Trouble Shooting G3516C
Trouble Shooting G3516C
Trouble Shooting G3516C
March 2004
Troubleshooting
G3516C and G3516E Engines
RWA1-Up (Engine)
GHP1-Up (Engine)
DKR1-Up (Engine)
i01658146
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
7
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
Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 314
Generator Output Power Sensor - Calibrate ....... 316
Index Section
Index ................................................................... 320
9
Troubleshooting Section
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.
i02051602 Actuators
Location of Components
SMCS Code: 1900
g01012402
Illustration 2
Right side view
(1) Throttle actuator
(2) Actuator for the compressor bypass valve
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.
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
g01052274
Illustration 7
Integrated temperature sensing module
15
Troubleshooting Section
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
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
i02051687
• 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
i02051696
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
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.
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
“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
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
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.
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)
i01727009 i01932222
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
• “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)
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
g01052348
Illustration 14
Internal view of the terminal box
(2) Mounting nut
(3) P2 connector
(4) P1 connector
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.
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
i02051773
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.
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)
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
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
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.
• 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
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.
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”.
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
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.
• 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.
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
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.
• 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
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
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”.
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)”.
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
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
Probable Causes
• Low operating voltage for the fuel metering valve
• Internal binding of the fuel metering valve
54
Troubleshooting Section
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
• 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 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.
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.
• 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”.
i01368495 i01727750
• 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
• 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”.
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
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”
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 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
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:
• 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.
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
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.
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.
Troubleshooting: • OK – STOP.
Perform the following diagnostic procedure: “+8V
Sensor Voltage Supply”
Results:
• OK – STOP.
67
Troubleshooting Section
• 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
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
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:
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
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.
Troubleshooting:
Results: i01728451
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”
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: • 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
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
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:
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:
Troubleshooting: Results:
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
Troubleshooting: Results:
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
Troubleshooting: • OK – STOP.
One of the following conditions is the source of the
diagnostic code: i01763043
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:
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
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
System Response:
Troubleshooting: Results:
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
Troubleshooting: Results:
The primary circuit of the transformer is diagnosed • A short circuit within the primary winding of the
with an open circuit. transformer
Troubleshooting: • OK – STOP.
One of the following conditions is the source of the
diagnostic code: i01762978
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:
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
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
System Response:
Troubleshooting: Results:
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
Troubleshooting: Results:
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
Troubleshooting: • OK – STOP.
One of the following conditions is the source of the
diagnostic code: i01763142
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:
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
System Response:
• OK – STOP.
The engine operation is not affected. The shutdown output is activated. The code is logged.
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
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
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
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:
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
• 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.
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
• 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:
• OK – STOP.
91
Troubleshooting Section
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
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
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
• OK – STOP.
95
Troubleshooting Section
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
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
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
• OK – STOP.
99
Troubleshooting Section
• 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.
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)”
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.
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
The alarm output is activated. The code is logged. Conditions Which Generate This Code:
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).
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:
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.
i01741170
• 0041 - 04 8 Volt DC Supply short to ground
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
• OK – STOP. • The load signal from the power sensor to the ECM
is greater than 4.8 VDC.
i02085887 Troubleshooting:
MID 036 - CID 1719 - FMI Perform the following diagnostic procedure:
04 Generator Output Power “Generator Output Power Sensor”
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
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
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.
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
System Response:
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.
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
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
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.
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
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:
Troubleshooting:
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.
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
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:
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
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
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.
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
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)”
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.
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
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
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
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.
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)”
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.
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
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:
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
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
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.
• OK – STOP.
125
Troubleshooting Section
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.
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
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
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)”
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)”
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)”
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.
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
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:
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.
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
System Response:
Troubleshooting:
Results:
• OK – STOP.
134
Troubleshooting Section
Troubleshooting with an
Event Code
i02053451
Event Codes
SMCS Code: 1901-038
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”.
3. Perform a visual inspection. Inspect the following • The complaint is not due to normal engine
operation.
items:
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
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 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.
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:
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.
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
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)”.
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:
• OK – STOP. Troubleshooting:
i01633763 i01877738
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.
The shutdown output is activated. The code is logged. The alarm output is activated. The code is logged.
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.
• OK – STOP. Results:
i01633765
• OK – STOP.
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.
• 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:
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.
Refer to Troubleshooting, “Engine Oil Pressure The fuel is shut off. The shutdown output is activated.
(Low)”. The code is logged.
141
Troubleshooting Section
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:
Results:
i01633832
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.
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:
Results: Results:
• OK – STOP. • OK – STOP.
i01729345
i01633956
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.
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.
Troubleshooting: Troubleshooting:
Results: Results:
• OK – STOP. • OK – STOP.
i01633972 i01746483
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)
• 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.
i01634059 • OK – STOP.
E264 Emergency Stop
Activated i01634093
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
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
Results: Results:
• OK – STOP. • OK – STOP.
i01637623 i01637634
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
Results: Results:
• OK – STOP. • OK – STOP.
148
Troubleshooting Section
i01637642 i01637648
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
Results: Results:
• OK – STOP. • OK – STOP.
i01637646 i01637651
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
Results: Results:
• OK – STOP. • OK – STOP.
149
Troubleshooting Section
i01637653 i01637663
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
Results: Results:
• OK – STOP. • OK – STOP.
i01637657 i01637665
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
Results: Results:
• OK – STOP. • OK – STOP.
150
Troubleshooting Section
i01637696 i01637702
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
Results: Results:
• OK – STOP. • OK – STOP.
i01637699 i01637706
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.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
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:
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.
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.
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
Results: Troubleshooting:
Results:
i01635416
Results: Troubleshooting:
Results:
i01635417
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.
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.
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.
Troubleshooting:
Results: Troubleshooting:
Results:
i01635429
Results: Troubleshooting:
Results:
i01635431
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)
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:
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
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.
Refer to Troubleshooting, “Exhaust Port Temperature The cylinder exhaust temperature has exceeded the
(High)”. trip point and the delay time has expired.
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.
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.
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
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
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)”.
• 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.
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:
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.
• 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.
Troubleshooting: i01635587
Refer to Troubleshooting, “Exhaust Port Temperature E821 Cyl #1 Exhaust Port Temp
(High)”. Deviating High
Results: SMCS Code: 1059-038
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.
• 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.
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)
• 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.
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
• 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.
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)
• 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.
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
• 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.
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)
• 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.
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
• 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.
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)
• 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.
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
• 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.
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)
• 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.
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
• 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.
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)
• 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.
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
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.
• OK – STOP. Results:
• OK – STOP.
i01637712
Results:
• OK – STOP.
i02053631
System Response:
Troubleshooting:
Results:
• OK – STOP.
i02053641
System Response:
Troubleshooting:
Results:
• OK – STOP.
176
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
g01054206
Illustration 22
Junction box
(1) 35 amp circuit breaker
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
Expected Result:
Results:
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”.
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
• 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
• 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:
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.
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.
STOP.
184
Troubleshooting Section
STOP.
STOP.
i02055144
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:
g01054206
Illustration 30
Junction box
(1) 35 amp circuit breaker
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:
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:
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.
• 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
g01054206
Illustration 39
Junction box
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
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
Expected Result:
Results:
STOP.
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.
Expected Result:
Results:
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
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.
• 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.
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.
200
Troubleshooting Section
g01054152
Illustration 48
Schematic diagram of the CAT data link
201
Troubleshooting Section
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
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
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:
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”.
• 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
g01054193
Illustration 53
Schematic for the circuit of the actuator for the bypass valve
206
Troubleshooting Section
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).
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
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.
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.
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”.
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:
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.
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
• 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:
Expected Result:
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:
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
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.
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).
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
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.
STOP.
219
Troubleshooting Section
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.
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:
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.
STOP.
STOP.
222
Troubleshooting Section
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.
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
Results:
STOP.
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.
• 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.
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.
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.
STOP.
Expected Result:
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
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.
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
Electric Start
Air Start
g01054994
Illustration 84
Schematic for the electric starting system
232
Troubleshooting Section
g01055038
Illustration 85
Schematic for the air starting system
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).
Expected Result:
Results:
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.
• 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.
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:
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.
g01055051
Illustration 90
“SM” circuit breaker
Expected Result:
Results:
g01055064
Illustration 93
Section view of the junction box
(1) Coil terminals on the magnetic switches
(2) Terminals on the “SM” circuit breaker
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.
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.
• 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
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
• 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:
Results:
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
• 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:
STOP.
Expected Result:
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.
Expected Result:
Results:
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
g01055398
Illustration 101
Schematic for the electrical power
250
Troubleshooting Section
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:
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
Expected Result:
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: 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”.
STOP.
i02059442
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.
g01055531
Illustration 108
Schematic for the circuit of the speed/timing sensor
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
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
Expected Result:
Results:
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
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.
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.
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
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:
g00931487
Illustration 117
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
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
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.
• 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:
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.
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:
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
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
g01054206
Illustration 129
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
• 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:
STOP.
• 1719-03
• 1719-04
• 1719-12
D. Stop the engine.
Expected Result:
Results:
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.
• 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.
• 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: 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 – 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:
• “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”.
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
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
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
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”.
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
g00863850
Illustration 141
Resistance versus temperature
(Y) Resistance in Ohms
(X) Temperature in degrees celsius (degrees fahrenheit)
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.
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.
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.
Expected Result:
Results:
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.
Turn OFF the gas supply before you perform this step.
STOP.
284
Troubleshooting Section
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:
Results:
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:
Expected Result:
Results:
STOP.
g01057657
Illustration 147
(4) Transformer
(5) Extension
(6) Secondary terminal for the spark plug
(7) O-ring seal
g00863850
Illustration 150
Resistance versus temperature
(Y) Resistance in Ohms
(X) Temperature in degrees celsius (degrees fahrenheit)
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.
Expected Result:
Results:
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.
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.
i01811734
Inspecting Electrical
Connectors
SMCS Code: 7553-040-WW
g00700045
Illustration 152
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.
• 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.
• 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:
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.
Results:
STOP.
g00690568
Illustration 156
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.
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:
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).
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
• 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
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:
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:
• 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”.
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)
STOP.
g01057762
Illustration 165
Schematic for the PWM sensors
303
Troubleshooting Section
g01054206
Illustration 166
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
• 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)
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
• 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.
Expected Result:
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.
The frequency is between 400 and 600 Hz. Inlet manifold air pressure J1-10 and J1-5
• 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:
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.
i02060038
Throttle Actuator
SMCS Code: 1716-038
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).
g01054206
Illustration 175
Junction box
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:
Results:
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.
Expected Result:
Results:
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.
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 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.
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.
• 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
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
• 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.
STOP.
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.
The potentiometer must have the following • Not OK – The potentiometer is not connected
characteristics: properly.
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
Expected Result:
Results:
STOP.
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
Expected Result:
Results:
STOP.
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
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
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.