or “41-04” code is active.
connections. Proceed to Test Step 2.
B. Disconnect each 8 volt sensor one at a time. After
• Not OK – At least one of the connectors, pins, and you disconnect each sensor, wait for at least 30
sockets are not connected properly. At least one seconds and then observe the “Active Diagnostic”
of the connectors and/or the wiring has corrosion, screen on Cat ET.
abrasion, and/or pinch points.
Note: An “Open Circuit” code will be generated for
Repair: Perform the necessary repairs and/or each sensor that is disconnected. This is normal.
replace parts, if necessary. Clear the codes after you complete this procedure.

STOP. Expected Result:

Test Step 2. Check for Diagnostic Codes The original “8 Volt DC Supply” diagnostic code is
deactivated when a particular sensor is disconnected.
A. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service Results:
Tools”.
• Yes – The original “8 Volt DC Supply” diagnostic
B. Switch the 35 amp circuit breaker ON. Set the code is deactivated when a particular sensor is
engine control to the STOP mode. disconnected. The sensor and/or the wiring for the
sensor has a short circuit.
C. Observe the “Active Diagnostic” screen on Cat ET.
Wait at least 30 seconds so that any codes may Repair: Perform the following procedure:
become activated. Look for these codes:
1. Reconnect the suspect sensor. Verify that the
• 41-03 8 Volt DC Supply short to +batt diagnostic code recurs.

• 41-04 8 Volt DC Supply short to ground 2. Disconnect the suspect sensor. Verify that the
diagnostic code is deactivated.
D. Observe the “Logged Diagnostic” screen on Cat
ET. Look for the same codes. If these conditions are true, repair the sensor
or the sensor’s harness. Replace parts, if
Expected Result: necessary.

The 41-03 code or the 41-04 code is not active. 3. Clear all of the diagnostic codes. Verify that the
problem is eliminated.
Results:
STOP.
• No codes – The 41-03 code or the 41-04 code is
not active. The 8 volt sensor supply is operating • No – The original “8 Volt DC Supply” diagnostic
correctly at this time. STOP. code is still active when a particular sensor is
disconnected. Do not reconnect the sensors.
• Active code – The 41-03 code or the 41-04 code Proceed to Test Step 4.
is active. Proceed to Test Step 3.
Test Step 4. Isolate the Wiring Harnesses
• Logged code – The 41-03 code or the 41-04 code from the Electronic Control Module
is not active. However, there is at least one logged
code for the 8 volt sensor supply. A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
Repair: There may be a problem with the wiring
and/or a connector. Refer to Troubleshooting, B. Use a 151-6320 Wire Removal Tool in order to
“Inspecting Electrical Connectors”. remove the wires from the following terminals:

Verify that the wiring and/or connectors are OK. • P1-4


Check for diagnostic codes again. Proceed to Test
Step 3, if necessary. • P2-56
190
Troubleshooting Section

• P2-57 C. Disconnect all of the 8 volt sensors.

C. Switch the 35 amp circuit breaker ON. Set the D. Disconnect the P1 connector and the P2
engine control to the STOP mode. connector.

D. Wait for at least 30 seconds and then observe the E. Measure the resistance between the terminals
“Active Diagnostics” screen on Cat ET. Determine that are listed in Table 11.
if a 41-03 code or a 41-04 code is active.
During each measurement, wiggle the harnesses
Expected Result: in order to check for an intermittent problem.
Be sure to wiggle the wires near each of the
No active codes connectors.

Results: Table 11
Points for the Measurement of Resistance for
• No codes – The 41-03 code or the 41-04 code is the Left Side of the Engine
not active. Disconnecting all of the 8 volt wiring
from the ECM eliminated the active “8 Volt DC Connector and Terminal Connector and Terminal
Supply” diagnostic code. There is a problem in a P1-4 (8 volt supply) All of the remaining
connector and/or the wiring in a harness. Proceed terminals on the P1
to Test Step 5. connector
All of the terminals on the
• Active code – There is an active 41-03 or 41-04 P2 connector
code. Disconnecting all of the 8 volt wiring from
the ECM did not eliminate the active “8 Volt DC P2-56 (8 volt supply) All of the remaining
Supply” diagnostic code. There may be a problem terminals on the P2
with the ECM. connector
All of the terminals on the
Repair: Set the engine control to the OFF/RESET P1 connector
mode. Switch the 35 amp circuit breaker OFF.
P2-57 (8 volt supply) All of the remaining
Insert all of the terminals that were removed. Pull terminals on the P2
connector
on the wires in order to verify that the terminals are
fully inserted into the connector. All of the terminals on the
P1 connector
It is unlikely that the ECM has failed. Exit this
procedure and perform this procedure again. If Expected Result:
the problem is not resolved, perform the following
steps: Each check of the resistance is greater than 20,000
Ohms.
Temporarily install a new ECM. Refer to
Troubleshooting, “Replacing the ECM”. Results:
If the problem is resolved with the new ECM,
install the original ECM and verify that the problem
• OK – Each check of the resistance is greater than
20,000 Ohms. The 8 volt wires and connectors do
returns. If the new ECM operates correctly and the not have a short circuit.
original ECM does not operate correctly, replace
the original ECM. Refer to Troubleshooting, Repair: Reconnect all of the connectors. Restore
“Replacing the ECM”. electrical power to the engine. Verify that the
original problem is resolved. If the problem is
STOP. resolved, the initial diagnostic code was probably
caused by a poor electrical connection.
Test Step 5. Check the Wiring Harnesses
If the problem is not resolved, refer to
A. Set the engine control to the OFF/RESET mode. Troubleshooting, “Inspecting Electrical
Switch the 35 amp circuit breaker OFF. Connectors”.
B. Insert all of the terminals that were removed. Pull STOP.
on the wires in order to verify that the terminals
are fully inserted into the connector.
191
Troubleshooting Section

• Not OK – At least one check of the resistance is The -03 code is probably caused by a problem in
less than 20,000 Ohms. There is a problem with a an engine harness. There may be an open circuit
connector and/or at least one of the 8 volt wires in a harness, or a short circuit to a positive voltage
in a harness. source in a harness. The next likely cause is a sensor
problem. The least likely cause is a problem with the
Repair: The problem may be inside the terminal ECM.
box. Alternatively, the problem may be in an engine
harness. The -04 code is probably caused by a short circuit to
ground in an engine harness. The next likely cause is
Repair the connection and/or the wire, when a sensor problem. The least likely cause is a problem
possible. Replace parts, if necessary. with the ECM.

STOP. Logged diagnostic codes provide a historical record.


Before you begin this procedure, use the Caterpillar
Electronic Technician (ET) to print the logged codes
i02055318
to a file.
Analog Sensor Signal This troubleshooting procedure may generate
SMCS Code: 5574-038 additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
System Operation Description: Clear the diagnostic code after the problem is
resolved.
Use this procedure to troubleshoot diagnostic codes
for open circuits or short circuits for the sensors of
these parameters:

• Engine coolant temperature


• Inlet air temperature
• Engine oil temperature
• Filtered engine oil pressure
• Unfiltered engine oil pressure
Note: The engine coolant temperature sensor does
not require +5 VDC from the Electronic Control
Module (ECM). The engine coolant temperature
sensor is a passive sensor of the analog type. The
sensor operates without a voltage supply from the
ECM.

The ECM can be configured for one of these types of


speed control:

• Potentiometer
• 4-20 ma
The “DESIRED SPEED” potentiometer (if equipped)
must be supplied with +5 VDC from the ECM. If the
“DESIRED SPEED” potentiometer has a short circuit
or the potentiometer’s wiring has a short circuit, a
262-03 or 262-04 diagnostic code may be activated.
There are no diagnostic codes for the circuit of the
“DESIRED SPEED” potentiometer.
192
Troubleshooting Section

g01054050
Illustration 38
Schematic for the analog sensors
193
Troubleshooting Section

Test Step 1. Inspect the Electrical • ECM J1/P1 connectors


Connectors and Wiring
• J6/P6, and J7/P7 connectors on the terminal
box

a. Check the torque of the Allen head screws for


the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws


for the terminal box’s connectors. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054206
Illustration 39
Junction box

A. Set the engine control to the OFF/RESET mode. Illustration 41


g01054057
Switch 35 amp circuit breaker (1) to the OFF Harness side of the ECM P1 connector
position.
(P1-2) 5 volt supply
(P1-3) Return
Note: For the following steps, refer to (P1-14) Signal for the inlet manifold air temperature
Troubleshooting, “Inspecting Electrical Connectors”. (P1-16) Signal for the desired speed
(P1-17) Signal for the engine oil temperature
(P1-18) 5 volt supply
(P1-24) Signal for the filtered engine oil pressure
(P1-26) Signal for the unfiltered engine oil pressure
(P1-27) Signal for the engine coolant temperature
(P1-35) Return

g01053664
Illustration 40
Terminal box
(2) J1/P1 connectors for the ECM
(3) J6/P6 connectors for the customer
(4) J7/P7 connectors for the harness from the 5 volt sensors

B. Thoroughly inspect each of the following


connectors:
194
Troubleshooting Section

g01053675
Illustration 42
Harness side of the J6 connector
(J6-5) 5 volt supply
(J6-15) Return
(J6-25) Signal for desired speed
(J6-35) Shield
g01054071
Illustration 43
Harness side of the J7 connector
(J7-3) Signal for the inlet manifold air temperature
(J7-4) Signal for the filtered engine oil pressure
(J7-5) Signal for the engine oil temperature
(J7-6) Signal for the unfiltered engine oil pressure
(J7-7) Signal for the engine coolant temperature
(J7-17) Return for the inlet manifold air temperature
(J7-18) Return for the filtered engine oil pressure
(J7-19) Return for the engine oil temperature
(J7-20) Return for the unfiltered engine oil pressure
(J7-21) Return for the engine coolant temperature
(J7-31) Shield for the inlet manifold air temperature
(J7-32) Shield for the filtered engine oil pressure
(J7-33) Shield for the engine oil temperature
(J7-34) Shield for the unfiltered engine oil pressure
(J7-35) Shield for the engine coolant temperature
(J7-45) 5 volt supply for the inlet manifold air temperature
(J7-46) 5 volt supply for the filtered engine oil pressure
(J7-47) 5 volt supply for the engine oil temperature
(J7-48) 5 volt supply for the unfiltered engine oil pressure

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


wires that are associated with the circuit for the
analog sensors.
195
Troubleshooting Section

Expected Result:

All connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.

Results:

• OK – All connectors, pins, and sockets are


connected properly. The connectors and the wiring
do not have corrosion, abrasion, or pinch points.
The components are in good condition with proper
connections. Proceed to Test Step 2.

• Not OK – At least one of the connectors, pins,


and/or sockets are not connected properly. At
least one of the connectors and/or the wiring has
corrosion, abrasion, or pinch points.

Repair: Perform the necessary repairs and/or


replace parts, if necessary.

STOP.

Test Step 2. Check for Diagnostic Codes


for the Power Supply

g01053697
A. Connect Cat ET to the service tool connector.
Illustration 44 Refer to Troubleshooting, “Electronic Service
Right side of the engine Tools”.
(5) Engine oil temperature sensor
(6) Unfiltered oil pressure sensor B. Switch the 35 amp circuit breaker ON. Set the
(7) Filtered oil pressure sensor engine control to the STOP mode.

C. Observe the “Active Diagnostic” screen on ET.


Allow a minimum of 30 seconds for any codes to
activate. Look for these codes:

• 262-03 5 Volt Sensor DC Power Supply short


to +batt

• 262-04 5 Volt Sensor DC Power Supply short


to ground

Expected Result:

There are no active “5 Volt Sensor DC Power Supply”


diagnostic codes.

Results:

• No codes – There are no active “5 Volt Sensor DC


Power Supply” diagnostic codes. Proceed to Test
Step 3.
g01054081
Illustration 45
Top view of the engine • Active code – There is an active “5 Volt Sensor DC
Power Supply” diagnostic code. This procedure will
(8) Engine coolant temperature sensor
(9) Engine coolant pressure sensor (outlet)
not work when this type of code is active.

d. Check the harness and wiring for abrasion Repair: Refer to Troubleshooting, “+5V Sensor
and for pinch points from the analog sensors Supply”.
to the ECM.
196
Troubleshooting Section

If necessary, return to this functional test in order • Active “open/short to +batt” (FMI 03) – There is an
to troubleshoot the analog sensor after the “+5 V active “open/short to +batt” diagnostic code. If you
Sensor Supply” diagnostic code has been resolved. are troubleshooting the sensor for engine coolant
temperature, proceed to Test Step 6. Otherwise,
STOP. proceed to Test Step 5.

Test Step 3. Check for Active Analog • Active “short to ground” (FMI 04) – There is an
Sensor Diagnostic Codes active “short to ground” diagnostic code. Proceed
to Test Step 4.
A. Observe the “Active Diagnostic” screen on Cat
ET. Wait at least 30 seconds so that any codes Test Step 4. Create an Open Circuit for
may become activated. Look for the codes that the Sensor
are listed in Table 12:
A. Set the engine control to the OFF/RESET mode.
Table 12

Analog Sensor Diagnostic Codes B. Disconnect the sensor that has the “short to
ground” diagnostic code.
100-03 Engine Oil Pressure open/short to +batt
100-04 Engine Oil Pressure short to ground C. Set the engine control to the STOP mode.
110-03 Engine Coolant Temperature open/short to D. Observe the “Active Diagnostic” screen on Cat ET.
+batt Allow a minimum of 30 seconds for any codes to
110-04 Engine Coolant Temperature short to ground activate. Look for an active “open/short to +batt”
diagnostic code.
172-03 Intake Manifold Air Temp open/short to +batt
172-04 Intake Manifold Air Temp short to ground Expected Result:
175-03 Engine Oil Temperature open/short to +batt There is an active “open/short to +batt” diagnostic
175-04 Engine Oil Temperature short to ground code for the disconnected sensor.
542-03 Unfiltered Engine Oil Pressure open/short to Results:
+batt
542-04 Unfiltered Engine Oil Pressure short to ground • Yes – Before the suspect sensor was
disconnected, there was an active “short to
ground” diagnostic code for the sensor. After the
B. If one of the above codes is active, identify the suspect sensor was disconnected, there was an
type of diagnostic according to the condition: the active “open/short to +batt” diagnostic code for the
diagnostic code is either “open/short to +batt” (FMI sensor.
03) or “short to ground” (FMI 04).
Repair: Reconnect the sensor. If the active “short
Expected Result: to ground” diagnostic code recurs, replace the
original sensor.
None of the above codes are active.
Verify that the code does not activate when the
Results: new sensor is installed. Clear the logged diagnostic
code from the ECM.
• No active codes – None of the above codes are
active. STOP.
Repair: If any of the above codes are logged • No – Before the suspect sensor was disconnected,
and the engine is not running properly, refer to there was an active “short to ground” diagnostic
Troubleshooting, “Troubleshooting Without a code for the sensor. After the suspect sensor
Diagnostic Code”. was disconnected, the active “open/short to
+batt” diagnostic code remained. If you are
If the engine is running properly at this time, troubleshooting the sensor for engine coolant
there may be an intermittent problem in the temperature, proceed to Test Step 6. Otherwise,
harness that is causing the codes to be logged. proceed to Test Step 5.
Refer to Troubleshooting, “Inspecting Electrical
Connectors”.

STOP.
197
Troubleshooting Section

Test Step 5. Check the Supply Voltage at


the Sensor Connector
A. Verify that the suspect sensor is disconnected
from the engine harness.

g00889801
Illustration 47
Harness connectors for the various sensors
(A) 5 volt supply
(B) Return
(C) Signal
g00889729 (1) Signal
Illustration 46
(2) Return
Harness connectors for the various sensors
(A) 5 volt supply B. At the harness connector for the suspect sensor,
(B) Return measure the voltage between terminals B and C,
(C) Signal
or between terminals 1 and 2.
B. At the harness connector for the suspect sensor, Expected Result:
measure the voltage between terminals A and B.
The voltage is between 6.0 VDC and 7.0 VDC.
Expected Result:
Results:
The voltage is between 4.5 VDC and 5.5 VDC.

Results:
• OK – The voltage between the signal terminal and
the return terminal is between 6.0 VDC and 7.0
VDC. The pull-up voltage that is created by the
• OK – The voltage between terminals A and B is ECM is present at the sensor connector. The signal
between 4.5 VDC and 5.5 VDC. The 5 volt supply wire and the return wire for the suspect sensor
is present at the sensor connector. Proceed to Test appear to be OK. Proceed to Test Step 8.
Step 6.
• Not OK – The voltage between the signal terminal
• Not OK – The voltage between terminals A and and the return terminal is not between 6.0 VDC
terminal B is not between 4.5 VDC and 5.5 VDC. and 7.0 VDC. The pull-up voltage that is created
The 5 volt supply is not present at the sensor by the ECM is not present at the sensor connector.
connector. The 5 volts must be present at the Proceed to Test Step 7.
sensor in order to continue this procedure. The 5
volt wiring problem may be inside the terminal box, Test Step 7. Check the Pull-Up Voltage
or in the engine harness. at the ECM
Repair: Verify that the wiring and/or connectors A. Set the engine control to the OFF/RESET mode.
are OK. Repair any faulty wiring and/or connectors, Switch the 35 amp circuit breaker OFF.
when possible. Replace parts, if necessary.
Refer to Troubleshooting, “Inspecting Electrical B. Use a 151-6320 Wire Removal Tool to remove
Connectors”. Check for diagnostic codes again. the signal wire for the suspect sensor from the
P1 connector.
STOP.
C. Use a jumper wire with Deutsch terminals on the
Test Step 6. Check the Pull-Up Voltage at ends. Insert one end of the jumper wire into the
the Sensor open terminal of the P1 connector.
A. Verify that the suspect sensor’s connector is D. Connect a multimeter lead to the end of the jumper
disconnected from the engine harness. wire that is not inserted into the connector.

E. At the harness side of the P1 connector, insert a


7X-1710 Multimeter Probe along terminal 3.

F. Connect the other multimeter lead to the probe.

G. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.
198
Troubleshooting Section

H. Measure the pull-up voltage at the ECM. Results:

Expected Result: • OK – No diagnostic codes are activated when a


good sensor is temporarily installed. Connecting a
The voltage is between 6.0 VDC and 7.0 VDC. new sensor resolved the problem.

Results: Repair: Perform the following procedure:

• OK – The pull-up voltage for the suspect sensor at 1. Reconnect the suspect sensor. Verify that the
the ECM is between 6.0 VDC and 7.0 VDC. The “open/short to +batt” diagnostic code recurs.
ECM is producing a pull-up voltage that is valid.
There is a problem with the signal wire between P1 2. Disconnect the suspect sensor. Verify that
and the harness connector for the sensor. There the “open/short to +batt” diagnostic code is
may be a problem with a connector. deactivated.

Repair: Perform the following procedure: 3. Connect the new connector. Verify that no
diagnostic codes are activated.
Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. If these conditions are true, replace the faulty
sensor with the new sensor. For the proper
Disconnect the multimeter leads. torque value for the new sensor, refer to the
Specifications manual.
Use a 151-6320 Wire Removal Tool to remove
the jumper wire from the P1 connector. 4. Clear all of the diagnostic codes. Verify that the
problem has been resolved.
Reinstall the terminal that was removed from the
P1 connector. Pull on the wire in order to verify STOP.
proper installation of the terminal.
• Not OK – The active “open/short to +batt” code
Verify that the wiring and/or connectors are OK. remains. Connecting a new sensor did not resolve
Repair any faulty wiring and/or connectors, when the problem. Proceed to Test Step 9.
possible. Replace any wiring and/or connectors, if
necessary. Refer to Troubleshooting, “Inspecting Test Step 9. Check the Operation of the
Electrical Connectors”. ECM
STOP. A. Verify that the signal wire for the suspect sensor
has been removed from the P1 connector.
• Not OK – The pull-up voltage for the suspect
sensor at the ECM is not between 6.0 VDC and B. Clear any existing diagnostic codes.
7.0 VDC. Proceed to Test Step 9.
C. Observe the “Active Diagnostic” screen on ET.
Test Step 8. Check the Sensor Allow a minimum of 30 seconds for any codes to
activate.
A. Temporarily connect a sensor that is known to be
good to the engine harness. An active “open/short to +batt” diagnostic code is
generated for the sensor.
B. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. D. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
C. Observe the “Active Diagnostic” screen on Cat
ET. Allow a minimum of 30 seconds for any codes E. Use a jumper wire that is the appropriate length
to activate. with Deutsch terminals on the ends. Install one
end of the jumper wire into the terminal for
Expected Result: the signal wire that was removed from the P1
connector. Install the other end of the jumper wire
No diagnostic codes are activated. into terminal 19 of the P1 connector. This will
replace the sensor circuit with a short circuit.

F. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.
199
Troubleshooting Section

G. Observe the “Active Diagnostic” screen on Cat i02055372


ET. Allow a minimum of 30 seconds for any codes
to activate. CAT Data Link
An active “short to ground” diagnostic code is SMCS Code: 1901-038
generated.
System Operation Description:
Expected Result:
The CAT data link is used to share information
Active “open/short to +batt” and “short to ground” between the following components:
diagnostic codes are generated according to the
above steps. • Electronic Control Module (ECM)

Results: • Integrated Temperature Sensing Module (ITSM)

• OK – Active “open/short to +batt” and “short to • Electronic service tool


ground” diagnostic codes are generated according
to the above steps. The ECM is operating correctly. • Electronic Modular Control Panel II+ (EMCP II+)
The initial diagnostic code was probably caused by
a poor electrical connection. • Customer installed components

Repair: Perform the following procedure: The ECM and the ITSM communicate with Cat ET
via the CAT data link.
Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. The CAT data link consists of two wires that are
twisted together. One wire is designated as +. The
Use a 151-6320 Wire Removal Tool to remove other wire is designated as -.
the jumper wire from the P1 connector.
The signals on the data link wires are a square
Reinstall the terminal that was removed from the wave type signal. The signals operate at a very high
P1 connector. Pull on the wire in order to verify frequency. The signals cannot be measured with
proper installation of the terminal. common service tools. Therefore, only continuity
measurements can be made on the wires for the
Resume normal operation. CAT data link.

STOP. The most likely cause of a diagnostic code for the


CAT data link are an open circuit or a short circuit.
• Not OK – No active “open/short to +batt” and Connector terminals that are not fully seated in the
“short to ground” diagnostic codes were generated. connector body can create an open circuit condition.
The ECM is not operating correctly. Be careful not to interchange the + wire and the - wire
in a connector. The CAT data link will not operate
Repair: It is unlikely that the ECM has failed. Exit if the + wire and the - wire are interchanged in a
this procedure and perform this entire procedure connector.
again. If the problem is not resolved, perform the
following steps: The CAT data link can fail if a module is not receiving
power. This can happen if there is a problem with the
Temporarily install a new ECM. Refer to wiring that provides power to the module.
Troubleshooting, “Replacing the ECM”.
The CAT data link can fail if a module is programmed
If the problem is resolved with the new ECM, with the wrong flash file, or if a module has not been
install the original ECM and verify that the problem programmed with a flash file. Verify that all modules
returns. If the new ECM operates correctly and the have been programmed with the proper flash file.
original ECM does not operate correctly, replace
the ECM. Refer to Troubleshooting, “Replacing
the ECM”.

STOP.
200
Troubleshooting Section

Perform this procedure for all problems that are


associated with the CAT data link. If this procedure
does not solve the problem, there may be a faulty
ignition transformer. A faulty ignition transformer can
cause the ECM to reset. When the reset occurs, the
ECM also generates a diagnostic code for the CAT
data link. If the engine is not running, the engine will
not start. If the engine is running, the engine will
shut down. Temporarily install a transformer that is
known to be good into a cylinder. Then check for the
diagnostic code. If the code is still active, install the
good transformer into a different cylinder. When the
suspect transformer is removed, the ECM will not
reset.

g01054152
Illustration 48
Schematic diagram of the CAT data link
201
Troubleshooting Section

Test Step 1. Inspect the Electrical


Connectors and Wiring

g01054154
Illustration 51
Rear view
g01054206
Illustration 49 (7) ITSM
Junction box (8) 14-pin connectors for the harness to the terminal box for the
ECM
(1) 35 amp circuit breaker
B. Thoroughly inspect each of the following
A. Set the engine control to the OFF/RESET mode. connectors:
Switch 35 amp circuit breaker (1) to the OFF
position.
• J1/P1 connectors
Note: For the following steps, refer to
Troubleshooting, “Inspecting Electrical Connectors”.
• J3/P3 connectors
• J5, J6, and J9/P9 connectors on the terminal
box

• 14-pin connectors (9) for the ITSM


a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (53 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054153
Illustration 50
Terminal box for the ECM
(2) Ground strap
(3) J5 connector for Cat ET
(4) J1/P1 connectors for the ECM
(5) J6 connector for the customer
(6) J9/P9 connectors for the CAT data link
202
Troubleshooting Section

D. Select the “File/Select ECM” menu on the Cat ET.


Verify that all of the modules are displayed on the
“ECM Selector” screen.

Verify that the following diagnostic codes are not


activated.

• 0590-09 Unable to communicate with Engine


ECM

• 1042-09 Unable to communicate with ITSM


Expected Result:

g01013130
All of the modules are displayed on the “ECM
Illustration 52 Selector” screen. There are no active diagnostic
Harness side of the ECM P1 connector codes for the CAT data link.
(P1-8) CAT data link +
(P1-9) CAT data link − Results:

c. Perform a 45 N (10 lb) pull test on each of the • OK – All of the modules are displayed on the “ECM
wires that are associated with the circuit for the Selector” screen. There are no active diagnostic
CAT data link. codes for the CAT data link. The problem seems
to be resolved.
d. Check the harnesses and wiring for abrasion
and for pinch points from the ITSM to the ECM. Repair: If any of the above codes are logged
and the engine is not running properly, refer to
Expected Result: Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
The connectors, pins, and sockets are connected
properly. The connectors and the wiring do not have If any of the above codes are logged and the
corrosion, abrasion, or pinch points. engine is running properly, there may be an
intermittent problem in a connector or a wiring
Results: harness. Refer to Troubleshooting, “Inspecting
Electrical Connectors”.
• OK – The components are in good condition with
proper connections. Proceed to Test Step 2. STOP.

• Not OK – The components are not in good • Not OK – At least one of the modules is not
condition and/or at least one connection is displayed on the “ECM Selector” screen. There
improper. may be an active diagnostic code for the CAT data
link. Proceed to Test Step 3.
Repair: Perform the necessary repairs and/or
replace parts, if necessary. Test Step 3. Check the Wiring for the CAT
Data Link
STOP.
A. Set the engine control to the OFF/RESET mode.
Test Step 2. Check the CAT Data Link Switch the 35 amp circuit breaker OFF.

A. Verify that the engine control is in the OFF/RESET B. Disconnect Cat ET from the service tool connector.
mode. Verify that the 35 amp circuit breaker is
OFF. C. Disconnect the following connectors:

B. Connect Cat ET to the service tool connector. • P1 connector


Refer to Troubleshooting, “Electronic Service
Tools”. • P6 connector (if equipped)
C. Set the engine control to the STOP mode. Switch • 14-pin connector from the ITSM
the 35 amp circuit breaker ON.
203
Troubleshooting Section

D. Measure the resistance between the points that 6. If the problem is not resolved, there may be a
are listed in Table 13. During each measurement, problem with the wiring for the CAT data link
wiggle the wires in the harness in order to check between the J6 connector and the customer’s
for an intermittent problem. Be sure to wiggle the equipment. Verify that the wiring for the CAT
wires near each of the connectors. data link between the J6 connector and the
customer’s equipment is working properly.
Table 13

Resistance Measurements for the CAT Data Link 7. If the problem is not resolved, there may
be a problem with the module that is not
Connector and Terminal Connector and Terminal communicating with Cat ET.
P1-8 J5-D
It is unlikely that a module has failed. Exit this
J6-7 procedure and perform this procedure again. If
Terminal J of the 14-pin the problem is not resolved, temporarily replace
connector on the ITSM the module that is not communicating. Refer
to Troubleshooting, “Replacing the ECM” or
P1-9 J5-E Troubleshooting, “Replacing the ITSM”. Verify
J6-17 that the problem is resolved.
Terminal N of the 14-pin If the problem is resolved with the new module,
connector on the ITSM reinstall the original module and verify that
P1-34 Ground strap for the ECM the problem returns. If the new module works
correctly and the original module does not work
P1-50 Ground strap for the ECM correctly, replace the original module. Refer
to Troubleshooting, “Replacing the ECM” or
Expected Result: Troubleshooting, “Replacing the ITSM”.

Each check of the resistance between the connectors STOP.


is less than 5 Ohms.
• Not OK – At least one check of the resistance for
Each check of the resistance between the connector the CAT data link is incorrect. There is a problem
and the ground strap is greater than 20,000 Ohms. with the wiring for the CAT data link.

Results: Repair: Repair the connection and/or the wire,


when possible. Replace parts, if necessary. Verify
• OK – Each check of the resistance for the CAT that the problem is resolved.
data link is within the specification. The wiring for
the CAT data link appears to be OK. STOP.

Repair: Perform the following procedure:


i02055519

1. Connect the following connectors: Compressor Bypass


• P1 connector SMCS Code: 1052-038-BV

• P6 connector (if equipped) System Operation Description:

• 14-pin connector to the ITSM A bypass valve is connected between the outlets
for the turbocharger compressors and the inlets for
2. Connect Cat ET to the service tool connector. the turbocharger compressors. The bypass valve
Refer to Troubleshooting, “Electronic Service is activated by an actuator. The Electronic Control
Tools”. Module (ECM) activates the actuator for the bypass
valve during these conditions:
3. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. • Turbocharger surge
4. Verify that Cat ET is able to communicate with • Engine shutdown
each of the modules.
Turbocharger Surge
5. If Cat ET is unable to communicate with a
module, there may be a problem with the supply
voltage to the module. Refer to Troubleshooting,
“Electrical Power Supply”.
204
Troubleshooting Section

A rapid drop in the output power of the generator If there is no ground on terminal N and the actuator
can cause the engine’s speed to quickly increase. is powered up, the actuator for the bypass valve and
The increased speed of the engine causes the the throttle actuator will have the same identification.
turbochargers to overspeed temporarily. This is The ECM will not communicate with the actuator for
called a turbocharger surge. Surging can damage the bypass valve. Instead, the ECM will activate a
the turbochargers. 1720-09 diagnostic code. The engine will not start.

The ECM continuously monitors the speed of the The electrical connector for the actuator is designed
engine. The ECM responds to a rapid increase in the so that the terminals for electrical power are
speed of the engine by activating the actuator for the connected before terminal N. For this reason,
bypass valve. The actuator opens the valve. electrical power must be removed before the
connector for the actuator is connected.
The valve allows the compressed air/fuel mixture in
the aftercooler’s inlet to flow into the intake of the
turbocharger’s compressor. This reduces the boost
pressure in the air inlet manifold.

Engine Shutdown

Engine shutdown occurs when the output for the fuel


control relay is OFF and the engine RPM is above
100. The ECM activates the actuator for the bypass
valve until the engine RPM drops to zero. This
scavenges any unburned gases in the components
of the system during engine shutdown.

CAN Data Link

The ECM and the actuator communicate via the CAN


data link. The ECM sends a command signal to the
actuator. The actuator sends the following information
to the ECM: actuator position, CCM heartbeat,
software version, and internal fault diagnosis.

If the ECM cannot communicate with the actuator,


the ECM activates a 1720-09 diagnostic code and
the engine is shut down. A 1720-09 diagnostic code
is probably caused by a problem with an electrical
connector or a harness. The next likely cause is a
problem with the actuator. The least likely cause is
a problem with the ECM.

Terminating resistors must be connected to each


end of the CAN data link. The terminating resistors
improve the communication between the devices. If
there is an intermittent diagnostic code for any of the
devices that are connected to the CAN data link, be
sure to check the terminating resistor that is inside
the terminal box. Also check the jumper wire that is
connected between terminals J and K on the actuator
for the bypass valve. Make repairs, when possible.
Replace parts, if necessary.

Identification on the CAN Data Link

When the actuator for the bypass valve is powered


up, the actuator looks for a ground on terminal N. If
there is a ground on terminal N, the actuator will have
a unique identification on the CAN data link.
205
Troubleshooting Section

g01054193
Illustration 53
Schematic for the circuit of the actuator for the bypass valve
206
Troubleshooting Section

Test Step 1. Inspect the Electrical


Connectors and Wiring

g01054200
Illustration 55
Terminal box
g01054206
Illustration 54 (2) Ground strap
Junction box (3) J1/P1 connectors for the ECM
(4) J9/P9 connectors for the CAN data link
(1) 35 amp circuit breaker (5) J10/P10 connectors for the terminating resistor for the CAN
data link
A. Set the engine control to the OFF/RESET mode.
Switch 35 amp circuit breaker (1) to the OFF B. Thoroughly inspect each of the following
position. connectors:

Note: For the following steps, refer to • J1/P1 connectors for the ECM
Troubleshooting, “Inspecting Electrical Connectors”.
• J9/P9 connectors on the terminal box
• Connectors on the actuator for the bypass valve
a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
207
Troubleshooting Section

g01054209
Illustration 56
Harness side of the ECM P1 connector
(P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +

g01057951
Illustration 58
Right side view
(6) Actuator for the bypass valve

g01054210
Illustration 57
Harness side of the ECM J9 connector
(J9-6) CAN data link +
(J9-12) CAN data link −
(J9-18) CAN shield

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


wires that are associated with the actuator for
the bypass valve.
208
Troubleshooting Section

g00935459
Illustration 59

d. Check the wiring for abrasion and for pinch Expected Result:
points from the actuator for the bypass valve
to the ECM. The 1720-09 code is not active.

Expected Result: Results:

All of the connectors, pins, and sockets are connected • OK – The 1720-09 code is not active. The
properly. The connectors and the wiring do not have communication between the ECM and the actuator
corrosion, abrasion, or pinch points. for the bypass valve appears to be OK at this time.
However, diagnostic codes may be logged.
Results:
Repair: If you are troubleshooting an intermittent
• OK – The components are in good condition with problem, refer to Troubleshooting, “Inspecting
proper connections. Proceed to Test Step 2. Electrical Connectors”.

• Not OK – The components are not in good Terminating resistors must be connected to each
condition and/or at least one connection is end of the CAN data link. The terminating resistors
improper. improve the communication between the devices.
If there is an intermittent diagnostic code for any of
Repair: Perform the necessary repairs and/or the devices that are connected to the CAN data
replace parts, if necessary. Ensure that all of link, be sure to check the terminating resistor that
the seals are properly installed. Ensure that the is inside the terminal box. Also check the jumper
connectors are properly engaged. Verify that the wire that is connected between terminals J and K
repair has eliminated the original problem. on the actuator for the bypass valve. Make repairs,
when possible. Replace parts, if necessary.
STOP.
STOP.
Test Step 2. Check for a Diagnostic Code
• Not OK (Active 1720-09) – The ECM has detected
A. Connect the Caterpillar Electronic Technician (ET) a problem with the communication between the
to the service tool connector. ECM and the actuator for the bypass valve.
Proceed to Test Step 3.
B. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.

C. Use Cat ET in order to determine if a 1720-09


diagnostic code is active.
209
Troubleshooting Section

Test Step 3. Check the CAN Data Link for Make repairs, when possible. Replace parts, if
Continuity Between the Actuator for the necessary.
Bypass Valve and the ECM
STOP.
A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. Test Step 4. Check the CAN Data Link for
a Short Circuit
B. Disconnect the P1 connector. Disconnect the
connector for the actuator for the bypass valve. A. Verify that the engine control is in the OFF/RESET
mode and that the 35 amp circuit breaker is OFF.
C. Use a multimeter to check for continuity between
the points that are listed in Table 14. During each B. Use a multimeter to check for continuity between
measurement, wiggle the harnesses in order to the points that are listed in Table 15. During each
check for an intermittent problem with the harness. measurement, wiggle the harnesses in order to
Be sure to wiggle the harness near each of the check for an intermittent problem with the harness.
connectors. Be sure to wiggle the harness near Be sure to wiggle the harness near each of the
the fuel metering valve and the throttle actuator. connectors. Be sure to wiggle the harness near
the fuel metering valve and the throttle actuator.
Table 14
Table 15
Points to Check for Continuity
Points to Check for Continuity
Connector and Harness Connector for the
Terminal Actuator for the Bypass Valve Connector and Terminal Connector and Terminal
P1-34 Terminal “B” (CAN data link −) P1-34 (CAN data link −) P1-50 (CAN data link +)
P1-42 (CAN shield)
P1-50 Terminal “A” (CAN data link +) P1-52 (+ Battery)
P1-42 Terminal “M” (CAN shield) Ground strap for the ECM
P1-50 (CAN data link +) P1-42 (CAN shield)
Expected Result: P1-52 (+ Battery)
Ground strap for the ECM
The continuity of the circuits between the terminals P1-42 (CAN shield) P1-52 (+ Battery)
is good. Ground strap for the ECM

Results:
Expected Result:
• OK – The continuity of the circuits between the All of the measurements indicate an open circuit.
terminals is good. Proceed to Test Step 4.
Results:
• Not OK – At least one of the continuity checks
indicates an open circuit. There is an open circuit
for the CAN data link between the actuator for the • OK – All of the measurements indicate an open
circuit. The CAN data link does not have a short
bypass valve and the ECM.
circuit.
Repair: The open circuit could be caused by a poor
Repair: Reconnect the P1 connector. Reconnect
electrical connection in a connector. Alternatively,
the connector for the actuator for the bypass valve.
the open circuit could be caused by one of the
following components:
Proceed to Test Step 5.
• The harness inside the terminal box • Not OK – At least one of the measurements
indicate a short circuit.
• The harness between the terminal box and the
fuel metering valve
Repair: The short circuit could be caused by a poor
electrical connection in a connector. Alternatively,
• The harness between the fuel metering valve the short circuit could be caused by one of the
and the throttle actuator
following components:
• The harness between the throttle actuator and • The harness inside the terminal box
the actuator for the bypass valve

• The fuel metering valve • The harness between the terminal box and the
fuel metering valve
• The throttle actuator
210
Troubleshooting Section

• The harness between the fuel metering valve 1. Temporarily install a new ECM. Refer to
and the throttle actuator Troubleshooting, “Replacing the ECM”. If
the problem is resolved with the new ECM,
• The harness between the throttle actuator and install the original ECM and verify that the
the actuator for the bypass valve problem returns. If the new ECM operates
correctly and the original ECM does not operate
• The fuel metering valve correctly, replace the original ECM. Refer to
Troubleshooting, “Replacing the ECM”. If the
• The throttle actuator problem is not resolved with a new ECM, install
the original ECM. Continue with this procedure.
Make repairs, when possible. Replace parts, if
necessary. 2. Temporarily install a new actuator for the throttle
actuator. If the new throttle actuator operates
STOP. correctly, the problem is resolved. If the new
throttle actuator does not operate correctly,
Test Step 5. Check for a Diagnostic Code install the original throttle actuator and continue
with this procedure.
A. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. 3. Temporarily install a new actuator for the bypass
valve. If the new actuator for the bypass valve
B. Use Cat ET in order to determine if a 1720-09 operates correctly, the problem is resolved. If
diagnostic code is active. the new actuator for the bypass valve does not
operate correctly, install the original actuator
Expected Result: for the bypass valve and continue with this
procedure.
The 1720-09 code is not active.
4. Temporarily install a new fuel metering valve.
Results: If the new fuel metering valve operates
correctly, the problem is resolved. If the new
• OK – The 1720-09 code is not active. The problem fuel metering valve does not operate correctly,
seems to be resolved. The initial diagnostic install the original fuel metering valve. Refer
code was probably caused by a poor electrical to Troubleshooting, “Inspecting Electrical
connection. Connectors”.

Repair: If there is an intermittent problem STOP.


that is causing the code to be logged, refer
to Troubleshooting, “Inspecting Electrical
i02055603
Connectors”.

STOP.
Desired Speed Input (4 - 20
mA)
• Not OK – The 1720-09 code is active.
SMCS Code: 1901-038
Repair: The active 1720-09 code could be caused
by one of the following components: System Operation Description:

• The ECM Note: For this troubleshooting procedure,


the “Desired Speed Input” configuration
• The throttle actuator parameter must be set to “4-20 mA Input” in the
“Service/Configuration” screen of the Caterpillar
• The actuator for the bypass valve Electronic Technician (ET). Do not select “PWM”.
The Electronic Control Module (ECM) cannot be
• The fuel metering valve configured to accept a PWM input signal for control
of the engine speed.
It is unlikely that any of the components that are
listed above have failed. Exit this procedure and The selection of the “4-20 mA Input” setting requires
perform this procedure again. If the 1720-09 code a 4 to 20 mA signal for regulation of the desired
remains active, perform the following procedure: engine speed. If the “Desired Speed Input” is set
to “0-5 VDC Input”, do not use this procedure to
troubleshoot the circuit.
211
Troubleshooting Section

When the desired speed input is correspondingly Test Step 1. Inspect the Electrical
configured, the ECM controls the engine speed Connectors and Wiring
according to the 4 to 20 mA current.

The value of the current corresponds to a range


of desired engine speeds between minimum high
idle and maximum high idle. The “Minimum Engine
High Idle Speed” and the “Maximum Engine High
Idle Speed” are set with the “Service/Configuration”
screen of ET. For more information, refer to Systems
Operation/Testing and Adjusting, “Electronic Control
System Parameters”.

When the “Idle/Rated” switch is in the Rated position,


a current value of 4.0 mA corresponds to the
programmed “Minimum Engine High Idle Speed”. A
current value of 20.0 mA corresponds to “Maximum
Engine High Idle Speed”. Current values within this
range will vary the desired engine speed in a linear
fashion between “Minimum Engine High Idle Speed”
and “Maximum Engine High Idle Speed”.

Current values that are greater than 22.0 mA will


activate the “524-03 Desired Engine Speed Sensor g01054206
Illustration 61
short to +batt” diagnostic code. Current values that
are less than 2.0 mA will activate the “524-04 Desired Junction box
Engine Speed Sensor short to ground” diagnostic (1) 35 amp circuit
code.
A. Set the engine control to the OFF/RESET mode.
The most likely causes of the diagnostic code are a Switch 35 amp circuit breaker (1) to the OFF
poor connection or a problem in a wiring harness. position.
The next likely cause is a problem with a component.
The least likely cause is a problem with the ECM. Note: For the following steps, refer to
Troubleshooting, “Inspecting Electrical Connectors”.
Logged diagnostic codes provide a historical record.
Before you begin this procedure, use ET to print the
logged codes to a file.

The troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.

g01054349
Illustration 62
Terminal box
g01054348
Illustration 60 (2) Ground strap
Schematic of the 4 to 20 mA desired speed input (3) J1/P1 connectors for the ECM
(4) J6/P6 connectors for the customer

B. Thoroughly inspect the following components:


212
Troubleshooting Section

• J1/P1 connectors for the ECM c. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the 4 to 20 mA
• J6/P6 connectors on the terminal box circuit.

• Wiring and the connections between the d. Check the harness and wiring for abrasion
terminal box and the device that supplies the and for pinch points between the device that
4 to 20 mA signal supplies the 4 to 20 mA signal and the ECM.

a. Check the torque of the Allen head screw for Expected Result:
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in). All connectors, pins, and sockets are connected
properly. The connectors and the wiring do not have
b. Check the torque of the Allen head screws corrosion, abrasion, or pinch points.
for the terminal box’s connectors. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in). Results:

• OK – The components are in good condition with


proper connections. If you are troubleshooting a
“524-03 Desired Engine Speed Sensor short to
+batt” diagnostic code, proceed to Test Step 2. If
you are troubleshooting a “524-04 Desired Engine
Speed Sensor short to ground” diagnostic code,
proceed to Test Step 5.

• Not OK – The components are not in good


condition and/or at least one connection is
improper.

Repair: Perform the necessary repairs and/or


replace parts, if necessary.
g01054364
Illustration 63
Harness side of the ECM P1 connector STOP.
(P1-36) + Signal
(P1-37) - Signal Test Step 2. Check for an Open Circuit
A. Remove the two wires (“+” and “-”) for the 4 to 20
mA signal from the device that supplies the 4 to
20 mA signal.

B. Install a jumper wire between the two wires (“+”


and “-”) that were removed from the device that
supplies the 4 to 20 mA signal.

C. Disconnect the P1 connector from the ECM.

D. Use an Ohmmeter to measure the resistance


between terminals P1-36 and P1-37 on the ECM
side of the P1 connector.

Expected Result:

The resistance is less than 5 Ohms.

Results:

Illustration 64
g01054367 • OK – The resistance is less than 5 Ohms. The
circuit is not open.
Harness side of the J6 connector
(J6-37) + Signal
(J6-27) - Signal
213
Troubleshooting Section

Repair: Remove the jumper wire. Insulate the wire Test Step 4. Check for a Short to Ground
leads with electrical tape in order to ensure that the at Terminal P1-37
leads do not create a short circuit.
A. Verify that the engine control is in the OFF/RESET
Proceed to Test Step 3. mode and that the 35 amp circuit breaker is OFF.

• Not OK – The resistance is greater than 5 Ohms. B. Make sure that the leads of the wires for the 4 to
There is a problem with a connector and/or the 20 mA signal do not create a short circuit.
wiring from the P1 connector.
C. Use an Ohmmeter to measure the resistance
Repair: The problem may be between the P1 between the ground strap for the ECM and
connector and the J6 connector. Alternatively, the terminal P1-37.
problem may be between the J6 connector and the
device that provides the 4 to 20 mA signal. Expected Result:

Repair the connection and/or the wire, when The resistance is greater than 20,000 Ohms.
possible. Replace parts, if necessary. Verify that
the problem is resolved. Results:

STOP. • Yes – The resistance is greater than 20,000 Ohms.


The wiring from terminal P1-37 appears to be OK.
Test Step 3. Check for a Short Circuit to
the +Battery at Terminal P1-36 Repair: Reconnect the P1 connector. Reconnect
the two wires (“+” and “-”) for the 4 to 20 mA signal
A. Verify that the engine control is in the OFF/RESET to the device that supplies the 4 to 20 mA signal.
mode and that the 35 amp circuit breaker is OFF.
Proceed to Test Step 7.
B. Make sure that there is no electrical power to the
device that provides the 4 to 20 mA signal. • No – The resistance is less than 20,000 Ohms.
There is a problem with a connection and/or the
C. Use an Ohmmeter to measure the resistance wiring that is connected to P1-37.
between terminals P1-36 and P1-57 on the ECM
side of the P1 connector. Repair: The problem may be between the P1
connector and the J6 connector. Alternatively, the
Expected Result: problem may be between the P6 connector and
the device that provides the 4 to 20 mA signal.
The resistance is greater than 20,000 Ohms.
Locate the wire with the short circuit and replace
Results: the wire. Verify that the problem is resolved.

• Yes – The resistance is greater than 20,000 Ohms. STOP.


The wiring from terminal P1-36 is not shorted to the
+Battery side. Do not reconnect any connectors. Test Step 5. Check for a Short Circuit to
Proceed to Test Step 4. the +Battery Side at Terminal P1-37
• No – The resistance is less than 20,000 Ohms. A. Verify that the engine control is in the OFF/RESET
There is a problem with a connection and/or the mode and that the 35 amp circuit breaker is OFF.
wiring from terminal P1-36.
B. Make sure that there is no electrical power to the
Repair: The problem may be between the P1 device that provides the 4 to 20 mA signal.
connector and the J6 connector. Alternatively, the
problem may be between the P6 connector and C. Remove the two wires (“+” and “-”) for the 4 to
the device that provides the 4 to 20 mA signal. 20 mA signal from the device that supplies the
4 to 20 mA signal. Insulate the wire leads with
Repair the connection and/or the wire, when electrical tape in order to ensure that the leads do
possible. Replace parts, if necessary. Verify that not create a short circuit.
the problem is resolved.
D. Disconnect the P1 connector from the ECM.
STOP.
E. Use an Ohmmeter to measure the resistance
between terminals P1-37 and P1-57.
214
Troubleshooting Section

Expected Result: Repair the connection and/or the wire, when


possible. Replace parts, if necessary. Verify that
The resistance is greater than 20,000 Ohms. the problem is resolved.

Results: STOP.

• Yes – The resistance is greater than 20,000 Ohms. Test Step 7. Check the Device that
The wiring from terminal P1-37 is not shorted to the Provides the 4 to 20 mA Signal
+Battery side. Do not reconnect any connectors.
Proceed to Test Step 6. Measure the 4 to 20 mA signal according to the
literature that is provided by the OEM of the device
• No – The resistance is less than 20,000 Ohms. that provides the 4 to 20 mA signal. Verify that the
There is a problem with a connection and/or the correct signal is provided to the ECM.
wiring from terminal P1-37.
Verify the correct 4 to 20 mA signal at terminals
Repair: The problem may be between the P1 P1-36 and P1-37.
connector and the J6 connector. Alternatively, the
problem may be between the J6 connector and the Expected Result:
device that provides the 4 to 20 mA signal.
The correct 4 to 20 mA signal is provided to the ECM.
Repair the connection and/or the wire, when
possible. Replace parts, if necessary. Verify that Results:
the problem is resolved.
• Yes – The correct 4 to 20 mA signal is provided
STOP. to the ECM. However, the ECM is not responding
correctly to the signal. There may be a problem
Test Step 6. Check for a Short Circuit to with the ECM.
Ground at Terminal P1-36
Repair: It is unlikely that the ECM is faulty. Exit
A. Verify that the engine control is in the OFF/RESET this procedure and perform this procedure again.
mode and that the 35 amp circuit breaker is OFF. If the problem is not resolved, replace the ECM
according to Troubleshooting, “Replacing the
B. Make sure that the ends of the wires for the 4 to ECM”. Verify that the problem is resolved.
20 mA signal do not create a short circuit.
STOP.
C. Use an Ohmmeter to measure the resistance
between ground strap (2) and terminal P1-36. • No – The ECM is not receiving the correct 4 to 20
mA signal. There is probably a problem with the
Expected Result: device that provides the 4 to 20 mA.

The resistance is greater than 20,000 Ohms. Repair: Service the device that provides the 4 to
20 mA according to the literature that is provided
Results: by the OEM of the device. Verify that the problem
is resolved.
• Yes – The resistance is greater than 20,000 Ohms.
The wiring from terminal P1-36 appears to be OK. STOP.
Do not reconnect any connectors. Proceed to Test
Step 7.
i02055795

• No – The resistance is less than 20,000 Ohms.


There is a problem with a connection and/or the
Detonation Sensors
wiring from terminal P1-36. SMCS Code: 1559-038
Repair: The problem may be between the P1 System Operation Description:
connector and the J9 connector. Alternatively, the
problem may be between the P9 connector and Detonation sensors are located on the upper cylinder
the device that provides the 4 to 20 mA signal. block between every two cylinders. Each sensor
monitors two adjacent cylinders. For example, one
sensor monitors cylinders 1 and 3 and one sensor
monitors cylinders 2 and 4.
215
Troubleshooting Section

An input from a detonation sensor that is diagnosed


by the ECM as “open/shorted to +battery” may
measure 0 VDC on a voltmeter. This is caused by the
lack of pull up resistors in the detonation sensor’s
circuits inside the ECM.

The ECM also supports related event codes when the


levels of detonation warrant a reaction from the ECM.
If the timing has been retarded by the maximum
amount and the level of detonation remains high,
the ECM will shut down the engine. Detonation
protection is disabled when the engine speed is less
than 250 rpm.

g01054387
Logged diagnostic codes provide a historical record.
Illustration 65 Before you begin this procedure, use the Caterpillar
Arrangement of the detonation sensors Electronic Technician (ET) to print the logged codes
to a file.
The Electronic Control Module (ECM) supplies 8
VDC in order to power the sensors. The detonation The most likely causes of the diagnostic code are a
sensors provide electrical signals to the ECM that poor connection or a problem in a wiring harness.
indicate mechanical engine vibrations. Each sensor The next likely cause is a problem with a sensor. The
outputs an electrical signal. The signal is amplified least likely cause is a problem with the ECM.
and the signal is filtered. The frequency of the signal
corresponds to the mechanical frequency of the The troubleshooting procedure may generate
vibrations. The amplitude of the signal is proportional additional diagnostic codes. Keep your mind on
to the intensity of the vibrations. correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
The ECM monitors the signals in order to determine resolved.
the presence and the severity of the detonation. The
ECM can retard the timing of the cylinders in order to
limit detonation levels. The timing may be retarded
for a single cylinder or for more than one cylinder.
The timing may be retarded for all of the cylinders,
if necessary. If retardation of the timing does not
sufficiently limit the detonation, the ECM will shut
down the engine.

The ECM can retard timing by as few as three


degrees for light detonation levels. The timing can
be retarded up to six degrees for severe detonation.
For most applications, the minimum allowable actual
timing is ten degrees BTC (five degrees BTC for
propane operation). A proportional strategy is used
for advancing the timing after the timing has been
retarded. The rate of advance is based upon the level
of detonation. The rate is faster for lighter detonation.
The fastest rate of proportional timing advance is one
degree per minute.

The ECM will diagnose the detonation sensors


for a signal that is shorted to the −Battery side, to
the +Battery side, or for an open circuit. To avoid
detecting vibrations that are not related to detonation,
the ECM only monitors a detonation sensor when
one of the pistons that is monitored by that sensor is
between top center and 40 degrees after top center
on the power stroke. Therefore, the “Block Tap”
method of testing the detonation sensors does not
work for the G3500C Engine.
216
Troubleshooting Section

g01054409
Illustration 66
Schematic for the detonation sensors
217
Troubleshooting Section

Test Step 1. Inspect the Electrical • J8/P8 connectors on the terminal box
Connectors and Wiring
• Connectors for each of the detonation sensors
a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054206
Illustration 67
Junction box
g01054419
Illustration 69
A. Set the engine control to the OFF/RESET mode. Harness side of the side of the ECM P2 connector
Switch 35 amp circuit breaker (1) to the OFF
(P2-36) Detonation sensor signal for cylinders 1 and 3
position. (P2-37) Detonation sensor signal for cylinders 5 and 7
(P2-38) Detonation sensor signal for cylinders 9 and 11
Note: For the following steps, refer to (P2-39) Detonation sensor signal for cylinders 13 and 15
Troubleshooting, “Inspecting Electrical Connectors”. (P2-44) Detonation sensor signal for cylinders 2 and 4
(P2-45) Detonation sensor signal for cylinders 6 and 8
(P2-46) Detonation sensor signal for cylinders 10 and 12
(P2-47) Detonation sensor signal for cylinders 14 and 16
(P2-54) Return for the detonation sensors
(P2-55) Return for the detonation sensors
(P2-56) 8 volt supply for the detonation sensors
(P2-57) 8 volt supply for the detonation sensors

g01054412
Illustration 68
Terminal box
(2) J2/P2 connectors for the ECM
(3) J8/P8 connectors for the detonation sensors

B. Thoroughly inspect each of the following


connectors:

• ECM J2/P2 connectors


218
Troubleshooting Section

g01053963
Illustration 70
Harness side of the J8 connector
(J8-1) 8 V Supply for the detonation sensor for cylinders 1 and 3
(J8-2) 8 V Supply for the detonation sensor for cylinders 9 and 11
(J8-3) 8 V Supply for the detonation sensor for cylinders 5 and 7
(J8-4) 8 V Supply for the detonation sensor for cylinders 13 and 15
(J8-5) 8 V Supply for the detonation sensor for cylinders 2 and 4
(J8-6) 8 V Supply for the detonation sensor for cylinders 6 and 8 g01053993
Illustration 71
(J8-7) 8 V Supply for the detonation sensor for cylinders 10 and 12
(J8-8) 8 V Supply for the detonation sensor for cylinders 14 and 16 Detonation sensors
(J8-11) Return for the detonation sensor for cylinders 1 and 3
(J8-12) Return for the detonation sensor for cylinders 5 and 7 d. Check the harness and wiring for abrasion and
(J8-13) Return for the detonation sensor for cylinders 9 and 11 for pinch points from the detonation sensors
(J8-14) Return for the detonation sensor for cylinders 13 and 15
(J8-15) Return for the detonation sensor for cylinders 2 and 4
to the ECM.
(J8-16) Return for the detonation sensor for cylinders 6 and 8
(J8-17) Return for the detonation sensor for cylinders 10 and 12 e. Make sure that the detonation sensors are
(J8-18) Return for the detonation sensor for cylinders 14 and 16 properly installed according to the torque in
(J8-21) Signal from the detonation sensor for cylinders 1 and 3 Specifications, “Detonation Sensors”.
(J8-22) Signal from the detonation sensor for cylinders 5 and 7
(J8-23) Signal from the detonation sensor for cylinders 9 and 11
(J8-24) Signal from the detonation sensor for cylinders 13 and 15 Expected Result:
(J8-25) Signal from the detonation sensor for cylinders 2 and 4
(J8-26) Signal from the detonation sensor for cylinders 6 and 8 All connectors, pins, and sockets are connected
(J8-27) Signal from the detonation sensor for cylinders 10 and 12
(J8-28) Signal from the detonation sensor for cylinders 14 and 16
properly. The connectors and the wiring do not
(J8-31) Shield for the detonation sensor for cylinders 1 and 3 have corrosion, abrasion, or pinch points. All of the
(J8-32) Shield for the detonation sensor for cylinders 5 and 7 detonation sensors are properly installed.
(J8-33) Shield for the detonation sensor for cylinders 9 and 11
(J8-34) Shield for the detonation sensor for cylinders 13 and 15 Results:
(J8-35) Shield for the detonation sensor for cylinders 2 and 4
(J8-36) Shield for the detonation sensor for cylinders 6 and 8
(J8-37) Shield for the detonation sensor for cylinders 10 and 12 • OK – The components are in good condition with
(J8-38) Shield for the detonation sensor for cylinders 14 and 16 proper connections. Proceed to Test Step 2.

c. Perform a 45 N (10 lb) pull test on each of the • Not OK – The components are not in good
wires that are associated with the circuit for the condition and/or at least one connection is
detonation sensors. improper.

Repair: Perform the necessary repairs and/or


replace parts, if necessary.

STOP.
219
Troubleshooting Section

Test Step 2. Check for Diagnostic Codes Table 16


for the 8 Volt DC Supply Code Description Cylinders
A. Connect Cat ET to the service tool connector. 1501-03 Cylinder #1 Detonation
Refer to Troubleshooting, “Electronic Service Sensor short to +batt
1 and 3
Tools”. 1501-04 Cylinder #1 Detonation
Sensor short to ground
B. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. 1502-03 Cylinder #2 Detonation
Sensor short to +batt
2 and 4
C. Observe the “Active Diagnostic” screen of Cat ET. 1502-04 Cylinder #2 Detonation
Wait at least 30 seconds so that any codes may Sensor short to ground
become activated. Look for these codes:
1505-03 Cylinder #5 Detonation
Sensor short to +batt
• “41-03 8 Volt DC Supply short to +batt” 5 and 7
1505-04 Cylinder #5 Detonation
• “41-04 8 Volt DC Supply short to ground” Sensor short to ground
1506-03 Cylinder #6 Detonation
Expected Result: Sensor short to +batt
6 and 8
Neither of the “8 Volt DC Supply” diagnostic codes 1506-04 Cylinder #6 Detonation
are active. Sensor short to ground
1509-03 Cylinder #9 Detonation
Results: Sensor short to +batt
9 and 11
• OK – Neither of the “8 Volt DC Supply” diagnostic 1509-04 Cylinder #9 Detonation
codes are active. Proceed to Test Step 3. Sensor short to ground
1510-03 Cylinder #10 Detonation
• Not OK – At least one of the “8 Volt DC Supply” Sensor short to +batt
diagnostic codes is active. 10 and 12
1510-04 Cylinder #10 Detonation
Sensor short to ground
Repair: The “8 Volt DC Supply” diagnostic code
must be resolved before you can proceed with this 1513-03 Cylinder #13 Detonation
functional test. Sensor short to +batt
13 and 15
1513-04 Cylinder #13 Detonation
Exit this procedure and refer to Troubleshooting, Sensor short to ground
“+8V Sensor Voltage Supply”.
1514-03 Cylinder #14 Detonation
If necessary, return to this functional test in order to Sensor short to +batt
14 and 16
troubleshoot the detonation sensor after the “8 Volt 1514-04 Cylinder #14 Detonation
DC Supply” diagnostic code has been resolved. Sensor short to ground

STOP.
Note: A “short to ground” diagnostic code can
Test Step 3. Check for Active Diagnostic indicate either an actual short to ground or an open
Codes for the Detonation Sensors circuit.

Note: The run relay and the crank terminate relay Expected Result:
must be energized before a diagnostic code for a
detonation sensor can be generated. Therefore, the None of the above diagnostic codes are active.
engine must be running. The engine will shut down
soon after the diagnostic code for the detonation Results:
sensor is activated.
• OK (No active codes) – None of the above codes
A. Start the engine and run the engine. are active at this time. The problem seems to
be resolved. The original diagnostic code was
B. Allow a minimum of 30 seconds for any diagnostic probably caused by a poor electrical connection in
codes to become active. Observe the “Active one of the harness connectors.
Diagnostic” screen of Cat ET and look for the
diagnostic codes that are listed in Table 16: Repair: If any of the above codes are logged
and the engine is not running properly, refer to
Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
220
Troubleshooting Section

If any of the above codes are logged and the Repair: The open circuit may be caused by a poor
engine is running properly, there may be an electrical connection or a wiring problem between
intermittent problem in a connector or a wiring the ECM and the connector for the sensor.
harness. Refer to Troubleshooting, “Inspecting
Electrical Connectors”. Repair the electrical connection and/or the wiring,
when possible. Replace the harness, if necessary.
STOP.
STOP.
• Not OK (Active Code) – A “short to +batt” or “short
to ground” diagnostic code was activated. Test Step 5. Measure the Voltage of the
Signal Wire at the Sensor
Repair: Note the diagnostic code and note the
location of the suspect detonation sensor.

Proceed to Test Step 4.

Test Step 4. Verify the Presence of the


Supply Voltage at the Sensor
A. Set the engine control to the OFF/RESET mode. Illustration 73
g00890518
Switch the 35 amp circuit breaker OFF.
Harness connector for the detonation sensors

B. Disconnect the detonation sensor with the (A) 8 volt supply


(B) Return
diagnostic code. (C) Signal

C. Switch the 35 amp circuit breaker ON. Set the A. Measure the voltage between terminals “B” and
engine control to the STOP mode. “C” on the harness connector for the suspect
sensor.

Expected Result:

The voltage is between 0.4 VDC and 0.6 VDC.

Results:
g00890518
Illustration 72 • Yes – The voltage is between 0.4 VDC and 0.6
Harness connector for the detonation sensors VDC.
(A) 8 volt supply
(B) Return Repair: Reconnect the suspect sensor. Start the
(C) Signal engine again and check for the diagnostic code.

D. Measure the voltage between terminals “A” and If the diagnostic code recurs, replace the
“B” on the harness connector for the sensor. detonation sensor with a known good detonation
sensor. Tighten the detonation sensor according to
Expected Result: the torque in Specifications, “Detonation Sensor”.
Verify that the problem is resolved.
The voltage is between 7.6 VDC and 8.4 VDC.
STOP.
Results:
• No – The voltage is not between 0.4 VDC and 0.6
• OK – The voltage is between 7.6 VDC and 8.4 VDC. If the voltage is less than 0.4 VDC, there
VDC. The correct voltage is available to the sensor. is probably a short to ground or an open circuit
Do not reconnect the sensor. Proceed to Test Step between the connector for the detonation sensor
5. and the ECM. If the voltage is greater than 4.8
VDC, there is probably a short circuit to a +Battery
• Not OK – The voltage is not between 7.6 VDC and source between the connector for the detonation
8.4 VDC. The correct voltage is not available to the sensor and the ECM. Proceed to Test Step 6.
sensor. There is probably an open circuit in the 8
volt supply or in the return for the sensor.
221
Troubleshooting Section

Test Step 6. Check the Operation of the F. Fabricate a jumper wire that is long enough to
ECM reach between the P1 connector and the P2
connector. Install Deutsch terminals on the ends.
A. Set the engine control to the OFF/RESET mode. Install one end of jumper wire (3) into the terminal
Switch the 35 amp circuit breaker OFF. for the signal wire that was removed from the P2
connector (1). Install the other end of the jumper
B. Use a 151-6320 Wire Removal Tool to remove wire into terminal 19 of the P1 connector (2). This
the signal wire for the suspect sensor from the will replace the sensor circuit with a short circuit
P2 connector. This will replace the sensor circuit to ground.
with an open circuit.
G. Start the engine. Observe the “Active Diagnostic”
C. Switch the 35 amp circuit breaker ON. Set the screen on Cat ET. Allow a minimum of 30 seconds
engine control to the STOP mode. for any codes to activate.

Note: The run relay and the crank terminate relay An active “short to ground” diagnostic code is
must be energized before a diagnostic code for a generated for the sensor.
detonation sensor can be generated. Therefore, the
engine must be running. The engine will shut down Expected Result:
soon after the diagnostic code for the detonation
sensor is activated. Active “open/short to +batt” and “short to ground”
diagnostic codes are generated according to the
D. Start the engine. Observe the “Active Diagnostic” above steps.
screen on Cat ET. Allow a minimum of 30 seconds
for any codes to activate. Results:

An active “open/short to +batt” diagnostic code is • OK – Active “open/short to +batt” and “short to
generated for the sensor. ground” diagnostic codes are generated according
to the above steps. The ECM is operating correctly.
E. Set the engine control to the OFF/RESET mode. There is probably an open circuit in a harness
between the ECM and the connector for the sensor.

Repair: Remove the jumper wire. Insert the


terminal that was removed from the P2 connector.
Pull on the wire in order to verify that the terminal
is fully inserted into the connector. Repair the
harness, when possible. Replace the harness, if
necessary.

STOP.

• Not OK – No active “open/short to +batt” and


“short to ground” diagnostic codes were generated.
The ECM is not operating correctly.

Repair: It is unlikely that the ECM has failed. Exit


this procedure and perform this procedure again. If
the problem is not resolved, perform the following
steps:

Temporarily install a new ECM. Refer to


g01054464 Troubleshooting, “Replacing the ECM”.
Illustration 74
ECM with jumper wire If the problem is resolved with the new ECM,
(1) P2 connector install the original ECM and verify that the problem
(2) P1 connector returns. If the new ECM operates correctly and the
(3) Jumper wire
original ECM does not operate correctly, replace
the original ECM. Refer to Troubleshooting,
“Replacing the ECM”.

STOP.
222
Troubleshooting Section

i02056148 If the fuel control relay is connected to P6, terminals


P6-21 and P6-24 are used.
ECM Output Circuit (Fuel
Control) If the fuel control relay is connected to P7, a jumper
wire must be connected between terminals P6-21
SMCS Code: 1901-038 and P6-31.

System Operation Description: This procedure may be used to troubleshoot either


configuration.
The Electronic Control Module (ECM) contains
the logic and the outputs for starting and stopping
the engine. The logic for starting and stopping is
customer programmable. The logic responds to
inputs from the following components: engine control
switch, emergency stop switch, remote start switch,
data link, and other inputs.

The fuel control relay is energize-to-run. To enable


fuel flow to the engine, the relay for the Gas Shutoff
Valve (GSOV) must be energized. The ECM provides
+Battery voltage to the relay for the GSOV when
the logic determines that fuel is required for engine
operation. For engine shutdown, the ECM removes
the voltage from the fuel control relay. This stops the
fuel flow.

The output circuit for the relay for the GSOV includes
the J6 connector. If the J6 connector is not used, a
jumper wire must be connected between terminals
21 and 31. The voltage will be removed from the
fuel control relay if the jumper wire is not connected.
The jumper wire must be connected in order for
the engine to start. The jumper wire must remain
connected in order for the engine to run. Refer to
Illustration 75 for the schematic diagram.

Logged diagnostic codes provide a historical record.


Before you begin this procedure, use the Caterpillar
Electronic Technician (ET) to print the logged codes
to a file.

The most likely causes of the diagnostic code are a


poor electrical connection or a problem in a wiring
harness. The next likely cause is a problem with the
GSOV. The least likely cause is a problem with the
ECM.

The troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.

Connections for the Fuel Control Relay

The fuel control relay may be connected to either of


the following connectors:

• P6 via wiring that is provided by the customer


• P7 via the engine harness
223
Troubleshooting Section

g01054862
Illustration 75
Optional connections for the fuel control relay

Test Step 1. Inspect the Electrical A. Switch 35 amp circuit breaker (1) to the OFF
Connectors and Wiring position.

g01054206
Illustration 76
Junction box
224
Troubleshooting Section

g01054867
Illustration 78
Harness side of the P2 connector
(P2-11) Circuit driver for the fuel control relay
(P2-21) Return

g01054864
Illustration 77
Terminal box
(2) J2/P2 connectors for the ECM
(3) J6/P6 connector for the customer
(4) J7/P7 connectors for the harness from the fuel control relay

B. Set the engine control to the OFF/RESET mode.

Note: For the following steps, refer to


Troubleshooting, “Inspecting Electrical Connectors”.

C. Thoroughly inspect the following connectors and


the wiring harnesses for the connectors:

• ECM J2/P2 connectors


• J6/P6, and J7/P7 connectors on the terminal
box

• Connectors for the fuel control relay Illustration 79


g01054869

Harness side of the J6 connector


a. Check the torque of the Allen head screw for (J6-21) Circuit driver for the fuel control relay
the ECM connectors. The proper torque is (J6-24) Return
6 ± 1 N·m (55 ± 9 lb in). (J6-31) Circuit for the fuel control relay

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
225
Troubleshooting Section

Results:

• OK – The components are in good condition with


proper connections. Proceed to Test Step 2.

• Not OK – The components are not in good


condition and/or at least one connection is
improper.

Repair: Perform the necessary repairs, when


possible. Replace parts, if necessary.

STOP.

Test Step 2. Check for Diagnostic Codes


A. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service
Tools”.

B. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.

C. Wait for 30 seconds and use Cat ET to check for


an active “17-05 Fuel Shutoff Valve open circuit”
diagnostic code.

If there is an active “17-05 Fuel Shutoff Valve


g01054872
Illustration 80 open circuit” diagnostic code, proceed to the
Harness side of the J7 connector “Results” for this Test Step. Otherwise, continue
(J7-50) Circuit driver for the fuel control relay this procedure.
(J7-64) Return
Note: The “17-05 Fuel Shutoff Valve open circuit”
c. Perform a 45 N (10 lb) pull test on each of the diagnostic code cannot be detected when the output
wires that are associated with the fuel control for the fuel control relay is ON. The output is ON
relay. when the engine control is in the START mode and
the engine speed is not zero.

D. Use Cat ET to check the logged diagnostic


codes. If there is a “17-06 Fuel Shutoff Valve
short to ground” or a “17-12 Fuel Shutoff Valve
malfunction” diagnostic code, clear the code.

Note: This diagnostic condition cannot be detected


by the ECM when the output for the fuel control relay
is OFF. The output is OFF when the engine control is
in the STOP mode.

E. To prevent the engine from starting, shut the gas


supply OFF.
g01054878
Illustration 81 Note: To provide the output for the fuel control relay,
Typical fuel control relay the sequence for engine start-up must be initiated.
Otherwise, a “17-06 Fuel Shutoff Valve short to
d. Check the harness and wiring for abrasion and ground” or a “17-12 Fuel Shutoff Valve malfunction”
pinch points from the fuel control relay to the diagnostic code cannot be generated.
ECM.
F. Set the engine control to the START mode for at
Expected Result: least 30 seconds. Then set the engine control to
the STOP mode.
All connectors, pins, and sockets are connected
properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
226
Troubleshooting Section

G. Use Cat ET to look for a logged “17-06 Fuel Test Step 3. Check for a Short Circuit to
Shutoff Valve short to ground” or a “17-12 Fuel the +Battery Side
Shutoff Valve malfunction” diagnostic code again.

Expected Result:

When the engine control was in the STOP mode, Gaseous fuel is present. Personal Injury or Death
there was no active “17-05 Fuel Shutoff Valve open can result from an open flame or spark igniting
circuit” diagnostic code. the gaseous fuel causing an explosion and/or fire.
Always use a gas detector to determine the pres-
After the engine was cranked, there was no logged ence of gaseous fuel when maintaining and ser-
“17-06 Fuel Shutoff Valve short to ground” or “17-12 vicing. Contact you local gas provider immediate-
Fuel Shutoff Valve malfunction” diagnostic code. ly for assistance in the event of a leak.

Results: Note: Open sparks can be generated during this test.

• OK – No diagnostic codes were generated. The A. Make sure that no combustible gas is present in
output for the fuel control relay seems to be OK at the surrounding atmosphere.
this time. The initial diagnostic code was probably
caused by a poor electrical connection. B. Verify that the engine control is in the STOP mode.
Repair: If there is an intermittent problem C. Disconnect the connector from the fuel control
that is causing the codes to be logged, refer relay. Then reconnect the connector. Listen for an
to Troubleshooting, “Inspecting Electrical audible click from the relay.
Connectors”.
If the ambient noise is too loud, touch the relay
STOP. when the relay is reconnected in order to feel the
vibration. The relay will vibrate when the relay is
• Not OK (“17-05 Fuel Shutoff Valve open circuit” de-energized and energized.
diagnostic code) – A “17-05 Fuel Shutoff Valve
open circuit” diagnostic code was activated. This Expected Result:
can be caused by an actual open circuit or by a
short circuit to the +Battery side. Proceed to Test There is no audible click and/or vibration when the
Step 3. relay is disconnected and reconnected. The relay is
not energized when the engine control is in the STOP
• Not OK (“17-06 Fuel Shutoff Valve short to ground” mode.
diagnostic code) – After the engine was cranked,
a “17-06 Fuel Shutoff Valve short to ground” Results:
diagnostic code was generated. Proceed to Test
Step 7. • OK – There is no audible click and/or vibration
when the relay is disconnected and connected.
• Not OK (“17-12 Fuel Shutoff Valve malfunction” There is no short circuit to the +Battery side. There
diagnostic code) – After the engine was cranked, is an open circuit. Proceed to Test Step 5.
a “17-12 Fuel Shutoff Valve malfunction” diagnostic
code was generated. The ECM disabled the • Not OK – There is an audible click and/or vibration
ignition. when the relay is disconnected and connected.
The relay is receiving power when the engine
Repair: Set the engine control to the OFF/RESET control is in the STOP mode. There is probably a
mode. Switch the 35 amp circuit breaker OFF. short circuit to the +Battery side in a connector or a
wiring harness. Proceed to Test Step 4.
Replace the fuel control relay.

STOP.
227
Troubleshooting Section

Test Step 4. Determine the Cause of the 4. Disconnect the connector from the fuel control
Energized Relay relay. Then reconnect the connector. Listen for
an audible click from the relay.

If the ambient noise is too loud, touch the relay


when the relay is reconnected in order to feel
Gaseous fuel is present. Personal Injury or Death the vibration. The relay will vibrate when the
can result from an open flame or spark igniting relay is de-energized and energized.
the gaseous fuel causing an explosion and/or fire.
Always use a gas detector to determine the pres- If the relay is not energized, there is an
ence of gaseous fuel when maintaining and ser- intermittent problem with a connector and/or the
vicing. Contact you local gas provider immediate- wiring. Refer to Troubleshooting, “Inspecting
ly for assistance in the event of a leak. Electrical Connectors”.

Note: Open sparks can be generated during this test. If the relay is energized, there may be a problem
with the ECM.
A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. It is unlikely that the ECM has failed. Exit this
procedure and perform this procedure again.
B. Use a 151-6320 Wire Removal Tool to remove If the problem is not resolved, perform the
terminals P2-11 and P2-21. following steps:

C. Switch the 35 amp circuit breaker ON. Set the Temporarily install a new ECM. Refer to
engine control to the STOP mode. Troubleshooting, “Replacing the ECM”.

D. Disconnect the connector from the fuel control If the problem is resolved with the new ECM,
relay. Then reconnect the connector. Listen for an install the original ECM and verify that the
audible click from the relay. problem returns. If the new ECM operates
correctly and the original ECM does not operate
If the ambient noise is too loud, touch the relay correctly, replace the original ECM. Refer to
when the relay is reconnected in order to feel the Troubleshooting, “Replacing the ECM”.
vibration. The relay will vibrate when the relay is
de-energized and energized. STOP.

Expected Result: • Not OK – There is an audible click and/or vibration


when the relay is disconnected and reconnected.
There is no audible click and/or vibration when the The relay is energized when the wiring is removed
relay is disconnected and reconnected. The relay is from the P2 connector. There is a short circuit to
not energized when the wiring is removed from the the +Battery side in a harness.
P2 connector.
Repair: Repair the wiring and/or the connector,
Results: when possible. Replace parts, if necessary.

• OK – There is no audible click and/or vibration STOP.


when the solenoid is disconnected and
reconnected. The relay is not energized when the Test Step 5. Create a Short Circuit in
wiring is removed from the P2 connector. order to Check for an Open Circuit

Repair: Use the following procedure to determine A. Set the engine control to the OFF/RESET mode.
whether the circuit driver for the relay is faulty: Switch the 35 amp circuit breaker OFF.

1. Set the engine control to the OFF/RESET B. Disconnect the fuel control relay’s connector.
mode. Switch the 35 amp circuit breaker OFF.

2. Reinstall terminals P2-11 and P2-21. Pull on


the wires in order to verify proper installation
of the terminals.

3. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.
228
Troubleshooting Section

If the problem is not resolved, replace the fuel


control relay.

STOP.

• Not OK – A “17-05 Fuel Shutoff Valve open circuit”


diagnostic code was generated when the jumper
wire was installed. There may be an open circuit in
a harness. Proceed to Test Step 6.

Test Step 6. Check the ECM


A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
g01054883
Illustration 82 B. Use the 151-6320 Wire Removal Tool to remove
(1) Connector for the fuel control relay terminals P2-11 and P2-21.
(2) Jumper wire

C. Install a jumper wire (2) into the two terminals of


the relay’s connector (1) on the engine harness.

D. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.

Note: The “17-05 Fuel Shutoff Valve open circuit”


diagnostic code can only be detected when the
output for the fuel control relay is OFF. The output is
OFF when the engine control is in the STOP mode
and the engine is not running.

E. Wait for 30 seconds and use the “Active


Diagnostic” screen of Cat ET to look for a “17-05
Fuel Shutoff Valve open circuit” diagnostic code.

Expected Result:

A “17-05 Fuel Shutoff Valve open circuit” diagnostic


code was not generated when the jumper wire was g01054887
Illustration 83
installed.
ECM P2 connector with jumper wire
Results: (1) Jumper wire
(2) P2 connector
• OK – A “17-05 Fuel Shutoff Valve open circuit”
diagnostic code was not generated when the C. Install a jumper wire (1) into terminals P2-11 and
jumper wire was installed. The harness and the P2-21. Pull on the jumper wire in order to verify
ECM are OK. There is a problem with the relay. proper installation.

Repair: Perform the following procedure: D. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.
1. Set the engine control to the OFF/RESET
mode. Switch the 35 amp circuit breaker OFF. Note: The “17-05 Fuel Shutoff Valve open circuit”
diagnostic code can only be detected when the
2. Remove the jumper wire from the relay’s output for the fuel control relay is OFF. The output is
connector on the engine harness. OFF when the engine control is in the STOP mode
and the engine is not running.
3. Inspect the relay’s connector for damage, for
moisture, and for corrosion. E. Wait for 30 seconds and use the “Active
Diagnostic” screen of Cat ET to look for an active
4. Make repairs, as needed. “17-05 Fuel Shutoff Valve open circuit” diagnostic
code.
229
Troubleshooting Section

Expected Result: Test Step 7. Create an Open Circuit in


order to Check for a Short Circuit to
There is no active “17-05 Fuel Shutoff Valve open Ground
circuit” diagnostic code.
A. Set the engine control to the OFF/RESET mode.
Results:
B. Disconnect the connector from the fuel control
• OK – When the jumper wire was installed, there relay.
was no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code. The ECM detects the C. Set the engine control to the STOP mode.
jumper wire at the P2 connector. However, the ECM
did not detect the jumper wire at the connector for D. Use Cat ET to clear the logged “17-06 Fuel Shutoff
the fuel control relay. There is a problem between Valve short to ground” diagnostic code.
the P2 connector and the connector for the fuel
control relay. E. To prevent the engine from starting, shut OFF the
main gas supply.
Repair: Perform the following procedure:
Note: To provide the output for the fuel control relay,
1. Set the engine control to the OFF/RESET the sequence for engine start-up must be initiated.
mode. Switch the 35 amp circuit breaker OFF. Otherwise, a “17-06 Fuel Shutoff Valve short to
ground” diagnostic code cannot be generated.
2. Use a 151-6320 Wire Removal Tool to remove
the jumper wire from the P2 connector. F. Set the engine control to the START mode for at
least 30 seconds. Then set the engine control to
3. Reinstall the terminals into P2-11 and P2-21. the STOP mode.
Pull on the wires in order to verify proper
installation of the terminals. G. Use Cat ET to look for a logged “17-06 Fuel
Shutoff Valve short to ground” diagnostic code
4. Thoroughly inspect the J6/P6 and J7/P7 again.
connectors. Inspect the wiring that is connected
to terminals J6-21 and J6-31. Expected Result:

5. Make repairs, if necessary. A “17-06 Fuel Shutoff Valve short to ground” was not
generated.
STOP.
Results:
• Not OK – When the jumper wire was installed, a
“17-05 Fuel Shutoff Valve open circuit” diagnostic • OK – When the relay was connected, a “short to
code was activated. The ECM did not detect the ground” diagnostic code was generated. When
jumper wire. There is a problem with the ECM. the relay was disconnected, no “short to ground”
diagnostic code was generated. There is a problem
Repair: Perform the following procedure: with the relay.

1. Set the engine control to the OFF/RESET Repair: Perform the following procedure:
mode. Switch the 35 amp circuit breaker OFF.
1. Set the engine control to the OFF/RESET
2. Use a 151-6320 Wire Removal Tool to remove mode. Switch the 35 amp circuit breaker OFF.
the jumper wire from the P2 connector.
2. Inspect the relay’s connectors for damage
3. Reinstall the terminals into P2-11 and P2-21. and/or for corrosion.
Pull on the wires in order to verify proper
installation of the terminals. 3. Make repairs, as needed.

4. Replace the ECM according to Troubleshooting, If the problem is not resolved, replace the relay.
“Replacing the ECM”. Verify that the problem is
resolved. STOP.

STOP. • Not OK – A “short to ground” diagnostic code


was generated when the relay was disconnected.
There is a problem with the wiring or with the ECM.
Proceed to Test Step 8.
230
Troubleshooting Section

Test Step 8. Check the ECM • Not OK – A “17-06 Fuel Shutoff Valve short to
ground” diagnostic code was generated when the
A. Set the engine control to the OFF/RESET mode. output to the relay was disconnected from the P2
Switch the 35 amp circuit breaker OFF. connector. There may be a problem with the ECM.

B. Use the 151-6320 Wire Removal Tool to remove Repair: Perform the following procedure:
terminal P2-11.
1. Set the engine control to the OFF/RESET
C. Switch the 35 amp circuit breaker ON. Set the mode. Switch the 35 amp circuit breaker OFF.
engine control to the STOP mode.
2. Reinstall the terminal that was removed from
D. Use Cat ET to clear the logged “17-06 Fuel Shutoff P2-11. Pull on the wire in order to verify proper
Valve short to ground” diagnostic code. installation of the terminal.

E. To prevent the engine from starting, shut OFF the 3. It is unlikely that the ECM has failed. Exit this
main gas supply. procedure and perform this procedure again.
If the problem is not resolved, perform the
Note: To provide the output for the fuel control relay, following steps:
the sequence for engine start-up must be initiated.
Otherwise, a “17-06 Fuel Shutoff Valve short to Temporarily install a new ECM. Refer to
ground” diagnostic code cannot be generated. Troubleshooting, “Replacing the ECM”.

F. Set the engine control to the START mode for at If the problem is resolved with the new ECM,
least 30 seconds. Then set the engine control to install the original ECM and verify that the
the STOP mode. problem returns. If the new ECM operates
correctly and the original ECM does not operate
G. Use Cat ET to look for a logged “17-06 Fuel correctly, replace the original ECM. Refer to
Shutoff Valve short to ground” diagnostic code Troubleshooting, “Replacing the ECM”.
again.
STOP.
Expected Result:
i02056781
The “17-06 Fuel Shutoff Valve short to ground”
diagnostic code was not generated. ECM Output Circuit (Starting
Results: Motor)
• OK – When the output to the relay was SMCS Code: 1901-038
disconnected from the P2 connector, the “17-06
Fuel Shutoff Valve short to ground” diagnostic System Operation Description:
code was not generated. However, a “short to
ground” diagnostic code was generated when the The Electronic Control Module (ECM) contains the
connector was disconnected from the fuel control logic and the outputs for starting the engine. The logic
relay. There is a problem in the wiring between the for starting is customer programmable. The logic
P2 connector and the connector for the fuel control responds to inputs from the following components:
relay. engine control switch, emergency stop switch, remote
start switch, data link, and other inputs.
Repair: Perform the following procedure:
Logged diagnostic codes provide a historical record.
1. Set the engine control to the OFF/RESET Before you begin this procedure, use the Caterpillar
mode. Switch the 35 amp circuit breaker OFF. Electronic Technician (ET) to print the logged codes
to a file.
2. Reinstall the terminal that was removed from
P2-11. Pull on the wire in order to verify proper The most likely causes of the diagnostic code are a
installation of the terminal. poor electrical connection or a problem in a wiring
harness. The next likely cause is a problem with a
3. Repair the harness, when possible. Replace magnetic switch or with a relay. The least likely cause
the harness, if necessary. is a problem with the ECM.

STOP.
231
Troubleshooting Section

The troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.

Electric Start

The ECM supplies +Battery voltage to two magnetic


switches when the logic determines that it is
necessary. Each magnetic switch provides +Battery
voltage to a solenoid on an electric starting motor.

The ECM removes the voltage when the crank


terminate relay is energized. The voltage is also
removed if the customer programmable “Overcrank
Time” has expired.

Air Start

The ECM supplies +Battery voltage to the air start


relay when the logic determines that it is necessary.
The ECM removes the voltage when the crank
terminate relay is energized. The voltage is also
removed if the customer programmable “Overcrank
Time” has expired.

g01054994
Illustration 84
Schematic for the electric starting system
232
Troubleshooting Section

g01055038
Illustration 85
Schematic for the air starting system

Test Step 1. Inspect the Electrical


Connectors and Wiring

g01055040
Illustration 87
Terminal box for the ECM
g01054206
Illustration 86 (2) J2/P2 connectors for the ECM
Junction box (3) J7/P7 connectors for the wiring from the starting system

A. Set the engine control to the OFF/RESET mode. B. Thoroughly inspect the following connectors and
Switch 35 amp circuit breaker (1) to the OFF the wiring harnesses for the connectors:
position.
• ECM J2/P2 connectors
Note: For the following steps, refer to
Troubleshooting, “Inspecting Electrical Connectors”. • J7/P7 connectors on the terminal box
a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
233
Troubleshooting Section

Expected Result:

All connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.

Results:

• OK – The components are in good condition with


proper connections. Proceed to Test Step 2.

• Not OK – The components are not in good


condition and/or at least one connection is
improper.
g01055043
Illustration 88 Repair: Perform the necessary repairs, when
Harness side of the P2 connector possible. Replace parts, if necessary.
(P2-10) Start command
(P2-20) Return for the start command STOP.

Test Step 2. Check for Diagnostic Codes


A. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service
Tools”.

B. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.

Note: The “444-05 Start Relay open circuit”


diagnostic code can only be detected when the
output for the start command is OFF. The output is
normally OFF when the engine control is in the STOP
mode or when the crank terminate relay is energized.

C. Wait for 30 seconds and use Cat ET to check


for an active “444-05 Start Relay open circuit”
diagnostic code.

If there is an active “444-05 Start Relay open


circuit” diagnostic code, proceed to the “Results”
for this Test Step. Otherwise, continue this
procedure.

D. Use Cat ET to check the logged diagnostic codes.


If there is a logged “444-06 Start Relay short to
ground” diagnostic code, clear the code.
g01055047
Illustration 89
Harness side of the J7 connector E. To prevent the engine from starting, shut the gas
(J7-28) Start command supply OFF.
(J7-56) Return for the start command
Note: The “444-06 Start Relay short to ground”
c. Perform a 45 N (10 lb) pull test on each of the diagnostic code can only be detected when the
wires that are associated with the circuit for the output for the start command is ON. The output is
starter motor relay. normally ON when the engine control is set from the
STOP mode to the START mode. The output remains
d. Check the harness and wiring for abrasion and ON until the crank terminate relay is energized.
for pinch points from the starter motor relay to
the ECM. F. Set the engine control to the START mode for at
least six seconds. Then set the engine control to
the STOP mode.
234
Troubleshooting Section

G. Use Cat ET to look for a logged “444-06 Start B. Ensure that the engine control is in the STOP
Relay short to ground” diagnostic code again. mode.

Expected Result: C. Disconnect the connector from the air start relay.
Then reconnect the connector. Listen for an
When the engine control was in the STOP mode, audible click from the relay.
there was no active “444-05 Start Relay open circuit”
diagnostic code. If the ambient noise is too loud, touch the air start
relay when the relay is reconnected in order to
After the engine was cranked, there was no logged feel the vibration. The relay will vibrate when the
“444-06 Start Relay short to ground” diagnostic code. relay is de-energized and energized.

Results: Expected Result:

• OK – No diagnostic codes were activated. The There is no audible click and/or vibration when the
output for the start command seems to be OK at air start relay is disconnected and reconnected. The
this time. The initial diagnostic code was probably relay is not energized when the engine control is in
caused by a poor electrical connection. the STOP mode.

Repair: If there is an intermittent problem Results:


that is causing the codes to be logged, refer
to Troubleshooting, “Inspecting Electrical • OK – There is no audible click and/or vibration
Connectors”. when the air start relay is disconnected and
connected. There is no short circuit to the +Battery
STOP. side. There is an open circuit. Proceed to Test
Step 4.
• Not OK (“444-05 Start Relay open circuit”
diagnostic code) – A “444-05 Start Relay open • Not OK – There is an audible click and/or vibration
circuit” diagnostic code was activated. This can when the air start relay is disconnected and
be caused by an actual open circuit or by a connected. The relay is receiving power when the
short circuit to the +Battery side. If the engine is engine control is in the STOP mode. Proceed to
equipped with an air starting system, proceed Test Step 6.
to Test Step 3. If the engine is equipped with an
electric starting system, proceed to Test Step 9. Test Step 4. Create a Short Circuit in
order to Check for an Open Circuit
• Not OK (“444-06 Start Relay short to ground”
diagnostic code) – After the engine was cranked, A. Set the engine control to the OFF/RESET mode.
a “444-06 Start Relay short to ground” diagnostic Switch the 35 amp circuit breaker OFF.
code was activated. If the engine is equipped with
an air starting system, proceed to Test Step 7. If B. Disconnect the harness connector from the air
the engine is equipped with an electric starting start relay.
system, proceed to Test Step 10.
C. Install a jumper wire into the two terminals of the
Test Step 3. Check for a Short Circuit to harness connector for the air start relay.
the +Battery Side
D. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.

E. Wait for 30 seconds and use the “Active


Gaseous fuel is present. Personal Injury or Death Diagnostic” screen of Cat ET to look for a “444-05
can result from an open flame or spark igniting Start Relay open circuit” diagnostic code.
the gaseous fuel causing an explosion and/or fire.
Always use a gas detector to determine the pres- Expected Result:
ence of gaseous fuel when maintaining and ser-
vicing. Contact you local gas provider immediate- A “444-05 Start Relay open circuit” diagnostic code
ly for assistance in the event of a leak. was not activated when the jumper wire was installed.

Note: Open sparks can be generated during this test.

A. Make sure that no combustible gas is present in


the surrounding atmosphere.
235
Troubleshooting Section

Results: Results:

• OK – A “444-05 Start Relay open circuit” diagnostic • OK – When the jumper wire was installed, there
code was not activated when the jumper wire was was no active “444-05 Start Relay open circuit”
installed. The ECM detected the short circuit. The diagnostic code. The ECM detects the jumper
harness and the ECM are OK. There is a problem wire at the P2 connector. However, the ECM
with the air start relay. did not detect the jumper wire at the relay’s
connector. There is a problem with the wiring.
Repair: Perform the following procedure:
The problem could be between the P2 connector
1. Set the engine control to the OFF/RESET and the J7 connector. Alternatively, the problem
mode. Switch the 35 amp circuit breaker OFF. could be in the P7 connector or the wiring that is
connected to the P7 connector.
2. Remove the jumper wire from the harness
connector. Repair: Perform the following procedure:

3. Inspect the relay’s connector and the harness 1. Set the engine control to the OFF/RESET
connector for the relay. Check for damage, for mode. Switch the 35 amp circuit breaker OFF.
moisture, and for corrosion.
2. Use a 151-6320 Wire Removal Tool to remove
4. Make repairs, as needed. the jumper wire from the P2 connector.

If the problem is not resolved, replace the air start 3. Reinstall terminals P2-10 and P2-20. Pull on
relay. the wires in order to verify proper installation
of the terminals.
STOP.
4. Repair the harness, when possible. Replace the
• Not OK – A “444-05 Start Relay open circuit” harness, if necessary.
diagnostic code was activated when the jumper
wire was installed. The ECM did not detect the STOP.
short circuit. Proceed to Test Step 5.
• No – When the jumper wire was installed, a
Test Step 5. Check the ECM “444-05 Start Relay open circuit” diagnostic code
was activated. The ECM did not detect the jumper
A. Ensure that the engine control is in the wire. There is a problem with the ECM.
OFF/RESET mode and that the 35 amp circuit
breaker is OFF. Repair: Perform the following procedure:

B. Use a 151-6320 Wire Removal Tool to remove 1. Set the engine control to the OFF/RESET
terminals P2-10 and P2-20. mode. Switch the 35 amp circuit breaker OFF.

C. Install a jumper wire into terminals P2-10 and 2. Use a 151-6320 Wire Removal Tool to remove
P2-20. Pull on the jumper wire in order to verify the jumper wire from the P2 connector.
proper installation.
3. Reinstall terminals P2-10 and P2-20. Pull on
D. Switch the 35 amp circuit breaker ON. Set the the wires in order to verify proper installation
engine control to the STOP mode. of the terminals.

E. Wait for 30 seconds and use the “Active It is unlikely that the ECM has failed. Exit this
Diagnostic” screen of Cat ET to look for an active procedure and perform this procedure again. If
“444-05 Start Relay open circuit” diagnostic code. the problem is not resolved, perform the following
steps:
Expected Result:
Temporarily install a new ECM. Refer to
There is no active “444-05 Start Relay open circuit” Troubleshooting, “Replacing the ECM”.
diagnostic code.
236
Troubleshooting Section

If the problem is resolved with the new ECM, If the problem is resolved with the new ECM,
install the original ECM and verify that the problem install the original ECM and verify that the problem
returns. If the new ECM operates correctly and the returns. If the new ECM operates correctly and the
original ECM does not operate correctly, replace original ECM does not operate correctly, replace
the original ECM. Refer to Troubleshooting, the original ECM. Refer to Troubleshooting,
“Replacing the ECM”. “Replacing the ECM”.

STOP. STOP.

Test Step 6. Create an Open Circuit in • Not OK – When the ECM was connected, the
order to Check for a Short Circuit relay was receiving power. When the ECM was
not connected, the relay was still receiving
A. Set the engine control to the OFF/RESET mode. power. There is a problem with the wiring.
Switch the 35 amp circuit breaker OFF.
The problem could be between the P2 connector
B. Use a 151-6320 Wire Removal Tool to remove and the J7 connector. Alternatively, the problem
terminals P2-10 and P2-20. could be in the P7 connector or the wiring that is
connected to the P7 connector.
C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. Repair: Repair the harness, when possible.
Replace the harness, if necessary.
D. To prevent the engine from starting, shut OFF the
main gas supply. STOP.

E. Set the engine control to the START mode for at Test Step 7. Create an Open Circuit at the
least six seconds. Then set the engine control to Air Start Relay
the STOP mode.
A. Set the engine control to the OFF/RESET mode.
Expected Result: Switch the 35 amp circuit breaker OFF.

There is no audible click and/or vibration when the B. Disconnect the harness connector from the air
relay is disconnected and reconnected. The relay is start relay.
not energized when the engine control is in the STOP
mode. C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.
Results:
D. To prevent the engine from starting, shut OFF the
• OK – When the ECM was connected, the relay main gas supply.
was receiving power. When the ECM was not
connected, the relay was not receiving power. Note: The “444-06 Start Relay short to ground”
There may be a problem with the ECM. diagnostic code can only be detected when the
output for the start command is ON. The output is
Repair: Perform the following procedure: normally ON when the engine control is set from the
STOP mode to the START mode. The output remains
1. Set the engine control to the OFF/RESET ON until the crank terminate relay is energized.
mode. Switch the 35 amp circuit breaker OFF.
E. Set the engine control to the START mode for at
2. Reinstall terminals P2-10 and P2-20. Pull on least six seconds. Then set the engine control to
the wires in order to verify proper installation the STOP mode.
of the terminals.
F. Use Cat ET to look for a logged “444-06 Start
It is unlikely that the ECM has failed. Exit this Relay short to ground” diagnostic code again.
procedure and perform this procedure again. If
the problem is not resolved, perform the following Expected Result:
steps:
A “444-06 Start Relay short to ground” was not
Temporarily install a new ECM. Refer to activated.
Troubleshooting, “Replacing the ECM”.
237
Troubleshooting Section

Results: Results:

• OK – A “444-06 Start Relay short to ground” • OK – When the wiring was disconnected from
diagnostic code was not activated when the air the ECM, a “444-06 Start Relay short to ground”
start relay was disconnected. There is a problem diagnostic code was not activated. There is a
with the air start relay. problem with the wiring. The problem could be
between the P2 connector and the J7 connector.
Repair: Perform the following procedure: Alternatively, the problem could be in the P7
connector or the wiring that is connected to the P7
1. Set the engine control to the OFF/RESET connector.
mode. Switch the 35 amp circuit breaker OFF.
Repair: Perform the following procedure:
2. Remove the jumper wire from the connector.
1. Set the engine control to the OFF/RESET
3. Inspect the connectors for the air start relay. mode. Switch the 35 amp circuit breaker OFF.
Check for damage, for moisture, and for
corrosion. 2. Reinstall terminals P2-10 and P2-20. Pull on
the wires in order to verify proper installation
4. Make repairs, as needed. of the terminals.

If the problem is not resolved, replace the air start 3. Repair the harness, when possible. Replace
relay. the harness, if necessary.

STOP. STOP.

• Not OK – A “444-06 Start Relay short to ground” • Not OK – When the wiring was disconnected from
diagnostic code was activated when the air start the ECM, a “444-06 Start Relay short to ground”
relay was disconnected. The air start relay is OK. diagnostic code was activated. There seems to be
Proceed to Test Step 8. a problem with the ECM.

Test Step 8. Check the ECM Repair: Perform the following procedure:

A. Set the engine control to the OFF/RESET mode. 1. Set the engine control to the OFF/RESET
Switch the 35 amp circuit breaker OFF. mode. Switch the 35 amp circuit breaker OFF.

B. Use the 151-6320 Wire Removal Tool to remove 2. Reinstall terminals P2-10 and P2-20. Pull on
terminals P2-10 and P2-20. the wires in order to verify proper installation
of the terminals.
C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. It is unlikely that the ECM has failed. Exit this
procedure and perform this procedure again. If
D. To prevent the engine from starting, shut OFF the the problem is not resolved, perform the following
main gas supply. steps:

Note: The “444-06 Start Relay short to ground” Temporarily install a new ECM. Refer to
diagnostic code can only be detected when the Troubleshooting, “Replacing the ECM”.
output for the start command is ON. The output is
normally ON when the engine control is set from the If the problem is resolved with the new ECM,
STOP mode to the START mode. The output remains install the original ECM and verify that the problem
ON until the crank terminate relay is energized. returns. If the new ECM operates correctly and the
original ECM does not operate correctly, replace
E. Set the engine control to the START mode for at the original ECM. Refer to Troubleshooting,
least six seconds. Then set the engine control to “Replacing the ECM”.
the STOP mode.
STOP.
F. Use Cat ET to look for a logged “444-06 Start
Relay short to ground” diagnostic code again.

Expected Result:

The “444-06 Start Relay short to ground” diagnostic


code was not activated.
238
Troubleshooting Section

Test Step 9. Check the “SM” Circuit 2. Wait for 30 seconds and use Cat ET to check
Breaker for an active “444-05 Start Relay open circuit”
diagnostic code.

If there is no active “444-05 Start Relay open


circuit” diagnostic code, the problem appears
to be resolved. Resume normal operation.

If there is an active “444-05 Start Relay open


circuit” diagnostic code, proceed to Test Step 10.

Test Step 10. Inspect the Inside of the


Junction Box
A. Disconnect the +24 V power supply from the
engine.

g01055051
Illustration 90
“SM” circuit breaker

A. Verify that the “SM” circuit breaker is in the ON


position.

Expected Result:

The “SM” circuit breaker is in the ON position.

Results:

• OK – The “SM” circuit breaker is in the ON


position. Proceed to Test Step 10.
g01055053
Illustration 91
• Not OK – The “SM” circuit breaker is not in the Terminals on the junction box
ON position.
B. Verify that the power is disconnected by checking
Repair: Switch the “SM” circuit breaker to the ON for voltage at the “+” and “-” terminals on the
position. junction box. The voltage on the terminals should
be zero VDC.
If the circuit breaker remains in the ON position, the
problem may be resolved. Perform the following
procedure:

1. Verify that the 35 amp circuit breaker is ON. Set


the engine control to the STOP mode.

Note: The “444-05 Start Relay open circuit”


diagnostic code can only be detected when the
output for the start command is OFF. The output is
normally OFF when the engine control is in the STOP
mode or when the crank terminate relay is energized.
239
Troubleshooting Section

g01055064
Illustration 93
Section view of the junction box
(1) Coil terminals on the magnetic switches
(2) Terminals on the “SM” circuit breaker

B. Use a multimeter to check for an open circuit


Illustration 92
g01055058 between the points that are listed in Table 17:
Fasteners for the junction box Table 17

C. Remove seven bolts and nuts. Open the junction Points to Check for an Open Circuit
box. Point Point

D. Inspect the inside of the junction box. Check P2-20 “+” terminal on the junction
for moisture and for corrosion. Verify that each box
electrical connection inside the junction box is P2-10 “+” terminal on the junction
securely connected. box
Each coil terminal (1) on “+” terminal on the junction
Expected Result: each magnetic switch box
The inside of the junction box does not have moisture Each terminal (2) on the “+” terminal on the junction
or corrosion. All of the electrical connections inside “SM” circuit breaker box
the junction box are securely connected.
Expected Result:
Results:
All of the measurements are an open circuit.
• OK – The inside of the junction box does not
have moisture or corrosion. All of the electrical Results:
connections inside the junction box are securely
connected. Proceed to Test Step 11. • OK – All of the measurements are an open circuit.
There is not a short circuit to the +Battery. Proceed
• Not OK – The inside of the junction box has to Test Step 12.
moisture or corrosion and/or there is a loose
electrical connection. • Not OK – At least one measurement is not an
open circuit. There is a short circuit to the +Battery.
Repair: Perform the necessary repairs, when
possible. Replace parts, if necessary. Repair: Repair the wiring and/or the connection,
when possible. Replace parts, if necessary.
STOP.
STOP.
Test Step 11. Check for an Open Circuit
Test Step 12. Check for a Short Circuit
A. Use a 151-6320 Wire Removal Tool to remove
terminals P2-10 and P2-20. A. Verify that the “SM” circuit breaker is in the ON
position.

B. Use a multimeter to check for a short circuit


between the points that are listed in Table 18:
240
Troubleshooting Section

Note: Refer to Illustration 84, if necessary. 1. Install the seven bolts and nuts for the junction
box.
Table 18
Points to Check for a Short Circuit 2. Reconnect the +24 V power supply to the
engine.
Point Point
P2-10 The connection for the Proceed to Test Step 14.
“SM”circuit breaker that
is connected to wire • Not OK – The resistance of a coil is not between
“P6B0A-RD” 16 Ohms and 20 Ohms. The resistance of a coil for
a magnetic switch is incorrect.
One of the connections for The other connection for
the “SM” circuit breaker the “SM” circuit breaker
Repair: Replace the magnetic switch. Verify that
The connection for the The coil terminal of each the original problem is resolved.
“SM” circuit breaker that magnetic switch that
is connected to wire is connected to wire STOP.
“P6B0B-RD” “C990-RD”
The coil terminal of each P2-20 Test Step 14. Check the Operation of the
magnetic switch that ECM
is connected to wire
“C991-BK” A. Verify that terminals P2-10 and P2-20 are removed
from the P2 connector.
Expected Result:
B. Verify that the 35 amp circuit breaker is ON. Verify
All of the measurements are less than two Ohms. that the “SM” circuit breaker is ON.

Results: Note: The “444-05 Start Relay open circuit”


diagnostic code can only be detected when the
• OK – All of the measurements are less than two output for the start command is OFF. The output is
Ohms. There is not an open circuit. Proceed to normally OFF when the engine control is in the STOP
Test Step 13. mode or when the crank terminate relay is energized.

• Not OK – At least one measurement is more than C. Set the engine control to the STOP mode.
two Ohms. There is a problem with the wiring or
with the “SM” circuit breaker. A “444-05 Start Relay open circuit” diagnostic
code should not be activated.
Repair: Repair the wiring and/or the connection,
when possible. Replace parts, if necessary. D. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
STOP.
E. Reinstall terminals P2-10 and P2-20. Pull on the
Test Step 13. Check the Coils for the wires in order to verify proper installation of the
Magnetic Switches terminals.

A. Use a multimeter to measure the resistance of the F. Switch the 35 amp circuit breaker ON.
coil for each magnetic switch.
Note: The “444-06 Start Relay short to ground”
Expected Result: diagnostic code can only be detected when the
output for the start command is ON. The output is
The resistance of each coil is between 16 and 20 normally ON when the engine control is set from the
Ohms. STOP mode to the START mode. The output remains
ON until the crank terminate relay is energized.
Results:
G. Set the engine control to the START mode.
Look for a “444-06 Start Relay short to ground”
• OK – The resistance of each coil is between 16 diagnostic code.
Ohms and 20 Ohms. The coil resistance for each
magnetic switch is correct.
A “444-06 Start Relay short to ground” diagnostic
Repair: code should not be activated.
241
Troubleshooting Section

Expected Result: Note: These circuits do not sink enough current for
illumination of standard incandescent lights. If a lamp
No diagnostic codes were activated. is burned out, replace the lamp with the lamp that is
specified in the engine’s Parts Manual.
Results:
“Run Relay” – This output indicates that the engine
• OK – No diagnostic codes were activated. The is in the “Run” status. The engine will start soon or the
initial diagnostic code was probably caused by a engine is running. While this output is energized, a
poor electrical connection. short circuit to a positive voltage source or excessive
current through the circuit will cause a diagnostic
Repair: If there is an intermittent problem code to become activated. The ECM cannot diagnose
that is causing the codes to be logged, refer this output while the output is OFF.
to Troubleshooting, “Inspecting Electrical
Connectors”. “Crank Terminate Relay” – This output indicates
that the engine rpm is greater than the programmed
STOP. engine speed that is required for disengagement of
the starting motor. While this output is energized, a
• Not OK – A diagnostic code was activated. There short circuit to a positive voltage source or excessive
may be a problem with the ECM. current through the circuit will cause a diagnostic
code to become activated. The ECM cannot diagnose
Repair: It is unlikely that the ECM has failed. Exit this output while the output is OFF.
this procedure and perform this procedure again. If
the problem is not resolved, perform the following “Engine Control Alarm Status” – This is the
steps: alarm output. This output indicates that the ECM
has detected an electrical problem or an abnormal
Temporarily install a new ECM. Refer to operating condition. While this output is energized, a
Troubleshooting, “Replacing the ECM”. short circuit to a positive voltage source or excessive
current through the circuit will cause a diagnostic
If the problem is resolved with the new ECM, code to become activated. The ECM cannot diagnose
install the original ECM and verify that the problem this output while the output is OFF.
returns. If the new ECM operates correctly and the
original ECM does not operate correctly, replace “Fault Relay” – This is the shutdown output.
the original ECM. Refer to Troubleshooting, This output indicates that a potentially damaging
“Replacing the ECM”. operating condition was detected by the ECM. The
ECM has shut down the engine. While this output is
STOP. energized, a short circuit to a positive voltage source
or excessive current through the circuit will cause
a diagnostic code to become activated. The ECM
i02057172
cannot diagnose this output while the output is OFF.
ECM Status Indicator Output A “323-03 Shutdown Lamp short to +batt” or “324-03
SMCS Code: 7400-038-IND Warning Lamp short to +batt” diagnostic code can
only be generated if a shutdown condition or an alarm
System Operation Description: condition is active. Failure to correct these serious
conditions can result in engine damage.
The Electronic Control Module (ECM) has four
outputs in order to indicate the status of engine Use the Caterpillar Electronic Technician (ET)
operation: “Run Relay”, “Crank Terminate Relay”, to determine the event code or the diagnostic
“Engine Control Alarm Status”, and “Fault Relay”. code that corresponds to the 323-03 or 324-03
These outputs can be used to energize indicator diagnostic code. Troubleshoot that event code or
lamps or the outputs can be used to interface with that diagnostic code before you troubleshoot
other controls. the 323-03 or 324-03 diagnostic code. Refer to
Troubleshooting, “Troubleshooting with an Event
The ECM opens an internal circuit in order to set an Code” or Troubleshooting, “Troubleshooting with a
output to OFF. The ECM closes the circuit in order to Diagnostic Code”.
set the output to ON. When the circuit is closed and
the output is ON, the ECM allows a maximum current The most likely causes of a diagnostic code for a
of 0.3 amperes to flow through the circuit to a ground status indicator is a poor electrical connection or a
that is inside the ECM. problem in a wiring harness. The next likely cause is
a problem with an indicator. The least likely cause is
If excessive current flows through the circuit, a a problem with the ECM.
diagnostic code is generated. A short circuit to the
+battery side will also activate a diagnostic code.
242
Troubleshooting Section

Logged diagnostic codes provide a historical record.


Before you begin this procedure, use ET to print the
logged codes to a file.

The troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.

g01055308
Illustration 94
Schematic for the status indicators

Test Step 1. Inspect the Electrical Note: Some indicators may obtain the status of the
Connectors and Wiring engine via a data link. If all of the status indicators
are not directly controlled by the ECM, do not
proceed with this test.

g01054206
Illustration 95
Junction box
g01055040
Illustration 96
A. Set the engine control to the OFF/RESET mode. Terminal box
Switch 35 amp circuit breaker (1) to the OFF (2) J2/P2 connectors for the ECM
position. (3) J6/P6 connectors for the customer

B. Thoroughly inspect each of the following


connectors:
243
Troubleshooting Section

• ECM J2/P2 connectors Note: These outputs do not provide enough current
for illumination of standard incandescent lights. If a
• J6/P6 connectors on the terminal box lamp is burned out, replace the lamp with the lamp
that is specified in the engine’s Parts Manual.
a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is d. Inspect the wiring and the receptacles for the
6 ± 1 N·m (55 ± 9 lb in). status indicators.

b. Check the torque of the Allen head screws for e. Check the harness and wiring for abrasion and
the connectors on the terminal box. The proper for pinch points from the customer’s equipment
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in). to the ECM.

Expected Result:

All connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.

Results:

• OK – The components are in good condition with


proper connections. Proceed to Test Step 2.

• Not OK – The components are not in good


condition and/or at least one connection is
improper.
g01055309
Illustration 97
Harness side of the P2 connector Repair: Perform the necessary repairs and/or
(P2-28) Run Relay replace parts, if necessary.
(P2-29) Crank Terminate Relay
(P2-30) Fault Relay STOP.
(P2-31) Engine Control Alarm Status
Test Step 2. Check for Diagnostic Codes
A. Connect Cat ET to the service tool connector
on the terminal box. Refer to Troubleshooting,
“Electronic Service Tools”.

B. Switch the 35 amp circuit breaker ON.

C. Attempt to start the engine and observe the status


indicators. Allow a minimum of 30 seconds for
any diagnostic codes to activate. Use the “Active
Diagnostic” screen on Cat ET to look for the codes
that are listed in Table 19:

g01055311
Illustration 98
Harness side of the J6 connector
(J6-22) Run Relay
(J6-23) Fault Relay
(J6-32) Crank Terminate Relay
(J6-33) Engine Control Alarm Status

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


wires that are associated with the circuit for the
status indicators.
244
Troubleshooting Section

Table 19 Repair: The 323-03 and 324-03 diagnostic codes


Diagnostic Codes and Descriptions with
can only be activated when the corresponding
Corresponding ECM Outputs indicator is activated. There may still be a problem
with the output for the alarm indicator or the
Code Description ECM Output shutdown indicator. The alarm and/or the shutdown
323-03 Shutdown Lamp short to “Fault Relay” must be activated.
+batt
Allow the engine operation to continue. Proceed
324-03 Warning Lamp short to “Engine Control to Test Step 3.
+batt Alarm Status”
443-03 Crank Terminate Relay “Crank • Not OK (Active 323-03 or 324-03 Diagnostic
short to +batt Terminate Code) – There is an active “323-03 Shutdown
Relay” Lamp short to +batt” or “324-03 Warning Lamp
short to +batt”. There must be a shutdown condition
445-03 Run Relay short to +batt “Run Relay”
before a 323-03 diagnostic code can be generated.
There must be an alarm condition before a 324-03
Expected Result: diagnostic code can be generated. Both of these
conditions are serious.
There are no active diagnostic codes. The “Engine
On” indicator and the “Crank Terminate” indicator (if Repair: Use Cat ET to determine the event code or
equipped) illuminated normally. The “Active Alarm” the diagnostic code that corresponds to the 323-03
indicator and the “Engine Failure” indicator did not or 324-03 diagnostic code. Troubleshoot that
illuminate. event code or that diagnostic code before you
troubleshoot the 323-03 or 324-03 diagnostic
Results: code. Refer to Troubleshooting, “Troubleshooting
with an Event Code” or Troubleshooting,
• Yes (Original 443-03 or 445-03 Diagnostic Code) – “Troubleshooting with a Diagnostic Code”.
The original diagnostic code was “443-03 Crank
Terminate Relay short to +batt” or “445-03 Run Exit this procedure. After you have resolved the
Relay short to +batt”. When the engine was started, condition, return to this procedure in order to
the “Run Relay” indicator and the “Crank Terminate troubleshoot the 323-03 and/or 324-03 diagnostic
Relay” indicator (if equipped) illuminated normally. code, if necessary.
The “Engine Control Alarm Status” indicator and
the “Fault Relay” indicator did not illuminate. There STOP.
are no active diagnostic codes.
• Not OK (Active 443-03 or 445-03 Diagnostic
Repair: The outputs for the status indicators seem Code) – When the engine was started, the “Run
to be operating correctly at this time. The original Relay” indicator and/or the “Crank Terminate
diagnostic code was probably caused by a poor Relay” indicator (if equipped) did not illuminate
electrical connection. normally. The “Engine Control Alarm Status”
indicator and the “Fault Relay” indicator did not
If there is an intermittent problem that is causing illuminate. A 443-03 or 445-03 diagnostic code
the codes to be logged, refer to Troubleshooting, was activated. There is a problem with the output
“Inspecting Electrical Connectors”. for the “Run Relay” indicator and/or the “Crank
Terminate Relay” indicator (if equipped). Proceed
STOP. to Test Step 4.

• Yes (Original 323-03 or 324-03 Diagnostic Test Step 3. Check for Proper Operation
Code) – The original diagnostic code was “323-03 of the Status Indicators for the Alarm and
Shutdown Lamp short to +batt” or “324-03 Warning Shutdown
Lamp short to +batt”. When the engine was started,
the “Run Relay” indicator and the “Crank Terminate Note: All active diagnostic codes and active event
Relay” indicator (if equipped) illuminated normally. codes must be cleared in order for the “Engine
The “Engine Control Alarm Status” indicator and Control Alarm Status” indicator to be OFF.
the “Fault Relay” indicator did not illuminate. There
are no active diagnostic codes. Allow the engine operation to continue for this
procedure. Operate the engine under low load.
245
Troubleshooting Section

Results:

• OK – The indicators, diagnostic codes, and


shutdown were activated according to the
“Expected Result”. The outputs for the status
indicators seem to be operating correctly at this
time. The original problem seems to be resolved.

Repair: The original diagnostic code was probably


caused by a poor electrical connection.

If there is an intermittent problem that is causing


the codes to be logged, refer to Troubleshooting,
“Inspecting Electrical Connectors”.

STOP.

• Not OK – The “Engine Control Alarm Status”


indicator and/or the “Fault Relay” indicator did
not illuminate normally when the sensors were
disconnected. A “323-03 Shutdown Lamp short to
Illustration 99
g01055312 +batt” and/or a “324-03 Warning Lamp short to
Right side view
+batt” diagnostic code was generated. There is a
problem with the output for the status indicators.
(1) Unfiltered engine oil pressure sensor
(2) Filtered engine oil pressure sensor
The “542-03” and the “100-03” diagnostic codes
were generated. The engine was shut down.
A. During engine operation, disconnect the connector Proceed to Test Step 4.
for the unfiltered engine oil pressure sensor
(1). Observe the “Engine Control Alarm Status”
indicator on the control panel (if equipped).

If you are only troubleshooting a “324-03 Warning


Lamp short to +batt”, proceed to the “Expected
Result”.

Note: When the filtered engine oil pressure sensor is


disconnected, the engine will shut down.

B. Disconnect the connector for the filtered engine oil


pressure sensor (2). Observe the “Fault Relay”
indicator on the control panel (if equipped).

C. Use the “Diagnostics” screen on Cat ET to look for


active diagnostic codes.

Expected Result:

The “Engine Control Alarm Status” indicator


illuminated and a “542-03 Unfiltered Engine Oil
Pressure open/short to +batt” diagnostic code was
activated when the unfiltered engine oil pressure
sensor is disconnected.

The “Fault Relay” indicator illuminated and a “100-03


Engine Oil Pressure open/short to +batt” diagnostic
code was activated when the filtered engine oil
pressure sensor is disconnected. The engine was
shut down.
246
Troubleshooting Section

Test Step 4. Measure the Voltage of the H. Insulate the end of the wire with electrical tape
Suspect Indicator at the P2 Connector in order to ensure that the wire does not create
a short circuit.

I. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.

J. Note the voltage that is displayed on the voltmeter.

Expected Result:

Before the suspect indicator was disconnected,


voltage was displayed on the voltmeter. After the
suspect indicator was disconnected, the voltmeter
displayed approximately zero volts.

Results:

• Yes – Before the suspect indicator was


disconnected, voltage was displayed on
the voltmeter. After the suspect indicator
was disconnected, the voltmeter displayed
approximately zero volts. There is a problem in the
customer’s equipment.

Repair: The problem could be caused by a poor


electrical connection, a wire, or a component in the
customer’s equipment.

Set the engine control to the OFF/RESET mode.


Illustration 100
g01055317 Switch the 35 amp circuit breaker OFF.
Terminal box
Thoroughly inspect all wiring and all connectors
(1) Ground strap for the ECM
(P2-28) Run Relay in the customer’s equipment. Refer to
(P2-29) Crank Terminate Relay Troubleshooting, “Inspecting Electrical
(P2-30) Fault Relay Connectors”.
(P2-31) Engine Control Alarm Status
If you suspect that the indicator has an internal
A. Set the engine control to the OFF/RESET mode. short circuit, temporarily install a known good
Switch the 35 amp circuit breaker OFF. indicator for the suspect indicator. Test the
indicator. Verify that the problem is resolved.
B. Insert a 7X-1710 Multimeter Probe into the
suspect control terminal in the P2 connector. Make the necessary repairs, when possible.
Replace parts, if necessary.
C. Connect the positive lead of a voltmeter to the end
of the 7X-1710 Multimeter Probe. Connect the STOP.
voltmeter’s negative lead to ground strap (1).
• No – Before the suspect indicator was
D. Switch the 35 amp circuit breaker ON. Set the disconnected, voltage was displayed on the
engine control to the STOP mode. voltmeter. After the suspect indicator was
disconnected, the voltage was still displayed on
E. Note the voltage that is displayed on the voltmeter. the voltmeter. Proceed to Test Step 5.
F. Set the engine control to the OFF/RESET mode. Test Step 5. Check the ECM
Switch the 35 amp circuit breaker OFF.
A. Set the engine control to the OFF/RESET mode.
G. If the customer has equipment for the status Switch the 35 amp circuit breaker OFF.
indicators, disconnect one wire from the suspect
indicator. Be sure to disconnect the wire that B. Disconnect the voltmeter leads and remove the
comes from the ECM. 7X-1710 Multimeter Probe from the P2 connector.
247
Troubleshooting Section

C. Use a 151-6320 Wire Removal Tool to remove Temporarily install a new ECM. Refer to
the suspect terminal from the ECM P2 connector. Troubleshooting, “Replacing the ECM”.

D. Insulate the terminal with electrical tape in order If the problem is resolved with the new ECM,
to ensure that the terminal does not create a short install the original ECM and verify that the problem
circuit. returns. If the new ECM operates correctly and the
original ECM does not operate correctly, replace
E. Fabricate a jumper wire with Deutsch terminals on the original ECM. Refer to Troubleshooting,
the ends. Insert one end of the jumper wire into “Replacing the ECM”.
the open terminal of the P2 connector.
STOP.
F. Connect a voltmeter lead to the end of the jumper
wire that is not inserted into the connector.
i02059218

G. Connect the other lead of the voltmeter to the


ground strap for the ECM.
Electrical Power Supply
SMCS Code: 1408-038
H. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. Observe the System Operation Description:
voltage reading on the voltmeter.
Electrical power is supplied to the following
Expected Result: components:
The voltmeter displays approximately zero volts.
• Electronic Control Module (ECM)
Results:
• Integrated Temperature Sensing Module (ITSM)
• The voltage is approximately zero – After the • Fuel metering valve
suspect terminal was removed from connector P2,
the reading on the voltmeter was approximately
zero. There is a problem with a connection and/or
• Actuator for the throttle
the wiring between the customer’s equipment and
the ECM.
• Actuator for the compressor bypass group
The cause of an intermittent power supply can occur
Repair: Perform the following procedure: on either the positive side or the negative side of the
power supply.
1. Switch the 35 amp circuit breaker OFF. Set the
engine control to the OFF/RESET mode. The 24 VDC power supply for the engine can be
provided by a battery or by an electrical power
2. Disconnect the voltmeter leads. supply. If the power is provided by an electrical power
supply, the maximum allowable AC ripple is 150 mV
3. Use a 151-6320 Wire Removal Tool to remove AC peak to peak. The minimum requirement for the
the jumper wire from the ECM P2 connector. power supply is 22 VDC at 30 amperes. The wiring
from the power supply to the ECM must provide a
4. Insert the terminal for the output wire into the P2 maximum voltage drop of 1.0 VDC.
connector. Pull on the wire in order to verify that
the terminal is fully inserted into the connector. The ECM input at terminal 70 of the P1 connector
(“Switched +Battery”) receives battery voltage from
Repair the connection and/or the wiring, when the engine control when the control is in the START
possible. Replace parts, if necessary. mode, in the STOP mode, or in the AUTO mode.
When the ECM detects battery voltage at this input,
STOP. the ECM will power up. When battery voltage is
removed from this input, the ECM will power down
• The voltage remained – After the suspect terminal after the engine has shut down.
was removed from the P2 connector, voltage was
still displayed on the voltmeter. There may be a The “168-02” diagnostic code indicates that the
problem with the ECM. voltage of the power supply is intermittent or low
while the engine is running. If the supply voltage
Repair: It is unlikely that the ECM has failed. Exit drops to zero and stays at zero, neither ECM will log
this procedure and perform this procedure again. If this code. The engine will shut down.
the problem is not resolved, perform the following
steps:
248
Troubleshooting Section

The “336-02” diagnostic code indicates that the ECM


has detected a problem with the circuit for the engine
control.

Logged diagnostic codes provide a historical record.


Before you begin this procedure, use the Caterpillar
Electronic Technician (ET) to print the logged codes
to a file.

This procedure may generate additional diagnostic


codes. Keep your mind on correcting the cause of the
original diagnostic code. Clear the diagnostic codes
after the problem is resolved.
249
Troubleshooting Section

g01055398
Illustration 101
Schematic for the electrical power
250
Troubleshooting Section

Test Step 1. Inspect the Electrical


Connectors and Wiring

g01055402
Illustration 103
Terminal box
g01055400
Illustration 102 (5) J5 connector for the service tool
Junction box (6) J1/P1 connectors for the ECM
(7) J6/P6 connectors for the customer
(1) Circuit breaker for the engine control (2.5 ampere) (8) J7/P7 connectors for the harness for electrical power
(2) Circuit breaker for the customer (10 ampere)
(3) Circuit breaker for the engine (35 ampere)
(4) Circuit breaker for the ECM output for the electrical starting B. Thoroughly inspect each of the following
motor (2.5 ampere) connectors:

A. Set the engine control to the OFF/RESET mode. • J1/P1 connectors


Switch 35 amp circuit breaker (3) to the OFF
position. • J5, J6/P6 and J7/P7 connectors on the terminal
box
Note: For the following steps, refer to
Troubleshooting, “Inspecting Electrical Connectors”. • Connectors for the 24 VDC power supply
• Connectors for the engine control
a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
251
Troubleshooting Section

g01055407
Illustration 104
Harness side of the P1 connector
(P1-31) Digital return
(P1-52) Unswitched +Battery
(P1-53) Unswitched +Battery
(P1-55) Unswitched +Battery
(P1-57) Unswitched +Battery
(P1-61) Stop
(P1-62) Start
(P1-63) -Battery
(P1-64) Auto
(P1-65) -Battery
(P1-67) -Battery
(P1-69) -Battery
(P1-70) Switched +Battery
g01055418
Illustration 106
Harness side of the J7 connector
(J7-57) Unswitched +Battery
(J7-58) Unswitched +Battery
(J7-60) Power for the engine control
(J7-61) Switched +Battery
(J7-62) Switched +Battery
(J7-65) Power for the customer
(J7-70) -Battery

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


wires that are associated with the electrical
power supply.

d. Check the harness and wiring for abrasion and


for pinch points from the power supply to the
ECM and from the engine control to the ECM.

Expected Result:

The connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
Illustration 105
g01055415 corrosion, abrasion, or pinch points.
Harness side of the J6 connector
Results:
(J6-1) +Battery for the customer (10 amperes)
(J6-4) Power for the engine control
(J6-14) Switched +Battery • OK – The components are in good condition with
(J6-19) Stop command proper connections. Proceed to Test Step 2.
(J6-29) Start command
(J6-36) Digital return
(J6-39) Auto command
• Not OK – The components are not in good
condition and/or at least one connection is
improper.
252
Troubleshooting Section

Repair: Perform the necessary repairs and/or Switch the 35 amp circuit breaker OFF.
replace parts, if necessary. Ensure that all of the
seals are properly installed. Make sure that the Proceed to Test Step 3.
connectors are properly fastened. Verify that the
repair has eliminated the problem. • Not OK – The ECM is not receiving the correct
voltage.
STOP.
Repair: Use a voltmeter to check the wiring. Refer
Test Step 2. Check the Voltage at the to the schematic for the electrical system. Locate
Power Supply and at the ECM the source of the voltage drop. Make repairs, as
needed.
A. Make sure that the engine will not crank during
this procedure. For an engine with an electric STOP.
starting motor, make sure that the battery cables
are disconnected from the motor. For an engine Test Step 3. Check the Engine Control
with an air starting motor, make sure that the Switch
pressurized air supply is OFF. Make sure that the
air is purged from the system. A. Make sure that the engine will not crank during
this procedure. For an engine with an electric
Note: If a power supply is used instead of batteries, starting motor, make sure that the battery cables
the minimum voltage for the power supply is 22 VDC. are disconnected from the motor. For an engine
Troubleshoot the power supply if the voltage is less with an air starting motor, make sure that the
than 22 VDC or more than 29 VDC. pressurized air supply is OFF. Make sure that the
air is purged from the system.
B. Measure the voltage at the terminals for the power
supply. Record the measurement. B. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service
C. Insert two 7X-1710 Multimeter Probes into the Tools”.
harness side of the P1 connector. Insert the first
probe into terminal 52. Insert the second probe C. Switch the 35 amp circuit breaker ON.
into terminal 63. Connect a multimeter to the
probes. Note: An “E225 Engine Overcrank” and/or an “E233
Low Engine Prelube Pressure” event code may be
D. Switch the 35 amp circuit breaker ON. generated during this step. After you have completed
this step, clear the events from the “Logged Events”
E. Measure the power supply voltage at the P1 screen of Cat ET.
connector. During the measurement, wiggle the
harness in order to check for an intermittent D. Observe the “Active Diagnostic” screen on Cat
problem. Be sure to wiggle the harness near each ET and set the engine control to the STOP mode,
of the connections. Record the measurement. the START mode, and the AUTO mode. Look for
an active “336-02 Incorrect ECS Switch inputs”
F. Switch the 35 amp circuit breaker OFF. Remove diagnostic code. Repeat this step several times.
the probes from the P1 connector.
Expected Result:
Expected Result:
A “336-02 Incorrect ECS Switch inputs” diagnostic
The voltage that is measured at the terminals for the code was not activated when the engine control was
power supply is at least 22 VDC. The voltage that is set to the STOP mode, the START mode, and the
measured at the P1 connector is within one volt of AUTO mode.
the voltage that was measured at the terminals for
the power supply. The voltage measurements are Results:
constant.
• OK – A “336-02 Incorrect ECS Switch inputs”
Results: diagnostic code was not activated. The inputs from
the engine control are correct. The problem seems
• OK – The ECM is receiving the correct voltage. to be resolved.

Repair: Perform the following procedure:


253
Troubleshooting Section

Repair: The problem may be intermittent. I. Set the engine control to the AUTO mode and
Refer to Troubleshooting, “Inspecting Electrical measure the voltage between terminals P1-31
Connectors”. and P1-64. The correct voltage measurement is
less than one volt.
STOP.
J. Remove the probe from terminal 31 and insert the
• Not OK – A “336-02 Incorrect ECS Switch inputs” probe into terminal 69. Remove the probe from
diagnostic code was activated. The ECM has terminal 64 and insert the probe into terminal 70.
detected an invalid pattern of inputs from the
engine control switch. Proceed to Test Step 4. K. Set the engine control to the STOP mode and
measure the voltage between terminals P1-69
Test Step 4. Check the Circuit of the and P1-70 connector. The correct voltage
Engine Control Switch measurement is at least 20 VDC.

A. Make sure that the engine will not crank during L. Set the engine control to the START mode and
this procedure. For an engine with an electric measure the voltage between terminals P1-69
starting motor, make sure that the battery cables and P1-70. The correct voltage measurement is
are disconnected from the motor. For an engine at least +20 VDC.
with an air starting motor, make sure that the
pressurized air supply is OFF. Make sure that the M. Set the engine control to the AUTO mode and
air is purged from the system. measure the voltage between terminals P1-69
and P1-70. The correct voltage measurement is at
B. Set the engine control to the OFF/RESET mode. least 20 VDC.
Switch the 35 amp circuit breaker OFF.
Expected Result:
C. Insert two 7X-1710 Multimeter Probes into the
harness side of the P1 connector. Insert the first The voltage checks are within the specifications.
probe into terminal 31. Insert the second probe
into terminal 61. Connect a multimeter to the Results:
probes.
• OK – The voltage checks are within the
D. Switch the 35 amp circuit breaker ON. specifications. Remove the probes from the P1
connector. Start the engine and run the engine. If
Note: An “E225 Engine Overcrank” and/or an “E233 the original problem is not resolved, the ECM may
Low Engine Prelube Pressure” event code may be have a problem.
generated during the test. After you have completed
the test, clear the events from the “Logged Events” Repair: It is unlikely that the ECM has failed.
screen of Cat ET. Perform the following procedure:

Note: During these measurements, wiggle the Temporarily install a new ECM. Refer to
harness in order to check for an intermittent problem. Troubleshooting, “Replacing the ECM”.
Be sure to wiggle the harness near each of the
connections. If the problem is resolved with the new ECM,
install the original ECM and verify that the problem
E. Set the engine control to the STOP mode and returns. If the new ECM operates correctly and the
measure the voltage between terminals P1-31 original ECM does not operate correctly, replace
and P1-61. The correct voltage measurement is the ECM. Refer to Troubleshooting, “Replacing
less than one volt. the ECM”.

F. Remove the probe from terminal 61 and insert the STOP.


probe into terminal 62.
• Not OK – The P1 connector does not have the
G. Set the engine control to the START mode and correct voltage.
measure the voltage between terminals P1-31
and P1-62. The correct voltage measurement is Repair: Perform the following steps:
less than one volt.
1. Set the engine control to the OFF/RESET
H. Remove the probe from terminal 62 and insert the mode. Switch the 35 amp circuit breaker OFF.
probe into terminal 64.
2. Disconnect the wires for the STOP, START, and
AUTO modes from the device that provides
engine control. The device may be a mechanical
switch or an electronic control.
254
Troubleshooting Section

3. If a mechanical switch provides engine control,


use an ohmmeter to check the contacts for the
switch. Set the switch to each position in order
to check the contacts. If an electronic control
provides engine control, check the control
according to the literature that is provided by
the OEM of the control. Verify that the correct
signals are generated by the electronic control.

4. If the engine control is faulty, replace the


control. If the problem is not resolved, repair the
harness, when possible. Replace the harness,
if necessary.

STOP.

i02059442

Engine Speed/Timing Sensor


SMCS Code: 1912-038

System Operation Description:

g00893441
Illustration 107
Speed/Timing sensor and timing ring

The speed/timing sensor provides information about The timing ring has a special tooth pattern that
engine speed and the position of the crankshaft to indicates the position of the camshaft and the
the Electronic Control Module (ECM). The sensor direction of rotation. The timing ring has 24 slots
is powered by the sensor supply (12 VDC) from the in the outer diameter. Twenty-one of the slots are
ECM. A magnetic pickup is located underneath the narrow. Three of the slots are about 2.5 times wider
plastic sliphead of the sensor. The timing ring is than the rest of the slots. When the engine rotates in
mounted on the rear of the left camshaft. As the teeth the normal direction, the slots pass the speed/timing
of the ring rotate past the sliphead of the sensor, the sensor in the following order:
sensor generates a signal that matches the pattern
of the teeth. • 1 wide slot
• 3 narrow slots
255
Troubleshooting Section

• 2 wide slots
• 18 narrow slots
The number one cylinder is at the top center position
when the rising edge of the third narrow slot passes
the center of the sliphead. All 24 teeth pass the
sliphead during one revolution of the camshaft or two
revolutions of the crankshaft.

With the information from the engine speed/timing


sensor, the ECM is able to calculate the positions of
the pistons in the cylinders. The ECM determines
the desired ignition timing according to the engine
speed and load. If detonation is detected in any of
the cylinders, the ECM retards the timing of the
affected cylinders. The ECM sends voltage pulses
to the ignition transformers for firing the spark plugs
according to the desired timing.

During engine operation, the ECM will shut down the


engine if the ECM detects a problem with the signal
from the speed/timing sensor. The ECM will activate
the corresponding diagnostic code.

If there is a problem with the engine speed/timing


sensor’s signal during start-up but no corresponding
diagnostic code is active, the ECM will not initiate the
ignition. The engine will not start. The corresponding
diagnostic code is not activated.

The most likely causes of the diagnostic code are a


poor electrical connection or a problem in a wiring
harness. The next likely cause is a problem with the
engine speed/timing sensor. The least likely cause is
a problem with the ECM.

Logged diagnostic codes provide a historical record.


Before you begin this procedure, use the Caterpillar
Electronic Technician (ET) to print the logged codes
to a file.

The troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.
256
Troubleshooting Section

g01055531
Illustration 108
Schematic for the circuit of the speed/timing sensor

Test Step 1. Inspect the Electrical


Connectors and Wiring.

g01055532
Illustration 110
Terminal box for the ECM
g01054206
Illustration 109 (2) J1/P1 connectors for the ECM
Junction box (3) J7/P7 connectors for the harness from the speed/timing sensor

(1) 35 amp circuit breaker


B. Thoroughly inspect the following connections:
A. Set the engine control to the OFF/RESET mode.
Switch 35 amp circuit breaker (1) to the OFF • ECM J1/P1 connectors
position.
• J7/P7 connectors on the terminal box
Note: For the following steps, refer to
a. Check the torque of the Allen head screw for
Troubleshooting, “Inspecting Electrical Connectors”.
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
257
Troubleshooting Section

g01055533
Illustration 111
Harness side of the P1 connector
(P1-33) Signal
(P1-43) 12 volt supply
(P1-51) Return

g01055543
Illustration 113
Left side view
(5) Speed/Timing sensor

d. Check the harness and wiring for abrasion and


for pinch points from the speed/timing sensor
to the ECM.

Expected Result:

The connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.

Results:

• OK – The components are in good condition with


proper connections. Proceed to Test Step 2.

• Not OK – The components are not in good


condition and/or at least one connection is
improper.

Repair: Perform the necessary repairs and/or


replace parts, if necessary.
g01055536 STOP.
Illustration 112
Harness side of the P7 connector
(P7-9) Signal
Test Step 2. Check the Sensor
(P7-23) Return
(P7-37) Shield A. Set the engine control to the OFF/RESET mode.
(P7-51) 12 volt supply Switch the 35 amp circuit breaker OFF.

c. Perform a 45 N (10 lb) pull test on each of the B. Remove the speed/timing sensor.
wires that are associated with the circuit for the
speed/timing sensor.
258
Troubleshooting Section

Note: The plastic sliphead is designed to contact


the tooth of the timing ring during installation. As
the timing ring begins to turn, the radial runout of
the timing ring will push the plastic sliphead into
the sensor body slightly. This provides the plastic
sliphead’s air gap with a self-adjusting function. The
maximum allowable clearance between the sliphead
and a tooth on the timing ring is 0.5 mm (0.02 inch).
g01055553
Illustration 114
Plastic sliphead for the speed/timing sensor c. Coat the threads of the sensor with 4C-5597
Anti-Seize Compound.
C. Inspect the condition of the plastic sliphead. Look
for signs of wear and for contaminants. Clean any d. Install the sensor. Tighten the sensor to
debris from the plastic sliphead. 40 ± 5 N·m (30 ± 4 lb ft).

D. Check the tension of the plastic sliphead. Gently Proceed to Test Step 3.
extend the plastic sliphead for a minimum of 4 mm
(0.16 inch). Then push back the plastic sliphead. • Not OK – The plastic sliphead is damaged and/or
the tension of the sliphead is insufficient.
Expected Result:
Repair: Install a new sensor. Calibrate the sensor.
The sensor is in good condition. At least 22 N (5 lb) Refer to Troubleshooting, “Engine Speed/Timing
of force is required to push in the plastic sliphead Sensor - Calibrate”.
from the extended position.
If the condition is not resolved, proceed to Test
Results: Step 3.

• OK – The sensor is not damaged. The tension of Test Step 3. Check for Active Diagnostic
the plastic sliphead is correct. Codes for the 12 Volt Sensor Supply

Repair: Install the sensor. A. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service
Tools”.
NOTICE
The plastic sliphead must be fully extended when the B. Switch the 35 amp circuit breaker ON. Set the
speed/timing sensor is installed so that the sensor engine control to the STOP mode.
maintains the correct clearance with the timing ring.
If the correct clearance is not maintained, the signal C. Use the “Active Diagnostic” screen on Cat ET.
from the sensor will not be generated. Look for the following codes:
Do not install the sensor’s plastic sliphead between • 145-03 12 Volt DC Power Supply short to +batt
the teeth of the timing ring. Damage to the plasic slip-
head will result. Before installing the sensor, ensure • 145-04 12 Volt DC Power Supply short to
that a tooth of the ring is visible in the mounting hole ground
for the sensor.
Expected Result:
1. Use the following steps to install the
speed/timing sensor: None of the above codes are active.

a. Ensure that a tooth on the timing ring is Results:


visible in the mounting hole for the sensor.
• No active codes – None of the above codes are
b. Fully extend the sliphead. active. However, at least one of the codes is
logged.

Repair: Clear the logged codes.

Proceed to Test Step 4.

• Active code – One of the above codes is active.


Proceed to Test Step 5.
259
Troubleshooting Section

Test Step 4. Use Cat ET to Check the Expected Result:


Engine RPM
The voltage is between 11.5 VDC and 13.5 VDC. A
A. Use the “Status - Group 1” screen in order to 145-03 diagnostic code or a 145-04 diagnostic code
observe “Engine Speed”. Observe the “Engine is not active.
Speed” parameter on the screen and set the
engine control to the START mode. Crank the Results:
engine.
• OK – The sensor is receiving correct supply
B. Continue to observe the screen and allow the voltage. A 145-03 diagnostic code or a 145-04
engine rpm to stabilize at the normal cranking diagnostic code is not active. Leave the breakout t
speed. connected. Proceed to Test Step 6.

C. Set the engine control to the STOP mode. • Not OK – The sensor is not receiving correct
supply voltage or a 145-03 diagnostic code or a
Expected Result: 145-04 diagnostic code is active. Remove the
breakout t. Proceed to Test Step 7.
Before the engine is cranked, the engine speed is
“0”. The engine speed increases until the speed Test Step 6. Isolate the Signal Voltage at
stabilizes at the normal cranking speed. When the the Sensor
engine is stopped, the speed decreases back to “0”.
A 320-03 diagnostic code or a 320-08 diagnostic A. Set the engine control to the OFF/RESET mode.
code are not activated.
B. Ensure that the breakout t is connected in series
Results: with the connectors for the speed/timing sensor.

• OK – The engine started and the engine C. Remove the wire from terminal “C” of the breakout
ran properly. A 320-03 diagnostic code or a t in order to isolate the sensor signal wire.
320-08 diagnostic code was not activated. The
speed/timing sensor is operating properly. STOP. D. Set the engine control to the STOP mode.
Measure the signal voltage between terminals “B”
• Not OK – The engine cranked. However, Cat and “C”.
ET did not display the correct engine speed or a
320-03 or a 320-08 diagnostic code was activated. E. Set the engine control to the START mode.
Proceed to Test Step 5. Crank the engine and measure the signal voltage
between terminals “B” and “C”.
• Not OK – The engine cranked but the engine did
not start. Cat ET displayed the correct engine Expected Result:
speed. A 320-03 diagnostic code or a 320-08
diagnostic code was not activated. The ECM is When the engine control is in the STOP mode, the
receiving a valid signal. voltage is less than 3.0 VDC or the voltage is greater
than 10.0 VDC.
Repair: Refer to Troubleshooting, “Engine Cranks
But Will Not Start”. Make repairs, as needed. The voltage varied between 2.0 VDC and 4.0 VDC
during cranking.
STOP.
Results:
Test Step 5. Measure the Sensor Supply
Voltage at the Sensor • OK – The sensor is producing the correct output
signal.
A. Set the engine control to the OFF mode.
Repair: Remove the breakout t from the
B. Install a 8T-8726 Adapter Cable As (Three-Pin connectors for the speed/timing sensor. Reconnect
Breakout) in series with the connectors for the the connectors for the speed/timing sensor.
speed/timing sensor.
Proceed to Test Step 7.
C. Set the engine control to the STOP mode.
Measure the supply voltage between terminals “A” • Not OK – The sensor is not producing the correct
and “B” of the breakout t. output signal.

Repair: Set the engine control to the OFF/RESET


mode. Switch the 35 amp circuit breaker OFF.
260
Troubleshooting Section

Remove the breakout t from the connectors for the If the problem is resolved with the new ECM,
speed/timing sensor. install the original ECM and verify that the problem
returns. If the new ECM operates correctly and the
Install a new speed/timing sensor. Calibrate original ECM does not operate correctly, replace
the sensor. Refer to Troubleshooting, “Engine the ECM. Refer to Troubleshooting, “Replacing
Speed/Timing Sensor - Calibrate”. the ECM”.

STOP. STOP.

Test Step 7. Measure the Sensor Supply Test Step 8. Isolate the Sensor Signal at
Voltage at the ECM the ECM and Measure the Sensor Signal
Voltage at the ECM
A. Set the engine control to the OFF/RESET mode.
A. Set the engine control to the OFF/RESET mode.
B. Use two 7X-1710 Multimeter Probes. Insert the
probes into terminals P1-33 and P1-51. B. Use a 151-6320 Wire Removal Tool to remove
terminals P1-33 and P1-51.
C. Set the engine control to the STOP mode.
Measure the supply voltage at the ECM. C. Connect the leads of a multimeter to the terminals
that were removed from the P1 connector.
Expected Result:
D. Set the engine control to the STOP mode.
The voltage is between 11.5 VDC and 13.5 VDC. A Measure the signal voltage between the terminals.
145-03 diagnostic code or a 145-04 diagnostic code Record the measurement.
is not active.
E. Set the engine control to the START mode.
Results: Crank the engine and measure the signal
voltage between the terminals again. Record the
• Yes – The sensor supply voltage at the ECM measurement.
is between 11.5 VDC and 13.5 VDC. A 145-03
diagnostic code or a 145-04 diagnostic code is not Expected Result:
active. The wiring and/or the connectors between
the sensor and the ECM has an open circuit or the When the engine control is in the STOP mode, the
circuit has excessive resistance. voltage is less than 3.0 VDC or the voltage is greater
than 10.0 VDC.
Repair: Set the engine control to the OFF/RESET
mode. Switch the 35 amp circuit breaker OFF. The voltage varied between 2.0 VDC and 4.0 VDC
Make the necessary repairs to the harness and/or during cranking.
connectors.
Results:
STOP.
• OK – Both of the measurements are correct.
• No – The ECM is not producing the correct sensor However, the ECM is not reading the signal. There
supply voltage or a 145-03 or a 145-04 diagnostic may be a problem with the ECM.
code is active. There may be a problem with the
ECM. Repair: It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again. If
Repair: It is unlikely that the ECM has failed. Exit the condition is not resolved, perform the following
this procedure and perform this procedure again. If steps:
the condition is not resolved, perform the following
steps: Temporarily install a new ECM. Refer to
Troubleshooting, “Replacing the ECM”.
Temporarily install a new ECM. Refer to
Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM,
install the original ECM and verify that the problem
returns. If the new ECM operates correctly and the
original ECM does not operate correctly, replace
the ECM. Refer to Troubleshooting, “Replacing
the ECM”.

STOP.
261
Troubleshooting Section

• Not OK – The signal voltage is not correct. There If the digital signal is not available, the valve will use
is an intermittent problem in the circuit for the the PWM signal. The ECM will activate a 1446-09
speed/timing sensor. diagnostic code. Engine performance will be affected.

Repair: Refer to Troubleshooting, “Inspecting Status Indicator for the Fuel Metering Valve
Electrical Connectors”. Make repairs, as needed.

STOP.

i02059842

Fuel Metering Valve


SMCS Code: 1741-038

System Operation Description:

The fuel metering valve is an electronic gas valve


that controls the flow of fuel to the engine. The valve
works with the master Electronic Control Module
(ECM) in order to ensure the correct flow of gas in all
conditions of engine operation.

The master ECM sends a command signal for the flow


of fuel and information about the specific gravity of
the gas to the fuel metering valve. The valve converts
the command signal and the information into a valve Illustration 115
g00996218
position that directly corresponds to the desired gas Status indicator for the fuel metering valve
flow. The position of the valve is compensated by
these additional factors that are internal to the valve: The fuel metering valve contains a status indicator.
absolute fuel pressure, differential pressure of the The indicator flashes in order to indicate the status
valve, and fuel temperature. of the valve. The color of the indicator indicates the
severity of the problem. During operation, the status
The following procedure tests whether the command indicator will flash one of the following colors:
signal for the flow of fuel and the information about
the specific gravity of the gas is properly sent Green – Normal operation
to the fuel metering valve by the master ECM.
The command signal is a 180 hertz PWM signal. Orange – The valve has detected a problem and the
Information about the specific gravity of the gas is valve continues to operate.
sent to the fuel metering valve via the CAN Data Link.
Red – The valve has detected a serious problem.
The fuel metering valve sends information to the The valve has shut down.
master ECM via the CAN Data Link. This procedure
also tests whether the following information is The flash code indicates the particular error that
properly sent to the master ECM by the fuel metering has been detected by the valve. Before performing
valve: position of the fuel valve, absolute fuel maintenance on the valve, observe the status
pressure, differential pressure of the valve, and fuel indicator. Refer to Installation and Operation Manual,
temperature. SEBU7630 for additional information.
During normal operation, the valve receives two
command signals from the ECM. One of the signals
is a digital signal that is received via the CAN data
link. The other signal is a pulse width modulated
signal (PWM) that is received via a pair of wires. The
valve will use the digital signal when both signals are
available.

If the PWM signal is not available, the valve


will continue to use the digital signal. The ECM
will activate a 1446-05 diagnostic code. Engine
performance will be affected.
262
Troubleshooting Section

g00952248
Illustration 116
Schematic for the circuit of the fuel metering valve
263
Troubleshooting Section

Test Step 1. Inspect the Electrical B. Thoroughly inspect each of the following
Connectors and Wiring connectors:

• Master ECM J1/P1 connectors


• J6/P6, J7/P7, and J9/P9 connectors on the
terminal box

• Connectors on the fuel metering valve


a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g00931487
Illustration 117

A. Set the engine control to the OFF/RESET mode.


Switch 35 amp circuit breaker (1) to the OFF
position.

Note: For the following steps, refer to


Troubleshooting, “Inspecting Electrical Connectors”.
g01012877
Illustration 119
Harness side of the ECM P1 connector
(P1-34) CAN Data Link −
(P1-42) CAN shield
(P1-50) CAN Data Link +
(P1-58) Signal for the fuel flow
(P1-60) Return for the signal for the fuel flow

g00931792
Illustration 118
Terminal box
(2) Ground strap
(3) J1/P1 connectors for the master ECM
(4) J6/P6 connectors for the customer
(5) J7/P7 connectors for the harness from the fuel metering valve
(6) J9/P9 connectors for the harness for the CAN data link
(7) J10/P10 connectors for the terminating resistor for the CAN
data link
264
Troubleshooting Section

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


wires that are associated with the fuel metering
valve.

g00931879
Illustration 120
Harness side of the J7 connector
(J7-11) Signal for the fuel flow
(J7-25) Return for the signal for the fuel flow
(J7-39) Shield
(J7-61) Switched +Battery

g00931976
Illustration 122
Top view of the engine. The 60 Hz configuration is shown. The
50 Hz configuration is similar.
(8) Fuel metering valve
(9) P24/J24 connectors for the fuel metering valve

d. Check the wiring for abrasion and for pinch


points from the fuel metering valve to the
master ECM.

Expected Result:
g00952267
Illustration 121
Harness side of the P24 connector for the fuel metering valve All of the connectors, pins, and sockets are connected
(P24-C) CAN Data Link +
properly. The connectors and the wiring do not have
(P24-D) CAN Data Link + to the throttle actuator corrosion, abrasion, or pinch points.
(P24-E) CAN Data Link − to the throttle actuator
(P24-F) CAN Data Link − Results:
(P24-K) Unswitched +Battery
(P24-L) −Battery
(P24-M) Switched +Battery • OK – The components are in good condition with
(P24-S) Signal for the fuel flow proper connections. Proceed to Test Step 2.
(P24-T) Return for the signal for the fuel flow
265
Troubleshooting Section

• Not OK – The components are not in good • Not OK (Active 1446-09) – The master ECM has
condition and/or at least one connection is detected an open circuit or a short circuit for the
improper. circuit of the CAN Data Link between the master
ECM and the fuel metering valve. Proceed to Test
Repair: Perform the necessary repairs and/or Step 4.
replace parts, if necessary. Ensure that all of
the seals are properly installed. Ensure that the • Not OK (Active 1446-12) – The fuel metering valve
connectors are properly engaged. Verify that the has detected an internal malfunction.
repair has eliminated the original problem.
Repair: Refer to Installation and Operation
STOP. Manual, SEBU7630, “Raptor Gas Regulation and
Metering Valve/Actuator System for Caterpillar”.
Test Step 2. Check for Diagnostic Codes
STOP.
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector on the terminal box. • Not OK (Active 1446-13) – The fuel metering valve
requires calibration.
B. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. Repair: Refer to Installation and Operation
Manual, SEBU7630, “Raptor Gas Regulation and
C. Use Cat ET to determine if any of the following Metering Valve/Actuator System for Caterpillar”.
diagnostic codes are active:
STOP.
• 1446-05 “Fuel Metering Module open circuit”
• Not OK (Active 1447-12) – There is a malfunction
• 1446-09 “Unable to communicate with Fuel of the sensor module in the fuel metering valve.
Metering Module”
Repair: Refer to Installation and Operation
• 1446-12 “Fuel Metering Module malfunction” Manual, SEBU7630, “Raptor Gas Regulation and
Metering Valve/Actuator System for Caterpillar”.
• 1446-13 “Fuel Metering Module calibration
required” STOP.

• 1447-12 “Fuel Metering Sensor Module Test Step 3. Check the Signal for the Fuel
malfunction” Flow
Expected Result: A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
There are no active diagnostic codes.
B. Insert two 7X-1710 Multimeter Probes into the
Results: harness side of the P1 connector. Insert the first
probe into terminal 58. Insert the second probe
• OK – There are no active diagnostic codes. The into terminal 60. Use a multimeter that is capable
signal and the communication between the master of measuring the frequency and the duty cycle.
ECM and the fuel metering valve appear to be OK Connect the multimeter to the probes.
at this time. However, diagnostic codes may be
logged. C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.
Repair: If you are troubleshooting an intermittent
problem, refer to Troubleshooting, “Inspecting D. Measure the DC voltage, the duty cycle, and the
Electrical Connectors”. frequency of the signal for the fuel flow.

STOP. Expected Result:

• Not OK (Active 1446-05) – The master ECM has The DC voltage is between 13.7 and 15.7.
detected an open circuit or a short circuit for the
circuit of the fuel flow signal between the ECM and The duty cycle is between 92 and 98 percent.
the fuel metering valve. Proceed to Test Step 3.
The frequency is between 175 and 185 hertz.
266
Troubleshooting Section

Results: Table 20
Points to Check for Continuity
• OK – The voltage, the duty cycle, and the
frequency of the signal for the fuel flow is correct at Connector and Terminal Connector and Terminal
the master ECM P1 connector. There is a problem P1-34 P24-F
with the fuel metering valve.
P1-50 P24-C
Repair: Replace the fuel metering valve. Verify
P1-34 Ground strap for the ECM
that the repair has eliminated the original problem.
P1-50 Ground strap for the ECM
STOP.
Expected Result:
• Not OK – The voltage, the duty cycle, and/or the
frequency of the signal for the fuel flow is not The continuity of the circuits between the terminals
correct at the master ECM P1 connector. Proceed is good.
to Test Step 5.
The continuity between the terminals and the ground
Test Step 4. Check the Continuity of the strap is open.
Wiring Harness for the CAN Data Link
Results:
A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
• OK – The continuity of the circuits is good. The
continuity of the circuit between the master ECM
B. Disconnect the master ECM J1/P1 connectors. and the ground strap is open.
Disconnect the harness connector for the fuel
metering valve. Repair: Perform the following steps:

1. Switch the 35 amp circuit breaker ON. Set the


engine control to the STOP mode.

2. Observe the “Active Diagnostic Codes” screen


of Cat ET.

If a “1446-09 Unable to communicate with Fuel


Metering Module” diagnostic code is activated,
troubleshoot the CAN data link. Refer to the
engine’s schematic diagram.

If a 1446-09 diagnostic code is not activated,


proceed to Test Step 6.
g00952177
Illustration 123
• Not OK – At least one of the following conditions
(P1) Connector for the ECM is found: There is an open circuit between the
(P24) Connector for the fuel metering valve
(P1-34) CAN Data Link − plug for the master ECM and the plug for the fuel
(P1-50) CAN Data Link + metering valve. There is a short circuit between the
(P24-F) CAN Data Link − plug for the master ECM and a component that is
(P24-C) CAN Data Link + at ground potential.
C. Use a multimeter to check for continuity between Repair: Perform the necessary repairs to the wiring
the points that are listed in Table 20. and/or connectors. Replace parts, if necessary.
Ensure that all of the seals are properly installed.
Ensure that the connectors are properly engaged.
Verify that the repair has eliminated the original
problem.

STOP.
267
Troubleshooting Section

Test Step 5. Check the Continuity of the Repair: Repair the wiring and/or connectors.
Circuit for the Fuel Flow Replace parts, if necessary. Ensure that all of
the seals are properly installed. Ensure that the
A. Set the engine control to the OFF/RESET mode. connectors are properly engaged. Verify that the
Switch the 35 amp circuit breaker OFF. repair has eliminated the original problem.

B. Disconnect the J1/P1 connector. STOP.

C. Disconnect the fuel metering valve J24/P24 Test Step 6. Check the Resistance of the
connector. Internal Circuit of the Fuel Metering Valve
A. Ensure the following conditions:

• The engine control is in the OFF/RESET mode.


• The 35 amp circuit breaker in the terminal box
is OFF.

• The fuel metering valve J24/P24 connectors


are disconnected.

g01012855
Illustration 124
(P1) Connector for the ECM
(P24) Connector for the fuel metering valve
(P1-58) Signal for the fuel flow
(P1-60) Return for the signal for the fuel flow
(P24-S) Signal for the fuel flow
(P24-T) Return for the signal for the fuel flow

D. Use a multimeter to check the continuity of the


following circuits:
g00952241
Illustration 125
• P1-58 and P24-S
J24 connector on the fuel metering valve
• P1-58 and the ground strap for the ECM (J24-S) Signal for the fuel flow
(J24-T) Return for the signal for the fuel flow
• P1-60 and P24-T
B. Measure the resistance between terminals J24-S
Expected Result: and J24-T.

The continuity of the circuits between the terminals Expected Result:


is good.
The resistance is between 315,000 ohms and
The continuity between the terminal and the ground 325,000 ohms.
strap is open.
Results:
Results:
• OK – The resistance is between 315,000 ohms
• OK – The continuity of the circuit between the and 325,000 ohms. Proceed to Test Step 7.
master ECM and the fuel metering valve is good.
The continuity of the circuit between the master • Not OK – The resistance is not between 315,000
ECM and the ground strap is open. Proceed to ohms and 325,000 ohms.
Test Step 6.
Repair: Replace the fuel metering valve. Verify
• Not OK – One or both of the following conditions is that the repair has eliminated the original problem.
found: There is an open circuit between the master
ECM and the fuel metering valve. There is a short STOP.
circuit between the master ECM and a component
that is at ground potential.
268
Troubleshooting Section

Test Step 7. Check the Supply Voltage to Results:


the Fuel Metering Valve
• OK – The voltage is correct at the P24 plug for the
A. Ensure the following conditions: fuel metering valve. However, the fuel metering
valve is not communicating with the master ECM.
• The engine control is in the OFF/RESET mode.
Repair: Replace the fuel metering valve. Verify
• The 35 amp circuit breaker in the terminal box that the repair has eliminated the original problem.
is OFF.
STOP.
• The fuel metering valve J24/P24 connectors
are disconnected. • Not OK – The voltage is not correct at the P24
plug for the fuel metering valve. There is an open
B. Switch the 35 amp circuit breaker ON. Set the circuit or a short circuit in the harness to the fuel
engine control to the STOP mode. metering valve.

Note: The “1446-05 Fuel Metering Module open Repair: Perform the necessary repairs for the
circuit” and “1446-09 Unable to communicate with wiring and/or the connectors. Replace parts, if
Fuel Metering Module” diagnostic codes will be necessary. Ensure that all of the seals are properly
activated. installed. Ensure that the connectors are properly
engaged. Verify that the repair has eliminated the
original problem.

STOP.

i02059851

Generator Output Power


Sensor
SMCS Code: 5574-038-PWR

System Operation Description:


g00952242
Illustration 126 The ECM monitors the generator’s output power in
P24 plug on the harness for the fuel metering valve order to accurately control the air/fuel ratio. The ECM
(P24-K) Unswitched +Battery uses a load signal from one of the following sources
(P24-L) −Battery in order to monitor the generator’s output power:
(P24-M) Switched +Battery
• Electronic Modular Control Panel II+ (EMCP II+)
C. Use a multimeter to measure the voltage between
the following terminals of the harness connector • Programmable Logic Controller (PLC)
for the fuel metering valve:
• Wattmeter
• P24-M and P24-L
The PLC and the wattmeter are also called power
• P24-K and P24-L sensors.

Expected Result: Only one load signal is connected to the ECM. If


the generator is equipped with the EMCP II+, the
The voltage between terminals P24-M and P24-L is ECM receives the load signal from the Generator
between 22.0 VDC and 24.0 VDC. Set Control + (GSC+) via the CAT data link. If
the generator is not equipped with the EMCP II+,
The voltage between terminals P24-K and P24-L the ECM receives the load signal from a power
terminals is 22.0 VDC and 24.0 VDC. sensor via terminal J1-25. The load signal from the
power sensor is an analog voltage. The load signal
increases from 0 VDC to 4.8 VDC as the generator’s
output increases to the maximum output.

1719-03 Diagnostic Code


269
Troubleshooting Section

On powerup, the ECM will start requesting


information on the generator’s load from the GSC+
via the CAT data link. If two seconds elapse and the
ECM does not receive a response from the GSC+,
the ECM will look for a load signal on terminal J1-25.
If there is no load signal on terminal J1-25, the ECM
will generate a 1719-03 diagnostic code. If the engine
is running, the engine will shut down.

A 1719-03 diagnostic code is also generated if the


voltage on terminal J1-25 ever exceeds 4.8 VDC. If
the engine is running, the engine will shut down.

1719-04 Diagnostic Code

This code only applies to engines that are equipped


with a power sensor.

If the engine load is greater than 20 percent and the


voltage on terminal J1-25 is less than 0.2 VDC, the
ECM will generate a 1719-04 diagnostic code. If the
engine is running, the engine will shut down.

1719-12 Diagnostic Code

This code only applies to engines that are equipped


with the EMCP II+.

The ECM calculates two values that represent the


engine’s load. One value is calculated by using the
information on the generator’s load from the GSC+.
The other value is calculated from the following
inputs:

• The value of the “Fuel Quality” parameter Illustration 127


g01064082

Schematic of the power sensor’s input with EMCP II+


• Inlet air temperature and pressure
For the actual wiring, refer to the generator’s schematic diagram.
• Other factors
The ECM compares the two values. If the value that
is calculated by using the information from the GSC+
is not within 20 percent of the other value, the ECM
will generate a 1719-12 diagnostic code. If the engine
is running, the engine will shut down.
270
Troubleshooting Section

Test Step 1. Inspect the Electrical


Connectors and Wiring

g01054206
Illustration 129

A. Set the engine control to the OFF/RESET mode.


Switch 35 amp circuit breaker (1) to the OFF
position.

Note: For the following steps, refer to


Troubleshooting, “Inspecting Electrical Connectors”.

g01064159
Illustration 128
Schematic of the power sensor’s input with a power sensor
For the actual wiring, refer to the generator’s schematic diagram.
The potentiometer is optional. For further information, refer to
Troubleshooting, “Generator Output Power Sensor - Calibrate”.

g01064163
Illustration 130
Terminal box
(2) J1/P1 connectors for the ECM
(3) J6/P6 connectors for the wiring from the power sensor

B. Thoroughly inspect the following components:

• ECM J1/P1 connectors


271
Troubleshooting Section

• J6/P6 connectors on the terminal box c. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the circuit for the
• The wiring and the connections between the power sensor.
ECM and the GSC+ (if equipped)
d. Check the harness and wiring for abrasion and
• The wiring and the connections between the for pinch points between the power sensor and
ECM and the power sensor (if equipped) the ECM.

a. Check the torque of the allen head screw for Expected Result:
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in). All connectors, pins, and sockets are connected
properly. The connectors and the wiring do not have
b. Check the torque of the allen head screws for corrosion, abrasion, or pinch points.
the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in). Results:

• OK – The components are in good condition with


proper connections. Proceed to Test Step 2.

• Not OK – The components are not in good


condition and/or at least one connection is
improper.

Repair: Perform the necessary repairs and/or


replace parts, if necessary.

STOP.

Test Step 2. Check for a Diagnostic Code


g01013245
Illustration 131 A. Connect the Cat Electronic Technician (ET) to the
Harness side of the ECM P1 connector service tool connector. Refer to Troubleshooting,
(P1-8) Cat data link + “Electronic Service Tools”.
(P1-9) Cat data link −
(P1-19) Load signal + B. Start the engine and run the engine. Attempt to
(P1-25) Load signal − apply at least a 30 percent load to the generator.

C. Observe the “Active Diagnostic” screen on ET.


Allow a minimum of 30 seconds for any codes to
activate. Look for these codes:

• 1719-03
• 1719-04
• 1719-12
D. Stop the engine.

Expected Result:

There are no active codes for the generator output


power sensor.

Results:

• No active codes – There are no active codes for


Illustration 132
g00952302 the generator output power sensor. There may be a
Harness side of the J6 connector
logged code for the generator output power sensor.
(J6-3) Load signal +
(J6-7) Cat data link +
(J6-13) Load signal −
(J6-17) Cat data link −
272
Troubleshooting Section

Repair: If there is a logged code for the Repair the harness or the connection, when
generator output power sensor, there may be possible. Replace parts, if necessary. Verify that
a problem with the wiring and/or a connector. the problem is resolved.
Refer to Troubleshooting, “Inspecting Electrical
Connectors”. STOP.

STOP. Test Step 4. Check the “Load Signal”


Wiring for Continuity
• Active 1719-03 code – There is an active 1719-03
code. If the generator is equipped with EMCP II+, Note: A potentiometer may be installed in the “load
proceed to Test Step 7. Otherwise, proceed to Test signal” wiring. A high resistance reading may be
Step 3. caused by the potentiometer.

• Active 1719-04 code – There is an active 1719-04 A. Check the continuity of the wiring between P1-25
code. Proceed to Test Step 5. and the power sensor.

• Active 1719-12 code – There is an active 1719-12 B. Check the continuity of the wiring between P1-19
code. Proceed to Test Step 7. and the power sensor.

Test Step 3. Check the “Load Signal” Expected Result:


Wiring for a Short Circuit
The “load signal” wiring has continuity.
A. Disconnect the P1 connector from the ECM.
Results:
B. Disconnect the “load signal” wires from the power
sensor. • OK – The “load signal” wiring has continuity.
Proceed to Test Step 6.
C. Check for continuity between P1-25 and all the
other terminals on the P1 connector. • Not OK – The “load signal” wiring has an open
circuit. The open circuit may be in a wire, in a
D. Check for continuity between P1-19 and all the connector, or in the potentiometer.
other terminals on the P1 connector.
Repair: Repair the component, when possible.
Expected Result: Replace parts, if necessary. Verify that the original
problem is resolved.
Each continuity check indicates an open circuit.
STOP.
Results:
Test Step 5. Check the “Load Signal +”
• OK – Each continuity check indicates an open Wire for a Short Circuit
circuit. The “load signal” wiring does not have a
short circuit. A. Verify that the engine control is in the OFF/RESET
mode and that the 35 amp circuit breaker is OFF.
Repair: Reconnect the P1 connector. Reconnect
the “load signal” wires to the power sensor. Be B. Disconnect the P1 connector from the ECM.
sure to observe the correct polarity.
C. Disconnect the “load signal +” wire from the power
Proceed to Test Step 4. sensor.

• Not OK – At least one continuity check indicates D. Check for continuity between P1-25 and all the
a short circuit. other terminals on the P1 connector.

Repair: The problem may be between the P1 Expected Result:


connector and the J6 connector. Alternatively, the
problem may be between the J6 connector and Each continuity check indicates an open circuit.
the power sensor.
Results:

• OK – Each continuity check indicates an open


circuit. The “load signal +” wire does not have a
short circuit.
273
Troubleshooting Section

Repair: Reconnect the P1 connector. Reconnect E. Measure the resistance between the points that
the “load signal +” wire to the power sensor. are listed in Table 21. During each measurement,
wiggle the wires in the harness in order to check
Proceed to Test Step 6. for an intermittent problem. Be sure to wiggle the
wires near each of the connectors.
• Not OK – At least one continuity check indicates
a short circuit. There is a short circuit in a harness Table 21
or in a connector. Resistance Measurements for the Cat Data Link

Repair: The problem may be between the P1 Connector and Terminal Connector and Terminal
connector and the J6 connector. Alternatively, the P1-8 Terminal 19 on the GSC+
problem may be between the J6 connector and the
generator output power sensor. P1-9 Terminal 20 on the GSC+
P1-8 Ground strap for the ECM
Repair the harness or the connection, when
possible. Replace parts, if necessary. Verify that P1-9 Ground strap for the ECM
the problem is resolved.
Expected Result:
STOP.
Each check of the resistance between the terminals
Test Step 6. Check the Power Sensor, the is less than 5 Ohms.
Potential Transformers, and the Current
Transformers Each check of the resistance between the terminals
and the ground strap is greater than 20,000 Ohms.
Verify that the power sensor, the potential
transformers, and the current transformers are Results:
operating correctly. Refer to the appropriate service
literature for the components. • OK – Each check of the resistance for the Cat
data link is within the specification. The wiring for
Expected Result: the Cat data link appears to be OK.
The components are operating correctly. Repair: Perform the following procedure:
Results: 1. Reconnect the wiring to the GSC+. Be sure to
connect each wire to the appropriate terminal.
• OK – The components are operating correctly.
Proceed to Test Step 13. 2. Reconnect the P1 connector.

• Not OK – At least one of the components is not Proceed to Test Step 8.


operating correctly.
• Not OK – At least one check of the resistance for
Repair: Repair the component, when possible. the Cat data link is incorrect. There is a problem
Replace the component, if necessary. Verify that with the wiring for the Cat data link.
the original problem is resolved.
Repair: Repair the connection and/or the wire,
STOP. when possible. Replace parts, if necessary. Verify
that the original problem is resolved.
Test Step 7. Check the Continuity of the
Cat Data Link STOP.
A. Set the engine control to the OFF/RESET mode. Test Step 8. Check the GSC+
Switch the 35 amp circuit breaker OFF.
Verify that the GSC+ is operating correctly. Refer to
B. Disconnect Cat ET from the service tool connector. the appropriate service literature for the EMCP II+.
C. Disconnect the wiring for the Cat data link from Expected Result:
the GSC+.
The GSC+ is operating correctly.
D. Disconnect the P1 connector from the ECM.
Results:

• OK – The GSC+ is operating correctly. Proceed to


Test Step 13.
274
Troubleshooting Section

• Not OK – The GSC+ is not operating correctly. Repair: Replace the appropriate sensor. Verify that
the original problem is resolved.
Repair: Repair the GSC+. Refer to the appropriate
service literature for the EMCP II+. Verify that the STOP.
original problem is resolved.
Test Step 11. Check the GSC+
STOP.
Verify that the GSC+ is operating correctly. Refer to
Test Step 9. Check the “Fuel Quality” the appropriate service literature for the EMCP II+.
parameter
Expected Result:
Verify that the value of the “Fuel Quality” parameter
is correct. Use the value that is obtained from the The GSC+ is operating correctly.
Caterpillar Software, LEKQ6378, “Methane Number
Program”. Results:

Expected Result: • OK – The GSC+ is operating correctly. Proceed to


Test Step 12.
The value of the “Fuel Quality” parameter is correct.
• Not OK – The GSC+ is not operating correctly.
Results:
Repair: Repair the GSC+. Refer to the appropriate
• OK – The value of the “Fuel Quality” parameter is service literature for the EMCP II+. Verify that the
correct. Proceed to Test Step 10. original problem is resolved.

• Not OK – The value of the “Fuel Quality” parameter STOP.


is not correct.
Test Step 12. Verify that the Output Power
Repair: Enter the correct value for the parameter. Reading is Correct
Verify that the original problem is resolved.
Operate the generator at various loads. Verify that
STOP. the value of the “Generator Real kW” parameter in
Status Group 1 is within 1 percent of the generator’s
Test Step 10. Check the Sensors for the output power.
Air Inlet Manifold
Expected Result:
A. If the engine is running, stop the engine.
The value of the “Generator Real kW” parameter is
B. Connect a pressure gauge and a temperature correct.
sensor to the air inlet manifold.
Results:
C. View the Status Group 1 on Cat ET. Compare
the values on the instruments with the following • OK – The value of the “Generator Real kW”
parameters: parameter is correct. Proceed to Test Step 13.

• “Inlet manifold air pressure (abs)” • Not OK – The value of the “Generator Real kW”
parameter is incorrect.
• “Inlet air temperature”
Repair: Refer to Troubleshooting, “Generator
Expected Result: Output Power Readings Do Not Match”.

The values of the parameters are correct. STOP.

Results: Test Step 13. Check the ECM


• OK – The values of the parameters are correct. It is unlikely that the ECM has failed. Exit this
Proceed to Test Step 8. procedure and perform this procedure again. If the
problem is not resolved, temporarily install a new
• Not OK – One or both of the values of the ECM. Refer to Troubleshooting, “Replacing the
parameters are incorrect. ECM”.
275
Troubleshooting Section

Expected Result: Outside the ECM, the return wire for each primary
circuit consists of an individual wire. Internally, the
The problem is resolved when a new ECM is return wires are grouped into four groups of four
installed. circuits. The circuits are connected via diodes.
Because of the diodes, a return wire that has a
Results: short circuit to the −Battery side will affect only one
cylinder. On the other hand, a return wire that has a
• OK – The problem is resolved when a new ECM short circuit to the +Battery side will simultaneously
is installed. affect all four cylinders in the group.

Repair: Install the original ECM and verify that the For the combinations of cylinders that can be affected
problem returns. If the new ECM operates correctly by a condition, refer to Table 22.
and the original ECM does not operate correctly,
replace the ECM. Table 22
Wiring Faults and the Combinations of
STOP. Cylinders that are Affected
Wiring Fault Cylinders
• Not OK – The problem is not resolved when a new
ECM is installed. Driver side open Only one cylinder
is affected.
Repair: Reinstall the original ECM. Consult with Return side open
Caterpillar customer service for large gas engines. Return side short to ground

STOP. Cylinder 1 or 15 1 and 15


Driver side short to +Battery
Cylinder 2 or 16 2 and 16
i02059854
Driver side short to +Battery
Ignition Transformers Primary Cylinder 3 or 13 3 and 13
Circuit Driver side short to +Battery
Cylinder 4 or 14 4 and 14
SMCS Code: 1561-038 Driver side short to +Battery
Cylinder 5 or 11 5 and 11
System Operation Description: Driver side short to +Battery
The Electronic Control Module (ECM) has internal Cylinder 6 or 12 6 and 12
circuit drivers for the ignition transformers. Each Driver side short to +Battery
circuit driver creates a signal of +108 volts. The signal Cylinder 7 or 9 7 and 9
goes to the high side of the primary circuits of the Driver side short to +Battery
ignition transformers. The transformers deliver high
voltage (8000 to 37,000 volts) to the spark plugs. The Cylinder 8 or 10 8 and 10
ignition wiring is continuous from the P2 connector to Driver side short to +Battery
the individual transformers. Return side short to +Battery 1, 3, 5, and 9

The circuits for the drivers and the returns are shared 2, 4, 6, and 10
inside the ECM. Therefore, a single problem may 7, 11, 13, and 15
generate either only one diagnostic code or multiple
codes. 8, 12, 14, and 16

Circuit Drivers Because the circuits are in pairs or groups,


multiple diagnostic codes can be activated for
Each circuit driver sends signals to two cylinders. a single problem. If multiple diagnostic codes are
For this reason, a high side short circuit will affect active for the primary ignition, troubleshooting the
two cylinders. circuits one at a time is an effective way to find the
root cause.
Return Path
Logged diagnostic codes provide a historical record.
Before you begin this procedure, use the Caterpillar
Electronic Technician (ET) to print the logged codes
to a file.
276
Troubleshooting Section

The most likely causes of the diagnostic code are a


poor electrical connection or a problem in a wiring
harness. The next likely cause is a problem with
an ignition transformer. The least likely cause is a
problem with the ECM.

g01057564
Illustration 133
Schematic for the primary ignition
277
Troubleshooting Section

Test Step 1. Inspect the Electrical a. Check the torque of the Allen head screw for
Connectors and Wiring the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

g01057571
Illustration 136
Harness side of the ECM P2 connector
(P2-1) Number 1 transformer’s circuit driver
(P2-2) Number 1 transformer’s return
(P2-3) Number 2 transformer’s circuit driver
(P2-4) Number 2 transformer’s return
g01054206
Illustration 134 (P2-24) Number 3 transformer’s circuit driver
(P2-25) Number 3 transformer’s return
A. Set the engine control to the OFF/RESET mode. (P2-26) Number 4 transformer’s circuit driver
(P2-27) Number 4 transformer’s return
Switch 35 amp circuit breaker (1) to the OFF (P2-14) Number 5 transformer’s circuit driver
position. (P2-15) Number 5 transformer’s return
(P2-16) Number 6 transformer’s circuit driver
Note: For the following steps, refer to (P2-17) Number 6 transformer’s return
(P2-5) Number 7 transformer’s circuit driver
Troubleshooting, “Inspecting Electrical Connectors”. (P2-18) Number 7 transformer’s return
(P2-52) Number 8 transformer’s circuit driver
(P2-62) Number 8 transformer’s return
(P2-32) Number 9 transformer’s circuit driver
(P2-33) Number 9 transformer’s return
(P2-34) Number 10 transformer’s circuit driver
(P2-35) Number 10 transformer’s return
(P2-48) Number 11 transformer’s circuit driver
(P2-49) Number 11 transformer’s return
(P2-50) Number 12 transformer’s circuit driver
(P2-51) Number 12 transformer’s return
(P2-58) Number 13 transformer’s circuit driver
(P2-59) Number 13 transformer’s return
(P2-60) Number 14 transformer’s circuit driver
(P2-61) Number 14 transformer’s return
(P2-40) Number 15 transformer’s circuit driver
(P2-41) Number 15 transformer’s return
(P2-42) Number 16 transformer’s circuit driver
(P2-43) Number 16 transformer’s return

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


wires that are associated with the circuit of the
ignition system.

C. Check the ignition harnesses and wiring for


Illustration 135
g01057567 abrasion and for pinch points from each ignition
transformer to the ECM.
Terminal box
(2) Harness for the primary ignition from the ECM to the Expected Result:
transformers
(3) J2/P2 connectors
All connectors, pins, and sockets are connected
B. Thoroughly inspect the following connectors: properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
• ECM J2/P2 connectors
278
Troubleshooting Section

Results:

• OK – The components are in good condition with Ignition systems can cause electrical shocks.
proper connections. Proceed to Test Step 2.
Avoid contacting the ignition system components
and wiring.
• Not OK – The components are not in good
condition and/or at least one connection is
Do not attempt to remove the valve covers when
improper.
the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
Repair: Perform the necessary repairs and/or
death may result and the ignition system will be
replace parts, if necessary.
damaged if the valve covers are removed during
engine operation. The engine will not operate
STOP.
without the valve covers.
Test Step 2. Check for Diagnostic Codes
for the Primary Circuit 1. Set the engine control to the OFF/RESET
mode. Switch the 35 amp circuit breaker OFF.
A. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service
Tools”.

B. Switch the 35 amp circuit breaker ON.

C. Attempt to start the engine. Use Cat ET in order


to determine if the following codes are active or
logged:

• 301-05 Ignition Transformer Primary #1 open


circuit through 316-05 Ignition Transformer
Primary #16 open circuit

• 301-06 Ignition Transformer Primary #1 short


through 316-06 Ignition Transformer Primary
#16 short

Note: If a diagnostic code for the primary circuit is


logged but not currently active, attempt to repeat the
condition that activated the code. Run the engine to
full operating temperature. g01057615
Illustration 137

Expected Result: (1) Cover


(2) Transformer
(3) 3-pin connector
None of the above diagnostic codes are active.
2. Remove cover (1) for the suspect cylinder.
Results: Inspect the harness and 3-pin connector (3)
of transformer (2). Check for corrosion, for
• Active “open circuit” – There is an open in the abrasion, and for pinch points.
primary circuit. Proceed to Test Step 6.
3. Reconnect the connectors, and reinstall the
• Active “short” – There is a short in the primary cover.
circuit. Proceed to Test Step 3.
If the problem persists, refer to Troubleshooting,
• Logged only – There may be an intermittent “Inspecting Electrical Connectors”.
problem in the ignition harness.
STOP.
Repair: Perform the following steps:
279
Troubleshooting Section

Test Step 3. Check the Transformer’s


Primary Circuit and the Secondary Circuit

Ignition systems can cause electrical shocks.


Avoid contacting the ignition system components
and wiring.

Do not attempt to remove the valve covers when


the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
death may result and the ignition system will be
damaged if the valve covers are removed during
engine operation. The engine will not operate
without the valve covers.

A. Set the engine control to the OFF/RESET mode.


Switch the 35 amp circuit breaker OFF.

g01057616
Illustration 139
Schematic for the primary circuit and for the secondary circuit
(4) 3-pin connector for the transformer
(5) Terminal A
(6) Terminal B
(7) Blocking diode
(8) Flyback diode
(9) Primary coil of the transformer
(10) Secondary coil of the transformer
(11) Resistor
(12) Spark plug gap

E. Measure the primary circuit by checking the


voltage of the blocking diode.
g01057615
Illustration 138
(1) Cover
(2) Transformer
(3) 3-pin connector

B. Remove cover (1) for the suspect cylinder.

C. Disconnect 3-pin connector (3). Visually inspect


the 3-pin connectors for corrosion and/or for
damage.

D. Remove transformer (2) from the cylinder head.


280
Troubleshooting Section

g00863850
Illustration 141
Resistance versus temperature
(Y) Resistance in Ohms
(X) Temperature in degrees celsius (degrees fahrenheit)

a. Set the multimeter to the 40,000 Ohm scale.


Illustration 140
g01057618 Measure the resistance between mounting
flange (13) and the extension’s internal terminal
(A) + Terminal
(B) - Terminal
(14) for the spark plug.
(13) Mounting flange
(14) Connector for the spark plug Expected Result:

a. Set the multimeter to the diode scale. Connect For the primary circuit, one of the voltage
the multimeter leads to terminals (A) and (B) of measurements is approximately 0.450 VDC. The
the 3-pin connector. The polarity of the leads other voltage measurement indicates an open circuit.
is not important. Measure the voltage between
the terminals. Record the measurement. For the secondary circuit, the resistance between the
screw for the ground spring and the connector for the
b. Reverse the multimeter leads. Measure the spark plug is within the acceptable tolerance.
voltage between the terminals again. Record
the measurement. Results:

F. Measure the resistance of the secondary circuit. • OK – All three of the measurements are correct.
Note: The resistance of the secondary coil will vary Repair: Perform the following steps:
with the temperature. Illustration 141 demonstrates
the relationship between the secondary coil’s 1. Install the spark plug according to the
resistance and the temperature. A reading that is instructions in Operation and Maintenance
within 1000 Ohms is acceptable. For example, if Manual, “Ignition System Spark Plugs -
the transformer’s temperature is 60 °C (140 °F), the Check/Adjust/Replace”.
correct resistance is between 21,000 and 23,000
Ohms. 2. Switch the suspect transformer with a
transformer from a different cylinder that is
known to be good. Install the transformers.
Install the valve covers.

3. Reset the control system. Restart the engine.


Clear any logged codes.

4. Operate the engine. Check for a recurrence of


the problem.
281
Troubleshooting Section

If the problem stays with the suspect transformer, Repair: Perform the following procedure:
replace the transformer.
1. Connect the ignition harness to the transformer.
If the problem stays with the suspect cylinder,
proceed to Test Step 4. 2. Set the engine control to the START mode and
observe the “Active Diagnostic” screen of Cat
• Not OK – At least one of the three measurements ET while you crank the engine. Look for a “short
is incorrect. circuit” code.

Repair: Replace the ignition transformer. Make Replace the transformer if the original “short
sure that you use the correct transformer for circuit” code is activated.
the G3516C Engine.
If the original “short circuit” code does not
STOP. return, the problem appears to be resolved.
Resume normal operation.
Test Step 4. Check for a Short Circuit
Between the ECM and the Transformer STOP.

Test Step 5. Disconnect the Wiring From


the ECM and Check for a Short Circuit
There is a strong electrical shock hazard when the
crankshaft is rotating.

Do not touch the wires that are associated with There is a strong electrical shock hazard when the
the ignition system when the engine is cranking crankshaft is rotating.
or when the engine is running.
Do not touch the wires that are associated with
the ignition system when the engine is cranking
NOTICE or when the engine is running.
The air inlet, the cylinders, and the exhaust system
can be filled with fuel when the gas supply is ON, the
ignition system is disabled, and the engine is cranked. NOTICE
The unburned fuel can ignite unexpectedly and cause The air inlet, the cylinders, and the exhaust system
damage. can be filled with fuel when the gas supply is ON, the
ignition system is disabled, and the engine is cranked.
Turn OFF the gas supply before you perform this step. The unburned fuel can ignite unexpectedly and cause
damage.
A. Shut OFF the fuel supply. Set the engine control Turn OFF the gas supply before you perform this step.
to the OFF mode.

B. Disconnect the 3-pin connector for the suspect A. Set the engine control to the OFF/RESET mode.
transformer. Switch the 35 amp circuit breaker OFF.

C. Set the engine control to the START mode and


observe the “Active Diagnostic” screen of Cat ET
while you crank the engine.

Expected Result:

The “short” code is active when the transformer’s


connector is disconnected.

Results:

• Yes – The “short” code was activated after


the transformer’s connector was disconnected.
Proceed to Test Step 5.
g01057571
Illustration 142
• No – The original “short” code was not Harness side of the P2 connector
activated after the transformer’s connector was
disconnected.
282
Troubleshooting Section

B. Use a 151-6320 Wire Removal Tool to remove • No – The ECM continued to activate a “short
the terminal for the circuit driver of the suspect circuit” diagnostic code after the wire was
cylinder from the ECM connector. For identification disconnected from the ECM. There is a problem
of the appropriate terminal, refer to Illustration 142 with the ECM.
and Table 23.
Repair: Replace the ECM. Refer to
Table 23 Troubleshooting, “Replacing the ECM”.
Cylinder and Corresponding Terminal of the P2
Connector for the Ignition Harness STOP.
Cylinder Terminal for the Circuit Test Step 6. Create a Short Circuit in the
Driver
Ignition Harness
1 P2-1
2 P2-3
3 P2-24
Ignition systems can cause electrical shocks.
4 P2-26 Avoid contacting the ignition system components
and wiring.
5 P2-14
6 P2-16 Do not attempt to remove the valve covers when
the engine is operating. The transformers are
7 P2-5
grounded to the valve covers. Personal injury or
8 P2-52 death may result and the ignition system will be
damaged if the valve covers are removed during
9 P2-32
engine operation. The engine will not operate
10 P2-34 without the valve covers.
11 P2-48
12 P2-50 NOTICE
The air inlet, the cylinders, and the exhaust system
13 P2-58 can be filled with fuel when the gas supply is ON, the
14 P2-60 ignition system is disabled, and the engine is cranked.
The unburned fuel can ignite unexpectedly and cause
15 P2-40 damage.
16 P2-42
Turn OFF the gas supply before you perform this step.
C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. A. Shut OFF the fuel supply. Set the engine control
to the OFF/RESET mode.
D. Set the engine control to the START mode and
observe the “Active Diagnostic” screen of Cat ET B. Remove the valve cover for the suspect cylinder.
while you crank the engine.
C. Disconnect the 3-pin connector for the transformer.
Expected Result: Inspect the connectors. Verify that the connectors
do not have damage or corrosion. Inspect the
An “open circuit” diagnostic code is activated for the harness. Verify that the harness does not have
circuit after removal of the wire for the circuit driver. damage or corrosion.

Results: D. Install a jumper wire into terminals A and B of the


3-pin connector on the ignition harness.
• Yes – The ECM detected an open circuit after the
wire was disconnected from the ECM. There is a E. Set the engine control to the START mode and
short circuit in the wiring. observe the “Active Diagnostic” screen of Cat ET
while you crank the engine. Look for the original
Repair: Set the engine control to the OFF/RESET “open circuit” code.
mode. Switch the 35 amp circuit breaker OFF.
Repair the harness, when possible. Replace the Expected Result:
harness, if necessary.
The original “open circuit” code is active.
STOP.
283
Troubleshooting Section

Results: Test Step 7. Check the Engine Harness


for an Open Circuit
• Yes – The original “open circuit” code was
activated after a short circuit was created in the
ignition harness. The ECM did not detect the
jumper wire. Reconnect the ignition harness to the
transformer. Proceed to Test Step 7. There is a strong electrical shock hazard when the
crankshaft is rotating.
• No – Cat ET displayed an active “short” diagnostic
code after a short circuit was created in the ignition Do not touch the wires that are associated with
harness. The harness and the ECM are OK. the ignition system when the engine is cranking
or when the engine is running.
Repair: Perform the following steps:
NOTICE
The air inlet, the cylinders, and the exhaust system
can be filled with fuel when the gas supply is ON, the
There is a strong electrical shock hazard when the ignition system is disabled, and the engine is cranked.
crankshaft is rotating. The unburned fuel can ignite unexpectedly and cause
damage.
Do not touch the wires that are associated with
the ignition system when the engine is cranking Turn OFF the gas supply before you perform this step.
or when the engine is running.
A. Shut OFF the fuel supply. Set the engine control to
NOTICE the OFF/RESET mode. Switch the 35 amp circuit
The air inlet, the cylinders, and the exhaust system breaker to the OFF position.
can be filled with fuel when the gas supply is ON, the
ignition system is disabled, and the engine is cranked.
The unburned fuel can ignite unexpectedly and cause
damage.

Turn OFF the gas supply before you perform this step.

1. Set the engine control to the OFF/RESET


mode. Switch the 35 amp circuit breaker OFF.

2. Remove the jumper wire from the 3-pin


connector of the ignition harness.

3. Reconnect the ignition harness to the


g01057571
transformer. Illustration 143
Harness side of the P2 connector
4. Set the engine control to the START mode and
observe the “Active Diagnostic” screen of Cat B. Use a 151-6320 Wire Removal Tool to remove
ET while you crank the engine. Look for the two terminals for the circuit driver of the suspect
original “open circuit” code. cylinder from the ECM connector. For identification
of the appropriate terminals, refer to Illustration
5. If the original “open circuit” code is activated, 143 and Table 24.
set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.

6. Replace the transformer. Make sure that you


use the correct transformer for the G3516C
Engine.

7. Clear all of the logged diagnostic codes.

STOP.
284
Troubleshooting Section

Table 24 2. Remove the jumper wire and reinstall the


Cylinders and Corresponding Terminals of the
terminals that were removed from the connector.
P2Connector for the Ignition Harnesses Pull on the wires in order to verify that the
terminals are fully inserted into the connector.
Cylinder Terminals for the
Cylinder 3. Repair the harness, when possible. Replace the
1 P2-1 and P2-2 harness, if necessary.
2 P2-3 and P2-4 STOP.
3 P2-24 and P2-25
• No – When the jumper wire was installed into the
4 P2-26 and P2-27 connector, a “Short circuit” diagnostic code was not
5 P2-14 and P2-15 activated. The ECM did not detect the jumper wire.
There is a problem with the ECM.
6 P2-16 and P2-17
7 P2-5 and P2-18 Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
8 P2-52 and P2-62
9 P2-32 and P2-33 STOP.

10 P2-34 and P2-35


i02059863
11 P2-48 and P2-49
12 P2-50 and P2-51
Ignition Transformers
13 P2-50 and P2-51
Secondary Circuit and Spark
14 P2-58 and P2-59 Plugs
15 P2-40 and P2-41 SMCS Code: 1555-038; 1561-038
16 P2-42 and P2-43
System Operation Description:

C. Install the ends of a jumper wire into the terminals The ignition transformers initiate combustion by
for the removed wires. This will replace the wiring providing high voltage to the spark plugs. The positive
with a short circuit. output from the secondary circuit of the transformer is
at the connection for the terminal of the transformer
D. Set the engine control to the START mode. Switch and the terminal of the spark plug. The transformers
the 35 amp circuit breaker to the ON position. are located underneath covers at the top of each
cylinder. Each transformer is grounded to the cylinder
E. Observe the “Active Diagnostic” screen of Cat head via a mounting flange.
ET while you crank the engine. Look for a “short
circuit” diagnostic code.

Expected Result:

A “short circuit” diagnostic code is activated for the


suspect cylinder. The original “open circuit” diagnostic
code is not active.

Results:

• Yes – When the jumper wire was installed into the


connector, a “short circuit” diagnostic code was
activated for the suspect cylinder. The original
“open circuit” diagnostic code was not active.
There is an open circuit in the wiring harness for
the suspect cylinder.

Repair: Perform the following steps:

1. Set the engine control to the OFF/RESET


mode. Switch the 35 amp circuit breaker OFF.
285
Troubleshooting Section

Note: Ignition transformers from Electronic Ignition


Systems (EIS) are not interchangeable with the
transformers in this engine.

Caterpillar spark plugs are high voltage devices


with internal resistors. The spark plugs operate at a
voltage that is greater than 5,000 volts.

Most ignition systems are not affected by resistance


in the secondary circuit. If a measurement of the
resistance is desired, a megohmmeter must be
used. A low voltage multimeter will not provide a
reliable reading of the resistance because oxidation
of the spark plug’s internal components will affect the
readings of those meters.

Test Step 1. Check the Status Screen of


Cat ET for the Output of the Secondary
Circuits of the Transformers

g01057652
Illustration 144
Ignition transformer and spark plug
(1) Mounting flange
(2) 3-pin connector
(3) Transformer
(4) Extension
(5) Secondary spark plug terminal Illustration 145
g01054206
(6) O-ring seal
(7) Hole in the spark plug’s precombustion chamber
A. Set the engine control to the OFF/RESET mode.
The secondary circuit of the transformer provides an Switch 35 amp circuit breaker (1) to the OFF
initial 8,000 to 37,000 volts to the spark plug. This position.
voltage ionizes the spark plug gap. This voltage is
then reduced to about 1000 volts. The total duration B. Connect Cat ET to the service tool connector.
of the spark is approximately 400 microseconds. Refer to Troubleshooting, “Electronic Service
Tools”.
The Electronic Control Module (ECM) can diagnose
the primary circuit of the ignition transformers for C. Switch the 35 amp circuit breaker ON. Set the
open circuits and/or for short circuits. Secondary engine control to the STOP mode.
open circuits and short circuits will not directly shut
down the engine. However, these conditions may D. Set up two status screens for Cat ET. Use eight
lead to misfire which can cause lugging of the engine. of the following labels for parameters on each
Lugging of the engine can cause a shutdown. status screen:

Logged diagnostic codes provide a historical record.


Before you begin this procedure, use the Caterpillar
Electronic Technician (ET) to print the logged codes
to a file.
286
Troubleshooting Section

Table 25 • Not OK – At least one of the outputs displayed a


Parameters for the Status Screens on Cat ET
value of 0 percent or a value that is greater than 90
percent. The ignition system components require
Screen 1 Screen 2 maintenance. Proceed to Test Step 2.
Group 8 Group 9
“Cylinder #1 Transformer “Cylinder #2 Transformer Test Step 2. Inspect the Transformer
Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage”
“Cylinder #3 Transformer “Cylinder #4 Transformer
Secondary Output Voltage Secondary Output Voltage Ignition systems can cause electrical shocks.
Percentage” Percentage” Avoid contacting the ignition system components
“Cylinder #5 Transformer “Cylinder #6 Transformer and wiring.
Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage” Do not attempt to remove the valve covers when
the engine is operating. The transformers are
“Cylinder #7 Transformer “Cylinder #8 Transformer grounded to the valve covers. Personal injury or
Secondary Output Voltage Secondary Output Voltage death may result and the ignition system will be
Percentage” Percentage”
damaged if the valve covers are removed during
“Cylinder #9 Transformer “Cylinder #10 Transformer engine operation. The engine will not operate
Secondary Output Voltage Secondary Output Voltage without the valve covers.
Percentage” Percentage”
“Cylinder #11 Transformer “Cylinder #12 Transformer A. Set the engine control to the OFF/RESET mode.
Secondary Output Voltage Secondary Output Voltage Switch the 35 amp circuit breaker OFF.
Percentage” Percentage”
“Cylinder #13 Transformer “Cylinder #14 Transformer
Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage”
“Cylinder #15 Transformer “Cylinder #16 Transformer
Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage”

E. Start the engine. Apply the normal load at rated


speed. Allow the engine to warm up to normal
operating temperature.

F. Observe the value of the output for the secondary


circuit of each transformer.

Expected Result:

The displayed value of the output for the secondary


circuit of each transformer is between 1 and 90
percent.
g01057615
Illustration 146
Results:
(1) Cover
(2) Transformer
• OK – The displayed value of the output for the (3) 3-pin connector
secondary circuit of each transformer is between 1
and 90 percent. The ignition system components B. Remove cover (1) for the suspect cylinder.
are operating properly.

Repair: Investigate other possible root causes of NOTICE


the problem. Troubleshoot the symptom. Refer Pulling on the wiring harness may break the wires. Do
to Troubleshooting, “Troubleshooting Without A not pull on the wiring harness.
Diagnostic Code”.
C. Disconnect the ignition harness from 3-pin
STOP. connector (3). Remove transformer (2) from the
engine.
287
Troubleshooting Section

Results:

• OK – The transformer appears to be in good


condition. Proceed to Test Step 3.

• Not OK – An inspection found a problem with the


transformer.

Repair: Repair the transformer, when possible.


Replace the transformer, if necessary. Be sure
to use the correct transformer for the G3516C
Engine.

Reset the control system. Restart the engine. Clear


the logged codes.

STOP.

Test Step 3. Check the Primary Circuit


and the Secondary Circuit

g01057657
Illustration 147
(4) Transformer
(5) Extension
(6) Secondary terminal for the spark plug
(7) O-ring seal

D. Inspect the body of transformer (4) and extension


(5) for corrosion and/or for damage.

E. Inspect internal O-ring seal (7) for damage.

F. The extension has an internal terminal for the


spark plug. Inspect the terminal for looseness,
for corrosion, and/or for damage. Insert a spark
plug into the extension and check the terminal for g01057676
Illustration 148
spring pressure. Schematic for the primary circuit and for the secondary circuit
(1) 3-pin connector for the transformer
NOTICE (2) Terminal A
The extension can be scratched and damaged with a (3) Terminal B
(4) Blocking diode
wire brush. Do not use a wire brush on the extension. (5) Flyback diode
(6) Primary coil of the transformer
(7) Secondary coil of the transformer
G. Clean any deposits from the inside of the (8) Resistor
extension. Use a 6V-7093 Brush with isopropyl (9) Spark plug gap
alcohol.
A. Measure the primary circuit by checking the
Expected Result: voltage of the blocking diode.

The transformer is in good condition.


288
Troubleshooting Section

g00863850
Illustration 150
Resistance versus temperature
(Y) Resistance in Ohms
(X) Temperature in degrees celsius (degrees fahrenheit)

a. Set the multimeter to the 40,000 Ohm scale.


Illustration 149
g01057660 Measure the resistance between mounting
flange (10) and the extension’s internal terminal
(A) + Terminal
(B) - Terminal
(11) for the spark plug.
(10) Mounting flange
(11) Connector for the spark plug Expected Result:

a. Set the multimeter to the diode scale. Connect For the primary circuit, one of the voltage
the multimeter leads to the terminal (A) and measurements is approximately 0.450 VDC. The
terminal (B) of the 3-pin connector. The polarity other voltage measurement indicates an open circuit.
of the leads is not important. Measure the
voltage between the terminals. Record the For the secondary circuit, the resistance between the
measurement. mounting flange and the secondary terminal for the
spark plug is within the acceptable tolerance.
b. Reverse the multimeter leads. Measure the
voltage between the terminals again. Record Results:
the measurement.
• OK – All three of the measurements are correct.
B. Measure the resistance of the secondary circuit. Proceed to Test Step 4.

Note: The resistance of the secondary coil will vary • Not OK – At least one of the measurements is
with the temperature. Illustration 150 demonstrates incorrect.
the relationship between the secondary coil’s
resistance and the temperature. A reading that is Repair: Make sure that the engine control is in
within 1000 Ohms is acceptable. For example, if the OFF/RESET mode and that the 35 amp circuit
the transformer’s temperature is 60 °C (140 °F), the breaker is OFF. Replace the ignition transformer.
correct resistance is between 21,000 and 23,000 Make sure that you use the correct transformer
Ohms. for the G3516C Engine.

STOP.

Test Step 4. Check the Spark Plug


A. Switch the 35 amp circuit breaker OFF.
289
Troubleshooting Section

Expected Result:

A diagnostic code is not generated.

Results:

• OK – A diagnostic code is not generated. Proceed


with normal operation. STOP.
g01057662
Illustration 151
Spark plug that has a precombustion chamber • Not OK – A diagnostic code is generated. Proceed
to Test Step 6.
B. Perform the following procedures according to
the instructions in the engine’s Operation and Test Step 6. Isolate the Spark Plug and
Maintenance Manual. the Transformer

a. Remove the spark plug from the cylinder head. A. Switch the suspect transformer with a transformer
from a different cylinder that is known to be good.
b. Inspect the spark plug. Install the transformers. Install the covers.

c. Clean the spark plug. B. Reset the control system. Clear any logged
diagnostic codes.
Note: For a spark plug with a precombustion
chamber, the resistance cannot be measured. C. Start the engine and operate the engine in order
The minimum service life of a spark plug with a to generate the diagnostic code again.
precombustion chamber is approximately 3000
service hours. The spark plug may be good for a Expected Result:
considerable period beyond 3000 service hours.
Experience at the particular site will help to determine The diagnostic code is generated for the suspect
the proper interval for replacement of the spark plug. transformer.

Expected Result: Results:

The spark plug is in good condition. • Yes – The diagnostic code is generated for the
suspect transformer.
Results:
Repair: Make sure that the engine control is in
• OK – The spark plug is in good condition. Proceed the OFF/RESET mode and that the 35 amp circuit
to Test Step 5. breaker is OFF. Replace the faulty transformer.
Make sure that you use the correct transformer
• Not OK – The spark plug is not in good condition. for the G3516C Engine. Reset the control system.
Clear any logged diagnostic codes.
Repair: Discard the spark plug. Install a new spark
plug according to the instructions in the engine’s STOP.
Operation and Maintenance Manual.
• No – The diagnostic code is generated for the
Reset the control system. Restart the engine. Clear original cylinder.
the logged codes.
Repair: Make sure that the engine control is
STOP. in the OFF/RESET mode and that the 35 amp
circuit breaker is OFF. Install a new spark plug
Test Step 5. Operate the Engine according to the instructions in Operation and
Maintenance Manual, “Ignition System Spark
A. Install the spark plug according to the instructions Plugs - Check/Adjust/Replace”. Reset the control
in the engine’s Operation and Maintenance system. Clear any logged diagnostic codes.
Manual.
STOP.
B. Install the transformer and the cover.

C. Reset the control system. Clear any logged


diagnostic codes.

D. Start the engine and operate the engine in order


to generate the diagnostic code again.
290
Troubleshooting Section

i01811734

Inspecting Electrical
Connectors
SMCS Code: 7553-040-WW

System Operation Description:

Many of the troubleshooting procedures direct you


to a specific electrical connector. Use the following
test steps to help determine whether the connector
is the cause of the problem. If a problem is found in
a connector, repair the connector and verify that the
problem is corrected.

Intermittent electrical problems are often caused


by poor connections. Always check for an active
diagnostic code before you open any connection.
Immediately after you reconnect the connector, check
for codes again. Sometimes, simply disconnecting
g00700064
a connector and then reconnecting the connector Illustration 153
can solve a problem. If this occurs, the following
conditions are likely causes: Deutsch connectors have a plastic housing. The pins
and the sockets are crimped onto the electrical wires.
• Loose terminals The connector has a locking mechanism in order to
hold the pins and the sockets. These connectors are
• Bent terminals repairable without cutting the wires.

• Improperly crimped terminals


• Improperly mated connectors
• Moisture
• Corrosion

g00700045
Illustration 152

The MS connectors have a metal housing. The pins


and the sockets are soldered to the electrical wires.
The solder connections are usually protected by a
chemical potting which prevents access to the solder
point.
291
Troubleshooting Section

g00928006
Illustration 154

Use the following test steps in order to thoroughly Repair: Repair the connectors and/or replace the
inspect the connectors and determine if the connectors. Reconnect all of the connectors.
connectors are the cause of the problem.
STOP.
Test Step 1. Check the Connectors.
Test Step 2. Check the Allen Head Screw
A. Always set the engine control to the OFF/RESET on the Rectangular Connectors
mode before you inspect electrical conductors.
Switch the 35 amp circuit breaker OFF. A. Ensure that each allen head screw is properly
tightened. Be careful not to overtighten the screw
B. For the MS connectors, make sure that the and break the screw.
receptacle is turned fully in the clockwise direction.
Check that the threading is properly aligned and B. When you connect a 70-pin connector to an
securely mated. Electronic Control Module (ECM), do not exceed
6 ± 1 N·m (55 ± 9 lb in) of torque on the screw.
C. For the Deutsch HD connectors, make sure that
the plug and the receptacle are aligned properly C. When you connect a rectangular connector to
with the index markings. Make sure that the the terminal box, do not exceed 2.25 ± 0.25 N·m
receptacle is turned fully in the clockwise direction. (20 ± 2 lb in) of torque on the screw.
Verify that the receptacle is clicked into the locked
position. Make sure that the two halves cannot Expected Result:
be pulled apart.
Each rectangular connector is secure and the allen
D. For the Deutsch DT style, make sure that the head screw is properly torqued.
orange wedge is used in order to lock the pins.
Check that the receptacle has clicked into the Results:
locked position. Make sure that the two halves
cannot be pulled apart. • OK – Proceed to Test Step 3.
Expected Result: • Not OK
All connectors are properly mated and free of Repair: Repair the connector or replace the
damage. connector, as required.

Results: Verify that the repair eliminates the problem.

• OK – Proceed to Test Step 2. STOP.

• Not OK
292
Troubleshooting Section

Test Step 3. Perform a Pull Test on Each c. Switch the 35 amp circuit breaker ON. Set
Wire Connection. the engine control to the STOP mode. Then
start the engine. Run the engine under normal
A. Each terminal and each connector should easily operating conditions.
withstand 45 N (10 lb) of pull and each wire should
remain in the connector body. This test checks d. Monitor the “Active Diagnostic Code” screen
whether the wire was properly crimped in the on Cat ET while you pull on all harnesses and
terminal and whether the terminal was properly connectors for the circuit with the active code.
inserted into the connector.
If the harness is being pulled and the active
B. The DT connectors use an orange wedge to lock diagnostic code disappears, there is a problem
the terminals in place. Ensure that the orange in the wiring or the connector.
wedge is not missing and that the orange wedge
is installed properly on the DT connectors. B. If there are no active diagnostic codes that pertain
to the circuit, perform the following test:
Note: Terminals should ALWAYS be crimped onto
the wires with a crimp tool. Do not solder terminals. a. Run the engine under normal operating
Use the 1U-5804 Crimp Tool. conditions.

Expected Result: b. Monitor the “Display Status” screen on Cat ET


while you pull on all harnesses and connectors
Each terminal and each connector easily withstands for the circuit.
45 N (10 lb) of pull and each wire remains in the
connector body. If the harness is being pulled and the reading
changes erratically, there is a problem in the
Results: wiring or the connector.

• OK – Proceed to Test Step 4. C. If there are no active diagnostic codes and there
are complaints about intermittent changes in
• Not OK speed or power cutouts, perform the following test:

Repair: Repair the circuit. a. Run the engine under normal operating
conditions.
Verify that the repair eliminates the problem.
b. Listen for speed burps or power cutouts while
STOP. the wiring and/or the connectors are pulled.

Test Step 4. Monitor the Electronic If the harness is being pulled and the engine
Service Tool While the Wiring and the has a speed burp or a power cutout, there could
Connectors Are Being Pulled. be a problem in the wiring or the connector.

Expected Result:

The problem appears to be external to the harnesses


There is a strong electrical shock hazard when and connectors. Pulling on the harness and on the
the crankshaft is rotating. Do not touch wires that connectors does not affect the active diagnostic
are associated with the ignition transformer cir- code, component status, or engine performance.
cuit when the engine is cranking or running.
Results:
A. If there is an active diagnostic code that pertains
to the circuit, perform the following steps: • OK – Proceed to Test Step 5.
a. Set the engine control to the OFF/RESET • Not OK
mode. Switch the 35 amp circuit breaker OFF.
Repair: Set the engine control to the OFF/RESET
b. Connect the Caterpillar Electronic Technician mode. Switch the 35 amp circuit breaker OFF.
(ET) to the service tool connector on the Repair the circuit.
terminal box.
Verify that the repair eliminates the problem.

STOP.
293
Troubleshooting Section

Test Step 5. Check Wires for Nicks or Test Step 6. Check the Connectors for
Abrasion in the Insulation. Moisture or Corrosion.
A. Set the engine control to the STOP mode. Allow
the engine to coast to a stop.

B. Set the engine control to the OFF/RESET mode.


Switch the 35 amp circuit breaker OFF.

C. Carefully inspect each wire for signs of abrasion,


of nicks, or of cuts.

The following areas are likely locations:

• Places with exposed insulation


• Points with wiring that rubs against the engine
• Places with wiring that rubs against a sharp
point

D. Check all of the hold down clamps for the harness


in order to verify that the harness is properly
clamped. Also, check all of the hold down Illustration 155
g00690571
clamps in order to verify that the harness is not
compressed by the clamps. Pull back the harness A. Ensure that the connector seals and the white
sleeves in order to check for flattening of the wires sealing plugs are in place. If any of the seals
by the clamps. or plugs are missing, replace the seal or plug. If
necessary, replace the connector.
Expected Result:

The wires do not have abrasion, nicks, or cuts and


the harness is properly clamped.

Results:

• OK – Proceed to Test Step 6.


• Not OK
Repair: Repair the wires or replace the wires, as
required.

Verify that the repair eliminates the problem.

STOP.

g00690568
Illustration 156

B. Check all of the wiring harnesses in order to verify


that the harness does not make a sharp bend
out of a connector. This will deform the connector
seal and this will create a path for the entrance
of moisture.

Thoroughly inspect each ECM connector for


evidence of moisture entry.
294
Troubleshooting Section

Note: It is normal to see some minor seal abrasion Verify that the repair eliminates the problem by
on the ECM connector seals. Minor seal abrasion will running the engine for several minutes and by
not allow the entry of moisture. checking again for moisture. If moisture reappears,
the moisture is wicking into the connector. Even
If moisture or corrosion is evident in the connector, if the moisture entry path is repaired, it may
the source of the moisture entry must be found and be necessary to replace the wires that have
the source of the moisture entry must be repaired. If moisture. These wires may have moisture that is
the repair is not made, the problem will recur. Simply trapped inside the insulation. Verify that the repair
drying the connector will not fix the problem. The eliminates the problem.
following list includes likely paths for the entrance
of moisture: STOP.

• Missing seals or plugs Test Step 7. Inspect the Connector


Terminals.
• Improperly installed seals or plugs
Verify that the terminals are not damaged. Verify that
• Nicks in exposed insulation the terminals are properly aligned in the connector
and verify that the terminals are properly located in
• Improperly mated connectors the connector.

Moisture can also wick from one connector through Expected Result:
the inside of a wire to an ECM connector. If moisture
is found in an ECM connector, thoroughly check all The terminals are properly aligned and the terminals
connectors and wires on the harness that connects to appear undamaged.
the ECM. The ECM is not the source of the moisture.
Do not replace an ECM if moisture is found in either Results:
ECM connector.
• OK – Proceed to Test Step 7.
Note: If corrosion is evident on the pins, sockets or
the connector, use only denatured alcohol to remove • Not OK
the corrosion. Use a cotton swab or a soft brush
to remove the corrosion. Do not use any cleaners Repair: Repair the terminals and/or replace the
that contain 1,1,1 trichloro-ethylene because 1,1,1 terminals, as required.
trichloro-ethylene may damage the connector.
Verify that the repair eliminates the problem.
Expected Result:
STOP.
All of the connectors are completely coupled and all
of the seals are completely inserted. The harness
and the wiring does not have corrosion, abrasion,
or pinch points.

Results:

• OK – Proceed to Test Step 7.


• Not OK
Repair: Repair the circuit. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled.
295
Troubleshooting Section

Test Step 8. Check the Individual i02060035


Retention of the Pins and Sockets.
Integrated Temperature
Sensing Module (ITSM)
SMCS Code: 1901-038

System Operation Description:

The Integrated Temperature Sensing Module (ITSM)


monitors type K thermocouples at each cylinder
exhaust port and at the inlets and outlets for both
turbochargers. The ITSM can also calculate the
average temperature for each cylinder bank (left and
right). Temperature readings of the thermocouples
are available over the CAT data link for use by the
Electronic Control Module (ECM) and other modules.
The temperatures can be viewed on the Caterpillar
Electronic Technician (ET).

The ITSM generates event codes for each of the


following programmable conditions:
g00690572
Illustration 157 • High exhaust temperature
Note: This is especially important for intermittent • High deviation of an exhaust port temperature
problems.
• Low deviation of an exhaust port temperature
A. One at a time, insert a new pin into each socket.
Make sure that the pin is properly gripped by the • High inlet temperature to the turbocharger turbine
socket.
• High outlet temperature from the turbocharger
B. One at a time, insert a new socket onto each pin. turbine
Make sure that the pin is properly gripped by the
socket. Verify that the socket holds the pin when A diagnostic code is generated by the ITSM for the
the connector hangs freely. circuit of any thermocouple that is shorted to the
+Battery side, shorted to ground, or open.
Expected Result:
Logged diagnostic codes provide a historical record.
Each socket firmly grips each pin. Before you begin this procedure, use Cat ET to print
the logged codes to a file.
Results:
This troubleshooting procedure may generate
• OK – The pins and sockets mate properly. STOP. additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
• Not OK – The pins and sockets do not mate Clear the diagnostic codes after the problem is
properly. resolved.

Repair: Repair any bad pins and sockets. Replace


the connectors, if necessary. Replace the wiring, if
necessary.

Verify that the repair eliminates the problem.

STOP.
296
Troubleshooting Section

g01057709
Illustration 158
Schematic for the circuit of the ITSM
297
Troubleshooting Section

Test Step 1. Inspect the Electrical • J7/P7 and J9/P9 connectors on the terminal box
Connectors and Wiring
a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (53 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054206
Illustration 159 g01057724
Illustration 161
Harness side of the ECM P1 connector
A. Set the engine control to the OFF/RESET mode.
Switch 35 amp circuit breaker (1) to the OFF (P1-8) CAT data link +
(P1-9) CAT data link −
position.

Note: For the following steps, refer to c. Perform a 45 N (10 lb) pull test on each of the
Troubleshooting, “Inspecting Electrical Connectors”. wires that are associated with the circuit for
the ITSM.

g01057721
Illustration 160
Terminal box
(2) J1/P1 connectors for the ECM
(3) J7/P7 connectors for the harness from the ITSM
(4) J9/P9 connectors for the CAT Data Link

B. Thoroughly inspect each of the following


connectors:

• J1/P1 connectors
298
Troubleshooting Section

g01057727
Illustration 162
Thermocouples
(5) Thermocouple for the temperature of a (6) Thermocouple for the temperature of the (7) Thermocouples for the temperature of
cylinder exhaust port exhaust inlet to the turbocharger turbine the turbocharger exhaust outlets

d. Carefully inspect the connectors for each of


the thermocouples. Check the harnesses and
wiring for abrasion and for pinch points from
each thermocouple to the ITSM.

g01057730
Illustration 163
ITSM
(8) 54-pin connectors for the harness to the thermocouples
(9) ITSM
(10) 14-pin connectors for the harness to the terminal box for
the ECM
299
Troubleshooting Section

e. Thoroughly inspect 54-pin connectors (8) and Repair: If any of the codes are logged, there may
14-pin connectors (10) for ITSM (9). Check be an intermittent condition that is causing the
the harnesses and wiring for abrasion and for codes to be generated. If the engine is not running
pinch points from the ITSM to the ECM. properly, refer to Troubleshooting, “Troubleshooting
Without a Diagnostic Code”.
Expected Result:
STOP.
All of the connectors, pins, and sockets are connected
properly. The connectors and the wiring do not have • Active “short to ground” or “short to +batt” – At
corrosion, abrasion, or pinch points. least one “short to ground” or “short to +batt”
diagnostic code is active. Proceed to Test Step 3.
Results:
• Active “open circuit” – At least one “open circuit”
• OK – The components are in good condition with diagnostic code is active. Proceed to Test Step 4.
proper connections. Proceed to Test Step 2.
Test Step 3. Create an Open Circuit
• Not OK – The components are not in good
condition and/or at least one connection is A. Set the engine control to the OFF/RESET mode.
improper. Switch the 35 amp circuit breaker OFF.

Repair: Perform the necessary repairs and/or B. Disconnect the connector for the thermocouple
replace parts, if necessary. If the wiring harness with the short circuit diagnostic code.
from the thermocouples to the ITSM requires
repair, replace the harness in order to ensure C. Switch the 35 amp circuit breaker ON. Set the
reliable operation. engine control to the STOP mode.

All of the wiring from the thermocouples to the D. Access the “Active Diagnostic” screen for the
ITSM must be type K. The polarity of the wires ITSM on Cat ET. Allow a minimum of 30 seconds
from each thermocouple to the ITSM must be for any diagnostic codes to be generated.
maintained in order for the ITSM to read the correct
temperatures. Expected Result:

STOP. There is an active “open circuit” diagnostic code for


the disconnected thermocouple.
Test Step 2. Verify the Active Diagnostic
Codes Results:

A. Access the “Active Diagnostic” screen for the • Yes – There is an active “open circuit” diagnostic
ITSM on Cat ET. Determine if any of the following code for the disconnected thermocouple. The
diagnostic codes for the thermocouples are active: ITSM and the harness are OK.

• 1489-03 through 1492-03 (“short to +batt”) Repair: Perform the following procedure:

• 1489-04 through 1492-04 (“short to ground”) 1. Thoroughly inspect the thermocouple’s


connectors. Ensure that the connectors and the
• 1489-05 through 1492-05 (“open circuit”) seals are in good condition.

• 1531-03 through 1546-03 (“short to +batt”) 2. Reconnect the thermocouple’s connectors and
check for an active short circuit diagnostic code.
• 1531-04 through 1546-04 (“short to ground”)
If the short circuit diagnostic code becomes
• 1531-05 through 1546-05 (“open circuit”) active again, there is a problem with the
thermocouple.
Expected Result:
3. Disconnect the suspect thermocouple and
None of the above diagnostic codes for the connect a thermocouple that is known to be
thermocouples are active. good. Do not install the thermocouple into the
engine yet.
Results:
4. Check for an active short circuit diagnostic code.
• No Active Codes – None of the above diagnostic
codes for the thermocouples are active.
300
Troubleshooting Section

If the diagnostic code is not generated with If the open circuit diagnostic code becomes
the good thermocouple, remove the suspect active again, there is a problem with the
thermocouple from the engine. Install the good thermocouple.
thermocouple.
3. Disconnect the suspect thermocouple and
5. Clear the logged diagnostic codes. connect a thermocouple that is known to be
good. Do not install the good thermocouple into
STOP. the engine yet.

• No – There is not an active “open circuit” diagnostic 4. Check for an active open circuit diagnostic code.
code for the disconnected thermocouple. There
is a short circuit between the harness for the If the diagnostic code is not generated with
thermocouple and the ITSM. Proceed to Test Step the good thermocouple, remove the suspect
5. thermocouple from the engine. Install the good
thermocouple.
Test Step 4. Create a Short Circuit
5. Clear the logged diagnostic codes.
A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. STOP.

B. Disconnect the connector for the thermocouple • No – When the jumper wire was installed, the
with the open circuit diagnostic code. “open circuit” diagnostic code recurred. There is
probably an open circuit in the harness between
C. Install a jumper wire into terminals A and B on the the ITSM and the connector for the thermocouple.
harness connector for the suspect thermocouple.
Repair: Remove the jumper wire.
D. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. Proceed to Test Step 5.

E. Access the “Active Diagnostic” screen for the Test Step 5. Check the ITSM
ITSM on Cat ET. Allow a minimum of 30 seconds
for any diagnostic codes to be generated. Observe A. Set the engine control to the OFF/RESET mode.
the “Active Diagnostic” screen. Switch the 35 amp circuit breaker OFF.

F. Remove the jumper wire and observe the “Active B. Disconnect the 54-pin connector from the ITSM.
Diagnostic” screen. Allow a minimum of 30 Thoroughly inspect the 54-pin connectors. Ensure
seconds for any diagnostic codes to be generated. that the connectors are in good condition.

Expected Result: C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.
When the jumper wire was installed, a “short circuit”
diagnostic code was generated. When the jumper Note: When the 54-pin connectors are disconnected,
wire was removed, the “open circuit” diagnostic code an active “open circuit” diagnostic code will be
recurred. generated for all of the thermocouples. This is
normal. Only pay attention to the diagnostic codes for
Results: the suspect thermocouple.

• Yes – When the jumper wire was installed, a D. Access the “Active Diagnostic” screen for the
“short circuit” diagnostic code was generated. ITSM on Cat ET. Allow a minimum of 30 seconds
When the jumper wire was removed, the “open for any diagnostic codes to be generated. Observe
circuit” diagnostic code recurred. The ITSM and the “Active Diagnostic” screen.
the harness are OK.
E. Set the engine control to the OFF/RESET mode.
Repair: Perform the following procedure: Switch the 35 amp circuit breaker OFF.

1. Thoroughly inspect the thermocouple’s F. Install a jumper wire into the terminals for the
connectors. Ensure that the connectors and the suspect sensor on the 54-pin connector on the
seals are in good condition. ITSM. For identification of the terminals, refer to
Illustration 158.
2. Reconnect the thermocouple’s connectors and
check for an active open circuit diagnostic code.
301
Troubleshooting Section

G. Switch the 35 amp circuit breaker ON. Set the 4. If the problem is resolved with the new ITSM,
engine control to the STOP mode. Observe the install the original ITSM and verify that the
“Active Diagnostic” screen. Allow a minimum of 30 problem returns. If the new ITSM operates
seconds for any diagnostic codes to be generated. correctly and the original ITSM does not operate
correctly, replace the original ITSM. Refer to
Expected Result: Troubleshooting, “Replacing the ITSM”.

When the 54-pin connectors were disconnected, an STOP.


“open circuit” diagnostic code was generated for the
suspect sensor. When the jumper wire was installed,
i02060037
a “short circuit” diagnostic code was generated.

Results:
PWM Sensor
SMCS Code: 5574-038
• Yes – When the 54-pin connectors were
disconnected, an “open circuit” diagnostic code System Operation Description:
was generated for the suspect sensor. When
the jumper wire was installed, a “short circuit” The engine contains the following Pulse Width
diagnostic code was generated. The ITSM is Modulated sensors (PWM):
OK. There is a problem in the harness between
the ITSM and the connector for the suspect
thermocouple.
• Engine coolant pressure (outlet)

Repair: Remove the jumper wire. Replace the


• Inlet manifold air pressure
harness in order to ensure reliable operation. Clear A PWM sensor produces a digital signal. In a digital
the logged diagnostic codes and verify that the signal, the duty cycle varies as the input condition
problem is resolved. changes. The frequency remains constant. Refer to
Illustration 164.
All of the wiring from the thermocouples to the
ITSM must be K type. The polarity of the wires
from each thermocouple to the ITSM must be
maintained in order for the ITSM to read the correct
temperatures.

STOP.

• No – Either of the following results or both of the


results occurred: When the 54-pin connectors were
disconnected, an “open circuit” diagnostic code
was not generated for the suspect sensor. When
the jumper wire was installed, a “short circuit”
diagnostic code was not generated. There may be
a problem with the ITSM.

Repair: It is unlikely that the ITSM has failed. Exit


this procedure and perform this procedure again. If
the problem is not resolved, perform the following
steps:

1. Set the engine control to the OFF/RESET


mode. Switch the 35 amp circuit breaker OFF.

2. Remove the jumper wire from the connector on


the ITSM.

3. Temporarily install a new ITSM. Refer to


Troubleshooting, “Replacing the ITSM”. Illustration 164
g00852792

Sample duty cycles that are low, medium, and high.

The Electronic Control Module (ECM) supplies 8.0 ±


0.8 VDC to each PWM sensor.
302
Troubleshooting Section

Note: Excessive pressure can generate false “noisy


signal” diagnostic codes.

If the actual inlet manifold air pressure is greater than


approximately 338 kPa (49 psi), a “106-08 Air Inlet
Pressure Sensor noisy signal” diagnostic code will be
generated. Although there is not a problem with the
sensor, the code will be generated.

If the actual engine coolant pressure is greater


than approximately 444 kPa (64 psi), a “109-08
Engine Coolant Outlet Pressure Sensor noisy signal”
diagnostic code will be generated. Although there
is not a problem with the sensor, the code will be
generated.

If a “106-08” or “109-08” diagnostic code is generated,


measure the absolute pressure with a pressure
gauge before you troubleshoot the sensor. If the
pressure is actually too high, reduce the pressure in
order to avoid activation of false diagnostic codes.

Logged diagnostic codes provide a historical record.


Before you begin this procedure, print the logged
codes to a file.

This troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.

g01057762
Illustration 165
Schematic for the PWM sensors
303
Troubleshooting Section

Test Step 1. Inspect the Electrical • J2/P2 connectors


Connectors and Wiring
• J7/P7 connectors for the harness from the PWM
sensors

• The connectors for each PWM sensor


a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054206
Illustration 166

A. Set the engine control to the OFF/RESET mode.


Switch 35 amp circuit breaker (1) to the OFF
position.
g01057769
Illustration 168
Note: For the following steps, refer to
Harness side of the P1 connector
Troubleshooting, “Inspecting Electrical Connectors”.
(P1-4) 8 volt supply
(P1-5) Return
(P1-10) Signal for inlet manifold air pressure

g01057771
Illustration 169
Harness side of the P2 connector
(P2-68) Signal for engine coolant pressure (outlet)

g01057764
Illustration 167
Terminal box for the ECM
(2) J2/P2 connectors for the ECM
(3) J1/P1 connectors for the ECM
(4) J7/P7 connectors for the PWM sensors

B. Thoroughly inspect the following connectors:

• J1/P1 connectors
304
Troubleshooting Section

g01057774
Illustration 170
Harness side of the P7 connector
(P7-1) Signal for inlet manifold air pressure
(P7-2) Signal for engine coolant pressure (outlet)
(P7-15) Return for inlet manifold air pressure
(P7-16) Return for engine coolant pressure (outlet)
(P7-29) Shield
(P7-30) Shield
(P7-43) 8 volt supply for the inlet manifold air pressure
(P7-44) 8 volt supply for the engine coolant pressure (outlet)

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


wires that are associated with the circuit for the
PWM sensors.
305
Troubleshooting Section

g01057815
Illustration 171
(5) Sensor for engine coolant pressure (6) Sensor for inlet manifold air pressure
(outlet)

d. Check the harness and wiring for abrasion and • 41-03 8 Volt DC Supply short to +batt
for pinch points from each of the PWM sensors
to the ECM. • 41-04 8 Volt DC Supply short to ground
Expected Result: Expected Result:

The connectors, pins, and sockets are connected There are no active “8 Volt DC Supply” diagnostic
properly. The connectors and the wiring do not have codes.
corrosion, abrasion, or pinch points.
Results:
Results:
• No codes – There are no active diagnostic codes
• OK – The components are in good condition with for the power supplies. Proceed to Test Step 3.
proper connections. Proceed to Test Step 2.
• Active code – There is an active diagnostic code
• Not OK – The components are not in good for the 8 volt power supply. This procedure will not
condition and/or at least one connection is work when this type of code is active.
improper.
Repair: Refer to Troubleshooting, “+8 V Sensor
Repair: Perform the necessary repairs and/or Voltage Supply”.
replace parts, if necessary.
STOP.
STOP.
Test Step 3. Check for Active Diagnostic
Test Step 2. Check for Active “8 Volt DC Codes for the PWM Sensors
Supply” Diagnostic Codes
A. Turn on the “Active Diagnostic” screen on Cat
A. Connect the Caterpillar Electronic Technician ET. Determine if any of these diagnostic codes
(ET) to the service tool connector. Refer to are active:
Troubleshooting, “Electronic Service Tools”.
• 106-03 Air Inlet Pressure Sensor open/short to
B. Switch the 35 amp circuit breaker ON. Set the +batt
engine control to the STOP mode.
• 106-08 Air Inlet Pressure Sensor noisy signal
C. Observe the “Active Diagnostic” screen on Cat ET.
Allow a minimum of thirty seconds for any codes • 109-03 Engine Coolant Outlet Pressure
to activate. Look for these codes: open/short to +batt
306
Troubleshooting Section

• 109-08 Engine Coolant Outlet Pressure noisy Results:


signal
• OK – The voltage is within the specification. The
Expected Result: correct voltage is present at the sensor connector.
Proceed to Test Step 5.
One of the above codes is active.
• Not OK – The voltage is not within the specification.
Results: The correct voltage is not present at the sensor
connector. The correct voltage must be present
• Yes – At least one of the above diagnostic codes at the sensor connector in order to continue this
is active. Proceed to Test Step 4. procedure.

• No – None of the above codes are active. Repair: Verify that the wiring and/or connectors
are OK. Repair any faulty wiring and/or connectors,
Repair: If any of the above codes are logged when possible. Replace any faulty wiring and/or
and the engine is not running properly, refer to connectors, if necessary. Refer to Troubleshooting,
Troubleshooting, “Troubleshooting Without a “Inspecting Electrical Connectors”.
Diagnostic Code”.
STOP.
If the engine is running properly at this time,
there may be an intermittent problem in the Test Step 5. Verify that +Battery Voltage
harness that is causing the codes to be logged. is Not Present in the Signal Wire
Refer to Troubleshooting, “Inspecting Electrical
Connectors”.

STOP.

Test Step 4. Verify the Supply Voltage to


the Sensor
A. Set the engine control to the OFF/RESET mode. Illustration 173
g00896299

Harness connector for the PWM sensors


B. Disconnect the suspect sensor.
(B) Return
(C) Signal
C. Set the engine control to the STOP mode.
A. At the harness connector for the suspect sensor,
measure the voltage between terminal (B) and
terminal (C).

Expected Result:

The voltage is between 7.0 VDC and 8.0 VDC.


g00896288
Illustration 172 Results:
Harness connector for the PWM sensors
(A) 8 volt supply • OK – The voltage is between 7.0 VDC and 8.0
(B) Return VDC. The battery voltage is not present in the
signal wire. Proceed to Test Step 6.
D. At the harness connector for the suspect sensor,
measure the voltage between terminals (A) and • Not OK – The voltage is approximately equal to the
(B). battery voltage. The signal wire is probably shorted
to the battery between the sensor and the ECM.
Expected Result:
Repair: Set the engine control to the OFF/RESET
The voltage is between 7.6 VDC and 8.4 VDC. mode. Switch the 35 amp circuit breaker OFF.
Repair the harness, when possible. Replace the
harness, if necessary.

STOP.
307
Troubleshooting Section

• Not OK – The voltage is approximately 0 volts. 4. Disconnect the sensor. Connect a sensor that is
The signal wire is probably shorted to ground known to be good. Do not install the new sensor
between the sensor and the ECM. into the engine yet.

Repair: Set the engine control to the OFF/RESET 5. Set the engine control to the STOP mode. Allow
mode. Switch the 35 amp circuit breaker OFF. a minimum of 30 seconds for any codes to
Repair the harness, when possible. Replace the activate.
harness, if necessary.
6. Check for an active diagnostic code. If the
STOP. code is not active for the new sensor, install
the sensor into the engine. Clear any logged
Test Step 6. Check the Signal at the diagnostic codes.
Sensor
STOP.
A. Set the engine control to the OFF/RESET mode.
Test Step 7. Check the Signal at the ECM
B. Install a 8T-8726 Adapter Cable As (Three-Pin
Breakout) at the harness connector for the suspect A. Set the engine control to the OFF/RESET mode.
sensor. Switch the 35 amp circuit breaker OFF.

C. Use a multimeter that is capable of measuring B. Insert two 7X-1710 Multimeter Probes into the
both the duty cycle and the frequency. Connect terminals that are appropriate for the suspect
the multimeter to terminal B and terminal C of the sensor.
breakout t.
The terminals for the connection of the probes are
D. Set the engine control to the STOP mode. identified in Table 26.

E. Measure the duty cycle and the frequency of the Table 26


suspect sensor. Terminals for the Connection of the Probes

Expected Result: Suspect Sensor Connector and Terminals


Engine coolant pressure J2-68 and J1-5
The duty cycle is between 5 percent and 95 percent. (outlet)

The frequency is between 400 and 600 Hz. Inlet manifold air pressure J1-10 and J1-5

Results: C. Use a multimeter that is capable of measuring


both the duty cycle and the frequency. Connect
• OK – The duty cycle is between 5 percent and the multimeter to the probes.
95 percent. The frequency is between 400 and
600 Hz. A valid signal is produced by the sensor. D. Switch the 35 amp circuit breaker ON. Set the
Proceed to Test Step 7. engine control to the STOP mode.

• Not OK – The duty cycle or the frequency is E. Measure the duty cycle and the frequency of the
incorrect. The sensor is receiving the correct suspect sensor.
supply voltage but the sensor is not producing a
valid signal. Expected Result:

Repair: Perform the following steps: The duty cycle is between 5 percent and 95 percent.

1. Thoroughly inspect the connector for the sensor The frequency is between 400 and 600 Hz.
according to Troubleshooting, “Inspecting
Electrical Connectors”. Results:

2. Check the duty cycle and the frequency of the • OK – The duty cycle is between 5 percent and 95
sensor signal again. percent. The frequency is between 400 and 600
Hz. The ECM is receiving a valid signal from the
3. If the duty cycle and the frequency of the sensor sensor.
signal are incorrect, set the engine control to
the OFF/RESET mode. Repair: Perform the following steps:

1. Set the engine control to the OFF/RESET


mode. Switch the 35 amp circuit breaker OFF.
308
Troubleshooting Section

2. Switch the 35 amp circuit breaker ON. Set the The ECM and the throttle actuator communicate
engine control to the STOP mode. via the CAN data link. The ECM sends a command
signal to the actuator. The actuator sends the
3. Check “Status Screen Group 2” on Cat ET. Look following information to the ECM: actuator position,
for a valid signal. CCM heartbeat, software version, and internal fault
diagnosis.
It is possible that the actual air inlet pressure is
less than the pressure that can be measured by If the ECM cannot communicate with the throttle
the sensor during low idle operation (26.7 kPa actuator, the ECM activates a 1440-09 diagnostic
(3.87 psi)). This causes the ECM to set the 106-03 code and the engine is shut down. A 1440-09
diagnostic code although there is no short circuit to diagnostic code is probably caused by a problem with
the +Battery side. In this case, adjust the derivative an electrical connector or a harness. The next likely
gain and the fuel quality in order to make the engine cause is a problem with the actuator. The least likely
more stable at low idle. Refer to Troubleshooting, cause is a problem with the ECM.
“System Configuration Parameters”.
Terminating resistors must be connected to each
Otherwise, verify that the ECM is receiving end of the CAN data link. The terminating resistors
the correct voltage. Refer to Troubleshooting, improve the communication between the devices. If
“Electrical Power Supply”. there is an intermittent diagnostic code for any of the
devices that are connected to the CAN data link, be
If the condition is not resolved, temporarily install sure to check the terminating resistor that is inside
a new ECM. Refer to Troubleshooting, “Replacing the terminal box. Also check the jumper wire that is
the ECM”. connected between terminals J and K on the actuator
for the bypass valve. Make repairs, when possible.
If the problem is resolved with the new ECM, Replace parts, if necessary.
install the original ECM and verify that the problem
returns. If the new ECM operates correctly and the Logged diagnostic codes provide a historical record.
original ECM does not operate correctly, replace Before you begin this procedure, use the Caterpillar
the original ECM. Refer to Troubleshooting, Electronic Technician (ET) to print the logged codes
“Replacing the ECM”. to a file.

STOP. This troubleshooting procedure may generate


additional diagnostic codes. Keep your mind on
• Not OK – The duty cycle or the frequency is correcting the cause of the original diagnostic code.
incorrect. The sensor is producing a valid signal Clear the diagnostic codes after the problem is
but the signal does not reach the ECM. There is a resolved.
problem in the harness between the sensor and
the ECM.

Repair: Repair the harness, when possible.


Replace the harness, if necessary.

STOP.

i02060038

Throttle Actuator
SMCS Code: 1716-038

System Operation Description:

The throttle actuator is an electronic actuator that


works with the Electronic Control Module (ECM) in
order to ensure the correct throttle position in all
conditions of engine operation.
309
Troubleshooting Section

g01057834
Illustration 174
Schematic for the circuit of the throttle actuator
310
Troubleshooting Section

Test Step 1. Inspect the Electrical B. Thoroughly inspect each of the following
Connectors and Wiring connectors:

• J1/P1 connectors
• J9/P9 connectors on the terminal box
• Connectors on the throttle actuator
a. Check the torque of the Allen head screw for
the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

b. Check the torque of the Allen head screws for


the connectors on the terminal box. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01054206
Illustration 175
Junction box

A. Set the engine control to the OFF/RESET position.


Switch 35 amp circuit breaker (1) to the OFF
position.

Note: For the following steps, refer to Illustration 177


g01054209
Troubleshooting, “Inspecting Electrical Connectors”. Harness side of the ECM P1 connector
(P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +

g01054200
Illustration 176
Terminal box
(2) Ground strap
(3) J1/P1 connectors for the ECM
(4) J9/P9 connectors for the CAN data link
(5) J10/P10 connectors for the terminating resistor for the CAN
data link
311
Troubleshooting Section

Expected Result:

All of the connectors, pins, and sockets are connected


properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.

Results:

• OK – The components are in good condition with


proper connections. Proceed to Test Step 2.

• Not OK – The components are not in good


condition and/or at least one connection is
improper.

Repair: Perform the necessary repairs and/or


replace parts, if necessary. Ensure that all of
the seals are properly installed. Ensure that the
connectors are properly engaged. Verify that the
repair has eliminated the original problem.

Illustration 178
g01054210 STOP.
Harness side of the ECM J9 connector
Test Step 2. Check for Diagnostic Codes
(J9-6) CAN data link +
(J9-12) CAN data link −
(J9-18) CAN shield A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector on the terminal box.
c. Perform a 45 N (10 lb) pull test on each of
the wires that are associated with the throttle B. Switch the 35 amp circuit breaker ON. Set the
actuator. engine control to the STOP mode.

C. Use Cat ET in order to determine if a 1440-09


diagnostic code is active.

Expected Result:

The 1440-09 code is not active.

Results:

• OK – The 1440-09 code is not active. The


communication between the ECM and the throttle
actuator appears to be OK at this time. However,
diagnostic codes may be logged.

Repair: If you are troubleshooting an intermittent


problem, refer to Troubleshooting, “Inspecting
Electrical Connectors”.

Terminating resistors must be connected to each


end of the CAN data link. The terminating resistors
g01057845 improve the communication between the devices.
Illustration 179
If there is an intermittent diagnostic code for any of
Right side view the devices that are connected to the CAN data
(6) Throttle actuator link, be sure to check the terminating resistor that
is inside the terminal box. Also check the jumper
d. Check the wiring for abrasion and for pinch wire that is connected between terminals J and K
points from the throttle actuator to the ECM. on the actuator for the bypass valve. Make repairs,
when possible. Replace parts, if necessary.

STOP.
312
Troubleshooting Section

• Not OK (Active 1440-09) – The ECM has detected • The fuel metering valve
a problem with the communication between the
ECM and the throttle actuator. Proceed to Test Make repairs, when possible. Replace parts, if
Step 3. necessary.

Test Step 3. Check the CAN Data Link for STOP.


Continuity Between the Throttle Actuator
and the ECM Test Step 4. Check the CAN Data Link for
a Short Circuit
A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. A. Verify that the engine control is in the OFF/RESET
mode and that the 35 amp circuit breaker is OFF.
B. Disconnect the P1 connector. Disconnect the
connector for the throttle actuator. B. Use a multimeter to check for continuity between
the points that are listed in Table 28. During each
C. Use a multimeter to check for continuity between measurement, wiggle the harnesses in order to
the points that are listed in Table 27. During each check for an intermittent problem with the harness.
measurement, wiggle the harnesses in order to Be sure to wiggle the harness near each of the
check for an intermittent problem with the harness. connectors. Be sure to wiggle the harness near
Be sure to wiggle the harness near each of the the fuel metering valve.
connectors. Be sure to wiggle the harness near
the fuel metering valve. Table 28
Points to Check for Continuity
Table 27
Connector and Terminal Connector and Terminal
Points to Check for Continuity
P1-34 (CAN Data Link −) P1-50 (CAN Data Link +)
Connector and Harness Connector for the P1-42 (CAN Shield)
Terminal Throttle Actuator P1-52 (+ Battery)
P1-34 Terminal B (CAN data link −) Ground strap for the ECM

P1-50 Terminal A (CAN data link +) P1-50 (CAN Data Link +) P1-42 (CAN Shield)
P1-52 (+ Battery)
P1-42 Terminal M (CAN shield) Ground strap for the ECM
P1-42 (CAN Shield) P1-52 (+ Battery)
Expected Result: Ground strap for the ECM

The continuity of the circuits between the terminals


Expected Result:
is good.
All of the measurements indicate an open circuit.
Results:
Results:
• OK – The continuity of the circuits between the
terminals is good. Proceed to Test Step 4.
• OK – All of the measurements indicate an open
circuit. The CAN data link does not have a short
• Not OK – At least one of the continuity checks circuit.
indicates an open circuit. There is an open circuit
for the CAN data link between the throttle actuator
Repair: Reconnect the P1 connector. Reconnect
and the ECM.
the connector for the throttle actuator.
Repair: The open circuit could be caused by a poor
Proceed to Test Step 5.
electrical connection in a connector. Alternatively,
the open circuit could be caused by one of the
following components: • Not OK – At least one of the measurements
indicate a short circuit.
• The harness inside the terminal box Repair: The short circuit could be caused by a poor
electrical connection in a connector. Alternatively,
• The harness between the terminal box and the the short circuit could be caused by one of the
fuel metering valve
following components:
• The harness between the fuel metering valve • The harness inside the terminal box
and the throttle actuator
313
Troubleshooting Section

• The harness between the terminal box and the 1. Temporarily install a new ECM. Refer to
fuel metering valve Troubleshooting, “Replacing the ECM”. If
the problem is resolved with the new ECM,
• The harness between the fuel metering valve install the original ECM and verify that the
and the throttle actuator problem returns. If the new ECM operates
correctly and the original ECM does not operate
• The fuel metering valve correctly, replace the original ECM. Refer to
Troubleshooting, “Replacing the ECM”. If the
Make repairs, when possible. Replace parts, if problem is not resolved with a new ECM, install
necessary. the original ECM. Continue with this procedure.

STOP. 2. Temporarily install a new throttle actuator. If


the new throttle actuator operates correctly,
Test Step 5. Check for Diagnostic Codes the problem is resolved. If the new throttle
actuator does not operate correctly, install the
A. Switch the 35 amp circuit breaker ON. Set the original throttle actuator and continue with this
engine control to the STOP mode. procedure.

B. Use Cat ET in order to determine if a 1440-09 3. Temporarily install a new actuator for the bypass
diagnostic code is active. valve. If the new actuator for the bypass valve
operates correctly, the problem is resolved. If
Expected Result: the new actuator for the bypass valve does not
operate correctly, install the original actuator
The 1440-09 code is not active. for the bypass valve and continue with this
procedure.
Results:
4. Temporarily install a new fuel metering valve.
• OK – The 1440-09 code is not active. The problem If the new fuel metering valve operates
seems to be resolved. The initial diagnostic correctly, the problem is resolved. If the new
code was probably caused by a poor electrical fuel metering valve does not operate correctly,
connection. install the original fuel metering valve. Refer
to Troubleshooting, “Inspecting Electrical
Repair: If there is an intermittent problem Connectors”.
that is causing the code to be logged, refer
to Troubleshooting, “Inspecting Electrical STOP.
Connectors”.

STOP.

• Not OK – The 1440-09 code is active.


Repair: The active 1440-09 code could be caused
by one of the following components:

• The ECM
• The throttle actuator
• The actuator for the bypass valve
• The fuel metering valve
It is unlikely that any of the components that are
listed above have failed. Exit this procedure and
perform this procedure again. If the 1440-09 code
remains active, perform the following procedure:
314
Troubleshooting Section

Calibration Procedures
i02059837

Engine Speed/Timing Sensor -


Calibrate
SMCS Code: 1912-524

System Operation Description:

The Electronic Control Module (ECM) has the ability


to calibrate the mechanical differences between
the Top Center (TC) of the flywheel and the TC of
the timing gear on the left rear camshaft gear. A
magnetic transducer signals the TC of the flywheel to
the ECM when the TC hole on the flywheel passes
beneath the transducer. The engine speed/timing
sensor signals the TC of the timing gear to the ECM.
Any offset between the TC of the flywheel and the TC
of the timing gear is stored into memory.

Calibration of the timing is required only after the


following circumstances:

• The ECM has been replaced.


• The timing gear and/or the rear gear train have
been adjusted.

• The timing gear and/or the rear gear train have


been replaced.

Note: The “261-13 Engine Timing calibration


required” diagnostic code is generated only for a
ECM that has never performed a timing calibration.

The calibration procedure is initiated with the


Caterpillar Electronic Technician (ET).
315
Troubleshooting Section

Test Step 1. Install the Transducer

g01055704
Illustration 180
Right side of view
(1) 6V-3093 Transducer Adapter (3) Connector for the 7X-1695 cable
(2) 6V-2197 Magnetic Transducer (4) 7X-1695 Cable

A. Set the engine control to the OFF/RESET mode. E. Connect Cat ET to the service tool connector
Remove the timing calibration plug from either the on the terminal box. For instructions, refer to
left side or the right side of the flywheel housing. Troubleshooting, “Electronic Service Tools”. Start
Install 6V-3093 Transducer Adapter (1) into the Cat ET.
hole.
Continue to the next test step.
NOTICE
The timing hole in the flywheel must not be aligned Test Step 2. Calibration
with the hole for the transducer. The transducer will
be damaged on engine start-up if the transducer is Note: A two-step process is used to calibrate
installed through both holes. Rotate the flywheel for the signal for the speed/timing sensor. The new
more than 10 degrees before or after the TC position timing reference is calculated first. The reference is
in order to move the flywheel hole away from the hole based on the signals from the transducer and the
for the transducer. Always confirm that the holes are speed/timing sensor. Next, the new timing reference
not aligned. is programmed into the permanent memory of the
ECM.

B. Make sure that the hole in the flywheel housing A. Start the engine. Operate the engine at the rated
for the transducer is not aligned with the timing speed and load.
hole in the flywheel. Remove the protective end
cap from 6V-2197 Magnetic Transducer (2). B. Select “Service” from the main menu on Cat
Insert the transducer into the adapter until the ET. Select “Calibrations” from the menu. Select
transducer contacts the surface of the flywheel. “Timing Calibration”.
Move the transducer 1 mm (0.04 inch) away from
the surface of the flywheel. Tighten the nut on the C. Use either of the following methods in order to
adapter in order to secure the transducer in place. initiate the calculation of the new timing reference:

C. Connect the one end of 7X-1695 Cable (4) to the • Press the space bar on the keyboard of the PC.
transducer. Connect the other end of the cable to
connector (3) on the side of the engine. • Click the left mouse button on the “Continue”
button in the lower left corner of the Cat ET
D. Set the engine control to the STOP mode. screen.
316
Troubleshooting Section

Cat ET will indicate “Please wait...Calculating the i02064755


new Timing Reference”. After a few moments,
Cat ET will display “The ECM has calculated the Generator Output Power
Timing Reference” and “Choose the Continue Sensor - Calibrate
button to program the Timing Reference”.
SMCS Code: 5574-524-PWR
D. Use either of the following methods in order to
program the new timing reference: System Operation Description:

• Press the space bar on the keyboard of the PC. The Electronic Control Module (ECM) must receive
an accurate signal that indicates the power output
• Click the left mouse button on the “Continue” of the generator. When the generator is stopped,
button in the lower left corner of the Cat ET the signal must be less than 0.01 VDC. The offset
screen. voltage is the voltage level of the signal when the
generator is stopped.
Expected Result:
An offset voltage above 0.01 VDC can be reduced by
After a few moments, Cat ET will display adding resistance to the circuit.
“CALIBRATION SUCCESSFUL”.
The following steps describe the procedure for adding
Results: the correct amount of resistance to the circuit in order
to reduce the offset voltage to an acceptable level.
• OK – The timing calibration was successful.
Disconnect the transducer and the cable. Remove Test Step 1. Identify the Configuration of
the adapter and reinstall the timing calibration plug. the Wiring
Replace the protective cover on the transducer.
STOP. A. Remove the electrical power from the engine.
• Not OK – Cat ET displayed “COULD NOT
CALIBRATE”. The calibration was unsuccessful.

Repair: If the calibration failed in the first step,


verify that the engine rpm was stable during the
calibration (± 50 rpm). Verify that there are no
active diagnostic codes which can prevent the
calibration. Repeat the calibration procedure.

If the calibration is still unsuccessful, check the


installation of the tools and the operation of the
tools. Check the 7X-1695 Cable for continuity.
Verify that the transducer is not bent, open,
or shorted internally. Repeat the calibration
procedure.

Excessive backlash in the gear train will cause


inconsistent timing. Refer to Disassembly and
Assembly for identifying and repairing a gear train
problem.

STOP.

• Not OK – The calibration was completed


successfully. However, the “261-13 Engine Timing
calibration required” diagnostic code is still active.

Repair: Replace the ECM according to the


instructions in Troubleshooting, “Replacing the
ECM”.

STOP.
317
Troubleshooting Section

g01058268
Illustration 181
Schematic for the wiring between the generator output power sensor and the ECM

B. Carefully inspect the wiring between the generator C. Adjust the potentiometer in order to create the
output power sensor and the ECM. Refer to minimum resistance across the terminals.
Illustration 181. Determine if a potentiometer has
been connected to the wiring. D. Refer to Illustration 181. Connect the
potentiometer to the wiring. Use 16 gauge wire in
Expected Result: order to make the connections. You may connect
the potentiometer to the positive terminal or to the
A potentiometer is connected to the wiring. negative terminal of the generator output power
sensor.
Results:
Expected Result:
• Yes – A potentiometer is connected to the wiring.
Proceed to Test Step 3. The potentiometer is connected correctly.

• No – A potentiometer is not connected to the Results:


wiring. Proceed to Test Step 2.
• OK – The potentiometer is connected properly.
Test Step 2. Install a Potentiometer Proceed to Test Step 4.

The potentiometer must have the following • Not OK – The potentiometer is not connected
characteristics: properly.

• 5000 Ohms Repair: Make repairs to the installation, as needed.

• Linear taper STOP.

• 10 turns Test Step 3. Adjust the Potentiometer to


the Minimum Value
The wattage rating of the potentiometer is not
important. 122-9457 Potentiometer meets these A. Disconnect one of the wires that is used to
specifications. connect the potentiometer to the circuit.

A. Connect the terminal for the wiper to an end B. Connect an ohmmeter to the end terminals of the
terminal. Use a piece of 16 gauge wire in order potentiometer.
to make the connection.
C. Adjust the potentiometer in order to create the
B. Connect an ohmmeter to the end terminals of the minimum resistance across the terminals.
potentiometer. Measure the resistance between
the end terminals.
318
Troubleshooting Section

D. Reconnect the wire to the circuit.

Expected Result:

The potentiometer is set to the minimum value.

Results:

• OK – The potentiometer is set to the minimum


value. Proceed to Test Step 4.

• Not OK – The potentiometer is not set to the


minimum value.

Repair: The potentiometer must be set to the


minimum value before you continue with this
procedure. Perform this Test Step again. When
the potentiometer is set to the minimum value,
continue with this procedure.

STOP.

Test Step 4. Adjust the Potentiometer


Note: The multimeter must be connected to the P1
connector.

g01058272
Illustration 182
Engine mounted terminal box
(P1-19) Return for the input from the generator output power
sensor
(P1-25) Input from the generator output power sensor

A. Insert 7X-1710 Multimeter Probes into terminals


P1-19 and P1-25. Connect a digital voltmeter to
the probes. The polarity of the connections is not
important.

B. Restore the electrical power to the engine. Set the


engine control to the STOP position.

C. Verify that the probes are making good contact


with the terminals inside the connector. Measure
the DC voltage at the terminals.

D. While you are measuring the voltage at


the terminals of the ECM, slowly adjust the
potentiometer. The voltage reading will decrease
as you increase the resistance. The adjustment
is correct when the voltage reading is between
±0.00 VDC and ±0.01 VDC. A reading of zero
VDC is ideal.
319
Troubleshooting Section

Expected Result:

The voltage decreases as the potentiometer is


adjusted. The final voltage is between ±0.0 VDC and
±0.01 VDC.

Results:

• OK – The voltage is between ±0.0 VDC and


±0.01 VDC. The calibration procedure has been
completed successfully.

Repair: Adjust the “Power Monitoring” parameters.


Refer to Systems Operation/Testing and Adjusting,
“Electronic Control System Parameters”.

STOP.

• Not OK – The potentiometer cannot be adjusted


in order to attain a DC voltage between ±0.0 VDC
and ±0.01 VDC.

Repair: Replace the potentiometer and perform


this entire procedure again.

STOP.
320
Index Section

Index
Numerics E128 Engine Oil Filter Diff Pressure Low
Shutdown........................................................... 140
+5V Sensor Voltage Supply................................. 176 E129 Engine Oil Filter Diff Pressure High
+8V Sensor Voltage Supply................................. 184 Warning ............................................................. 141
E130 Engine Oil Filter Diff Pressure High
Shutdown........................................................... 141
A E135 Low Jacket Water Pressure Shutdown ...... 141
E223 High Gas Temperature ............................... 142
Analog Sensor Signal .......................................... 191 E224 High Jacket Water Inlet Pressure............... 142
E225 Engine Overcrank ...................................... 142
E226 Driven Equipment Not Ready..................... 142
C E229 Fuel Energy Content Setting Low .............. 143
E230 Fuel Energy Content Setting High.............. 143
Calibration Procedures ........................................ 314 E231 Fuel Quality Out of Range.......................... 143
CAT Data Link ..................................................... 199 E243 High Left Turbo Turbine Outlet
Compressor Bypass ............................................ 203 Temperature....................................................... 143
Customer Passwords ............................................ 26 E244 High Right Turbo Turbine Outlet
Temperature....................................................... 144
E245 High Right Turbo Turbine Inlet
D Temperature....................................................... 144
E246 High Left Turbo Turbine Inlet Temperature.. 145
Desired Speed Input (4 - 20 mA)......................... 210 E264 Emergency Stop Activated......................... 145
Detonation ............................................................. 35 E268 Unexpected Engine Shutdown................... 145
Probable Causes ............................................... 35 E269 Customer Shutdown Requested ................ 145
Recommended Repairs ..................................... 36 E270 Driven Equipment Shutdown Requested ... 146
Detonation Sensors ............................................. 214 E337 High Engine Oil to Engine Coolant Diff
Diagnostic Codes .................................................. 63 Temp .................................................................. 146
Active Diagnostic Codes .................................... 64 E401 Cylinder #1 Detonation............................... 147
Logged Diagnostic Codes.................................. 64 E402 Cylinder #2 Detonation............................... 147
Diagnostic Functional Tests................................. 176 E403 Cylinder #3 Detonation............................... 147
Driven Equipment .................................................. 37 E404 Cylinder #4 Detonation............................... 147
Probable Causes ............................................... 37 E405 Cylinder #5 Detonation............................... 148
Recommended Repairs ..................................... 37 E406 Cylinder #6 Detonation............................... 148
E407 Cylinder #7 Detonation............................... 148
E408 Cylinder #8 Detonation............................... 148
E E409 Cylinder #9 Detonation............................... 149
E410 Cylinder #10 Detonation............................. 149
E004 Engine Overspeed Shutdown .................... 136 E411 Cylinder #11 Detonation ............................. 149
E016 High Engine Coolant Temperature E412 Cylinder #12 Detonation............................. 149
Shutdown........................................................... 136 E413 Cylinder #13 Detonation............................. 150
E017 High Engine Coolant Temperature E414 Cylinder #14 Detonation............................. 150
Warning ............................................................. 137 E415 Cylinder #15 Detonation............................. 150
E019 High Engine Oil Temperature Shutdown .... 137 E416 Cylinder #16 Detonation............................. 150
E020 High Engine Oil Temperature Warning....... 137 E421 Cylinder #1 Detonation Shutdown.............. 151
E026 High Inlet Air Temperature Shutdown ........ 137 E422 Cylinder #2 Detonation Shutdown.............. 151
E027 High Inlet Air Temperature Warning ........... 138 E423 Cylinder #3 Detonation Shutdown.............. 151
E038 Low Engine Coolant Temperature E424 Cylinder #4 Detonation Shutdown.............. 151
Warning ............................................................. 138 E425 Cylinder #5 Detonation Shutdown.............. 152
E040 Low Engine Oil Pressure Shutdown........... 138 E426 Cylinder #6 Detonation Shutdown.............. 152
E042 Low System Voltage Shutdown.................. 139 E427 Cylinder #7 Detonation Shutdown.............. 152
E043 Low System Voltage Warning .................... 139 E428 Cylinder #8 Detonation Shutdown.............. 152
E050 High System Voltage Warning ................... 139 E429 Cylinder #9 Detonation Shutdown.............. 153
E053 Low Fuel Pressure Warning....................... 139 E430 Cylinder #10 Detonation Shutdown............ 153
E096 High Fuel Pressure .................................... 140 E431 Cylinder #11 Detonation Shutdown............ 153
E100 Low Engine Oil Pressure Warning ............. 140 E432 Cylinder #12 Detonation Shutdown............ 154
E127 Engine Oil Filter Diff Pressure Low E433 Cylinder #13 Detonation Shutdown............ 154
Warning ............................................................. 140 E434 Cylinder #14 Detonation Shutdown............ 154
E435 Cylinder #15 Detonation Shutdown............ 154
321
Index Section

E436 Cylinder #16 Detonation Shutdown............ 155 E865 High Gas Fuel Differential Pressure........... 174
E801 Cylinder #1 High Exhaust Port Temp ......... 155 E866 Low Gas Fuel Flow Rate............................ 174
E802 Cylinder #2 High Exhaust Port Temp ......... 155 E867 Improper Gas Flow Control Valve
E803 Cylinder #3 High Exhaust Port Temp ......... 156 Response........................................................... 175
E804 Cylinder #4 High Exhaust Port Temp ......... 156 E868 Gas Flow Control Valve Malfunction .......... 175
E805 Cylinder #5 High Exhaust Port Temp ......... 156 ECM Output Circuit (Fuel Control)....................... 222
E806 Cylinder #6 High Exhaust Port Temp ......... 157 ECM Output Circuit (Starting Motor).................... 230
E807 Cylinder #7 High Exhaust Port Temp ......... 157 ECM Status Indicator Output............................... 241
E808 Cylinder #8 High Exhaust Port Temp ......... 158 ECM Will Not Accept Factory Passwords.............. 37
E809 Cylinder #9 High Exhaust Port Temp ......... 158 Probable Causes ............................................... 37
E810 Cylinder #10 High Exhaust Port Temp ....... 158 Recommended Repairs ..................................... 37
E811 Cylinder #11 High Exhaust Port Temp........ 159 Electrical Connectors and Functions ..................... 15
E812 Cylinder #12 High Exhaust Port Temp ....... 159 Harness Wire Identification ................................ 15
E813 Cylinder #13 High Exhaust Port Temp ....... 159 Junction Box ...................................................... 17
E814 Cylinder #14 High Exhaust Port Temp ....... 160 Terminal Box ...................................................... 15
E815 Cylinder #15 High Exhaust Port Temp ....... 160 Electrical Power Supply....................................... 247
E816 Cylinder #16 High Exhaust Port Temp ....... 161 Electronic Service Tool Will Not Communicate with
E821 Cyl #1 Exhaust Port Temp Deviating High.. 161 ECM (The Caterpillar Electronic Technician (ET)
E822 Cyl #2 Exhaust Port Temp Deviating High.. 161 Will Not Communicate With an Electronic Control
E823 Cyl #3 Exhaust Port Temp Deviating High.. 162 Module (ECM) and/or the Integrated Temperature
E824 Cyl #4 Exhaust Port Temp Deviating High.. 162 Sensing Module (ITSM))...................................... 37
E825 Cyl #5 Exhaust Port Temp Deviating High.. 163 Probable Causes ............................................... 37
E826 Cyl #6 Exhaust Port Temp Deviating High.. 163 Recommended Repairs ..................................... 37
E827 Cyl #7 Exhaust Port Temp Deviating High.. 163 Electronic Service Tools ........................................ 17
E828 Cyl #8 Exhaust Port Temp Deviating High.. 164 Caterpillar Electronic Technician (ET)................ 18
E829 Cyl #9 Exhaust Port Temp Deviating High.. 164 Electronic Troubleshooting ...................................... 9
E830 Cyl #10 Exhaust Port Temp Deviating Engine Coolant Temperature (High) ...................... 38
High ................................................................... 165 Probable Causes ............................................... 38
E831 Cyl #11 Exhaust Port Temp Deviating Recommended Repairs ..................................... 38
High ................................................................... 165 Engine Coolant Temperature (Low)....................... 39
E832 Cyl #12 Exhaust Port Temp Deviating Probable Causes ............................................... 39
High ................................................................... 165 Recommended Repairs ..................................... 39
E833 Cyl #13 Exhaust Port Temp Deviating Engine Cranks but Will Not Start ........................... 40
High ................................................................... 166 Probable Causes ............................................... 40
E834 Cyl #14 Exhaust Port Temp Deviating Recommended Repairs ..................................... 40
High ................................................................... 166 Engine Misfires, Runs Rough or Is Unstable......... 41
E835 Cyl #15 Exhaust Port Temp Deviating Probable Causes ............................................... 41
High ................................................................... 167 Recommended Repairs ..................................... 41
E836 Cyl #16 Exhaust Port Temp Deviating Engine Monitoring System..................................... 19
High ................................................................... 167 Changing the Settings of the Monitoring
E841 Cyl #1 Exhaust Port Temp Deviating Low .. 167 System ............................................................. 19
E842 Cyl #2 Exhaust Port Temp Deviating Low .. 168 Default Settings of the Monitoring System......... 21
E843 Cyl #3 Exhaust Port Temp Deviating Low .. 168 Monitoring Parameters....................................... 20
E844 Cyl #4 Exhaust Port Temp Deviating Low .. 169 Programmable Parameters of the Integrated
E845 Cyl #5 Exhaust Port Temp Deviating Low .. 169 Temperature Sensing Module .......................... 24
E846 Cyl #6 Exhaust Port Temp Deviating Low .. 169 Engine Oil Filter Differential Pressure ................... 42
E847 Cyl #7 Exhaust Port Temp Deviating Low .. 170 Probable Causes ............................................... 42
E848 Cyl #8 Exhaust Port Temp Deviating Low .. 170 Recommended Repairs ..................................... 42
E849 Cyl #9 Exhaust Port Temp Deviating Low .. 171 Engine Oil Pressure (Low)..................................... 43
E850 Cyl #10 Exhaust Port Temp Deviating Probable Causes ............................................... 43
Low .................................................................... 171 Recommended Repairs ..................................... 43
E851 Cyl #11 Exhaust Port Temp Deviating Low.. 171 Engine Oil Temperature (High) .............................. 44
E852 Cyl #12 Exhaust Port Temp Deviating Probable Causes ............................................... 44
Low .................................................................... 172 Recommended Repairs ..................................... 44
E853 Cyl #13 Exhaust Port Temp Deviating Engine Overcrank.................................................. 44
Low .................................................................... 172 Probable Causes ............................................... 44
E854 Cyl #14 Exhaust Port Temp Deviating Recommended Repairs ..................................... 44
Low .................................................................... 173 Engine Overload.................................................... 45
E855 Cyl #15 Exhaust Port Temp Deviating Probable Causes ............................................... 45
Low .................................................................... 173 Recommended Repairs ..................................... 45
E856 Cyl #16 Exhaust Port Temp Deviating Engine Overspeed................................................. 46
Low .................................................................... 173 Probable Causes ............................................... 46
E864 Low Gas Fuel Differential Pressure ........... 174 Recommended Repairs ..................................... 46
322
Index Section

Engine Shutdown .................................................. 46 Gas Fuel Flow Rate (Low)..................................... 54


Probable Causes ............................................... 46 Probable Causes ............................................... 54
Recommended Repairs ..................................... 46 Recommended Repairs ..................................... 55
Engine Shutdown (Unexpected)............................ 47 Gas Temperature (High) ........................................ 55
Probable Causes ............................................... 47 Probable Causes ............................................... 55
Recommended Repair ....................................... 47 Recommended Repairs ..................................... 55
Engine Shutdown without a Diagnostic Code........ 48 Generator Output Power Readings Do Not
Probable Causes ............................................... 48 Match ................................................................... 56
Recommended Repairs ..................................... 48 Probable Causes ............................................... 56
Engine Speed/Timing Sensor .............................. 254 Recommended Repairs ..................................... 56
Engine Speed/Timing Sensor - Calibrate ............ 314 Generator Output Power Sensor ......................... 268
Engine Starts but Stalls Immediately..................... 49 Generator Output Power Sensor - Calibrate ....... 316
Probable Causes ............................................... 49
Recommended Repairs ..................................... 49
Engine Timing Does Not Match Programmed I
Timing .................................................................. 50
Probable Causes ............................................... 50 Ignition Transformers Primary Circuit .................. 275
Recommended Repairs ..................................... 50 Ignition Transformers Secondary Circuit and Spark
Engine Will Not Crank ........................................... 50 Plugs.................................................................. 284
Probable Causes ............................................... 50 Important Safety Information ................................... 2
Recommended Repairs ..................................... 50 Inlet Air Temperature (High) .................................. 57
Event Codes ........................................................ 134 Probable Causes ............................................... 57
Active Event Codes.......................................... 135 Recommended Repairs ..................................... 57
Diagnostic Codes and Event Codes ................ 135 Inspecting Electrical Connectors ......................... 290
Logged Event Codes ....................................... 136 Integrated Temperature Sensing Module
Operator Information........................................ 135 (ITSM)................................................................ 295
Other Symptoms .............................................. 135 Intermittent Engine Shutdown ............................... 58
Troubleshooting ............................................... 135 Probable Causes ............................................... 58
Exhaust Port Temperature (High) .......................... 51 Recommended Repairs ..................................... 58
Probable Causes ............................................... 51
Recommended Repairs ..................................... 51
Exhaust Port Temperature (Low)........................... 52 J
Probable Causes ............................................... 52
Recommended Repairs ..................................... 52 Jacket Water Inlet Pressure (High)........................ 59
Probable Causes ............................................... 59
Recommended Repairs ..................................... 59
F Jacket Water Pressure (Low) ................................ 59
Probable Causes ............................................... 59
Factory Passwords ................................................ 27 Recommended Repairs ..................................... 59
Factory Passwords Worksheet.............................. 27 Jacket Water to Engine Oil Differential Temperature
Flash Programming ............................................... 27 (Low).................................................................... 60
Flash Programming............................................ 27 Probable Causes ............................................... 60
Fuel Energy Content.............................................. 53 Recommended Repairs ..................................... 60
Probable Causes ............................................... 53
Recommended Repairs ..................................... 53
Fuel Metering Valve....................................... 53, 261 L
Probable Causes ............................................... 53
Recommended Repairs ..................................... 53 Location of Components......................................... 11
Fuel Pressure ........................................................ 53 Actuators............................................................. 11
Probable Causes ............................................... 53 Fuel Metering Valve ............................................ 11
Recommended Repairs ..................................... 53 Integrated Temperature Sensing Module........... 14
Sensors............................................................... 11
Thermocouples .................................................. 13
G

Gas Fuel Differential Pressure (High).................... 54 M


Probable Causes ............................................... 54
Recommended Repairs ..................................... 54 MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open
Gas Fuel Differential Pressure (Low) .................... 54 circuit ................................................................... 64
Probable Causes ............................................... 54 MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short
Recommended repairs....................................... 54 to ground.............................................................. 65
323
Index Section

MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve MID 036 - CID 0306 - FMI 05 Ignition Transformer
malfunction .......................................................... 65 Primary #6 open circuit ........................................ 77
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short MID 036 - CID 0306 - FMI 06 Ignition Transformer
to +batt................................................................. 65 Primary #6 short .................................................. 77
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short MID 036 - CID 0307 - FMI 05 Ignition Transformer
to ground.............................................................. 66 Primary #7 open circuit ........................................ 77
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0307 - FMI 06 Ignition Transformer
open/short to +batt............................................... 66 Primary #7 short .................................................. 78
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0308 - FMI 05 Ignition Transformer
short to ground..................................................... 67 Primary #8 open circuit ........................................ 78
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure MID 036 - CID 0308 - FMI 06 Ignition Transformer
Sensor short to +batt ........................................... 67 Primary #8 short .................................................. 78
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure MID 036 - CID 0309 - FMI 05 Ignition Transformer
Sensor noisy signal.............................................. 67 Primary #9 open circuit ........................................ 79
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure MID 036 - CID 0309 - FMI 06 Ignition Transformer
open/short to +batt............................................... 68 Primary #9 short .................................................. 79
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet MID 036 - CID 0310 - FMI 05 Ignition Transformer
Pressure Sensor noisy signal .............................. 68 Primary #10 open circuit ...................................... 80
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0310 - FMI 06 Ignition Transformer
Temperature open/short to +batt ......................... 68 Primary #10 short ................................................ 80
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0311 - FMI 05 Ignition Transformer
Temperature short to ground ............................... 69 Primary #11 open circuit ...................................... 80
MID 036 - CID 0145 - FMI 03 12 Volt DC Power MID 036 - CID 0311 - FMI 06 Ignition Transformer
Supply short to +batt............................................ 69 Primary #11 short................................................. 81
MID 036 - CID 0145 - FMI 04 12 Volt DC Power MID 036 - CID 0312 - FMI 05 Ignition Transformer
Supply short to ground......................................... 69 Primary #12 open circuit ...................................... 81
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0312 - FMI 06 Ignition Transformer
intermittent/erratic ................................................ 70 Primary #12 short ................................................ 81
MID 036 - CID 0172 - FMI 03 Intake Manifold Air MID 036 - CID 0313 - FMI 05 Ignition Transformer
Temp open/short to +batt..................................... 70 Primary #13 open circuit ...................................... 82
MID 036 - CID 0172 - FMI 04 Intake Manifold Air MID 036 - CID 0313 - FMI 06 Ignition Transformer
Temp short to ground........................................... 71 Primary #13 short ................................................ 82
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature MID 036 - CID 0314 - FMI 05 Ignition Transformer
open/short to +batt............................................... 71 Primary #14 open circuit ...................................... 82
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature MID 036 - CID 0314 - FMI 06 Ignition Transformer
short to ground..................................................... 71 Primary #14 short ................................................ 83
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0315 - FMI 05 Ignition Transformer
calibration required .............................................. 72 Primary #15 open circuit ...................................... 83
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC MID 036 - CID 0315 - FMI 06 Ignition Transformer
Power Supply short to +batt ................................ 72 Primary #15 short ................................................ 84
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC MID 036 - CID 0316 - FMI 05 Ignition Transformer
Power Supply short to ground ............................. 73 Primary #16 open circuit ...................................... 84
MID 036 - CID 0301 - FMI 05 Ignition Transformer MID 036 - CID 0316 - FMI 06 Ignition Transformer
Primary #1 open circuit ........................................ 73 Primary #16 short ................................................ 84
MID 036 - CID 0301 - FMI 06 Ignition Transformer MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor
Primary #1 short .................................................. 73 short to +batt........................................................ 85
MID 036 - CID 0302 - FMI 05 Ignition Transformer MID 036 - CID 0320 - FMI 08 Engine Speed/Timing
Primary #2 open circuit ........................................ 74 signal abnormal ................................................... 85
MID 036 - CID 0302 - FMI 06 Ignition Transformer MID 036 - CID 0323 - FMI 03 Shutdown Lamp short
Primary #2 short .................................................. 74 to +batt................................................................. 85
MID 036 - CID 0303 - FMI 05 Ignition Transformer MID 036 - CID 0324 - FMI 03 Warning Lamp short to
Primary #3 open circuit ........................................ 74 +batt..................................................................... 86
MID 036 - CID 0303 - FMI 06 Ignition Transformer MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Primary #3 short .................................................. 75 inputs ................................................................... 86
MID 036 - CID 0304 - FMI 05 Ignition Transformer MID 036 - CID 0401 - FMI 05 Ignition Transformer
Primary #4 open circuit ........................................ 75 Secondary #1 open circuit ................................... 86
MID 036 - CID 0304 - FMI 06 Ignition Transformer MID 036 - CID 0401 - FMI 06 Ignition Transformer
Primary #4 short .................................................. 76 Secondary #1 short to ground ............................. 87
MID 036 - CID 0305 - FMI 05 Ignition Transformer MID 036 - CID 0402 - FMI 05 Ignition Transformer
Primary #5 open circuit ........................................ 76 Secondary #2 open circuit ................................... 87
MID 036 - CID 0305 - FMI 06 Ignition Transformer MID 036 - CID 0402 - FMI 06 Ignition Transformer
Primary #5 short .................................................. 76 Secondary #2 short to ground ............................. 87
324
Index Section

MID 036 - CID 0403 - FMI 05 Ignition Transformer MID 036 - CID 0444 - FMI 06 Start Relay short to
Secondary #3 open circuit ................................... 88 ground................................................................ 100
MID 036 - CID 0403 - FMI 06 Ignition Transformer MID 036 - CID 0445 - FMI 03 Run Relay short to
Secondary #3 short to ground ............................. 88 +batt................................................................... 100
MID 036 - CID 0404 - FMI 05 Ignition Transformer MID 036 - CID 0524 - FMI 03 Desired Engine Speed
Secondary #4 open circuit ................................... 89 Sensor short to +batt ......................................... 100
MID 036 - CID 0404 - FMI 06 Ignition Transformer MID 036 - CID 0524 - FMI 04 Desired Engine Speed
Secondary #4 short to ground ............................. 89 Sensor short to ground ...................................... 101
MID 036 - CID 0405 - FMI 05 Ignition Transformer MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
Secondary #5 open circuit ................................... 89 Pressure open/short to +batt ............................. 101
MID 036 - CID 0405 - FMI 06 Ignition Transformer MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
Secondary #5 short to ground ............................. 90 Pressure short to ground ................................... 101
MID 036 - CID 0406 - FMI 05 Ignition Transformer MID 036 - CID 1042 - FMI 09 Unable to communicate
Secondary #6 open circuit ................................... 90 with ITSM........................................................... 102
MID 036 - CID 0406 - FMI 06 Ignition Transformer MID 036 - CID 1440 - FMI 09 Unable to communicate
Secondary #6 short to ground ............................. 91 with Throttle Actuator Drv .................................. 102
MID 036 - CID 0407 - FMI 05 Ignition Transformer MID 036 - CID 1446 - FMI 05 Fuel Metering Module
Secondary #7 open circuit ................................... 91 open circuit ........................................................ 102
MID 036 - CID 0407 - FMI 06 Ignition Transformer MID 036 - CID 1446 - FMI 09 Unable to communicate
Secondary #7 short to ground ............................. 91 with Fuel Metering Module................................. 103
MID 036 - CID 0408 - FMI 05 Ignition Transformer MID 036 - CID 1446 - FMI 12 Fuel Metering Module
Secondary #8 open circuit ................................... 92 malfunction ........................................................ 103
MID 036 - CID 0408 - FMI 06 Ignition Transformer MID 036 - CID 1446 - FMI 13 Fuel Metering Module
Secondary #8 short to ground ............................. 92 calibration required ............................................ 103
MID 036 - CID 0409 - FMI 05 Ignition Transformer MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor
Secondary #9 open circuit ................................... 92 Module malfunction............................................ 104
MID 036 - CID 0409 - FMI 06 Ignition Transformer MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation
Secondary #9 short to ground ............................. 93 Sensor open/short to +batt ................................ 104
MID 036 - CID 0410 - FMI 05 Ignition Transformer MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation
Secondary #10 open circuit ................................. 93 Sensor short to ground ...................................... 104
MID 036 - CID 0410 - FMI 06 Ignition Transformer MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation
Secondary #10 short to ground ........................... 94 Sensor open/short to +batt ................................ 105
MID 036 - CID 0411 - FMI 05 Ignition Transformer MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation
Secondary #11 open circuit ................................. 94 Sensor short to ground ...................................... 105
MID 036 - CID 0411 - FMI 06 Ignition Transformer MID 036 - CID 1505 - FMI 03 Cylinder #5 Detonation
Secondary #11 short to ground............................ 95 Sensor open/short to +batt ................................ 105
MID 036 - CID 0412 - FMI 05 Ignition Transformer MID 036 - CID 1505 - FMI 04 Cylinder #5 Detonation
Secondary #12 open circuit ................................. 95 Sensor short to ground ...................................... 106
MID 036 - CID 0412 - FMI 06 Ignition Transformer MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation
Secondary #12 short to ground ........................... 95 Sensor open/short to +batt ................................ 106
MID 036 - CID 0413 - FMI 05 Ignition Transformer MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation
Secondary #13 open circuit ................................. 96 Sensor short to ground ...................................... 106
MID 036 - CID 0413 - FMI 06 Ignition Transformer MID 036 - CID 1509 - FMI 03 Cylinder #9 Detonation
Secondary #13 short to ground ........................... 96 Sensor open/short to +batt ................................ 107
MID 036 - CID 0414 - FMI 05 Ignition Transformer MID 036 - CID 1509 - FMI 04 Cylinder #9 Detonation
Secondary #14 open circuit ................................. 96 Sensor short to ground ...................................... 107
MID 036 - CID 0414 - FMI 06 Ignition Transformer MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation
Secondary #14 short to ground ........................... 97 Sensor open/short to +batt ................................ 107
MID 036 - CID 0415 - FMI 05 Ignition Transformer MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation
Secondary #15 open circuit ................................. 97 Sensor short to ground ...................................... 108
MID 036 - CID 0415 - FMI 06 Ignition Transformer MID 036 - CID 1513 - FMI 03 Cylinder #13 Detonation
Secondary #15 short to ground ........................... 98 Sensor open/short to +batt ................................ 108
MID 036 - CID 0416 - FMI 05 Ignition Transformer MID 036 - CID 1513 - FMI 04 Cylinder #13 Detonation
Secondary #16 open circuit ................................. 98 Sensor short to ground ...................................... 108
MID 036 - CID 0416 - FMI 06 Ignition Transformer MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation
Secondary #16 short to ground ........................... 99 Sensor open/short to +batt ................................ 109
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation
short to +batt........................................................ 99 Sensor short to ground ...................................... 109
MID 036 - CID 0444 - FMI 05 Start Relay open MID 036 - CID 1719 - FMI 03 Generator Output
circuit ................................................................... 99 Power Sensor open/short to +batt ..................... 109
325
Index Section

MID 036 - CID 1719 - FMI 04 Generator Output MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port
Power Sensor short to ground ............................ 110 Temp Sensor short to +batt ............................... 120
MID 036 - CID 1719 - FMI 12 Generator Output MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port
Power Sensor malfunction.................................. 110 Temp Sensor short to ground ............................ 121
MID 036 - CID 1720 - FMI 09 Turbocharger MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port
Compressor Bypass Valve Actuator not Temp Sensor open circuit .................................. 121
communicating on link ........................................ 110 MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port
MID 111 - CID 0591 - FMI 12 EEPROM checksum Temp Sensor short to +batt ............................... 122
fault or ECM not programmed ............................ 110 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port
MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sensor short to ground ............................ 122
Temp Sens short to +batt.................................... 111 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port
MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sensor open circuit .................................. 122
Temp Sens short to ground................................. 111 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port
MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sensor short to +batt ............................... 123
Temp Sens open circuit ...................................... 111 MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port
MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sensor short to ground ............................ 123
Temp Sens short to +batt.................................... 112 MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port
MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sensor open circuit .................................. 123
Temp Sens short to ground................................. 112 MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port
MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sensor short to +batt ............................... 124
Temp Sens open circuit ...................................... 112 MID 111 - CID 1539 - FMI 04 Cyl #9 Exhaust Port
MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sensor short to ground ............................ 124
Temp Sens short to +batt.................................... 113 MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port
MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sensor open circuit .................................. 125
Temp Sens short to ground................................. 113 MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port
MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sensor short to +batt ............................... 125
Temp Sens open circuit ...................................... 113 MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port
MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sensor short to ground ............................ 125
Temp Sens short to +batt.................................... 114 MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port
MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sensor open circuit .................................. 126
Temp Sens short to ground................................. 114 MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port
MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sensor short to +batt ............................... 126
Temp Sens open circuit ...................................... 114 MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port
MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to ground ............................ 126
Temp Sensor short to +batt ................................ 115 MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port
MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor open circuit .................................. 127
Temp Sensor short to ground ............................. 115 MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port
MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor short to +batt ............................... 127
Temp Sensor open circuit ................................... 116 MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port
MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to ground ............................ 128
Temp Sensor short to +batt ................................ 116 MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port
MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Temp Sensor open circuit .................................. 128
Temp Sensor short to ground ............................. 116 MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port
MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor short to +batt ............................... 128
Temp Sensor open circuit ................................... 117 MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port
MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to ground ............................ 129
Temp Sensor short to +batt ................................ 117 MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port
MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor open circuit .................................. 129
Temp Sensor short to ground ............................. 117 MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port
MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor short to +batt ............................... 129
Temp Sensor open circuit ................................... 118 MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port
MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to ground ............................ 130
Temp Sensor short to +batt ................................ 118 MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port
MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor open circuit .................................. 130
Temp Sensor short to ground ............................. 119 MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port
MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor short to +batt ............................... 131
Temp Sensor open circuit ................................... 119 MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port
MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to ground ............................ 131
Temp Sensor short to +batt ................................ 119 MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port
MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor open circuit .................................. 131
Temp Sensor short to ground ............................ 120 MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port
MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor short to +batt ............................... 132
Temp Sensor open circuit .................................. 120
326
Index Section

MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port


Temp Sensor short to ground ............................ 132
MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port
Temp Sensor open circuit .................................. 132

Programming Parameters ..................................... 26


PWM Sensor ....................................................... 301

Replacing the ECM................................................ 29


Replacing the ITSM ............................................... 31

Self-Diagnostics..................................................... 10
Symptoms.............................................................. 35
Diagnostic Codes and Event Codes .................. 35
Operator Information.......................................... 35
Other Symptoms ................................................ 35
System Configuration Parameters......................... 28
System Overview..................................................... 9
Air/Fuel Ratio Control........................................... 9
Engine Monitoring and Protection...................... 10
Engine Speed Governing..................................... 9
Ignition Control................................................... 10
Introduction .......................................................... 9
Start/Stop Sequencing ......................................... 9
System Voltage...................................................... 60
Probable Causes ............................................... 60
Recommended Repairs ..................................... 60

Table of Contents..................................................... 3
Throttle Actuator .................................................. 308
Troubleshooting Data Sheet.................................. 33
Report the Service Information .......................... 34
Troubleshooting Section.......................................... 9
Troubleshooting with a Diagnostic Code ............... 63
Troubleshooting with an Event Code................... 134
Troubleshooting without a Diagnostic Code .......... 35
Turbocharger Turbine Temperature (High) ............ 60
Probable Causes ............................................... 60
Recommended Repairs ..................................... 61
Turbocharger Turbine Temperature (Low)............. 61
Probable Causes ............................................... 61
Recommended Repairs ..................................... 61
327
Index Section
©2004 Caterpillar
All Rights Reserved Printed in U.S.A.

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