3516B

RENR2270-02 June 2002
Troubleshooting
G3516B Generator Set Engines and G3516B Engines For Caterpillar Built Generator Sets and Power Modules
CSC1-Up (Generator Set) CFD1-Up (Power Module) CME1-Up (Generator Set) CEY1-Up (Engine) 7EZ1-Up (Engine) CTW1-Up (Engine)
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
3 Table of Contents
Table of Contents
Troubleshooting Section
Electronic Troubleshooting System Overview .................................................... 9 Self-Diagnostics .................................................... 10 Electrical Connectors and Functions .................... 11 Electronic Service Tools ........................................ 18 Engine Monitoring System .................................... 21 Programming Parameters Programming Parameters ..................................... Customer Passwords ............................................ Factory Passwords ................................................ Factory Passwords Worksheet ............................. Flash Programming .............................................. System Configuration Parameters ........................ Replacing the ECM ............................................... Replacing the ITSM .............................................. Troubleshooting Data Sheet ................................. 28 28 29 29 29 30 36 38 39
Intermittent Engine Shutdown ............................... 65 Jacket Water Inlet Pressure (High) ....................... 66 Jacket Water Pressure (Low) ................................ 67 Jacket Water to Engine Oil Differential Temperature (Low) ................................................................... 67 System Voltage ..................................................... 68 Turbocharger Turbine Temperature (High) ............ 68 Turbocharger Turbine Temperature (Low) ............. 69 Troubleshooting with a Diagnostic Code Diagnostic Codes .................................................. 70 MID 036 - CID 0017 - FMI 05 Fuel Shutoff Value open circuit .......................................................... 71 MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground ............................................................. 72 MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction .......................................................... 72 MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt ................................................................ 72 MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground ............................................................. 73 MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt .............................................. 73 MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground .................................................... 74 MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt .......................................... 74 MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal ............................................. 74 MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt .............................................. 75 MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal ............................. 75 MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt ......................... 75 MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground ............................... 76 MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt ........................................... 76 MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground ........................................ 76 MID 036 - CID 0168 - FMI 02 System Voltage intermittent/erratic ............................................... 77 MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt .................................... 77 MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground .......................................... 78 MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt .............................................. 78 MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground .................................................... 79 MID 036 - CID 0261 - FMI 13 Engine Timing calibration required ............................................. 79 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt ........................................... 79 MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground ........................................ 80 MID 036 - CID 0301 - FMI 05 Cylinder 1 - Transformer Primary open circuit ............................................ 80 MID 036 - CID 0301 - FMI 06 Cylinder 1 - Transformer Primary short ...................................................... 81 MID 036 - CID 0302 - FMI 05 Cylinder 2 - Transformer Primary open circuit ............................................ 81
Troubleshooting without a Diagnostic Code Symptoms ............................................................. 41 Detonation ............................................................ 41 Driven Equipment ................................................. 43 ECM Will Not Accept Factory Passwords ............. 43 Electrohydraulic System Oil Pressure (Low) ......... 43 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With the Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)) ..................................... 45 Engine Coolant Temperature (High) ..................... 45 Engine Coolant Temperature (Low) ...................... 47 Engine Cranks but Will Not Start .......................... 47 Engine Misfires, Runs Rough or Is Unstable ........ 48 Engine Oil Filter Differential Pressure ................... 50 Engine Oil Pressure (Low) .................................... 50 Engine Oil Temperature (High) ............................. 51 Engine Overcrank ................................................. 51 Engine Overload ................................................... 52 Engine Overspeed ................................................ 53 Engine Pre-Lube Pressure (Low) ......................... 53 Engine Shutdown .................................................. 54 Engine Shutdown (Unexpected) ........................... 55 Engine Shutdown without a Diagnostic Code ....... 56 Engine Starts but Stalls Immediately .................... 57 Engine Timing Does Not Match Programmed Timing ................................................................. 58 Engine Will Not Crank ........................................... 59 Exhaust Port Temperature (High) ......................... 60 Exhaust Port Temperature (Low) .......................... 61 Fuel Energy Content ............................................. 61 Fuel Pressure ....................................................... 62 Fuel Metering Valve .............................................. 62 Gas Fuel Differential Pressure (High) ................... 62 Gas Fuel Differential Pressure (Low) .................... 63 Gas Fuel Flow Rate (Low) .................................... 63 Gas Temperature (High) ....................................... 64 Inlet Air Temperature (High) .................................. 64
4 Table of Contents
MID 036 - CID 0302 - FMI 06 Cylinder 2 - Transformer Primary short ...................................................... 81 MID 036 - CID 0303 - FMI 05 Cylinder 3 - Transformer Primary open circuit ............................................ 82 MID 036 - CID 0303 - FMI 06 Cylinder 3 - Transformer Primary short ...................................................... 82 MID 036 - CID 0304 - FMI 05 Cylinder 4 - Transformer Primary open circuit ............................................ 82 MID 036 - CID 0304 - FMI 06 Cylinder 4 - Transformer Primary short ...................................................... 83 MID 036 - CID 0305 - FMI 05 Cylinder 5 - Transformer Primary open circuit ............................................ 83 MID 036 - CID 0305 - FMI 06 Cylinder 5 - Transformer Primary short ...................................................... 84 MID 036 - CID 0306 - FMI 05 Cyinder 6 - Transformer Primary open circuit ............................................ 84 MID 036 - CID 0306 - FMI 06 Cylinder 6 - Transformer Primary short ...................................................... 84 MID 036 - CID 0307 - FMI 05 Cylinder 7 - Transformer Primary open circuit ............................................ 85 MID 036 - CID 0307 - FMI 06 Cylinder 7 - Transformer Primary short ...................................................... 85 MID 036 - CID 0308 - FMI 05 Cylinder 8 - Transformer Primary open circuit ............................................ 85 MID 036 - CID 0308 - FMI 06 Cylinder 8 - Transformer Primary short ...................................................... 86 MID 036 - CID 0309 - FMI 05 Cylinder 9 - Transformer Primary open circuit ............................................ 86 MID 036 - CID 0309 - FMI 06 Cylinder 9 - Transformer Primary short ...................................................... 87 MID 036 - CID 0310 - FMI 05 Cylinder 10 Transformer Primary open circuit ........................ 87 MID 036 - CID 0310 - FMI 06 Cylinder 10 Transformer Primary short .................................. 87 MID 036 - CID 0311 - FMI 05 Cylinder 11 Transformer Primary open circuit ........................ 88 MID 036 - CID 0311 - FMI 06 Cylinder 11 Transformer Primary short .................................. 88 MID 036 - CID 0312 - FMI 05 Cylinder 12 Transformer Primary open circuit ........................ 88 MID 036 - CID 0312 - FMI 06 Cylinder 12 Transformer Primary short .................................. 89 MID 036 - CID 0313 - FMI 05 Cylinder 13 Transformer Primary open circuit ........................ 89 MID 036 - CID 0313 - FMI 06 Cylinder 13 Transformer Primary short .................................. 90 MID 036 - CID 0314 - FMI 05 Cylinder 14 Transformer Primary open circuit ........................ 90 MID 036 - CID 0314 - FMI 06 Cylinder 14 Transformer Primary short .................................. 90 MID 036 - CID 0315 - FMI 05 Cylinder 15 Transformer Primary open circuit ........................ 91 MID 036 - CID 0315 - FMI 06 Cylinder 15 Transformer Primary short .................................. 91 MID 036 - CID 0316 - FMI 05 Cylinder 16 Transformer Primary open circuit ........................ 91 MID 036 - CID 0316 - FMI 06 Cylinder 16 Transformer Primary short .................................. 92 MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt ....................................................... 92
MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................... 93 MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt ................................................................ 93 MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt .................................................................... 93 MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs .................................................................. 94 MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open circuit ................................................................... 94 MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short to ground ............................................................. 94 MID 036 - CID 0339 - FMI 05 Engine Pre-lube Pressure Switch open circuit ............................... 95 MID 036 - CID 0401 - FMI 05 Cylinder 1 - Transformer Secondary open circuit ....................................... 95 MID 036 - CID 0401 - FMI 06 Cylinder 1 - Transformer Secondary short to ground ................................. 95 MID 036 - CID 0402 - FMI 05 Cylinder 2 - Transformer Secondary open circuit ....................................... 96 MID 036 - CID 0402 - FMI 06 Cylinder 2 - Transformer Secondary short to ground ................................. 96 MID 036 - CID 0403 - FMI 05 Cylinder 3 - Transformer Secondary open circuit ....................................... 97 MID 036 - CID 0403 - FMI 06 Cylinder 3 - Transformer Secondary short to ground ................................. 97 MID 036 - CID 0404 - FMI 05 Cylinder 4 - Transformer Secondary open circuit ....................................... 97 MID 036 - CID 0404 - FMI 06 Cylinder 4 - Transformer Secondary short to ground ................................. 98 MID 036 - CID 0405 - FMI 05 Cylinder 5 - Transformer Secondary open circuit ....................................... 98 MID 036 - CID 0405 - FMI 06 Cylinder 5 - Transformer Secondary short to ground ................................. 99 MID 036 - CID 0406 - FMI 05 Cylinder 6 - Transformer Secondary open circuit ....................................... 99 MID 036 - CID 0406 - FMI 06 Cylinder 6 - Transformer Secondary short to ground ................................. 99 MID 036 - CID 0407 - FMI 05 Cylinder 7 - Transformer Secondary open circuit ..................................... 100 MID 036 - CID 0407 - FMI 06 Cylinder 7 - Transformer Secondary short to ground ............................... 100 MID 036 - CID 0408 - FMI 05 Cylinder 8 - Transformer Secondary open circuit ..................................... 100 MID 036 - CID 0408 - FMI 06 Cylinder 8 - Transformer Secondary short to ground ............................... 101 MID 036 - CID 0409 - FMI 05 Cylinder 9 - Transformer Secondary open circuit ..................................... 101 MID 036 - CID 0409 - FMI 06 Cylinder 9 - Transformer Secondary short to ground ............................... 102 MID 036 - CID 0410 - FMI 05 Cylinder 10 Transformer Secondary open circuit ................. 102 MID 036 - CID 0410 - FMI 06 Cylinder 10 Transformer Secondary short to ground ........... 103 MID 036 - CID 0411 - FMI 05 Cylinder 11 Transformer Secondary open circuit ................. 103 MID 036 - CID 0411 - FMI 06 Cylinder 11 Transformer Secondary short to ground ........... 103 MID 036 - CID 0412 - FMI 05 Cylinder 12 Transformer Secondary open circuit ................. 104
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MID 036 - CID 0412 - FMI 06 Cylinder 12 Transformer Secondary short to ground ........... 104 MID 036 - CID 0413 - FMI 05 Cylinder 13 Transformer Secondary open circuit ................. 104 MID 036 - CID 0413 - FMI 06 Cylinder 13 Transformer Secondary short to ground ........... 105 MID 036 - CID 0414 - FMI 05 Cylinder 14 Transformer Secondary open circuit ................. 105 MID 036 - CID 0414 - FMI 06 Cylinder 14 Transformer Secondary short to ground ........... 106 MID 036 - CID 0415 - FMI 05 Cylinder 15 Transformer Secondary open circuit ................. 106 MID 036 - CID 0415 - FMI 06 Cylinder 15 Transformer Secondary short to ground ........... 107 MID 036 - CID 0416 - FMI 05 Cylinder 16 Transformer Secondary open circuit ................. 107 MID 036 - CID 0416 - FMI 06 Cylinder 16 Transformer Secondary short to ground ........... 107 MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt ..................................................... 108 MID 036 - CID 0444 - FMI 05 Start Relay open circuit ................................................................. 108 MID 036 - CID 0444 - FMI 06 Start Relay short to ground ............................................................... 108 MID 036 - CID 0445 - FMI 03 Run Relay short to +batt .................................................................. 109 MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt ........................................ 109 MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground ..................................... 109 MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt ............................ 110 MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground .................................. 110 MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM .......................................................... 110 MID 036 - CID 1086 - FMI 09 Oxygen Sensor Element not communicating on link .................. 111 MID 036 - CID 1086 - FMI 13 Oxygen Sensor Element calibration required ............................. 111 MID 036 - CID 1087 - FMI 03 Oxygen Sensor Buffer Module short to +batt ........................................ 112 MID 036 - CID 1087 - FMI 08 Oxygen Sensor Buffer Module noisy signal .......................................... 112 MID 036 - CID 1088 - FMI 05 Oxygen Sensor Power Supply open circuit ............................................ 112 MID 036 - CID 1088 - FMI 06 Oxygen Sensor Power Supply short to ground ...................................... 113 MID 036 - CID 1440 - FMI 05 Throttle Actuator Driver open circuit ........................................................ 113 MID 036 - CID 1440 - FMI 06 Throttle Actuator Driver short to ground .................................................. 113 MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit ........................................................ 114 MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module ................................ 114 MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction ........................................................ 114 MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required ........................................... 115 MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction ........................................... 115
MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt ............................... 115 MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground ..................................... 116 MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Sensor open/short to +batt ............................... 116 MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Sensor short to ground ..................................... 116 MID 036 - CID 1505 - FMI 03 Cylinder #5 Detonation Sensor open/short to +batt ............................... 117 MID 036 - CID 1505 - FMI 04 Cylinder #5 Detonation Sensor short to ground ..................................... 117 MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ............................... 117 MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Sensor short to ground ..................................... 118 MID 036 - CID 1509 - FMI 03 Cylinder #9 Detonation Sensor open/short to +batt ............................... 118 MID 036 - CID 1509 - FMI 04 Cylinder #9 Detonation Sensor short to ground ..................................... 118 MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt ............................... 119 MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground ..................................... 119 MID 036 - CID 1513 - FMI 03 Cylinder #13 Detonation Sensor open/short to +batt ............................... 119 MID 036 - CID 1513 - FMI 04 Cylinder #13 Detonation Sensor short to ground ..................................... 120 MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt ............................... 120 MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground ..................................... 120 MID 036 - CID 1758 - FMI 03 Specific Humidity Sensor open/short to +batt ............................... 121 MID 036 - CID 1758 - FMI 08 Specific Humidity Sensor signal abnormal .................................... 121 MID 036 - CID 1759 - FMI 03 Exhaust Back Pressure Sensor open/short to +batt ............................... 122 MID 036 - CID 1759 - FMI 08 Exhaust Back Pressure Sensor signal abnormal .................................... 122 MID 111 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed ........................... 122 MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt .................................. 123 MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sens short to ground ............................... 123 MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sens open circuit ..................................... 123 MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt .................................. 124 MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sens short to ground ............................... 124 MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sens open circuit ..................................... 124 MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sens short to +batt .................................. 125 MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sens short to ground ............................... 125 MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sens open circuit ..................................... 125 MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sens short to +batt .................................. 126
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MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sens short to ground ............................... 126 MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sens open circuit ..................................... 126 MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt ............................... 127 MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground ............................ 127 MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit ................................. 128 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt ............................... 128 MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground ............................ 128 MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit ................................. 129 MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt ............................... 129 MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground ............................ 130 MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit ................................. 130 MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt ............................... 130 MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground ............................ 131 MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit ................................. 131 MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ............................... 132 MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ............................ 132 MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit ................................. 132 MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt ............................... 133 MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground ............................ 133 MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit ................................. 133 MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt ............................... 134 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ............................ 134 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit ................................. 135 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ............................... 135 MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground ............................ 135 MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit ................................. 136 MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt ............................... 136 MID 111 - CID 1539 - FMI 04 CYL #9 Exhaust Port Temp Sensor short to ground ............................ 137 MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit ................................. 137 MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt ............................... 137
MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground ............................ 138 MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit ................................. 138 MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ............................... 139 MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ............................ 139 MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit ................................. 139 MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ............................... 140 MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground ............................ 140 MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit ................................. 141 MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ............................... 141 MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground ............................ 141 MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit ................................. 142 MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ............................... 142 MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground ............................ 143 MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit ................................. 143 MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ............................... 143 MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ............................ 144 MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit ................................. 144 MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt ............................... 145 MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground ............................ 145 MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit ................................. 145 Troubleshooting with an Event Code Event Codes ...................................................... E004 Engine Overspeed Shutdown .................... E015 High Engine Coolant Temperature Derate .. E016 High Engine Coolant Temperature Shutdown .......................................................... E017 High Engine Coolant Temperature Warning ............................................................. E019 High Engine Oil Temperature Shutdown ... E020 High Engine Oil Temperature Warning ...... E025 High Inlet Air Temperature Derate ............. E026 High Inlet Air Temperature Shutdown ........ E027 High Inlet Air Temperature Warning .......... E038 Low Engine Coolant Temperature Warning ............................................................. E040 Low Engine Oil Pressure Shutdown .......... E042 Low System Voltage Shutdown ................. E043 Low System Voltage Warning .................... E050 High System Voltage Warning ................... E053 Low Fuel Pressure Warning ...................... 147 149 149 149 150 150 150 151 151 151 151 152 152 152 153 153
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E096 High Fuel Pressure .................................... E100 Low Engine Oil Pressure Warning ............. E127 Engine Oil Filter Diff Pressure Low Warning ............................................................. E128 Engine Oil Filter Diff Pressure Low Shutdown .......................................................... E129 Engine Oil Filter Diff Pressure High Warning ............................................................. E130 Engine Oil Filter Diff Pressure High Shutdown .......................................................... E135 Low Jacket Water Pressure Shutdown ...... E223 High Gas Temperature .............................. E224 High Jacket Water Inlet Pressure .............. E225 Engine Overcrank ...................................... E226 Driven Equipment Not Ready .................... E229 Fuel Energy Content Setting Low .............. E230 Fuel Energy Content Setting High ............. E231 Fuel Quality Out of Range ......................... E233 Low Engine Pre-Lube Pressure ................ E242 Engine Overload ........................................ E243 High Left Turbo Turbine Outlet Temperature ...................................................... E244 High Right Turbo Turbine Outlet Temperature ...................................................... E245 High Right Turbo Turbine Inlet Temperature ...................................................... E246 High Left Turbo Turbine Inlet Temperature .. E247 Low Left Turbo Turbine Outlet Temperature ...................................................... E248 Low Right Turbo Turbine Outlet Temperature ...................................................... E249 Low Right Turbo Turbine Inlet Temperature ...................................................... E250 Low Left Turbo Turbine Inlet Temperature .. E253 Detonation Derate Requested ................... E254 No Detonation Derate Action Taken .......... E264 Emergency Stop Activated ........................ E266 Low Hydrax Oil Pressure ........................... E268 Unexpected Engine Shutdown .................. E269 Customer Shutdown Requested ............... E270 Driven Equipment Shutdown Requested .. E337 High Engine Oil to Engine Coolant Diff Temp ................................................................. E401 Cylinder #1 Detonation .............................. E402 Cylinder #2 Detonation .............................. E403 Cylinder #3 Detonation .............................. E404 Cylinder #4 Detonation .............................. E405 Cylinder #5 Detonation .............................. E406 Cylinder #6 Detonation .............................. E407 Cylinder #7 Detonation .............................. E408 Cylinder #8 Detonation .............................. E409 Cylinder #9 Detonation .............................. E410 Cylinder #10 Detonation ............................ E411 Cylinder #11 Detonation ............................ E412 Cylinder #12 Detonation ............................ E413 Cylinder #13 Detonation ............................ E414 Cylinder #14 Detonation ............................ E415 Cylinder #15 Detonation ............................ E416 Cylinder #16 Detonation ............................ E421 Cylinder #1 Detonation Shutdown ............. E422 Cylinder #2 Detonation Shutdown ............. E423 Cylinder #3 Detonation Shutdown ............. E424 Cylinder #4 Detonation Shutdown .............
153 153 154 154 154 155 155 155 155 156 156 156 156 157 157 157 157 158 158 159 159 159 160 160 161 161 161 161 162 162 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 168
E425 Cylinder #5 Detonation Shutdown ............. E426 Cylinder #6 Detonation Shutdown ............. E427 Cylinder #7 Detonation Shutdown ............. E428 Cylinder #8 Detonation Shutdown ............. E429 Cylinder #9 Detonation Shutdown ............. E430 Cylinder #10 Detonation Shutdown ........... E431 Cylinder #11 Detonation Shutdown ........... E432 Cylinder #12 Detonation Shutdown ........... E433 Cylinder #13 Detonation Shutdown ........... E434 Cylinder #14 Detonation Shutdown ........... E435 Cylinder #15 Detonation Shutdown ........... E436 Cylinder #16 Detonation Shutdown ........... E801 Cylinder #1 High Exhaust Port Temp ........ E802 Cylinder #2 High Exhaust Port Temp ........ E803 Cylinder #3 High Exhaust Port Temp ........ E804 Cylinder #4 High Exhaust Port Temp ........ E805 Cylinder #5 High Exhaust Port Temp ........ E806 Cylinder #6 High Exhaust Port Temp ........ E807 Cylinder #7 High Exhaust Port Temp ........ E808 Cylinder #8 High Exhaust Port Temp ........ E809 Cylinder #9 High Exhaust Port Temp ........ E810 Cylinder #10 High Exhaust Port Temp ...... E811 Cylinder #11 High Exhaust Port Temp ...... E812 Cylinder #12 High Exhaust Port Temp ...... E813 Cylinder #13 High Exhaust Port Temp ...... E814 Cylinder #14 High Exhaust Port Temp ...... E815 Cylinder #15 High Exhaust Port Temp ...... E816 Cylinder #16 High Exhaust Port Temp ...... E821 Cyl #1 Exhaust Port Temp Deviating High .. E822 Cyl #2 Exhaust Port Temp Deviating High .. E823 Cyl #3 Exhaust Port Temp Deviating High .. E824 Cyl #4 Exhaust Port Temp Deviating High .. E825 Cyl #5 Exhaust Port Temp Deviating High .. E826 Cyl #6 Exhaust Port Temp Deviating High .. E827 Cyl #7 Exhaust Port Temp Deviating High .. E828 Cyl #8 Exhaust Port Temp Deviating High .. E829 Cyl #9 Exhaust Port Temp Deviating High .. E830 Cyl #10 Exhaust Port Temp Deviating High ................................................................... E831 Cyl #11 Exhaust Port Temp Deviating High ................................................................... E832 Cyl #12 Exhaust Port Temp Deviating High ................................................................... E833 Cyl #13 Exhaust Port Temp Deviating High ................................................................... E834 Cyl #14 Exhaust Port Temp Deviating High ................................................................... E835 Cyl #15 Exhaust Port Temp Deviating High ................................................................... E836 Cyl #16 Exhaust Port Temp Deviating High ................................................................... E841 Cyl #1 Exhaust Port Temp Deviating Low .. E842 Cyl #2 Exhaust Port Temp Deviating Low .. E843 Cyl #3 Exhaust Port Temp Deviating Low .. E844 Cyl #4 Exhaust Port Temp Deviating Low .. E845 Cyl #5 Exhaust Port Temp Deviating Low .. E846 Cyl #6 Exhaust Port Temp Deviating Low .. E847 Cyl #7 Exhaust Port Temp Deviating Low .. E848 Cyl #8 Exhaust Port Temp Deviating Low .. E849 Cyl #9 Exhaust Port Temp Deviating Low .. E850 Cyl #10 Exhaust Port Temp Deviating Low ...................................................................
168 168 169 169 169 169 170 170 170 171 171 171 171 172 172 173 173 173 174 174 174 175 175 176 176 176 177 177 178 178 179 179 179 180 180 181 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188
8 Table of Contents
E851 Cyl #11 Exhaust Port Temp Deviating Low ................................................................... E852 Cyl #12 Exhaust Port Temp Deviating Low ................................................................... E853 Cyl #13 Exhaust Port Temp Deviating Low ................................................................... E854 Cyl #14 Exhaust Port Temp Deviating Low ................................................................... E855 Cyl #15 Exhaust Port Temp Deviating Low ................................................................... E856 Cyl #16 Exhaust Port Temp Deviating Low ................................................................... E864 Low Gas Fuel Differential Pressure ........... E865 High Gas Fuel Differential Pressure .......... E866 Low Gas Fuel Flow Rate ........................... E867 Improper Gas Flow Control Valve Response .......................................................... E868 Gas Flow Control Valve Malfunction ..........
188 189 189 189 190 190 191 191 191 191 192
Diagnostic Functional Tests +5V Sensor Voltage Supply ................................ 193 +8V Sensor Voltage Supply ................................ 204 Analog Sensor Signal ......................................... 213 Desired Speed Input (4 - 20 mA) ........................ 222 Detonation Sensors ............................................ 228 ECM Output Circuit (Fuel Control) ...................... 236 ECM Output Circuit (Prelubrication Oil Pump) .... 247 ECM Output Circuit (Starting Motor) ................... 258 ECM Status Indicator Output .............................. 268 Electrical Power Supply ...................................... 274 Engine Speed/Timing Sensor ............................. 281 Fuel Metering Valve ............................................ 287 Fuel Metering Valve ............................................ 295 Ignition Transformers Primary Circuit .................. 303 Ignition Transformers Secondary Circuit and Spark Plugs ................................................................. 314 Inspecting Electrical Connectors ........................ 320 Integrated Temperature Sensing Module (ITSM) ............................................................... 325 Oxygen Sensor Buffer Supply ............................. 333 Oxygen Sensor Signal ........................................ 342 Prelubrication System ......................................... 354 PWM Sensor ....................................................... 358 Throttle Actuator Solenoid .................................. 365 Calibration Procedures Engine Speed/Timing Sensor - Calibrate ........... 375 Oxygen Sensor - Calibrate ................................. 377
Index Section
Index ................................................................... 383
9 Troubleshooting Section
Troubleshooting Section Electronic Troubleshooting

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Desired engine speed is determined by the status of the idle/rated switch, the desired speed input (analog voltage or 4 to 20 mA), and parameters such as maximum engine high idle speed that are programmed into the software. Actual engine speed is detected via a signal from the speed/timing sensor. Parameters such as governor gain can be programmed with Cat ET.
System Overview
SMCS Code: 1901-038
Ignition Control
The ECM provides variable ignition timing that is sensitive to detonation. Each cylinder has an ignition transformer that is located under the valve cover for the cylinder. To initiate combustion, the ECM sends a pulse of approximately 100 volts to the primary coil of each ignition transformer at the appropriate time and for the appropriate duration. The transformers step up the voltage in order to create a spark across the spark plug electrode. Detonation sensors monitor the engine for excessive detonation. The G3516B Engine has eight detonation sensors. Each sensor monitors two adjacent cylinders. The sensors generate data on vibration that is processed by the ECM in order to determine detonation levels. If detonation reaches an unacceptable level, the ECM retards the ignition timing of the affected cylinder or cylinders. If retarding the timing does not limit detonation to an acceptable level, the ECM shuts down the engine. The ECM provides extensive diagnostics for the ignition system. The ECM also provides a switch for ignition timing in order to allow operation with alternate fuels such as propane that require a timing offset.
Introduction
The Electronic Control Module (ECM) controls most of the functions of the engine. The module is an environmentally sealed unit that is mounted in a terminal box on the engine. The ECM monitors various inputs from sensors in order to activate relays, solenoids, etc at the appropriate levels. The ECM supports the following five primary functions:
Engine speed governing Ignition control Air/Fuel ratio control Start/Stop sequencing Engine monitoring and protection
Engine Speed Governing

The ECM maintains the desired engine speed by controlling the actuator for the throttle. The actuator is located at the flange of the air inlet manifold. The actuator is electrically controlled and hydraulically actuated. A high pressure pump provides hydraulic pressure with oil from a system that is separate from the engine oil. The high pressure oil supply is monitored by a pressure switch that generates an event code if the pressure drops below an acceptable level. The throttle position is controlled in open loop mode: there is no feedback from the throttle position. The ECM issues a throttle command that represents a percent of the level of electrical current. The output can be viewed on the Caterpillar Electronic Technician (ET). The actual throttle position can be viewed on a mechanical pointer that is built into the mechanism of the throttle.
Air/Fuel Ratio Control

The ECM provides control of the air/fuel mixture for performance and efficiency at low emission levels. The system consists of an electronic fuel metering valve, an oxygen sensor, output drivers in the ECM, and maps in the ECM. The control compensates for changes in the BTU of the fuel in order to maintain desired emission levels. Note: The 50 Hz applications and the 60 Hz applications use different fuel metering valves. The following steps describe the basic operation: 1. The ECM determines the desired flow rates for the air and the fuel. The flow rates are determined by these factors:
Desired engine speed Actual engine speed
Calculated engine load

2. The maps of the data for the desired flow of air and fuel are sent in the form of a PWM signal to the fuel metering valve. 3. The ECM monitors the amount of oxygen in the exhaust gas via the oxygen sensor. The ECM adjusts the signal for the flow of air and fuel in order to achieve the desired level of exhaust oxygen. This process is repeated continuously during engine operation.
Problems with engine operation such as low oil pressure produce an event code. The ECM can issue a warning, a derating, or a shutdown. This depends on the severity of the condition. For more information, see Troubleshooting, Troubleshooting With An Event Code. Problems with the electronic system such as an open circuit produce a diagnostic code. For more information, see Troubleshooting, Troubleshooting With A Diagnostic Code.
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Start/Stop Sequencing
The ECM contains the logic and the outputs for control of engine prelubrication, starting, and shutdown. The customer programmable logic responds to signals from the following components: engine control switch, emergency stop switch, remote start switch, data link, and other inputs. To control the engine at the appropriate times, the ECM provides +Battery voltage to the relays for the prelube pump, the starting motor, and the gas shutoff valve. When the programmable logic determines that the prelubrication function is necessary, the ECM supplies +Battery voltage to the relay for the prelube pump. The system may also be programmed to perform a postlube cycle during engine shutdown in order to ensure that the turbocharger has adequate lubrication during shutdown. When the programmable logic determines that it is necessary to crank the engine, the ECM supplies +Battery voltage to the relay for the starting motor. The ECM removes the voltage when the programmable crank terminate speed is reached or when a programmable cycle crank time has expired. The engine has an energize-to-run type of gas shutoff valve. When the programmable logic determines that fuel is required to start the engine or to run the engine, the ECM supplies +Battery voltage to the valve. For more information on programmable parameters, see Troubleshooting, Programming Parameters.
Self-Diagnostics
SMCS Code: 1901-038 The Electronic Control Module (ECM) has the ability to detect problems with the electronic system and with engine operation. When a problem is detected, a code is generated. An alarm may also be generated. There are two types of codes:
Diagnostic Event
Diagnostic Code When a problem with the electronic system is detected, the ECM generates a diagnostic code. This indicates the specific problem with the circuitry. Diagnostic codes can have two different states:
Active Logged
Active Code An active diagnostic code indicates that an active problem has been detected. Active codes require immediate attention. Always service active codes prior to servicing logged codes. Logged Code Every generated code is stored in the permanent memory of the ECM. The codes are logged. Event Code An event code is generated by the detection of an abnormal engine operating condition. For example, an event code will be generated if the oil pressure is too low. In this case, the event code indicates the symptom of a problem.
Engine Monitoring and Protection

The ECM monitors both the engine operation and the electronic system.
Logged codes may not indicate that a repair is needed. The problem may have been temporary. The problem may have been resolved since the logging of the code. If the system is powered, it is possible to generate an active diagnostic code whenever a component is disconnected. When the component is reconnected, the code is no longer active. Logged codes may be useful to help troubleshoot intermittent problems. Logged codes can also be used to review the performance of the engine and the electronic system.
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The schematic also identifies the size of the wire. The size or gauge of the wire is called the American Wire Gauge (AWG). Unless the schematic specifies a different size, you may assume that the wire is 16 AWG.
Electrical Connectors and Functions

SMCS Code: 1408-038
Harness Wire Identification

Caterpillar identifies different wires with eleven different solid colors. Table 1 lists the color codes of the wiring.
Table 1
Color Codes for Wiring Code BK BR BU GN GY OR PK PU RD WH YL Color Black Brown Blue Green Gray Orange Pink Purple Red White Yellow
In addition to the color, the entire length of each wire is stamped with a specific circuit number that is repeated on every 25 mm (1 inch) of the wire. The actual wires are identified on the schematic. For example, a code of J011-RD on the schematic identifies a red wire that is stamped with the circuit number J011. This particular wire is the engine harness wire for the primary signal of the transformer in the number one cylinder. For all Caterpillar engine harnesses with electronic ignition systems, the code of J011-RD identifies the wire for the primary signal of the transformer in the number one cylinder.
Terminal Box
Illustration 1 The connectors on the terminal box connect the Electronic Control Module (ECM) to various engine controls, sensors, actuators, etc. (1) Emergency stop button (2) Service tool connector J23 for the Caterpillar Electronic Technician (3) Connector J29 for the gauge panel (4) Connector J16 for the fuel metering valve (5) Connector J15 for the prelube pump (6) Connector J14 for the air starting motor (7) Connector J13 for the gas shutoff valve (8) Connector J12 for the analog sensors (9) Connector J11 for the detonation sensors (10) Connector J10 for the speed/timing sensor, throttle actuator, oxygen buffer, and electrohydraulic actuator (11) Connector J5 for the Integrated temperature sensing module (12) Connector J7 (if equipped) for the versatile control module (13) Connector J9 for the customer
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Illustration 2 Components inside the terminal box (14) Electronic Control Module (ECM) (15) ECM connector P2 (16) ECM connector P1 (17) Ground strap (18) P50 connector for calibration of the speed/timing sensor (19) Circuit breaker CB2 for the control panel (20) Circuit breaker CB1 for the ECM
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Sensors
Sensors provide information to the electronic control module. The information enables the module to control the engine as efficiently as possible over a wide range of operating conditions. The information is used for monitoring engine operation. The sensors also enable the activation of alarms, derates, and shutoffs in response to abnormal operation. Illustrations 3 and 4 show the locations of the sensors.
Illustration 3 (1) Pressure switch for the coolant pump (inlet) (2) Detonation sensor (3) Electrohydraulic actuators pressure switch (4) Inlet air temperature sensor
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(5) Engine coolant temperature sensor
Illustration 4 (6) Pressure sensor for filtered oil (7) Pressure sensor for unfiltered oil (8) Engine coolant pressure sensor (outlet) (9) Oxygen sensor (10) Inlet manifold air pressure sensor (11) Engine oil temperature sensor (12) Buffer for the oxygen sensor (13) Speed/timing sensor
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Illustration 5 (14) The humidity sensor (if equipped) is located on the inlet air piping or the inside of the air cleaner housing. (15) Atmospheric pressure sensor (if equipped)
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The functions of the sensors are described below. Pressure switch for the coolant pump (inlet) (1) A pressure switch is located at the inlet for the engine jacket water. If the inlet pressure is too high, the switch will activate a shutdown. To observe the status of the switch, use the Caterpillar Electronic Technician (ET) to view the Engine Coolant Pump Pressure parameter. The contacts of the switch are between pin B and pin C. The contact opens at 462 41 kPa (67 6 psi). Closure of the contact is required in order for the engine to run. Detonation sensors (2) The detonation sensors monitor the engine for mechanical engine vibrations. Each sensor monitors two cylinders. The sensor produces a voltage signal that is proportional to the engine detonation. This information is processed by the electronic control module in order to determine detonation levels. To eliminate detonation, the electronic control module retards the timing of the cylinder, if necessary. If excessive detonation continues, the electronic control module will shut down the engine. To observe the value of the output of the sensors, use Cat ET to view the Cylinder #X Detonation Level. The X is the number for the particular cylinder.
Electrohydraulic actuators pressure switch (3) The electrohydraulic actuator has a pressure switch for the oil supply. Insufficient oil pressure will activate an engine shutdown. To observe the status of the switch, use Cat ET to view the Hydrax Pressure Switch Status. The contacts of the switch are between pin A and pin B. The contact closes at a maximum of 1206 kPa (175 psi). The contact opens at 700 103 kPa (102 15 psi). Closure of the contact is required in order for the engine to run. Inlet air temperature sensor (4) A sensor for monitoring the air inlet temperature is located in the elbow before the number one cylinder head. Excessive inlet air temperature can activate an alarm, a derating, or a shutdown during high load or low load operation. The trip points for activation can be programmed with Cat ET. To observe the value of the output of the sensor, use Cat ET to view the Inlet Air Temperature parameter. The sensor can measure a range of 40 to 120 C (40 to 248 F).
Engine coolant temperature sensor (5) The temperature sensor is located in the water temperature regulator housing. To monitor the coolant temperature, the element must be in contact with the coolant. If overheating occurs due to low coolant level or no coolant, the sensor will not function properly. A high coolant temperature will activate an alarm, a derating, or a shutdown. A low coolant temperature will only activate an alarm. The trip points for the activation can be programmed with Cat ET. The engine can be restarted after a shutdown due to high engine coolant temperature. However, another shutdown will occur after one minute if the temperature remains high. To observe the value of the output of the sensor, use Cat ET to view the Engine Coolant Temperature parameter. The sensor can measure a range of 40 to 150 C (40 to 302 F). Oil pressure sensors (6) and (7) The engine oil pressure is measured before the oil filters and after the oil filters. An alarm or a shutdown can be activated by any of the following occurrences: low filtered oil pressure, low oil filter differential pressure, and high oil filter differential pressure. The trip point for the activation of an alarm or a shutdown for oil filter differential pressure can be programmed with Cat ET. To observe the value of the output of the sensor, use Cat ET to view the Engine Oil Pressure or the Unfiltered Engine Oil Pressure parameter. Both of the sensors measure pressure in the range of 0 to 1135 kPa (0 to 165 psi). Engine coolant pressure sensor (8) A pressure switch is located at the outlet for the engine jacket water. If the outlet pressure is too low, the electronic control module will activate a shutdown. The trip point is calculated according to the equation in Table 2. The trip point for the shutdown depends on the value of the signal from the engine coolant temperature sensor.
Table 2
Oxygen sensor (9) and oxygen buffer (12) The oxygen sensor and the oxygen buffer generate a signal that is proportional to the percent of oxygen in the exhaust manifold. The electronic control module uses the signal to adjust for variation of fuel energy content. The signal is also used for adjusting the air/fuel ratio in order to achieve the level of emissions that is desired. To observe the output value of the sensor, use Cat ET to view the Actual Oxygen parameter. Inlet air pressure sensor (10) The sensor for inlet air pressure is connected to the air inlet manifold. The sensor monitors the absolute manifold air pressure. This is the atmospheric pressure plus the gauge pressure. The information is used by the electronic control module to determine the engine load. To observe the output value of the sensor, use Cat ET to view the Inlet Manifold Air Pressure (abs) parameter. The sensor measures pressure in the range of 20 to 339 kPa (3 to 49 psi). Engine oil temperature sensor (11) An oil temperature sensor measures the engine oil temperature. A high oil temperature will activate an alarm or a shutdown. The trip points can be programmed with Cat ET. The electronic control module compares the oil temperature to the coolant temperature. An engine oil temperature that is significantly high in comparison to a lower coolant temperature will activate an alarm or a shutdown. To observe the output value of the sensor, use Cat ET to view the Engine Oil Temperature parameter. The sensor measures temperature in the range of 40 to 120 C (40 to 248 F). Speed/timing sensor (13) The engine speed/timing sensor is located on the rear end of the left camshaft. The engine speed/timing sensor provides accurate information to the electronic control module about the position of the crankshaft and the engine rpm. The electronic control module uses the position of the crankshaft in order to determine ignition timing. If an overspeed occurs, the electronic control module shuts down the engine. The speed for the trip point of the shutdown can be programmed with Cat ET. To observe the engine speed in rpm, use Cat ET to view the Engine Speed parameter. Humidity Sensor (14) Refer to Illustration 5 for the location of the humidity sensor (if equipped). The humidity sensor generates a digital signal that is proportional to the specific humidity of the inlet air. The signal is used for adjusting the air/fuel ratio in order to achieve the level of emissions that is desired. To observe the output value of the sensor, use Cat ET to view the Specific Humidity parameter.
Calculation of the Trip Point for the Engine Coolant Pressure Shutdown (5.665 T) 420.46 = X
T is the temperature of the jacket water in Degree Celsius. X is the trip point for the shutdown in kPa.
To convert kPa to psi, divide the kPa by 6.89. To observe the value of the output of the engine coolant pressure sensor, use Cat ET to view the Engine Coolant Pressure (abs) parameter. The sensor measures pressure in the range of 0 to 472 kPa (0 to 69 psi). The measured pressure is absolute.
Exhaust Back Pressure(15) The sensor for atmospheric pressure (if equipped) is located near the exhaust duct above the turbochargers. The sensor monitors the atmospheric pressure. The electronic control module uses the signal to adjust the air/fuel ratio in order to achieve the level of emissions that is desired. To observe the output value of the sensor, use Cat ET to view the Exhaust Back Pressure parameter.
Thermocouples
Thermocouples provide information to the Integrated Temperature Sensing Module (ITSM). The information is used to monitor engine operation. The thermocouples also enable alarms and shutoffs to be activated.
Illustration 6 (16) Thermocouple for the temperature of the cylinder exhaust port (17) Thermocouple for the temperature of the exhaust inlet to the turbocharger turbine (18) Thermocouples for the temperature of the turbocharger exhaust outlet
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Cylinder Exhaust Temperature (16) Thermocouples measure the exhaust temperatures from the exhaust port of each cylinder. An alarm or a shutdown is activated if the exhaust temperature from any cylinder is too high or if the exhaust temperature from any cylinder deviates excessively from the average temperature of all of the cylinders. The trip points can be programmed with Cat ET. To observe the value of the output of the thermocouples, use Cat ET to view the Cylinder #X Exhaust Port. The X is the number for the particular cylinder. The thermocouples measure temperature in the range of 0 to 600 C 10 C (32 to 1112 F 18 F).
Exhaust Inlet to the Turbocharger Turbine (17) A thermocouple is mounted at the inlet for the exhaust gas of each turbocharger turbine. An alarm or a shutdown is activated if the temperature of the exhaust to the turbine is too high or too low. The trip points can be programmed with Cat ET. To observe the value of the output of the thermocouples, use Cat ET to view the Left Bank Turbine Inlet Temp or the Right Bank Turbine Inlet Temp. The thermocouples measure temperature in the range of 0 to 600 C 10 C (32 to 1112 F 18 F).
Exhaust Outlet from the Turbocharger Turbine (18) A thermocouple is mounted at the outlet for the exhaust gas of each turbocharger turbine. An alarm or a shutdown is activated if the temperature of the exhaust from either turbine is too high or too low. The trip points can be programmed with Cat ET. To observe the value of the output of the thermocouples, use Cat ET to view the Left Bank Turbine Outlet Temp or the Right Bank Turbine Outlet Temp. The thermocouples measure temperature in the range of 0 to 600 C 10 C (32 to 1112 F 18 F).
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Electronic Service Tools

SMCS Code: 1901-038 Caterpillar Electronic Service Tools are designed to help the service technician:
Obtain data. Diagnose problems. Read parameters. Program parameters. Calibrate sensors.
The tools that are listed in Table 3 are required in order to enable a service technician to perform the procedures.
Integrated Temperature Sensing Module
Illustration 7 Integrated temperature sensing module
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The integrated temperature sensing module monitors thermocouples that are located at the exhaust port of each cylinder. Thermocouples are also mounted at the inlets and outlets to the turbochargers. The temperatures are broadcast over data links for use with other modules. The integrated temperature sensing module calculates the average temperature for each bank. Event codes are generated if the following conditions occur:
The temperature is higher than the limit that is

programmed.
The temperature is lower than the limit that is

programmed.
The temperature of a cylinder deviates

significantly from the average temperature for all of the cylinders.
Table 3
Service Tools Pt. No. N/A Description Personal Computer (PC) Functions This PC configuration is recommended: Intel Pentium II 333 mHz processor 64 megabyte of RAM 4.3 GB hard drive 14X speed CD-ROM drive This PC configuration has the minimum requirements: IBM PC compatible 100 MHz processor 32 megabyte of RAM 10 MB of available hard drive space CD-ROM drive 3.5 inch 1.44-MB floppy disk drive Windows NT or Windows 95 RS232 port with 16550AF UART VGA monitor or display Single user license for Cat ET If a more recent version of this software is available, the more recent version may be used. Data subscription for all engines The communication adapter is connected between the PC (Cat ET) and the ECM. This cable connects the PC to the 171-4401 Communication Adapter II. This cable connects the PC to the 171-4401 Communication Adapter II. This cable connects the 171-4401 Communication Adapter II to the 7X-1414 Data Link Cable As. The communication adapter is connected between the PC (Cat ET) and the ECM. This cable connects the PC (Cat ET) to the 7X-1701 Communication Adapter. This cable connects the 7X-1701 Communication Adapter to the 7X-1414 Data Link Cable As. This cable connects the service tool connector on the engine mounted terminal box to the 139-4166 Adapter Cable As. This breakout harness is for use between the jacks and the plugs of the sensors. This tool is used for the removal of pins and sockets from Deutsch connectors and AMP connectors. This tool is used for work with CE electrical connectors. The multimeter is used for the testing and the adjusting of electronic circuits. The probes are used with the multimeter to measure voltage in wiring harnesses without disconnecting the harnesses. The tester is used to test for voltage in circuits, relays, bulbs, wires, and switches.
N/A
Personal Computer (PC)
JERD2124 Version 2001B JERD2129 171-4401 196-0055 160-0141 207-6845 7X-1701 7X-1425 139-4166 7X-1414 8T-8726 151-6320 1U-5804 9U-7330 7X-1710 5P-7277
(1) (2) (3)
Software
Software Communication Adapter II (1) Serial Cable As Serial Cable As

(1)(2)
(2)
Adapter Cable As (1)(3) Communication Adapter Serial Cable As Adapter Cable As Data Link Cable As Adapter Cable As Wire Removal Tool Crimp Tool Digital Multimeter Multimeter Probes Voltage Tester
This item is included in the 171-4400 Communication Adapter Gp. Either the 160-0141 or the 196-0055 cable may be used. Either the 160-0133 or the 207-6845 cable may be used.
Note: Either the 171-4401 Communication Adapter II or the 7X-1700 Communication Adapter Gp can be used. However, the 7X-1700 Communication Adapter Gp is no longer serviced.
Caterpillar Electronic Technician (ET)

The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. Cat ET can display the following information:
Parameters Diagnostic codes Event codes Engine configuration Status of the monitoring system
Cat ET can perform the following functions:
Diagnostic tests Sensor calibration

Illustration 8
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Flash downloading Set parameters Connecting Cat ET with the 171-4401 Communication Adapter II
The battery supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET and the communication adapter to the engine. 1. Turn the engine control switch to the OFF position.
(1) PC (2) 196-0055 Serial Cable or the 160-0141 Serial Cable (3) 171-4401 Communication Adapter II (4) 207-6845 Adapter Cable (5) 7X-1414 Data Link Cable
2. Connect cable (2) to the RS232 serial port of PC (1). 3. Connect cable (2) to communication adapter (3). 4. Connect cable (4) to communication adapter (3). 5. Connect cable (4) to cable (5). 6. Connect cable (5) to the service tool connector of the terminal box. 7. Turn the engine control switch to the ON position. The engine should be OFF. If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, Electronic Service Tool Will Not Communicate With ECM.
Connecting Cat ET with the 7X-1701 Communication Adapter

The battery supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET and the communication adapter to the engine.
1. Turn the engine control switch to the OFF position.
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Engine Monitoring System

SMCS Code: 1901-038 The Electronic Control Module (ECM) monitors the operating parameters of the engine. The ECM can initiate responses if a specific engine parameter exceeds an acceptable range. Three possible responses may be available for each parameter: WARNING, DERATE, and SHUTDOWN. Some of the responses are not available for some of the parameters. Use the Caterpillar Electronic Technician (ET) to perform the following activities:
Select the available responses. Program the level for monitoring. Program delay times for each response.
The default settings for the parameters are programmed at the factory. To accommodate unique applications and sites, the parameters may be reprogrammed with Cat ET. The screens of Cat ET provide guidance for the changing of trip points. Note: Some of the parameters are protected by factory passwords. Other parameters can be changed with customer passwords.
Illustration 9 (1) (2) (3) (4) (5) PC 7X-1425 Serial Cable 7X-1701 Communication Adapter 139-4166 Adapter Cable 7X-1414 Data Link Cable
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Changing the Settings of the Monitoring System

Use the following procedure to change settings of the parameters: 1. Use Cat ET and select the Service/Monitoring System screen. 2. Highlight the desired parameter. Then click on the Change button in the lower left corner of the screen. The Change Monitor System screen will appear. 3. Change the State to On or Off.
2. Connect cable (2) to the RS232 serial port of PC (1). 3. Connect cable (2) to communication adapter (3). 4. Connect cable (4) to communication adapter (3). 5. Connect cable (4) to cable (5). 6. Connect cable (5) to the service tool connector of the terminal box. 7. Turn the engine control switch to the ON position. The engine should be OFF. If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, Electronic Service Tool Will Not Communicate With ECM.
4. Set the Trip Point and the Delay Time according to the Allowed Values in the lower half of the screen. 5. Click the OK button. If a password is required, the Enter Passwords screen will appear. Enter the correct passwords and then click the OK button. The new settings will be effective immediately.
Monitoring Parameters
Low System Voltage
The trip point for this parameter is set at the factory. The trip point cannot be changed. If the system voltage reaches the trip point, the ECM will generate a warning or a shutdown.
High Jacket Water to the Engine Oil Temperature Differential

If the differential temperature of the jacket water and the engine oil reaches the trip point, the ECM will generate a warning or a shutdown.
Low Gas Fuel Differential Pressure

If the fuel differential pressure reaches the trip point, the ECM will generate a warning.
High Engine Coolant Temperature

If the engine coolant temperature reaches the trip point, the ECM will generate a warning, a derating, or a shutdown.
High Gas Fuel Differential Pressure

If the fuel differential pressure reaches the trip point, the ECM will generate a warning.
Low Engine Coolant Temperature

If the engine coolant temperature reaches the trip point, the ECM will generate a warning.
High System Voltage

The trip point for this parameter is set at the factory. The trip point cannot be changed. If the system voltage reaches the trip point, the ECM will generate a warning or a shutdown.
Engine Overspeed
If the engine speed reaches the trip point, the ECM will activate an engine shutdown. A typical trip point is 118 percent of the engines rated speed.
High Engine Oil Temperature

If the engine oil temperature reaches the trip point, the ECM will generate a warning or a shutdown.
Trip Points of the Engine Load for High Inlet Air Temperature
This feature provides a trip point between high engine load and low engine load. The trip point is used for events that involve high inlet air temperature. The trip point for the events is based on the engine load. The possible responses of the system include warning, derating, and shutdown. If the load is greater than the trip point, the trip point for the High Inlet Air Temperature at High Engine Load event is used for the logging of the high inlet air temperature. If the load is less than the trip point, the trip point for the High Inlet Air Temperature at Low Engine Load event is used for the logging of the high inlet air temperature.
High Oil Filter Differential Pressure

The trip point for this parameter is set at the factory. The trip point cannot be changed. The parameter cannot be turned off. The parameter is always ON. If the engine oil filter differential pressure reaches the trip point, the ECM will generate a warning or a shutdown.
Low Oil Filter Differential Pressure

The trip point for this parameter is set at the factory. The trip point cannot be changed. The parameter cannot be turned off. The parameter is always ON. If the engine oil filter differential pressure reaches to the trip point, the ECM will generate a warning or a shutdown.
High Inlet Air Temperature at Low Engine Load

The Service/Configuration screen of Cat ET defines the High Inlet Air Temp Engine Load Set Point. The ECM can activate a warning, a derating, or a shutdown if the inlet air temperature reaches the trip point during the low load operation that is defined.
High Fuel Temperature

If the engine oil temperature reaches the trip point, the ECM will generate a warning.
Low Fuel Pressure

If the fuel pressure reaches the trip point, the ECM will generate a warning.
High Inlet Air Temperature at High Engine Load

The Service/Configuration screen of Cat ET defines the High Inlet Air Temp Engine Load Set Point. The ECM can activate a warning, a derating, or a shutdown if the inlet air temperature reaches the trip point during the high load operation that is defined.
If more than one derating is active, the ECM will automatically use the largest value that is programmed for a derating of the desired engine speed. When a derating of 0 percent is achieved, all of the deratings are deactivated.
Default Settings of the Monitoring System

Examples of the default settings for the parameters are listed in Table 4. The values may have changed. Use the Cat ET to determine the programming for your engine. Many of the items can be reprogrammed in order to accommodate the requirements of individual sites.
High Fuel Pressure

The ECM will activate a warning if the fuel pressure reaches the trip point.
Engine Power Derating

The ECM can automatically derate the engine power in order to protect the engine from undesirable operating conditions. The ECM can derate the engine power in response to the following operating conditions:
E015 High Engine Coolant Temperature E025 High Inlet Air Temperature at Low Engine
Load
E025 High Inlet Air Temperature at High Engine

Load
E242 Engine Overload

The derating for the engine coolant and the inlet air temperatures can be programmed to be ON or OFF with Cat ET. The default setting for the derating is OFF. The temperature for the trip point and the delay time are also programmable. The range for the temperature for the trip point and the delay time is limited. If one of these three deratings is activated, the ECM will reduce the desired engine speed by 0.1 percent per each second. After the condition which activated the derating is gone, the ECM will increase desired engine speed by 0.1 percent per each second. The derating is deactivated when a derating of 0 percent is achieved and the original desired engine speed is restored. For example, if the desired engine speed is 1507 rpm and a derating is activated, the desired engine speed will be reduced to 1477 rpm in 20 seconds. If the condition that activated the derating is gone after 20 seconds, the desired engine speed will return to 1507 rpm in 20 seconds. In this example, the incident lasted for 40 seconds. The derating for Engine Overload is programmed to be ON at the factory. This derating cannot be adjusted via Cat ET. The default value for the derating is 110 percent of the rated load.
Table 4
Default Settings of the Programmable Monitoring System Parameter Low System Voltage High Engine Coolant Temperature Low Engine Coolant Temperature Engine Overspeed High Engine Oil Temperature High Oil Filter Differential Pressure Low Oil Filter Differential Pressure High Fuel Temperature Low Fuel Pressure High Jacket Water to Engine Oil temperature Differential Low Gas Fuel Differential Pressure High Gas Fuel Differential Pressure High System Voltage High Inlet Air Temperature at Low Engine Load High Inlet Air Temperature at High Engine Load High Fuel Pressure
(1)
Event Code E043 (1) E042 (3) E017 (1) E016 (3) E015 (2) E038 (1)
System Response Warning Shutdown Warning Shutdown Derating Warning
State
Trip Point 20 volts
Delay in Seconds 20 10
Security Level Password
Range
Range of the Delay in Seconds
On
(1)
18 volts 113 C 111 C 109 C 5 C 1770 rpm 102 C 104 C
This item cannot be programmed.
On On
(1)
80 to 129 C 20 Customer 5 to 80 C 1200 to 2125 rpm 85 to 102 C 85 to 104 C 80 to 138 kPa 1 to 60
Off On
E004 (3) E020 (1) E019 (3) E129 (1) E130 (3) E127 (1) E128 (3) E223 (1)
Shutdown Warning Shutdown Warning Shutdown Warning Shutdown On

(1)
0 20
Factory Customer Factory Customer Factory Customer Factory
103 kPa 138 kPa 35 kPa 7 kPa 60 C 20 10 10
7 to 80 kPa 0 to 60 C 1 to 60
On E053 (1) E123 (1) On E124 (3) Shutdown

(1)
Warning
105 kPa 14 C 20 C
Customer
100 to 135 kPa 0 to 20 C
20 Factory
E864 (1) On E865 (1) Warning On

(1)
5 kPa 10 35 kPa Customer 0 to 35 kPa
E050 (1) E027 (1) E025 (2) E026 (3) E027 (1) E025 (2) E026 (3) E096 (1) Derating Shutdown Warning Derating Shutdown Warning
34 volts 69 C 100 C 73 C 53 C 100 C 57 C 135 kPa
20 ec
This item cannot be programmed. 32 to 85 C
On Off On
(1)
20 Customer
On Off On
(1)
32 to 100 C
1 to 60
On
10
100 to 135 kPa
This parameter is permanently active. This parameter cannot be turned off.
Separate timers are used in the ECM for each response that is associated with a parameter. If a trip point is reached, the timer for that event is started. For example, the warning for High Engine Coolant Temperature E017 (1) can be set to 95 C with a five second delay. The timer starts counting if the coolant temperature reaches 95 C. If the temperature is not reduced to less than 95 C within five seconds, the event becomes active and the event is logged.
Conditions for Parameters

Some of the programmable parameters are dependent on the status of an ECM output before the parameters are allowed to function. Some of the parameters are allowed to function after the crank terminate relay has been energized for more than 30 seconds. Other parameters are allowed to function after the output for the fuel control relay is energized. Some parameters are not dependent upon any conditions. The conditions are designed to eliminate false events during start-up if the customer has programmed a delay time to zero. The conditions are listed in Table 5.
Table 5
Conditions for Activation for Monitoring the Parameters Parameter Low System Voltage High Engine Coolant Temperature Low Engine Coolant Temperature Engine Overspeed High Engine Oil Temperature High Oil Filter Differential Pressure Low Oil Filter Differential Pressure High Fuel Temperature Low Fuel Pressure High Jacket Water to Engine Oil Temp Differential Low Gas Fuel Differential Pressure High Gas Fuel Differential Pressure High System Voltage High Inlet Air Temperature at Low Engine Load High Inlet Air Temperature at High Engine Load High Fuel Pressure The fuel control relay is energized. None The crank terminate relay is energized for more than 30 seconds. The fuel control relay is energized. The crank terminate relay is energized for more than 30 seconds. The fuel control relay is energized. None The crank terminate relay is energized for more than 30 seconds. None None The crank terminate relay is energized for more than 30 seconds. Condition
Use care when you program the trip points and the delay times. Ensure that the response of the ECM is correct for the application. The monitoring system will accept any settings within the ranges.
If the trip point for a shutdown is programmed to activate before the trip point for a warning, the engine will shut down and the warning will not be activated.
Programmable Parameters of the Integrated Temperature Sensing Module

The Integrated Temperature Sensing Module (ITSM) monitors the temperatures of the cylinder exhaust ports, the inlets of the turbocharger turbine, and the outlets of the turbocharger turbines. If a temperature exceeds an acceptable range, the ITSM can initiate a WARNING or SHUTDOWN. Both of the responses are available for all of the parameters. Use Cat ET to perform the following activities:
Select the available responses. Program the level for monitoring. Program delay times for each response.
Note: To initiate the responses, the ITSM sends commands to the ECM via the Cat Data Link. If the connection between the ITSM and the ECM is not correct, the ITSM cannot initiate any response. The default settings for the parameters are programmed at the factory. To accommodate unique applications and sites, the parameters may be reprogrammed with Cat ET. The screens of Cat ET provide guidance for changing trip points. Table 6 lists default examples of the values for the parameters. However, the values may have changed. Use Cat ET to determine the programming for your engine. The items can be reprogrammed in order to accommodate the requirements of individual sites. Use care when you program the trip points and the delay times. Ensure that the response of the ITSM is correct for the application. The monitoring system will accept any setting within the ranges. If the trip point for a shutdown is programmed to activate before the trip point for a warning, the engine will shut down and the warning will not be activated.
Table 6
Default Settings for the Integrated Temperature Sensing Module Parameter Event Code System Response State Trip Point Delay in Seconds Security Level Password Range Range of the Delay in Seconds
High Exhaust Temperature
E801 (1) through E816 (1) E801 (3) through E816 (3)
Warning
495 C
5 100 to 1000 C
Shutdown
650 C
Exhaust Port Temperature High Deviation
Warning On Shutdown
50 C
150 C 10 to 500 C
Exhaust Port Temperature Low Deviation
Warning
50 C
Shutdown
150 C Customer 1 to 6000 495 C 650 C 495 C 650 C Off 250 C 100 C 250 C 100 C

High Turbo Turbine Inlet Temperature
E245 (1) E246 (1) E245 (3) E246 (3) E243 (1) E244 (1) E243 (3) E244 (3) E249 (1) E250 (1) E249 (3) E250 (3) E247 (1) E248 (1) E247 (3) E248 (3)
Warning Shutdown Warning Shutdown Warning Shutdown Warning Shutdown
10
High Turbo Turbine Outlet Temperature
Low Turbo Turbine Inlet Temperature
100 to 1000 C
Low Turbo Turbine Outlet Temperature
Separate timers are used in the ITSM for each response that is associated with a parameter. If a trip point is exceeded, the timer for that event is started. For example, the warning for the High Exhaust Temperature (E801 (1)) can be set to 495 C with a five second delay. The timer starts counting if the exhaust port temperature of the number 1 cylinder reaches 495 C. If the temperature is not reduced to less than 495 C within five seconds, the event becomes active and the event is logged.
Programming Parameters
i01726978
Programming Parameters
SMCS Code: 1901-038 Programmable parameters enable the engine to be configured in order to meet the requirements of the application. The system configuration parameters must be programmed when the application is installed. Perform this programming before the initial engine start-up. Data from a gas analysis and data on engine performance are required in order to determine the correct settings for the ignition timing and the exhaust oxygen. Incorrect programming of parameters may lead to complaints about performance and/or to engine damage. Programmable parameters can be classified into the following types: engine identification, timing control, air/fuel ratio control, speed control, and start/stop control. If the Electronic Control Module (ECM) is replaced, the appropriate parameters must be copied from the old ECM. This can be done with the Copy Configuration feature of the Caterpillar Electronic Technician (ET). Alternatively, the settings can be recorded on paper and then programmed into the new module. NOTICE Changing the parameters during engine operation can cause the engine to operate erratically. This can cause engine damage. Only change the settings of the parameters when the engine is STOPPED.
The customer passwords can be changed, if necessary. The customer passwords or a factory password is needed in order to change the customer passwords. If the customer passwords are forgotten, factory passwords can be acquired from Caterpillar. After the customer passwords are entered, the passwords are required in order to change certain parameters. Once the passwords are entered successfully, the passwords are not requested again until another screen is accessed or the data link is interrupted. This feature is enabled by programming two customer passwords. Use the following procedure to program the passwords. The same procedure is used to change the passwords: 1. Access the Service/Configuration screen of the Caterpillar Electronic Technician (ET). 2. Highlight the Customer Password #1 parameter. Click on the Change button in the lower right corner of the screen. Note: Be sure to record the customer passwords. Store the passwords securely. The passwords can have a maximum of eight characters. Alphanumeric characters may be used. The passwords are case sensitive. 3. Enter the password in the Change Parameter Value dialog box and click on the OK button. 4. Highlight the Customer Password #2 parameter. Click on the Change button in the lower right corner of the screen. 5. Enter the password in the Change Parameter Value dialog box and click on the OK button. The passwords are now programmed into the memory of the Electronic Control Module (ECM). Make a copy of Table 7 and record your passwords. Store the passwords securely.
Table 7
i01726982
Customer Passwords
SMCS Code: 1901 Certain monitoring system parameters and system configuration parameters may be protected with customer passwords. Use of the passwords helps to prevent free access to the modification of the parameters. If the customer passwords are not programmed, all of the parameters are unprotected.
Customer Passwords Customer Password #1 Customer Password #2
i01727009
i01727016
Factory Passwords
SMCS Code: 1901-038 Factory level security passwords are required for clearing certain logged events and for changing certain programmable parameters. Because of the passwords, only authorized personnel can make changes to some of the programmable items in the Electronic Control Module (ECM). When the correct passwords are entered, the changes are programmed into the ECM. Factory passwords are required to program the following shutdowns:
Factory Passwords Worksheet

SMCS Code: 1901-038 Note: A mistake in recording this information will result in incorrect passwords.
Table 8
Factory Passwords Worksheet Dealer Code Customers Name Address
Engine Overspeed
Telephone Number
High Engine Oil Temperature High Oil Filter Differential Pressure Low Oil Filter Differential High Jacket Water to Engine Oil Temperature
Differential The Enter Factory Passwords screen on Cat ET will display the following parameters. To obtain the proper passwords, the information must be given to an authorized Caterpillar dealer:
Information from the Enter Factory Passwords Screen on the Caterpillar Electronic Technician (ET) Serial Number for Cat ET Engine Serial Number ECM Serial Number Diagnostic Clock(1) Total Tattletale Reason Code Factory Passwords Factory Password (No. 1) Factory Password (No. 2)
Current ECM Serial number of the service tool Serial number of the engine
(1)
Do not obtain this information from the service meter.
i01726985
Serial number of the ECM Diagnostic clock Total Tattletale Reason

The old interlock code is required to change the interlock code on a used ECM. The passwords are controlled by Caterpillar. The passwords may only be obtained by an authorized Caterpillar dealer. The passwords may only be used for one programming session. After you exit the Enter Factory Passwords screen on Cat ET, a different set of passwords will be required before you can program the ECM. Factory passwords are not required for the first hour of operation for a new ECM. After the hour expires, factory passwords are required for some of the programming.
Flash Programming
SMCS Code: 1901-038 Software is located in the flash memory of the Electronic Control Module (ECM) and the Integrated Temperature Sensing Module (ITSM). The Caterpillar Electronic Technician (ET) can be used to flash new software into the ECM or the ITSM. This is the only method for updating the software. The module that contains the software cannot be physically removed from the ECM. This eliminates the risk of moisture entry into the ECM due to improper seal installation. The flash is accomplished by transferring the data from Cat ET to the module via data link wiring. The Software, JERD2124 or Software, JERD2129 is used.
Flash Programming
If the slowest baud rate of Cat ET is selected, flash programming can last up to 15 minutes. Be sure to set the baud rate to the fastest rate for your PC. To select the baud rate, use the Utilities/ Preferences option on the Cat ET. Select the Communications tab and click on Advanced.... Then select the baud rate from the Advanced Communication Settings menu and click the OK button. If a communication error occurs, select a slower baud rate in order to improve the reliability. Note: The 141-1957 Electronic Control (ITSM) will not function properly with the Software, 190036601.fls. Do not use any subsequent version such as Software, 190036602.fls and Software, 190036603.fls, etc. Do not flash this software into the 141-1957 Electronic Control. 1. Connect Cat ET to the service tool connector. 2. Turn the engine control switch to the STOP position. Cat ET will not flash if the engine control switch is in the OFF or START position. 3. Select WinFlash from the Utilities menu on the Cat ET. WinFlash will try to detect an ECM. 4. When an ECM has been detected, the ECM Selector window will appear. Select the appropriate ECM and then select OK. The Flash File Selection window will appear. 5. The flash files are located on a disk drive and in a directory. Select the correct disk drive and the directory from Drives and Directories on Cat ET. A list of flash files will appear. 6. Select the correct file from the list of flash files. Read the Description and the File Info in order to verify that the correct file is selected. Select Open. 7. Select the Begin Flash button in order to program the personality module. When the flash is completed, this message will appear: Flash Completed Successfully.
8. Program the configuration parameters and the monitoring system parameters. The parameters must be programmed in order to ensure proper engine operation. Refer to Troubleshooting, Engine Monitoring System and Troubleshooting, System Configuration Parameters. 9. Start the engine and check for proper operation. a. If a diagnostic code of 268-02 Check Programmable Parameters is generated, program any parameters that were not in the original software. b. Access the Configuration screen under the Service menu in order to determine the parameters that require programming. Look under the Tattletale column. All of the parameters should have a tattletale of 1 or more. If a parameter has a tattletale of 0, program that parameter.
WinFlash Error Messages

If you receive any error messages during flash programming, click on the Cancel button in order to stop the process. Access the information about the ECM Summary under the Information menu. Make sure that you are flashing the correct file for your engine.
i01756490
System Configuration Parameters

SMCS Code: 1901-038 Certain parameters are unique for each engine application. Table 9 is a list of the parameters that can be configured for G3500B Engines. The values of the parameters can be viewed on the Configuration screen of the Caterpillar Electronic Technician (ET).
Table 9
Configuration Parameters for G3500B Engines Information for the Electronic Control Module (ECM) Engine Serial Number Equipment ID Customer Password #1 Customer Password #2 Total Tattletale
(continued)
(Table 9, contd)
(Table 9, contd)
Configuration Parameters for G3500B Engines KW Meter Offset KW Meter KW/Volt Timing Control First Desired Timing Second Desired Timing Air/Fuel Ratio Control Fuel Quality Gas Specific Gravity Fuel Specific Heat Ratio
(1)
Configuration Parameters for G3500B Engines Override Parameters Oxygen Sensor Override Requested Detonation Derate Percentage Override
(1)
This parameter is only for 60 Hz engines.
Information for the Electronic Control Module (ECM)

Engine Serial Number
The engine serial number is programmed into the ECM at the factory. The number is stamped on the engine Information Plate.
Desired Oxygen At Full Load Oxygen Feedback Feature Enabled Status Air/Fuel Proportional Gain Air/Fuel Integral Gain Speed Control Low Idle Speed Minimum Engine High Idle Speed Maximum Engine High Idle Speed Engine Accel. Rate Desired Speed Input Configuration Governor Type Setting Grid Status Engine Speed Droop Governor Proportional Gain Governor Integral Gain Governor Derivative Gain Auxiliary Proportional Governor Gain 1 Auxiliary Integral Governor Gain 1 Auxiliary Derivative Governor Gain 1 Start/Stop Control Driven Equipment Delay Time Crank Terminate Speed Engine Purge Cycle Time Engine Cooldown Duration Cycle Crank Time Engine Overcrank Time Engine Speed Drop Time Engine Pre-lube Time Out Period Monitoring and Protection High Inlet Air Temp Engine Load Set Point
(continued)
Equipment ID
The customer can assign an Equipment ID for the purpose of identification.
Customer Passwords
Two customer passwords can be entered. The passwords are used to protect certain configuration parameters from unauthorized changes. Use the following procedure to enter the customer passwords: 1. Use Cat ET and select the Service/Configuration screen. 2. Highlight Customer Password #1 or Customer Password #2. Then click the Change button in the lower left corner of the screen. 3. Enter the password in the Change Parameter Value dialog box. Then click the OK button. The password is immediately programmed into the ECM memory. Note: Factory level security passwords are required for clearing certain logged events and for changing certain programmable parameters. Because of the passwords, only authorized personnel can make changes to some of the programmable items in the ECM. When the correct passwords are entered, the changes are programmed into the ECM.
Total Tattletale
This item displays the number of changes that have been made to the configuration parameters.
kW Meter Offset
This parameter is unavailable at the time of publication.
Air/Fuel Ratio Control

Fuel Quality
This parameter is programmed to the Lower Heating Value (LHV) of the primary fuel. The fuel ratio control of the ECM will compensate for some inaccuracy in this setting. The ECM assumes a corrected value that is equal to the customer programmed Fuel Energy Content that is multiplied by the Fuel Correction Factor. This factor is displayed on the Cat ET screen. An event code is generated if the Fuel Correction Factor exceeds a limit that is programmed at the factory. The event code will indicate the need to reprogram this value. The ECM reverts to the customer programmed Fuel Energy Content during start-up. The ECM also reverts to the customer programmed Fuel Energy Content when a problem is detected in the oxygen sensors circuit. An accurate customer programmed Fuel Energy Content value that is determined by a laboratory is recommended. The Fuel Quality parameter can be used to change the air/fuel ratio when the engine is not operating in Oxygen Feedback mode. The operation in Oxygen Feedback is determined by the engines rating, the application, and the load. Normally, the engine does not operate in Oxygen Feedback mode when the load is between 0 percent and up to 25 or 40 percent load. The engine will not operate in Oxygen Feedback when the Oxygen Feedback Enable Status parameter is disabled. The operation of the engine will not change if the Fuel Quality parameter is changed and the Oxygen Feedback Enable Status is enabled. The Fuel Correction Factor will automatically compensate.
kW Meter kW/Volt
Timing Control
First Desired Timing
The First Desired Timing is determined with the methane number of the primary fuel that is used. Use the Engine Performance Sheet, Fuel Usage Guide. The ECM selects the First Desired Timing when the switch for the selection of the timing is in the open position.
Second Desired Timing

The Second Desired Timing is determined with the methane number of the alternate fuel that is used and the Engine Performance Sheet, Fuel Usage Guide. The gas engines ECM selects the Second Desired Timing when the timing selection switch is in the closed position. If an alternate fuel is not used, enter the same timing that was entered in the First Desired Timing.
Desired Timing
The Desired Timing parameter allows the customer to electronically program the timing of the ignition spark of the electronic system in order to meet the needs for specific applications and specific installations. The desired timing is programmed with Cat ET. The desired timing value can be changed while the engine is running or while the engine is stopped. The value that is entered for the desired timing is the ignition timing when the engine is operating at rated speed and at full load. Note: The actual ignition timing at a given instance may vary from the desired timing value. This variance is due to variations in the engine speed or the detonation. The range for programming the desired timing is 0 to 40 degrees before the top center (TC) position.
Gas Specific Gravity

The value for the fuel metering valve requires an input for the Gas Specific Gravity in order to precisely meter the air/fuel ratio. The Gas Specific Gravity can be obtained by a gas analysis of the fuel.
Desired Oxygen at Full Load

Program the Desired Oxygen at Full Load parameter to the percent of exhaust oxygen that is stated in the Engine Performance Sheet for your application. This parameter is used to trim the oxygen map that is preprogrammed in the gas engines ECM at the factory. If the measured exhaust oxygen or the NOX emissions are not the required value, increase the Desired Oxygen at Full Load parameter in order to lean the engine or decrease the Desired Oxygen at Full Load parameter in order to richen the fuel mixture.
Speed Control
Low Idle Speed
Program this parameter to the desired low idle rpm. The low idle rpm can be programmed from 500 to 1100 rpm.
Minimum Engine High Idle Speed

Program this parameter to the desired minimum high idle rpm. The actual high idle speed is regulated by the desired speed input. The regulation is linear in proportion to the input. An input of 0 percent results in the minimum high idle rpm and an input of 100 percent results in the maximum high idle rpm.
Oxygen Feedback Enable Status

The Oxygen Feedback Enable Status can be set to Enable or Disable. This feature allows the system for the fuel correction factor to be disabled in order to troubleshoot. For example, the disabling of this feature can help determine whether the air/fuel ratio control is the cause of instability. If an exhaust oxygen sensor fails, this parameter can be set to Disable in order to allow the engine to run in the open loop mode until a new sensor is obtained. An emissions analyzer must be used to verify the emissions level. The Fuel Quality parameter must be adjusted in order to adjust the air/fuel mixture. Note: Do not operate an engine that is unattended in the open loop mode if the fuel has an LHV that is changing. The engine risks a shutdown due to lean misfire or detonation.
Maximum Engine High Idle Speed

Program this parameter to the desired maximum high idle rpm. The actual high idle speed is regulated by the desired speed input. The regulation is linear in proportion to the input. An input of 0 percent results in the minimum high idle rpm and an input of 100 percent results in the maximum high idle rpm.
Speed Selection
The desired speed operates at low idle speed or high idle speed. The speed is selected by the position of the idle/rated switch and by the status of the engine oil pressure. If the switch is in the idle position, the ECM will always select the low idle speed. If the engine oil pressure is less than the trip point for the low oil pressure warning, the ECM will always select low idle speed regardless of the position of the idle/rated switch. If the oil pressure is greater than the trip point for the low oil pressure warning and the switch is in the rated position, the ECM will select the high idle speed.
Air/Fuel Ratio Proportional Gain

The Air/Fuel Ratio Proportional Gain determines the response of the fuel metering valve to the magnitude of error for the fuel ratio. The factory default setting is 0. This value should not require adjustment. If problems occur, this is one of the last parameters that should be adjusted. The adjustable range is 50 to +50. Negative values reduce the magnitude and positive values increase the magnitude.
Engine Accel. Rate

This parameter controls the rate for engine response to a change in the desired engine speed. For example, the engine can be programmed to accelerate at a rate of 50 rpm per second when the Idle/Rated switch is turned to the Rated position.
Air/Fuel Ratio Integral Gain

The Air/Fuel Ratio Integral Gain determines the response of the fuel metering valve to the error that is accumulated over time for the air/fuel ratio. The factory default setting is 0. This value should not require adjustment. If problems occur, this is one of the last parameters that should be adjusted. The adjustable range is 50 to +50. Negative values reduce the magnitude and positive values increase the magnitude.
Desired Speed Input Configuration

The ECM reads the desired engine speed from a throttle position sensor. The parameter Desired Speed Input Configuration will determine the type of signal from the throttle position sensor. The output signal from the throttle position sensor can be either 0 to 5 VDC or 4 to 20 mA.
Note: Do not select PWM for the desired speed input. The ECM is not configured to accept a pulse width modulated signal for input of the desired engine speed.
Governor Proportional Gain

Note: The default values that are programmed into the ECM for the governor gain settings should be sufficient for most applications. If you have a problem with instability, always investigate other causes before you adjust the governor gain settings. These other conditions can cause instability: diagnostic codes, unstable gas pressure, incorrect throttle angle, and position of the wastegate. The Governor Proportional Gain determines the throttle response of the governor to the magnitude of the error in engine speed. This parameter is based on a proportional multiplier. This parameter changes the reaction of the governor when the Grid Status parameter is OFF. If this gain is adjusted and the Grid Status is ON, the stability is not affected. To change this parameter, use the Graph feature on the Governor Gain screen. The graph provides the best method for observing the effects of the adjustment on engine stability. If changing this gain causes no effect, check the Grid Status in order to make sure that the status is OFF.
Governor Type Setting

The Governor Type Setting parameter can be set to Isochronous Mode or to Droop Mode. This setting is dependent upon the application of the engine. The status of the Governor Type Setting can be observed on the Status Group 5 Governor Type Setting on Cat ET. There are two methods for selecting the setting. For some engines, the ECM is programmed to read the status of terminal J1-13. If the terminal is unconnected, the governor is set to Isochronous Mode. If the terminal is grounded, the governor is set to Droop Mode. To set the governor to Droop Mode, fabricate a jumper wire with Deutsch connectors on both ends. Connect one end to terminal J1-13 and connect the other end to terminal J1-31 (return). For other engines, the configuration parameter is programmed with Cat ET.
Governor Integral Gain Grid Status

The generators Grid Status parameter can be set to On or Off. The Grid Status can be observed on the Status Group 5 Grid Status on Cat ET. The ECM is programmed to read the status of terminal J1-66. If the terminal is unconnected, the Grid Status is Off. If the terminal is grounded, the Grid Status is On. To set the Grid Status to On, fabricate a jumper wire with Deutsch connectors on both ends. Connect one end to terminal J1-66 and connect the other end to terminal J1-31 (return). This parameter determines the throttle response of the governor to the error of engine speed that is accumulated over time. This parameter is based on an integral multiplier. This parameter changes the reaction of the governor when the Grid Status parameter is OFF. If this gain is adjusted and the Grid Status is ON, the stability is not affected. To change this parameter, use the Graph feature on the Governor Gain screen. The graph provides the best method for observing the effects of the adjustment on engine stability. If changing this gain causes no effect, check the Grid Status in order to make sure that the status is OFF.
Engine Speed Droop

This programmable parameter allows precise control of the droop for applications such as load sharing. The Governor Type Setting parameter must be set to Droop. The droop can be programmed to a value between 0 and 10 percent.
Governor Derivative Gain

This parameter changes the governors response to the rate of change in the engine speed fluctuation. This parameter is based on a derivative multiplier when the Grid Status parameter is Off. If the gain is changed and the Grid Status is On, the stability of the engine will not change. This parameter is changed with the Graph feature on the Governor Gain screen. The graph provides the best method for observing the effects of the adjustment on engine stability. If changing this gain causes no effect, check the Grid Status in order to make sure that the status is OFF.
Auxiliary Proportional Governor Gain 1

This parameter changes the governors response. This parameter is based on a proportional multiplier when the engines Grid Status parameter is On. If the gain is changed and the Grid Status is Off, the stability of the engine will not change. This parameter is changed with the Graph feature on the Governor Gain screen. The graph provides the best method for observing the effects of the adjustment on engine stability. If changing this gain causes no effect, check the Grid Status in order to make sure that the status is OFF.
Crank Terminate Speed

The ECM disengages the starting motor when the engine speed exceeds the programmed Crank Terminate Speed. The default value of 250 rpm should be sufficient for all applications.
Engine Purge Cycle Time

The Engine Purge Cycle Time is the duration of time for the engine to crank without fuel before the crank cycle. The Engine Purge Cycle Time allows any unburned fuel to exit through the exhaust before you fire the engine.
Auxiliary Integral Governor Gain 1

This parameter changes the governors response. This parameter is based on an integral multiplier when the engines Grid Status parameter is On. If the gain is changed and the Grid Status is Off, the stability of the engine will not change. This parameter is changed with the Graph feature on the Governor Gain screen. The graph provides the best method for observing the effects of the adjustment on engine stability. If changing this gain causes no effect, check the Grid Status in order to make sure that the status is ON.
Engine Cooldown Duration

When the ECM receives a Stop request, the engine will continue to run in the Cooldown Mode for the programmed cooldown period. The Cooldown Mode is exited early if a request for an emergency stop is received by the ECM. If the Engine Cooldown Duration is programmed to zero, the engine will immediately shut down when the ECM receives a Stop request.
Cycle Crank Time

The Cycle Crank Time is the amount of time for activation of the starting motor and the gas shutoff valve for start-up. If the engine does not start within the specified time, the attempt to start is suspended for a Rest Cycle that is equal to the Cycle Crank Time.
Auxiliary Derivative Governor Gain 1

This parameter changes the governors response. This parameter is based on a derivative multiplier when the engines Grid Status parameter is On. If the gain is changed and the Grid Status is Off, the stability of the engine will not change. This parameter is changed with the Graph feature on the Governor Gain screen. The graph provides the best method for observing the effects of the adjustment on engine stability. If changing this gain causes no effect, check the Grid Status in order to make sure that the status is ON.
Engine Overcrank Time

The Engine Overcrank Time determines the length of time for the ECM to attempt to start the engine. An event is generated if the engine does not start within this period of time. Example Setting
Table 10
Start/Stop Control Parameters

Driven Equipment Delay Time
The ECM provides a switch input for the driven equipment in order to delay engine start-up until the equipment is ready. The ECM will not attempt to start the engine until the switch closes to ground and the prelubrication is complete. An event code is generated if the programmed time for the driven equipment elapses without the closure of the switch. The delay time for the switch must be programmed to 0 in order to disable this feature.
Examples of the Settings for Start-up Parameter Purge Cycle Time Cycle Crank Time Overcrank Time Time 10 seconds 30 seconds 280 seconds
The following sequence will occur if the parameters are programmed according to the example in Table 10: 1. The fuel and the ignition are OFF. The engine will crank for 10 seconds in order to purge gas from the engine via the exhaust system.
2. The fuel and the ignition are enabled. The engine will continue to crank for a maximum of 30 seconds. 3. If the engine does not start, the ignition, the fuel, and the starting motor are disabled for a 30 second Rest Cycle. With this example, a complete cycle is 70 seconds: a purge cycle of 10 seconds, a cycle crank of 30 seconds, and a rest cycle of 30 seconds. The Overcrank Time of 280 seconds allows a maximum of four crank cycles.
Override Parameters
Oxygen Sensor Override
This parameter enables the oxygen sensor and the oxygen buffer to be energized when the engine is not running. The override facilitates troubleshooting of the sensors electrical circuit.
Requested Detonation Derate Percentage Override

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Engine Speed Drop Time

After the cooldown period has elapsed, the ECM shuts off the gas shutoff valve. The ignition continues until the engine speed drops below 40 rpm. If the engine rpm does not drop at least 100 rpm within the programmed drop time, the ECM terminates the ignition and the ECM issues an emergency stop.
Replacing the ECM

SMCS Code: 1901-038 The Electronic Control Module (ECM) contains no moving parts. Replacement of the ECM can consume much time. Before you replace an ECM, follow the troubleshooting procedures in this manual in order to be sure that replacement of the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem. Install a test ECM in place of the suspect ECM. Transfer the software from the suspect ECM to the test ECM. Program all the parameters for the test ECM in order to match the parameters of the suspect ECM. The parameters must match. Refer to the following test steps for details on programming the parameters. If the test ECM resolves the problem, reconnect the suspect ECM. Verify that the problem recurs. If the problem recurs, replace the suspect ECM with the test ECM. Note: If the parameters cannot be read from the suspect ECM, the parameters must be obtained from records or from the factory. Perform the following procedure to replace the ECM. 1. Use the Service/Copy Configuration/ECM Replacement function of the Caterpillar Electronic Technician (ET). Save the file. You can select Load from ECM. You may also select the Print function in order to obtain a paper copy of the parameter settings. Note: Before you replace an ECM, record all of the logged events.
Engine Pre-Lube Time Out Period

The ECM can energize a prelube pump prior to cranking the engine. The ECM uses a switch input to monitor the engine for acceptable oil pressure. After the prelube is completed, the prelube switch closes. If the ECM does not detect closure of the prelube switch within the programmable Engine Pre-Lube Time Out Period, the ECM monitors the engine oil pressure sensor. If the oil pressure is insufficient, an event code is activated and the starting sequence is terminated. The range for the Engine Pre-Lube Time Out Period is 30 to 300 seconds.
Monitoring and Protection

High Inlet Air Temp Engine Load Setpoint
The programmable setpoint is a value that separates low engine load from high engine load for events that are activated by high inlet air temperature. An Engine Load Factor can be displayed on a Cat ET status screen. If the load factor is less than the setpoint and the inlet air temperature reaches the trip point, a High Inlet Air Temperature at Low Engine Load event is activated. If the load factor is greater than the setpoint and the inlet air temperature reaches the trip point, a High Inlet Air Temperature at High Engine Load event is activated.
a. Connect the Cat ET with the communications adapter. Select Service/Copy Configuration/ECM Replacement from the pull-down menu on Cat ET. Cat ET will load the configuration parameters and the monitoring system parameters of the suspect ECM. b. Select Load from ECM in the lower left corner of the Cat ET screen. Select the suspect ECM and select OK. After the loading is complete, the Cat ET will display this message: The data has been successfully loaded from the ECM. Select OK. c. Select File/Disconnect F8 from the pull-down menu. Note: Do not terminate the Cat ET. 2. Replace the ECM. a. Turn the engine control switch to the OFF/RESET position.
Note: Rubber grommets behind the ECM are held in place by the mounting studs. The grommets help to reduce vibration. The grommets may fall when the ECM is removed. Be sure not to lose the grommets. e. Remove the ECM from the terminal box. 3. Install the replacement ECM. a. Use the mounting hardware to install the new ECM. Use a mounting nut to fasten the ground strap for the ECM to the upper left mounting stud. Then install the other three mounting nuts. Check the mounting hardware and the ECM for correct installation. A correctly installed ECM will move slightly on the rubber grommets. If the ECM cannot move slightly on the grommets, check that the washers, spacers, and grommets are positioned correctly. b. Use a 4 mm Allen wrench to connect the P1 and P2 connectors to the ECM. Tighten the screws to a torque of 6 Nm (55 lb in). 4. Program the configuration parameters and the monitoring system parameters into the replacement ECM. a. Switch circuit breaker (1) to the ON position. b. Turn the engine control switch to the STOP position. c. Select File/Select ECM from the pull-down menu. d. Select the replacement ECM and click OK. e. Select Service/Copy Configuration/ECM Replacement from the pull-down menu. Click OK on the window. f. Select Program ECM from the lower left corner of the screen. Select the replacement ECM and click OK. If the correct ECM is shown, select Yes. g. After the loading is complete, a window with the message Programming Conflict Warning will appear. Select OK. h. A window with the message Program ECM Results will appear. Select OK. Note: When you program a new ECM, factory passwords are not required for the first hour of operation. After one hour, factory passwords are required for changing the parameters that are normally protected with factory passwords.
Illustration 10
g00887172
b. Switch circuit breaker (1) to the OFF position. c. Use a 4 mm Allen wrench to disconnect connector P2 (3) and connector P1 (4). d. Remove mounting nut (2) in order to disconnect the ground strap. Remove the three remaining mounting nuts.
5. Calibrate the oxygen sensor and the speed/timing sensor. See Troubleshooting, Oxygen Sensor - Calibrate and Troubleshooting, Engine Speed/Timing Sensor - Calibrate.
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a. Connect Cat ET with the communications adapter. Select Service/Copy Configuration/ECM Replacement from the pull-down menu. Cat ET will load the configuration parameters and the monitoring parameters from the ECM. b. Select Load from ECM in the lower left corner of the screen. Select the suspect ITSM and select OK. After the loading is complete, Cat ET will display this message: The data has been successfully loaded from the ECM. Select OK. c. Select File/Disconnect F8 from the pull-down menu. Note: Do not exit from Cat ET. 2. Replace the ITSM. a. Turn the engine control switch to the OFF/RESET position.
Replacing the ITSM

SMCS Code: 1901-038 The Integrated Temperature Sensing Module (ITSM) contains no moving parts. Replacement of the ITSM can consume much time. Before you replace an ITSM, follow the troubleshooting procedures in this manual in order to be sure that replacement of the ITSM will correct the problem. Use the following guidelines to verify that the suspect ITSM is the cause of the problem: Install a test ITSM in place of the suspect ITSM. Transfer the software from the suspect ITSM to the test ITSM. Program all the parameters for the test ITSM in order to match the parameters of the suspect ITSM. The parameters must match. Refer to the following steps for details on programming the parameters. If the test ITSM resolves the problem, reconnect the suspect ITSM. Verify that the problem recurs. If the problem recurs, replace the suspect ITSM with the test ITSM. Note: The 141-1957 Electronic Control (ITSM) will not function properly with the Software, 190036601.fls. Do not use any subsequent version such as Software, 190036602.fls and Software, 190036603.fls, etc. Do not flash this software into the 141-1957 Electronic Control. Use the following procedure to replace the ITSM: Note: If the parameters cannot be read from the suspect ITSM, the parameters must be obtained from records or from the factory. 1. Use the Service/Copy Configuration/ECM Replacement function of the Caterpillar Electronic Technician (ET) in order to transfer the software from the suspect ITSM. You may also select the Print function in order to obtain a paper copy of the parameter settings. Note: Before you replace an ITSM, record all of the logged events.
Illustration 11 (1) Circuit breaker in the terminal box for the ECM
g00887190
b. Switch the 16 amp circuit breaker for the ECM (1) to the OFF position.
a. Use the mounting hardware to install the new ITSM. If all of the hardware has been removed, lubricate the bottom washers between the mounting plate and the rubber grommets. Be sure to install ground strap (9) between one of the washers on the mounting flange and the nut. Check the mounting hardware and the ITSM for correct installation. A properly installed ITSM will move slightly on the rubber grommets. If the ITSM cannot move slightly on the grommets, check that the washers and grommets are positioned correctly.
Illustration 12 Connectors for the ITSM (2) P40 connector from the thermocouples to the ITSM (3) P18 connector from the ITSM to the terminal box
g00743125
b. Connect connectors (2) and (3) to the ITSM. 4. Program the configuration parameters and the monitoring system parameters into the replacement ITSM. a. Switch the circuit breaker in the terminal box ON. b. Turn the engine control switch to the STOP position. c. Select File/Select ECM from the pull-down menu of Cat ET. d. Select the Replacement ITSM and click OK. e. Select Service/Copy Configuration/ECM Replacement from the pull-down menu. Click OK on the window.
c. Disconnect connectors (2) and (3) from the ITSM.
Illustration 13 Mounting hardware for the ITSM (4) (5) (6) (7) (8) (9) Nut Washer Mounting flange on the ITSM Rubber grommet Washer Ground strap
g00743195
f. Select Program ECM from the lower left corner of the screen. Select the replacement ITSM and click OK. g. After the loading is complete, a window with the message Programming Complete will appear. Select OK. Note: When you program a new ITSM, factory passwords are not required. Also, the ITSM does not require calibration.
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Note: One of the mounts for the ITSM has a ground strap that is attached between the nut and the washer. d. Remove the 4 mounting nuts (4) and washers (5) from mounting flanges (6) of the ITSM. The ground strap must also be detached from one of the studs. Note: Rubber grommets for the ITSM are held in place on the mounting studs. The grommets help to reduce vibration. The grommets may fall when the ITSM is removed. Be sure not to lose the grommets. e. Remove the ITSM from the engine. 3. Install the replacement ITSM. Orient the 54 pin P40 connector toward the right of the engine.
Troubleshooting Data Sheet

SMCS Code: 1901-038 To help troubleshoot a gas engine, complete the information in Table 11. Be sure to include the units of measurement.
Table 11
Data Sheet for Troubleshooting Customer and installation Engine model and driven equipment Engine serial number Service hours LHV of fuel Compression ratio Methane number of fuel Application Altitude Fuel rate Brand of oil and type of oil Throttle angle Inlet manifold air temperature Turbocharger exhaust temperature PPM of NOx (3) (4) Jacket water temperature (5) (6) (7) (8) in out Detonation level Air restriction Ignition timing Pressure to the regulator
Differential pressure of the regulator Engine rpm Percent load
Inlet manifold air pressure Turbocharger boost pressure Exhaust stack temperature Cylinder exhaust port temperatures Aftercooler water temperature Comments left right % O2 (1) (2) in out
Location of temperature probe left right PPM of CO (9) (10) Engine oil temperature (11) (12) Exhaust stack pressure Brand of exhaust analyzer (13) (14) in out (15) (16)
Report the Service Information

After you have successfully repaired the engine, it is important to provide good information about the repair. The following topics are recommended for your report: Complaint Include a description of the customers complaint in the report. Cause Provide a specific description of the cause of the failure. Include the method that was used in order to diagnose the problem. If diagnostic codes or event codes were generated, include all of the codes and the status of the codes. Indicate your determination of the problem. For example, if you performed a diagnostic functional test, identify the test procedure. For example, a visual inspection revealed abrasion of a wire in a harness. Be specific: dynamometer testing of the engine produced power below specifications at 1800 rpm due to the loss of an ignition transformer. Repair Explain your repair of the problem. For example, you may have installed a new wiring harness. You may have replaced the ignition transformer per instructions from the factory.
The providing of complete, accurate information will help Caterpillar to provide better service to you and to the customer.
Troubleshooting without a Diagnostic Code

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Operator Information
Obtain the following information from the operator:
The occurrence and the time of the occurrence
Symptoms
SMCS Code: 1000-038; 1901-038 Some engine symptoms can be unrelated to the electronic control system. This section is for troubleshooting problems that have symptoms without active diagnostic codes. Conditions such as poor fuel quality or improperly adjusted valves can cause some engine symptoms. For basic troubleshooting of the engine, perform the following steps first in order to diagnose a malfunction. 1. Gather information about the complaint from the operator. 2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to error of the operator. 3. Perform a visual inspection. Inspect the following items:
Determine the conditions for the occurrence. The

conditions will include the engine rpm and the load.
Determine if there are any systems that were

installed by the dealer or the customer that could cause the symptom.
Determine whether any other occurrences

happened in addition to the symptom.
Diagnostic Codes and Event Codes

Examine the following information regarding any codes:
The probable cause of the symptom is correlated

to the code.
The code was generated when the symptom

occurred.
Codes that are repeatedly logged The complaint is not due to normal engine
operation.
Fuel supply Oil level Oil supply Wiring Connectors

4. Check the diagnostic codes and event codes. Repair any active codes. If these inspections do not reveal any problems, identify the probable causes with the procedures in this manual that best describe the symptoms. See Troubleshooting, Troubleshooting With A Diagnostic Code or see Troubleshooting, Troubleshooting With Event Codes. Check each probable cause according to the tests that are recommended. Be sure to check the connectors. This is specially true for problems that are intermittent. See Troubleshooting, Inspecting Electrical Connectors. Narrow the probable cause. Consider the operator information, the conditions of operation, and the history of the engine.
Other Symptoms
If other occurrences happened in addition to the symptom, investigate the following conditions:
The other occurrences are related to the

symptom.
The symptoms have a probable cause that is

common.
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Detonation
SMCS Code: 1901-038
Probable Causes
Excessive load High inlet air temperature Incorrect air/fuel ratio Incorrect timing Faulty circuit for the timing selection switch
Changes in the fuel quality The engine speed/timing sensor is not calibrated. Faulty circuit for the detonation sensor(s) Excessive deposits in the combustion chamber
Use the Caterpillar Electronic Technician (ET) to check the ignition timing during engine operation with a load. Compare the timing to the recommended timing in the Engine Performance, Fuel Usage Guide. Adjust the ignition timing according to the recommended timing in the Engine Performance, Fuel Usage Guide.
Recommended Repairs
Excessive Load
Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven equipment and test the engine.
Check the Timing Selection Switch

Check the position of the timing selection switch. Verify that the switch is in the correct position for the type of gas that is used. If the position of the switch is correct, troubleshoot the circuit for the switch. Refer to the electrical schematic for the engine.
Check the Inlet Manifold Air Pressure

The calculated engine load increases when the inlet manifold air pressure increases. Measure the inlet manifold air pressure during engine operation with a load. For specific data on the engine, refer to the engine Technical Marketing Information.
Check for Event Codes Regarding the Fuel

Check for the following event codes:
Check the Inlet Air Temperature

High inlet air temperature can cause detonation. Check the inlet air temperature. Look for the following event codes:
E229 (1) Fuel Energy Content Setting Low

(warning)
E230 (1) Fuel Energy Content Setting High

(warning)
E025 (2) High Inlet Air Temperature (derating) E026 (3) High Inlet Air Temperature (shutdown) E027 (1) High Inlet Air Temperature (warning)
Refer to Troubleshooting, Inlet Air Temperature (High).
E231 (3) Fuel Quality Out Of Range (shutdown)

Refer to Troubleshooting, Fuel Energy Content.
Calibrate the Engine Speed/Timing Sensor

Note: Only perform this procedure if work on the engine may have affected the engine timing. Also, perform this procedure if the engine speed/timing sensor has not been calibrated. Calibrate the engine speed/timing sensor. Refer to Troubleshooting, Engine Speed/Timing Sensor Calibrate.
Air/Fuel Ratio
An air/fuel mixture that is too rich will cause detonation. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable. Make sure that the fuel metering valve is operating correctly. Verify that the exhaust emissions are correct.
Check the Detonation Sensors

Troubleshoot the detonation sensors. Refer to Troubleshooting, Detonation Sensors.
Check the Ignition Timing

Note: Data from a fuel analysis is required for this procedure.
Check for Deposits in the Cylinders

Overfilling of engine oil can lead to deposits. Make sure that the engine oil level is correct. Note: Excessive deposits contribute to guttering of the valves.
Use a borescope to inspect the cylinders. Look for the following conditions:
i01727336
Deposits on the valve seats Deposits on the valve faces Deposits on the cylinder walls that are above the
upper limit of the piston stroke
ECM Will Not Accept Factory Passwords

SMCS Code: 1901-038
Probable Causes
One of the following items may not be recorded correctly on the Caterpillar Electronic Technician (ET):
Signs of internal leaks

Signs of internal leaks include excessive consumption of engine oil, blue smoke, and excessive detonation. If excessive deposits and/or signs of internal leaks are found, investigate the cause of the condition. Make repairs, as needed.
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Passwords Serial Numbers Total Tattletale Reason Code
Driven Equipment
SMCS Code: 1901-038
Recommended Repairs
1. Verify that the correct passwords were entered. Check every character in each password. Turn the engine control switch to the OFF/RESET position for 30 seconds and then retry. 2. Verify that Cat ET is on the Factory Password screen. 3. Verify that the following information from Cat ET has been recorded correctly:
Probable Causes
The Electronic Control Module (ECM) has
received a Start Inhibit or a Shutdown signal.
The circuit for the signal is faulty.
Recommended Repairs
Check the Driven Equipment
Determine whether the driven equipment has generated a Start Inhibit or Shutdown request. Determine the cause for the request. Service the driven equipment according to the recommendations of the OEM of the equipment.
Serial Number of the engine Serial Number of the ECM Serial Number of the Cat ET Total Tattletale Reason Code
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Check the Circuit for the Switch

The circuit for the switch must remain closed in order to allow the engine to run. Check wiring between the driven equipment and the ECM connector for damage and/or corrosion. Refer to Troubleshooting, Inspecting Electrical Connectors. Repair the wiring, as needed. Check the resistance of the circuit between terminals 21 and 31 of the P1 connector. The correct resistance of the circuit is 5 ohms or less. If the resistance is greater than 5 ohms, locate the source of the excessive resistance. Make repairs, as needed.
Electrohydraulic System Oil Pressure (Low)

SMCS Code: 1901-038
Probable Causes
The electrohydraulic systems oil level is low. The electrical circuit for the electrohydraulic oil
pressure switch is open.
There is an open circuit in the wiring harness
between the electrohydraulic oil pressure switch and the Electronic Control Module (ECM). is insufficient.
5. Use Cat ET to observe the Hydrax Pressure Switch Status. The status of the switch should be Closed.
The oil pressure for the electrohydraulic system
Recommended Repairs
Check the Electrohydraulic Systems Oil Level
Observe the electrohydraulic systems oil level in the sight gauge on the tank. If necessary, pour oil into the tank until the oil level is between the ADD and FULL marks on the sight gauge. Check for oil leaks.
6. Continue to observe the Hydrax Pressure Switch Status. Wiggle the yellow wire and pull on the wire from the harness connector to the ECM P2 connector. The status of the switch should still be Closed. If the Hydrax Pressure Switch Status momentarily changes to Open, the harness has an intermittent circuit. If there is an intermittent circuit, locate the problem. Make repairs to the harness, when possible. After the harness is repaired, remove the jumper wire from the 3-pin connector. Reconnect the connector. If the harness cannot be repaired, replace the harness.
Open Circuit for the Electrohydraulic Oil Pressure Switch

The electrohydraulic oil pressure switch must remain closed while the engine is running. If the switch opens for more than 1 second, an E266 (3) event code is generated and the engine is shut down. The switch opens at 700 103 kPa (102 15 psi). The switch closes at 1206 kPa (175 psi). Check for proper operation of the switch. Apply a known pressure to the electrohydraulic system. While you apply the pressure, use a ohmmeter to observe the status of the contact for the switch between pin A and pin B. If the switch does not function properly, replace the switch.
Check the Oil Pressure of the Electrohydraulic System

The electrohydraulic oil pressure switch is designed to close at 1206 kPa (175 psi). The switch is designed to open at 700 103 kPa (102 15 psi). The switch must remain closed during engine operation. Use a gauge to check the oil pressure of the electrohydraulic system at the outlet for the hydraulic pump while the engine is cranking or running. Check the pressure while the engine is at normal operating temperature, when possible. If the pressure is less than 1206 kPa (175 psi), inspect the electrohydraulic system for leaks. Inspect the hydraulic pump. Make repairs, as needed.
Open Circuit in the Wiring Harness

Use the following procedure to check the harness. Do not operate the engine during this procedure. 1. Turn the engine control switch to the STOP position. 2. Use the Caterpillar Electronic Technician (ET) to observe the Hydrax Pressure Switch Status. The status of the switch should be Open. 3. Disconnect the 3-pin connector at the electrohydraulic oil pressure switch. 4. Attach a jumper wire between pin A and pin B on the harness connector.
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Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With the Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM))
SMCS Code: 1901-038
2. Disconnect the communication adapter and the cables from the service tool connector. Then reconnect the communication adapter. If you are using the 7X-1700 Communication Adapter Gp, refer to Special Instruction, SEHS9264, Using the 7X1700 Communication Adapter Group. If you are using the 171-4401 Communication Adapter II, refer to Manual, NEHS0758, Communication Adapter II Users Manual. 3. Verify that battery voltage is present between terminal A and terminal B of the service tool connector. If the communication adapter is not receiving power, the display will be blank.
Probable Causes
Electrical power supply Electrical connectors Communication adapter and/or cables Electronic service tool
Electronic Service Tool

In order to eliminate Cat ET as the problem, connect Cat ET to a different engine. If the same problem occurs with a different engine, check Cat ET and the related equipment in order to determine the cause of the problem.
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Recommended Repairs
Electrical Power Supply
Engine Coolant Temperature (High)

SMCS Code: 1901-038
Check power to the ECM or the ITSM. Refer to Troubleshooting, Electrical Power Supply. Note: If the modules are not receiving battery voltage, the modules will not communicate.
Probable Causes
High ambient temperature and/or high inlet air
temperature
Electrical Connectors
Check the following components:
Low coolant level and/or coolant leakage Insufficient flow of air or coolant through the
radiator or heat exchanger
Battery connections and ground to the ECM or

the ITSM
Faulty water temperature regulators Faulty coolant temperature sensor and/or circuit Insufficient flow of coolant through the engine Exhaust restriction Excessive load Incorrect ignition timing
Wiring harnesses and the connectors for the ECM

or the ITSM
Wiring harnesses and the connectors for the ECM

or the ITSM in the terminal box Refer to Troubleshooting, Inspecting Electrical Connectors.
Communication Adapter and/or Cables

1. Check the condition of the fuse for the communication adapter.
Incorrect air/fuel ratio
Recommended Repairs
Check for High Ambient Temperature and/or High Inlet Air Temperature
Determine if the ambient air temperature is within the design specifications for the cooling system. Check for high inlet air temperature. Refer to Troubleshooting, Inlet Air Temperature (High). Determine the cause of the high air temperature. Make corrections, when possible.
Replace the water temperature regulators, if necessary.
Check the Coolant Temperature Sensor and/or the Circuit

Check the reading of the coolant temperature on Caterpillar Electronic Technician (ET). The temperature should rise steadily as the engine is warmed. Ensure that the temperature is reasonable. If the reading on Cat ET for the coolant temperature is not reasonable, troubleshoot the circuit and the coolant temperature sensor. Refer to Troubleshooting, Analog Sensor Signal.
Check for a Low Coolant Level and/or Coolant Leakage

Note: Low coolant level can be the effect of overheating rather than the cause. Check the coolant level. Run the engine to operating temperature. Inspect the cooling system for leaks. Determine whether the leak occurs before the engine overheats. Add coolant, if necessary. If leaking is found, make the necessary repairs.
Check the Flow of Coolant Through the Engine

During normal operation, check the status of the following components:
Switch for the inlet pressure of the jacket water Sensor for the outlet pressure of the jacket water
If the flow of coolant through the engine is not sufficient, determine the cause of the obstruction. Make necessary repairs.
Check for Insufficient Flow of Air and Coolant Through the Radiator or Heat Exchanger
Radiator Check the fins of the radiator for obstructions. Check the fan for proper operation. If the radiator fins are obstructed, clean the fins. If the fan does not operate properly, make the necessary repairs. Heat Exchanger Check for sufficient flow and temperature of the cooling water through the heat exchanger. If the flow of cooling water through the heat exchanger is insufficient, determine the location of the obstruction. If the temperature of the cooling water is too high, determine the cause. Make the necessary repairs.
Check the Exhaust Restriction

Check the back pressure of the exhaust system. Refer to Systems Operation/Testing and Adjusting, Air Inlet and Exhaust System. If the back pressure exceeds the specifications for the engine, determine the cause of the excessive back pressure. Make the necessary repairs.
Excessive Load
Ignition Timing
Note: Data from a fuel analysis is required for this procedure. Use an electronic service tool to check for the correct desired ignition timing. Compare the timing to the recommended timing in the Engine Performance, Fuel Usage Guide. Adjust the ignition timing according to the recommended timing in the Engine Performance, Fuel Usage Guide.
Check the Water Temperature Regulators

Check the water temperature regulators for proper operation. Refer to Systems Operation/Testing and Adjusting, Testing the Cooling System.
Air/Fuel Ratio
An air/fuel mixture that is too rich will cause overheating. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable. Strike the gas pressure regulator with a soft hammer. If the engine speed changes, inspect the internal parts of the gas pressure regulator for wear. Inspect the gas pressure regulators diaphragm for leaks. Make sure that the valve moves freely. The valve must seat correctly. Ensure that the fuel metering valve is operating correctly. Verify that the exhaust emissions are correct.
i01727368

The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. Allow the engine to cool and then start the engine. Check the hose at the outlet for the jacket water. If the hose is warm and normal operating temperature is not achieved yet, a regulator may be stuck open. If the water temperature regulators are malfunctioning, check the water temperature regulators according to Systems Operation/Testing and Adjusting, Testing the Cooling System. Replace the water temperature regulators, if necessary.
i01727427
Engine Cranks but Will Not Start

SMCS Code: 1000-038; 1901-038
Engine Coolant Temperature (Low)

SMCS Code: 1901-038
Probable Causes
Fuel supply Electrical connectors or power supply No signal from the speed/timing sensor Ignition system Excessive load
Probable Causes
Faulty jacket water heater Faulty coolant temperature sensor and/or circuit Faulty water temperature regulators
Recommended Repairs
Check the Jacket Water Heater
Determine if the jacket water heaters are functioning properly. If the jacket water heaters are not functioning properly, determine the cause of the malfunction of the heaters. Make the necessary repairs.
Recommended Repairs
Fuel Supply
Make sure that fuel is supplied at a sufficient pressure that is stable. Make sure that the size of the fuel line is sufficient. Inspect the fuel system for leaks. The following conditions can cause the engine to malfunction:
Check the Coolant Temperature Sensor and/or the Circuit

Check the reading of the coolant temperature with the Caterpillar Electronic Technician (ET). The temperature should rise steadily as the engine is warmed. Ensure that the temperature is reasonable. If the reading on Cat ET for the coolant temperature is not reasonable, troubleshoot the circuit and the coolant temperature sensor. Refer to Troubleshooting, Analog Sensor Signal.
Low fuel pressure High fuel pressure Poor fuel quality

Make sure that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel was changed.
Inspect the fuel system components: fuel filter, gas pressure regulator, gas shutoff valve, and fuel metering valve. Verify that the systems components are operating correctly. Replace the fuel filter, if necessary.
i01727449
Engine Misfires, Runs Rough or Is Unstable

SMCS Code: 1000-038; 1901-038
Electrical Connectors or Power Supply

There may be an intermittent interruption of power. Check the wiring harnesses and the connectors. Inspect the connectors in the terminal box. Inspect the battery connections and the ground. Inspect the wiring from the battery to the Electronic Control Module (ECM). Inspect the wires and the power relay. Check the power and ground connections. Refer to Troubleshooting, Electrical Power Supply.
Probable Causes
Cold cylinder Electrical connectors or power supply Ignition system Fuel supply Incorrect air/fuel ratio Air inlet restriction Exhaust restriction Incorrect valve lash Cylinder head and related components Throttle
No Signal from the Engine Speed/Timing Sensor

Make sure that the speed/timing sensor is installed correctly. Refer to Troubleshooting, Speed/Timing Sensor. Make sure that the timing wheel is correctly installed.
Ignition System
Inspect the ignition transformers for loose connections, moisture, short circuits, and open circuits. Inspect the primary wiring and the secondary electrical connections. Make sure that the correct transformers and spark plugs are installed. Inspect the extenders for signs or pin holes and arcing. Maintain the spark plug according to Operation and Maintenance Manual, Ignition System Spark Plugs. Make sure that the ignition timing is correct.
Recommended Repairs
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating temperature, etc), test the engine under the conditions. Troubleshooting the symptom under other conditions can give misleading results. The Caterpillar Electronic Technician (ET) and the Integrated Temperature Sensing Module (ITSM) can be used to detect a misfiring cylinder. Use the following procedure: 1. Use the Data Link/Select ECM option on the Cat ET to select the ITSM. 2. Select Diagnostics/Diagnostic Tests. 3. Select the suspect cylinder and click the Start button in the lower left corner of the screen. Cat ET will display a graph of the cylinders exhaust gas temperature. The output voltage of the transformers secondary circuit, the engine speed, and the desired engine speed are also displayed.
Excessive Load
Cold Cylinder
Locate the misfiring cylinder. Check the following components for failure: spark plug, extender, ignition transformer, and primary wiring. Inspect the extender for signs of pin holes and/or arcing. Refer to Troubleshooting, Ignition Transformers Secondary Circuit and Spark Plugs.
Replace the fuel filter, if necessary.
Air/Fuel Ratio
An air/fuel mixture that is too rich or too lean will have an adverse effect on engine operation. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable. Verify that the exhaust emissions are correct.

There may be an intermittent interruption of power. Check the wiring harnesses and the connectors. Inspect the connectors in the terminal box. Inspect the battery connections and the ground. Inspect the wiring from the battery to the control modules. Refer to Troubleshooting, Electrical Power Supply.
Air Inlet Restriction

The maximum allowable air inlet restriction is 3.75 kPa (15 inches of H2O). If the indication is higher than the maximum permissible restriction, clean the filter element or install a new filter element. Check the restriction again. If the restriction remains too high, inspect the air inlet piping for obstructions. For more information, refer to Systems Operation/Testing and Adjusting, Restriction of Air Inlet and Exhaust.
Ignition System
Inspect the ignition transformers for loose connections, moisture, short circuits, and open circuits. Inspect the primary wiring and the secondary electrical connections. Make sure that the correct transformers and spark plugs are installed. Inspect the extenders for signs or pin holes and arcing. Maintain the spark plug according to the engines Operation and Maintenance Manual. Make sure that the ignition timing is correct.
Exhaust Restriction
Check for restriction in the exhaust system. Refer to Systems Operation/Testing and adjusting, Restriction of Air Inlet and Exhaust.
Incorrect Valve Lash

Check the valve lash. Refer to Systems Operation, Testing And Adjusting, Valve Lash and Valve Bridge Adjustment.
Fuel Supply
Cylinder Head and Related Components

Measure the cylinder compression. Refer to the engines Operation and Maintenance Manual, Cylinder Pressure - Measure/Record. Inspect the components of the valve train for good condition. Check for signs of damage and/or wear to the valves, cylinder head gasket, etc. Inspect the condition of the camshafts. If a camshaft is replaced, new valve lifters must be installed.

Make sure that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel was changed. Inspect the fuel system components: fuel filter, gas pressure regulator, gas shutoff valve, and fuel metering valve. Verify that the systems components are operating correctly.
Throttle
Make sure that the throttle actuator is operating properly. If the motion of the actuator is sticky and/or rough, service the actuator. For electrohydraulic actuators, make sure that the hydraulic oil is not contaminated.
i01727473
i01727510
Engine Oil Filter Differential Pressure

SMCS Code: 1308-035
Engine Oil Pressure (Low)

SMCS Code: 1901-038
Probable Causes
Low engine oil level Incorrect viscosity Contaminated engine oil Faulty oil pressure sensors Improper circulation of the engine oil Worn components
Probable Causes
Plugged oil filter or faulty oil filter Faulty oil pressure sensor and/or circuit Malfunctioning of the oil filter bypass valve
Recommended Repairs
Check the Oil Filters
Check the oil filter differential pressure. Do not allow the differential pressure to exceed 103 kPa (15 psi). If the oil filter differential pressure is too high, change the oil filter elements. Inspect the oil filters for good condition. Replace any suspect oil filter.
Recommended Repairs
Low Engine Oil Level
Check the oil level. Add oil, as needed.
Contaminated Engine Oil

Engine oil that is contaminated with another liquid will cause low engine oil pressure. High engine oil level can be an indication of contamination. Obtain an analysis of the engine oil. Determine the reason for contamination of the engine oil and make the necessary repairs. Change the engine oil and the engine oil filter. For the correct engine oil to use, refer to Operation and Maintenance Manual, Engine Oil.
Check the Oil Pressure Sensors and/or Circuits

Use the Caterpillar Electronic Technician (ET) to compare the readings for the filtered oil pressure and the unfiltered oil pressure while the engine is OFF. Make sure that the sensors are correctly wired. If the readings are not approximately zero for both of the sensors, the sensors are wired improperly. Troubleshoot the sensor circuit(s). Refer to Troubleshooting, Analog Sensor Signal.
Incorrect Viscosity
Make sure that the engine is supplied with the correct engine oil. For the correct engine oil to use, refer to Operation and Maintenance Manual, Engine Oil.
Check the Oil Filter Bypass Valve

An oil filter bypass valve that is stuck in the closed position can cause a high reading for differential pressure when the oil is cold. An oil filter bypass valve that is stuck in the open position can cause a low reading for differential pressure when the oil is hot. Check the operation of the oil filter bypass valve. For more information, see Systems Operation/Testing and Adjusting, Measuring Engine Oil Pressure. If the oil filter bypass valve is faulty, repair the valve, when possible. Replace the valve, if necessary.
Faulty Engine Oil Pressure Sensors

Use the Caterpiller Electronic Technician (ET) to compare the readings of the filtered engine oil pressure and the unfiltered engine oil pressure while the engine is OFF. Both readings should be close to zero pressure. If a reading is significantly different from zero, replace the suspect engine oil pressure sensor.
Improper Circulation of the Engine Oil

Several factors could cause improper circulation of the engine oil:
Recommended Repairs
Check the Oil Temperature Sensor and/or the Circuit
Check the reading of the oil temperature on the Caterpillar Electronic Technician (ET). The temperature should rise steadily as the engine is warmed. Ensure that the temperature is reasonable. If the reading on Cat ET for the oil temperature is not reasonable, troubleshoot the circuit for the oil temperature sensor. Refer to Troubleshooting, Analog Sensor Signal.
The engine oil filter is clogged. Replace the

engine oil filter.
An engine oil line or a passage for engine oil is

disconnected or broken.
The engine oil cooler is clogged. Thoroughly

clean the engine oil cooler.
There is a problem with a piston cooling jet.

Breakage, a restriction, or incorrect installation of a piston cooling jet will cause seizure of the piston.
Check the Flow of Coolant Through the Oil Cooler

Oil Coolers that are Cooled with Jacket Water Check for High Engine Coolant Temperature events. Refer to Troubleshooting, Engine coolant Temperature (High). Oil Coolers that are Cooled by the Separate Circuit Compare the temperature of the coolant at the inlet of the oil cooler to the regulated temperature. If the inlet temperature is OK, check the temperature of the coolant at the outlet of the oil cooler. A high temperature difference indicates an insufficient flow rate. Investigate the cause of the obstruction. Make the necessary repairs.
The inlet screen of the suction tube for the engine

oil pump can have a restriction. This restriction will cause cavitation and a loss of engine oil pressure. Check the inlet screen on the suction tube and remove any material that may be restricting engine oil flow.
The suction tube is drawing in air. Check the joints

of the tube for cracks or a damaged O-ring seal.
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.
The engine oil pumps pressure regulating valve

or a bypass valve is stuck in the open position. Clean the valve. Replace parts, if necessary.
Worn Components
Excessive clearance at the crankshaft or camshaft bearings will cause low engine oil pressure. Also, inspect the clearance between the rocker arm shafts and the rocker arms. Check the engine components for excessive clearance. Obtain an analysis of the engine oil. Check the analysis for the level of wear metals in the engine oil.
i01727521
Check the Flow of Oil Through the Oil Cooler

Run the engine at normal operating temperature. Determine the pressure differential between the inlet and the outlet of the oil cooler. For comparative data, refer to the Technical Marketing Information for the engine. If the pressure differential between the inlet and the outlet of the oil cooler exceeds the data that is published for the engine, there is an insufficient flow of oil through the oil cooler. Determine the cause of the obstruction. Make the necessary repairs.
i01727544
Engine Oil Temperature (High)

SMCS Code: 1901-038
Probable Causes
Faulty oil temperature sensor and/or circuit Insufficient flow of coolant through the oil cooler Insufficient flow of oil through the oil cooler
Engine Overcrank
SMCS Code: 1901-038
Probable Causes
The gas supply to the engine is insufficient.
A feature for engine protection prevents the

engine from starting.
Check the Engine Speed

The ECM must detect a minimum of 50 rpm before the gas and the ignition are supplied to the engine. Use Cat ET to monitor the engine speed while you crank the engine. If no engine speed is displayed on Cat ET or if the engine speed is not stable, troubleshoot the speed/timing sensor. Refer to Troubleshooting, Engine Speed/Timing Sensor.
The starting motor circuit is faulty. There is no engine speed signal to the Electronic
Control Module (ECM).
The ignition system is not functioning or the switch

for the ignition timing is not in the correct position.
The quality of the gas does not match the

parameter for Fuel Quality.
Check for Diagnostic Codes

Check for active diagnostic codes that relate to the ignition system. If there is at least one active diagnostic code that relates to the ignition system, troubleshoot the diagnostic code. Check the position of the timing selection switch. Verify that the switch is in the correct position for the type of gas that is used.
Recommended Repairs
Check the Gas Supply to the Engine
Check for low gas pressure. Observe the angle of the throttle plate while you crank the engine. If the gas pressure is low, refer to Troubleshooting, Fuel Pressure. If the throttle does not open, troubleshoot the electrohydraulic oil system. The gas supply lines may require purging before servicing.
Check the Fuel Quality

Compare the Low Heat Value (LHV) of the gas supply to the Fuel Quality parameter that is programmed by the customer into the ECM. The ECM uses the setting for start-up and for air/fuel ratio control at low loads. If the LHV of the fuel does not match the Fuel Quality parameter that is programmed into the ECM, program the ECM with the correct setting for the Fuel Quality parameter.
i01746204
Check for Active Shutdowns

Use the Caterpillar Electronic Technician (ET) to check for active diagnostic codes or event codes which may prevent the engine from starting. Correct the cause of the active code. Before the engine can be started, the control system must be power cycled. Turn the engine control switch to the OFF/RESET position. Then turn the switch to the STOP position.
Engine Overload
SMCS Code: 1901-038
Check the Status of the Relay for the Starting Motor

Attempt to start the engine while you observe the status of the relay for the starting motor on Cat ET. If the status of the relay for the starting motor indicates that the engine should crank but no cranking occurs, troubleshoot the starting circuit. Refer to Systems Operation/Testing and Adjusting, Air/Electric Starting System. If the engine should crank and cranking occurs, check the engine rpm.
Probable Causes
Excessive inlet manifold air pressure The Low Heat Value (LHV) of the gas or the
specific gravity of the gas is significantly different from the value that is programmed.
The oxygen sensor is not accurate.
Recommended Repairs
Check the Inlet Manifold Air Pressure
The calculated engine load increases when the inlet manifold air pressure increases. Measure the inlet manifold air pressure during engine operation with a load. For specific data on the engine, refer to the engine Technical Marketing Information.
The trip point or engine overspeed may be too low. Verify that the trip point for the engine overspeed is properly programmed. Typically, this parameter is set at 118 percent of rated speed. This parameter requires a factory password in order to change the trip point. Change the trip point to an acceptable speed.
Obtain a Fuel Analysis and Program the Fuel Energy Content

Obtain an analysis of the gas in order to determine the LHV. Program the correct LHV for the Fuel Quality configuration parameter. If the quality of the gas is not consistent, obtain several analyses over a period of time. Program the Fuel Quality configuration parameter to the average value of the LHV.
Check for Diagnostic Codes that Relate to the Signal from the Signal Driver in the ECM
Check for diagnostic codes that relate to the actuator of the throttle. Investigate the diagnostic code(s). Make the necessary repairs.
Check for Binding of the Actuator

Slide the electrohydraulic actuators rod in and out while you feel the motion. If the motion is sticky and/or rough, investigate the cause of the binding. Make the necessary repairs.
Check the Oxygen Sensor

Calibrate the oxygen sensor. Refer to Troubleshooting, Oxygen Sensor - Calibrate. If the oxygen sensor could not be calibrated successfully, refer to Troubleshooting, Oxygen Sensor Buffer Supply and Troubleshooting, Oxygen Sensor Signal.
i01727554
Check the Driven Equipment

Determine if the driven equipment has additional inputs of energy that could drive the engine beyond the rated rpm. Make corrections to the installation in order to prevent the overspeed from recurring.
Engine Overspeed
SMCS Code: 1000-038; 1901-038
Check for Slow Governor Response

Observe the Speed Governor Adjustment screen on the Caterpillar Electronic Technician (ET). Look for the engine response to the worst cases for step-loading and unloading. Use Throttle Bump feature of Cat ET in order to disturb steady state engine operation. If the undershoot or the overshoot of the engine speed is excessive, refer to Troubleshooting, Engine Misfires, Runs Rough Or Is Unstable .
i01727564
Probable Causes
Low trip point for engine overspeed Signal from the signal driver in the Electronic
Control Module (ECM) for the actuator of the throttle
Binding of the actuator for the throttle Energy of the driven equipment Slow governor response
Engine Pre-Lube Pressure (Low)

SMCS Code: 1901-038
Recommended Repairs
Check the Trip Point
Note: Do not program the trip point for engine overspeed higher than the maximum ratings of the driven equipment.
Probable Causes
Low engine oil level Low pressure from the prelube pump The prelube pump is not energized.
The prelube pressure switch is faulty.
i01727572
Recommended Repairs
Check the Engine Oil Level
Check the engine oil level. Add oil until the oil level is between the ADD and FULL marks on the oil level gauge. Inspect the lubrication system for leaks.
Engine Shutdown
SMCS Code: 1901-038
Probable Causes
The Emergency Stop button is pressed. The circuit for the emergency stop is faulty. The normal stop switch that is installed by the
customer is activated.
Check the Pressure of the Prelube Pump

Measure pressure at the outlet of the prelube pump. The prelube pressure switch will not close unless a pressure of 9 3 kPa (1.3 0.4 psi) is achieved. Determine the cause of the low pressure. Look for leaks in the oil lines for the prelube pump. Ensure that the pump is operating correctly. Make repairs, as needed.
The circuit for the normal stop switch is faulty. Either switch is activated by excessive vibration.
Recommended Repairs
Talk to the operator
Ask the operator if the stop was intentional. Make sure that the reason for the stop has been corrected. Reset the control system. Resume normal operation. If the stop was accidental, reset the control system. Resume normal operation.
Check the Power Source for the Prelube Pump

Make sure that the prelube pump is supplied with the correct voltage and current. Check the Caterpillar Electronic Technician (ET) for these logged diagnostic codes: MID 036 - CID 338 - FMI 05 Pre-lube Relay open circuit and MID 036 - CID 338 - FMI 06 Pre-lube Relay short to ground. Refer to Troubleshooting, ECM Start/Stop Output.
Check the Circuit for the Stop Switches

Note: The circuit for the normal stop switch and the circuit for the emergency stop switch must remain closed in order for the engine to run. Inspect the wiring between the switches and the connector of the electronic control module. Look for damage and/or corrosion. Refer to Troubleshooting, Inspecting Electrical Connectors. For the emergency stop switch, close the switch and check the resistance between terminals 22 and 31 of the P1 connector. For the normal stop switch, close the switch and check the resistance between terminals 23 and 31 of the P1 connector. The correct resistance between the terminals is less than 5 ohms. If the resistance is greater than 5 ohms, locate the source of the excessive resistance. Make repairs, as needed.
Check the Prelube Pressure Switch

The prelube pressure switch must close before the starting motor relay will be energized. Make sure that the switch operates in the following manner:
When the engine oil pressure rises above

9 3 kPa (1.3 0.4 psi), terminals A and B close.
When the engine oil pressure falls below 7 kPa

(1 psi), terminals A and B open. Check Cat ET for a logged 339 - 05 Engine Pre-Lube Pressure switch open circuit diagnostic code. If the diagnostic code is logged, refer to Troubleshooting, Prelubrication System.
Inspect the Stop Switches

Inspect the stop switches for evidence of damage that has been caused by vibration. Disassemble the switches. Inspect the components for looseness, cracks, and abrasion. Use an ohmmeter and toggle the switches in order to check for proper electrical operation. Replace any faulty components.
i01727612
17-06 Fuel Shutoff Valve short to ground 17-12 Fuel Shutoff Valve malfunction
Refer to Troubleshooting, ECM Output Circuit (Fuel Control). Make repairs, as needed.
Check the Inputs to the ECS

Troubleshoot for the 336-02 Incorrect ECS Switch inputs diagnostic code. Refer to Troubleshooting, Electrical Power Supply. Make repairs, as needed.
Engine Shutdown (Unexpected)

SMCS Code: 1901-038
Check the Relay for the Prelube

Troubleshoot for the following diagnostic codes:
Probable Causes
There is a problem with the Gas Shutoff Valve
(GSOV).
338-05 Pre-Lube Relay open circuit 338-06 Pre-Lube Relay short to ground
Refer to Troubleshooting, ECM Output Circuit (Prelubrication Oil Pump). Make repairs, as needed.
Incorrect input(s) to the Engine Control Switch

(ECS)
There is a problem with the relay for the prelube. There is a problem with the switch for the prelube. There is a problem with the Crank Terminate
relay.
Check the Pressure Switch for the Prelube

Troubleshoot for the 339-05 Engine Pre-Lube Pressure Switch open circuit diagnostic code. Refer to Troubleshooting, Prelubrication System. Make repairs, as needed.
There is a problem with the relay for the starting

motor.
A shutdown has been requested by the driven

equipment.
Check the Crank Terminate Relay

Troubleshoot for the 443-03 Crank Terminate Relay short to +batt diagnostic code. Refer to Troubleshooting, ECM Status Indicator Output. Make repairs, as needed.
There is a problem with the Run relay. The Crank Terminate Speed is incorrectly
programmed.
The Cycle Crank Time is incorrectly

programmed.
Check the Start Relay

The Engine Overcrank Time is incorrectly

programmed.
444-05 Start Relay open circuit 444-06 Start Relay short to ground
Refer to Troubleshooting, ECM Output Circuit (Starting Motor). Make repairs, as needed.
The delay time for the driven equipment is

excessive.
Recommended Repair
Check the Circuit for the GSOV
17-05 Fuel Shutoff Valve open circuit
Check for a Request for a Shutdown by the Driven Equipment

Determine whether a shutdown for the driven equipment has been requested. Refer to Troubleshooting, Driven Equipment. Make corrections, as needed.
If the Cycle Crank Time is insufficient, the Engine Overcrank Time can elapse before the engine is able to start. Use Cat ET to check the Engine Overcrank Time. Use Cat ET to increase the Engine Overcrank Time, if necessary.
Check the Run Relay

Troubleshoot for the 445-03 Run Relay short to +batt diagnostic code. Refer to Troubleshooting, ECM Status Indicator Output. Make repairs, as needed.
Check the Driven Equipment Delay Time

The Driven Equipment Delay Time is a parameter that can be configured. The ECM provides a switch input for the driven equipment in order to delay engine start-up until the driven equipment is ready. The ECM will not attempt to start the engine until the switch input for the driven equipment closes to ground and the prelubrication (if equipped) is complete. An event code is generated if the Driven Equipment Delay Time elapses without closure of the switch input. To disable this feature, program the delay time to zero. If the programmed delay time is too long, the engine may not start. Use Cat ET to check the Driven Equipment Delay Time. Use Cat ET to program the delay time to a reasonable amount of time.
i01727650
Check the Crank Terminate Speed

The Crank Terminate Speed is a parameter that can be configured. The Electronic Control Module (ECM) disengages the starting motor when the engine exceeds the programmed Crank Terminate Speed. The default value of 250 rpm should be sufficient for all applications. If the Crank Terminate Speed is too slow, the engine will shut down. Use the Caterpillar Electronic Technician (ET) to check the programmed Crank Terminate speed. Use Cat ET to adjust the Crank Terminate Speed, if necessary.
Check the Cycle Crank Time

The Cycle Crank Time is a parameter that can be configured. This parameter determines the time for engagement of the starting motor and the gas shutoff valve during the crank cycle. If the engine does not start within the programmed Cycle Crank Time, the attempt to start is suspended for an equal Rest cycle. If the Cycle Crank Time is insufficient, the Engine Overcrank Time can elapse before the engine is able to start. Use Cat ET to check the Cycle Crank Time. Use Cat ET to increase the time, if necessary.
Engine Shutdown without a Diagnostic Code

SMCS Code: 1000-038; 1901-038
Probable Causes
An external shutdown or a customer shutdown
was requested.
The battery power to the Electronic Control

Module (ECM) is lost.
The ECM has lost the supply voltage for the

speed/timing sensor.
Check the Engine Overcrank Time

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 not start within the programmed Engine Overcrank time, the attempt to start is terminated. An E225 (3) Engine Overcrank event is generated.
There is a problem with the fuel supply. A cylinder or cylinders are misfiring.
Recommended Repairs
External Shutdown or Customer Shutdown
Check the ECM and the integrated temperature sensing module for logged codes of events that are shutdowns.
Locate the misfiring cylinder. Check the following components for failure: spark plug, extender, ignition transformer, and primary wiring. Inspect the extender for signs of pin holes and/or arcing. Refer to Troubleshooting, Ignition Transformers Secondary Circuit and Spark Plugs.
i01727661
Battery Power to the ECM

1. Refer to Troubleshooting, Electrical Power Supply. 2. Inspect the ground strap and the battery for connections that are loose and/or corroded. 3. Inspect the ECM and the terminal box for proper installation of the connectors. 4. Check the circuit breaker for the ECM in the terminal box.
Engine Starts but Stalls Immediately

SMCS Code: 1000-038; 1901-038
Probable Causes
Fuel supply Electrical connectors or power supply Engine speed/timing sensor Ignition system Excessive load
Speed/Timing Sensor
A loss of supply voltage to the speed/timing sensor will cause a shutdown. Refer to Troubleshooting, Engine Speed/Timing Sensor.
Recommended Repairs
Fuel Supply
Fuel Supply Check the fuel supply pressure. Inspect the fuel lines for foreign objects and for
obstructions that can block the fuel supply.
Misfiring Cylinders
For a shutdown that is due to misfiring cylinders, the shutdown is likely to occur only when the engine is operating under a load. The Caterpillar Electronic Technician (ET) and the Integrated Temperature Sensing Module (ITSM) can be used to detect a misfiring cylinder. Use the following procedure: 1. Use the Data Link/Select ECM screen on Cat ET to select the ITSM. 2. Select Diagnostics/Diagnostic Tests. 3. Select the suspect cylinder and click the Start button in the lower left corner of the screen. Cat ET will display a graph of the cylinders exhaust gas temperature. The transformers secondary circuit, the engine speed, and the desired engine speed are also displayed.

Make sure that the fuel pressure is correct. When possible, interview the operator in order to determine if fuel quality is in question. Try to determine if the source of the fuel was changed. Inspect the fuel system components: fuel filter, gas pressure regulator, gas shutoff valve, fuel metering valve, and actuator for the throttle. Verify that the systems components are operating correctly. Replace the fuel filter, if necessary.

1. Check the wiring harnesses and the connectors. Inspect the connectors in the terminal box. Inspect the battery connections and the ground. Refer to Troubleshooting, Inspecting Electrical Connectors. 2. Use the Caterpillar Electronic Technician (ET) to check for the 168-02 diagnostic code for System Voltage Intermittent. If this diagnostic code is logged, proceed to Troubleshooting, Electrical Power Supply. 3. Inspect the wiring from the battery to the Electronic Control Module (ECM). Refer to the Electrical System Schematic. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refer to Troubleshooting, Electrical Power Supply for more information.
i01727671
Engine Timing Does Not Match Programmed Timing

SMCS Code: 1901-038
Probable Causes
The timing may be retarded due to detonation. The timing may be retarded due to the selection
of the map for speed or the map for load.
The timing selection switch may be closed.
Recommended Repairs
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating temperature, etc), test the engine under the conditions. Troubleshooting the symptom under other conditions can give misleading results.
Engine Speed/Timing Sensor

Make sure that the speed/timing sensor is installed correctly. See Troubleshooting, Speed/Timing Sensor. Make sure that the timing wheel is correctly installed.
Detonation
Use the Caterpillar Electronic Technician (ET) to review the logged codes. Look for codes E401-1 through E416-1. Refer to the topic in Troubleshooting for the particular event code.
Ignition System
Inspect the ignition transformers for loose connections, moisture, short circuits, and open circuits. Inspect the primary wiring and the secondary electrical connections. Make sure that the correct transformers and spark plugs are installed. Inspect the extenders for signs or pin holes and arcing. Maintain the spark plug according to the engines Operation and Maintenance Manual.
Map
Use the Service/Configuration screen of Cat ET in order to verify the value that is programmed for the timing. Check the First Desired Timing and the Second Desired Timing. Refer to Systems Operation/Testing And Adjusting, Programming Parameters.
Timing Selection Switch

1. Verify that the timing selection switch is in the correct position. The open position selects the First Desired Timing and the closed position selects the Second Desired Timing. 2. Verify that the circuit of the switch has continuity to terminals J1-20 (input) and J1-31 (return) at the electronic control module. Make sure that the continuity is not inverted or incorrect. 3. Verify that the switch toggles properly. The action of the lever is smooth.
Excessive Load
i01746410
Engine Will Not Crank

SMCS Code: 1000-038; 1901-038
Inspect the pinion and the flywheel ring gear for damage. If the teeth of the pinion and/or the flywheel ring gear are worn or broken, replace the parts. If the pinion does not engage correctly with the flywheel, the pinion shaft may be stuck. Remove the pinion. Grease the splines of the drive shaft and the pinion. If the pinion does not engage the flywheel, the clutch jaws may be broken. Before you remove the starting motor, turn the crankshaft by hand. Ensure that a mechanical failure inside the engine is not preventing the crankshaft from turning. If the crankshaft will turn by hand, try the starting motor again. If the starting motor does not turn the crankshaft, remove the starting motor. Repair the starting motor or replace the starting motor.
Probable Causes
Batteries and/or battery cables Starting motor solenoid and/or starting circuit Starter motor pinion or flywheel ring gear Low air pressure Static load Wiring for the starting system Internal mechanical problem
Low Air Pressure

Determine the cause of the low air pressure. Inspect the air lines for leaks. Repair any leaks in the air lines.
Recommended Repairs
Batteries and/or Battery Cables
1. Inspect the main power switch, battery posts, and battery cables for loose connections and corrosion. If the battery cables are corroded, remove the battery cables and clean the battery cables. Tighten any loose connections. 2. Inspect the batteries. a. Charge the batteries. Refer to Special Instruction, Battery Test Procedure. b. Load test the batteries. Refer to Special Instruction, Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries.
Static Load
Make sure that the driven equipment is not preventing the crankshaft from turning. Try to turn the crankshaft by hand. If necessary, disengage the driven equipment and test the engine.
Wiring
If you suspect that the wiring is faulty, refer to Troubleshooting, Electrical Power Supply.
Internal Mechanical Problem

If the crankshaft will not turn and the driven equipment is disengaged, remove the spark plugs. Check for fluid in the cylinders. If this is not the problem, the engine must be disassembled in order to investigate internal mechanical problems. Possible internal problems include the following conditions:
Starting Motor Solenoid or Starting Circuit

1. Test the operation of the starting motor solenoid. If the solenoid does not operate properly, install a new solenoid. 2. Check the wiring to the starting motor solenoid.
Bearing seizure Piston seizure Valve and piston contact
Starting Motor or Flywheel Ring Gear

If the pinion engages the flywheel but the flywheel does not turn, there may be a problem with the starting motor. If the starting motor turns but the flywheel does not turn, inspect the gear teeth, the clutch jaws, or other parts.
i01727679
Excessive Load
Exhaust Port Temperature (High)

SMCS Code: 1901-038
Probable Causes
High inlet air temperature Inlet air restriction Air/fuel ratio Excessive load Incorrect timing Exhaust restriction A buildup of deposits in the cylinder or internal
oil leaks
Note: Data from a fuel analysis is required for this procedure. Use the Caterpillar Electronic Technician (ET) to check the ignition timing during engine operation with a load. Compare the timing to the recommended timing in the Engine Performance, Fuel Usage Guide. Adjust the ignition timing according to the recommended timing in the Engine Performance, Fuel Usage Guide.
Measure the Exhaust Restriction

Measure the exhaust restriction during engine operation with a load. For data that is specific to the engine, refer to the Technical Marketing Information. Investigate the cause of the exhaust restriction. Perform adjustments and/or make repairs, as needed.
Recommended Repairs
Check the Inlet Air Temperature
High inlet air temperature can cause detonation. Check the inlet air temperature. Refer to Troubleshooting, Inlet Air Temperature (High).
Check for Deposits in the Cylinder and Check for Internal Oil Leaks
Inlet Air Restriction

The maximum allowable inlet air restriction is 3.75 kPa (15 inches of H2O). If the indication is higher than the maximum permissible restriction, clean the filter element or install a new filter element. Check the restriction again. If the restriction remains too high, inspect the air inlet piping before the air cleaner for obstructions.
Deposits on the valve seats Deposits on the valve faces Deposits on the cylinder walls that are above the
Air/Fuel Ratio
An air/fuel mixture that is too rich will increase the exhaust temperature. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable. Verify that the exhaust emissions are correct.
Signs of internal oil leaks

Other signs of internal oil leaks include high oil consumption and blue smoke. Note: Excessive deposits contribute to guttering of the valves. If excessive deposits and/or signs of internal oil leaks are found, investigate the cause of the condition. Make repairs, as needed.
i01727687
Check for Insufficient Ignition

Use Cat ET to check for logged diagnostic codes that relate to the ignition system. Troubleshoot the code. Refer to Troubleshooting, Ignition Transformers Primary Circuit. If no logged diagnostic codes are present for the suspect cylinder, inspect the components of the ignition system for the cylinder. Refer to Troubleshooting, Ignition Transformers Secondary Circuit and Spark Plugs.
Exhaust Port Temperature (Low)

SMCS Code: 1901-038
Probable Causes
Operation with a light load Active diagnostic code from the Integrated
Temperature Sensing Module (ITSM)
Check the Cylinder Compression

Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression. If low compression is found, investigate the cause of the low compression. Make repairs, as needed.
i01727698
A faulty thermocouple Insufficient ignition Low cylinder compression
Recommended Repairs
Check for Misfire
Operation with a low load can result in low exhaust temperatures. Operate the engine at low idle or near low idle in order to identify a misfire problem. Troubleshoot the cause of the misfire. Refer to Troubleshooting, Engine Misfires,Runs Rough or Is Unstable.
Fuel Energy Content

SMCS Code: 1901-038
Probable Causes
The Low Heat Value (LHV) of the gas or the
specific gravity of the gas is significantly different from the value that is programmed into the electronic control module. sensor needs to be calibrated.
Check for Diagnostic Codes from the Integrated Temperature Sensing Module (ITSM)
Use the Caterpillar Electronic Technician (ET) to check for diagnostic codes that relate to the thermocouples for exhaust temperatures. Troubleshoot the code.
The oxygen sensor is not accurate or the oxygen Condensation is forming in the gas.
Recommended Repairs
Obtain a Fuel Analysis and Program the Fuel Quality Parameter
Obtain an analysis of the gas in order to determine the LHV. Program the Fuel Quality parameter to the actual value of the LHV. If the quality of the gas is not consistent, obtain several analyses over a period of time. Program the Fuel Quality parameter to the average value of the LHV.
Check for Suspect Thermocouples

Observe the temperatures from the thermocouples after the engine is shut off. When the engine is operating properly, the temperatures from similar locations are reduced at a similar rate. Also, the temperatures from similar locations are comparable. If any discrepancies are found, switch the suspect thermocouple for another thermocouple. If the temperature problem follows the thermocouple, replace the thermocouple. If the temperature problem stays at the original location of the suspect thermocouple, investigate the cause for the low temperature.
Check the Oxygen Sensor

Calibrate the oxygen sensor. Refer to Troubleshooting, Oxygen Sensor - Calibrate.
If the oxygen sensor could not be calibrated successfully, refer to Troubleshooting, Oxygen Sensor Buffer Supply and Troubleshooting, Oxygen Sensor Signal.
Recommended Repairs
Check the Battery Voltage
Check the battery voltage for the fuel metering valve. Refer to Troubleshooting, Electrical Power Supply. Make repairs, as needed.
Check the Dryer for the Gas

Check the dryer for the gas for proper operation. Repair the dryer, if necessary.
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Check the Fuel Metering Valve

Shut OFF the fuel supply. Disconnect the fuel lines from the fuel metering valve. Visually inspect the internal mechanism of the valve. Check for binding due to dirt and/or contamination. Check for binding due to wear of internal components. Clean the valve, if necessary. If the valve is binding due to wear of internal components, refer to the literature that is provided by the OEM of the valve.
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Fuel Pressure
SMCS Code: 1250-035
Probable Causes
Incorrect setting of the gas pressure regulator Faulty gas pressure regulator
Recommended Repairs
Check the Gas Pressure Regulator
Use the Caterpillar Electronic Technician (ET) to observe the absolute fuel pressure and the fuel differential pressure. The fuel metering valve requires a gas supply that is regulated to a pressure between 10 to 35 kPa (1.5 to 5 psi). If the fuel pressure is not within the acceptable range, adjust the gas pressure regulator in order to achieve the correct pressure. Verify that the emissions are within specifications. If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
i01369469
Gas Fuel Differential Pressure (High)

SMCS Code: 1901-038
Probable Causes
Excessive fuel supply pressure Leaks in the piping after the fuel metering valve
Recommended Repairs
Check the Fuel Supply Pressure
Check the pressure of the fuel supply to the fuel metering valve for high pressure. The maximum allowable pressure to the fuel metering valve is 35 kPa (5 psi). Adjust the gas pressure regulator in order to achieve the correct pressure. If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
Fuel Metering Valve

SMCS Code: 1901-038
Probable Causes
Low battery voltage Internal binding of the fuel metering valve
Check for Leaks

Use a gas detector to check for leaks in the piping between the outlet of the fuel metering valve and the turbocharger compressor. Repair the piping, if necessary.
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Gas Fuel Differential Pressure (Low)

SMCS Code: 1901-038
Inspect the fuel supply lines to the fuel metering valve for obstructions. Clean the lines and make repairs, as needed. Check the Gas Shutoff Valve (GSOV) for proper operation. Verify that the valve is fully open when the valve is energized. Verify that the GSOV does not stick in a partially open position. Repair the GSOV. Replace the GSOV, if necessary.
Probable Causes
Improper installation of the fuel metering valve Low fuel supply pressure Obstructed fuel supply Obstructed fuel outlet
Check the Fuel Outlet for Obstructions

Inspect the piping for obstructions between the fuel metering valve and the inlet to the turbocharger compressor. Clean the piping and make repairs, as needed.
i01727721
Recommended repairs
Check the Installation of the Fuel Metering Valve
An E864 Low Gas Fuel Differential Pressure event will be generated if the fuel metering valve is installed backward. When the fuel metering valve is properly installed, the end with the electrical connector is connected to the air system which leads to the inlet of the turbocharger compressor. The opposite end of the valve is connected to the pressurized gas supply. Check for proper installation of the fuel metering valve. Ensure that the fuel metering valve is installed properly.
Gas Fuel Flow Rate (Low)

SMCS Code: 1901-038
Probable Causes
High fuel temperature Faulty gas pressure regulator or low fuel supply
pressure
Obstructions in the fuel supply Inadequate fuel energy content or moisture in

the gas
Recommended Repairs
Check the Fuel Temperature
Measure the temperature of the gas that is entering the fuel metering valve. Compare the measurement to the reading for the fuel temperature on the Caterpillar Electronic Technician (ET). Check Cat ET for a E223 High Gas Temperature event code. If the temperature on Cat ET is different, determine the reason for the faulty signal from the fuel metering valve. If the fuel temperature is high, determine the cause of the high fuel temperature. Check for proper operation of the equipment that treats the gas prior to the engine. If there is an active E223 High Gas Temperature event code, refer to Troubleshooting, Gas Temperature (High). Make repairs, as needed.

The fuel metering valve requires a minimum pressure of 10 kPa (1.5 psi) for the gas supply. Check the outlet pressure from the gas pressure regulator. Adjust the gas pressure regulator in order to achieve the correct pressure. If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
Check the Fuel Supply for Obstructions

Check the fuel filter for restriction. Replace the fuel filter, if necessary. Inspect the screen inside the inlet of the fuel metering valve for cleanliness. Clean the screen, if necessary.

Check the outlet pressure from the gas pressure regulator. The fuel metering valve requires a minimum pressure of 10 kPa (1.5 psi) for the gas supply. If the pressure of the gas supply is too low, adjust the gas pressure regulator in order to achieve the correct pressure. If the gas pressure regulator cannot be adjusted to the correct setting, repair the regulator or replace the regulator.
i01727732
Gas Temperature (High)

SMCS Code: 1901-038
Probable Causes
The temperature of the gas is too high. The fuel metering valve has sent faulty data to the
electronic control module.
Recommended Repairs
Investigate the Cause of the High Temperature
Check for proper operation of the equipment that treats the gas prior to the engine. If a problem is found for the equipment that treats the gas prior to the engine, repair the equipment, as needed.
Check the Fuel Supply for Obstructions

Check the fuel filter for restriction. Replace the fuel filter, if necessary. Inspect the screen inside the inlet of the fuel metering valve for cleanliness. Clean the screen, if necessary. Inspect the fuel supply lines to the fuel metering valve for obstructions. Clean the lines and make repairs, as needed. Check the Gas Shutoff Valve (GSOV) for proper operation. Verify that the valve is fully open when the valve is energized. Verify that the GSOV does not stick in a partially open position. Repair the GSOV. Replace the GSOV, if necessary.
Check the Data from the Fuel Metering Valve

Measure the temperature of the gas that is entering the fuel metering valve. Compare the measurement to the reading for the temperature on the Caterpillar Electronic Technician (ET). If the measurement for the temperature is significantly different from the reading on Cat ET, determine the reason for the faulty data from the fuel metering valve. Make repairs, as needed.
i01623042
Obtain a Fuel Analysis

If the fuel energy content is too low, the fuel metering valve could demand an excessive supply of fuel. Check Cat ET for a E230 (1) Fuel Energy Content Setting High event code. If the code is present, refer to Troubleshooting, Fuel Energy Content. Obtain an analysis of the gas in order to determine the LHV. Program the Fuel Energy Content to the actual value of the LHV. If the quality of the gas is not consistent, obtain several analyses over a period of time. Program the Fuel Energy Content to the average value of the LHV.
Inlet Air Temperature (High)

SMCS Code: 1901-038
Probable Causes
High ambient air temperature High coolant temperature High inlet air restriction and/or high altitude Faulty inlet air temperature sensor and/or circuit Insufficient flow of cooling water through the
aftercooler
Check the Dryer for the Gas

Check the dryer for the gas for proper operation. Repair the dryer, if necessary.
Insufficient flow of air through the aftercooler
Recommended Repairs
High Ambient Air Temperature
Determine if the ambient air temperature is within the design specifications for the cooling system. Determine the cause of the high air temperature. Make corrections, when possible.
If there is a high differential between the inlet temperature and the outlet temperature of the coolant for the aftercooler, perform the following procedures:
Check the water circuit of the aftercooler for

obstructions.
Check the pump for proper operation. Make repairs, if necessary. Check for Sufficient Flow of Air Through the Aftercooler
Determine the pressure differential of the inlet air across the aftercooler. For specific data, refer to the Technical Marketing Information for the engine. If the pressure differential of the air across the aftercooler does not match the specifications, clean the aftercooler.
i01727744
Coolant Temperature
Refer to Troubleshooting, Engine Coolant Temperature (High).
Check for High Inlet Air Restriction and/or High Altitude

When inlet air pressure is low, the turbocharger works harder in order to achieve the desired inlet manifold pressure. This increases inlet air temperature. Measure the inlet air pressure while the engine is operating under load. For specific data, refer to the Technical Marketing Information for the engine. Inlet Air Restriction Check for plugged air filters. Check for obstructions to the air inlet. Replace the air filters and/or remove the obstruction from the air inlet. High Altitude Make sure that the settings for the engine are correct for the altitude.
Intermittent Engine Shutdown

SMCS Code: 1000-038; 1901-038 Note: Use this procedure only if the engine shuts down completely and the engine must be restarted.
Probable Causes
Active engine shutdown Electrical connectors Circuit breaker Engine speed/timing signal Fuel supply Spark plug
Check the Temperature Sensor and/or the Circuit

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 temperature are approximately equal. If the reading is not correct, switch the sensor with a sensor that is known to be good. Verify that the problem is solved.
Recommended Repairs
Active Engine Shutdown
Use the Caterpillar Electronic Technician (ET) to check for any active engine shutdowns and/or logged engine shutdowns. Determine the reason for the shutdown. After correcting the problem, cycle the engine control switch to the OFF/RESET position for at least 15 seconds before you try to restart the engine.
Check for Sufficient Flow of Cooling Water Through the Aftercooler

Check the inlet temperature of the coolant for the aftercooler. Compare the reading to the regulated temperature. If the temperature is OK, check the outlet temperature of the coolant. A high temperature differential indicates an insufficient flow rate.
Electrical Connectors
1. Check the wiring harnesses and the connectors. Inspect the connectors in the terminal box. Inspect the battery connections and the ground. Refer to Troubleshooting, Inspecting Electrical Connectors. 2. Use Cat ET to check for the 168-02 diagnostic code for System Voltage Intermittent. If this diagnostic code is logged, proceed to Troubleshooting, Electrical Power Supply. 3. Inspect the wiring from the battery to the electronic control module. Refer to the Electrical System Schematic. Inspect the wires and the power relay. Check the power and ground connections to the ECM. Refer to Troubleshooting, Electrical Power Supply for more information.
i01368495
Jacket Water Inlet Pressure (High)

SMCS Code: 1901-038
Probable Causes
The circuit for the engine coolant pump pressure
switch (inlet) is OPEN.
The pressure at the inlet for the jacket water is

excessive.
Recommended Repairs
Check the Circuit for the Engine Coolant Pump Pressure Switch (Inlet)
The circuit for the switch must remain closed in order to avoid an E224 High Jacket Water Inlet Pressure event. Check wiring for damage or corrosion. Refer to Troubleshooting, Inspecting Electrical Connectors. If a problem with the wiring for the circuit is found, repair the wiring, as needed.
Circuit Breakers
Check the circuit breaker in the terminal box. The circuit breaker may exceed the trip point due to overheating. Reset the circuit breaker if the circuit breaker is tripped.
Engine Speed/Timing Signal

Loss of the signal from the speed/timing sensor will cause a shutdown. Use Cat ET to check for logged diagnostic codes. For more information, refer to Troubleshooting, Engine Speed/Timing Sensor.
Check the Inlet Pressure of the Jacket Water

The engine coolant pump pressure switch (inlet) is designed to open across pin B and pin C at a pressure of 462 41 kPa (67 6 psi). Use a gauge to check the pressure at the inlet for the jacket water. If the pressure is less than 462 41 kPa (67 6 psi) but the event code E224 High Jacket Water Inlet Pressure is occurring, replace the pressure switch at the inlet for the jacket water. If a pressure of at least 462 41 kPa (67 6 psi) is measured at the inlet for the jacket water, the high pressure may be caused by a restriction in the jacket water system. Inspect the system for restrictions. Make repairs, as needed.
Fuel Supply
1. Check the fuel lines for the following problems: restrictions, obstructions, collapsed lines, and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines. 2. Check the restriction of the fuel filter. If the fuel pressure is low, replace the fuel filter. 3. Check the fuel quality. 4. Check the fuel pressure. Refer to Systems Operation/Testing and Adjusting, Fuel System for the correct pressure values. If the fuel pressure is still low, check the gas regulator and the fuel metering valve.
Spark Plug
An engine shutdown that is due to a faulty spark plug is likely to occur when the engine is operating under a load. Refer to Troubleshooting, Ignition Transformers Secondary Circuit and Spark Plugs.
Note: If the outlet pressure of the coolant is greater than approximately 444 kPa (64 psi), a 109-08 diagnostic code will be generated. The Engine Coolant Outlet Pressure Sensor noisy signal diagnostic will be generated although there is no malfunction in the electrical circuit. If this code is generated, verify the actual outlet pressure of the 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.
i01727750
Check for plugging of the radiator or the heat

exchanger. impeller.
Inspect the jacket water pump for damage to the

Make the necessary repairs.
i01727753
Jacket Water to Engine Oil Differential Temperature (Low)

SMCS Code: 1901-038
Jacket Water Pressure (Low)

SMCS Code: 1901-038
Probable Causes
High oil temperature and low coolant temperature Faulty temperature sensor and/or circuit Faulty water temperature regulators
Probable Causes
Low coolant level Insufficient flow of coolant
Recommended Repairs
Check the Coolant Level and Inspect the Cooling System for Leaks
Check coolant level. If the coolant level is low, inspect the cooling system for leaks. If the coolant level is low, fill the cooling system. If leaks are found, make the necessary repairs.
Recommended Repairs
Check the Engine Coolant Temperature and the Oil Temperature
Use the Caterpillar Electronic Technician (ET) to check for the following event codes:
E123 (1) Jacket Water to Oil Temperature Low

(warning)
Check the Flow of Coolant

Use the Caterpillar Electronic Technician (ET) to observe the pressure at the jacket water outlet with the engine OFF. Then observe the reading during engine operation. If the reading is not reasonable or if the reading is not within specifications, install a pressure gauge near the pressure sensor at the jacket water outlet. Compare the gauge reading with the reading from Cat ET. If the readings from the comparative gauge do not agree approximately with Cat ET, troubleshoot the circuit for the pressure sensor at the jacket water outlet. Refer to Troubleshooting, PWM Sensor. If the readings from the comparative gauge agree approximately with Cat ET, check the following components:
E124 (3) Jacket Water to Oil Temperature

(shutdown)
E019 (3) High Engine Oil Temperature (shutdown) E020 (1) High Engine Oil Temperature (warning) E038 (1) Low Engine Coolant Temperature
(warning) If one or more of the codes are active, troubleshoot the code(s).
Check the Temperature Sensors and/or Circuits

Use Cat ET in order to verify that the oil temperature and the engine coolant temperature are reasonable. If one or both of the readings are incorrect, troubleshoot the circuit(s). Refer to Troubleshooting, Analog Sensor Signal.
Check the water temperature regulators for

proper operation.

The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. Allow the engine to cool and then start the engine. Check the tube at the outlet for the jacket water. If the tube is warm and normal operating temperature is not achieved yet, a regulator may be stuck open. Check the water temperature regulators according to Systems Operation/Testing and Adjusting, Testing the Cooling System. Replace the water temperature regulators, if necessary.
i01368006
E026 (3) High Inlet Air Temperature (shutdown) E027 (1) High Inlet Air Temperature (warning)
If one or more of the codes is active, refer to Troubleshooting, Inlet Air Temperature (High).

Note: Data from a fuel analysis is required for this procedure. Use Cat ET to check the ignition timing during engine operation with a load. Compare the timing to the recommended timing in the Engine Performance, Fuel Usage Guide. Adjust the ignition timing according to the recommended timing in the Engine Performance, Fuel Usage Guide.
System Voltage
SMCS Code: 1901-038
Probable Causes
There is a problem with the electrical system.
Measure the Exhaust Restriction

Measure the exhaust restriction during engine operation with a load. For data that is specific to the engine, refer to the Technical Marketing Information. Investigate the cause of the exhaust restriction. Perform adjustments and/or make repairs, as needed.
i01727763
Recommended Repairs
Troubleshoot the electrical system. Refer to Troubleshooting, Electrical Power Supply.
Turbocharger Turbine Temperature (High)

SMCS Code: 1052-038
Check for Deposits in the Cylinder and Check for Internal Oil Leaks
Deposits on the valve seats
Probable Causes
High inlet manifold temperature Advanced timing Exhaust restriction A buildup of deposits in the cylinder or internal
oil leaks
Deposits on the valve faces Deposits on the cylinder walls that are above the
Signs of internal oil leaks

Other signs of internal oil leaks include high oil consumption and blue smoke. Note: Excessive deposits contribute to guttering of the valves. If excessive deposits and/or signs of internal oil leaks are found, investigate the cause of the condition. Make repairs, as needed.
Recommended Repairs
Check for Event Codes for High Inlet Manifold Air Temperature
Use the Caterpillar Electronic Technician (ET) to check for the following event codes:
E025 (2) High Inlet Air Temperature (derating)
i01727766
Turbocharger Turbine Temperature (Low)

SMCS Code: 1052-038
When the engine is operating properly, the temperatures from similar locations are reduced at a similar rate. Also, the temperatures from similar locations are comparable. If any discrepancies are found, switch the suspect thermocouple for another thermocouple. If the temperature problem follows the thermocouple, replace the thermocouple. If the temperature problem stays at the original location of the thermocouple, investigate the cause for the low temperature.
Probable Causes
Operation with a light load Diagnostic code from the Integrated Temperature
Sensing Module (ITSM)
Low temperature from the cylinder exhaust ports A faulty temperature sensor Faulty ignition Low cylinder compression
Check for Diagnostic Codes that Relate to Ignition

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

Inspect the components of the ignition system for the suspect cylinder bank. Refer to Troubleshooting, Ignition Transformers Secondary Circuit and Spark Plugs. Make repairs, as needed.
Recommended Repairs
Check for Misfire
Operation with a low load can result in low exhaust temperatures. Operate the engine at low idle or near low idle in order to identify a misfire problem. Troubleshoot the cause of the misfire. Refer to Troubleshooting, Engine Misfires, Runs Rough or Is Unstable.
Check the Cylinder Compression

Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression. If low compression is found, investigate the cause of the low compression. Make repairs, as needed.
Check for Diagnostic Codes from the Integrated Temperature Sensing Module (ITSM)
Use the Caterpillar Electronic Technician (ET) to check for diagnostic codes that relate to the thermocouples. Troubleshoot the code.
Check the Temperatures of the Cylinder Exhaust Ports

Observe the temperatures for the exhaust ports of the cylinders in the suspect bank. If any of the temperatures for the exhaust ports are significantly different, determine the reason for the difference in the exhaust port temperatures. Make repairs, as needed.
Check for Suspect Thermocouples

Observe the temperatures from the thermocouples for the turbochargers after the engine is shut off.
Troubleshooting with a Diagnostic Code

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Table 12
Failure Mode Identifiers FMI 00 01 02 03 04 05 06 07 08 09 Description of Failure Data valid but above normal operating range Data valid but below normal operating range Data erratic, intermittent or incorrect Voltage above normal or shorted high Voltage below normal or shorted low Current below normal or open circuit Current above normal or grounded circuit Mechanical system not responding properly Abnormal frequency, pulse, or period Abnormal update Abnormal rate of change Failure mode not identifiable Bad device or component Out of calibration Not used Not used Parameter not available Module not responding Sensor supply fault Condition not met Not used
Diagnostic Codes
SMCS Code: 1901-038 Diagnostic codes alert the operator that a problem in the electronic system has been detected. Diagnostic codes also indicate the nature of the problem to the service technician. The Caterpillar Electronic Technician (ET) is a software program that is designed to run on a personal computer. Diagnostic codes may be viewed on a personal computer that has Cat ET software. Diagnostic codes consist of the module identifier (MID), the component identifier (CID), and the failure mode identifier (FMI). Module Identifier (MID) The MID is a code with two or three digits that indicates the electronic module which generated the diagnostic code. The MID for the Electronic Control Module (ECM) is 36. The MID for the Integrated Temperature Sensing Module (ITSM) is 111. Some electronic displays do not display the MID because the module which generates the code is obvious. Component Identifier (CID) The CID is a number with three or four digits. The CID indicates the component that generated the code. For example, the CID number 0017 identifies the fuel shutoff valve. Failure Mode Identifier (FMI) The FMI is a two digit code that indicates the type of failure. Table 12 is a list of the failure mode identifiers that are adapted from the SAE J1587 standard.
10 11 12 13 14 15 16 17 18 19 20
Note: Do not confuse diagnostic codes with event codes. For information on event codes, see Troubleshooting, Troubleshooting with an Event Code. Illustration 14 represents the operating range of an oil temperature sensor. The diagram is a reference. Do not use the diagram to troubleshoot the oil temperature sensor.
This information is a valuable indicator for troubleshooting intermittent problems. Any logged diagnostic codes will automatically be deleted if no additional occurrences are recorded in 100 hours. Some diagnostic codes may be easily triggered. Some diagnostic codes may log occurrences that did not result in complaints. The most likely cause of an intermittent problem is a faulty connection or damaged wiring. The next likely cause is a component failure. The least likely cause is the failure of the ECM. Diagnostic codes that are logged repeatedly may indicate a problem that needs special investigation. Note: Always clear logged diagnostic codes after investigating and correcting the problem which generated the code.
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Illustration 14 Typical operating range of an oil temperature sensor
g00791619
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Value open circuit
SMCS Code: 1901-038 Conditions Which Generate This Code:
(1) In these areas, the output voltage of the sensor is too high or too low. The output is outside of the normal range. The electronic problem will generate a diagnostic code. (2) In this area, the oil temperature above 102 C (216 F) is higher than normal. The output voltage of the sensor will generate an event code for a warning, a derating, or a shutdown for high oil temperature. The sensor does not have an electronic problem. (3) This area represents the normal operating temperature for the engine oil. The normal output voltage of the sensor is between 0.2 and 4.1 volts.
The output to the fuel control relay from the

Electronic Control Module (ECM) is OFF.
When no electrical load is provided, a resistor in

the fuel shutoff valve rises to the +Battery side. Note: This code cannot be detected by the ECM when the output for the fuel control relay is ON. The output is normally ON when the engine control switch is in the START position and the engine RPM is greater than zero. System Response: No fuel is provided to the engine. The alarm output is activated. The code is logged. Possible Performance Effect: The engine will not start due to the lack of fuel. Troubleshooting:
Active Diagnostic Codes

An active diagnostic code represents a problem with the electronic control system. Correct the problem as soon as possible. When an active diagnostic code is generated, the Active Alarm indicator (Engine Control Alarm Status on Cat ET) is activated in order to alert the operator. If the condition that generated the code is momentary, the message disappears from the list of active diagnostic codes. The diagnostic code becomes logged.
Logged Diagnostic Codes

When the ECM generates a diagnostic code the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock. The ECM will record the following information when a code is generated:
The most likely cause is one of the following conditions:
An open circuit in the harness or in the fuel

control relay
The hour of the first occurrence of the code The hour of the last occurrence of the code The number of occurrences of the code A short circuit to the +Battery in the harness or
in the fuel control relay Perform the following diagnostic procedure: ECM Output Circuit (Fuel Control)
Results:
i01741131
OK STOP.
i01727848
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction

SMCS Code: 1901-038 Conditions Which Generate This Code: The driver in the Electronic Control Module (ECM) for the gas shutoff valve is OFF but the engine still runs. System Response: The ECM will disable the ignition system and the gas shutoff valve in order to shut down the engine. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: ECM Output Circuit (Fuel Control) Results:
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground
The output for the fuel control relay is ON. The Electronic Control Module (ECM) detects
excessive current on the output for the fuel control relay.
Note: This condition cannot be detected by the ECM when the output for the fuel control relay is OFF. The output is normally OFF when the engine control switch is in the OFF/RESET position. System Response: The ECM will continue attempting to energize the relay. The engine may shut down due to a lack of fuel. The alarm output is activated. The code is logged. Possible Performance Effect: The engine will not start due to the lack of fuel. Troubleshooting: The condition is probably caused by a short circuit in the harness or by an internal short circuit in the fuel control relay. Perform the following diagnostic procedure: ECM Output Circuit (Fuel Control) Results:
OK STOP.
i01727944
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt

SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage supply from the Electronic Control Module (ECM) to one of the following sensors has exceeded the normal range.
Detonation sensors Sensor for inlet manifold air pressure Sensor for engine coolant pressure
System Response: Default values are assumed for the inputs to the ECM from all of the 8 volt analog sensors. All of the diagnostic codes for the 8 volt analog sensors to the ECM are disabled while this code is active.
OK STOP.
The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: +8V Sensor Voltage Supply Results:
i01728439
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt
SMCS Code: 1924-038 Conditions Which Generate This Code: The signal from the filtered oil pressure sensor to the Electronic Control Module (ECM) is greater than 4.8 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:
OK STOP.
i01727976
262 - 03 5 Volt Sensor DC Power Supply short

to +batt
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground

SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage supply from the Electronic Control Module (ECM) to one of the following sensors is below the normal range.

to ground System Response: The ECM assumes the last valid value for the engine oil pressure. The monitoring of the oil pressure is disabled. This disables the engine protection for low oil pressure and excessive oil pressure. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down. Troubleshooting: This condition indicates an open circuit or a short circuit to a positive voltage source. Perform the following diagnostic procedure: Analog Sensor Signal Results:
Detonation sensors Sensor for inlet manifold air pressure Sensor for engine coolant pressure
System Response: Default values are assumed for the inputs to the ECM from all of the 8 volt analog sensors. All of the diagnostic codes for the 8 volt analog sensors to the ECM are disabled while this code is active. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled,the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: +8V Sensor Voltage Supply Results:
OK STOP.
OK STOP.
i01728444
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground
SMCS Code: 1924-038 Conditions Which Generate This Code: The signal from the filtered oil pressure sensor to the Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:
Additionally, neither of the following diagnostic codes are active:
41 - 03 8 Volt DC Supply short to +batt 41 - 04 8 Volt DC Supply short to ground

System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: This condition indicates the possibility of an open circuit or a short circuit. Perform the following diagnostic procedure: PWM Sensor Results:

to +batt

to ground System Response: The ECM assumes the last valid value for the engine oil pressure. The monitoring of the oil pressure is disabled. This disables the engine protection for low oil pressure and excessive oil pressure. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Analog Sensor Signal Results:
OK STOP.
i01636377
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal
SMCS Code: 1901-038 Conditions Which Generate This Code: The duty cycle or the frequency for the inlet manifold pressure sensor is out of range. Additionally, neither of the following diagnostic codes are active:
OK STOP.
i01636347
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt
SMCS Code: 1901-038 Conditions Which Generate This Code: The duty cycle for the inlet manifold pressure sensor is greater than the maximum value.
System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
Troubleshooting: Perform the following diagnostic procedure: PWM Sensor Results:
i01691110
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal
OK STOP.
i01631733
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt
SMCS Code: 1901-038 Conditions Which Generate This Code: The duty cycle of the pressure sensor for the outlet of the engine coolant is greater than the maximum limit. Additionally, neither of the following diagnostic codes are active:
The duty cycle or the frequency of the signal from the pressure sensor for the outlet of the engine coolant is out of range. Additionally, neither of the following diagnostic codes are active:

System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not affected. Troubleshooting: Perform the following diagnostic procedure: PWM Sensor Results:

System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not affected. Troubleshooting: The condition indicates a possible open circuit or a short circuit. Perform the following diagnostic procedure: PWM Sensor Results:
OK STOP.
i01728446
MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt
SMCS Code: 1906-038 Conditions Which Generate This Code: The signal from the engine coolant temperature sensor to the Electronic Control Module (ECM) is greater than 4.8 VDC for at least five seconds. System Response: The ECM assumes the last valid value for engine coolant temperature. The monitoring of the coolant temperature is disabled. This disables the engine protection for low coolant temperature and high coolant temperature.
OK STOP.
The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down. Troubleshooting: This condition indicates the possibility of an open circuit or a short circuit. Perform the following diagnostic procedure: Analog Sensor Signal Results:
i01728448
MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt
SMCS Code: 1901-038 Conditions Which Generate This Code: The electronic control module has been powered up for at least five seconds. The 12 volt sensor supply voltage becomes greater than 14.2 V for at least one second. System Response: If the engine is running, the fuel is shut off. The shutdown output is activated. The code is logged.
OK STOP.
i01728447
Possible Performance Effect: The engine is shut down or the engine will not start. Troubleshooting: Perform the following diagnostic procedure: Engine Speed/Timing Sensor Results:
MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground
SMCS Code: 1906-038 Conditions Which Generate This Code: The signal from the engine coolant temperature sensor to the Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds. System Response: The ECM assumes the last valid value for the engine coolant temperature. The monitoring of the coolant temperature is disabled. This disables the engine protection for low coolant temperature and high coolant temperature. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: Since the engine protection is disabled, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Analog Sensor Signal Results:
OK STOP.
i01728449
MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground
SMCS Code: 1901-038 Conditions Which Generate This Code: The electronic control module has been powered up for at least five seconds. The 12 volt sensor supply voltage becomes less than 11 VDC for at least one second. System Response: If the engine is running, the fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down or the engine will not start.
OK STOP.
Troubleshooting: Perform the following diagnostic procedure: Engine Speed/Timing Sensor Results:
i01728451
MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt
OK STOP.
i01728450
MID 036 - CID 0168 FMI 02 System Voltage intermittent/erratic

SMCS Code: 1401-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered for at least 5 seconds. The engine is running. Either of the two following conditions occur:
The Electronic Control Module (ECM) has been powered for at least five seconds. The signal from the inlet manifold temperature sensor to the ECM is greater than 4.8 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:

to +batt
262 -04 5 Volt Sensor DC Power Supply short to

ground System Response: The ECM assumes the last valid value for the inlet manifold air temperature. The monitoring of the inlet manifold air temperature is disabled. This disables the engine protection for high inlet manifold air temperature. The air/fuel ratio control cannot compensate for the inlet air temperature. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: The condition indicates a possible open circuit or a short circuit to a positive voltage source. Perform the following diagnostic procedure: Analog Sensor Signal Results:
The battery voltage is less than 6 VDC for a

minimum of 0.060 seconds. The voltage returns to the normal range within 0.015 seconds.
There are three voltage readings of less than 6

VDC within 7 seconds. System Response: The alarm output is activated. The code is logged. Note: If battery voltage is lost and the voltage does not return, the ECM will not log this diagnostic code. The engine will shut down. Possible Performance Effect: The intermittent problem may not affect engine operation. However, the engine may experience speed burps, intermittent shutdowns, and/or complete shutdowns. Troubleshooting: Perform the following diagnostic procedure: Electrial Power Supply Results:
OK STOP.
OK STOP.
i01728453
i01728456
MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground
SMCS Code: 1901-038 Conditions Which Generate This Code: The signal from the inlet manifold temperature sensor to the Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt
SMCS Code: 1901-038 Conditions Which Generate This Code: 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. Additionally, neither of the following diagnostic codes are active:

to +batt

to +batt

to ground System Response: The ECM assumes the last valid value for the inlet manifold air temperature. The monitoring of the inlet manifold air temperature is disabled. This disables the engine protection for high inlet manifold air temperature. The air/fuel ratio control cannot compensate for the inlet air temperature. The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting:

to ground System Response: The ECM assumes the last valid value for the engine oil temperature. The monitoring of the engine oil temperature is disabled. Also, the monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled. This disables the engine protection for both parameters. The shutdown output is activated. The code is logged. Possible Performance Effect: Since engine protection is disabled, the engine is shut down. Troubleshooting:
Perform the following diagnostic procedure: Analog Sensor Signal Results:
The condition indicates a possible open circuit or a short circuit to a positive voltage source. Perform the following diagnostic procedure: Analog Sensor Signal Results:
OK STOP.
OK STOP.
i01728458
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The timing will be advanced or the timing will be retarded. Either condition will result in reduced engine performance. If the condition is not corrected, engine damage will result. Troubleshooting: Calibrate the engine speed/timing sensor. Perform the following diagnostic procedure: Engine Speed/Timing Sensor - Calibrate Results:
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground
SMCS Code: 1901-038 Conditions Which Generate This Code: The signal from the engine oil temperature sensor to the Electronic Control Module (ECM) is less than 0.2 VDC for at least five seconds. Additionally, neither of the following diagnostic codes are active:

to +batt

to ground System Response: The ECM assumes the last valid value for the engine oil temperature. The monitoring of the engine oil temperature is disabled. Also, monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled. This disables the engine protection for both parameters. The shutdown output is activated. The code is logged. Possible Performance Effect: Since engine protection is disabled, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Analog Sensor Signal Results:
OK STOP.
i01728460
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt
SMCS Code: 1408-038-NS Conditions Which Generate This Code: The supply voltage from the Electronic Control Module (ECM) to the sensors for the following parameters is exceeding the normal level:
Inlet manifold air temperature Engine oil temperature Filtered engine oil pressure Unfiltered engine oil pressure
System Response: All of the inputs to the ECM for the 5 volt analog sensors assume default values. All other diagnostic codes for the 5 volt analog sensors are disabled while this diagnostic code is active. The Status screen of Caterpillar Electronic Technician (ET) indicates a Sensor Supply Fault for each sensor. This indicates that the sensors are not operating due to an active diagnostic code. The shutdown indicator is activated. The code is logged.
OK STOP.
i01636386
MID 036 - CID 0261 - FMI 13 Engine Timing calibration required

SMCS Code: 1905-038 Conditions Which Generate This Code: The timing calibration has not been performed.
Possible Performance Effect: Since engine protection is disabled, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: +5V Sensor Voltage Supply Results:
Troubleshooting: The condition indicates a possible short circuit to ground or a short circuit between the sensor supply and the return. Perform the following diagnostic procedure: +5V Sensor Voltage Supply Results:
OK STOP.
i01728462
OK STOP.
i01728464
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground
SMCS Code: 1408-038-NS Conditions Which Generate This Code: The supply voltage from the Electronic Control Module (ECM) to the sensors for the following parameters is less than the normal level:
MID 036 - CID 0301 - FMI 05 Cylinder 1 - Transformer Primary open circuit
SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
Inlet manifold air temperature Engine oil temperature Filtered engine oil pressure Unfiltered engine oil pressure
System Response: All of the inputs to the ECM for the 5 volt analog sensors assume default values. All other diagnostic codes for the 5 volt analog sensors are disabled while this diagnostic code is active. The Status screen of the Caterpillar Electronic Technician (ET) indicates a Sensor Supply Fault for each sensor. This indicates that the sensors are not operating due to an active diagnostic code. The shutdown output is activated. The code is logged. Possible Performance Effect: Since engine protection is disabled, the engine is shut down.
A broken circuit drivers wire for the transformer A broken return wire for the transformer An open circuit within the primary winding of the
transformer (ECM)
An internal failure of the electronic control module

Perform the following diagnostic procedure: Ignition Transformers Primary Circuit Results:
OK STOP.
i01728465
Troubleshooting: One of the following conditions is the source of the diagnostic code:
MID 036 - CID 0301 - FMI 06 Cylinder 1 - Transformer Primary short

SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting:
transformer (ECM)
An internal failure of the Electronic Control Module

OK STOP.
i01728470
One of the following conditions is the source of the diagnostic code:
The wiring from the circuit driver for the

transformer to the coil has a short circuit.

SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
There is a short circuit within the transformer. There is an internal failure of the Electronic
Control Module (ECM). Perform the following diagnostic procedure: Ignition Transformers Primary Circuit Results:
OK STOP.
i01728469
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire.

Control Module (ECM). Perform the following diagnostic procedure: Ignition Transformers Primary Circuit
Results:
i01728473
OK STOP.
i01728471

SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

transformer (ECM)

OK STOP.
i01728474
OK STOP.
SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged.
Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
There is an internal failure of the Electronic

transformer
OK STOP.
i01728478

(ECM) Perform the following diagnostic procedure: Ignition Transformers Primary Circuit Results:
SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response:
OK STOP.
i01728475
The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting:

transformer (ECM)

OK STOP.
There is a short circuit within the transformer.
i01728479

transformer

OK STOP.
i01728481


SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response:
OK STOP.
i01728480
The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:
MID 036 - CID 0306 - FMI 05 Cyinder 6 - Transformer Primary open circuit

i01728485

OK STOP.
i01728484
The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

transformer (ECM)
OK STOP.
i01728490

OK STOP.
Results:
OK STOP.
i01728496
transformer (ECM)

OK STOP.
i01728493

transformer (ECM)

OK STOP.

i01728499

SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting:
transformer (ECM)

OK STOP.
i01728508


OK STOP.
i01728504
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

Results:
i01728513
OK STOP.
i01728512


transformer (ECM)

OK STOP.
i01728515
OK STOP.

transformer
OK STOP.
i01728523

SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response:
OK STOP.
i01728518
The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting:

transformer (ECM)

OK STOP.
i01728527

transformer

OK STOP.
i01728535


SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response:
OK STOP.
i01728531
The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

i01728545

OK STOP.
i01728539
The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

transformer (ECM)
OK STOP.
i01728548

OK STOP.
Results:
OK STOP.
i01728554
transformer (ECM)
MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt

SMCS Code: 1912-038 Conditions Which Generate This Code: To activate this code, all of the following conditions must occur: The Electronic Control Module (ECM) has been powered for at least one second. The pattern of the timing reference gear is lost for more than one second. The engine speed is greater than 150 rpm. Neither of the following diagnostic codes are active:

OK STOP.
i01728552

145 - 03 12 Volt DC Power Supply short to +batt 145 - 04 12 Volt DC Power Supply short to ground
Note: The 0320 - 03 code is set after the pattern of the timing reference gear is lost for more than one second. However, the logic hesitates for 1.5 seconds before the code is activated. If a 145 - 03 or 145 - 04 is activated during the 1.5 seconds, then the 0320 - 03 code is deactivated. System Response: If the engine is running, the ignition signals stop. The shutdown output is activated. The code is logged. Possible Performance Effect:
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: If the engine is running, the engine will be shut down. If the engine is not running, the engine will not start. Troubleshooting: Perform the following diagnostic procedure: Engine Speed/Timing Sensor Results:

OK STOP.
i01728556
System Response: The ECM limits the current for the shutdown output to 0.3 amperes. The code is logged. Possible Performance Effect: The engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: ECM Status Indicator Output Results:
MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal

SMCS Code: 1912-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) must be powered for at least one second. The engine speed is greater than 150 rpm. One of the following two conditions occurs:
An invalid pattern for the timing reference gear

is detected. For example, reverse rotation is detected.
OK STOP.
i01728563
The pattern for the timing reference gear is lost for less than one second.
System Response: If the engine is running, the ignition signals stop. The shutdown output is activated. The code is logged. Possible Performance Effect: If the engine is running, the engine will be shut down. If the engine is not running, the engine will not start. Troubleshooting: Perform the following diagnostic procedure: Engine Speed/Timing Sensor Results:
MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt

SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the alarm output. Note: This diagnostic condition cannot be detected when the alarm output is OFF. System Response: The ECM limits the current for the alarm output to 0.3 amperes. The code is logged. Possible Performance Effect: The engine operation is not affected.
OK STOP.
Troubleshooting:
i01728557
MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt

SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the shutdown output. Note: This diagnostic condition cannot be detected when the shutdown output is OFF.
Perform the following diagnostic procedure: ECM Status Indicator Output Results:
OK STOP.
i01728570
Possible Performance Effect: The prelubrication will probably be disabled. Troubleshooting: Perform the following diagnostic procedure: ECM Output Circuit (Prelubrication Oil Pump) Results:
MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs

SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects an invalid combination on these inputs from the Engine Control Switch (ECS): Switched +Battery, Start, Stop, and Auto. System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: If the engine is running, the engine will be shut down. Troubleshooting: Perform the following diagnostic procedure: Electrical Power Supply Results:
OK STOP.
i01728581
MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short to ground

SMCS Code: 1319-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the output to the prelube relay. This indicates a possible short circuit to the Battery side. Note: This diagnostic condition can only be detected by the ECM when the output for the prelube relay is ON. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is still OPEN. System Response: The ECM will continue to attempt to energize the relay. The alarm output is activated. The code is logged. Possible Performance Effect: The prelubrication will probably be disabled. Troubleshooting: Perform the following diagnostic procedure: ECM Output Circuit (Prelubrication Oil Pump) Results:
OK STOP.
i01728575
MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open circuit

SMCS Code: 1319-038 Conditions Which Generate This Code: An open circuit or a short circuit to the +Battery side is detected while the output from the Electronic Control Module (ECM) to the prelube relay is OFF. Note: This diagnostic condition can only be detected by the ECM when the output for the prelube relay is OFF. The output is normally OFF when the engine control switch is in the STOP position and/or when the prelube pressure switch is CLOSED. System Response: An internal resistor rises to the +Battery side when no electrical load is present. This indicates an open circuit in the harness or the solenoid. The alarm output is activated. The code is logged.
OK STOP.
i01728588
System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
MID 036 - CID 0339 - FMI 05 Engine Pre-lube Pressure Switch open circuit
SMCS Code: 1901-038 Conditions Which Generate This Code: The prelube pressure switch is OPEN. The oil pressure that is measured from the engine oil pressure sensor is greater than 50 kPa (7.25 psi). System Response: The Electronic Control Module (ECM) normally monitors the prelube pressure switch. In this case, the engine oil pressure sensor will be monitored. This determines if the prelube pump is supplying oil to the engine. If an E233 (3) Low Engine Prelube Pressure event is active, the output to the starting motor will not be energized and the engine will not start. The alarm output is activated. The code is logged. The output to the prelube relay remains energized until the engine control switch is turned to the STOP position. Possible Performance Effect: The prelubrication will probably be disabled. Troubleshooting: Perform the following diagnostic procedure: Prelubrication System Results:
There is a problem with the transformers ground. The winding of the transformers secondary circuit
is open.
There is a problem with the connection to the

spark plugs terminal post.
The spark plug has internal damage or an open

circuit.
The spark plug gap is too wide.

Perform the following diagnostic procedure: Ignition Transformers Secondary Circuit and Spark Plugs Results:
OK STOP.
i01632184
MID 036 - CID 0401 - FMI 06 Cylinder 1 - Transformer Secondary short to ground
i01685945
OK STOP.
MID 036 - CID 0401 - FMI 05 Cylinder 1 - Transformer Secondary open circuit
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with an open circuit.
The transformers secondary circuit is diagnosed with a short circuit. System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
Troubleshooting: One of the following conditions is the source of the problem:

The spark plug is fouled. The spark plug gap is closed. The winding of the transformers secondary circuit
is shorted. Perform the following diagnostic procedure: Ignition Transformers Secondary Circuit and Spark Plugs Results:
OK STOP.
i01632192
OK STOP.
i01685951
The transformers secondary circuit is diagnosed with a short circuit. System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect:
The transformers secondary circuit is diagnosed with an open circuit. System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect:
The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
The spark plug is fouled. The spark plug gap is closed.

The cylinder will misfire.
The winding of the transformers secondary circuit

Troubleshooting: One of the following conditions is the source of the problem: is shorted. Perform the following diagnostic procedure: Ignition Transformers Secondary Circuit and Spark Plugs Results:
is open.
OK STOP.

spark plugs terminal post. circuit.
i01685955
System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with an open circuit. System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
OK STOP.
i01685958
There is a problem with the transformers ground. The winding of the transformers secondary circuit is open. There is a problem with the connection to the
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with an open circuit. System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged.

circuit.

OK STOP.
i01632203
Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with a short circuit.
is open.

i01685960
The spark plug has internal damage or an open The spark plug gap is too wide.
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with an open circuit. System Response:
OK STOP.
i01632257
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with a short circuit. System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: Generation of the diagnostic code does not affect engine performance. However, the engine will probably misfire. This will cause the engine to run rough. The engine may shut down. Troubleshooting: One of the following conditions is the source of the problem:
is open.


circuit.

OK STOP.
OK STOP.
i01632261
is open.


circuit.

OK STOP.
i01632269
OK STOP.
i01685964

i01632278
OK STOP.
i01685988
The transformers secondary circuit is diagnosed with a short circuit. System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
is open.
OK STOP.
i01685995

OK STOP.
System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect:


is open.
OK STOP.
i01686000


circuit.

OK STOP.
i01632318
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with a short circuit. System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
is open.


i01686011
OK STOP.
i01632336
The transformers secondary circuit is diagnosed with an open circuit. System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
is open.


circuit.

OK STOP.
OK STOP.
i01632343
is open.


circuit.

OK STOP.
i01632349
OK STOP.
i01686017

i01632360
OK STOP.
i01686022
The transformers secondary circuit is diagnosed with a short circuit. System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
is open.
OK STOP.
i01686029

OK STOP.
System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect:


is open.
OK STOP.
i01686036


circuit.

OK STOP.
i01632384
SMCS Code: 1901-038 Conditions Which Generate This Code: The transformers secondary circuit is diagnosed with a short circuit. System Response: The status of the transformers secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.
The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
is open.


i01686039
OK STOP.
i01632392
The transformers secondary circuit is diagnosed with an open circuit. System Response: The status of the transformers secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem:
is open.


circuit.

OK STOP.
OK STOP.
i01632402
is open.


circuit.

OK STOP.
i01632407
OK STOP.
i01686042

Note: This diagnostic condition can only be detected by the ECM when the output for the starting motor relay is OFF. The output is normally OFF when the engine control switch is in the STOP position or when the crank terminate relay is energized. System Response: An internal resistor rises to the +Battery side when no electrical load is present. The alarm output is activated. The code is logged. Possible Performance Effect: The engine will be unable to crank. Troubleshooting: The harness or the relay probably has an open circuit. Perform the following diagnostic procedure: ECM Output Circuit (Starting Motor) Results:
OK STOP.
i01728635
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt
SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the crank terminate relay. Note: This diagnostic condition cannot be detected when the output for the crank terminate relay is OFF. The output is normally OFF when the engine control switch is in the STOP position. System Response: The ECM will limit the current for the crank terminate relay to 0.3 amperes. The alarm output is activated. The code is logged. Troubleshooting: Perform the following diagnostic procedure: ECM Status Indicator Output Results:
OK STOP.
i01728642
MID 036 - CID 0444 - FMI 06 Start Relay short to ground

SMCS Code: 1426-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the output of the starting motor relay. Note: This diagnostic condition can only be detected by the ECM when the output for the starting motor relay is ON. The output is normally ON when the engine control switch is turned from the STOP position to the START position. The output is ON until the crank terminate relay is energized. System Response: The ECM will continue to attempt to energize the relay. The alarm output is activated. The code is logged. Possible Performance Effect: The engine will probably be unable to crank.
OK STOP.
i01728639
MID 036 - CID 0444 - FMI 05 Start Relay open circuit

SMCS Code: 1426-038 Conditions Which Generate This Code: The output from the Electronic Control Module (ECM) for the starting motor relay is OFF. An open circuit or a short circuit to the +Battery is detected.
Troubleshooting: This condition indicates an short circuit in the harness or the relay. Perform the following diagnostic procedure: ECM Output Circuit (Starting Motor) Results:
System Response: When the Idle/Rated switch is in the Rated position, the ECM assumes a default value for the desired engine speed. The alarm output is activated. The code is logged. Possible Performance Effect: The default value for the desired engine speed is equal to the Minimum Engine High Idle Speed that is programmed on the Service/Configuration screen of the Caterpillar Electronic Technician (ET). Troubleshooting: The diagnostic code is generated by one of the following conditions:
OK STOP.
i01728646
MID 036 - CID 0445 - FMI 03 Run Relay short to +batt

SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the run relay. Note: This diagnostic condition cannot be detected when the output for the Run relay is OFF. The output is normally OFF when the engine control switch is in the STOP position. System Response: The ECM will limit the current to 0.3 amperes. The Status screen of the Caterpillar Electronic Technician (ET) will display Relay Fault. The code is logged. Troubleshooting: Perform the following diagnostic procedure: ECM Status Indicator Output Results:
A short circuit to the +Battery side A short circuit to ground

Perform the following diagnostic procedure: Desired Speed Input (4 - 20 mA) Results:
OK STOP.
i01728659
MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground
SMCS Code: 1907-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for at least five seconds. The current to the ECM for the desired speed input is less than 2 mA for more than five seconds.
OK STOP.
i01728651
MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt
SMCS Code: 1907-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for at least five seconds. The current to the ECM for the desired speed input is greater than 22 mA for more than five seconds.
System Response: When the Idle/Rated switch is in the Rated position, the ECM assumes a default value for the desired engine speed. The alarm output is activated. The code is logged. Possible Performance Effect: The default value for the desired engine speed is equal to the Minimum Engine High Idle Speed that is programmed on the Service/Configuration screen of the Caterpillar Electronic Technician (ET).
Troubleshooting: The diagnostic code is generated by one of the following conditions:
i01728669
An open circuit or a short circuit to ground An open circuit or a short circuit to the +Battery
Perform the following diagnostic procedure: Desired Speed Input (4 - 20 mA) Results:
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground
SMCS Code: 1924-038 Conditions Which Generate This Code: The signal to the Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is less than 0.2 VDC for at least five seconds. Also, neither of the following diagnostic codes are active:
OK STOP.
i01728660

to +batt
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt
SMCS Code: 1924-038 Conditions Which Generate This Code: The signal to the Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is greater than 4.8 VDC for at least five seconds. Also, neither of the following diagnostic codes are active:

to ground System Response: The ECM assumes the last valid value for unfiltered engine oil pressure. Monitoring for restriction of the oil filters is disabled. The alarm output is activated. The code is logged. Troubleshooting: Perform the following diagnostic procedure: Analog Sensor Signal Results:

to +batt

to ground System Response:
OK STOP.
i01728675
The ECM assumes the last valid value for unfiltered engine oil pressure. Monitoring for restriction of the oil filters is disabled. The alarm output is activated. The code is logged. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Analog Sensor Signal Results:
MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM

SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for at least five seconds. The Integrated Temperature Sensing Module (ITSM) has sent ten consecutive messages to the ECM via the CAT Data Link. None of the messages have been received by the ECM.
OK STOP.
Note: This diagnostic code is logged by the ECM only. This code is not activated or logged by the ITSM. Although there is a failure to communicate with the ECM, the ITSM may still be able to communicate with the Caterpillar Electronic Technician (ET). System Response: The alarm output is activated. The code is logged. Note: If ET cannot communicate with the ITSM, the values for the ITSM Status Parameter will display Unavailable. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module Results:
Disconnected oxygen sensor Burned out heater for the oxygen sensor
Perform the following diagnostic procedure: Oxygen Sensor Signal Results:
OK STOP.
i01636406
MID 036 - CID 1086 - FMI 13 Oxygen Sensor Element calibration required
SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen sensor is out of tolerance.
OK STOP.
i01636401
System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until calibration of the oxygen sensor is successfully completed. The alarm output is activated. The code is logged.
MID 036 - CID 1086 - FMI 09 Oxygen Sensor Element not communicating on link
SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen buffer has been powered for at least 60 seconds. The duty cycle for the oxygen signal is between 10 and 20 percent. The following diagnostic code is NOT active: 1088 - 06 Oxygen Sensor Power Supply short to ground. System Response: Compensation for fuel quality is disabled. The diagnostic code remains active until the duty cycle of the oxygen sensor is greater than 20 percent for at least five seconds. The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance and emissions may be affected. Troubleshooting: A duty cycle of 10 to 20 percent is the default output when a load for the heater of the oxygen sensor is NOT detected by the oxygen buffer. In this case, check for one of the following conditions:
Possible Performance Effect: Engine performance and emissions may be affected. Troubleshooting: Calibrate the oxygen sensor. Perform the following diagnostic procedure: Oxygen Sensor - Calibrate Results:
OK STOP.
i01636414
System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until the following conditions occur:
MID 036 - CID 1087 - FMI 03 Oxygen Sensor Buffer Module short to +batt
SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen buffer has been powered for at least 60 seconds. The frequency (PWM) for the oxygen signal is below 375 Hz. The following diagnostic code is NOT active: 1088 - 06 Oxygen Sensor Power Supply open circuit. System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until the frequency for the oxygen signal is greater than 375 Hz for at least five seconds. The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance and emissions may be affected. Troubleshooting: Perform the following diagnostic procedure: Oxygen Sensor Signal Results:
The frequency for the oxygen signal is less than

625 Hz.
A duty cycle between 10 and 90 percent is

present for at least five seconds. The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance and emissions may be affected. Troubleshooting: Perform the following diagnostic procedure: Oxygen Sensor Signal Results:
OK STOP.
i01728689
MID 036 - CID 1088 - FMI 05 Oxygen Sensor Power Supply open circuit
SMCS Code: 1096-038 Conditions Which Generate This Code: Power to the oxygen buffer is OFF but the Electronic Control Module (ECM) receives a signal from the buffer. System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until a consistent oxygen signal is present for at least five seconds. The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance and emissions may be affected. Troubleshooting: Perform the following diagnostic procedure: Oxygen Sensor Buffer Supply
OK STOP.
i01636422
MID 036 - CID 1087 - FMI 08 Oxygen Sensor Buffer Module noisy signal
SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen buffer has been powered for at least 60 seconds. The frequency (PWM) for the oxygen signal is more than 625 Hz OR the duty cycle is not within the valid range of 10 to 90 percent. The following diagnostic code is NOT active: 1088 - 06 Oxygen Sensor Power Supply open circuit.
Results:
The signal driver inside the Electronic Control
OK STOP.
i01728696
Module (ECM) for the throttle solenoid is energized. However, the output current is below normal. This indicates an open circuit.
MID 036 - CID 1088 - FMI 06 Oxygen Sensor Power Supply short to ground
SMCS Code: 1096-038 Conditions Which Generate This Code: The supply voltage for the oxygen buffer is shorted to the Battery side. Note: This diagnostic condition can only be detected by the Electronic Control Module (ECM) when the signal driver for the oxygen buffer is ON. Terminal 13 of the J2/P2 connectors is the signal driver for the oxygen buffer. The signal driver is normally ON when the engine control switch is in the START position. System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until a consistent oxygen signal is present for at least five seconds. The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance and emissions may be affected. Troubleshooting: Perform the following diagnostic procedure: Oxygen Sensor Buffer Supply Results:
The J2 - 64 circuit is shorted to ground.

System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: If the engine is operating, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Throttle Actuator Solenoid Results:
OK STOP.
i01728715
MID 036 - CID 1440 - FMI 06 Throttle Actuator Driver short to ground
SMCS Code: 1901-038 Conditions Which Generate This Code: One of the following conditions will generate this code:
The signal driver inside the Electronic Control

Module (ECM) for the throttle solenoid is energized. The output current is above normal. This indicates a short circuit in the solenoid for the throttle actuator.
OK STOP.
i01728706
The J2 - 63 circuit is shorted to ground. The J2 - 63 circuit is shorted to the +Battery.

System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: If the engine is operating, the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Throttle Actuator Solenoid
MID 036 - CID 1440 - FMI 05 Throttle Actuator Driver open circuit
SMCS Code: 1901-038 Conditions Which Generate This Code: One of the following conditions will generate this code:
Results:
i01728733
OK STOP.
i01728721
MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module
SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for more than 5 seconds. Ten consecutive messages have been sent from the fuel metering valve to the ECM via the CAN Data Link. None of the messages have been received by the ECM. System Response: The Alarm Status is activated. The Status Parameter for Fuel Valve Position, Fuel Pressure (abs), Fuel Valve Differential Pressure, and Fuel Temperature are frozen on the Caterpillar Electronic Technician (ET). The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance is affected. Troubleshooting:
MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit
SMCS Code: 1901-038 Conditions Which Generate This Code: To generate this diagnostic code, all of the following conditions must occur:
The Electronic Control Module (ECM) has been

powered up for more than 5 seconds.
The battery voltage is greater than 20 VDC. The flow rate of the fuel is less than 481 Nm3/hr
(300 CFM).
The voltage of the signal is less than X for 5
seconds. The calculation for X is given in Table 13.
Table 13
X =
3.0 V
G 1.75 V 300 CFM
Perform the following diagnostic procedure: Fuel Metering Valve Results:
G is the flow of the fuel in CFM.
System Response: The Status Parameter for Fuel Valve Position will display 0 % on the Caterpillar Electronic Technician (ET). The alarm output is activated. The code is logged. Possible Performance Effect: Engine performance is affected. Troubleshooting: Perform the following diagnostic procedure: Fuel Metering Valve Results:
OK STOP.
i01728740
MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction

SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve sends a signal to the Electronic Control Module (ECM) via the CAN data link. The signal indicates that there is a problem with the fuel metering valve. System Response: The code is logged. The shutdown output is activated.
OK STOP.
Possible Performance Effect: The engine is shut down. Troubleshooting:
System Response: The code is logged. The shutdown output is activated. Possible Performance Effect:
Perform the following diagnostic procedure: Fuel Metering Valve Results:
The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Fuel Metering Valve
OK STOP.
i01619975
Results:
MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required
SMCS Code: 1901-038 Conditions Which Generate This Code: The Gas Fuel Properties have not been programmed for the fuel metering valve. System Response: The code is logged. The alarm output is activated. Possible Performance Effect: The fuel metering valve is shutdown. This prevents the engine from running. Troubleshooting: Perform the following diagnostic procedure: Fuel Metering Valve Results:
OK STOP.
i01741170
MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt
SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds. Neither of the following diagnostic codes are active:
System Response:
OK STOP.
i01728751
The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Detonation Sensors Results:
MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction
SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve sends a signal to the Electronic Control Module (ECM) via the CAN data link. The signal indicates that there is a problem with the fuel metering valves sensor module.
OK STOP.
i01741177
System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: Detonation Sensors Results:
MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground
SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:
OK STOP.
i01741184
i01741181
OK STOP.
OK STOP.
i01741187
OK STOP.
i01741202
i01741197
OK STOP.
OK STOP.
i01741203
OK STOP.
i01741208
i01741207
OK STOP.
OK STOP.
i01741209
OK STOP.
i01741213
i01741210
OK STOP.
OK STOP.
i01741219
OK STOP.
i01741227
i01741222
OK STOP.
OK STOP.
i01741260
i01741264
MID 036 - CID 1758 - FMI 03 Specific Humidity Sensor open/short to +batt
SMCS Code: 1901-038-NS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up; CTW1-Up Conditions Which Generate This Code: The duty cycle of the pressure sensor for the specific humidity of the inlet air is greater than the maximum limit. Additionally, neither of the following diagnostic codes are active:
MID 036 - CID 1758 - FMI 08 Specific Humidity Sensor signal abnormal
SMCS Code: 1901-038-NS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up; CTW1-Up Conditions Which Generate This Code: The duty cycle or the frequency of the signal from the pressure sensor for the specific humidity of the inlet air is out of range. Additionally, neither of the following diagnostic codes are active:
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not affected. Troubleshooting: The condition indicates a possible open circuit or a short circuit. Perform the following diagnostic procedure: PWM Sensor Results:
262-035 Volt DC Supply short to +batt 262-045 Volt DC Supply short to ground
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not affected. Troubleshooting: Perform the following diagnostic procedure: PWM Sensor Results:
OK STOP. OK STOP.
i01741313
i01754491
MID 036 - CID 1759 - FMI 03 Exhaust Back Pressure Sensor open/short to +batt
SMCS Code: 1061-038-PXS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up; CTW1-Up Conditions Which Generate This Code: The duty cycle of the pressure sensor for the atmospheric pressure is greater than the maximum limit. Additionally, neither of the following diagnostic codes are active:
MID 036 - CID 1759 - FMI 08 Exhaust Back Pressure Sensor signal abnormal
SMCS Code: 1061-038-PXS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up; CTW1-Up Conditions Which Generate This Code: The duty cycle or the frequency of the signal from the atmospheric pressure sensor is out of range. Additionally, neither of the following diagnostic codes are active:

System Response:

System Response: The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged. Possible Performance Effect: Possible Performance Effect: The engine performance is not affected. The engine performance is not affected. Troubleshooting: Troubleshooting: The condition indicates a possible open circuit or a short circuit. Perform the following diagnostic procedure: PWM Sensor Results: Perform the following diagnostic procedure: PWM Sensor Results:
OK STOP.
i01636449
OK STOP.
MID 111 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed
SMCS Code: 1901-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a problem within the EPROM circuit.
System Response: Monitoring of the exhaust temperature is lost. Also, protection against high exhaust temperatures is lost. The alarm output is activated. The code is logged. Troubleshooting: There is a problem with the ITSM. Replace the ITSM. Follow the instructions in Troubleshooting, Replacing the ITSM. Results:
i01728777
MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sens short to ground
SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger:
A short circuit to the Battery side A short circuit to the ground

i01728761
OK STOP.
System Response: Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Shorted to Ground for the port of the turbine. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt
SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger. System Response: Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the port of the turbine. This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728782
MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sens open circuit
SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the port of the turbine.
OK STOP.
Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
i01728791
MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sens short to ground
i01728785
OK STOP.
MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt

OK STOP.
i01728794
MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sens open circuit
SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger.
OK STOP.
System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the port of the turbine. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
i01728797
MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sens short to ground

System Response:
OK STOP.
i01728795
MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sens short to +batt
Monitoring of the temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Shorted to Ground for the port of the turbine. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728800
MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sens open circuit
SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the port of the turbine.
OK STOP.
Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
i01728806
MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sens short to ground
i01728804
OK STOP.
MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sens short to +batt

OK STOP.
i01728813
MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sens open circuit
SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger.
OK STOP.
System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Also, protection for the port is lost. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the port of the turbine. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
Results:
OK STOP.
i01728826
MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.
OK STOP.
i01728819

System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Shorted to ground for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting:
MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM)
Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728828
System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728835
i01728833
OK STOP.

System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine.
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) 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 Shorted to ground for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
Results:
OK STOP.
i01728852
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response:
OK STOP.
i01728837
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM)
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728912
i01728915

System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Shorted to ground for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728917
OK STOP.
The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728928
OK STOP.
i01728923

System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Shorted to ground for the cylinder.
OK STOP.
i01728934
A short circuit to the ground

SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect:
OK STOP.
i01728953
Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder.
OK STOP.
i01728940
A short circuit to the Battery side
i01728968
OK STOP.
i01728959
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01728976
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.
OK STOP.
OK STOP.
i01728999
OK STOP.
i01728993
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder.

System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Shorted to ground for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
i01729015
SMCS Code: 1919 Conditions Which Generate This Code:
OK STOP.
i01729006
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01729019
OK STOP.
OK STOP.
i01729257
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting:
OK STOP.
i01729025
Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM)
Results:
i01729264
OK STOP.
i01729262
MID 111 - CID 1539 - FMI 04 CYL #9 Exhaust Port Temp Sensor short to ground

OK STOP.
i01729267
OK STOP.
OK STOP.
i01729271
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response:
OK STOP.
i01729270
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.

i01729275
OK STOP.
i01729273
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.

OK STOP.
i01729277
OK STOP.
OK STOP.
i01729281
OK STOP.
i01729278
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder.

System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Shorted to ground for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.
i01729287
OK STOP.
i01729284
The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM) Results:
OK STOP.
i01729291
OK STOP.
OK STOP.
i01729297
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting:
OK STOP.
i01729294
Perform the following diagnostic procedure: Integrated Temperature Sensing Module (ITSM)
Results:
i01729306
OK STOP.
i01729303

OK STOP.
i01729307
OK STOP.
OK STOP.
i01729312
SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response:
OK STOP.
i01729310
Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The Status screen of the Caterpillar Electronic Technician (ET) displays Open/Shorted High for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected.

i01729316
OK STOP.
i01729314
The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.

OK STOP.
i01729319
OK STOP.
OK STOP.
Troubleshooting with an Event Code

i01729324
Event Codes
SMCS Code: 1901-038 Use this section for the troubleshooting of problems that have generated event codes but do not have active diagnostic codes. When the event code is generated, the event is active. Any generated code becomes logged in the permanent memory of the Electronic Control Module (ECM). Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high coolant temperature has been detected. Events do not indicate problems with the electronic system. Event codes also indicate the nature of the problem. The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. Event codes may be viewed on a personal computer that has the Cat ET software. Illustration 15 represents the operating range of an oil temperature sensor. The diagram is a reference. Do not use the diagram to troubleshoot the oil temperature sensor.
Illustration 15 Typical operating range of an oil temperature sensor
g00791619
(1) In these areas, the output voltage of the sensor is too high or too low. The output is outside of the normal range. The electronic problem will generate a diagnostic code. (2) In this area, the oil temperature above 102 C (216 F) is higher than normal. The output voltage of the sensor will generate an event code for a warning, a derating, or a shutdown for high oil temperature. The sensor does not have an electronic problem. (3) This area represents the normal operating temperature for the engine oil. The normal output voltage of the sensor is between 0.2 and 4.1 volts.
The following format is used for event codes:
EXXX (X) Description of the code

The E means that the code is an event code. The XXX represents a numeric identifier for the event code. The fourth (X) represents a numeric identifier for the severity of the code. This is followed by a description of the code. See the following example:
E004 (3) Engine Overspeed Shutdown

The numbers that indicate the severity of the event code are defined below: Warning (1) This condition represents a serious problem with engine operation. However, this condition does not require a deration or a shutdown. Derate (2) For this condition, the engine power is reduced in order to help prevent possible engine damage. Shutdown (3) For this condition, the engine is shut down in order to help prevent possible engine damage.
These responses to certain events may be programmed into the ECM. If the responses are programmed, Cat ET can display the event. If the responses are not programmed, the display will not appear. However, the occurrence of any event will cause the event code to be logged in the ECM. Note: Do not confuse event codes with diagnostic codes. For information on diagnostic codes, see Troubleshooting, Troubleshooting with a Diagnostic Code. Perform the following tasks before you troubleshoot the event code:
Be sure to check the connectors. This is specially true for problems that are intermittent. See Troubleshooting, Inspecting Electrical Connectors. Narrow the probable cause. Consider the operator information, the conditions of operation, and the history of the engine.
Operator Information
Obtain the following information from the operator:
The occurrence and the time of the occurrence Determine the conditions for the occurrence. The
conditions will include the engine rpm and the load.
Gather enough information about the complaint in

order to describe the symptom(s) adequately. engine operation.
Verify that the complaint is not due to normal Repair all active diagnostic codes. See
Determine if there are any systems that were

installed by the dealer or the customer that could cause the symptom.
Troubleshooting, Troubleshooting With A Diagnostic Code.
Determine whether any other occurrences

happened in addition to the symptom.
Troubleshooting
For basic troubleshooting of the engine, perform the following steps first in order to diagnose a malfunction. 1. Gather information about the complaint from the operator. 2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to error of the operator. 3. Perform a visual inspection. Inspect the following items:
Diagnostic Codes and Event Codes

Examine the following information regarding any codes:
The probable cause of the symptom is correlated

to the code.
The code was generated when the symptom

occurred.
Codes that are repeatedly logged The complaint is not due to normal engine
operation.
Fuel supply Oil level Oil supply Wiring Connectors

4. Check the diagnostic codes and event codes. Repair any active codes. If these inspections do not reveal any problems, identify the probable causes with the procedures in this manual that best describe the symptoms. Check each probable cause according to the tests that are recommended.
Other Symptoms
If other occurrences happened in addition to the symptom, investigate the following conditions:
The other occurrences are related to the

symptom.
The symptoms have a probable cause that is

common.
Active Event Codes

An active event code represents a problem with engine operation. Correct the problem as soon as possible.
When an event code is active, the Active Alarm indicator (Engine Control Alarm Status on Cat ET) is activated in order to alert the operator. If the condition that generated the code is momentary, the message disappears. The event code will be logged in the ECM memory. Active event codes are listed in ascending numerical order. The code with the lowest number is listed first.
Troubleshooting: Refer to Troubleshooting, Engine Overspeed. Results:
OK STOP.
i01637572
Logged Event Codes

When the ECM generates an event code the ECM logs the code in permanent memory. The ECM has an internal diagnostic clock. The ECM will record the following information when a code is generated:
E015 High Engine Coolant Temperature Derate

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine coolant temperature has exceeded the trip point and the delay time has expired. No other codes for the engine coolant are active. System Response: The alarm output is activated. The event is logged. Possible Performance Effect: The engine power is reduced. Troubleshooting: Refer to Troubleshooting, Engine Coolant Temperature (High). Results:
The hour of the first occurrence of the code The hour of the last occurrence of the code The number of occurrences of the code
This information can be helpful for troubleshooting intermittent problems. Logged codes can also be used to review the performance of the engine. Any logged event codes will automatically be deleted if no additional occurrences are recorded in 100 hours. Logged events are listed in chronological order. The most recent event code is listed first. Note: Always clear logged event codes after investigating and correcting the problem which generated the code.
i01729333
OK STOP.
i01633543
E004 Engine Overspeed Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The engine rpm has exceeded the trip point that is programmed into the Electronic Control Module (ECM) and the delay time has expired. The ECM has determined that the detected speed is accurate. System Response: The gas shutoff valve and the ignition are shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
E016 High Engine Coolant Temperature Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine coolant temperature has exceeded the trip point and the delay time has expired. No other codes for the engine coolant are active. System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Engine Coolant Temperature (High). Results:
i01633603
E019 High Engine Oil Temperature Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil temperature has exceeded the trip point and the delay time has expired. No other codes for the engine oil temperature are active. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut off. Troubleshooting: Refer to Troubleshooting, Engine Oil Temperature (High). Results:
OK STOP.
i01633545
E017 High Engine Coolant Temperature Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine coolant temperature has exceeded the trip point and the delay time has expired. No other codes for the engine coolant are active. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
OK STOP.
i01633605
The engine operation is not immediately affected. However, if the coolant temperature continues to rise, the engine will be shut down. Troubleshooting: Refer to Troubleshooting, Engine Coolant Temperature (High). Results:
E020 High Engine Oil Temperature Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil temperature has exceeded the trip point and the delay time has expired. No other codes for the engine oil temperature are active. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the engine oil temperature continues to rise, the engine can be shut down.
OK STOP.
Troubleshooting: Refer to Troubleshooting, Engine Oil Temperature (High). Results:
Possible Performance Effect: The engine is shut down. Troubleshooting:
OK STOP.
i01637574
Refer to Troubleshooting, Inlet Air Temperature (High). Results:
E025 High Inlet Air Temperature Derate

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The inlet air temperature has exceeded the setpoint and the delay time has expired. No other codes for the inlet air temperature are active. System Response: The alarm output is activated. The event is logged. Possible Performance Effect: The engine power is reduced. Troubleshooting: Refer to Troubleshooting, Inlet Air Temperature (High). Results:
OK STOP.
i01633756
E027 High Inlet Air Temperature Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The inlet air temperature has exceeded the trip point and the delay time has expired. No other codes for the inlet air temperature are active. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the inlet air temperature continues to rise, the engine may be shut down. Troubleshooting:
OK STOP.
Refer to Troubleshooting, Inlet Air Temperature (High).
i01633755
E026 High Inlet Air Temperature Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The inlet air temperature has exceeded the trip point and the delay time has expired. No other codes for the inlet air temperature are active. System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
Results:
OK STOP.
i01633757
E038 Low Engine Coolant Temperature Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The temperature of the engine coolant is less than the trip point and the delay time has expired. No other codes for the coolant temperature are active.
System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. Troubleshooting: Refer to Troubleshooting, Engine Coolant Temperature (Low). Results:
i01633763
E042 Low System Voltage Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage is less than the trip point and the delay time has expired. No other codes for the system voltage are present. System Response: The shutdown output is activated. The code is logged.
OK STOP.
i01633762
E040 Low Engine Oil Pressure Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 10 seconds. The engine oil pressure is less than the trip point and the delay time has expired. No codes for the engine oil pressure sensor are active. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Engine Oil Pressure (Low). Results:
Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, System Voltage. Results:
OK STOP.
i01633765
E043 Low System Voltage Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage is less than the trip point and the delay time has expired. No other codes for the system voltage are present. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the system voltage continues to be reduced, the engine will be shut down. Troubleshooting: Refer to Troubleshooting, System Voltage. Results:
OK STOP.
OK STOP.
i01633766
i01637590
E050 High System Voltage Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage is greater than the trip point and the delay time has expired. No other codes for the system voltage are present. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the system voltage continues to increase the circuit breaker will switch OFF and the engine will be shut down. Troubleshooting: Refer to Troubleshooting, System Voltage. Results:
E096 High Fuel Pressure

SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel pressure is higher than the trip point and the delay time has expired. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the fuel pressure continues to increase, the supply may exceed the maximum limit for the fuel metering valve. Troubleshooting: Refer to Troubleshooting, Fuel Pressure. Results:
OK STOP.
i01633787
OK STOP.
i01637578
E053 Low Fuel Pressure Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel pressure is less than the trip point and the delay time has expired. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the fuel pressure continues to be reduced, the supply may become inadequate for the fuel metering valve. Troubleshooting: Refer to Troubleshooting, Fuel Pressure. Results:
E100 Low Engine Oil Pressure Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least ten seconds. The engine oil pressure is less than the trip point and the delay time has expired. There are no active codes for the engine oil pressure sensor. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the oil pressure continues to be reduced, the engine may be shut down. Troubleshooting: Refer to Troubleshooting, Engine Oil Pressure (Low).
OK STOP.
Results:
Possible Performance Effect: The engine is shut down.

i01633790
OK STOP.
Troubleshooting: Refer to Troubleshooting, Engine Oil Filter Differential Pressure. Results:
E127 Engine Oil Filter Diff Pressure Low Warning

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil filter differential pressure is less than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors. System Response:
OK STOP.
i01633828
E129 Engine Oil Filter Diff Pressure High Warning

The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the engine oil filter differential pressure continues to be reduced, the engine may be shut down. Troubleshooting: Refer to Troubleshooting, Engine Oil Filter Differential Pressure. Results: The crank terminate relay is set and the engine has been running for at least 30 seconds. The oil filter differential pressure is greater than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the oil filter differential pressure continues to increase, the engine may be shut down.
i01633814
OK STOP.
Troubleshooting: Refer to Troubleshooting, Engine Oil Filter Differential Pressure. Results:
E128 Engine Oil Filter Diff Pressure Low Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The oil filter differential pressure is less than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors. System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
OK STOP.
i01633832
Results:
E130 Engine Oil Filter Diff Pressure High Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil filter differential pressure is greater than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Engine Oil Filter Differential Pressure. Results:
OK STOP.
i01633954
E223 High Gas Temperature

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The temperature of the gas has exceeded the trip point and the delay timer has expired. There are no active codes for the fuel temperature sensor. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. However, if the fuel temperature continues to increase, the air/fuel ratio and the inlet manifold air temperature can be affected. Troubleshooting: Refer to Troubleshooting, Gas Temperature (High).
i01633833
OK STOP.
Results:
E135 Low Jacket Water Pressure Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least ten seconds. The pressure of the jacket water is less than the trip point and the delay time has expired. There are no active codes for the pressure sensor at the outlet for the jacket water. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut off. Troubleshooting: Refer to Troubleshooting, Jacket Water Pressure (Low).
OK STOP.
i01633956
E224 High Jacket Water Inlet Pressure

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 10 seconds. The trip point for high pressure at the inlet for the jacket water has been exceeded and the delay time has expired. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
Troubleshooting: Refer to Troubleshooting, Jacket Water Inlet Pressure (High). Results:
Troubleshooting: Refer to Troubleshooting, Driven Equipment. Results:
OK STOP.
i01633959
OK STOP.
i01633972
E225 Engine Overcrank

SMCS Code: 1901-038 Conditions Which Generate This Code: The engine did not start within the programmed parameters for starting. System Response: The fuel is shut off. Engine cranking is prevented. The code is logged. Possible Performance Effect: The engine will not start. Troubleshooting: Refer to Troubleshooting, Engine Overcrank. Results:
E229 Fuel Energy Content Setting Low

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The fuel correction factor is less than the trip point for 20 seconds. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance may be erratic. Troubleshooting: Refer to Troubleshooting, Fuel Energy Content. Results:
OK STOP.
i01729345
OK STOP.
E226 Driven Equipment Not Ready

SMCS Code: 1901-038 Conditions Which Generate This Code: The engine is ready to start. However, the Electronic Control Module (ECM) has received a signal which indicates that the driven equipment is not ready for the engine to start. System Response: The shutdown output is activated. Engine cranking is prevented. The code is logged. Possible Performance Effect: The engine will not start.
i01633976
E230 Fuel Energy Content Setting High

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The fuel correction factor is greater than the trip point for 20 seconds. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance may be erratic.
Troubleshooting: Refer to Troubleshooting, Fuel Energy Content. Results:
Troubleshooting: Refer to Troubleshooting, Engine Pre-Lube Pressure (Low). Results:
OK STOP.
i01746483
OK STOP.
i01729352
E231 Fuel Quality Out of Range

E242 Engine Overload

The crank terminate relay is set and the engine has been running for at least 30 seconds. The Low Heat Value (LHV) of the fuel is less than the trip point OR the LHV of the fuel is greater than the trip point for 20 seconds. System Response:
The calculation by the Electronic Control Module (ECM) for the engine load is greater than 110 percent of the rated load. System Response: The alarm output is activated. The code is logged.
The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut off. Troubleshooting: Refer to Troubleshooting, Fuel Energy Content. Results:
Possible Performance Effect: The engine power is reduced. Troubleshooting: Refer to Troubleshooting, Engine Overload. Results:
OK STOP.
i01634015 i01634004
OK STOP.
E233 Low Engine Pre-Lube Pressure

SMCS Code: 1901-038 Conditions Which Generate This Code: The prelube oil pressure is less than the trip point and the delay time has expired. System Response: The shutdown output is activated. Starting of the engine is prevented. The signal driver for the prelube pump remains activated. The code is logged. Possible Performance Effect: The engine will not start.
E243 High Left Turbo Turbine Outlet Temperature

SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the left turbocharger turbine has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
E243 (1) High Left Turbo Turbine Outlet

Temperature (warning)
E243 (3) High Left Turbo Turbine Outlet

Temperature (shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect:
Troubleshooting: Refer to Troubleshooting, Turbocharger Turbine Temperature (High). Results:
OK STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: SMCS Code: 1052-038 Refer to Troubleshooting, Turbocharger Turbine Temperature (High). Results: Conditions Which Generate This Code: The temperature at the inlet for the right turbocharger turbine has exceeded the trip point and the delay time has expired. System Response:
i01634039 i01634041
E245 High Right Turbo Turbine Inlet Temperature
OK STOP.
E244 High Right Turbo Turbine Outlet Temperature

SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the right turbocharger turbine has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
The following event codes are logged according to the trip points for the temperature:
E245 (1) High Right Turbo Turbine Inlet

E245 (3) High Right Turbo Turbine Inlet

Temperature (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Turbocharger Turbine Temperature (High). Results:
E244 (1) High Right Turbo Turbine Outlet

E244 (3) High Right Turbo Turbine Outlet

Temperature (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect:
OK STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
i01634043
System Response: The following event codes are logged according to the trip points for the temperature:
E246 High Left Turbo Turbine Inlet Temperature

SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the inlet for the left turbocharger turbine has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
E247 (1) Low Left Turbo Turbine Outlet

E247 (3) Low Left Turbo Turbine Outlet

Temperature (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Turbocharger Turbine Temperature (Low). Results:
E246 (1) High Left Turbo Turbine Inlet Temperature

(warning)
E246 (3) High Left Turbo Turbine Inlet Temperature

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Turbocharger Turbine Temperature (High). Results:
OK STOP.
i01634050
E248 Low Right Turbo Turbine Outlet Temperature

SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the right turbocharger turbine is less than the trip point and the delay time has expired.
OK STOP.
i01634046
E247 Low Left Turbo Turbine Outlet Temperature

SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the left turbocharger turbine is less than the trip point and the delay time has expired.
E248 (1) Low Right Turbo Turbine Outlet

E248 (3) Low Right Turbo Turbine Outlet

Temperature (shutdown) If a warning is generated, the alarm output is activated.
If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Turbocharger Turbine Temperature (Low). Results:
Troubleshooting: Refer to Troubleshooting, Turbocharger Turbine Temperature (Low). Results:
OK STOP.
i01634056
E250 Low Left Turbo Turbine Inlet Temperature

OK STOP.
i01634054
The temperature at the inlet for the left turbocharger turbine is less than the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
E249 Low Right Turbo Turbine Inlet Temperature

SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the inlet for the right turbocharger turbine is less than the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
E250 (1) Low Left Turbo Turbine Inlet Temperature

(warning)
E250 (3) Low Left Turbo Turbine Inlet Temperature

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Turbocharger Turbine Temperature (Low). Results:
E249 (1) Low Right Turbo Turbine Inlet

E249 (3) Low Right Turbo Turbine Inlet

Temperature (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
OK STOP.
i01637596
System Response: The gas shutoff valve (GSOV) and the ignition are shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut off. Troubleshooting: Refer to Troubleshooting, Engine Shutdown. Results:
E253 Detonation Derate Requested

SMCS Code: 1550 Conditions Which Generate This Code: A derating is requested for detonation. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine power is reduced. Troubleshooting: Refer to Troubleshooting, Detonation. Results:
OK STOP.
i01634061
E266 Low Hydrax Oil Pressure

OK STOP.
i01637600
E254 No Detonation Derate Action Taken

SMCS Code: 1550 Conditions Which Generate This Code: A derating was requested for detonation but the derating did not occur. System Response: The alarm output is activated. The code is logged. Troubleshooting: Refer to Troubleshooting, Detonation. Results:
The crank terminate relay has been energized for at least 30 seconds. The pressure switch for the electrohydraulic actuator system opens for more than one second. This indicates no oil pressure to the system. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Electrohydraulic System Oil Pressure (Low). Results:
OK STOP.
OK STOP.
i01634059
E264 Emergency Stop Activated

SMCS Code: 1901-038 Conditions Which Generate This Code: The input for the emergency stop is activated.
i01634063
i01634097
E268 Unexpected Engine Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine is running. The engine rpm is less than the programmed speed of the postlube cycle for 200 ms. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Engine Shutdown (Unexpected). Results:
E270 Driven Equipment Shutdown Requested

SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine is running. The input requests a shutdown for 200 ms. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Driven Equipment. Results:
OK STOP. OK STOP.
i01634093 i01619830
E337 High Engine Oil to Engine Coolant Diff Temp

E269 Customer Shutdown Requested

SMCS Code: 1901-038 Conditions Which Generate This Code: The engine is either cranking or running. The input for the stop is set for 200 ms. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut off. Troubleshooting:
The crank terminate relay is set and the engine has been running for at least 30 seconds. The differential between the temperature of the engine oil and the temperature of the engine coolant has exceeded the trip point. Also, the delay time has expired. There are no active codes for the sensors for the engine oil temperature and the engine coolant. System Response: The following event codes are logged according to the trip points for the temperature differential:
E337 (1) High Engine Oil to Engine Coolant Diff

Temp (warning)
E337 (3) High Engine Oil to Engine Coolant Diff

Refer to Troubleshooting, Engine Shutdown. Results: Temp (shutdown) If a warning is activated, the alarm output is activated.
OK STOP.
If a shutdown is activated, the shutdown output is activated. Possible Performance Effect:
System Response: The alarm output is activated. The code is logged. Possible Performance Effect:
If a warning is generated, the engine operation is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Troubleshooting: Refer to Troubleshooting, Detonation.
Refer to Troubleshooting, Jacket Water to Engine Oil Temperature (Low). Results:
Results:
OK STOP.
i01637627 i01637607
OK STOP.
E403 Cylinder #3 Detonation

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinders detonation sensor. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Troubleshooting: Refer to Troubleshooting, Detonation. Results:

OK STOP.
i01637634 i01637623
OK STOP.

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinders detonation sensor.

System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Troubleshooting: Refer to Troubleshooting, Detonation. Results:
OK STOP.
i01637642
OK STOP.
i01637648


OK STOP.
i01637646
OK STOP.
i01637651


OK STOP.
i01637653
OK STOP.
i01637663


OK STOP.
i01637657
OK STOP.
i01637665


OK STOP.
i01637696
OK STOP.
i01637702


OK STOP.
i01637699
OK STOP.
i01637706


i01634746
E422 Cylinder #2 Detonation Shutdown

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response:
OK STOP.
i01634664

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Detonation. Results:
The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Detonation. Results:
OK STOP.
i01634838

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting, Detonation.
OK STOP.
Results:
Possible Performance Effect: The engine is shut down.

i01635415
OK STOP.
Troubleshooting: Refer to Troubleshooting, Detonation. Results:

OK STOP.
i01635417
The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response:
Troubleshooting: Refer to Troubleshooting, Detonation. Results: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
i01635416
OK STOP.

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged.
OK STOP.
i01635420
Results:

OK STOP.
i01635423

i01635421
OK STOP.
Results:

OK STOP.
i01635424

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down.
System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect:
OK STOP.
i01635428
The engine is shut down. Troubleshooting: Refer to Troubleshooting, Detonation. Results:

OK STOP.
i01635431

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor. System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect:
OK STOP.
The engine is shut down.
i01635429

SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinders detonation sensor.
OK STOP.
i01635433
Results:

OK STOP.
i01635436

i01635435
OK STOP.
Results:

OK STOP.
i01635494
E801 Cylinder #1 High Exhaust Port Temp

SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
E801 (1) Cylinder #1 High Exhaust Port Temp

(warning)

(shutdown)
If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect:
Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:
OK STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: SMCS Code: 1901-038 Refer to Troubleshooting, Exhaust Port Temperature (High). Results: Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response:
i01635500 i01635503
OK STOP.


(warning)

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results: Possible Performance Effect:

(warning)

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
OK STOP.
If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
i01635505

(warning)


(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:

(warning)

OK STOP.
i01635511

OK STOP.
i01635508

(warning)


(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected.
The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:
i01635513

SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.
OK STOP.
i01635512


(warning)


(warning)

OK STOP.
i01635546

OK STOP.
Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:

(warning)

OK STOP.
i01635556

OK STOP.
i01635549

(warning)



(warning)

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off.
OK STOP.
i01635568


(warning)


(warning)
E812 (3) Cylinder #12 High Exhaust Port Temp (shutdown)

If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:
OK STOP.
i01635577

OK STOP.
i01635570


(warning)

(shutdown) If a warning is generated, the alarm output is activated.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting:
Results:
OK STOP.
i01635584

Refer to Troubleshooting, Exhaust Port Temperature (High). Results:
The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response:
OK STOP.
i01635578

SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response:

(warning)

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. 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. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:

(warning)

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High).
OK STOP.
i01635587
i01635593
E821 Cyl #1 Exhaust Port Temp Deviating High

SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

E821 (1) Cyl #1 Exhaust Port Temp Deviating

High (warning)

High (warning)

High (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:

OK STOP.
OK STOP.
i01635600


High (warning)


High (warning)

OK STOP.
i01635605

SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
OK STOP.
i01635604


High (warning)

High (shutdown) If a warning is generated, the alarm output is activated.
If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (High). Results:
OK STOP.
i01635614

OK STOP.
i01635612

The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

High (warning)


High (warning)

High (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
OK STOP.
i01635616


High (warning)


High (warning)

OK STOP.
i01635634

OK STOP.
i01635618


High (warning)

OK STOP.
i01635645

OK STOP.
i01635641

The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

High (warning)


High (warning)

OK STOP.
i01635653


High (warning)


High (warning)

OK STOP.
i01635658

OK STOP.
i01635656


High (warning)

OK STOP.
i01635664
E841 Cyl #1 Exhaust Port Temp Deviating Low

OK STOP.
i01635661

The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:
E841 (1) Cyl #1 Exhaust Port Temp Deviating Low

(warning)

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (Low). Results:

High (warning)

OK STOP.
i01635667

SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

(warning)


(warning)

OK STOP.
i01635670

SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.
OK STOP.
i01635668


(warning)

If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (Low). Results:
Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (Low). Results:
OK STOP.
i01635673

OK STOP.
i01635672


(warning)


(warning)

(shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
OK STOP.
i01635677


(warning)


(warning)

OK STOP.
i01635683

OK STOP.
i01635680


(warning)

OK STOP.
i01635685

OK STOP.
i01635684


Low (warning)

Low (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting, Exhaust Port Temperature (Low). Results:

Low (warning)

Low (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
OK STOP.
i01635688


Low (warning)


Low (warning)

OK STOP.
i01635692

OK STOP.
i01635691


Low (warning)

Low (shutdown) If a warning is generated, the alarm output is activated.
OK STOP.
i01635695

OK STOP.
i01635694


Low (warning)


Low (warning)

Low (shutdown) If a warning is generated, the alarm output is activated. If a shutdown is generated, the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated, the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.
OK STOP.
i01637712
Results:
E864 Low Gas Fuel Differential Pressure

SMCS Code: 1901-038 Conditions Which Generate This Code: The gas shutoff valve (GSOV) is energized. The difference in fuel pressure between the outlet and the inlet of the fuel metering valve is less than the trip point. The delay time has expired. System Response: The alarm output is activated. The code is logged.
OK STOP.
i01637720
E866 Low Gas Fuel Flow Rate

SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve is fully open. However, the flow rate that is computed by the valve does not match the fuel demand for a delay time of 5 seconds. System Response:
Possible Performance Effect: The alarm output is activated. The code is logged. The engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting, Gas Fuel Differential Pressure (Low). Results: Possible Performance Effect: The engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting, Gas Fuel Flow Rate (Low). Results:
i01637716
OK STOP. OK STOP.
i01637722
E865 High Gas Fuel Differential Pressure

SMCS Code: 1901-038 Conditions Which Generate This Code: The Gas Shutoff Valve (GSOV) is energized. The difference in fuel pressure between the inlet and the outlet of the fuel metering valve is greater than the trip point. The delay time has expired. System Response:
E867 Improper Gas Flow Control Valve Response

SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve is not responding correctly to the ECM and the delay time has expired. System Response:
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged. Possible Performance Effect: Possible Performance Effect: The engine performance is not immediately affected. Troubleshooting: Troubleshooting: Refer to Troubleshooting, Gas Fuel Differential Pressure (High). Refer to Troubleshooting, Fuel Metering Valve. The engine performance is not immediately affected.
Results:
OK STOP.
i01637725
E868 Gas Flow Control Valve Malfunction

SMCS Code: 1901-038 Conditions Which Generate This Code: The ECM has detected a malfunction for the fuel metering valve and the delay time has expired. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting, Fuel Metering Valve. Results:
OK STOP.
Diagnostic Functional Tests

i01726283
+5V Sensor Voltage Supply

SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) supplies 5.0 0.5 VDC to the sensors for these parameters:
Inlet air temperature Engine oil temperature Unfiltered engine oil pressure Filtered engine oil pressure Humidity (if equipped)
The ECM also provides 5 VDC to the DESIRED SPEED potentiometer (if equipped). A +5 Volt Sensor DC Power Supply short to ground diagnostic code will be activated if both of these conditions occur:
The desired speed signal wire is shorted to

ground.
The DESIRED SPEED potentiometer is near

the maximum desired speed or at the maximum desired speed. A +5 V sensor supply diagnostic code is probably caused by a short circuit or an open circuit in a harness. The next likely cause is a sensor problem. The least likely cause is a problem with the ECM. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved. The 5 V diagnostic code is probably caused by a short circuit or an open circuit in a harness. The next likely cause is a sensor problem. The least likely cause is a problem with the ECM.
Illustration 16 Schematic for the analog sensors
g00888350
Test Step 1. Inspect the Electrical Connectors and Wiring

A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Note: For the following steps, refer to Troubleshooting, Inspecting Electrical Connectors.
Illustration 18 Harness side of the ECM P1 connector (2) +5 volt supply (3) Return (11) Signal for the humidity (14) Signal for the inlet manifold air temperature (16) Signal for the desired speed (17) Signal for the engine oil temperature (18) +5 volt supply (24) Signal for the filtered engine oil pressure (26) Signal for the unfiltered engine oil pressure (35) Return
g00888440
Illustration 17
g00888377
(1) ECM connectors J1/P1 (2) J12/P12 connectors for the 5 V sensors (3) J19/P19 connectors for the harness from the control panel (if equipped) (4) 16 amp circuit breaker (5) J9/P9 connectors for the customer (if equipped)
B. Thoroughly inspect each of the following connectors:
ECM J1/P1 connectors J12/P12, J19/P19, and J9/P9 connectors on

the terminal box a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 1 Nm (55 9 lb in).
Illustration 19 Harness side of the P12 connector (A) +5 volt supply (C) Return (E) Signal for the unfiltered engine oil pressure (F) Signal for the filtered engine oil pressure (G) Signal for the humidity (H) Signal for the engine oil temperature (K) Signal for the inlet air temperature
g00888444
Illustration 20 Harness side of the P19 connector (if equipped) (S) +5 volt supply (T) Signal for desired speed (U) Return
g00888526
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 5 V sensors.
Illustration 22 (7) Filtered oil pressure sensor (8) Unfiltered oil pressure sensor (9) Oil temperature sensor
g00888432
Illustration 21 (5) Inlet air temperature sensor (6) Engine coolant temperature sensor
g00888384
Illustration 23 (10) Humidity sensor (if equipped)
g00888429
c. Check the harness and wiring for abrasion and pinch points from the 5 V sensors to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Observe the Active Diagnostic screen on Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for these codes:
262-03 5 Volt Sensor DC Power Supply short

to +batt
OK All of the connectors, pins, and sockets

to ground E. Observe the Logged Diagnostic screen on Cat ET. Look for the same codes. Expected Result:
are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK At least one of the connectors, pins, or sockets are not connected properly. At least one of the connectors and the wiring has corrosion, abrasion, and/or pinch points.
Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
The 262-03 code or the 262-04 code is not active or logged. Results:
No codes There are no active codes or logged

codes. Proceed to Test Step 3.
Test Step 2. Check for Diagnostic Codes

A. Connect Cat ET to the service tool connector on the terminal box. B. Rotate the DESIRED SPEED potentiometer (if equipped) counterclockwise to the minimum speed position.
Active code The 262-03 code or the 262-04

code is active. Proceed to Test Step 6.
Logged code The 262-03 code or the 262-04

code is not active. However, there is at least one logged code for the +5 volt sensor supply.
Repair: There may be a problem with the wiring and/or a connector. Refer to Troubleshooting, Inspecting Electrical Connectors. Verify that the wiring and/or connectors are OK. Check for diagnostic codes again. Proceed to Test Step 3, if necessary.
Test Step 3. Check the Analog Speed Circuit

Note: If the engine is not equipped with a DESIRED SPEED potentiometer, proceed to Test Step 8. A. Rotate the DESIRED SPEED potentiometer (if equipped) clockwise to the maximum speed position. Expected Result: The 262-03 code or the 262-04 code is not active.
Illustration 24
g00888515
Results:
P19 connector on the terminal box
No codes Rotating the DESIRED SPEED

potentiometer clockwise to the maximum speed position did not cause an active code. The +5 V sensor voltage supply is operating correctly at this time. Resume normal operation. STOP.
B. Disconnect the P19 connector from the terminal box.
Active code Rotating the DESIRED SPEED

potentiometer clockwise to the maximum speed position caused an active code. There is a problem with the analog speed circuit. Proceed to Test Step 4.
Test Step 4. Disconnect the P19 Connector and Check the Wiring for the Potentiometer
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
Illustration 25 Harness connector P19 (P19-B) -BATT (P19-T) Signal wire for the DESIRED SPEED potentiometer
g00888532
C. Measure the resistance from terminal B to T on harness connector P19. Expected Result: The resistance is greater than 20,000 ohms. Results:
OK The resistance is greater than 20,000 ohms.

The wiring on the outside of the terminal box for the DESIRED SPEED potentiometer appears to be OK. Proceed to Test Step 5.
Not OK The resistance is less than 20,000
Results:
ohms. There is a problem with the wiring on the outside of the terminal box for the DESIRED SPEED potentiometer.
OK The resistance is greater than 20,000 ohms.

The wiring inside the terminal box appears to be OK. The problem appears to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Reconnect all of the connectors. Resume normal operation. STOP.
Repair: Perform the following procedure: 1. Carefully inspect the following items:
Connector P19 The harness from the P19 connector to the

DESIRED SPEED potentiometer 2. Verify that all connections are in good condition and free of moisture. Verify that the harness from the P19 connector to the DESIRED SPEED potentiometer is in good condition. 3. Perform any necessary repairs or replace parts, if necessary. 4. Reconnect all of the connectors and perform this procedure again. Verify that the original problem is resolved. STOP.

ohms. There is a problem with a connector and/or the wiring inside the terminal box. Repair: Repair the connector and/or wiring, when possible. Replace the wiring, if necessary. STOP.
Test Step 6. Isolate the Wiring Harnesses from the ECM

A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Reconnect the P1 connector to the ECM.
Test Step 5. Check the Wiring Inside the Terminal Box

A. Disconnect the P1 connector from the ECM.
Illustration 26 ECM side of the P1 connector
g00862380
(P1-16) Signal wire for the DESIRED SPEED potentiometer (P1-69) Ground
B. Measure the resistance between terminals 16 and 69 of connector P1. Expected Result: The resistance is greater than 20,000 ohms.
Illustration 27 ECM connector P1 (P1-2) + 5 volt supply for the analog sensors (P1-18) +5 volt supply for the DESIRED SPEED potentiometer
g00888555
C. Use a 151-6320 Wire Removal Tool to remove terminal 2 and terminal 18 from the P1 connector. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. E. Use Cat ET to look for diagnostic codes. Expected Result: No active codes Results:
No codes The 262-03 code or the 262-04 code
Illustration 28 ECM connector P1 (P1-18) +5 V supply
g00862455
is not active. Disconnecting all of the +5 V wiring from the ECM eliminated the active 5 Volt Sensor Supply diagnostic code. There is a problem with a connector and/or the wiring in a harness. Proceed to Test Step 7. code is active. Disconnecting all of the +5 V wiring from the ECM did not eliminate the +5 V diagnostic code. 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 the problem is not resolved, perform the following steps: 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP.
B. Insert terminal 18 into the P1 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector. C. Rotate the DESIRED SPEED potentiometer clockwise to the maximum speed position. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. E. Use Cat ET to look for diagnostic codes. Expected Result: No active codes Results:
Active code The 262-03 code or the 262-04
No codes The 262-03 code or the 262-04

code is not active. Connecting the wiring for the analog speed circuit to the ECM did not cause a diagnostic code. The wiring for the analog speed circuit appears to be OK. Proceed to Test Step 8.
Test Step 7. Connect the +5 V Wiring for the Analog Speed Circuit to the ECM
Active codes The 262-03 code or the 262-04

code is active. Connecting the wiring for the analog speed circuit to the ECM caused a diagnostic code. Proceed to Test Step 4.
Test Step 8. Connect the +5 V Wiring for the Sensors to the ECM
Engine oil temperature Unfiltered engine oil pressure Filtered engine oil pressure Humidity (if equipped)
C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: An Open Circuit code will be generated for each sensor that is disconnected. This is normal. Clear the codes after you complete this procedure. D. Observe the Active Diagnostic screen on Cat ET. Verify that the 262-03 code or the 262-04 code is not active. E. Reconnect the sensors for the following parameters one at a time. After you reconnect each sensor, wait for at least 30 seconds and then observe the Active Diagnostic screen on Cat ET.
Illustration 29 ECM connector P1 (P1-2) +5 V supply
g00862457
B. Insert terminal 2 into the P1 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Use Cat ET to look for diagnostic codes.
Inlet air temperature Engine oil temperature

Expected Result:
Unfiltered engine oil pressure

No active codes
Filtered engine oil pressure

Results:
Humidity No codes The 262-03 code or the 262-04

code is not active. Connecting the 5 VDC for the sensors did not cause a diagnostic code. The problem appears to be resolved. Repair: The initial diagnostic code was probably caused by a poor electrical connection. Resume normal operation. STOP. Expected Result: The original 5 Volt Sensor diagnostic code is activated when a particular sensor is disconnected. Results:
Yes The original 5 Volt Sensor diagnostic Active code The 262-03 code or the 262-04
code is active. Connecting the 5 VDC for the sensors caused a diagnostic code. Proceed to Test Step 9. code is activated when a particular sensor is reconnected. The sensor and/or the wiring for the sensor has a short circuit. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. 2. Disconnect the suspect sensor. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the sensors for the following parameters: 3. Turn the engine control switch to the STOP position. Use Cat ET to clear the Logged 262-03 or 262-04 code. 4. Reconnect the suspect sensor. Verify that the diagnostic code recurs. If these conditions are true, replace the sensor.
Test Step 9. Disconnect the +5 V Sensors and Look For Active Diagnostic Codes.
Inlet air temperature
5. Clear all of the diagnostic codes. Verify that the problem is eliminated. STOP.
Table 14
Measure the Resistance for the Engine Harness. Connector and Terminal P1-2 +5 V supply Connector and Terminal P1-14 (inlet air temperature) P1-17 (engine oil temperature) P1-26 (unfiltered engine oil pressure) P1-24 (filtered engine oil pressure) P1-11 (humidity) P1-3 (analog return) Ground strap for the engine P1-69 (battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal)
No The original 5 Volt Sensor diagnostic code

was still active while all of the +5 V sensors were disconnected. Do not reconnect the sensors. Proceed to Test Step 10.
Test Step 10. Check the Harnesses

A. Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the P1 connector. Verify that all of the sensors for the following parameters are disconnected from the engine harness:
Inlet air temperature Engine oil temperature Unfiltered engine oil pressure Filtered engine oil pressure Humidity
Expected Result: Each check of the resistance is greater than 20,000 ohms. Results:
OK Each check of the resistance is greater

than 20,000 ohms. The +5 V wires in the engine harnesses do not have a problem. The problem appears to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Reconnect all of the connectors. Resume normal operation. STOP.
Not OK At least one check of the resistance is

g00888578
less than 20,000 ohms. There is a problem with a connector and/or at least one of the +5 V wires in a harness. Proceed to Test Step 11.
Test Step 11. Check the Engine Harness

A. Disconnect the P12 connector. Verify that all of the sensors are disconnected.
C. Measure the resistance between terminal (2) of the P1 connector and the points that are listed in Table 14. During each measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors for the disconnected sensors. Also, wiggle the harness at the P12 connector.
Test Step 12. Check the Terminal Boxs Harness

A. Disconnect the P19 connector. Verify that P12, and P1 are also disconnected. This will isolate the terminal boxs harness.
Illustration 31 Harness connector P12
g00888586
B. Measure the resistance between terminal A of the P12 connector and the points that are listed in Table 15. During each measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors.
Table 15
g00888578
Measure the Resistance for the Engine Harness. Connector and Terminal P12-A +5 V supply Connector and Terminal P12-C (analog return / shield)
B. Measure the resistance between terminal 2 of the P1 connector and the points that are listed in Table 16. During each measurement, wiggle the wires in the terminal box in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
Table 16
P12-K (inlet air temperature) P12-H (engine oil temperature) P12-E (unfiltered engine oil pressure) P12-F (filtered engine oil pressure) P12-G (humidity) Ground strap for the engine P1-57 (unswitched +battery terminal) P1-69 (battery terminal) P1-70 (switched +battery terminal)
Measure the Resistance for the Engine Harness. Connector and Terminal P1-2 +5 V supply Connector and Terminal P1-14 (inlet air temperature) P1-17 (engine oil temperature) P1-26 (unfiltered engine oil pressure) P1-24 (filtered engine oil pressure) P1-11 (humidity) P1-3 (analog return) Ground strap for the engine P1-69 (battery terminal) P1-57 (unswitched +battery terminal)
Expected Result: Each check of the resistance is greater than 20,000 ohms. Results: Expected Result:
P1-70 (switched +battery terminal)

than 20,000 ohms. The +5 V wires in the engine harness do not have a problem. Proceed to Test Step 12.
Each check of the resistance is greater than 20,000 ohms. Results:
Not OK Repair the engine harness, when

possible. Replace the harness, if necessary. STOP.
OK Each check of the resistance is greater than

20,000 ohms. The problem seems to be resolved. The initial diagnostic code was probably caused by a poor electrical connection.
Repair: Reconnect all of the connectors and resume normal operation. STOP.

less than 20,000 ohms. There is a problem with a connector and/or at least one of the +5 V wires in the terminal box. Repair: Repair the terminal boxs harness, when possible. Replace the harness, if necessary. STOP.
i01731152
+8V Sensor Voltage Supply

SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) supplies 8.0 0.8 VDC to these sensors:
Sensor for engine coolant pressure (outlet) Sensor for inlet air pressure Sensor for atmospheric pressure (if equipped) All of the detonation sensors
A +8 V sensor supply diagnostic code is probably caused by a short circuit or an open circuit in a harness. The next likely cause is a sensor problem. The least likely cause is a problem with the ECM. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 33 Schematic for the 8 V sensors
g00888910
Test Step 1. Inspect the Electrical Connectors and Wiring.

Illustration 35 Harness side of the ECM P1 connector (P1-4) +8 V supply for the pressure sensors (P1-5) Return for the pressure sensors
g00888926
Illustration 34 (1) ECM J2/P2 connectors (2) ECM connectors J1/P1 (3) J12/P12 connectors for the 8 V sensors (4) J11/P11 connectors for the detonation sensors (5) 16 amp circuit breaker
g00888914
Illustration 36 Harness side of the ECM P2 connector (P2-54) (P2-55) (P2-56) (P2-57) Return for the detonation sensors Return for the detonation sensors +8 V supply for the detonation sensors +8 V supply for the detonation sensors
g00888929
ECM J1/P1 and J2/P2 connectors J12/P12 and J11/P11 connectors on the
terminal box a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 1 Nm (55 9 lb in).
Illustration 37 Harness side of the P11 connector (A) Return for the detonation sensors (E) Return for the detonation sensors (F) +8 V supply for the detonation sensors (J) +8 V supply for the detonation sensors
g00888905
Illustration 38 Harness side of the P12 connector (L) +8 V supply for the sensors (N) Return
g00888904
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 8 V sensors.
Illustration 39 (6) Sensor for engine coolant pressure (outlet) (7) Detonation sensor (8) Sensor for inlet air pressure
g00888920
Illustration 40 (9) Sensor for atmospheric pressure (if equipped)
g00888924
c. Check the harness and wiring for abrasion and pinch points from the 8 V sensors to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. C. Observe the Active Diagnostic screen on Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for these codes:
41-03 8 Volt DC Supply short to +batt 41-04 8 Volt DC Supply short to ground
D. Observe the Logged Diagnostic screen on Cat ET. Look for the same codes. Expected Result: The 41-03 code or the 41-04 code is not active.

Not OK At least one of the connectors, pins,

and sockets are not connected properly. At least one of the connectors and/or the wiring have corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP. Results:
No codes The 41-03 code or the 41-04 code is

not active. The +8 volt sensor supply is operating correctly at this time. STOP.
Active code The 41-03 code or the 41-04 code

is active. Proceed to Test Step 3.

A. Connect Cat ET to the service tool connector on the terminal box.
Logged code The 41-03 code or the 41-04
code is not active. However, there is at least one logged code for the 8 volt sensor supply.
Repair: There may be a problem with the wiring and/or a connector. Refer to Troubleshooting, Inspecting Electrical Connectors. Verify that the wiring and/or connectors are OK. Check for diagnostic codes again. Proceed to Test Step 3, if necessary.
Test Step 4. Isolate the Wiring Harnesses from the ECM

Test Step 3. Disconnect the 8 V Sensors and Look for Active Diagnostic Codes.
A. Turn on the Active Diagnostic screen on Cat ET. Verify that the 41-03 or 41-04 code is active. B. Disconnect each 8 V sensor one at a time. After you disconnect each sensor, wait for at least 30 seconds and then observe the Active Diagnostic screen on Cat ET. Note: An Open Circuit code will be generated for each sensor that is disconnected. This is normal. Clear the codes after you complete this procedure. Expected Result: The original 8 Volt DC Supply diagnostic code is deactivated when a particular sensor is disconnected. Results:
Yes The original 8 Volt DC Supply diagnostic

code is deactivated when a particular sensor is disconnected. The sensor and/or the wiring for the sensor has a short circuit. Repair: Perform the following procedure: 1. Reconnect the suspect sensor. Verify that the diagnostic code recurs. 2. Disconnect the suspect sensor. Verify that the diagnostic code is deactivated. If these conditions are true, repair the sensor or the sensors harness. Replace parts, if necessary. 3. Clear all of the diagnostic codes. Verify that the problem is eliminated. STOP.
Illustration 41 Harness side of ECM P1 connector and P2 connector (P1-4) +8 V supply for the pressure sensors (P2-56) +8 V supply for the detonation sensors (P2-57) +8 V supply for the detonation sensors
g00888983
B. Use a 151-6320 Wire Removal Tool to remove the wires from the following terminals:
Terminal 56 and 57 of the P2 connector (1) Terminal 4 of the P1 connector (2)

C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Wait for at least 30 seconds and then observe the Active Diagnostics screen on Cat ET. Determine if a 41-03 code or a 41-04 code is active.
No The original 8 Volt DC Supply diagnostic

code is still active when a particular sensor is disconnected. Do not reconnect the sensors. Proceed to Test Step 4.
Expected Result: No active codes Results:
No codes The 41-03 code or the 41-04 code is
not active. Disconnecting all of the +8 V wiring from the ECM eliminated the active 8 Volt DC Supply diagnostic code. There is a problem in a connector and/or the wiring in a harness. Proceed to Test Step 5.
Active code There is an active 41-03 or 41-04

code. Disconnecting all of the +8 V wiring from the ECM did not eliminate the active 8 Volt DC Supply diagnostic code. 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 the problem is not resolved, perform the following steps: 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP.
Illustration 42 Harness side of the ECM P2 connector (P2-56) +8 V supply for the detonation sensors (P2-57) +8 V supply for the detonation sensors
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Test Step 5. Check the Wiring Harness Inside the Terminal Box
A. Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM OFF.
B. Insert terminals 56 and 57 into the P2 connector. Insert terminal 4 into the P1 connector. Pull on the wires in order to verify that the terminals are fully inserted into the connector. C. Disconnect the following connectors:
Connectors P2 and P1 Connectors P11 and P12

This will isolate the +8 V wiring inside the terminal box.
Table 17
Points for the Measurement of Resistance Connector and Terminal P1-4 (+8 VDC) Connector and Terminal P1-5 (Digital return) P1-10 (Digital sensor signal) P1-12 (Digital sensor signal) P2-68 (Digital sensor signal) P2-56 (+8 VDC) P2-36 (Detonation sensor signal) P2-37 (Detonation sensor signal) P2-38 (Detonation sensor signal) P2-39 (Detonation sensor signal) P2-54 (Digital return) P2-57 (+8 VDC) P2-44 (Detonation sensor signal) P2-45 (Detonation sensor signal) P2-46 (Detonation sensor signal) P2-47 (Detonation sensor signal) P2-55 (Digital return) P1-4 (+8 VDC) P2-56 P2-57 P1-4 P2-56 P2-57 P1-4 P2-56 P2-57 P1-4 P2-56 P2-57 P1-70 (Switched +Battery) P1-57 (Unswitched +Battery) P1-69 (Battery terminal) Engine ground
Illustration 43 (1) ECM side of the P1 connector (2) ECM side of the P2 connector
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Note: For the functions of the terminals, refer to Table 17. D. Measure the resistance between the terminals that are listed in Table 17. During each measurement, wiggle the wires inside the terminal box in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
Expected Result: Each check of the resistance is greater than 20,000 ohms.
Results:
Table 18

20,000 ohms. The +8 V wires and connectors in the terminal box do not have a short circuit. Proceed to Test Step 6.
Measure the Resistance for the Harness. Connector and Terminal P11-F +8 V supply Connector and Terminal P11-A (return) P11-B (detonation sensor signal) P11-C (detonation sensor signal) P11-D (detonation sensor signal)

less than 20,000 ohms. There is a problem with the wiring inside the terminal box. Repair: Repair the terminal boxs harness, when possible. Replace the harness, if necessary. STOP.
P11-E (return) P11-G (detonation sensor signal) P11-H (detonation sensor signal) P11-I (detonation sensor signal) P11-K (detonation sensor signal) P11-L (detonation sensor signal) Ground strap for the engine P1-69 (battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal) P11-J +8 V supply P11-A (return) P11-B (detonation sensor signal) P11-C (detonation sensor signal) P11-D (detonation sensor signal) P11-E (return)
Test Step 6. Check the Harness for the Detonation Sensors

A. Verify that all of the detonation sensors are disconnected.
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P11-G (detonation sensor signal) P11-H (detonation sensor signal) P11-I (detonation sensor signal)
Note: For the functions of the terminals, refer to Table 18. B. Measure the resistance between the points that are listed in Table 18. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
P11-K (detonation sensor signal) P11-L (detonation sensor signal) Ground strap for the engine P1-69 (battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal)
Expected Result: Each check of the resistance is greater than 20,000 ohms.
Results:
Table 19

than 20,000 ohms. The harness for the detonation sensors appears to be OK. Proceed to Test Step 7.
Measure the Resistance for the Harness. Connector and Terminal P12-L +8 V supply Connector and Terminal P12-D (atmospheric pressure) P12-M (inlet air pressure) P12-N (return) P12-P (engine coolant pressure) Ground strap for the engine P1-69 (battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal)

less than 20,000 ohms. There is a problem with a connector and/or at least one of the +8 V wires in the harness for the detonation sensors. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
Test Step 7. Check the Harness for the +8 V Pressure Sensors

A. Verify that the sensors for the following parameters are disconnected: Expected Result:
Engine coolant pressure Inlet air pressure Atmospheric pressure
Each check of the resistance is greater than 20,000 ohms. Results:

20,000 ohms. The problem seems to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Reconnect all of the connectors and resume normal operation. STOP.

less than 20,000 ohms. There is a problem with a connector and/or at least one of the +8 V wires in the harness for the pressure sensors. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
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Note: For the functions of the terminals, refer to Table 19. B. Measure the resistance between the points that are listed in Table 19. During each measurement, wiggle the wires in the harness in order to check for an intermittent problem. Be sure to wiggle the wires near each of the connectors.
Analog Sensor Signal

SMCS Code: 1901-038 System Operation Description: Use this procedure to troubleshoot diagnostic codes for open circuits or short circuits for the sensors of these parameters:
Engine coolant temperature Inlet air temperature
Engine oil temperature Filtered engine oil pressure Unfiltered engine oil pressure
Note: The engine coolant temperature sensor does not require +5 VDC from the Electronic Control Module (ECM). The engine coolant temperature sensor is a passive sensor of the analog type. The sensor operates without a voltage supply from the ECM. The ECM can be configured for one of these types of speed control:
Potentiometer 4-20 ma
The DESIRED SPEED potentiometer (if equipped) must be supplied with +5 VDC from the ECM. If the DESIRED SPEED potentiometer has a short circuit or the potentiometers 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. The -03 code is probably caused by a problem in an engine harness. There may be an open circuit in a harness, or a short circuit to a positive voltage source in a harness. The next likely cause is a sensor problem. The least likely cause is a problem with the ECM. The -04 code is probably caused by a short circuit to ground in an engine harness. The next likely cause is a sensor problem. The least likely cause is a problem with the ECM. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic code after the problem is resolved.
Illustration 46 Schematic for the analog sensors
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Note: For the following steps, refer to Troubleshooting, Inspecting Electrical Connectors.
Illustration 49 Harness side of the P12 connector (A) +5 volt supply (C) Return (K) Signal for the inlet manifold air temperature (H) Signal for the engine oil temperature (F) Signal for the filtered engine oil pressure (E) Signal for the unfiltered engine oil pressure (J) Signal for the engine coolant temperature
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Illustration 47 Terminal box (1) ECM connectors J1/P1 (2) J12/P12 connectors for the analog sensors (3) 16 amp circuit breaker
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the analog sensors.
B. Thoroughly inspect the following connectors:
ECM J1/P1 connectors J12/P12 connectors on the terminal box

a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 1 Nm (55 9 lb in).
Illustration 50
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(4) Inlet air temperature sensor (5) Engine coolant temperature sensor
Illustration 48 Harness side of the ECM P1 connector (2) +5 volt supply (3) Return (14) Signal for the inlet manifold air temperature (17) Signal for the engine oil temperature (24) Signal for the filtered engine oil pressure (26) Signal for the unfiltered engine oil pressure (27) Signal for the engine coolant temperature
C. Observe the Active Diagnostic screen on ET. Allow a minimum of 30 seconds for any codes to activate. Look for these codes:

to +batt

to ground Expected Result: There are no active 5 Volt Sensor DC Power Supply diagnostic codes. Results:
No codes There are no active 5 Volt Sensor

DC Power Supply diagnostic codes. Proceed to Test Step 3.
Illustration 51 (6) Filtered oil pressure sensor (7) Unfiltered oil pressure sensor (8) Oil temperature sensor
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Active code There is an active 5 Volt Sensor DC

Power Supply diagnostic code. This procedure will not work when this type of code is active.
c. Check the harness and wiring for abrasion and pinch points from the analog sensors to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
Repair: Refer to Troubleshooting, +5V Sensor Supply. If necessary, return to this functional test in order to troubleshoot the analog sensor after the +5 V Sensor Supply diagnostic code has been resolved. STOP.
Test Step 3. Check for Active Analog Sensor Diagnostic Codes

A. Observe the Active Diagnostic screen on Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for the codes that are listed in Table 20:


and/or sockets are not connected properly. At least one of the connectors and/or the wiring have corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check for Diagnostic Codes for the Power Supply
A. Connect Cat ET to the service tool connector on the terminal box. B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
Table 20
Analog Sensor Diagnostic Codes 100-03 100-04 110-03 110-04 172-03 172-04 175-03 175-04 542-03 542-04 Engine Oil Pressure open/short to +batt Engine Oil Pressure short to ground Engine Coolant Temperature open/short to +batt Engine Coolant Temperature short to ground Intake Manifold Air Temp open/short to +batt Intake Manifold Air Temp short to ground Engine Oil Temperature open/short to +batt Engine Oil Temperature short to ground Unfiltered Engine Oil Pressure open/short to +batt Unfiltered Engine Oil Pressure short to ground
Test Step 4. Create an Open Circuit for the Sensor

A. Turn the engine control switch to the OFF/RESET position. B. Disconnect the sensor that has the short to ground diagnostic code. C. Turn the engine control switch to the STOP position. D. Observe the Active Diagnostic screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. Look for an active open/short to +batt diagnostic code. Expected Result: There is an active open/short to +batt diagnostic code for the disconnected sensor. Results:
B. If one of the above codes is active, identify the type of diagnostic according to the condition: the diagnostic code is either open/short to +batt (FMI 03) or short to ground (FMI 04). Expected Result: None of the above codes are active. Results:
Yes Before the suspect sensor was
disconnected, there was an active short to ground diagnostic code for the sensor. After the suspect sensor was disconnected, there was an active open/short to +batt diagnostic code for the sensor. The voltage between terminal A and terminal B is +5.0 0.5 volts.
No active codes None of the above codes are

active. Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, Troubleshooting Without a Diagnostic Code. If the engine is running properly at this time, there may be an intermittent problem in the harness that is causing the codes to be logged. Refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Repair: Reconnect the sensor. If the active short to ground diagnostic code recurs, replace the original sensor. Verify that the code does not activate when the new sensor is installed. Clear the logged diagnostic code from the ECM. STOP.
No Before the suspect sensor was

disconnected, there was an active short to ground diagnostic code for the sensor. After the suspect sensor was disconnected, the active open/short to +batt diagnostic code remained. If you are troubleshooting the sensor for engine coolant temperature, proceed to Test Step 6. Otherwise, proceed to Test Step 5.
Active open/short to +batt (FMI 03) There is

an active open/short to +batt diagnostic code. If you are troubleshooting the sensor for engine coolant temperature, proceed to Test Step 6. Otherwise, proceed to Test Step 5.
Test Step 5. Check the Supply Voltage at the Sensor Connector

A. Verify that the suspect sensor is disconnected from the engine harness.
Active short to ground (FMI 04) There is an

active short to ground diagnostic code. Proceed to Test Step 4.
Illustration 52 Harness connectors for the various sensors (A) +5 volt supply (B) Return (C) Signal
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Illustration 53 Harness connectors for the various sensors (A) +5 volt supply (B) Return (C) Signal (1) Signal (2) Return
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B. At the harness connector for the suspect sensor, measure the voltage between terminal A and terminal B. Expected Result: The voltage between terminal A and terminal B is +5.0 0.5 VDC. Results:
B. At the harness connector for the suspect sensor, measure the voltage between terminal B and terminal C, or between terminal 1 and terminal 2. Expected Result: The voltage between the signal terminal and the return terminal is +6.5 0.5 VDC. Results:
OK The voltage between terminal A and
terminal B is +5.0 0.5 VDC. +5 V is present at the sensor connector. Proceed to Test Step 6. terminal C is not +5.0 0.5 VDC. +5 V is not present at the sensor connector. The +5 V supply voltage must be present at the sensor in order to continue this procedure. The +5 V wiring problem may be inside the terminal box, or in the engine harness. Repair: Verify that the wiring and/or connectors are OK. Repair any faulty wiring and/or connectors, when possible. Replace any faulty wiring and/or connectors, if necessary. Refer to Troubleshooting, Inspecting Electrical Connectors. Check for diagnostic codes again. STOP.
OK The voltage between the signal terminal

and the return terminal is +6.5 0.5 VDC. The pull-up voltage that is created by the ECM is present at the sensor connector. The signal wire and the return wire for the suspect sensor appear to be OK. Proceed to Test Step 8.
Not OK The voltage between terminal B and
Not OK The voltage between the signal terminal

and the return terminal is not +6.5 0.5 VDC. The pull-up voltage that is created by the ECM is not present at the sensor connector. Proceed to Test Step 7.
Test Step 7. Check the Pull-Up Voltage at the ECM

Test Step 6. Check the Pull-Up Voltage at the Sensor

A. Verify that the suspect sensors connector is disconnected from the engine harness.
Expected Result: The pull-up voltage for the suspect sensor at the ECM is +6.5 0.5 VDC. Results:
OK The pull-up voltage for the suspect sensor

at the ECM is 6.5 0.5 VDC. The ECM is producing a pull-up voltage that is valid. There is a problem with the signal wire between P1 and the harness connector for the sensor. There may be a problem with a connector. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Disconnect the multimeter leads. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Reinstall the terminal that was removed from the P1 connector. Pull on the wire in order to verify proper installation of the terminal. Verify that the wiring and/or connectors are OK. Repair any faulty wiring and/or connectors, when possible. Replace any wiring and/or connectors, if necessary. Refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Illustration 54 Harness side of the ECM P1 connector (3) Analog return (14) Inlet air temperature (17) Oil temperature (24) Filtered oil pressure (26) Unfiltered oil pressure (27) Engine coolant temperature
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B. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P1 connector. C. Use a jumper wire with Deutsch terminals on the ends. Insert one end of the jumper wire into the open terminal of the P1 connector. D. Connect a multimeter lead to the end of the jumper wire that is not inserted into the connector. E. At the harness side of the P1 connector, insert a 7X-1710 Multimeter Probe along terminal 3. F. Connect the other multimeter lead to the probe. G. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. H. Measure the pull-up voltage at the ECM.
Not OK The pull-up voltage for the suspect

sensor at the ECM is not +6.5 0.5 VDC. Proceed to Test Step 9.
Test Step 8. Check the Sensor

A. Temporarily connect a sensor that is known to be good to the engine harness. B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. C. Observe the Active Diagnostic screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. Expected Result: No diagnostic codes are activated.
Results:
Test Step 9. Check the Operation of the ECM
OK No diagnostic codes are activated when a

good sensor is temporarily installed. Connecting a new sensor resolved the problem. Repair: Perform the following procedure: 1. Reconnect the suspect sensor. Verify that the open/short to +batt diagnostic code recurs. 2. Disconnect the suspect sensor. Verify that the open/short to +batt diagnostic code is deactivated. 3. Connect the new connector. Verify that no diagnostic codes are activated. If these conditions are true, replace the faulty sensor with the new sensor. For the proper torque value for the new sensor, refer to the Specifications manual. 4. Clear all of the diagnostic codes. Verify that the problem has been resolved. STOP.
Not OK The active open/short to +batt code

remains. Connecting a new sensor did not resolve the problem. Proceed to Test Step 9.
Illustration 55 Harness side of the ECM P1 connector (3) Analog return (14) Inlet manifold air temperature (17) Oil temperature (19) Unused ground for the ECM (24) Filtered oil pressure (26) Unfiltered oil pressure (27) Engine coolant temperature
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A. Verify that the signal wire for the suspect sensor has been removed from the P1 connector. B. Clear any existing diagnostic codes. C. Observe the Active Diagnostic screen on ET. Allow a minimum of 30 seconds for any codes to activate. An active open/short to +batt diagnostic code is generated for the sensor. D. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM to the OFF position. E. Use a jumper wire that is the appropriate length with Deutsch terminals on the ends. Install one end of the jumper wire into the terminal for the signal wire that was removed from the P1 connector. Install the other end of the jumper wire into terminal (19) of the P1 connector. This will replace the sensor circuit with a short circuit.
F. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. G. Observe the Active Diagnostic screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active short to ground diagnostic code is generated. Expected Result: Active open/short to +batt and short to ground diagnostic codes are generated according to the above steps. Results:
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.
i01738063
Desired Speed Input (4 - 20 mA)

SMCS Code: 1901-038 System Operation Description: Note: For this troubleshooting procedure, the Desired Speed Input configuration parameter must be set to 4-20 mA Input in the Service/Configuration screen of the Caterpillar Electronic Technician (ET). Do not select PWM. The Electronic Control Module (ECM) cannot be configured to accept a PWM input signal for control of the engine speed. The selection of the 4-20 mA Input setting requires a 4 to 20 mA signal for regulation of the desired engine speed. If the Desired Speed Input is set to 0-5 VDC Input, do not use this procedure to troubleshoot the circuit. When the desired speed input is correspondingly configured, the ECM controls the engine speed according to the 4 to 20 mA current. The value of the current corresponds to a range of desired engine speeds between minimum high idle and maximum high idle. The Minimum Engine High Idle Speed and the Maximum Engine High Idle Speed are set with the Service/Configuration screen of ET. For more information, refer to Systems Operation/Testing and Adjusting, Electronic Control System Parameters. When the Idle/Rated switch is in the Rated position, a current value of 4.0 mA corresponds to the programmed Minimum Engine High Idle Speed. A current value of 20.0 mA corresponds to Maximum Engine High Idle Speed. Current values within this range will vary the desired engine speed in a linear fashion between Minimum Engine High Idle Speed and Maximum Engine High Idle Speed. The ECM will generate a diagnostic code in response to current outside of the range of 4 to 20 mA.
OK Active open/short to +batt and short

to ground diagnostic codes are generated according to the above steps. The ECM is operating correctly. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Reinstall the terminal that was removed from the P1 connector. Pull on the wire in order to verify proper installation of the terminal. Resume normal operation. STOP.
Not OK No active open/short to +batt

and short to ground diagnostic codes were generated. The ECM is not operating correctly. Repair: It is unlikely that the ECM has failed. Perform this entire procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to Troubleshooting, Replacing the ECM.
Current values that are greater than 22.0 mA will activate the 524-03 Desired Engine Speed Sensor short to +batt diagnostic code. Current values that are less than 2.0 mA will activate the 524-04 Desired Engine Speed Sensor short to ground diagnostic code. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. The next likely cause is a problem with a component. The least likely cause is a problem with the ECM. Logged diagnostic codes provide an historical record. Before you begin this procedure, use ET to print the logged codes to a file. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 57 (1) ECM connectors J1/P1 (2) 16 amp circuit breaker (3) J9/P9 Connectors for the customer (if equipped)
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B. Thoroughly inspect the following components:
ECM J1/P1 connectors J9/P9 connectors on the terminal box Wiring and the connections between the
terminal box and the device that supplies the 4 to 20 mA signal
Illustration 56 Schematic of the 4 to 20 mA desired speed input
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Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
OK The components are in good condition with

proper connections. If you are troubleshooting a 524-03 Desired Engine Speed Sensor short to +batt diagnostic code, proceed to Test Step 3. If you are troubleshooting a 524-04 Desired Engine Speed Sensor short to ground diagnostic code, proceed to Test Step 5.
Not OK The components are not in good

condition and/or at least one connection is improper. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check for an Open Circuit

Illustration 58 Harness side of the ECM P1 connector (1) ECM P1 connector (P1-36) + Signal (P1-37) - Signal
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A. Remove the two wires (+ and -) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal. B. Install a jumper wire between the two wires (+ and -) that were removed from the device that supplies the 4 to 20 mA signal. C. Disconnect the ECM P1 connector.
Illustration 59 Harness side of the P9 connector (P9-K) + Signal (P9-P) - Signal
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Illustration 60 ECM side of the P1 connector (P1-36) + Signal (P1-37) - Signal
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the 4 to 20 mA circuit. c. Check the harness and wiring for abrasion and pinch points between the device that supplies the 4 to 20 mA signal and the ECM.
D. Use an ohmmeter to measure the resistance between terminals (P1-36) and (P1-37) on the ECM side of the P1 connector.
Expected Result: The resistance is less than 5 ohms. Results:
OK The resistance is less than 5 ohms. The

circuit is not open. Repair: Remove the jumper wire. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. Proceed to Test Step 3.
Not OK The resistance is greater than 5 ohms.

There is a problem with a connector and/or the wiring from the P1 connector.
Repair: The problem may be between the ECM P1 connector and the J9 connector. Alternatively, the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
Illustration 61 (1) Harness connector P1 (P1-36) + Signal (P1-57) +Battery
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Test Step 3. Check for a Short Circuit to the +Battery Side at the ECM P1 Terminal 36
A. Verify that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF. B. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal.
C. Use an ohmmeter to measure the resistance between terminals (P1-36) and (P1-57). Expected Result: The resistance is greater than 20,000 ohms. Results:
Yes The resistance is greater than 20,000

ohms. The wiring from terminal P1-36 is not shorted to the +Battery side. Do not reconnect any connectors. Proceed to Test Step 4.
No The resistance is less than 20,000 ohms.
There is a problem with a connection and/or the wiring from terminal P1-36. Repair: The problem may be between the ECM P1 connector and the J9 connector. Alternatively, the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
Test Step 4. Check for a Short to Ground at the ECM P1 Terminal 37

A. Verify that the engine control switch is in the OFF/RESET position and the 16 amp circuit breaker for the ECM OFF. B. Make sure that the leads of the wires for the 4 to 20 mA signal do not create a short circuit.
There is a problem with a connection and/or the wiring that is connected to P1-37. Repair: The problem may be between the ECM P1 connector and the J9 connector. Alternatively, the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. Locate the wire with the short circuit and replace the wire. Verify that the problem is resolved. STOP.
Test Step 5. Check for a Short Circuit to the +Battery Side at the ECM P1 Terminal 37
A. Verify that the engine control switch is in the OFF/RESET position and the 16 amp circuit breaker for the ECM OFF. B. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal. C. Remove the two wires (+ and -) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. D. Disconnect the ECM P1 connector.
Illustration 62 (1) Ground strap (2) P1 connector (P1-37) - Signal
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C. Use an ohmmeter to measure the resistance between terminal (P1-37) and the ECM ground strap. Expected Result: The resistance is greater than 20,000 ohms. Results:
Yes The resistance is greater than 20,000 ohms.

The wiring from terminal P1-37 appears to be OK. Repair: Reconnect the ECM P1 connector. Reconnect the two wires (+ and -) for the 4 to 20 mA signal to the device that supplies the 4 to 20 mA signal. Proceed to Test Step 7.
Test Step 6. Check for a Short Circuit to Ground at the ECM P1 Terminal 36
A. Verify that the engine control switch is in the OFF/RESET position and the 16 amp circuit breaker for the ECM OFF. B. Make sure that the ends of the wires for the 4 to 20 mA signal do not create a short circuit.
Illustration 63 (1) Connector P1 (P1-37) - Signal (P1-57) +Battery
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E. Use an ohmmeter to measure the resistance between terminals (P1-37) and (P1-57). Expected Result: The resistance is greater than 20,000 ohms. Results:
Illustration 64 (1) Ground strap (2) P1 connector (P1-36) + Signal
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ohms. The wiring from terminal P1-37 is not shorted to the +Battery side. Do not reconnect any connectors. Proceed to Test Step 6.
C. Use an ohmmeter to measure the resistance between terminal (P1-36) and the ECM ground strap. Expected Result: The resistance is greater than 20,000 ohms. Results:
There is a problem with a connection and/or the wiring from terminal P1-37. Repair: The problem may be between the ECM P1 connector and the J9 connector. Alternatively, the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
ohms. The wiring from terminal P1-36 appears to be OK. Do not reconnect any connectors. Proceed to Test Step 2. There is a problem with a connection and/or the wiring from terminal P1-36.
Repair: The problem may be between the ECM P1 connector and the J9 connector. Alternatively, the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. Repair the connection and/or the wire, when possible. Replace parts, if necessary. Verify that the problem is resolved. STOP.
Results:
Yes The correct 4 to 20 mA signal is provided

to the ECM. However, the ECM is not responding correctly to the signal. There may be a problem with the ECM. Repair: It is unlikely that the ECM is faulty. Exit this procedure and perform this procedure again. If the problem is not resolved, replace the ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.
Test Step 7. Check the Device that Provides the 4 to 20 mA Signal

Measure the 4 to 20 mA signal according to the literature that is provided by the OEM of the device that provides the 4 to 20 mA signal. Verify that the correct signal is provided to the ECM.
No The ECM is not receiving the correct 4 to
20 mA signal. There is probably a problem with the device that provides the 4 to 20 mA. Repair: Service the device that provides the 4 to 20 mA according to the literature that is provided by the OEM of the device. Verify that the problem is resolved. STOP.
i01738479
Detonation Sensors
SMCS Code: 1559-038 System Operation Description: Detonation sensors are located on the upper cylinder block between every two cylinders. Each sensor monitors two adjacent cylinders. For example, one sensor monitors cylinders 1 and 3. The Electronic Control Module (ECM) supplies 8 VDC in order to power the sensors. The detonation sensors provide electrical signals to the ECM that indicate mechanical engine vibrations. Each sensor outputs an electrical signal. The signal is amplified and the signal is filtered. The frequency of the signal corresponds to the mechanical frequency of the vibrations. The amplitude of the signal is proportional to the intensity of the vibrations. The ECM monitors the signals in order to determine the presence and the severity of the detonation. The ECM retards the timing 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 engine is shut down.
Illustration 65 Harness side of the P1 connector (1) ECM P1 connector (P1-36) + Signal (P1-37) - Signal
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Verify the correct 4 to 20 mA signal at the ECM P1 terminals (36) and (37). Expected Result: The correct 4 to 20 mA signal is provided to the ECM.
The ECM can retard timing by as few as three degrees for light detonation levels. The timing can be retarded up to six degrees for severe detonation. For most applications, the minimum allowable actual timing is ten degrees BTC (five degrees BTC for propane operation). A proportional strategy is used for advancing the timing after the timing has been retarded. The rate of advance is based upon the level of detonation. The rate is faster for lighter detonation. The fastest rate of proportional timing advance is one degree per minute. The ECM will diagnose the detonation sensors for a signal that is shorted to the Battery side, the +Battery side, or an open circuit. To avoid detecting vibrations that are not related to detonation, the ECM only monitors a detonation sensor on the firing stroke, when one of the sensors cylinders is between top center and 40 degrees after top center. Therefore, the Block Tap method of testing the detonation sensors does not work for the G3500B Engine. An input from a detonation sensor that is diagnosed by the ECM as open/shorted to +battery may measure 0 VDC on a voltmeter. The ECM also supports related event codes when the levels of detonation warrant a reaction from the ECM. If the timing has been retarded by the maximum amount and the level of detonation remains high, the ECM will shut down the engine. Detonation protection is disabled when the engine speed is less than 250 rpm. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. The next likely cause is a problem with a sensor. The least likely cause is a problem with the ECM. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 66 Schematic for the detonation sensors
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Illustration 69 Harness side of the side of the P11 connector (J11-B) Signal for cylinders 1 and 3 (J11-C) Signal for cylinders 5 and 7 (J11-D) Signal for cylinders 9 and 11 (J11-G) Signal for cylinders 13 and 15 (J11-L) Signal for cylinders 14 and 16 (J11-K) Signal for cylinders 10 and 12 (J11-I) Signal for cylinders 6 and 8 (J11-H) Signal for cylinders 2 and 4 (J11-A) Return (right side) (J11-E) Return (left side) (J11-J) +8 V supply (right side) (J11-F) +8 V supply (left side)
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Illustration 67 (1) ECM connectors J2/P2 (2) J11/P11 connectors for the detonation sensors (3) 16 amp circuit breaker
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the detonation sensors.
Illustration 70 Detonation sensors
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Illustration 68 Harness side of the side of the ECM P2 connector (P2-36) (P2-37) (P2-38) (P2-39) (P2-44) (P2-45) (P2-46) (P2-47) (P2-54) (P2-55) (P2-56) (P2-57) Signal for cylinders 1 and 3 Signal for cylinders 5 and 7 Signal for cylinders 9 and 11 Signal for cylinders 13 and 15 Signal for cylinders 2 and 4 Signal for cylinders 6 and 8 Signal for cylinders 10 and 12 Signal for cylinders 14 and 16 Return (right side) Return (left side) +8 V supply (right side) +8 V supply (left side)
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c. Check the harness and wiring for abrasion and pinch points from the detonation sensors to the ECM. d. Make sure that the detonation sensors are properly installed according to the torque in Specifications, Detonation Sensors. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. All of the detonation sensors are properly installed.
Results:
Test Step 3. Check for Active Diagnostic Codes for the Detonation Sensors
Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. Therefore, the engine must be running. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. A. Start the engine and run the engine. B. Allow a minimum of 30 seconds for any diagnostic codes to become active. Observe the Active Diagnostic screen of Cat ET and look for the diagnostic codes that are listed in Table 21:
Table 21

proper connections. Proceed to Test Step 2.

Test Step 2. Check for Diagnostic Codes for the +8 V Sensor Supply
A. Connect Cat ET to the service tool connector on the terminal box. B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. C. Observe the Active Diagnostic screen of Cat ET. Wait at least 30 seconds so that any codes may become activated. Look for these codes:
Code 1501-03 1501-04 1502-03 1502-04
Description Cylinder #1 Detonation Sensor short to +batt Cylinder #1 Detonation Sensor short to ground Cylinder #2 Detonation Sensor short to +batt
Cylinders
1 and 3
2 and 4 Cylinder #2 Detonation Sensor short to ground Cylinder #5 Detonation Sensor short to +batt Cylinder #5 Detonation Sensor short to ground Cylinder #6 Detonation Sensor short to +batt 6 and 8 Cylinder #6 Detonation Sensor short to ground Cylinder #9 Detonation Sensor short to +batt Cylinder #9 Detonation Sensor short to ground Cylinder #10 Detonation Sensor short to +batt Cylinder #10 Detonation Sensor short to ground Cylinder #13 Detonation Sensor short to +batt Cylinder #13 Detonation Sensor short to ground Cylinder #14 Detonation Sensor short to +batt Cylinder #14 Detonation Sensor short to ground 14 and 16 10 and 12
41-03 8 Volt DC Supply short to +batt 41-04 8 Volt DC Supply short to ground
Expected Result: Neither of the 8 Volt DC Supply diagnostic codes are active. Results:
1505-03 1505-04 1506-03 1506-04 1509-03 1509-04 1510-03
5 and 7
OK Neither of the 8 Volt DC Supply diagnostic

codes are active. Proceed to Test Step 3.
9 and 11
Not OK At least one of the 8 Volt DC Supply

diagnostic codes is active. Repair: The 8 Volt DC Supply diagnostic code must be resolved before you can proceed with this functional test. Exit this procedure and refer to Troubleshooting, +8V Sensor Voltage Supply. If necessary, return to this functional test in order to troubleshoot the detonation sensor after the 8 Volt DC Supply diagnostic code has been resolved. STOP.
1510-04 1513-03 1513-04 1514-03 1514-04
13 and 15
Note: A short to ground diagnostic code can indicate either an actual short to ground or an open circuit. Expected Result: None of the above diagnostic codes are active. Results:
D. Measure the voltage between terminal A and terminal B on the harness connector for the sensor. Expected Result: The voltage is between 7.6 VDC and 8.4 VDC. Results:
OK (No active codes) None of the above codes

are active at this time. The problem seems to be resolved. The original diagnostic code was probably caused by a poor electrical connection in one of the harness connectors. Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, Troubleshooting Without a Diagnostic Code. If any of the above codes are logged and the engine is running properly, there may be an intermittent problem in a connector or a wiring harness. Refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
OK The voltage is between 7.6 VDC and 8.4

VDC. The correct voltage is available to the sensor. Do not reconnect the sensor. Proceed to Test Step 5.
Not OK The voltage is not between 7.6 VDC
and 8.4 VDC. The correct voltage is not available to the sensor. There is probably an open circuit in the +8 volt supply or in the return for the sensor. Repair: The open circuit may be caused by a poor electrical connection or a wiring problem between the ECM and the connector for the sensor. If only one detonation sensor has a diagnostic code, the open circuit for the +8 volt supply is in the engine harness. Repair the electrical connection and/or the wiring, when possible. If more than one detonation sensor has a diagnostic code, use the following procedure to locate the open circuit for the +8 volt supply: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
Not OK (Active Code) A short to +batt or

short to ground diagnostic code was activated. Repair: Note the diagnostic code and note the location of the suspect detonation sensor. Proceed to Test Step 4.
Test Step 4. Verify the Presence of the Supply Voltage at the Sensor
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the sensor with the diagnostic code. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
Illustration 71 Harness connector for the detonation sensors (A) +8 V (B) Return (C) Signal
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Illustration 72 (1) P11 connector (2) J11 connector
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2. Disconnect the P11 connector (1) from the J11 connector (2) on the side of the terminal box.
3. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
Test Step 5. Measure the Voltage of the Signal Wire at the Sensor
Illustration 74 Harness connector for the detonation sensors (A) +8 V (B) Return (C) Signal
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A. Measure the voltage between terminals (B) and (C) on the harness connector for the suspect sensor. Expected Result: The voltage is between 0.4 VDC and 0.6 VDC.
Illustration 73 Side view of the terminal box and the J11 connector
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Results:
Yes The voltage is between 0.4 VDC and 0.6

VDC. Repair: Reconnect the suspect sensor. Start the engine again and check for the diagnostic code. If the diagnostic code recurs, replace the detonation sensor with a known good detonation sensor. Tighten the detonation sensor according to the torque in Specifications, Detonation Sensor. Verify that the problem is resolved. STOP.
4. Measure the voltage between the terminals that are listed in Table 22.
Table 22
Points for the Measurement of Voltage Connector and Terminal J11-J +8 V supply for the detonation sensors on the right side of the engine J11-F +8 V supply for the detonation sensors on the left side of the engine Connector and Terminal J11-A Return (right side)
J11-E Return (left side)
No The voltage is not between 0.4 VDC and

0.6 VDC. If the voltage is less than 0.4 VDC, there is probably a short to ground or an open circuit between the connector for the detonation sensor and the ECM. If the voltage is greater than 4.8 VDC, there is probably a short circuit to a +Battery source between the connector for the detonation sensor and the ECM. Proceed to Test Step 6.
If both of the voltage measurements are between 7.6 VDC and 8.4 VDC, the open circuit is in the engine harness. Repair the engine harness, when possible. Replace the harness, if necessary. If either of the voltage measurements are not between 7.6 VDC and 8.4 VDC, the open circuit is in the terminal boxs harness. Repair the terminal boxs harness, when possible. Replace the harness, if necessary. STOP.
Test Step 6. Check the Operation of the ECM

Illustration 75 (P1-19) (P2-36) (P2-37) (P2-38) (P2-39) (P2-44) (P2-45) (P2-46) (P2-47) Unused ground for the ECM Signal for cylinders 1 and 3 Signal for cylinders 5 and 7 Signal for cylinders 9 and 11 Signal for cylinders 13 and 15 Signal for cylinders 2 and 4 Signal for cylinders 6 and 8 Signal for cylinders 10 and 12 Signal for cylinders 14 and 16
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Illustration 76 (1) ECM connector P2 (2) Jumper wire (3) ECM connector P1
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B. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P2 connector. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. Therefore, the engine must be running. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. D. Start the engine. Observe the Active Diagnostic screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active open/short to +batt diagnostic code is generated for the sensor. E. Turn the engine control switch to the OFF/RESET position.
F. Fabricate a jumper wire that is long enough to reach between the P1 connector and the P2 connector. Install Deutsch terminals on the ends. Install one end of the jumper wire (2) into the terminal for the signal wire that was removed from the P2 connector (1). Install the other end of the jumper wire into terminal 19 of the P1 connector (3). G. Start the engine. Observe the Active Diagnostic screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. An active short to ground diagnostic code is generated for the sensor. Expected Result: Active open/short to +batt and short to ground diagnostic codes are generated according to the above steps. Results:
OK Active open/short to +batt and short

to ground diagnostic codes are generated according to the above steps. The ECM is operating correctly. There is probably an open circuit in the engine harness between the ECM and the connector for the sensor.
Repair: Remove the jumper wire. Insert the terminal that was removed from the P2 connector. Pull on the wire in order to verify that the terminal is fully inserted into the connector. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with the GSOV. The least likely cause is a problem with the ECM. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Not OK No active open/short to +batt
and short to ground diagnostic codes were generated. The ECM is not operating correctly. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP.
i01741418
ECM Output Circuit (Fuel Control)

SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) contains the logic and the outputs for control of prelubrication, starting, and shutdown of the engine. The logic for starting and stopping is customer programmable. The logic responds to inputs from the following components: engine control switch, emergency stop switch, remote start switch, data link, and other inputs. The fuel control relay is energize-to-run. To enable fuel flow to the engine, the relay for the Gas Shutoff Valve (GSOV) must be energized. The ECM provides +Battery voltage to the relay for the GSOV when the logic determines that fuel is required for engine operation. For engine shutdown, the ECM removes the voltage from the fuel control relay. This stops the fuel flow.
Illustration 77 Schematic of the output circuit for the fuel control relay
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ECM J2/P2 connectors Terminal boxs connectors (J13/P13) Connector for the fuel control relay
a. Check the torque of the Allen head screw for the 70-pin connectors. The proper torque is 6 1 Nm (55 9 lb in).
Illustration 78
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Illustration 79 Harness side of the ECM P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return
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(1) ECM J2/P2 connectors (2) Terminal boxs J13/P13 connectors for the fuel control relay (3) 16 amp circuit breaker (4) 6 amp circuit breaker
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 6 amp circuit breaker OFF. Note: For the following steps, refer to Troubleshooting, Inspecting Electrical Connectors. B. Thoroughly inspect the following connectors and the wiring harnesses for the connectors:

condition and/or at least one connection is improper.
Repair: Perform the necessary repairs, when possible. Replace parts, if necessary. STOP.

A. Connect Cat ET to the service tool connector on the terminal box. B. Switch the 16 amp circuit breaker for the ECM ON. Switch the 6 amp circuit breaker ON. Turn the engine control switch to the STOP position. C. Wait for 30 seconds and use Cat ET to check for an active 17-05 Fuel Shutoff Valve open circuit diagnostic code.
Illustration 80 (5) Connector P13 for the fuel control relay (P13-A) Circuit driver for the fuel control relay (P13-B) Return
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If there is an active 17-05 Fuel Shutoff Valve open circuit diagnostic code, proceed to the Results for this Test Step. Otherwise, continue this procedure. Note: The 17-05 Fuel Shutoff Valve open circuit diagnostic code cannot be detected when the output for the fuel control relay is ON. The output is ON when the engine control switch is in the START position and the engine speed is not zero. D. Use Cat ET to check the logged diagnostic codes. If there is a 17-06 Fuel Shutoff Valve short to ground or a 17-12 Fuel Shutoff Valve malfunction diagnostic code, clear the code. Note: This diagnostic condition cannot be detected by the ECM when the output for the fuel control relay is OFF. The output is OFF when the engine control switch is in the STOP position.
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel control relay.
Illustration 81 Fuel control relay
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E. To prevent the engine from starting, shut the gas supply OFF. Note: To provide the output for the fuel control relay, the sequence for engine start-up must be initiated. Otherwise, a 17-06 Fuel Shutoff Valve short to ground or a 17-12 Fuel Shutoff Valve malfunction diagnostic code cannot be generated. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position. G. Use Cat ET to look for a logged 17-06 Fuel Shutoff Valve short to ground or a 17-12 Fuel Shutoff Valve malfunction diagnostic code again.
c. Check the harness and wiring for abrasion and pinch points from the ECM to the fuel control relay. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:

Expected Result: When the engine control switch was in the STOP position, there was no active 17-05 Fuel Shutoff Valve open circuit diagnostic code. After the engine was cranked, there was no logged 17-06 Fuel Shutoff Valve short to ground or 17-12 Fuel Shutoff Valve malfunction diagnostic code. Results:
Test Step 3. Check for a Short Circuit to the +Battery Side
OK No diagnostic codes were generated. The
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak. Note: Open sparks can be generated during this test. A. Make sure that no combustible gas is present in the surrounding atmosphere. B. Ensure that the engine control switch is in the STOP position.
output for the fuel control relay seems to be OK at this time. The initial diagnostic code was probably caused by a poor electrical connection.
Repair: If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Not OK (17-05 Fuel Shutoff Valve open circuit
diagnostic code) A 17-05 Fuel Shutoff Valve open circuit diagnostic code was activated. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Proceed to Test Step 3. diagnostic code) After the engine was cranked, a 17-06 Fuel Shutoff Valve short to ground diagnostic code was generated. Proceed to Test Step 8.
Not OK (17-06 Fuel Shutoff Valve short to ground
Not OK (17-12 Fuel Shutoff Valve malfunction

diagnostic code) After the engine was cranked, a 17-12 Fuel Shutoff Valve malfunction diagnostic code was generated. The ECM disabled the ignition. Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Replace the fuel control relay. STOP.
Illustration 82 Fuel control relay (1) Connector for the fuel control relay (2) Relay
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C. Disconnect the connector (1) from the relay (2). Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the engine control switch is in the STOP position.
Results:
B. Disconnect connector P13 (1) from the terminal box. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
OK There is no audible click and/or vibration

when the relay is disconnected and connected. There is no short circuit to the +Battery side. There is an open circuit. Proceed to Test Step 5.
Not OK There is an audible click and/or

vibration when the relay is disconnected and connected. The relay is receiving power when the engine control switch is in the STOP position. There is probably a short circuit to the +Battery side in a connector or a wiring harness. Proceed to Test Step 4.
Test Step 4. Determine the Cause of the Energized Relay
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak. Note: Open sparks can be generated during this test. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
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D. Disconnect the connector (2) from the relay (3). Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the P13 connector is disconnected. Results:

when the solenoid is disconnected and reconnected. The solenoid is not energized when the P13 connector is disconnected. Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty:
Illustration 83
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(1) Terminal boxs P13 connector for the fuel control relay
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak. Note: Open sparks can be generated during this test. 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reconnect the P13 connector to the terminal box.
g00891901
5. Disconnect the connector (2) from the relay (3). Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. If the relay is energized, there is a problem with a connector and/or wiring in the terminal box. Repair the wiring and/or the connector, when possible. Replace parts, if necessary. If the relay is not energized, there may be a problem with the ECM. Continue with this procedure. 6. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 7. Reinstall terminal 11 and terminal 21 into the P2 connector. Pull on the wires in order to verify proper installation of the terminals. 8. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. 9. Disconnect the connector from the fuel control relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. If the relay is not energized, there is an intermittent problem with a connector and/or the wiring. Refer to Troubleshooting, Inspecting Electrical Connectors.
Illustration 85 Harness side of the ECM P2 connector (1) ECM P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return
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3. Use a 151-6320 Wire Removal Tool to remove terminals (P2-11) and (P2-21) from the P2 connector (1). 4. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
If the relay is energized, there may be a problem with the ECM. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP.
D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: The 17-05 Fuel Shutoff Valve open circuit diagnostic code can only be detected when the output for the fuel control relay is OFF. The output is OFF when the engine control switch is in the STOP position and the engine is not running. E. Wait for 30 seconds and use the Active Diagnostic screen of Cat ET to look for a 17-05 Fuel Shutoff Valve open circuit diagnostic code. Expected Result: A 17-05 Fuel Shutoff Valve open circuit diagnostic code was not generated when the jumper wire was installed. Results:

vibration when the relay is disconnected and reconnected. The relay is energized when the P13 connector is disconnected. There is a short circuit to the +Battery side in the engine harness. Repair: Repair the connector and/or wiring in the engine harness, when possible. Replace the engine harness, if necessary. STOP.
OK A 17-05 Fuel Shutoff Valve open circuit

diagnostic code was not generated when the jumper wire was installed. The harness and the ECM are OK. There is a problem with the relay. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the jumper wire from the relays connector on the engine harness. 3. Inspect the relays connectors for damage, moisture, and corrosion. 4. Make repairs, as needed. If the problem is not resolved, replace the fuel control relay. STOP.
Test Step 5. Create a Short Circuit in order to Check for an Open Circuit
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the fuel control relay.
Not OK A 17-05 Fuel Shutoff Valve open

circuit diagnostic code was generated when the jumper wire was installed. There may be an open circuit in the engine harness. Proceed to Test Step 6.

Illustration 87 (1) Connector for the fuel control relay (2) Jumper wire
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A. Ensure that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF.
C. Install a jumper wire (2) into the two terminals of the relays connector (1) on the engine harness.
B. Disconnect the P13 connector from the terminal box. Inspect the P13 and J13 connectors for damage, moisture, and corrosion. Make repairs, if necessary.
Not OK When the jumper wire was installed, a
17-05 Fuel Shutoff Valve open circuit diagnostic code was activated. The ECM did not detect the jumper wire in the J13 connector. There is a problem in the terminal box. Proceed to test Step 7.
Test Step 7. Check the ECM

A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Remove the jumper wire from the J13 connector.
Illustration 88 (1) Connector J13 for the fuel control relay (2) Jumper wire
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C. Install a jumper wire into the two terminals of the J13 connector. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: The 17-05 Fuel Shutoff Valve open circuit diagnostic code can only be detected when the output for the fuel control relay is OFF. The output is OFF when the engine control switch is in the STOP position and the engine is not running. E. Wait for 30 seconds and use Cat ET to check for an active 17-05 Fuel Shutoff Valve open circuit diagnostic code. Expected Result: There is no active 17-05 Fuel Shutoff Valve open circuit diagnostic code. Results:
Illustration 89 Harness side of the ECM P2 connector (1) ECM P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return
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C. Use the 151-6320 Wire Removal Tool to remove terminals (P2-11) and (P2-21).
OK When the jumper wire was installed, there

was no active 17-05 Fuel Shutoff Valve open circuit diagnostic code. There is a problem in the engine harness. Repair: Repair the engine harness, when possible. Replace the engine harness, if necessary. STOP.
Results:

was no active 17-05 Fuel Shutoff Valve open circuit diagnostic code. The ECM detects the jumper wire at the P2 connector. However, the ECM did not detect the jumper wire at the J13 connector. There is a problem between the ECM P2 connector and the terminal box J13 connector. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 3. Reinstall the terminals into P2-11 and P2-21. Pull on the wires in order to verify proper installation of the terminals. 4. Disconnect the ECM J2/P2 connectors. Inspect the connectors for damage, moisture, and corrosion.
Illustration 90 Harness side of the ECM P2 connector (2) Jumper wire (P2-11) Circuit driver for the fuel control relay (P2-21) Return
g00892003
5. Thoroughly inspect the terminal box J13 connector for the engine harness. 6. Use an ohmmeter to measure the resistance between the P2-11 terminal and the J13-A terminal. Also, measure the resistance between the P2-21 terminal and the J13-B terminal. If the resistance measurements are less than 5 ohms, the circuit has good continuity. Otherwise, there is an open circuit. Make repairs, if necessary. STOP.
D. Install a jumper wire (2) into terminals (P2-11) and (P2-21). Pull on the jumper wire in order to verify proper installation. E. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: The 17-05 Fuel Shutoff Valve open circuit diagnostic code can only be detected when the output for the fuel control relay is OFF. The output is OFF when the engine control switch is in the STOP position and the engine is not running. F. Wait for 30 seconds and use the Active Diagnostic screen of Cat ET to look for an active 17-05 Fuel Shutoff Valve open circuit diagnostic code. Expected Result: There is no active 17-05 Fuel Shutoff Valve open circuit diagnostic code.
No When the jumper wire was installed, a

17-05 Fuel Shutoff Valve open circuit diagnostic code was activated. The ECM did not detect the jumper wire. There is a problem with the ECM. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 3. Reinstall the terminals into P2-11 and P2-21. Pull on the wires in order to verify proper installation of the terminals.
4. Replace the ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.
Results:
OK When the relay was connected, a short

to ground diagnostic code was generated. When the relay was disconnected, no short to ground diagnostic code was generated. There is a problem with the relay. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Inspect the connections of the relay for damage and/or corrosion. 3. Make repairs, as needed. If the problem is not resolved, replace the relay. STOP.
Test Step 8. Create an Open Circuit in order to Check for a Short Circuit to Ground
A. Turn the engine control switch to the OFF/RESET position.
Not OK A short to ground diagnostic code

was generated when the relay was disconnected. Proceed to Test Step 9.
g00891892
Test Step 9. Create an Open Circuit at the Terminal Box

B. Disconnect the connector (1) from the relay (2). C. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 17-06 Fuel Shutoff Valve short to ground diagnostic code. E. To prevent the engine from starting, shut OFF the main gas supply. Note: To provide the output for the fuel control relay, the sequence for engine start-up must be initiated. Otherwise, a 17-06 Fuel Shutoff Valve short to ground diagnostic code cannot be generated. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position. G. Use Cat ET to look for a logged 17-06 Fuel Shutoff Valve short to ground diagnostic code again. Expected Result: A 17-06 Fuel Shutoff Valve short to ground was not generated.
Illustration 92 (1) P13 connector for the fuel control relay
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B. Disconnect connector P13 (1) from the terminal box.
C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 17-06 Fuel Shutoff Valve short to ground diagnostic code. E. To prevent the engine from starting, shut OFF the main gas supply. Note: To provide the output for the fuel control relay, the sequence for engine start-up must be initiated. Otherwise, a 17-06 Fuel Shutoff Valve short to ground diagnostic code cannot be generated. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position. G. Use Cat ET to look for a logged 17-06 Fuel Shutoff Valve short to ground diagnostic code again. Expected Result: A 17-06 Fuel Shutoff Valve short to ground was not generated. Results:

OK A 17-06 Fuel Shutoff Valve short to ground

diagnostic code was not generated when the P13 connector was disconnected. There is a problem in the engine harness. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reconnect the P13 connector. 3. Repair the engine harness, when possible. Replace the harness, if necessary. STOP.
Illustration 93 Harness side of the ECM P2 connector (P2-11) Circuit driver for the fuel control relay
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B. Use the 151-6320 Wire Removal Tool to remove terminal (P2-11). C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 17-06 Fuel Shutoff Valve short to ground diagnostic code. E. To prevent the engine from starting, shut OFF the main gas supply. Note: To provide the output for the fuel control relay, the sequence for engine start-up must be initiated. Otherwise, a 17-06 Fuel Shutoff Valve short to ground diagnostic code cannot be generated. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position.
Not OK A 17-06 Fuel Shutoff Valve short to
ground diagnostic code was generated when the P13 connector was disconnected. There is probably a short circuit to ground in the terminal box. Repair: Reconnect the P13 connector. Proceed to Test Step 10.
G. Use Cat ET to look for a logged 17-06 Fuel Shutoff Valve short to ground diagnostic code again. Expected Result: The 17-06 Fuel Shutoff Valve short to ground diagnostic code was not generated. Results:
i01742661
ECM Output Circuit (Prelubrication Oil Pump)

SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) contains the logic and the outputs for control of prelubrication, starting, and shutdown of the engine. The logic for starting and stopping is customer programmable. The logic responds to inputs from the following components: engine control switch, emergency stop switch, remote start switch, data link, and other inputs. The output for the prelube relay will not operate if the emergency stop button is activated or if the engine speed is greater than 0 rpm. When the conditions permit operation and the logic determines that lubrication is required, the ECM provides +Battery voltage to the prelube relay. After activation, the prelube pump will operate until one of the following occurrences:
OK When the output to the relay was

disconnected from the ECM P2 connector, the 17-06 Fuel Shutoff Valve short to ground diagnostic code was not generated. However, a short to ground diagnostic code was generated when the P13 connector was disconnected from the terminal box. There is a problem in the terminal box between the P2 connector and the terminal box P13 connector. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reinstall the terminal that was removed from P2-11. Pull on the wire in order to verify proper installation of the terminal. 3. Repair the terminal boxs harness, when possible. Replace the harness, if necessary. STOP.
The prelube pressure switch closes. The programmable Engine Pre-lube Time Out
Period expires.
The emergency stop button is pressed.

The output for the prelube relay can also be operated with a manual switch. When the switch is closed, a +Battery signal is sent to the ECM. The ECM provides +Battery voltage to the prelube relay until the switch is released or until the prelube pressure switch closes. The prelubrication system also operates after shutdown. This ensures that the turbocharger has adequate lubrication during coastdown. When the engine reaches 0 rpm, the output for the prelube relay will operate for three minutes. When +Battery voltage is supplied to the prelube relay, the ECM also provides +Battery voltage to the Prelube Active indicator in the control panel (if equipped). Before you troubleshoot the prelubrication system, make sure that the ECM is programmed properly. The Engine Pre-Lube Time Out Period must be programmed to a value between 30 and 300 seconds. Make sure that the hardware is installed: prelube pump, prelube relay, prelube pressure switch, and manual prelube switch. Make sure that the wiring is installed. Refer to the engines electrical schematic.
Not OK A 17-06 Fuel Shutoff Valve short to
ground diagnostic code was generated when the output to the relay was disconnected from the ECM P2 connector. There seems to be a problem with the ECM. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reinstall the terminal that was removed from P2-11. Pull on the wire in order to verify proper installation of the terminal. 3. Replace the ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.
If Caterpillar did not supply the prelubrication system, the prelubrication function and the E233 (3) event code are disabled. The 338-05, 338-06, and 339-05 diagnostic codes are also disabled. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with the prelube relay. The least likely cause is a problem with the ECM. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 95
g00892158
(1) ECM J2/P2 connectors (2) Terminal boxs J15/P15 connectors for the prelube relay (3) 16 amp circuit breaker (4) 6 amp circuit breaker
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 6 amp circuit breaker OFF. Note: For the following steps, refer to Troubleshooting, Inspecting Electrical Connectors. B. Thoroughly inspect the following connectors and the wiring harnesses for the connectors:
ECM J2/P2 connectors Terminal boxs connectors (J15/P15) Connector for the prelube relay
Illustration 94 Schematic for the prelube relay
g00892150

Repair: Perform the necessary repairs, when possible. Replace parts, if necessary. STOP.

Illustration 96 Harness side of the ECM P2 connector (P2-12) Circuit driver for the prelube relay (P2-22) Return
g00892163
B. Switch the 16 amp circuit breaker for the ECM ON. Switch the 6 amp circuit breaker ON. Turn the engine control switch to the STOP position. C. Wait for 30 seconds and use Cat ET to check for an active 338-05 Prelube Relay open circuit diagnostic code. If there is an active 338-05 Prelube Relay open circuit diagnostic code, proceed to the Results for this Test Step. Otherwise, continue this procedure. Note: The 338-05 Prelube Relay open circuit diagnostic code can only be detected when the ECM output for the prelube relay is OFF. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed. D. Use Cat ET to check the logged diagnostic codes. If there is a 338-06 Prelube Relay short to ground diagnostic code, clear the code. E. Activate the manual prelube switch for at least 30 seconds. Then release the switch.
Illustration 97 (5) Connector P15 for the prelube relay (P15-A) Circuit driver for the prelube relay (P15-B) Return
g00892166
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the prelube relay. c. Check the harness and wiring for abrasion and pinch points from the ECM to the prelube relay. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
Note: The 338-06 Prelube Relay short to ground diagnostic code can only be detected when the ECM output for the prelube relay is ON. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. F. Use Cat ET to look for a logged 338-06 Prelube Relay short to ground diagnostic code again. Expected Result: When the engine control switch was in the STOP position, there was no active 338-05 Prelube Relay open circuit diagnostic code. After the manual prelube switch was operated, there was no logged 338-06 Prelube Relay short to ground diagnostic code.

Results:
Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the engine control switch is in the STOP position. Results:

output for the prelube relay seems to be OK at this time. The initial diagnostic code was probably caused by a poor electrical connection. Repair: If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
when the relay is disconnected and connected. There is no short circuit to the +Battery side. There is an open circuit. Proceed to Test Step 5. vibration when the relay is disconnected and connected. The relay is receiving power when the engine control switch is in the STOP position. There is probably a short circuit to the +Battery side in a connector or a wiring harness. Proceed to Test Step 4.
Not OK (338-05 Prelube Relay open circuit

diagnostic code) A 338-05 Prelube Relay open circuit diagnostic code was activated. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Proceed to Test Step 3.
Not OK (338-06 Prelube Relay short to ground
diagnostic code) After the manual prelube switch was operated, a 338-06 Prelube Relay short to ground diagnostic code was generated. Proceed to Test Step 8.
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak. Note: Open sparks can be generated during this test. A. Make sure that no combustible gas is present in the surrounding atmosphere. B. Ensure that the engine control switch is in the STOP position. C. Disconnect the connector from the prelube relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized.
Illustration 98 (1) Terminal boxs P15 connector for the prelube relay
g00892192
B. Disconnect connector P15 (1) from the terminal box. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Disconnect the connector from the prelube relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the P15 connector is disconnected. Results:
Illustration 99 Harness side of the ECM P2 connector (2) ECM P2 connector (P2-12) Circuit driver for the prelube relay (P2-22) Return
g00892199

when the relay is disconnected and reconnected. The relay is not energized when the P15 connector is disconnected. Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty:
3. Use a 151-6320 Wire Removal Tool to remove terminals (P2-12) and (P2-22) from the P2 connector (2). 4. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
5. Disconnect the connector from the prelube relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. If the relay is energized, there is a problem with a connector and/or wiring in the terminal box. Repair the wiring and/or the connector, when possible. Replace parts, if necessary. If the relay is not energized, there may be a problem with the ECM. Continue with this procedure. 6. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 7. Reinstall terminal 12 and terminal 22 into the P2 connector. Pull on the wires in order to verify proper installation of the terminals. 8. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. 9. Disconnect the connector from the prelube relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. If the relay is not energized, there is an intermittent problem with a connector and/or the wiring. Refer to Troubleshooting, Inspecting Electrical Connectors. If the relay is energized, there may be a problem with the ECM. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP.
vibration when the relay is disconnected and reconnected. The relay is energized when the P15 connector is disconnected. There is a short circuit to the +Battery side in the engine harness. Repair: Repair the connector and/or wiring in the engine harness, when possible. Replace the harness, if necessary. STOP.
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the harness connector from the prelube relay.
Illustration 100 Typical solenoid connector on an engine harness
g00892215
C. Install a jumper wire into the two terminals of the relays connector on the engine harness. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: The 338-05 Prelube Relay open circuit diagnostic code can only be detected when the ECM output for the prelube relay is OFF. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed.
E. Wait for 30 seconds and use the Active Diagnostic screen of Cat ET to look for a 338-05 Prelube Relay open circuit diagnostic code. Expected Result: A 338-05 Prelube Relay open circuit diagnostic code was not generated when the jumper wire was installed. Results:
OK A 338-05 Prelube Relay open circuit
diagnostic code was not generated when the jumper wire was installed. The harness and the ECM are OK. There is a problem with the relay. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the jumper wire from the relays connector on the engine harness. 3. Inspect the relays connectors for damage, moisture, and corrosion.
Illustration 101 (1) Connector J15 for the prelube relay (2) Jumper wire
g00892226
C. Install a jumper wire (2) into the two terminals of the J15 connector (1). D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: The 338-05 Prelube Relay open circuit diagnostic code can only be detected when the ECM output for the prelube relay is OFF. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed. E. Wait for 30 seconds and use Cat ET to check for an active 338-05 Prelube Relay open circuit diagnostic code. Expected Result: There is no active 338-05 Prelube Relay open circuit diagnostic code. Results:
4. Make repairs, as needed. If the problem is not resolved, replace the relay. STOP.
Not OK A 338-05 Prelube Relay open circuit

diagnostic code was generated when the jumper wire was installed. There may be an open circuit in the engine harness. Proceed to Test Step 6.

A. Ensure that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF. B. Disconnect the P15 connector from the terminal box. Inspect the P15 and J15 connectors for damage, moisture, and corrosion. Make repairs, if necessary.
was no active 338-05 Prelube Relay open circuit diagnostic code. There is a problem in the engine harness. Repair: Repair the engine harness, when possible. Replace the harness, if necessary. STOP.

338-05 Prelube Relay open circuit diagnostic code was activated. The ECM did not detect the jumper wire in the J15 connector. There is a problem in the terminal box. Proceed to test Step 7.

Illustration 103 Harness side of the ECM P2 connector (2) Jumper wire (P2-12) Circuit driver for the prelube relay (P2-22) Return
g00892247
D. Install a jumper wire (2) into terminals (P2-12) and (P2-22). Pull on the jumper wire in order to verify proper installation. E. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
Illustration 102 Harness side of the ECM P2 connector (1) ECM P2 connector (P2-12) Circuit driver for the prelube relay (P2-22) Return
g00892236
Note: The 338-05 Prelube Relay open circuit diagnostic code can only be detected when the ECM output for the prelube relay is OFF. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed. F. Wait for 30 seconds and use the Active Diagnostic screen of Cat ET to look for an active 338-05 Prelube Relay open circuit diagnostic code. Expected Result: There is no active 338-05 Prelube Relay open circuit diagnostic code.
Results:

was no active 338-05 Prelube Relay open circuit diagnostic code. The ECM detects the jumper wire at the P2 connector. However, the ECM did not detect the jumper wire at the J15 connector. There is a problem between the ECM P2 connector and the terminal box J15 connector. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 3. Reinstall the terminals into P2-12 and P2-22. Pull on the wires in order to verify proper installation of the terminals. 4. Disconnect the ECM J2/P2 connectors. Inspect the connectors for damage, moisture, and corrosion. 5. Thoroughly inspect the terminal box J15 connector for the engine harness. 6. Use an ohmmeter to measure the resistance between the P2-12 terminal and the J15-A terminal. Also, measure the resistance between the P2-22 terminal and the J15-B terminal. If the resistance measurements are less than 5 ohms, the circuit has good continuity. Otherwise, there is an open circuit. Make repairs, if necessary.
4. Replace the ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.
A. Turn the engine control switch to the OFF/RESET position. B. Disconnect the connector from the prelube relay. C. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 338-06 Prelube Relay short to ground diagnostic code. Note: The 338-06 Prelube Relay short to ground diagnostic code can only be detected when the ECM output for the prelube relay is ON. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. E. Activate the manual prelube switch for at least 30 seconds. Then release the switch. F. Use Cat ET to look for a logged 338-06 Prelube Relay short to ground diagnostic code again. Expected Result: After the manual prelube switch was operated, there was no logged 338-06 Prelube Relay short to ground diagnostic code. Results:
STOP.

338-05 Prelube Relay open circuit diagnostic code was activated. The ECM did not detect the jumper wire. There is a problem with the ECM. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 3. Reinstall the terminals into P2-12 and P2-22. Pull on the wires in order to verify proper installation of the terminals.

Not OK After the manual prelube switch was

operated, a 338-06 Prelube Relay short to ground diagnostic code was logged. Proceed to Test Step 9.
Expected Result: A 338-06 Prelube Relay short to ground was not generated. Results:

OK A 338-06 Prelube Relay short to ground

diagnostic code was not generated when the P15 connector was disconnected. There is a problem in the engine harness. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reconnect the P15 connector. 3. Repair the engine harness, when possible. Replace the harness, if necessary. STOP.
Not OK A 338-06 Prelube Relay short to

ground diagnostic code was generated when the P15 connector was disconnected from the terminal box. There is probably a short circuit to ground in the terminal box. Repair: Reconnect the P15 connector.
Illustration 104 (1) P15 connector for the prelube relay
g00892192
Proceed to Test Step 10.
B. Disconnect connector P15 (1) from the terminal box. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 338-06 Prelube Relay short to ground diagnostic code. Note: The 338-06 Prelube Relay short to ground diagnostic code can only be detected when the ECM output for the prelube relay is ON. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. E. Activate the manual prelube switch for at least 30 seconds. Then release the switch. F. Use Cat ET to look for a logged 338-06 Prelube Relay short to ground diagnostic code again.

Results:

disconnected from the ECM P2 connector, the 338-06 Prelube Relay short to ground diagnostic code was not generated. However, a short to ground diagnostic code was generated when the P15 connector was disconnected from the terminal box. There is a problem in the terminal box between the ECM connector and the terminal box J15 connector. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reinstall the terminal that was removed from P2-12. Pull on the wire in order to verify proper installation of the terminal. 3. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Illustration 105 Harness side of the ECM P2 connector (P2-12) Circuit driver for the prelube relay
g00892315
Not OK A 338-06 Prelube Relay short to
ground diagnostic code was generated when the output to the relay was disconnected from the ECM P2 connector. There seems to be a problem with the ECM. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reinstall the terminal that was removed from P2-12. Pull on the wire in order to verify proper installation of the terminal. 3. Replace the ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.
B. Use the 151-6320 Wire Removal Tool to remove terminal (P2-12). C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 338-06 Prelube Relay short to ground diagnostic code. Note: The 338-06 Prelube Relay short to ground diagnostic code can only be detected when the ECM output for the prelube relay is ON. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. E. Activate the manual prelube switch for at least 30 seconds. Then release the switch. F. Use Cat ET to look for a logged 338-06 Prelube Relay short to ground diagnostic code again. Expected Result: The 338-06 Prelube Relay short to ground diagnostic code was not generated.
i01742945
ECM Output Circuit (Starting Motor)

SMCS Code: 1901-038 System Operation Description: The ECM contains the logic and the outputs for control of prelubrication, starting, and shutdown of the engine. The logic for starting and stopping is customer programmable. The logic responds to inputs from the following components: engine control switch, emergency stop switch, remote start switch, data link, and other inputs. The ECM supplies +Battery voltage to the starter motor relay when the logic determines that it is necessary. The ECM removes the voltage when the crank terminate relay is energized. The voltage is also removed if the customer programmable Overcrank Time has expired. Logged diagnostics provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with the starter motor relay. The least likely cause is a problem with the ECM. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 106 Schematic for the starter motor relays circuit
g00892362
Illustration 107
g00892383
(1) ECM J2/P2 connectors (2) Terminal boxs J14/P14 connectors for the starter motor relays circuit (3) 16 amp circuit breaker (4) 6 amp circuit breaker
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Note: For the following steps, refer to Troubleshooting, Inspecting Electrical Connectors. B. Thoroughly inspect the following connectors and the wiring harnesses for the connectors:
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the starter motor relay. c. Check the harness and wiring for abrasion and pinch points from the ECM to the starter motor relay. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
ECM J2/P2 connectors Terminal box J14/P14 connectors Connector for the starter motor relays circuit


condition and/or at least one connection is improper. Repair: Perform the necessary repairs, when possible. Replace parts, if necessary. STOP.

Illustration 108 Harness side of the ECM P2 connector (P2-10) Terminal for the starter motor relays circuit (P2-20) Return
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B. Switch the 16 amp circuit breaker for the ECM ON. Switch the 6 amp circuit breaker ON. Turn the engine control switch to the STOP position. Note: The 444-05 Start Relay open circuit diagnostic code can only be detected when the ECM output for the starter motor relay is OFF. The output is normally OFF when the engine control switch is in the STOP position or when the crank terminate relay is energized. C. Wait for 30 seconds and use Cat ET to check for an active 444-05 Start Relay open circuit diagnostic code. If there is an active 444-05 Start Relay open circuit diagnostic code, proceed to the Results for this Test Step. Otherwise, continue this procedure. D. Use Cat ET to check the logged diagnostic codes. If there is a 444-06 Start Relay short to ground diagnostic code, clear the code. E. To prevent the engine from starting, shut the gas supply OFF.
Illustration 109 (5) Connector P14 for the starter motor relays circuit (P14-A) Terminal for the starter motor relays circuit (P14-B) Return
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Note: The 338-06 Prelube Relay short to ground diagnostic code can only be detected when the ECM output for the starter motor relay is ON. The output is normally ON when the engine control switch is turned from the STOP position to the START position. The output remains ON until the crank terminate relay is energized. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position. G. Use Cat ET to look for a logged 444-06 Start Relay short to ground diagnostic code again. Expected Result: When the engine control switch was in the STOP position, there was no active 444-05 Start Relay open circuit diagnostic code. After the engine was cranked, there was no logged 444-06 Start Relay short to ground diagnostic code. Results:
Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak. Note: Open sparks can be generated during this test. A. Make sure that no combustible gas is present in the surrounding atmosphere. B. Ensure that the engine control switch is in the STOP position. C. Disconnect the connector from the starter motor relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the starter motor relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the engine control switch is in the STOP position. Results:
output for the starter motor relay seems to be OK at this time. The initial diagnostic code was probably caused by a poor electrical connection.
Repair: If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Not OK (444-05 Start Relay open circuit
diagnostic code) A 444-05 Start Relay open circuit diagnostic code was activated. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Proceed to Test Step 3. diagnostic code) After the engine was cranked, a 444-06 Start Relay short to ground diagnostic code was generated. Proceed to Test Step 8.

when the relay is disconnected and connected. There is no short circuit to the +Battery side. There is an open circuit. Proceed to Test Step 4.
Not OK (444-06 Start Relay short to ground
vibration when the relay is disconnected and connected. The relay is receiving power when the engine control switch is in the STOP position. There is probably a short circuit to the +Battery side in a connector or a wiring harness. Proceed to Test Step 5.
Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay is not energized when the P14 connector is disconnected. Results:
when the relay is disconnected and reconnected. The relay is not energized when the P14 connector is disconnected. Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty:
Illustration 110 (1) Connector P14 for the starter motor relays circuit
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B. Disconnect connector P14 (1) from the terminal box. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Disconnect the connector from the starter motor relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized.
6. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 7. Reinstall terminal 10 and terminal 20 into the P2 connector. Pull on the wires in order to verify proper installation of the terminals. 8. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. 9. Disconnect the connector from the starter motor relay. Then reconnect the connector. Listen for an audible click from the relay. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. If the relay is not energized, there is an intermittent problem with a connector and/or the wiring. Refer to Troubleshooting, Inspecting Electrical Connectors. If the relay is energized, there may be a problem with the ECM. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP. If the ambient noise is too loud, touch the relay when the relay is reconnected in order to feel the vibration. The relay will vibrate when the relay is de-energized and energized. If the relay is energized, there is a problem with a connector and/or wiring in the terminal box. Repair the wiring and/or the connector, when possible. Replace parts, if necessary. If the relay is not energized, there may be a problem with the ECM. Continue with this procedure.
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3. Use a 151-6320 Wire Removal Tool to remove terminals (P2-10) and (P2-20) from the P2 connector (1). 4. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. 5. Disconnect the connector from the starter motor relay. Then reconnect the connector. Listen for an audible click from the relay.

vibration when the relay is disconnected and reconnected. The relay is energized when the P14 connector is disconnected. There is a short circuit to the +Battery side in the engine harness. Repair: Repair the connector and/or wiring in the engine harness, when possible. Replace the engine harness, if necessary. STOP.
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the harness connector from the starter motor relay.
4. Make repairs, as needed. If the problem is not resolved, replace the relay. STOP.
Not OK A 444-05 Start Relay open circuit
diagnostic code was generated when the jumper wire was installed. There may be an open circuit in the engine harness. Proceed to Test Step 6.

A. Ensure that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF. B. Disconnect the P14 connector from the terminal box. Inspect the P14 and J14 connectors for damage, moisture, and corrosion. Make repairs, if necessary.
Illustration 112 Typical relay connector on an engine harness
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C. Install a jumper wire into the two terminals of the relays connector on the engine harness. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. E. Wait for 30 seconds and use the Active Diagnostic screen of Cat ET to look for a 444-05 Start Relay open circuit diagnostic code. Expected Result: A 444-05 Start Relay open circuit diagnostic code was not generated when the jumper wire was installed. Results:
Illustration 113 (1) Connector J14 for the starter motor relays circuit (2) Jumper wire
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OK A 444-05 Start Relay open circuit

diagnostic code was not generated when the jumper wire was installed. The harness and the ECM are OK. There is a problem with the relay. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the jumper wire from the relays connector on the engine harness. 3. Inspect the relays connectors for damage, moisture, and corrosion.
C. Install a jumper wire (2) into the two terminals of the J14 connector (1). D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. E. Wait for 30 seconds and use Cat ET to check for an active 444-05 Start Relay open circuit diagnostic code. Expected Result: There is no active 444-05 Start Relay open circuit diagnostic code.
Results:

was no active 444-05 Start Relay open circuit diagnostic code. There is a problem in the engine harness. Repair: Repair the engine harness, when possible. Replace the harness, if necessary. STOP.
444-05 Start Relay open circuit diagnostic code was activated. The ECM did not detect the jumper wire in the J14 connector. There is a problem in the terminal box. Proceed to test Step 7.

Illustration 115 Harness side of the ECM P2 connector (1) Jumper wire (P2-10) Terminal for the starter motor relays circuit (P2-20) Return
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D. Install a jumper wire (1) into terminals (P2-10) and (P2-20). Pull on the jumper wire in order to verify proper installation. E. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. F. Wait for 30 seconds and use the Active Diagnostic screen of Cat ET to look for an active 444-05 Start Relay open circuit diagnostic code. Expected Result: There is no active 444-05 Start Relay open circuit diagnostic code. Results:
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OK When the jumper wire was installed,
there was no active 444-05 Start Relay open circuit diagnostic code. The ECM detects the jumper wire at the P2 connector. However, the ECM did not detect the jumper wire at the J14 connector. There is a problem between the ECM P2 connector and the terminal box J14 connector.
Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 3. Reinstall the terminals into P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals. 4. Disconnect the ECM J2/P2 connectors. Inspect the connectors for damage, moisture, and corrosion. 5. Thoroughly inspect the terminal box J14 connector for the engine harness. 6. Use an ohmmeter to measure the resistance between the P2-10 terminal and the J14-A terminal. Also, measure the resistance between the P2-20 terminal and the J14-B terminal. If the resistance measurements are less than 5 ohms, the circuit has good continuity. Otherwise, there is an open circuit. Make repairs, if necessary. STOP.
B. Disconnect the connector from the starter motor relay. C. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 444-06 Start Relay short to ground diagnostic code. E. To prevent the engine from starting, shut OFF the main gas supply. Note: The 338-06 Prelube Relay short to ground diagnostic code can only be detected when the ECM output for the starter motor relay is ON. The output is normally ON when the engine control switch is turned from the STOP position to the START position. The output remains ON until the crank terminate relay is energized. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position. G. Use Cat ET to look for a logged 444-06 Start Relay short to ground diagnostic code again. Expected Result: A 444-06 Start Relay short to ground was not generated. Results:
444-05 Start Relay open circuit diagnostic code was activated. The ECM did not detect the jumper wire. There is a problem with the ECM. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 3. Reinstall the terminals into P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals. 4. Replace the ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.

Not OK A short to ground diagnostic code

was generated when the relay was disconnected. Proceed to Test Step 9.

Results:
OK A 444-06 Start Relay short to ground

diagnostic code was not generated when the P14 connector was disconnected. There is a problem in the engine harness. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reconnect the P14 connector. 3. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Not OK A 444-06 Start Relay short to ground

diagnostic code was generated when the P14 connector was disconnected from the terminal box. There is probably a short circuit to ground in the terminal box. Repair: Reconnect the P14 connector.
Illustration 116 (1) Connector P14 for the starter motor relays circuit
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B. Disconnect connector P14 (1) from the terminal box. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 444-06 Start Relay short to ground diagnostic code. E. To prevent the engine from starting, shut OFF the main gas supply. Note: To provide the output for the starter motor relay, the sequence for engine start-up must be initiated. Otherwise, a 444-06 Start Relay short to ground diagnostic code cannot be generated. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position. G. Use Cat ET to look for a logged 444-06 Start Relay short to ground diagnostic code again. Expected Result: A 444-06 Start Relay short to ground was not generated.

Results:

disconnected from the ECM P2 connector, the 444-06 Start Relay short to ground diagnostic code was not generated. However, a short to ground diagnostic code was generated when the P14 connector was disconnected from the terminal box. There is a problem in the terminal box between the ECM connector and the terminal box J14 connector. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reinstall the terminal that was removed into P2-10. Pull on the wire in order to verify proper installation of the terminal. 3. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Illustration 117 Harness side of the ECM P2 connector (P2-10) Terminal for the starter motor relays circuit
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Not OK A 444-06 Start Relay short to ground
diagnostic code was generated when the output to the relay was disconnected from the ECM P2 connector. There seems to be a problem with the ECM. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reinstall the terminal that was removed into P2-10. Pull on the wire in order to verify proper installation of the terminal. 3. Replace the ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.
B. Use the 151-6320 Wire Removal Tool to remove terminal (P2-10). C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Use Cat ET to clear the logged 444-06 Start Relay short to ground diagnostic code. E. To prevent the engine from starting, shut OFF the main gas supply. Note: To provide the output for the starter motor relay, the sequence for engine start-up must be initiated. Otherwise, a 444-06 Start Relay short to ground diagnostic code cannot be generated. F. Turn the engine control switch to the START position for at least 30 seconds. Then turn the engine control switch to the STOP position. G. Use Cat ET to look for a logged 444-06 Start Relay short to ground diagnostic code again. Expected Result: The 444-06 Start Relay short to ground diagnostic code was not generated.
i01740308
ECM Status Indicator Output

SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) has four outputs in order to indicate the status of engine operation: Run Relay, Crank Terminate Relay, Engine Control Alarm Status, and Fault Relay. These outputs can be used to energize indicator lamps or the outputs can be used to interface with other controls. When the output is OFF, the circuit is open. The output provides a maximum current of 0.3 amperes to the ECM. The ECM grounds the current to the negative terminal of the battery in order to activate the appropriate output. If any of the outputs have a short circuit to the +Battery side or excessive current, a diagnostic code is generated. Note: These outputs do not provide enough current for illumination of standard incandescent lights. If a lamp is burned out, replace the lamp with the lamp that is specified in the engines Parts Manual. Run Relay This output indicates that the engine is in the Run status. The engine will start soon or the engine is running. While this output is energized, a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become activated. The ECM cannot diagnose this output while the output is OFF. Crank Terminate Relay This output indicates that the engine rpm is greater than the programmed engine speed that is required for disengagement of the starting motor. While this output is energized, a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become Activated. The ECM cannot diagnose this output while the output is OFF. Engine Control Alarm Status This is the alarm output. This output indicates that the ECM has detected an electrical problem or an abnormal operating condition. While this output is energized, a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become Activated. The ECM cannot diagnose this output while the output is OFF.
Fault Relay This is the shutdown output. This output indicates that a potentially damaging operating condition was detected by the ECM. The ECM has shut down the engine. While this output is energized, a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become Activated. The ECM cannot diagnose this output while the output is OFF. A 323-03 Shutdown Lamp short to +batt or 324-03 Warning Lamp short to +batt diagnostic code can only be generated if a shutdown condition or an alarm condition is active. Failure to correct these serious conditions can result in engine damage. Use the Caterpillar Electronic Technician (ET) to determine the event code or the diagnostic code that corresponds to the 323-03 or 324-03 diagnostic code. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-03 or 324-03 diagnostic code. Refer to Troubleshooting, Troubleshooting with an Event Code or Troubleshooting, Troubleshooting with a Diagnostic Code. The most likely causes of a diagnostic code for a status indicator is a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with an indicator. The least likely cause is a problem with the ECM. Logged diagnostic codes provide an historical record. Before you begin this procedure, use ET to print the logged codes to a file. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 118 Schematic for the status indicators
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A. Turn the engine control switch to the OFF/RESET position. Note: Some indicators may obtain the status of the engine via a data link. If all of the status indicators are not directly controlled by the ECM, do not proceed with this test.
Illustration 119 (1) ECM J2/P2 connectors (2) Connector J19/P19 for the optional control panel (3) 16 amp circuit breaker for the ECM (4) 6 amp circuit breaker (5) Customer connector J9/P9 (if equipped)
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B. Switch circuit breakers (3) and (4) OFF. Thoroughly inspect each of the following connectors:
ECM J2/P2 connectors J19/P19 and J9/P9 connectors on the terminal

box a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 1 Nm (55 9 lb in).
Illustration 122 Harness side of the P19 connector (if equipped) (P19-E) Crank Terminate Relay (P19-F) Fault Relay (P19-G) Engine Control Alarm Status
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Illustration 120 Harness side of the P2 connector (P2-28) (P2-29) (P2-30) (P2-31) Run Relay Crank Terminate Relay Fault Relay Engine Control Alarm Status
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the status indicators. Note: These outputs do not provide enough current for illumination of standard incandescent lights. If a lamp is burned out, replace the lamp with the lamp that is specified in the engines Parts Manual. c. Inspect the wiring and the receptacles for the status indicators. d. Check the harness and wiring for abrasion and pinch points from the customers equipment to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points.
Illustration 121 Harness side of the P9 connector (if equipped) (P9-V) Run Relay (P9-R) Crank Terminate Relay (P9-M) Fault Relay (P9-U) Engine Control Alarm Status
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Results:



A. Connect Cat ET to the service tool connector on the terminal box. Switch the 16 amp circuit breaker for the ECM ON. Switch the 6 amp circuit breaker ON. B. Attempt to start the engine and observe the status indicators. Allow a minimum of 30 seconds for any diagnostic codes to activate. Use the Active Diagnostic screen on Cat ET to look for the codes that are listed in Table 23:
Table 23
Yes (Original 323-03 or 324-03 Diagnostic Code)

The original diagnostic code was 323-03 Shutdown Lamp short to +batt or 324-03 Warning Lamp short to +batt. When the engine was started, the Run Relay indicator and the Crank Terminate Relay indicator (if equipped) illuminated normally. The Engine Control Alarm Status indicator and the Fault Relay indicator did not illuminate. There are no active diagnostic codes.
Diagnostic Codes and Descriptions with Corresponding ECM Outputs Code 323-03 324-03 443-03 Description Shutdown Lamp short to +batt Warning Lamp short to +batt Crank Terminate Relay short to +batt Run Relay short to +batt ECM Output Fault Relay Engine Control Alarm Status Crank Terminate Relay Run Relay
Repair: The 323-03 and 324-03 diagnostic codes can only be activated when the corresponding indicator is activated. There may still be a problem with the output for the alarm indicator or the shutdown indicator. The alarm and/or the shutdown must be activated. Allow the engine operation to continue. Proceed to Test Step 3.
Not OK (Active 323-03 or 324-03 Diagnostic
445-03
Code) There is an active 323-03 Shutdown Lamp short to +batt or 324-03 Warning Lamp short to +batt. There must be a shutdown condition before a 323-03 diagnostic code can be generated. There must be an alarm condition before a 324-03 diagnostic code can be generated. Both of these conditions are serious. Repair: Use Cat ET to determine the event code or the diagnostic code that corresponds to the 323-03 or 324-03 diagnostic code. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-03 or 324-03 diagnostic code. Refer to Troubleshooting, Troubleshooting with an Event Code or Troubleshooting, Troubleshooting with a Diagnostic Code. Exit this procedure. After you have resolved the condition, return to this procedure in order to troubleshoot the 323-03 and/or 324-03 diagnostic code, if necessary. STOP.
Expected Result: There are no active diagnostic codes. The Engine On indicator and the Crank Terminate indicator (if equipped) illuminated normally. The Active Alarm indicator and the Engine Failure indicator did not illuminate. Results:
Yes (Original 443-03 or 445-03 Diagnostic Code)

The original diagnostic code was 443-03 Crank Terminate Relay short to +batt or 445-03 Run Relay short to +batt. When the engine was started, the Run Relay indicator and the Crank Terminate Relay indicator (if equipped) illuminated normally. The Engine Control Alarm Status indicator and the Fault Relay indicator did not illuminate. There are no active diagnostic codes. Repair: The outputs for the status indicators seem to be operating correctly at this time. The original diagnostic code was probably caused by a poor electrical connection. If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Not OK (Active 443-03 or 445-03 Diagnostic

Code) When the engine was started, the Run Relay indicator and/or the Crank Terminate Relay indicator (if equipped) did not illuminate normally. The Engine Control Alarm Status indicator and the Fault Relay indicator did not illuminate. A 443-03 or 445-03 diagnostic code was activated. There is a problem with the output for the Run Relay indicator and/or the Crank Terminate Relay indicator (if equipped). Proceed to Test Step 4.
Test Step 3. Check for Proper Operation of the Status Indicators for the Alarm and Shutdown
Allow the engine operation to continue for this procedure.
Results:
OK The indicators, diagnostic codes, and

shutdown were activated according to the Expected Result. The outputs for the status indicators seem to be operating correctly at this time. The original problem seems to be resolved. Repair: The original diagnostic code was probably caused by a poor electrical connection. If there is an intermittent problem that is causing the codes to be logged, refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Not OK The Engine Control Alarm Status

indicator and/or the Fault Relay indicator did not illuminate normally when the sensors were disconnected. A 323-03 Shutdown Lamp short to +batt and/or a 324-03 Warning Lamp short to +batt diagnostic code was generated. There is a problem with the output for the status indicators. The 542-03 and the 100-03 diagnostic codes were generated. The engine was shut down. Proceed to Test Step 4.
Illustration 123 (1) Unfiltered engine oil pressure sensor (2) Filtered engine oil pressure sensor (3) Connectors for the engine oil pressure sensors (4) Terminal box
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A. During engine operation, disconnect the connector (3) that is appropriate for the unfiltered engine oil pressure sensor. Observe the Engine Control Alarm Status indicator on the control panel (if equipped). If you are only troubleshooting a 324-03 Warning Lamp short to +batt, proceed to the Expected Result. Note: When the filtered engine oil pressure sensor is disconnected, the engine will shut down. B. Disconnect the connector (3) that is appropriate for the filtered engine oil pressure sensor. Observe the Fault Relay indicator on the control panel (if equipped). C. Use the Diagnostics screen on Cat ET to look for active diagnostic codes. Expected Result: The Engine Control Alarm Status indicator illuminated and a 542-03 Unfiltered Engine Oil Pressure open/short to +batt diagnostic code was activated when the unfiltered engine oil pressure sensor is disconnected. The Fault Relay indicator illuminated and a 100-03 Engine Oil Pressure open/short to +batt diagnostic code was activated when the filtered engine oil pressure sensor is disconnected. The engine was shut down.
Test Step 4. Measure the Voltage of the Suspect Indicator at the ECM P2 Connector
G. If the customer has equipment for the status indicators, disconnect the output wire from the suspect indicator. Disconnect the end of the wire that is attached to the indicator. H. Insulate the end of the wire with electrical tape in order to ensure that the wire does not create a short circuit. I. Switch circuit breakers (4) and (5) ON. Turn the engine control switch to the STOP position. J. Note the voltage that is displayed on the voltmeter. Expected Result: Before the suspect indicator was disconnected, voltage was displayed on the voltmeter. After the suspect indicator was disconnected, the voltmeter displayed approximately zero volts. Results:
Yes Before the suspect indicator was
Illustration 124
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disconnected, voltage was displayed on the voltmeter. After the suspect indicator was disconnected, the voltmeter displayed approximately zero volts. There is a problem in the control panel (if equipped) or in the customers equipment. Repair: The problem could be caused by a poor electrical connection, a wire, or a component in the customers equipment. Turn the engine control switch to the OFF/RESET position. Switch circuit breakers (4) and (5) OFF. Thoroughly inspect all of the wiring and the connectors in the customers equipment. Refer to Troubleshooting, Inspecting Electrical Connectors. If you suspect that the indicator has an internal short circuit, temporarily install a known good indicator for the suspect indicator. Test the indicator. Verify that the problem is resolved. Make the necessary repairs, when possible. Replace parts, if necessary. STOP.
Location of the output wires for the status indicators on the harness side of the P2 connector (1) Ground strap (2) ECM J2/P2 connectors (3) Connector J19/P19 for the optional control panel (4) 16 amp circuit breaker (5) 6 amp circuit breaker (6) Customer connector J9/P9 (if equipped) (P2-28) Run Relay (P2-29) Crank Terminate Relay (P2-30) Fault Relay (P2-31) Engine Control Alarm Status
A. Turn the engine control switch to the OFF/RESET position. Switch circuit breakers (4) and (5) OFF. B. Insert a 7X-1710 Multimeter Probe into the suspect control terminal in the ECM P2 connector. C. Connect the positive lead of a voltmeter to the end of the 7X-1710 Multimeter Probe. Connect the voltmeters negative lead to ground strap (1). D. Switch circuit breakers (4) and (5) ON. Turn the engine control switch to the STOP position. E. Note the voltage that is displayed on the voltmeter. F. Turn the engine control switch to the OFF/RESET position. Switch circuit breakers (4) and (5) OFF.
No Before the suspect indicator was
disconnected, voltage was displayed on the voltmeter. After the suspect indicator was disconnected, the voltage was still displayed on the voltmeter. The problem is between the indicator and the ECM. Repair: Do not disconnect the voltmeter. Perform the following procedure:
1. Disconnect customer connector P9 (5) (if equipped) from the terminal box. 2. Switch circuit breakers (4) and (5) ON. Turn the engine control switch to the STOP position. Observe the reading on the voltmeter. Results The voltage is approximately zero. After customer connector (P9) was disconnected, the reading on the voltmeter was approximately zero. There is a problem with a connection and/or the wiring between customer connector P9 and the indicator in the customers equipment. Turn the engine control switch to the OFF/RESET position. Switch circuit breakers (3) and (4) OFF. Repair the connection and/or the wiring, when possible. Replace parts, if necessary. Stop The voltage remained. After customer connector P9 was disconnected, voltage was still displayed on the voltmeter. Proceed to the next Step. 3. Turn the engine control switch to the OFF/RESET position. Switch circuit breakers (4) and (5) OFF. 4. Use a 151-6320 Wire Removal Tool to remove the suspect terminal from the ECM P2 connector. 5. Insulate the output wire with electrical tape in order to ensure that the wire does not create a short circuit. 6. Fabricate a jumper wire with Deutsch terminals on the ends. Insert one end of the jumper wire into the open terminal of the P1 connector. 7. Connect a voltmeter lead to the end of the jumper wire that is not inserted into the connector. 8. Connect the other lead of the voltmeter to the ECM ground strap (1). 9. Switch circuit breakers (4) and (5) ON. Turn the engine control switch to the STOP position. Observe the voltage reading on the voltmeter. Results
The voltage is approximately zero. After the suspect terminal was removed from connector P2 (2), the reading on the voltmeter was approximately zero. There is a problem with a connection and/or the wiring between the customers equipment and the terminal box. Turn the engine control switch to the OFF/RESET position. Switch circuit breakers (4) and (5) OFF. Repair the connection and/or the wiring, when possible. Replace parts, if necessary. Stop The voltage remained. After the suspect terminal was removed from connector P2(2), voltage was still displayed on the voltmeter. There may be a problem with the ECM. It is unlikely that the ECM has failed. Perform this entire procedure again. If the problem is not resolved, perform the following steps: 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.
i01756459
Electrical Power Supply

SMCS Code: 1401-038 System Operation Description: This procedure tests whether proper voltage is supplied to the Electronic Control Module (ECM), the Integrated Temperature sensing Module, and the fuel metering valve. In addition to troubleshooting diagnostic codes, use this procedure if you suspect that the ECM, the Integrated Temperature Sensing Module, or the fuel metering valve are not receiving the proper supply voltage. The cause of an intermittent power supply can occur on either the positive side or the negative side of the power supply. The 24 VDC power supply for the engine can be provided by a battery or by an electrical power supply. The minimum requirement for the power supply is 22 VDC at 16 amperes. The power supply should be routed through a dedicated fuse or through a dedicated circuit breaker.
The ECM input at terminal 70 of the P1 connector (Switched +Battery) receives battery voltage from the engine control switch when the switch is in the START, STOP, or AUTO position. When the ECM detects battery voltage at this input, the ECM will power up. When battery voltage is removed from this input, the ECM will power down after the engine has shut down. The 168-02 diagnostic code indicates that the voltage of the power supply is intermittent or low while the engine is running. If the supply voltage drops to zero and stays at zero, the ECM will not log this code. The engine will shut down. The 336-02 diagnostic code indicates that the ECM has detected a problem with the circuit for the engine control switch. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 125 Schematic for the electrical power source
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Illustration 127 ECM connector P1
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply:
Unswitched +Battery terminals 52, 53, 55,

and 57
Battery terminals 63, 65, 67, and 69 Switched +Battery terminal 70

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Illustration 126 (1) J1/P1 connectors for the ECM (2) J16/P16 connectors for the fuel metering valve (3) J23 connector for the service tool (4) J19/P19 connector for the gauge panel (5) 16 amp circuit breaker (6) 6 amp circuit breaker (7) J15/P5 connectors for the ITSM (8) J9/P9 connector for the customer
c. Check the harness and wiring for abrasion and pinch points from the power supply to the ECM and from the engine control switch to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
B. Disconnect the J1/P1 connectors. Inspect the J1 connector and the P1 connector for damage, corrosion, and moisture. Reconnect the J1/P1 connectors. C. Thoroughly inspect the following connections:

proper connections. Proceed to Test Step 2. condition and/or at least one connection is improper. Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Make sure that the connectors are properly fastened. Verify that the repair has eliminated the problem. STOP.
Electrical connections to each of the circuit

breakers
Connectors for the 24 VDC power supply Connectors for the engine control switch
Test Step 2. Check the Voltage at the Power Supply and at the ECM
A. Make sure that the engine will not crank during this procedure. For an engine with an electric starting motor, make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system. Note: If a power supply is used instead of batteries, the minimum voltage for the power supply is 22 VDC at 16 amperes. Troubleshoot the power supply if the voltage is less than 22 VDC or more than 29 VDC. B. Measure the voltage at the terminals for the power supply. Record the voltage.
E. Measure the power supply voltage at the P1 connector. During the measurement, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. Expected Result: The voltage that is measured at the terminals for the power supply is at least 22 VDC. The voltage that is measured at the P1 connector is within 2 VDC of the voltage that was measured at the terminals for the power supply. The voltage measurements are constant. Results:
OK The ECM is receiving the correct voltage at

the P1 connector. Repair: Perform the following procedure: Switch the 16 amp circuit breaker for the ECM OFF. Remove the probes from connector P1. Proceed to Test Step 3.
Not OK The ECM is not receiving the correct

voltage at the P1 connector. Repair: Perform the following procedure: 1. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the probes from connector P1. 3. Use a voltmeter to check the wiring. Refer to the appropriate schematic for the electrical system. Locate the source of the voltage drop. 4. Make repairs, as needed. STOP.
Illustration 128 Harness side of ECM connector P1
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Test Step 3. Check the Engine Control Switch

A. Make sure that the engine will not crank during this procedure. For an engine with an electric starting motor, make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system. B. Connect Cat ET to the service tool connector.
C. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 52. Insert the second probe into terminal 63. Connect a multimeter to the probes. D. Switch the 16 amp circuit breaker for the ECM ON.
C. Switch the 16 amp circuit breaker for the ECM ON. Note: An E225 Engine Overcrank and/or an E233 Low Engine Prelube Pressure event code may be generated during this step. After you have completed this step, clear the events from the Logged Events screen of Cat ET. D. Observe the Active Diagnostic screen on Cat ET and turn the engine control switch to the STOP position, the START position, and the AUTO position. Look for an active 336-02 Incorrect ECS Switch inputs diagnostic code. Repeat this step several times. Expected Result: A 336-02 Incorrect ECS Switch inputs diagnostic code was not activated when the engine control switch was turned to the STOP position, the START position, and the AUTO position. Results:
OK A 336-02 Incorrect ECS Switch inputs

diagnostic code was not activated. The inputs to the engine control switch are correct. The problem seems to be resolved. Repair: The problem may be intermittent. Refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Illustration 129 Harness side of ECM connector P1
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C. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 31. Insert the second probe into terminal 61. Connect a multimeter to the probes. D. Switch the 16 amp circuit breaker for the ECM ON. Note: An E225 Engine Overcrank and/or an E233 Low Engine Prelube Pressure event code may be generated during the test. After you have completed the test, clear the events from the Logged Events screen of Cat ET. Note: During these measurements, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. E. Turn the engine control switch to the STOP position and measure the voltage between terminal 31 and terminal 61 of the P1 connector. The correct voltage measurement is less than one volt. F. Remove the probe from terminal 61 and insert the probe into terminal 62.
Not OK A 336-02 Incorrect ECS Switch inputs

diagnostic code was activated. The ECM has detected an invalid pattern for the input to the engine control switch. Proceed to Test Step 4.
Test Step 4. Check the Circuit of the Engine Control Switch

A. Make sure that the engine will not crank during this procedure. For an engine with an electric starting motor, make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system. B. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
G. Turn the engine control switch to the START position and measure the voltage between terminal 31 and terminal 62 of the P1 connector. The correct voltage measurement is less than one volt. H. Remove the probe from terminal 62 and insert the probe into terminal 64. I. Turn the engine control switch to the AUTO position and measure the voltage between terminal 31 and terminal 64 of the P1 connector. The correct voltage measurement is less than one volt. J. Remove the probe from terminal 31 and insert the probe into terminal 69. Remove the probe from terminal 64 and insert the probe into terminal 70. K. Turn the engine control switch to the STOP position and measure the voltage between terminal 69 and terminal 70 of the P1 connector. The correct voltage measurement is at least +20 VDC. L. Turn the engine control switch to the START position and measure the voltage between terminal 69 and terminal 70 of the P1 connector. The correct voltage measurement is at least +20 VDC. M. Turn the engine control switch to the AUTO position and measure the voltage between terminal 69 and terminal 70 of the P1 connector. The correct voltage measurement is at least +20 VDC. Expected Result: The voltage checks are within the specifications. Results:
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.
Not OK The P1 connector does not have the

correct voltage. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Disconnect the wires for the STOP, START, and AUTO positions from the engine control switch. 3. Use an ohmmeter to check the contacts for the switch. Turn the switch to each position in order to check the contacts. 4. If the engine control switch is faulty, replace the switch. If the problem is not resolved, repair the harness, when possible. Replace the harness, if necessary. STOP.
OK The voltage checks are within the

specifications. Remove the probes from the P1 connector. Start the engine and run the engine. If the original problem is not resolved, the ECM may have a problem. Repair: It is unlikely that the ECM has failed. Perform the following procedure: Temporarily install a new ECM. Refer to Troubleshooting, Replacing the ECM.
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Engine Speed/Timing Sensor

SMCS Code: 1912-038 System Operation Description:
Illustration 130 Speed/Timing sensor and timing ring
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The speed/timing sensor provides information about engine speed and the position of the crankshaft to the Electronic Control Module (ECM). The sensor is powered by the sensor supply (12 VDC) from the ECM. A magnetic pickup is located in the plastic sliphead of the sensor. The timing ring is mounted on the rear of the left camshaft. As the teeth of the ring rotate past the sliphead of the sensor, the sensor generates a signal that matches the pattern of the teeth. The timing ring has a special tooth pattern that indicates the position of the camshaft and the direction of rotation. The timing ring has 24 slots in the outer diameter. Twenty-one of the slots are narrow. Three of the slots are about 2.5 times wider than the rest of the slots. When the engine rotates in the normal direction, the slots pass the speed/timing sensor in the following order:
The number one cylinder is at the top center position when the rising edge of the third narrow slot passes the center of the sliphead. All 24 teeth pass the sliphead during one revolution of the camshaft or two revolutions of the crankshaft. With the information from the engine speed/timing sensor, the ECM is able to calculate the positions of the pistons in the cylinders. The ECM determines the desired ignition timing according to the engine speed and load. If detonation is detected in any of the cylinders, the ECM retards the timing of the affected cylinders. The ECM sends voltage pulses to the ignition transformers for firing the spark plugs according to the desired timing. During engine operation, the ECM will shut down the engine if the ECM detects a problem with the signal from the speed/timing sensor. The ECM will activate the corresponding diagnostic code. If there is a problem with the engine speed/timing sensors signal during start-up but no corresponding diagnostic code is active, the ECM will not initiate the ignition. The engine will not start. The corresponding diagnostic code is not activated. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with the engine speed/timing sensor. The least likely cause is a problem with the ECM.
1 wide slot 3 narrow slots 2 wide slots 18 narrow slots
Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
Illustration 131 Schematic for the circuit of the speed/timing sensor
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Test Step 1. Inspect the Electrical Connectors and Wiring.

Illustration 132
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(1) ECM connectors J1/P1 (2) J10/P10 connectors for the harness from the speed/timing sensor
B. Thoroughly inspect the ECM J1/P1 connectors, the terminal box J10/P10 connectors, and the connectors for the speed/timing sensor. a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 1 Nm (55 9 lb in).
c. Check the harness and wiring for abrasion and pinch points from the speed/timing sensor to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:

Illustration 133 Harness side of the ECM P1 connector (33) Signal (43) +12 volt supply (51) Return
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Test Step 2. Check the Sensor

Illustration 134 Harness side of the P10 connector (T) +12 volt supply (U) Return (V) Signal
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the speed/timing sensor.
Illustration 136 (1) Speed/timing sensor
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B. Remove the speed/timing sensor (1).
Illustration 137 Speed/timing sensor Illustration 135 Speed/timing sensor (1) Connector for the speed/timing sensor (2) Speed/timing sensor
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(2) Sliphead
C. Inspect the condition of the plastic sliphead (2). Look for signs of wear and contaminants. Clean any debris from the plastic sliphead. D. Check the tension of the plastic sliphead (2). Gently extend the plastic sliphead for a minimum of 4 mm (0.16 inch). Then push back the plastic sliphead. Expected Result: The sensor is in good condition. At least 22 N (5 lb) of force is required to push in the plastic sliphead from the extended position. Results:
Not OK The plastic sliphead is damaged and/or

the tension of the sliphead is insufficient. Repair: Install a new sensor. Calibrate the sensor. Refer to Troubleshooting, Engine Speed/Timing Sensor - Calibrate. If the condition is not resolved, proceed to proceed to Test Step 3.
Test Step 3. Check for Active Diagnostic Codes for the 12 Volt Sensor Supply
A. Connect Cat ET to the service tool connector on the terminal box. B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. C. Use the Active Diagnostic screen on Cat ET. Look for the following codes:
OK The sensor is not damaged. The tension of

the plastic sliphead is correct. Repair: Install the sensor. NOTICE The plastic sliphead must be fully extended when the speed/timing sensor is installed so that the sensor maintains the correct clearance with the timing ring. If the correct clearance is not maintained, the signal from the sensor will not be generated. Do not install the sensors plastic sliphead between the teeth of the timing ring. Damage to the plasic sliphead will result. Before installing the sensor, ensure that a tooth of the ring is visible in the mounting hole for the sensor. 1. Use the following steps to install the speed/timing sensor: a. Ensure that a tooth on the timing ring is visible in the mounting hole for the sensor. b. Fully extend the sliphead. Note: The plastic sliphead is designed to contact the tooth of the timing ring during installation. As the timing ring begins to turn, the radial runout of the timing ring will push the plastic sliphead into the sensor body slightly. This provides the plastic slipheads air gap with a self-adjusting function. The maximum allowable clearance between the sliphead and a tooth on the timing ring is 0.5 mm (0.02 inch). c. Coat the threads of the sensor with 4C-5597 Anti-Seize Compound. d. Install the sensor. Tighten the sensor to 40 5 Nm (30 4 lb ft). Proceed to Test Step 3.
145-03 12 Volt DC Power Supply short to +batt 145-04 12 Volt DC Power Supply short to
ground Expected Result: None of the above codes are active. Results:

active. However, at least one of the codes is logged. Repair: Clear the logged codes. Proceed to Test Step 4.
Active code One of the above codes is active.

Test Step 4. Use Cat ET to Check the Engine RPM

A. Use the Status - Group 1 screen in order to observe Engine Speed. Observe the Engine Speed parameter on the screen and turn the engine control switch to the START position. Crank the engine. B. Continue to observe the screen and allow the engine rpm to stabilize at the normal cranking speed. C. Turn the engine control switch to the STOP position.
Expected Result: Before the engine is cranked, the engine speed is 0. The engine speed increases until the speed stabilizes at the normal cranking speed. When the engine is stopped, the speed decreases back to 0. A 320-03 diagnostic code or a 320-08 diagnostic code is not activated. Results:
Test Step 6. Isolate the Signal Voltage at the Sensor

A. Turn the engine control switch to the OFF/RESET position. B. Ensure that the breakout t is connected in series with the connectors for the speed/timing sensor. C. Remove the wire from terminal C of the breakout t in order to isolate the sensor signal wire from the ECM terminal J1-33. D. Turn the engine control switch to the STOP position. Measure the signal voltage between terminal C and terminal B. E. Turn the engine control switch to the START position. Crank the engine and measure the signal voltage between terminal C and terminal B. Expected Result: When the engine control switch is in the STOP position, the voltage is less than 3.0 VDC or the voltage is greater than 10.0 VDC. The voltage varied between 2.0 VDC and 4.0 VDC during cranking. Results:
OK The engine started and the engine

ran properly. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. The speed/timing sensor is operating properly. STOP.
Not OK The engine cranked. However, Cat

ET did not display the correct engine speed or a 320-03 or a 320-08 diagnostic code was activated. Proceed to Test Step 5.
Not OK The engine cranked but the engine did

not start. Cat ET displayed the correct engine speed. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. The ECM is receiving a valid signal.
Repair: Refer to Troubleshooting, Engine Cranks But Will Not Start. Make repairs, as needed. STOP.
Test Step 5. Measure the Sensor Supply Voltage at the Sensor

A. Turn the engine control switch to the OFF position. B. Install a 8T-8726 Adapter Cable As (3 Pin Breakout) in series with the connectors for the speed/timing sensor. C. Turn the engine control switch to the STOP position. Measure the supply voltage between Terminal A and terminal B of the breakout t. Expected Result: The supply voltage is 12.5 1.0 VDC. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Results:
OK The sensor is producing the correct output

signal. Repair: Remove the breakout t from the connectors for the speed/timing sensor. Reconnect the connectors for the speed/timing sensor. Proceed to Test Step 8.
Not OK The sensor is not producing the correct

output signal. Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Remove the breakout t from the connectors for the speed/timing sensor. Install a new speed/timing sensor. Calibrate the sensor. Refer to Troubleshooting, Engine Speed/Timing Sensor - Calibrate. STOP.
OK The sensor is receiving correct supply

voltage. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Leave the breakout t connected. Proceed to Test Step 6.
Not OK The sensor is not receiving correct
supply voltage or a 145-03 diagnostic code or a 145-04 diagnostic code is active. Remove the breakout t. Proceed to Test Step 7.
Test Step 7. Measure the Sensor Supply Voltage at the ECM

Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Make the necessary repairs to the harness and/or connectors. STOP.
No The ECM is not producing the correct

sensor supply voltage or a 145-03 or a 145-04 diagnostic 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 the condition is not resolved, perform the following steps: 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.
Test Step 8. Measure the Sensor Signal Voltage at the ECM

Illustration 138 Harness side of the ECM P1 connector (33) Signal (43) +12 volt supply (51) Return
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B. Use two 7X-1710 Multimeter Probes. Insert the probes into terminals 43 and 51 of the P1 connector. C. Turn the engine control switch to the STOP position. Measure the supply voltage at the ECM. Expected Result: The voltage is 12.5 1.0 VDC. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Results:
Yes The sensor supply voltage at the ECM is

12.5 1.0 VDC. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. The wiring and/or the connectors between the sensor and the ECM has an open circuit or the circuit has excessive resistance.
Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the condition is not resolved, perform the following steps: 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.
Not OK The signal voltage is not correct. There

is an intermittent problem in the circuit for the speed/timing sensor. Repair: Refer to Troubleshooting, Inspecting Electrical Connectors. Make repairs, as needed. STOP.
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Illustration 139 Harness side of the ECM P1 connector (33) Signal (51) Return
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Fuel Metering Valve

SMCS Code: 1741 S/N: 7EZ1-Up
B. Use a 151-6320 Wire Removal Tool to remove the wire from terminal 33 of the ECM P1 connector. C. Turn the engine control switch to the STOP position. Use two 7X-1710 Multimeter Probes in order to measure the signal voltage between terminal 33 and terminal 51 of the ECM P1 connector. D. Turn the engine control switch to the START position. Crank the engine and measure the signal voltage between terminal 33 and terminal 51 of the ECM P1 connector. Expected Result: When the engine control switch is in the STOP position, the voltage is less than 3.0 VDC or the voltage is greater than 10.0 VDC. The voltage varied between 2.0 VDC and 4.0 VDC during cranking. Results:
S/N: CSC1-Up; CTW1-Up System Operation Description: The fuel metering valve is an electronic gas valve that controls the flow of fuel to the engine. The valve works with the Electronic Control Module (ECM) in order to ensure the correct flow of gas in all conditions of engine operation. The ECM sends a command signal for the flow of fuel and information about the specific gravity of the gas to the fuel metering valve. The valve converts the command signal and the information into a valve position that directly corresponds to the desired gas flow. The position of the valve is compensated by these additional factors that are internal to the valve: a signal for absolute fuel pressure, differential pressure of the valve, and fuel temperature sensors. The following procedure tests whether the command signal for the flow of fuel and the information about the specific gravity of the gas is properly sent to the fuel metering valve by the ECM. The command signal is a 180 hertz PWM signal. Information about the specific gravity of the gas is sent to the fuel metering valve via the CAN Data Link.
OK The signal voltage is correct. However, the

ECM is not reading the signal. There may be a problem with the ECM.
The fuel metering valve sends information to the ECM via the CAN Data Link. This procedure tests whether the following information is properly sent to the ECM by the fuel metering valve: position of the fuel valve, absolute fuel pressure, differential pressure of the valve, and fuel temperature. A diagnostic code is probably caused by a problem with a wiring harness or a connector. The next likely cause is a problem with the fuel metering valve. The least likely cause is a problem with the ECM. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic code after the problem is resolved.
Illustration 140 Schematic for the circuit of the fuel metering valve
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Illustration 143 Harness side of the P16 connector (A) +Battery (B) CAN Data Link + (C) CAN Data Link (D) CAN shield (E) Signal for fuel flow (H) -Battery
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Illustration 141 (1) ECM connectors J1/P1 (2) J16/P16 connectors for the fuel metering valve
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Illustration 144 Harness side of the P24 connector (B) CAN high out (G) Signal in (K) Switched +Battery (L) Battery (N) Can Data Link + (R) Switched +Battery (S) CAN low out (V) CAN Data Link
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the fuel metering valve.
Illustration 142 Harness side of the P1 connector (34) (42) (50) (58) (63) (65) (67) (69) CAN Data Link CAN shield CAN Data Link + PWM out 1 (fuel flow) -Battery -Battery -Battery -Battery
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C. Observe the Active Diagnostic screen on Cat ET. wait at least 30 seconds so that any codes may become activated. Look for these codes:
1446-05 Fuel Metering Module open circuit 1446-09 Unable to communicate with Fuel
Metering Module
1446-12 Fuel Metering Module malfunction 1446-13 Fuel Metering Module calibration
required Expected Result: None of the above codes are active. Results:

Illustration 145 (1) Fuel metering valve
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active. Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
c. Check the harness and wiring for abrasion and pinch points from the fuel metering valve to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
Not OK (Active 1446-05) The ECM has detected

an open circuit or a short circuit for the circuit of the fuel flow signal between the ECM and the fuel metering valve. Proceed to Test Step 3.

an open circuit or a short circuit for the circuit of the CAN Data Link between the ECM and the fuel metering valve. Proceed to Test Step 4.
are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. The components are in good condition with proper connections. Proceed to Test Step 2. sockets are not connected properly. At least one of the connectors and the wiring has corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Not OK (Active 1446-12) The fuel metering

valve has detected an internal malfunction. Repair: Refer to Operation and Calibration Manual, Tecjet Gas Control Valve. STOP.
Not OK At least one of the connectors, pins, or

valve requires calibration. Repair: Refer to Operation and Calibration Manual, Tecjet Gas Control Valve. STOP.

A. Connect Cat ET to the service tool connector on the terminal box. B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
Test Step 3. Check the Signal for the Fuel Flow

Test Step 4. Check the Continuity of the Wiring Harness for the Circuit of the CAN Data Link
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the ECM J1/P1 connectors. Disconnect the fuel metering valve J24/P24 connectors.
Illustration 146 ECM P1 terminals for the signal of the fuel flow (58) PWM out 1 (63) Battery
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B. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 58. Insert the second probe into terminal 63. Use a multimeter that is capable of measuring the frequency and the duty cycle. Connect the multimeter to the probes. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Measure the DC voltage, the duty cycle, and the frequency of the signal for the fuel flow. Expected Result: The DC voltage is between 13.7 and 15.7. The duty cycle is between 92 and 98 percent. The frequency is between 175 and 185 hertz. Results:
Illustration 147
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Connectors for Data Link circuits that are external to the terminal box (1) P19 connector for the gauge panel (2) P5 connector for the integrated temperature sensing module (3) P7 connector (if equipped) (4) P9 Connector for the customer
C. Disconnect the P19, P5, P7, and P9 connectors from the terminal box.
OK The voltage, the duty cycle, and the

frequency of the signal for the fuel flow is correct at the ECM P1 connector. There is a problem with the fuel metering valve. Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.
Not OK The voltage, the duty cycle, and/or the

frequency of the signal for the fuel flow is not correct at the ECM P1 connector. Proceed to Test Step 5.
Repair: Perform the following steps: 1. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. 2. Observe the Active Diagnostic Codes screen of Cat ET as you reconnect the following connectors one at a time: J5/P5, J7/P7, J9/P9, and J19/P19. If a 1446-09 Unable to communicate with Fuel Metering Module diagnostic code is activated, troubleshoot the circuit that is external to the terminal box. If a 1446-09 diagnostic code is not activated, proceed to Test Step 6.
Illustration 148 (P1) Connector for the ECM (P24) Connector for the fuel metering valve (P1-34) Can Data Link (P1-50) Can Data Link + (P24-V) Can Data Link (P24-N) Can Data Link + (P24-S) CAN low out
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Not OK At least one of the following conditions

is found: There is an open circuit between the ECM P1 connector and the connector for the fuel metering valve. There is a short circuit between the ECM P1 connector and a component that is at ground potential. The resistance of the terminals on the P24 connector is incorrect. Repair: Perform the necessary repairs to the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
D. Use a multimeter to check for continuity or resistance between the points that are listed in Table 24.
Table 24
Points to Check for Continuity Connector and Terminal P1-34 P1-50 P1-34 P1-50 Connector and Terminal P24-V P24-N ECM ground strap ECM ground strap Points to Check for Resistance P24-B P24-S
Test Step 5. Check the Continuity of the Circuit for the Fuel Flow
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the ECM J1/P1 connectors. C. Disconnect the fuel metering valve J24/P24 connectors.
Expected Result: The continuity of the circuits between the terminals is good. The continuity between the terminals and the ECM ground strap is open. The resistance between the P24-B terminal and the P24-S terminal is 120 5 ohms. Results:
OK The continuity of the circuit between the

ECM P1 connector and the connector for the fuel metering valve is good. The continuity of the circuit between the ECM P1 connector and the ECM ground strap is open. The resistance of the terminals on the P24 connector is correct.
B. Ensure that the ECM J1/P1 connectors are disconnected.
Illustration 149 (P1) Connector for the ECM (P24) Connector for the fuel metering valve (P1-58) PWM out 1 (fuel flow) (P24-G) Signal in
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D. Use a multimeter to check the continuity of the following circuits:
P1-58 and P24-G P1-58 and the ECM ground strap

Expected Result: The continuity of the circuits between the terminals is good. The continuity between the terminal and the ECM ground strap is open. Results:
Illustration 150
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Connectors for Data Link circuits that are external to the terminal box (1) P19 connector for the gauge panel (2) P5 connector for the integrated temperature sensing module (3) P7 connector (if equipped) (4) P9 connector for the customer
C. Disconnect the P19, P5, P7, and P9 connectors from the terminal box. D. Use a multimeter to check the continuity of the circuits that are listed in Table 25:
Table 25

ECM and the fuel metering valve is good. The continuity of the circuit between the ECM and the ECM ground strap is open. Proceed to Test Step 7.
Points to Check for Continuity Connector and Terminal P1-42 P1-42 P1-42 P1-42 P1-42 P1-58 Connector and Terminal J5-D J7-H J9-a J16-D J19-R ECM ground strap
Not OK One or both of the following conditions

is found: There is an open circuit between the ECM and the fuel metering valve. There is a short circuit between the ECM and a component that is at ground potential. Repair: Repair the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Expected Result: The continuity of the circuits between the terminals is good. The continuity between the terminal and the ECM ground strap is open.
Test Step 6. Check the Wire Shield of the CAN Data Link
Results:
OK The continuity of the circuits of the wire

shield for the CAN Data Link is good. The continuity of the circuit between P1-58 and the ECM ground strap is open. Repair: Perform the following steps: 1. Reconnect the P16 connector. Do not connect the P24 connector to the fuel metering valve. 2. Check the continuity again between the ECM P1-58 terminal and the ECM ground strap. If a short circuit is found between the ECM P1-58 terminal and the ECM ground strap, replace the harness for the fuel metering valve. If the circuit between the ECM P1-58 terminal and the ECM ground strap is still open, proceed to Test Step 8.
Illustration 151 J24 connector on the fuel metering valve (G) Signal in (L) Battery
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B. Measure the resistance between terminal J24-G and terminal J24-L. Expected Result: The resistance between terminal J24-G and terminal J24-L is 12,700 500 ohms. Results:

is found: At least one of the circuits of the wire shield for the CAN Data Link is open. There is a short circuit between the ECM P1-58 terminal and a component that is at ground potential. Repair: Repair the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
OK The resistance between terminal J24-G and

terminal J24-L is 12,700 500 ohms. Proceed to Test Step 8.
Not OK The resistance between terminal J24-G

and terminal J24-L is not 12,700 500 ohms. Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.
Test Step 7. Check the Resistance of the Internal Circuit of the Fuel Metering Valve
A. Ensure the following conditions:
The engine control switch is in the OFF/RESET

position.
Test Step 8. Check the Supply Voltage to the Fuel Metering Valve
The 16 amp circuit breaker in the terminal box

for the ECM is OFF.

position.
The fuel metering valve J24/P24 connectors

are disconnected.
The 16 amp circuit breaker for the ECM is OFF. The fuel metering valve J24/P24 connectors
are disconnected. B. Reconnect the J5/P5, J7/P7, J9/P9, and J19/P19 connectors on the terminal box. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
Note: The 1446-05 Fuel Metering Module open circuit and 1446-09 Unable to communicate with Fuel Metering Module diagnostic codes will be activated.
Repair: Perform the necessary repairs for the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
i01749466
Fuel Metering Valve

SMCS Code: 1741 S/N: CSC1-Up S/N: CFD1-Up
Illustration 152 (K) +Battery (L) Battery (R) +Battery
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S/N: CME1-Up S/N: CEY1-Up System Operation Description: The fuel metering valve is an electronic gas valve that controls the flow of fuel to the engine. The valve works with the ECM in order to ensure the correct flow of gas in all conditions of engine operation. The Electronic Control Module (ECM) sends a command signal for the flow of fuel and information about the specific gravity of the gas to the fuel metering valve. The valve converts the command signal and the information into a valve position that directly corresponds to the desired gas flow. The position of the valve is compensated by these additional factors that are internal to the valve: a signal for absolute fuel pressure, differential pressure of the valve, and fuel temperature sensors. The following procedure tests whether the command signal for the flow of fuel and the information about the specific gravity of the gas is properly sent to the fuel metering valve by the ECM. The command signal is a 180 hertz PWM signal. Information about the specific gravity of the gas is sent to the fuel metering valve via the CAN Data Link. The fuel metering valve sends information to the ECM via the CAN Data Link. This procedure also tests whether the following information is properly sent to the ECM by the fuel metering valve: position of the fuel valve, absolute fuel pressure, differential pressure of the valve, and fuel temperature.
P24 connector on the harness for the fuel metering valve
D. Use a multimeter to measure the voltage between the following terminals of the P24 harness connector for the fuel metering valve:
P24-K and P24-L P24-R and P24-L

Expected Result: The battery voltage between the P24-K and P24-L terminals is 24 2 VDC. The battery voltage between the P24-R and P24-L terminals is 24 2 VDC. Results:
OK The battery voltage is good at the

P24 harness connector for the fuel metering valve. However, the fuel metering valve is not communicating with the ECM. Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.
Not OK The battery voltage to the P24 harness

connector for the fuel metering valve is open or the voltage is shorted to a component that is at ground potential.
Illustration 153 Schematic for the circuit of the fuel metering valve
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ECM J1/P1 connectors J16/P16 connectors for the fuel metering valve
Illustration 155 Harness side of the ECM P1 connector (34) (42) (50) (58) (60) (63) (65) (67) (69) CAN Data Link CAN shield CAN Data Link + PWM out 1 (fuel flow) Return Battery Battery Battery Battery
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Illustration 154 (1) ECM connectors J1/P1 (2) J16/P16 connectors for the fuel metering valve
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Illustration 156 Harness side of the P16 connector (A) Switched +Battery (B) CAN Data Link + (C) CAN Data Link (D) CAN shield (E) Signal for the fuel flow (F) Return (H) Battery
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Illustration 158 (1) Fuel metering valve
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c. Check the wiring for abrasion and pinch points from the fuel metering valve to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:

Illustration 157 Harness side of the P24 connector (C) CAN Data Link + (F) CAN Data Link (L) Battery (M) Switched +battery (P) CAN Resistor + (R) CAN Resistor (S) Signal for the fuel flow (T) Return
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel metering valve.
Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.

A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. C. Use Cat ET to determine if any of the following diagnostic codes are active:
1446-05 Fuel Metering Module open circuit 1446-09 Unable to communicate with Fuel
Metering Module
Repair: Refer to Installation and Operation Manual, Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar. STOP.
1446-12 Fuel Metering Module malfunction 1446-13 Fuel Metering Module calibration
required
Test Step 3. Check the Signal for the Fuel Flow

1447-12 Fuel Metering Sensor Module

malfunction Expected Result: There are no active diagnostic codes. Results:
OK There are no active diagnostic codes. The

signal and the communication between the ECM and the fuel metering valve appear to be OK at this time. However, diagnostic codes may be logged. Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Illustration 159 ECM P1 terminals for the signal of the fuel flow (58) PWM out 1 (60) Battery
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an open circuit or a short circuit for the circuit of the fuel flow signal between the ECM and the fuel metering valve. Proceed to Test Step 3.

an open circuit or a short circuit for the circuit of the CAN Data Link between the ECM and the fuel metering valve. Proceed to Test Step 4.
B. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 58. Insert the second probe into terminal 60. Use a multimeter that is capable of measuring the frequency and the duty cycle. Connect the multimeter to the probes. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Measure the DC voltage, the duty cycle, and the frequency of the signal for the fuel flow. Expected Result: The DC voltage is between 13.7 and 15.7. The duty cycle is between 92 and 98 percent. The frequency is between 175 and 185 hertz.

valve has detected an internal malfunction. Repair: Refer to Installation and Operation Manual, Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar. STOP.

valve requires calibration. Repair: Refer to Installation and Operation Manual, Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar. STOP.
Results:
OK The voltage, the duty cycle, and the Not OK (Active 1447-12) There is a malfunction
of the sensor module in the fuel metering valve. frequency of the signal for the fuel flow is correct at the ECM P1 connector. There is a problem with the fuel metering valve.
Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.
Not OK The voltage, the duty cycle, and/or the

frequency of the signal for the fuel flow is not correct at the ECM P1 connector. Proceed to Test Step 5.
Test Step 4. Check the Continuity of the Wiring Harness for the Circuit of the CAN Data Link
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the ECM J1/P1 connectors. Disconnect the fuel metering valve J24/P24 connectors.
Illustration 161 (P1) Plug for the ECM (P24) Plug for the fuel metering valve (P1-34) Can Data Link (P1-50) Can Data Link + (P24-F) Can Data Link (P24-C) Can Data Link + (P24-P) Jumper wire (P24-R) Jumper wire
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D. Use a multimeter to check for continuity between the points that are listed in Table 26.
Table 26
Points to Check for Continuity Connector and Terminal P1-34 P1-50 P1-34 P1-50 P24-P Connector and Terminal P24-F P24-C ECM ground strap ECM ground strap P24-R
Expected Result:
Illustration 160
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The continuity of the circuits between the terminals is good. The continuity between the terminals and the ECM ground strap is open. The continuity between the P24-P terminal and the P24-R terminal is good. Results:
Connectors for Data Link circuits that are external to the terminal box (1) ECM ground strap (2) P19 connector for the gauge panel (3) P5 connector for the integrated temperature sensing module (4) J7 connector (if equipped) (5) J9 connector for the customer
C. Disconnect the P19, P5, P7, and P9 connectors from the terminal box.
OK The continuity of the circuits is good. The

continuity of the circuit between the plug for the ECM and the ECM ground strap is open. The continuity between the P24-P terminal and the P24-R terminal is good. Repair: Perform the following steps: 1. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
2. Observe the Active Diagnostic Codes screen of Cat ET as you reconnect the following connectors one at a time: J5/P5, J7/P7, J9/P9, and J19/P19. If a 1446-09 Unable to communicate with Fuel Metering Module diagnostic code is activated, troubleshoot the circuit that is external to the terminal box. If a 1446-09 diagnostic code is not activated, proceed to Test Step 6.
Not OK At least one of the following conditions

is found: There is an open circuit between the plug for the ECM and the plug for the fuel metering valve. There is a short circuit between the plug for the ECM and a component that is at ground potential. The continuity between the P24-P terminal and the P24-R terminal is open. Repair: Perform the necessary repairs to the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Illustration 162 (P1) Plug for the ECM (P24) Plug for the fuel metering valve (P1-58) PWM out 1 (fuel flow) (P1-60) Return (P24-S) PWM out 1 (fuel flow) (P24-T) Return
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D. Use a multimeter to check the continuity of the following circuits:
P1-58 and P24-S P1-58 and the ECM ground strap
Test Step 5. Check the Continuity of the Circuit for the Fuel Flow
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the ECM J1/P1 connector. C. Disconnect the fuel metering valve J24/P24 connector.
P1-60 and P24-T

Expected Result: The continuity of the circuits between the terminals is good. The continuity between the terminal and the ECM ground strap is open. Results:

ECM and the fuel metering valve is good. The continuity of the circuit between the ECM and the ECM ground strap is open. Proceed to Test Step 7.

is found: There is an open circuit between the ECM and the fuel metering valve. There is a short circuit between the ECM and a component that is at ground potential. Repair: Repair the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Test Step 6. Check the Wire Shield of the CAN Data Link
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Ensure that the ECM J1/P1 connectors are disconnected.
The continuity between the terminal and the ECM ground strap is open. Results:
OK The continuity of the circuits of the wire

shield for the CAN Data Link is good. The continuity of the circuit between P1-58 and the ECM ground strap is open. Repair: Perform the following steps: 1. Reconnect the J16/P16 connection on the terminal box. Do not connect the J24/P24 connection on the fuel metering valve. 2. Check the continuity again between the ECM P1-58 terminal and the ECM ground strap. If a short circuit is found between the ECM P1-58 terminal and the ECM ground strap, replace the harness for the fuel metering valve. If the circuit between the ECM P1-58 terminal and the ECM ground strap is still open, proceed to Test Step 8.

Illustration 163
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Connectors for Data Link circuits that are external to the terminal box (1) ECM ground strap (2) P19 connector for the gauge panel (3) P5 connector for the integrated temperature sensing module (4) J7 connector (if equipped) (5) J9 connector for the customer
is found: At least one of the circuits of the wire shield for the CAN Data Link is open. There is a short circuit between the ECM P1-58 terminal and a component that is at ground potential. Repair: Repair the wiring and/or connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
C. Disconnect the P19, P5, P7, and P9 connectors from the terminal box. D. Use a multimeter to check the continuity of the circuits that are listed in Table 27:
Table 27
Test Step 7. Check the Resistance of the Internal Circuit of the Fuel Metering Valve
Points to Check for Continuity Connector and Terminal P1-42 P1-42 P1-42 P1-42 P1-42 P1-58 Connector and Terminal J5-D J7-H J9-a J16-D J19-R ECM ground strap

position.
The 16 amp circuit breaker in the terminal box

for the ECM is OFF.
The fuel metering valve J24/P24 connectors

are disconnected.
Expected Result: The continuity of the circuits between the terminals is good.
C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: The 1446-05 Fuel Metering Module open circuit and 1446-09 Unable to communicate with Fuel Metering Module diagnostic codes will be activated.
Illustration 164 J24 connector on the fuel metering valve (J24-S) Signal for the fuel flow (J24-T) Return
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B. Measure the resistance of the circuit between terminal J24-S and terminal J24-T. Expected Result: The resistance of the circuit between terminal J24-S and terminal J24-T is 320,000 5000 ohms. Results:
Illustration 165 P24 plug on the harness for the fuel metering valve (K) Unswitched +Battery (M) Switched +Battery (L) Battery
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OK The resistance of the circuit between
terminal J24-S and terminal J24-T is 320,000 5000 Ohms. Proceed to Test Step 8.
D. Use a multimeter to measure the voltage between the following terminals of the P24 harness connector for the fuel metering valve:
P24-M and P24-L Not OK The resistance of the circuit between

terminal J24-S and terminal J24-T is not 320,000 5000 Ohms. Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.
P24-K and P24-L

Expected Result: The battery voltage between the P24-M and P24-L terminals is 24 2 VDC. The battery voltage between the P24-K and P24-L terminals is 24 2 VDC. Results:
Test Step 8. Check the Supply Voltage to the Fuel Metering Valve
OK The battery voltage is good at the P24

plug for the fuel metering valve. However, the fuel metering valve is not communicating with the ECM. Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.

position.
The 16 amp circuit breaker for the ECM is OFF. The fuel metering valve J24/P24 connectors
are disconnected. B. Reconnect the J5/P5, J7/P7, J9/P9, and J19/P19 connectors on the terminal box.
Not OK The battery voltage to the P24 plug for

the fuel metering valve is open or the voltage is shorted to a component that is at ground potential.
Repair: Perform the necessary repairs for the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
i01745958
Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with an ignition transformer. The least likely cause is a problem with the ECM.
Ignition Transformers Primary Circuit

SMCS Code: 1561-038 System Operation Description: The Electronic Control Module (ECM) has internal circuit drivers for the transformers. The circuit drivers send a signal of +108 volts through terminals that are in pairs. The signal goes to the high side of the primary circuits of the ignition transformers. The transformers deliver high voltage (8000 to 37,000 volts) to the spark plugs. The pairs of cylinders that are opposite by 360 degrees in the firing order reach Top Center simultaneously. These pairs of cylinders share the same high side circuit driver inside the ECM. This means that a short circuit to the high side on any cylinder will also affect the cylinder that is opposite by 360 degrees. If any cylinders high side has an open circuit, only that cylinder is affected. Each following pair of cylinders are supplied by one of the eight high side circuit drivers: 1-15, 2-16, 3-13, 4-14, 5-11, 6-12, 7-9, and 8-10. Note: The ECM has internal returns for the transformers circuits. Externally, these returns consist of individual terminals for each primary circuit. Internally, these returns are grouped into four groups of four circuits. Each of the circuits are connected via 16 diodes. Because of the diodes, a return short circuit to the Battery side will affect only one cylinder. On the other hand, a return short circuit to the +Battery side can simultaneously affect all four return circuits in a single group. Each following group of cylinders are coupled by an internal diode to one low side circuit driver: 1-3-5-9, 2-4-6-10, 7-11-13-15, and 8-12-14-16. Because the circuits are in pairs or groups, multiple diagnostic codes can be activated for a single problem. If multiple diagnostic codes are active for the primary ignition, troubleshooting the circuits one at a time is an effective way to find the root cause.
Illustration 166
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Schematic for the ignition system

Illustration 168 Harness side of the ECM P2 connector (P2-1) Number 1 transformers circuit driver (P2-2) Number 1 transformers return (P2-3) Number 2 transformers circuit driver (P2-4) Number 2 transformers return (P2-24) Number 3 transformers circuit driver (P2-25) Number 3 transformers return (P2-26) Number 4 transformers circuit driver (P2-27) Number 4 transformers return (P2-14) Number 5 transformers circuit driver (P2-15) Number 5 transformers return (P2-16) Number 6 transformers circuit driver (P2-17) Number 6 transformers return (P2-5) Number 7 transformers circuit driver (P2-18) Number 7 transformers return (P2-52) Number 8 transformers circuit driver (P2-62) Number 8 transformers return (P2-32) Number 9 transformers circuit driver (P2-33) Number 9 transformers return (P2-34) Number 10 transformers circuit driver (P2-35) Number 10 transformers return (P2-48) Number 11 transformers circuit driver (P2-49) Number 11 transformers return (P2-50) Number 12 transformers circuit driver (P2-51) Number 12 transformers return (P2-58) Number 13 transformers circuit driver (P2-59) Number 13 transformers return (P2-60) Number 14 transformers circuit driver (P2-61) Number 14 transformers return (P2-40) Number 15 transformers circuit driver (P2-41) Number 15 transformers return (P2-42) Number 16 transformers circuit driver (P2-43) Number 16 transformers return
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Illustration 167 ECM connectors J2/P2
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B. Thoroughly inspect the ECM J2/P2 connectors. a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 1 Nm (55 9 lb in).
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit of the ignition system.
301-06 Cylinder 1 Transformer Primary short

through 316-06 Cylinder 16 Transformer Primary short
Note: If a diagnostic code for the primary circuit is logged but not currently active, attempt to repeat the condition that generated the code. Run the engine to full operating temperature. Expected Result: None of the above diagnostic codes are active. Results:
Illustration 169 Bulkhead connector on the front housing
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Active open circuit There is an open in the

primary circuit. Proceed to Test Step 5.
C. Inspect the bulkhead connector for the ignition harness. D. Check the ignition harness and wiring for abrasion and pinch points from the bulkhead connector to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
Active short There is a short in the primary

circuit. Proceed to Test Step 3.
Logged only There may be an intermittent

problem in the ignition harness. Repair: Perform the following steps:
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.

proper connections. Proceed to Test Step 2. condition and/or at least one connection is improper.
Test Step 2. Check for Diagnostic Codes for the Primary Circuit
A. Connect Cat ET to the service tool connector on the terminal box. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. B. Attempt to start the engine and use Cat ET. Determine if the following codes are active or logged:
301-05 Cylinder 1 Transformer Primary open

circuit through 316-05 Cylinder 16 Transformer Primary open circuit
Illustration 170 (1) (2) (3) (4) (5) Valve cover Transformer 2-pin connector Camshaft cover Ignition harness
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Illustration 171 (1) Valve cover (2) Transformer (3) 2-pin connector
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2. Remove valve cover (1) for the suspect cylinder. Inspect the harness and the 2-pin connector (3) of transformer (2). 3. Remove camshaft cover (4) and inspect ignition harness (5) for abrasion, exposed wires, and damage. 4. Inspect the engine harness. Refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
B. Remove the valve cover (1) of the suspect cylinder. C. Disconnect the 2-pin connector (3). Visually inspect the 2-pin connector for corrosion and/or damage. D. Remove the transformer (2) from the cylinder head.
Test Step 3. Check the Transformers Primary Circuit and the Secondary Circuit
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
a. Set the multimeter to the diode scale. Connect the multimeter leads to the terminals (13,14) of the 2-pin connector. The polarity of the leads is not important. Measure the voltage between the terminals. Record the measurement. b. Reverse the multimeter leads. Measure the voltage between the terminals again. Record the measurement. F. Measure the resistance of the secondary circuit. Note: The resistance of the secondary coil will vary with the temperature. Illustration 174 demonstrates the relationship between the secondary coils resistance and the temperature. A reading that is within 1000 ohms is acceptable. For example, if the transformers temperature is 60 C (140 F), the correct resistance is between 21,000 and 23,000 ohms.
Illustration 172 (4) 2-pin connector for the transformer (5) + Terminal (6) - Terminal (7) Flyback diode (8) Blocking diode (9) Primary coil of the transformer (10) Secondary coil of the transformer (11) Plug resistor (12) Spark plug gap
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Schematic for the primary circuit and the secondary circuit
E. Measure the primary circuit by checking the voltage of the blocking diode.
Illustration 174 Resistance versus temperature (Y) Resistance in ohms (X) Temperature in degrees celsius (degrees fahrenheit)
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a. Set the multimeter to the 40,000 ohm scale. Measure the resistance between the screw for the ground spring (15) and the connector for the spark plug (16). Expected Result: For the primary circuit, one of the voltage measurements is approximately 0.450 VDC. The other voltage measurement is infinite. For the secondary circuit, the resistance between the screw for the ground spring and the connector for the spark plug is within the acceptable tolerance.
Illustration 173 (13) + Terminal (14) - Terminal (15) Screw for the ground spring (16) Connector for the spark plug
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Results:
OK All three of the measurements are correct.

Repair: Perform the following steps:
1. Install the spark plug according to the instructions in Operation and Maintenance Manual, Ignition System Spark Plugs Check/Adjust/Replace. 2. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Install the transformers. Install the valve covers. 3. Reset the control system. Restart the engine. Clear any logged codes. 4. Operate the engine. Check for a recurrence of the problem. If the problem stays with the suspect transformer, replace the transformer. If the problem stays with the suspect cylinder, proceed to Test Step 4.
Note: Additional diagnostic codes will be generated during this test. Disregard the additional codes. Pay attention to the original short code. Expected Result: The original short code is active when the bulkhead connector is disconnected. Results:
Yes The original short code was generated

after the bulkhead connector was disconnected. The short circuit is probably located in the harness between the bulkhead connector and the ECM P2 connector. Repair: Locate the short circuit. Refer to Troubleshooting, Inspecting Electrical Connectors. Make repairs, as needed. If the condition is not corrected, proceed to Test Step 5.
Not OK At least one of the three measurements

is incorrect. Repair: Replace the ignition transformer. Make sure that you use the correct transformer for the G3500B Engine. STOP.
No The original short code was not generated
after the bulkhead connector was disconnected. The short circuit is in the ignition harness that is inside of the engine block. Proceed to Test Step 8.
Test Step 4. Check for a Short Circuit Between the P2 Connector and the Bulkhead Connector
Test Step 5. Create an Open Circuit in the Ignition Harness
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE 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. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. A. Shut OFF the fuel supply. Turn the engine control switch to the OFF position. Disconnect the ignition harness from the bulkhead connector. B. Turn the engine control switch to the START position and observe the Active Diagnostic screen of Cat ET while you crank the engine.
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. NOTICE 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. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. A. Shut OFF the fuel supply. Turn the engine control switch to the OFF/RESET position.
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE 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. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the jumper wire from the 2-pin connector of the ignition harness. Thoroughly inspect the connectors for the transformer. Refer to Troubleshooting, Inspecting Electrical Connectors. 3. Connect the ignition harness to the transformer. 4. Turn the engine control switch to the START position and observe the Active Diagnostic screen of Cat ET while you crank the engine. Look for the original open circuit code. 5. If the original open circuit code is generated, turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 6. Replace the transformer. Make sure that you use the correct transformer for the G3500B Engine. 7. Clear all of the logged diagnostic codes. STOP.
Illustration 175 (1) Valve cover (2) 2-pin connector for the ignition harness
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B. Remove valve cover (1) for the suspect cylinder. C. Disconnect the 2-pin connector (2). Inspect the connectors of the harness and the transformer for damage and/or corrosion. Inspect the harness. D. Install a jumper wire into the terminals of the 2-pin connector on the ignition harness. E. Turn the engine control switch to the START position and observe the Active Diagnostic screen of Cat ET while you crank the engine. Look for the original open circuit code. Expected Result: The original open circuit code is active. Results:
Yes The original open circuit code was

generated after a short circuit was created in the ignition harness. The ECM did not detect the jumper wire. Proceed to Test Step 6.
No Cat ET displayed an active short
diagnostic code after a short circuit was created in the ignition harness. The harness and the ECM are OK. Repair: Perform the following steps:
Test Step 6. Check the Engine Harness for an Open Circuit
Table 28
Cylinders and Corresponding Terminals of the Bulkhead Connector for the Ignition Harness Cylinder Terminals for the Circuit Driver A V C X E c G e J h N k L n S r Return Terminals B W D Z F d H f R j P m M p K s
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE 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. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. A. Shut OFF the fuel supply. Turn the engine control switch to the OFF/RESET position. B. Disconnect the bulkhead connector.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
D. Turn the engine control switch to the START position and observe the Active Diagnostic screen of Cat ET while you crank the engine. Look for the original open circuit diagnostic code. Expected Result: The original open circuit diagnostic code is not active. However, a short diagnostic code is generated for the suspect cylinder. Results:
Yes When the jumper wire was installed into

Illustration 176
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Terminals on the bulkhead connector of the ignition harness
C. Install the ends of the jumper wire into the terminals of the connector on the external engine harness side of the bulkhead connector for the suspect cylinder. The cylinders and the terminals are identified in Table 28 and Illustration 176.
the harness, the original open circuit diagnostic code was not active. However, a short diagnostic code was generated for the suspect cylinder. The external engine harness and the ECM are OK. The internal ignition harness in the engine block has an open circuit. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the camshaft covers from the bank of the engine with the suspect cylinder.
3. Inspect the internal ignition harness for abrasion, exposed wires, or other damage. Be sure to inspect the harness inside the front of the engine. Repair the harness, when possible. Replace the harness, if necessary. STOP.
No When the jumper wire was installed into

the external engine harness, the original open circuit diagnostic code was generated. The ECM did not detect the jumper wire. The open circuit is probably in the external engine harness. Repair: Refer to Troubleshooting, Inspecting Electrical Connectors. Make repairs, as needed. If the condition is not corrected, proceed to Test Step 7.
Illustration 177
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Note: For identification of the terminals, refer to Illustration 177 and Table 29. a. If you are troubleshooting a short diagnostic code, remove the wire from the terminal for the circuit driver of the suspect cylinder. b. If you are troubleshooting an open circuit diagnostic code, remove the wires from the terminal for the circuit driver AND from the return of the suspect cylinder. Then install the ends of the jumper wire into the terminals for the removed wires.
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE 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. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the ECM J2/P2 connectors. Thoroughly inspect the connectors for corrosion, moisture, and other damage. Make repairs, if necessary. C. Use a 151-6320 Wire Removal Tool to remove wiring from the ECM P2 connector. The removal of the wiring depends on the original diagnostic code.
Table 29
Cylinders and Corresponding Terminals of the ECM P2 Connector for the Ignition Harness Cylinder Terminals for the Circuit Driver 1 3 24 26 14 16 5 52 32 34 48 50 58 60 40 42 Return Terminals 2 4 25 27 15 17 18 62 33 35 49 51 59 61 41 43
Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Repair the harness, when possible. Replace the harness, if necessary. STOP.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
No A diagnostic code was NOT generated

according to the Expected Result. There is a problem with the ECM. Repair: Replace the ECM. Follow the instructions in Troubleshooting, Replacing the ECM. STOP.
Test Step 8. Check the Ignition Transformer for a Short Circuit
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. NOTICE 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. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Remove the valve cover for the suspect cylinder. C. Inspect the ignition harness for abrasion, exposed wires, or other damage. D. Disconnect the ignition harness from the transformer. Thoroughly inspect the 2-pin connector on the transformer. E. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
D. Reconnect all of the connectors. If any valve covers were removed, install the valve covers. E. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. F. Turn the engine control to the START position and observe the Active Diagnostic screen of Cat ET while you crank the engine. Expected Result: An open circuit diagnostic code is generated for the circuit after removal of the wire for the circuit driver. A short diagnostic code is generated for the circuit with the installed jumper wire. Results:
Yes A diagnostic code was generated
according to the Expected Result. The ECM is operating correctly. There is a problem with the ignition harness.
F. Do not reconnect the transformer. Turn the engine control switch to the START position and observe the Active Diagnostic screen of Cat ET while you crank the engine. Expected Result: An open circuit diagnostic code is generated for the circuit with the disconnected transformer. Results:
5. If the short circuit code is generated again, turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Replace the transformer. Make sure that you use the correct transformer for the G3500B Engine. 6. Clear all of the logged diagnostic codes. STOP.
Yes An open circuit diagnostic code was
No An open circuit diagnostic code was not

generated for the circuit with the disconnected transformer. The short circuit is in the internal ignition harness. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the camshaft covers from the bank of the engine with the suspect cylinder. 3. Inspect the internal ignition harness for abrasion, exposed wires, or other damage. Repair the harness, when possible. Replace the harness, if necessary. STOP.
i01755380
generated for the circuit with the disconnected transformer. Repair: Perform the following steps:
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. NOTICE 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. The unburned fuel can ignite unexpectedly and cause damage. Turn OFF the gas supply before you perform this step. 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Thoroughly inspect the 2-pin connectors for the internal ignition harness and the transformer. Refer to Troubleshooting, Inspecting Electrical Connectors. 3. Reconnect the internal ignition harness to the transformer. 4. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the START position and observe the Active Diagnostic screen of Cat ET while you crank the engine.
Ignition Transformers Secondary Circuit and Spark Plugs

SMCS Code: 1561-038 System Operation Description: The ignition transformers initiate combustion by providing high voltage to the spark plugs. The positive output from the secondary circuit of the transformer is at the connection for the terminal of the transformer and the terminal of the spark plug. The transformers are located underneath the valve covers. Each transformer is grounded to a valve cover via a ground spring.
Note: Ignition transformers from Electronic Ignition Systems (EIS) are not interchangeable with the transformers in this engine. Caterpillar spark plugs are high voltage devices with internal resistors. The spark plugs operate at a voltage that is greater than 5,000 volts. Most ignition systems are not affected by resistance in the secondary circuit. If a measurement of the resistance is desired, a megohmmeter must be used. A low voltage multimeter will not provide a reliable reading of the resistance because oxidation of the spark plugs internal components will affect the readings of those meters.
Test Step 1. Check the Status Screen of Cat ET for the Output of the Secondary Circuits of the Transformers
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Connect Cat ET to the service tool connector on the terminal box. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Set up two Status screens for Cat ET. Use eight of the following labels for parameters on each Status screen:
Illustration 178 Ignition transformer and spark plug (1) Ground spring (2) 2-pin connector (3) secondary spark plug terminal (4) Extension (5) O-ring seal (6) Hole in the spark plugs precombustion chamber
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The secondary circuit of the transformer provides an initial 8,000 to 37,000 volts to the spark plug. This voltage ionizes the spark plug gap. This voltage is then reduced to about 1000 volts. The total duration of the spark is approximately 400 microseconds. The Electronic Control Module (ECM) can diagnose the primary circuit of the ignition transformers for open circuits and/or for short circuits. Secondary open circuits and short circuits will not directly shut down the engine. However, these conditions may lead to misfire which can cause lugging of the engine. Lugging of the engine can cause a shutdown. Logged diagnostic codes provide an historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file.
Table 30
Not OK At least one of the outputs displayed

Screen 1 Group 8 Screen 2 Group 9 Cylinder #2 Transformer Secondary Output Voltage Percentage Cylinder #4 Transformer Secondary Output Voltage Percentage Cylinder #6 Transformer Secondary Output Voltage Percentage Cylinder #8 Transformer Secondary Output Voltage Percentage Cylinder #10 Transformer Secondary Output Voltage Percentage Cylinder #12 Transformer Secondary Output Voltage Percentage Cylinder #14 Transformer Secondary Output Voltage Percentage Cylinder #16 Transformer Secondary Output Voltage Percentage
Parameters for the Status Screens on Cat ET
a value of 0 percent or a value that is greater than 90 percent. The ignition system components require maintenance. Proceed to Test Step 2.
Cylinder #1 Transformer Secondary Output Voltage Percentage Cylinder #3 Transformer Secondary Output Voltage Percentage Cylinder #5 Transformer Secondary Output Voltage Percentage Cylinder #7 Transformer Secondary Output Voltage Percentage Cylinder #9 Transformer Secondary Output Voltage Percentage Cylinder #11 Transformer Secondary Output Voltage Percentage Cylinder #13 Transformer Secondary Output Voltage Percentage Cylinder #15 Transformer Secondary Output Voltage Percentage
Test Step 2. Inspect the Transformer
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
E. Start the engine. Apply the normal load at rated speed. Allow the engine to warm up to normal operating temperature. F. Observe the value of the output for the secondary circuit of each transformer. Expected Result: The displayed value of the output for the secondary circuit of each transformer is between 1 and 90 percent. Results:
Illustration 179 (1) Valve cover (2) 2-pin connector
g00893893
OK The displayed value of the output for

the secondary circuit of each transformer is between 1 and 90 percent. The ignition system components are operating properly. Repair: Investigate other possible root causes of the problem. Troubleshoot the symptom. Refer to Troubleshooting, Troubleshooting Without A Diagnostic Code. STOP.
B. Remove the valve cover of the suspect cylinder. NOTICE Pulling on the wiring harness may break the wires. Do not pull on the wiring harness. C. Disconnect the ignition harness from the ignition transformer. Remove the transformer from the engine.
I. Clean any deposits from the inside of the extension. Use a 6V-7093 Brush with isopropyl alcohol. Expected Result: The transformer is in good condition. Results:
OK The transformer appears to be in good

condition. Proceed to Test Step 3.
Not OK An inspection found a problem with the

transformer. Repair: Repair the transformer, when possible. Replace the transformer, if necessary. Be sure to use the correct transformer for the G3500B Engine. Reset the control system. Restart the engine. Clear the logged codes. STOP.
Illustration 180 (1) (2) (3) (4) (5) (6) Screw Ground spring Spacer secondary terminal for the spark plug Extension O-ring seal
g00715304
Test Step 3. Check the Primary Circuit and the Secondary Circuit
D. Inspect the body of the transformer and the ground spring for corrosion and/or damage. Verify that the screws for the ground spring are secure. E. Inspect the secondary terminal for the spark plug (4) inside the extension for corrosion and/or damage. F. Inspect the O-ring seal inside the extension for damage. G. Check for a secure connection between the transformer and the spark plug. Note: Punch through is caused by misfire in the engine that does not generate a diagnostic code. H. Check the extension near the spacer for signs of punch through (pin holes) and/or arcing. NOTICE The extension can be scratched and damaged with a wire brush. Do not use a wire brush on the extension.
Illustration 181 (1) (2) (3) (4) (5) (6) (7) (8) (9) 2-pin connector for the transformer + Terminal - Terminal Flyback diode Blocking diode Primary coil of the transformer Secondary coil of the transformer Plug resistor Spark plug gap
g00898121
Schematic for the primary circuit and the secondary circuit
A. Measure the primary circuit by checking the voltage of the blocking diode.
Illustration 183 Resistance versus temperature (Y) Resistance in ohms (X) Temperature in degrees celsius (degrees fahrenheit)
g00863850
Illustration 182 (10) + Terminal (11) - Terminal (12) Screw for the ground spring (13) Secondary terminal for the spark plug
g00898124
a. Set the multimeter to the 40,000 ohm scale. Measure the resistance between the screw for the ground spring (12) and the connector for the spark plug (13). Expected Result: For the primary circuit, one of the voltage measurements is approximately 0.450 VDC. The other voltage measurement is infinite. For the secondary circuit, the resistance between the screw for the ground spring and the connector for the spark plug is within the acceptable tolerance. Results:
a. Set the multimeter to the diode scale. Connect the multimeter leads to the terminals (10,11) of the 2-pin connector. The polarity of the leads is not important. Measure the voltage between the terminals. Record the measurement. b. Reverse the multimeter leads. Measure the voltage between the terminals again. Record the measurement. B. Measure the resistance of the secondary circuit. Note: The resistance of the secondary coil will vary with the temperature. Illustration 183 demonstrates the relationship between the secondary coils resistance and the temperature. A reading that is within 1000 ohms is acceptable. For example, if the transformers temperature is 60 C (140 F), the correct resistance is between 21,000 and 23,000 ohms.
OK All three of the measurements are correct.

Not OK At least one of the measurements is

incorrect. Repair: Make sure that the engine control switch to the OFF/RESET position and the 16 amp circuit breaker for the ECM is OFF. Replace the ignition transformer. Make sure that you use the correct transformer for the G3500B Engine. STOP.
Test Step 4. Check the Spark Plug

A. Switch the 16 amp circuit breaker for the ECM OFF.
D. Start the engine and operate the engine in order to generate the diagnostic code again. Expected Result: A diagnostic code is not generated. Results:
Illustration 184 Spark plug that has a precombustion chamber
g00837850
OK A diagnostic code is not generated.

Proceed with normal operation. STOP. Proceed to Test Step 6.
B. Perform the following procedures according to the instructions in the engines Operation and Maintenance Manual. a. Remove the spark plug from the cylinder head. b. Inspect the spark plug. c. Clean the spark plug. Note: For a spark plug with a precombustion chamber, the resistance cannot be measured. The minimum service life of a spark plug with a precombustion chamber is approximately 3000 service hours. The spark plug may be good for a considerable period beyond 3000 service hours. Experience at the particular site will help to determine the proper interval for replacement of the spark plug. Expected Result: The spark plug is in good condition. Results:
Not OK A diagnostic code is generated. Test Step 6. Isolate the Spark Plug and the Transformer
A. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Install the transformers. Install the valve covers. B. Reset the control system. Clear any logged diagnostic codes. C. Start the engine and operate the engine in order to generate the diagnostic code again. Expected Result: The diagnostic code is generated for the suspect transformer. Results:
Yes The diagnostic code is generated for the

suspect transformer. Repair: Make sure that the engine control switch to the OFF/RESET position and the 16 amp circuit breaker for the ECM is OFF. Replace the faulty transformer. Make sure that you use the correct transformer for the G3500B Engine. Reset the control system. Clear any logged diagnostic codes. STOP.
OK The spark plug is in good condition.

Not OK The spark plug is not in good condition.

Repair: Discard the spark plug. Install a new spark plug according to the instructions in the engines Operation and Maintenance Manual. Reset the control system. Restart the engine. Clear the logged codes. STOP.
No The diagnostic code is generated for the

original cylinder. Repair: Make sure that the engine control switch to the OFF/RESET position and the 16 amp circuit breaker for the ECM is OFF. Install a new spark plug according to the instructions in Operation and Maintenance Manual, Ignition System Spark Plugs - Check/Adjust/Replace. Reset the control system. Clear any logged diagnostic codes. STOP.
Test Step 5. Operate the Engine

A. Install the spark plug according to the instructions in the engines Operation and Maintenance Manual. B. Install the transformer and the valve cover. C. Reset the control system. Clear any logged diagnostic codes.
i01746137
Inspecting Electrical Connectors

SMCS Code: 1901-038 System Operation Description: Many of the troubleshooting procedures direct you to a specific electrical connector. Use the following test steps to help determine whether the connector is the cause of the problem. If a problem is found in a connector, repair the connector and verify that the problem is corrected. Intermittent electrical problems are often caused by poor connections. Always check for an active diagnostic code before you open any connection. Immediately after you reconnect the connector, check for codes again. Sometimes, simply disconnecting a connector and then reconnecting the connector can solve a problem. If this occurs, the following conditions are likely causes:
Illustration 186
g00700064
Loose terminals Bent terminals Improperly crimped terminals Improperly mated connectors Moisture Corrosion
Deutsch connectors have a plastic housing. The pins and the sockets are crimped onto the electrical wires. The connector has a locking mechanism in order to hold the pins and the sockets. These connectors are repairable without cutting the wires.
Illustration 185
g00700045
The MS Connectors have a metal housing. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected by a chemical potting which prevents access to the solder point.
Illustration 187
g00700442
Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem.
Expected Result: All connectors are properly mated and free of damage. Results:
Test Step 1. Check the Connectors.

A. Always turn the engine control switch to the OFF/RESET position before you inspect electrical conductors. Switch the 16 amp circuit breaker for the ECM OFF. B. For the MS connectors, make sure that the receptacle is turned fully in the clockwise direction. Check that the threading is properly aligned and securely mated. C. For the Deutsch HD connectors, make sure that the plug and the receptacle are aligned properly with the index markings. Make sure that the receptacle is turned fully in the clockwise direction. Verify that the receptacle is clicked into the locked position. Make sure that the two halves cannot be pulled apart. D. For the Deutsch DT style, make sure that the orange wedge is used in order to lock the pins. Check that the receptacle has clicked into the locked position. Make sure that the two halves cannot be pulled apart.
OK Proceed to test step 2. Not OK

Repair: Repair the connectors and/or replace the connectors. Reconnect all of the connectors. STOP.
Test Step 2. Check the Allen Head Screw on the ECM Connector.
A. Ensure that the allen head screw is properly tightened. Be careful not to overtighten the screw and break the screw. B. When you connect the 70-pin connector to the Electronic Control Module (ECM), do not exceed 6 1 Nm (55 9 lb in) of torque on the screw. Expected Result: The ECM connector is secure and the allen head screw is properly torqued.
Results:
A. If there is an active diagnostic code that pertains to the circuit, perform the following steps: a. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. b. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. c. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Then start the engine. Run the engine under normal operating conditions. d. Monitor the Active Diagnostic Code screen on Cat ET while you pull on all harnesses and connectors for the circuit with the active code. If the harness is being pulled and the active diagnostic code disappears, there is a problem in the wiring or the connector. B. If there are no active diagnostic codes that pertain to the circuit, perform the following test: a. Run the engine under normal operating conditions. b. Monitor the Display Status screen on Cat ET while you pull on all harnesses and connectors for the circuit. If the harness is being pulled and the reading changes erratically, there is a problem in the wiring or the connector. C. If there are no active diagnostic codes and there are complaints about intermittent changes in speed or power cutouts, perform the following test: a. Run the engine under normal operating conditions. b. Listen for speed burps or power cutouts while the wiring and/or the connectors are pulled. If the harness is being pulled and the engine has a speed burp or a power cutout, there could be a problem in the wiring or the connector. Expected Result:
OK Proceed to Test Step 3. Not OK

Repair: Repair the connector or replace the connector, as required. Verify that the repair eliminates the problem. STOP.
Test Step 3. Perform a Pull Test on Each Wire Connection.

A. Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector. B. The DT connectors use an orange wedge to lock the terminals in place. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors. Note: Terminals should ALWAYS be crimped onto the wires by using a Crimp Tool. Do not solder terminals. Use the 1U-5804 Crimp Tool. Expected Result: Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body. Results:

Repair: Repair the circuit. Verify that the repair eliminates the problem. STOP.
Test Step 4. Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled.
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch wires that are associated with the ignition transformer circuit when the engine is cranking or running.
The problem appears to be external to the harnesses and connectors. Pulling on the harness and the connectors has no effect on the active diagnostic code, component status, or engine performance.
Results:
Test Step 6. Check the Connectors for Moisture or Corrosion.

Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Repair the circuit. Verify that the repair eliminates the problem. STOP.
Test Step 5. Check Wires for Nicks or Abrasion in the Insulation.

A. Turn the engine control switch to the STOP position. Allow the engine to coast to a stop. B. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. C. Carefully inspect each wire for signs of abrasion, nicks, or cuts. The following areas are likely locations:
Illustration 188
g00690571
Places with exposed insulation Points with wiring that rubs against the engine Places with wiring that rubs against a sharp
point D. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also, check all of the hold down clamps in order to verify that the harness is not compressed by the clamps. Pull back the harness sleeves in order to check for flattening of the wires by the clamps. Expected Result: The wires are free of abrasion, nicks, or cuts and the harness is properly clamped. Results:
A. Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector.

Repair: Repair the wires or replace the wires, as required. Verify that the repair eliminates the problem. STOP.
Illustration 189
g00690568
B. Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. This will deform the connector seal and this will create a path for the entrance of moisture. Thoroughly inspect ECM J1/P1 and J2/P2 connectors for evidence of moisture entry.
Note: It is normal to see some minor seal abrasion on the ECM connector seals. Minor seal abrasion will not allow the entry of moisture. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the repair is not made, the problem will recur. Simply drying the connector will not fix the problem. The following list includes likely paths for the entrance of moisture:
Verify that the repair eliminates the problem by running the engine for several minutes and by checking again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, it may be necessary to replace the wires that have moisture. These wires may have moisture that is trapped inside the insulation. Verify that the repair eliminates the problem. STOP.
Missing seals or plugs Improperly installed seals or plugs Nicks in exposed insulation Improperly mated connectors
Moisture can also wick from one connector through the inside of a wire to the ECM connector. If moisture is found in the ECM connector, thoroughly check all connectors and wires on the harness that connects to the ECM. The ECM is not the source of the moisture. Do not replace an ECM if moisture is found in either ECM connector. Note: If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. Do not use any cleaners that contain 1,1,1 trichloro-ethylene because 1,1,1 trichloro-ethylene may damage the connector. Expected Result:
Test Step 7. Inspect the Connector Terminals.

Verify that the terminals are not damaged. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector. Expected Result: The terminals are properly aligned and the terminals appear undamaged. Results:

Repair: Repair the terminals and/or replace the terminals, as required. Verify that the repair eliminates the problem. STOP.
All of the connectors are completely coupled and all of the seals are completely inserted. The harness and the wiring is free of corrosion, abrasion, and pinch points. Results:

Repair: Repair the circuit. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.
Test Step 8. Check the Individual Retention of the Pins and Sockets.
i01754840
Integrated Temperature Sensing Module (ITSM)

SMCS Code: 1901-038 System Operation Description: The Integrated Temperature Sensing Module (ITSM) monitors K type thermocouples at each cylinder exhaust port and at the inlets and outlets for both turbochargers. The ITSM can also calculate the average temperature for each cylinder bank (left and right). Temperature readings of the thermocouples are available over the CAT Data Link for use by the Electronic Control Module (ECM) and other modules. The temperatures can be viewed on the Caterpillar Electronic Technician (ET). The ITSM generates event codes for each of the following programmable conditions:
Illustration 190
g00690572
High exhaust temperature High deviation of an exhaust port temperature Low deviation of an exhaust port temperature
Note: This is especially important for intermittent problems. A. One at a time, insert a new pin into each socket. Make sure that the pin is properly gripped by the socket. B. One at a time, insert a new socket onto each pin. Make sure that the pin is properly gripped by the socket. Verify that the socket holds the pin when the connector hangs freely. Expected Result: Each socket firmly grips each pin. Results:
High inlet temperature to the turbocharger turbine High outlet temperature from the turbocharger
turbine A diagnostic code is generated by the ITSM for the circuit of any thermocouple that is shorted to the +Battery side, shorted to ground, or open. Logged diagnostic codes provide an historical record. Before you begin this procedure, use Cat ET to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved. Note: The 141-1957 Electronic Control (ITSM) will not function properly with a personality module date code that is dated after March 1998. Do not FLASH any software with a personality module date code that is dated after March 1998 into the 141-1957 Electronic Control.
OK The pins and sockets mate properly. STOP. Not OK The pins and sockets do not mate
properly. Repair: Repair any bad pins and sockets. Replace the connectors, if necessary. Replace the wiring, if necessary. Verify that the repair eliminates the problem. STOP.
Illustration 191 Schematic for the circuit of the ITSM
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The ECM is connected to the ITSM via the J1/P1 connectors and the terminal box J5/P5 connectors. The J1/P1 and J5/P5 connectors are not shown. For the actual wiring, refer to the schematic for the engine electrical system.

Illustration 194
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ECM J1/P1 connectors J5/P5, J7 (if equipped), and J9/P9 (if

equipped) connectors on the terminal box
Illustration 192 G3516 Engine cylinders (A) Inlet valve (B) Exhaust valve (C) Flywheel
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Illustration 195 Harness side of the ECM P1 connector (8) CAT data link + (9) CAT data link
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Illustration 193 Terminal box (1) ECM connectors J1/P1 (2) J5/P5 connectors for the ITSM (3) J7 connector (if equipped) (4) J9/P9 connector for the customer (if equipped)
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the ITSM.
Illustration 196 Harness and thermocouples
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Illustration 197 Harness and connectors for the thermocouples (P40) Connector for the harness to the ITSM (1 through 16) Cylinders (17) Outlet for the right turbine (18) Outlet for the left turbine (19) Right turbine inlet (20) Left turbine inlet
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Illustration 198 Connectors for the ITSM
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(1) J18/P18 connectors for the harness to the terminal box (2) J40/P40 connectors for the harness to the thermocouples
Illustration 199 Connectors for the harness from the ITSM to the terminal box (1) P5 connector to the terminal box (2) P18 connector to the ITSM
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c. Thoroughly inspect the J18/P18 connectors and the J40/P40 connectors. Carefully inspect the connectors for each of the thermocouples. Check the harnesses and wiring for abrasion and pinch points from each component to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:


Illustration 200 Terminal box (1) ECM connectors J1/P1 (2) J5/P5 connectors for the ITSM (3) J7 connector for the Versatile Control Module (if equipped) (4) J9/P9 connector for the customer (if equipped)
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Repair: Perform the necessary repairs and/or replace parts, if necessary. Note that all of the wiring for the thermocouples must be K type. STOP.
Test Step 2. Use Cat ET to Check the Communications from the ITSM
B. Disconnect the terminal box J7/P7 and J9/P9 connectors (if equipped). C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Select the ITSM under the File/Select ECM menu of Cat ET. Access the ITSM Configuration Parameter screen. Observe the display. Expected Result: V16,2 Turbos is displayed in the Value column of the ITSM Application Type.
Results:
Test Step 3. Check the Continuity of the CAT Data Link

A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the ECM J1/P1 connectors. C. Disconnect the ITSM J18/P18 connectors.
OK V16,2 Turbos is displayed in the Value

column of the ITSM Application Type. The ITSM seems to be communicating properly. Repair: Before you continue, perform the following procedure in order to make sure that the CAT Data Link is OK: 1. Reconnect the terminal box J7/P7 connectors (if equipped). Check Cat ET for an active 1042-09 Unable to communicate with ITSM diagnostic code. 2. Reconnect the terminal box J9/P9 connectors (if equipped). Check Cat ET again for an active 1042-09 diagnostic code. If either connection activates the 1042-09 diagnostic code, troubleshoot the circuits of the CAT Data Link that are external to the terminal box. The terminals are listed in Table 31.
Table 31
D. Use a multimeter to check for continuity of the circuits that are listed in Table 32:
Table 32
Check for Continuity Connector and Terminal P1-8 Connector and Terminal P18-J J23-D P18-J P1-9 J23-D P18-N J23-E P18-N J23-D J23-E J23-E Engine block
J7/P7 and J9/P9 Connections for the CAT Data Link Terminal P7-E P9-c P7-M P9-g Function CAT Data Link + CAT Data Link
Expected Result: The continuity of the circuits between the terminals is good. The continuity of the circuits between the terminals and the engine block are open. Results:
If no 1042-09 diagnostic code is generated, proceed to Test Step 3.
Not OK V16,2 Turbos is not displayed in the

Value column of the ITSM Application Type. The ITSM is not communicating normally. Repair: Perform the following Steps: 1. Access the Service/Configuration screen of Cat ET. Select Change in the lower left corner of the Configuration screen. 2. Select V16,2 Turbos for a New Value. If the ITSM cannot be selected, ensure that the flash programming of the ITSM has been performed. This is normally only needed for a replacement ITSM. For instructions on flash programming of the ITSM, refer to Troubleshooting, Replacing the ITSM. If the original problem is not resolved, proceed to Test Step 3.
OK The continuity of the circuits between the

terminals is good. The continuity of the circuits between the terminals and the engine block are open. Repair: If the original problem is not resolved, verify that voltage is supplied to the ITSM P18-A and P18-B terminal. Refer to the schematic of the engine electrical system and Troubleshooting, Electrical Power Supply. If the voltage supply is good but the ITSM does not communicate, replace the ITSM. Follow the instructions in Troubleshooting, Replacing the ITSM. STOP.

are found: The continuity of any circuit between the ECM P1 connector, the service tool J23 connector, and the ITSM P18 connector is open. There is a short circuit to the engine block.
Test Step 5. Create an Open Circuit

A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the connector for the thermocouple with the short circuit diagnostic code. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Access the Active Diagnostic screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Expected Result:
Repair: Repair the wiring and/or the connectors. If necessary, replace the wiring and/or connectors. Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged. Verify that the repair has eliminated the original problem. STOP.
Test Step 4. Verify the Active Diagnostic Codes

A. Access the Active Diagnostic screen for the ITSM on Cat ET. Determine if any of the following diagnostic codes for the thermocouples are active:
There is an active open circuit diagnostic code for the disconnected thermocouple. Results:
1489-03 through 1492-03 (short to +batt) 1489-04 through 1492-04 (short to ground) 1489-05 through 1492-05 (open circuit) 1531-03 through 1546-03 (short to +batt) 1531-04 through 1546-04 (short to ground) 1531-05 through 1546-05 (open circuit)
Expected Result: None of the above diagnostic codes for the thermocouples are active. Results:
Yes There is an active open circuit diagnostic

code for the disconnected thermocouple. The ITSM and the harness are OK. Repair: Perform the following procedure: 1. Thoroughly inspect the thermocouples connectors. Ensure that the connectors and the seals are in good condition. 2. Reconnect the thermocouples connectors and check for an active short circuit diagnostic code. If the short circuit diagnostic code becomes active again, there is a problem with the thermocouple. 3. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. Do not install the thermocouple into the engine yet. 4. Check for an active short circuit diagnostic code. If the diagnostic code is not generated with the good thermocouple, remove the suspect thermocouple from the engine. Install the good thermocouple. 5. Clear the logged diagnostic codes. STOP.
No Active Codes None of the above diagnostic

codes for the thermocouples are active. Repair: If any of the codes are logged, there may be an intermittent condition that is causing the codes to be generated. If the engine is not running properly, refer to Troubleshooting, Troubleshooting Without a Diagnostic Code. STOP.
Active short to ground or short to +batt At

least one short to ground or short to +batt diagnostic code is active. Proceed to Test Step 5.
Active open circuit At least one open circuit

diagnostic code is active. Proceed to Test Step 6.
No There is not an active open circuit
diagnostic code for the disconnected thermocouple. There is a short circuit between the harness for the thermocouple and the ITSM. Proceed to Test Step 7.
If the open circuit diagnostic code becomes active again, there is a problem with the thermocouple. 3. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. Do not install the good thermocouple into the engine yet. 4. Check for an active open circuit diagnostic code. If the diagnostic code is not generated with the good thermocouple, remove the suspect thermocouple from the engine. Install the good thermocouple. 5. Clear the logged diagnostic codes. STOP.
Test Step 6. Create a Short Circuit

A. Fabricate a jumper wire that is approximately 100 to 150 mm (4 to 6 inches) long with Deutsch terminals on both ends. B. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. C. Disconnect the connector for the thermocouple with the open circuit diagnostic code. D. Install the jumper wire into terminal A and terminal B on the harness connector from the ITSM. E. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. F. Access the Active Diagnostic screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Observe the Active Diagnostic screen. G. Remove the jumper wire and observe the Active Diagnostic screen. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Expected Result: When the jumper wire was installed, a short circuit diagnostic code was generated. When the jumper wire was removed, the open circuit diagnostic code recurred. Results:
No When the jumper wire was installed, the
open circuit diagnostic code recurred. There is probably an open circuit in the harness between the ITSM and the connector for the thermocouple. Repair: Remove the jumper wire. Proceed to Test Step 7.
Test Step 7. Check the ITSM

A. Fabricate a jumper wire that is approximately 100 to 150 mm (4 to 6 inches) long with Deutsch terminals on both ends. B. Turn the engine control switch to the OFF/RESET position. Switch the circuit breaker for the ECM OFF. C. Disconnect the P40 plug from the ITSM. Thoroughly inspect the J40/P40 connectors. Ensure that the connectors are in good condition. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Note: When the J40/P40 connectors are disconnected, an active open circuit diagnostic code will be generated for all of the thermocouples that are associated with the ITSM. This is normal. Only pay attention to the diagnostic codes for the suspect thermocouple. E. Access the Active Diagnostic screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Observe the Active Diagnostic screen.
Yes When the jumper wire was installed, a

short circuit diagnostic code was generated. When the jumper wire was removed, the open circuit diagnostic code recurred. The ITSM and the harness are OK. Repair: Perform the following procedure: 1. Thoroughly inspect the thermocouples connectors. Ensure that the connectors and the seals are in good condition. 2. Reconnect the thermocouples connectors and check for an active open circuit diagnostic code.
F. Turn the engine control switch to the OFF/RESET position. Switch the circuit breaker for the ECM OFF. G. Install the jumper wire into the terminals for the suspect sensor on the J40 connector. For identification of the terminals, refer to Illustration 191. H. Switch the circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Observe the Active Diagnostic screen. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Expected Result: When the J40/P40 connectors were disconnected, an open circuit diagnostic code was generated for the suspect sensor. When the jumper wire was installed, a short circuit diagnostic code was generated. Results:
4. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. Observe the Active Diagnostic screen. Allow a minimum of 30 seconds for any diagnostic codes to be generated. 5. Verify that no diagnostic codes are generated with the good ITSM. 6. Turn the engine control switch to the OFF/RESET position. Switch the circuit breaker for the ECM OFF. 7. Reconnect the original ITSM to the P18 plug from the terminal box. Reconnect the P40 plug to the original ITSM. 8. Verify that the diagnostic code recurs with the original ITSM. 9. Replace the ITSM. See Troubleshooting, Replacing the ITSM. STOP.
i01747684
Yes When the J40/P40 connectors were

disconnected, an open circuit diagnostic code was generated for the suspect sensor. When the jumper wire was installed, a short circuit diagnostic code was generated. The ITSM is OK. There is a problem in the harness between the ITSM and the connector for the suspect thermocouple. Repair: Remove the jumper wire. Repair the harness, when possible. Replace the harness, if necessary. Clear the logged diagnostic codes and verify that the problem is resolved. STOP.
Oxygen Sensor Buffer Supply

SMCS Code: 1901-038 System Operation Description: The oxygen buffer uses an oxygen sensor in order to measure the concentration of oxygen in the engine exhaust. The oxygen buffer receives power from terminal 13 of the J2/P2 connector on the ECM. The return circuit is through terminal 23 of the J2/P2 connector. The buffer provides a power supply of 1.5 amperes and 10.5 volts between the positive VH and negative VH terminals in order to power a resistive type of heater in the oxygen sensor. After this heater raises the temperature of the sensing element to 700 C (1292 F), the buffer regulates the current from the positive IP terminal to the negative IP terminal. This keeps the voltage between the positive VS terminal and negative VS terminal relatively constant. The amount of current is a measure of the concentration of oxygen in the exhaust gases. The current will vary from 0 mA at 0 percent of oxygen to approximately 8.7 mA at 21 percent of oxygen. The oxygen buffer measures this current. The buffer converts the current to a Pulse Width Modulated signal (PWM) with a nominal frequency of 500 Hz. This signal is supplied to terminal 67 of the ECM J2/P2 connector.
No Either of the following results or both of the

results occurred: When the J40/P40 connectors were disconnected, an open circuit diagnostic code was not generated for the suspect sensor. When the jumper wire was installed, a short circuit diagnostic code was not generated. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Remove the jumper wire. Disconnect the P18 connector from the ITSM. 3. Connect an ITSM that is known to be good to the P18 plug from the terminal box. Connect the P40 plug to the good ITSM. Make sure that the good ITSM has the correct flash programming. See Troubleshooting, Replacing the ITSM.
The duty cycle of the PWM signal has a range of 30 to 65 percent. The 30 percent corresponds to 0 percent of oxygen and the 65 percent corresponds to 21 percent of oxygen. These values vary slightly between different buffers and sensors. Calibration is required for every new buffer. Calibration of the buffer is also required after every 1500 service hours. Some applications may require more frequent calibration or less frequent calibration. The oxygen buffer is equipped with a diagnostic circuit that detects the current which is provided to the heating element of the oxygen sensor. If this current is too low, the buffer assumes that the oxygen sensor has failed or the sensor is disconnected from the oxygen buffer. This will cause the PWM signal from the oxygen buffer to change to a duty cycle of approximately 15 percent. The ECM interprets this condition as a diagnostic condition. The ECM will generate a diagnostic code that can be viewed with the Caterpillar Electronic Technician (ET). The sensor provides a wet reading that is slightly lower than a dry reading. The wet reading is multiplied by a conversion factor of approximately 1.25 in order to obtain the reading that is displayed on Cat ET. This allows oxygen readings from Cat ET to be compared to dry readings from an emissions analyzer. The ECM uses the signal of the percent of oxygen for two functions:
Make corrections for variation of fuel BTU. Maintain desired emissions levels.
If an incorrect signal is detected by the ECM, a diagnostic code is activated and compensation for fuel quality is disabled. Problems with the circuit for the oxygen signal must be repaired as soon as possible because of the effects on engine performance and emissions.
Illustration 201 Schematic of the circuit for the oxygen buffer and the oxygen sensor
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During operation, the oxygen sensor may reach temperatures that exceed 700 C (1292 F). Severe personal injury and property damage will result from contact with a hot oxygen sensor. Do not touch the sensor during engine operation, calibration, or testing. Allow the sensor to cool before moving the sensor. Wear gloves that resist heat. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
Illustration 202
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(1) ECM connectors J2/P2 (2) J10/P10 connectors for the harness from the oxygen buffer
B. Thoroughly inspect the following connections:

Illustration 203 Harness side of the ECM P2 connector (13) +24 Volt supply for the buffer (23) Return (53) Shield (67) Oxygen signal (PWM)
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Illustration 205
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(1) Oxygen sensor (2) Connectors for the oxygen sensor (3) Oxygen buffer (4) J651/P651 connectors for the harness from the terminal box (5) J652/P652 connectors for the harness to the oxygen sensor
c. Check the harness and wiring for abrasion and pinch points from the oxygen sensor to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
Illustration 204 Harness side of the P10 connector (K) +24 Volt supply for the buffer (H) Shield (L) Return (M) Oxygen signal (PWM)
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the oxygen buffer.

condition and/or at least one connection is improper. Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Make sure that the connections are properly fastened. Verify that the repair has eliminated the problem. STOP.
Test Step 2. Check for Diagnostic Codes for the Oxygen Buffer
A. Connect Cat ET to the service tool connector on the terminal box. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. B. Access the Logged Diagnostic Codes screen on Cat ET. If the following codes are logged, clear the codes:
Test Step 3. Check the Supply Voltage for the Oxygen Buffer
1088-05 Oxygen Sensor Power Supply open

circuit
1088-06 Oxygen Sensor Power Supply short

to ground C. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. D. Select Oxygen Sensor Override under the Description column. E. Select Change in the lower left corner of the screen. A popup window with the title Change Parameter Value will appear. F. Select a New Value of On and then select OK. Allow a minimum of ten seconds for the diagnostic codes to be activated. The oxygen buffer is now ON. The Value of the Oxygen Sensor Override should change to On. Note: After you exit the Override Parameters screen, the Value of the Oxygen Sensor Override is automatically changed to OFF when the engine control switch is not in the START position. G. Access the Logged Diagnostic Codes screen again. Look for the 1088-05 or 1088-06 diagnostic codes again. Expected Result: A 1088-05 or 1088-06 diagnostic code is logged. Results:
Illustration 206 (1) P651 connector
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B. Disconnect the P651 connector from the oxygen buffer. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. E. Select Change in the lower left corner of the screen. F. Select a New Value of On and then select OK. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the Oxygen Sensor Override is automatically changed to OFF when the engine control switch is not in the START position.
Logged 1088-05 diagnostic code The supply for

the buffer has an open circuit or a short circuit to the +Battery side. Proceed to Test Step 3. the buffer has a short circuit to ground. Proceed to Test Step 5.
Logged 1088-06 diagnostic code The supply for
No codes The supply for the buffer is OK. STOP.
Test Step 4. Check the Voltage at the Terminal Box
Illustration 207 P651 harness connector for the oxygen buffer (A) +24 Volt supply (B) Return
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G. Measure the voltage between terminal A and terminal B of the P651 connector on the harness. Expected Result: The supply voltage for the oxygen buffer is greater than 18 VDC. Results:
Illustration 208
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OK The supply voltage for the oxygen buffer is greater than 18 VDC. The buffer is receiving the correct supply voltage.
Repair: Reconnect the connectors. Determine whether the diagnostic code recurs. If the problem is not resolved, turn the engine control switch to the OFF/RESET position and switch the 16 amp circuit breaker for the ECM OFF. Replace the oxygen buffer. After you replace the buffer, calibrate the oxygen sensor. Follow the instructions in Troubleshooting, Oxygen Sensor Calibrate. STOP.
(1) P10 connector for the harness from the oxygen buffer
A. Disconnect the P10 connector from the terminal box.
Not OK The supply voltage is less than 18 VDC.

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B. Measure the voltage between terminals K and L on the J10 connector. Expected Result: The voltage is greater than 18 VDC.
Results:
OK The voltage is greater than 18 VDC. There

is a problem with the harness between the terminal box and the oxygen buffer. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the oxygen sensor is automatically changed to OFF when the engine control switch is not in the START position. H. Access the Logged Diagnostic Codes screen again. Look for the 1088-06 diagnostic code. Expected Result: There is a logged 1088-06 diagnostic code. Results:
Not OK The voltage is less than 18 VDC.

Test Step 5. Disconnect the Oxygen Buffer and Check for a Short to Ground
Yes The supply for the buffer still has a short

circuit. Proceed to Test Step 7.
No The supply for the buffer does not have a
short circuit when the buffer is disconnected. The harness to the buffer is OK. Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Inspect the buffer J651 connector for corrosion and/or damage. Make repairs, as needed. If the condition is not resolved, replace the buffer. Be sure to calibrate the oxygen sensor after you replace the buffer. Refer to Troubleshooting, Oxygen Sensor - Calibrate.
STOP.
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Test Step 6. Create a Short Circuit in the Harness

B. Disconnect the P651 connector from the oxygen buffer. C. Turn the engine control switch to the STOP position. D. Access the Logged Diagnostic Codes screen on Cat ET. If a 1088-06 diagnostic code is logged, clear the code. E. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. F. Select Change in the lower left corner of the screen. G. Select a New Value of On and then select OK. Wait for a minimum of 65 seconds.
The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the oxygen sensor is automatically changed to OFF when the engine control switch is not in the START position. I. Access the Logged Diagnostic Codes screen again. Look for the 1088-05 diagnostic code. Expected Result: The 1088-05 diagnostic code is not logged when the circuit for the supply to the buffer is shorted by the jumper wire. Results:
OK The 1088-05 diagnostic code is not logged

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when the circuit for the supply to the buffer is shorted by the jumper wire. The harness and the ECM are OK. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Inspect the J651 connector on the oxygen buffer for corrosion and other damage. Make repairs, as needed.
B. Disconnect the P651 connector from the oxygen buffer.
Illustration 212 P651 harness connector for the oxygen buffer (A) +24 volt supply (B) Return
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If the condition is not resolved, replace the oxygen buffer. Be sure to calibrate the oxygen sensor after you replace the buffer. Refer to Troubleshooting, Oxygen Sensor - Calibrate. STOP.
C. Install the ends of a jumper wire into terminals A and B of the P651 connector. D. Turn the engine control switch to the STOP position. E. Access the Logged Diagnostic Codes screen on Cat ET. If a 1088-05 diagnostic code is logged, clear the code. F. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. G. Select Change in the lower left corner of the screen. H. Select a New Value of On and then select OK. Wait for 65 seconds.
Not OK The 1088-05 diagnostic code is logged

when the circuit for the supply to the buffer is shorted by the jumper wire. The ECM does not detect the short circuit. Proceed to Test Step 7.
Test Step 7. Check the Supply for the Oxygen Buffer at the ECM
Note: After you exit the Override Parameters screen, the status of the oxygen sensor is automatically changed to OFF when the engine control switch is not in the START position.
Illustration 213 Harness side of the ECM P2 connector (13) Supply for the buffer (23) Return
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Illustration 214
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B. Use a 151-6320 Wire Removal Tool to remove terminals (P2-13) and (P2-23) of the ECM P2 connector. This will create an open circuit between the buffer and the ECM. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Access the Logged Diagnostic Codes screen on Cat ET. If a 1088-05 or 1088-06 diagnostic code is logged, clear the code. E. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. F. Select Change in the lower left corner of the screen. G. Select a New Value of On and then select OK. Wait for a minimum of 65 seconds. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds.
Harness side of the ECM P2 connector (2) Jumper wire (13) Supply for the buffer (23) Return
H. Install a jumper wire (2) into terminals (P2-13) and (P2-23). Pull on the jumper wire in order to verify proper installation. This will create a short circuit between the supply and the return of the buffer circuit. I. Access the Logged Diagnostic Codes screen again. Allow a minimum of ten seconds for any diagnostic codes to be activated. Look for the 1088-05 or 1088-06 diagnostic code. Expected Result: When an open circuit was created, a 1088-05 diagnostic code was activated. When a short circuit was created, a 1088-06 diagnostic code was activated.
Results:
i01748331
Yes When an open circuit was created in the

P2 connector, a 1088-05 diagnostic code was activated. When a short circuit was created with the jumper wire in the P2 connector, a 1088-06 diagnostic code was activated. The ECM is OK. There is a problem in the harness between the ECM and the oxygen buffer. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Reinstall the terminals into P2-12 and P2-23. Pull on the wires in order to verify proper installation of the terminals. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Oxygen Sensor Signal

SMCS Code: 1901-038 System Operation Description: The oxygen sensor is used by the oxygen buffer in order to measure the concentration of oxygen in the engine exhaust. The oxygen buffer receives power from terminal 13 of the J2/P2 connector on the Electronic Control Module (ECM). The return circuit is through terminal 23 of the J2/P2 connector. The buffer provides a power supply of 1.5 amperes and 10.5 volts between the positive VH and negative VH terminals in order to power a resistive type of heater in the oxygen sensor. After this heater raises the temperature of the sensing element to 700 C (1292 F), the buffer regulates the current from the positive IP terminal to the negative IP terminal. This keeps the voltage between the positive VS terminal and negative VS terminal relatively constant. The amount of current is a measure of the concentration of oxygen in the exhaust gases. The current will vary from 0 mA at 0 percent of oxygen to approximately 8.7 mA at 21 percent of oxygen. The oxygen buffer measures this current. The buffer converts the current to a Pulse Width Modulated signal (PWM) with a nominal frequency of 500 Hz. This signal is supplied to terminal 67 of the ECM J2/P2 connector. The duty cycle of the PWM signal has a range of 30 to 60 percent. The 30 percent corresponds to 0 percent of oxygen and the 60 percent corresponds to 21 percent of oxygen. These values vary slightly between different buffers and sensors. Calibration is required for every new buffer. Calibration of the buffer is also required after every 1500 service hours. Some applications may require more frequent calibration or less frequent calibration. The oxygen buffer is equipped with a diagnostic circuit that detects the current which is provided to the heating element of the oxygen sensor. If this current is too low, the buffer assumes that the oxygen sensor has failed or the sensor is disconnected from the oxygen buffer. This will cause the PWM signal from the oxygen buffer to change to a duty cycle of approximately 15 percent. The ECM interprets this condition as a diagnostic condition. The ECM will generate a diagnostic code that can be viewed with the Caterpillar Electronic Technician (ET).
No The ECM did not detect an open circuit

and/or a short circuit. There may be a problem with the ECM. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Reinstall the terminals into P2-12 and P2-23. Pull on the wires in order to verify proper installation of the terminals. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP.
The sensor provides a wet reading that is slightly lower than a dry reading. The wet reading is multiplied by a conversion factor of approximately 1.25 in order to obtain the reading that is displayed on Cat ET. This allows oxygen readings from Cat ET to be compared to dry readings from a meter such as a Teledyne meter. The ECM uses the signal of the percent of oxygen for two functions:
Make corrections for variation of fuel BTU. Maintain desired emissions levels.
If an incorrect signal is detected by the ECM, a diagnostic code is generated and compensation for fuel quality is disabled. Problems with the circuit for the oxygen signal must be repaired as soon as possible because of the effects on engine performance and emissions.
Illustration 215 Schematic of the circuit for the oxygen sensor and the oxygen buffer
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During operation, the oxygen sensor may reach temperatures that exceed 700 C (1292 F). Severe personal injury and property damage will result from contact with a hot oxygen sensor. Do not touch the sensor during engine operation, calibration, or testing. Allow the sensor to cool before moving the sensor. Wear gloves that resist heat. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures.
Illustration 218 Harness side of the P10 connector (K) +24 volt supply for the buffer (H) Return (L) Return (M) Oxygen signal Illustration 216
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(1) ECM connectors J2/P2 (2) J10/P10 connector for the harness from the oxygen buffer
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the oxygen sensor.
B. Thoroughly inspect the following connections:

Illustration 219
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Illustration 217 Harness side of the ECM P2 connector (13) +24 volt supply for the buffer (23) Return (53) Return (67) Oxygen signal
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(1) Oxygen sensor (2) Connectors for the oxygen sensor (3) Oxygen buffer (4) J651/P651 connectors for the harness from the terminal box (5) J652/P652 connectors for the harness to the oxygen sensor
c. Check the harness and wiring for abrasion and pinch points from the oxygen sensor to the ECM.
Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
D. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. E. Select Change in the lower left corner of the screen. F. Select a New Value of On and then select OK. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the Oxygen Sensor Override is automatically changed to OFF when the engine control switch is not in the START position.

Not OK At least one of the connectors, pins, or

sockets are not connected properly. At least one of the connectors and/or the wiring has corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Measure the Supply Voltage for the Heater at the Connector for the Oxygen Sensor
Illustration 221 Harness connector for the oxygen sensor (A) VH+ (B) VH-
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G. Measure the voltage between terminals A and B on the harness connector for the oxygen buffer. Expected Result:
Illustration 220 (1) Connector for the oxygen sensor
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The voltage is greater than 9 VDC. Results:
B. Disconnect the oxygen sensor from the engine harness. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
OK The voltage is greater than 9 VDC. The

correct supply voltage for the heater of the oxygen sensor is present at the harness connector. Proceed to Test Step 3.
Not OK The voltage is less than 9 VDC. The
supply voltage for the heater of the oxygen sensor is not present at the harness connector. Proceed to Test Step 6.
1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Inspect the connections and the harness from the oxygen buffer to the oxygen sensor. Look for corrosion and other damage. Refer to Troubleshooting, Inspecting Electrical Connectors. 3. Make repairs, as needed. If the connectors and the harness appear to be OK, install an oxygen sensor that is known to be good. Calibrate the oxygen sensor. Refer to Troubleshooting, Oxygen Sensor - Calibrate. 4. Verify that the condition is resolved with the new oxygen sensor. If the condition is not resolved, replace the oxygen buffer. Be sure to calibrate the oxygen sensor after you replace the buffer. Refer to Troubleshooting, Oxygen Sensor - Calibrate. STOP.

A. Access the Logged Diagnostic Codes screen on Cat ET. If the following codes are logged, clear the codes:
1086-09 Oxygen Sensor Element not

communicating on link
1087-03 Oxygen Buffer Module short to +batt 1087-08 Oxygen Buffer Module noisy signal 1088-05 Oxygen Sensor Power Supply open
circuit

to ground B. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. C. Select Change in the lower left corner of the screen. D. Select a New Value of On and then select OK. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the Oxygen Sensor Override is automatically changed to OFF when the engine control switch is not in the START position. E. Access the Logged Diagnostic Codes screen again. Look for the following diagnostic codes again: 1086-09, 1087-03, 1087-08, 1088-05, and 1088-06. Expected Result: At least one of the above diagnostic codes are logged. Results:
Logged 1087-03 or 1087-08 Diagnostic Code

The PWM signal is noisy or the signal is missing. Proceed to Test Step 4.

There is a problem with the supply voltage for the oxygen buffer.
Repair: Refer to Troubleshooting, Oxygen Sensor Buffer Supply. STOP.
No Codes The circuit for the oxygen sensor is

OK. STOP.
Test Step 4. Check the Harness for Open Circuits and Short Circuits
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect the following connectors: J1/P1, J2/P2, and J651/P651. Thoroughly inspect all of the connectors for corrosion and/or moisture. Make repairs, if necessary.
Logged 1086-09 A 1086-09 diagnostic code

is active. Repair: Perform the following steps:
Illustration 222 (B) Return (C) Oxygen signal
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P651 harness connector for the terminal box to the oxygen buffer
C. Install the ends of a jumper wire into terminals B and C of the P651 connector. D. Use an ohmmeter to check for continuity between the terminals that are listed in Table 33.
Table 33
Points to Check P2-67 Signal (1) P2-67 Signal (2) P2-23 Return J1-69 battery terminal Engine block P2-13 supply All of the remaining terminals in the P2 connector
(1) (2)
Illustration 223
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Check for continuity. Check for a short circuit.
B. Use a 151-6320 Wire Removal Tool to remove terminal P2-67 from the ECM P2 connector.
Expected Result: The resistance between terminals 67 and 23 of the P2 connector is less than 2 ohms. All of the other ohmmeter readings are greater than 20,000 ohms. Results:
OK The resistance between terminals 67 and

23 of the P2 connector is less than 2 ohms. All of the other ohmmeter readings are greater than 20,000 ohms. Proceed to Test Step 5.
Not OK There is a problem with the harness

between the terminal box and the oxygen buffer. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
Test Step 5. Isolate the Oxygen Signal and Check the Signal at the ECM
A. Remove the jumper wire from the P651 connector. Reconnect the J1/P1, J2/P2, and J651/P651 connectors.
Illustration 224
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C. Insert a 7X-1710 Multimeter Probe along terminal P2-23 of the ECM P2 connector. D. Use a multimeter that is capable of measuring the duty cycle and the frequency. Connect one lead of the multimeter to terminal that was removed from P2-67. E. Connect the other multimeter lead to the 7X-1710 Multimeter Probe. F. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. G. Access the Diagnostic Override screen of the Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. H. Select Change in the lower left corner of the screen. I. Select a New Value of On and then select OK. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the Oxygen Sensor Override is automatically changed to OFF when the engine control switch is not in the START position. Note: Do not remove the wire from terminal 23 of the P2 connector. Use a 7X-1710 Multimeter Probe to make contact with terminal 23. J. Measure the signal between the wire that was removed from terminal 67 and terminal 23 (return) of the ECM P2 connector. Expected Result: The signal for the duty cycle is between 20 and 90 percent. The signal for the frequency is between 375 and 625 Hz. Results:
2. Reinstall the wire into terminal 67 of the ECM P2 connector. Pull on the wire in order to verify proper installation of the terminal. 3. Remove the 7X-1710 Multimeter Probe from terminal P2-23. 4. Turn the engine control switch to the STOP position. Clear all of the logged diagnostic codes. 5. Turn ON the oxygen buffer. Use Cat ET to check for logged 1087-03 and 1087-08 diagnostic codes. 6. If either of the codes are present, replace the ECM according to Troubleshooting, Replacing the ECM. STOP.
Not OK The harness is OK. However, the

Repair: Perform the following steps:
oxygen signal is not present at the loose wire.
1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Reinstall the wire into terminal 67 of the ECM P2 connector. Pull on the wire in order to verify proper installation of the terminal. 3. Remove the 7X-1710 Multimeter Probe from terminal P2-23. 4. Install an oxygen buffer that is known to be good. 5. Verify that the condition has been resolved. If the condition is not resolved, replace the oxygen sensor. Be sure to calibrate the oxygen sensor after you replace the buffer and/or the sensor. Refer to Troubleshooting, Oxygen Sensor - Calibrate. STOP.
Test Step 6. Measure the Supply Voltage for the Heater at the Oxygen Buffer
OK A valid oxygen signal is present at the

loose wire. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position.
Illustration 225
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Illustration 226 J652 connector on the oxygen buffer (A) VH+ (B) VH
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(1) P652 connector for the harness to the oxygen sensor
B. Disconnect the P652 connector from the oxygen buffer. C. Turn the engine control switch to the STOP position. D. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. E. Select Change in the lower left corner of the screen. F. Select a New Value of On and then select OK. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the Oxygen Sensor Override is automatically changed to OFF when the engine control switch is not in the START position.
G. Measure the voltage between terminals J652-A and J652-B on the oxygen buffer. Expected Result: The voltage is greater than 9 VDC. Results:
OK The voltage is greater than 9 VDC. The

correct supply voltage for the heater of the oxygen sensor is present at the oxygen buffer. There is a problem with the harness for the oxygen sensor. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
Not OK The voltage is less than 9 VDC. The
correct supply voltage for the heater of the oxygen sensor is not present at the oxygen buffer. Proceed to Test Step 7.
Test Step 7. Check the Supply Voltage for the Oxygen Buffer
G. Measure the voltage between terminals A and B of the P651 connector on the harness. Expected Result: The voltage is greater than 18 VDC. Results:
OK The oxygen buffer is receiving the correct

supply voltage for the heater in the oxygen sensor. However, the buffer is not sending the supply to the heater for the oxygen sensor. Repair: Perform the following procedures: Reconnect the J651/P651 connectors for the oxygen buffer. Repeat Test Step 2. If the condition is not resolved, replace the oxygen buffer. Be sure to calibrate the oxygen sensor after you replace the buffer.
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Not OK The oxygen buffer is not receiving

the correct supply voltage for the heater in the oxygen sensor. Proceed to Test Step 8.
B. Disconnect the P651 connectors from the oxygen buffer. C. Turn the engine control switch to the STOP position. D. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. E. Select Change in the lower left corner of the screen. F. Select a New Value of On and then select OK. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds. Note: After you exit the Override Parameters screen, the status of the Oxygen Sensor Override is automatically changed to OFF when the engine control switch is not in the START position.
Illustration 229
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(1) P10 connector for the harness from the oxygen buffer
A. Disconnect the P10 connector from the terminal box.

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B. Measure the voltage between terminals K and L on the J10 connector. Expected Result: The voltage is greater than 18 VDC. Results:
B. Disconnect the P651 connector from the oxygen buffer.
OK The voltage is greater than 18 VDC. There

is a problem with the harness between the terminal box and the oxygen buffer.
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Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
C. Install the ends of a jumper wire into terminals A and B of the P651 connector. D. Turn the engine control switch to the STOP position. E. Access the Logged Diagnostic Codes screen on Cat ET. If a 1088-05 diagnostic code is logged, clear the code. F. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. G. Select Change in the lower left corner of the screen. H. Select a New Value of On and then select OK. Wait for 65 seconds. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds.
Not OK The voltage is less than 18 VDC.

Test Step 9. Create a Short Circuit in the Harness

Note: After you exit the Override Parameters screen, the status of the oxygen sensor is automatically changed to OFF when the engine control switch is not in the START position. I. Access the Logged Diagnostic Codes screen again. Look for the 1088-05 diagnostic code. Expected Result: The 1088-05 diagnostic code is not logged when the circuit for the supply to the buffer is shorted by the jumper wire. Results:
OK The 1088-05 diagnostic code is not logged

when the circuit for the supply to the buffer is shorted by the jumper wire. The harness and the ECM are OK. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Inspect the J651 connector on the oxygen buffer for corrosion and other damage. Make repairs, as needed. If the condition is not resolved, replace the oxygen buffer. Be sure to calibrate the oxygen sensor after you replace the buffer. Refer to Troubleshooting, Oxygen Sensor - Calibrate. STOP.
Illustration 233 Harness side of the ECM P2 connector (13) +24 volt supply (23) Return
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B. Use a 151-6320 Wire Removal Tool to remove terminals (P2-13) and (P2-23) from the ECM P2 connector. This will create an open circuit between the buffer and the ECM. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Access the Logged Diagnostic Codes screen on Cat ET. If a 1088-05 or 1088-06 diagnostic code is logged, clear the code. E. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. F. Select Change in the lower left corner of the screen. G. Select a New Value of On and then select OK. Wait for a minimum of 65 seconds. The oxygen buffer is now ON. The status of the Oxygen Sensor Override should change to On. Wait for 65 seconds.
Not OK The 1088-05 diagnostic code is logged

when the circuit for the supply to the buffer is shorted by the jumper wire. The ECM does not detect the short circuit. Proceed to Test Step 10.
Note: After you exit the Override Parameters screen, the status of the oxygen sensor is automatically changed to OFF when the engine control switch is not in the START position.
Results:
Yes When an open circuit was created in the

P2 connector, a 1088-05 diagnostic code was activated. When a short circuit was created with the jumper wire in the P2 connector, a 1088-06 diagnostic code was activated. The ECM is OK. There is a problem in the harness between the ECM and the oxygen buffer. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Reinstall the terminals into P2-12 and P2-23. Pull on the wires in order to verify proper installation of the terminals. Repair the harness, when possible. Replace the harness, if necessary. STOP.
No The ECM did not detect an open circuit

and/or a short circuit. There may be a problem with the ECM.
Illustration 234 Harness side of the ECM P2 connector (2) Jumper wire (13) +24 volt supply (23) Return
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Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Reinstall the terminals into P2-12 and P2-23. Pull on the wires in order to verify proper installation of the terminals. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to 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 original ECM. Refer to Troubleshooting, Replacing the ECM. STOP.
H. Install a jumper wire (2) into terminals (P2-13) and (P2-23). Pull on the jumper wire in order to verify proper installation. This will create a short circuit between the supply and the return of the buffer circuit. I. Access the Logged Diagnostic Codes screen again. Allow a minimum of ten seconds for any diagnostic codes to be activated. Look for the 1088-05 or 1088-06 diagnostic code. Expected Result: When an open circuit was created, a 1088-05 diagnostic code was activated. When a short circuit was created, a 1088-06 diagnostic code was activated.
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Prelubrication System
SMCS Code: 1319-038 System Operation Description: The prelube system is an option. During the prestart, the Electronic Control Module (ECM) can energize the prelube pump before cranking the engine in order to provide lubrication to the engine bearings. The ECM uses the input from the prelube pressure switch in order to monitor the lubrication pressure. Closure of the pressure switch indicates that sufficient oil pressure has been achieved. After the pressure switch closes, the prelube pump can continue to operate for a programmable period of time (Engine Pre-Lube Time Out Period). The pump is de-energized when the process of prelubrication is completed. The A and B contacts of the prelube pressure switch close at a pressure of 9 3 kPa (1.3 0.4 psi). The A and B contacts of the prelube pressure switch open at a pressure of 7 kPa (1 psi). If the prelube pressure switch is closed before the prestart, the prelube pump will run for the programmed Engine Pre-Lube Time Out Period. If the ECM does not detect closure of the pressure switch within the programmed period of time, the ECM monitors the engine oil pressure sensor in order to determine whether lubrication has occurred. If the prelubrication does not occur, an E233 Low Engine Prelube Pressure event code is generated. The starting sequence is terminated. Under the following circumstances, the prelube pump is energized until the prelube pressure switch closes:
For the prelube system to work, the Engine Pre-Lube Time Out Period must be programmed for a time period between 30 and 300 seconds. The range for the Engine Pre-Lube Time Out Period is 30 to 300 seconds. If the Engine Pre-Lube Time Out Period is not programmed for a time period between 30 and 300 seconds or if the engine is not equipped with the prelubrication function, the prelubrication is disabled. The engine will crank without the prelubrication. The following codes cannot be generated:
E233 Low Engine Prelube Pressure 338-05 Pre-Lube Relay open circuit 338-06 Pre-Lube Relay short to ground 339-05 Engine Pre-Lube Pressure Switch open
circuit Note: To troubleshoot the circuit for the prelube relay, see Troubleshooting, ECM Start/Stop Output.
Illustration 235 Schematic of the prelube system
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The manual prelube switch is closed. The emergency stop switch is open. The engine speed is zero.
The pump will operate until one of these conditions occur:
J1-30 and J1-31 are connected to the prelube pressure switch via the J12/P12 connectors on the terminal box. J1-56 is connected to the manual prelube switch via the J9/P9 connectors on the terminal box. The J12/P12 and J9/P9 connectors are not shown. For the actual wiring, refer to the schematic for the engine electrical system. Closure of the prelube pressure switch indicates that the lubrication pressure is acceptable. Closure of the manual prelube switch selects the operation of the prelube system.
The prelube pressure switch closes. The manual prelube switch opens. The emergency stop switch closes.
Test Step 1. Check the Programming of the ECM and Check for the Proper Hardware
A. Check the Service/Configuration screen on the Caterpillar Electronic Technician (ET). Verify that the time that is programmed for the Engine Pre-Lube Time Out Period parameter is between 30 and 300 seconds.
B. Verify that the following components are installed:
Results:
Prelube pump Prelube pump relay Prelube pressure switch Manual prelube switch
Not OK The Engine Pre-Lube Time Out

Period parameter is not programmed for a time period between 30 and 300 seconds. All of the components are installed. The wiring is installed. Repair: Program the Engine Pre-Lube Time Out Period for a time period between 30 and 300 seconds. STOP.
Not OK The Engine Pre-Lube Time Out Period

parameter is programmed for a time period between 30 and 300 seconds. None of the components are installed and/or the wiring is not installed. Repair: The engine is not equipped for the prelube system. The prelube system is an option that can be added. Program the Engine Pre-Lube Time Out Period for zero seconds. STOP.
OK The Engine Pre-Lube Time Out Period

parameter is programmed for a time period between 30 and 300 seconds. All of the components are installed. The wiring is installed. Proceed to Test Step 2.

Illustration 236 Harness sides of the P1 and P2 connectors (P1-30) (P1-31) (P1-56) (P2-12) (P2-22) Prelube pressure switch Digital return Manual prelube switch Prelube relay Return
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C. Verify that the wiring is present in the terminals that are shown in Illustration 236. Expected Result: The Engine Pre-Lube Time Out Period parameter is programmed for a time period between 30 and 300 seconds. All of the components are installed. The wiring is installed.
Table 34
Terminals for the Wiring of the Prelube System P1-30 Pressure switch P1-56 Manual switch P1-31 Return P2-12 Relay P2-22 Return J9-D Manual switch J12-R Return J12-T Pressure switch J15-A J15-B
Illustration 237 (1) ECM connectors J2/P2 (2) ECM connectors J1/P1 (3) J15/P15 connectors for the prelube pumps solenoid (4) J12/P12 connectors for the prelube pressure switch (5) J9/P9 connectors for the manual prelube switch
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c. Check the harness and wiring for abrasion and pinch points from the prelube pressure switch and the manual prelube switch to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
B. Check the terminals for the prelube pressure switch and the manual prelube switch. Thoroughly inspect each of the following connectors:
ECM J1/P1 and J2/P2 connectors J9/P9, J12/P12, and J15/P15 connectors on
the terminal box a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 1 Nm (55 9 lb in). b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the prelube system. The wires are listed in Table 34.


Test Step 3. Use Cat ET to Check for Logged Diagnostic Codes

A. Connect Cat ET to the service tool connector on the terminal box. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. B. Observe the Logged Diagnostic screen on Cat ET. Look for these codes: 338-05 Pre-Lube Relay open circuit and 338-06 Pre-lube Relay short to ground. Expected Result: Neither of the codes are logged.
Results:
E269 Customer Shutdown Requested E270 Driven Equipment Shutdown Requested

A. Turn the engine control switch to the OFF/RESET position. B. Reconnect the wires to the terminals of the prelube pressure switch.
OK Neither of the codes are logged. Proceed

to Test Step 4.
Not OK One of the codes is logged.

Repair: Refer to Troubleshooting, ECM Start/Stop Output. STOP.
Test Step 4. Check the Prelube Pressure Switch

A. Turn the engine control switch to the OFF/RESET position. B. Disconnect the wires from the terminals of the prelube pressure switch. C. Measure the resistance between the terminals of the prelube pressure switch. D. Turn the engine control switch to the STOP position. Turn the manual prelube switch ON. Make sure that the prelube pump is ON. E. Measure the resistance between the terminals of the prelube pressure switch. Expected Result: When the prelube pump is OFF, the resistance is greater than 2000 ohms. When the prelube pump is ON, the resistance is less than 2 ohms. Results:
Illustration 238 Harness side of the P1 connector (30) Prelube pressure switch (31) Return
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OK The resistance is correct. Proceed to test

Step 5.
Not OK The resistance is not correct. The

contacts of the prelube pressure switch are stuck in the closed position or the open position. Repair: Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM OFF. Replace the prelube pressure switch. STOP.
C. Use a 151-6320 Wire Removal Tool to remove terminals P1-30 and P1-31. D. Connect a multimeter to the terminals that were removed from the P1 connector. E. Measure the resistance of the prelube pressure switch. F. Turn the engine control switch to the STOP position. Turn the manual prelube switch ON. Make sure that the prelube pump is ON. G. Measure the resistance of the prelube pressure switch. Expected Result: When the prelube pump is OFF, the resistance is greater than 2000 ohms. When the prelube pump is ON, the resistance is less than 2 ohms.
Test Step 5. Check the Circuit of the Prelube Pressure Switch

Note: The following diagnostic codes and event codes may be logged during this test. The codes are caused by removing the P1-31 terminal. Reinstall the terminal and clear the codes after the test:
336-02 Incorrect ECS Switch inputs
Results:
Note: Excessive pressure can generate false noisy signal diagnostic codes. If the actual inlet manifold air pressure is greater than approximately 338 kPa (49 psi), a 106-08 Air Inlet Pressure Sensor noisy signal diagnostic code will be generated. Although there is not a problem with the sensor, the code will be generated. If the actual engine coolant pressure is greater than approximately 444 kPa (64 psi), a 109-08 Engine Coolant Outlet Pressure Sensor noisy signal diagnostic code will be generated. Although there is not a problem with the sensor, the code will be generated. If a 106-08 or 109-08 diagnostic code is generated, measure the absolute pressure with a pressure gauge before you troubleshoot the sensor. If the pressure is actually too high, reduce the pressure in order to avoid activation of false diagnostic codes. Logged diagnostic codes provide an historical record. Before you begin this procedure, print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.
OK The resistance is correct. The ECM is not

reading the circuit for the prelube pressure switch correctly. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Insert terminals 30 and 31 into the P1 connector. Pull on the wires in order to verify that the terminals are fully inserted into the connector. Replace the ECM according to the instructions in Troubleshooting, Replacing the ECM. STOP.
Not OK The resistance is not correct. There is a

short circuit or an open circuit in at least one of the wires for the prelube pressure switch. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Insert terminals 30 and 31 into the P1 connector. Pull on the wires in order to verify that the terminals are fully inserted into the connector. Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM OFF. Repair the harness, when possible. Replace the harness, if necessary. STOP.
i01754772
PWM Sensor
SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) supplies 8.0 0.8 VDC to the following sensors:
Engine coolant pressure (outlet) Inlet manifold air pressure Atmospheric pressure (if equipped)
The ECM supplies 5.0 0.5 VDC to the humidity sensor (if equipped).
Illustration 239 Schematic of the circuit for the PWM sensors
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Illustration 240 (1) ECM connectors J2/P2 (2) ECM connectors J1/P1 (3) J12/P12 connectors for the PWM sensors
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ECM J1/P1 connectors ECM J2/P2 connectors J12/P12 connectors on the terminal box
Illustration 243 Harness side of the P12 connector (A) +5 volt supply (C) Return (D) Signal for atmospheric pressure (G) Signal for humidity (L) +8 volt supply (M) Signal for inlet manifold air pressure (N) Return (P) Signal for engine coolant pressure (outlet)
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Illustration 241 Harness sides of the ECM P1 connector (2) + 5 volt supply (3) Return (4) +8 volt supply (5) Return (10) Signal for inlet manifold air pressure (11) Signal for humidity (12) Signal for atmospheric pressure
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the PWM sensors.
Illustration 242 Harness sides of the ECM P2 connector (68) Signal for engine coolant pressure (outlet)
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Illustration 244 (1) Sensor for engine coolant pressure (outlet) (2) Sensor for inlet manifold air pressure
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Illustration 245 (3) Sensor for humidity (4) Sensor for atmospheric pressure
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c. Check the harness and wiring for abrasion and pinch points from each of the PWM sensors to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
C. Observe the Active Diagnostic screen on Cat ET. Allow a minimum of thirty seconds for any codes to activate. Look for these codes:
41-03 8 Volt DC Supply short to +batt 41-04 8 Volt DC Supply short to ground 262-03 5 Volt Sensor DC Supply short to +batt 262-04 5 volt Sensor DC Supply short to
ground Expected Result: There are no active 8 Volt DC Supply diagnostic codes or 5 Volt Sensor DC Supply diagnostic codes. Results:

No codes There are no active diagnostic codes

for the power supplies. Proceed to Test Step 3.
Test Step 2. Check for Active 8 Volt DC Supply Diagnostic Codes and 5 Volt Sensor DC Supply Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. B. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position.
Active code There is an active diagnostic code

for a power supply. This procedure will not work when this type of code is active.
Repair: Refer to Troubleshooting, +8 V Sensor Voltage Supply, or Troubleshooting, +5 V Sensor Voltage Supply. STOP.
Test Step 3. Check for Active Diagnostic Codes for the PWM Sensors
A. Turn on the Active Diagnostic screen on Cat ET. Determine if any of these diagnostic codes are active:
C. Turn the engine control switch to the STOP position.
106-03 Air Inlet Pressure Sensor open/short

to +batt
106-08 Air Inlet Pressure Sensor noisy signal 109-03 Engine Coolant Outlet Pressure
open/short to +batt
Illustration 246 Harness connector for the PWM sensors (A) +8 volt supply or +5 volt supply (B) Return
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109-08 Engine Coolant Outlet Pressure noisy

signal
1758-03 Specific Humidity Sensor open/short

to +batt
D. At the harness connector for the suspect sensor, measure the voltage between terminal A and terminal B. Expected Result: The voltage between terminal A and terminal B is +8.0 0.4 VDC. If you are troubleshooting the humidity sensor, the voltage is +5.0 0.5 VDC. Results:
1758-08 Specific Humidity Sensor noisy signal 1759-03 Exhaust Back Pressure Sensor
open/short to +batt
1759-08 Exhaust Back Pressure Sensor noisy

signal Expected Result: One of the above codes is active. Results:
OK The voltage is within the specification. The
correct voltage is present at the sensor connector. Proceed to Test Step 5.
Not OK The voltage is not within the

specification. The correct voltage is not present at the sensor connector. The correct voltage must be present at the sensor connector in order to continue this procedure. The wiring problem may be inside the terminal box, or in the engine harness. Repair: Verify that the wiring and/or connectors are OK. Repair any faulty wiring and/or connectors, when possible. Replace any faulty wiring and/or connectors, if necessary. Refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Yes At least one of the above diagnostic codes

is active. Proceed to Test Step 4.
No None of the above codes are active.

Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, Troubleshooting Without a Diagnostic Code. If the engine is running properly at this time, there may be an intermittent problem in the harness that is causing the codes to be logged. Refer to Troubleshooting, Inspecting Electrical Connectors. STOP.
Test Step 4. Verify the Supply Voltage to the Sensor

A. Turn the engine control switch to the OFF/RESET position. B. Disconnect the suspect sensor.
Test Step 5. Verify that +Battery Voltage is Not Present in the Signal Wire
C. Use a multimeter that is capable of measuring both the duty cycle and the frequency. Connect the multimeter to terminal B and terminal C of the breakout t. D. Turn the engine control switch to the STOP position. E. Measure the duty cycle and the frequency of the suspect sensor.
Illustration 247 Harness connector for the PWM sensors (B) Return (C) Signal
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Expected Result: The duty cycle is between 5 percent and 95 percent for the engine coolant pressure sensor, the inlet manifold pressure sensor, or the atmospheric pressure sensor. The duty cycle is between 10 and 90 percent for the humidity sensor. The frequency is between 400 and 600 Hz. Results:
A. At the harness connector for the suspect sensor, measure the voltage between terminal B and terminal C. Expected Result: The voltage is between 7.0 and 8.0 volts. Results:
OK The duty cycle is between 5 percent and

95 percent for the engine coolant pressure sensor, the inlet manifold pressure sensor, or the atmospheric pressure sensor. The duty cycle is between 10 and 90 percent for the humidity sensor. The frequency is between 400 and 600 Hz. A valid signal is produced by the sensor. Proceed to Test Step 7.
OK The voltage is between 7.0 and 8.0 volts.

The +Battery voltage is not present in the signal wire. Proceed to Test Step 6.
Not OK The voltage is approximately equal to

the Battery voltage. The signal wire is probably shorted to the +Battery between the sensor and the ECM. Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Not OK The duty cycle or the frequency is

incorrect. The sensor is receiving the correct supply voltage but the sensor is not producing a valid signal. Repair: Perform the following steps: 1. Thoroughly inspect the connector for the sensor according to Troubleshooting, Inspecting Electrical Connectors. 2. Check the duty cycle and the frequency of the sensor signal again. 3. If the duty cycle and the frequency of the sensor signal are incorrect, turn the engine control switch to the OFF/RESET position. 4. Disconnect the sensor. Connect a sensor that is known to be good. Do not install the new sensor into the engine yet. 5. Turn the engine control switch to the OFF/RESET position. 6. Turn the engine control switch to the STOP position. Allow a minimum of 30 seconds for any codes to activate.
Not OK The voltage is approximately 0 volts.

The signal wire is probably shorted to ground between the sensor and the ECM. Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Repair the harness, when possible. Replace the harness, if necessary. STOP.
Test Step 6. Check the Signal at the Sensor

A. Turn the engine control switch to the OFF/RESET position. B. Install a 8T-8726 Adapter Cable As (Three-Pin Breakout) at the harness connector for the suspect sensor.
7. Check for an active diagnostic code. If the code is not active for the new sensor, install the sensor into the engine. Clear any logged diagnostic codes. STOP.
The terminals for the connection of the probes are identified in Table 35.
Table 35
Terminals for the Connection of the Probes Suspect Sensor Engine coolant pressure (outlet) Inlet manifold air pressure Atmospheric pressure Humidity Connector and Terminals J2-68 and J1-5 J1-10 and J1-5 J1-12 and J1-5 J1-11 and J1-3
Test Step 7. Check the Signal at the ECM

C. Use a multimeter that is capable of measuring both the duty cycle and the frequency. Connect the multimeter to the probes. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. E. Measure the duty cycle and the frequency of the suspect sensor. Expected Result: The duty cycle is between 5 percent and 95 percent for the engine coolant pressure sensor, the inlet manifold pressure sensor, or the atmospheric pressure sensor. The duty cycle is between 10 and 90 percent for the humidity sensor. Results:
OK The duty cycle is between 5 percent and

95 percent for the engine coolant pressure sensor, the inlet manifold pressure sensor, or the atmospheric pressure sensor. The duty cycle is between 10 and 90 percent for the humidity sensor. The frequency is between 400 and 600 Hz. The ECM is receiving a valid signal from the sensor. Repair: Perform the following steps:
Illustration 248 Harness side of the ECM P1 and P2 connectors (1) P1 connector (2) P2 connector (P1-3) Return (P1-5) Return (P1-10) Signal for inlet manifold air pressure (P1-11) Signal for humidity (P1-12) Signal for atmospheric pressure (P2-68) Signal for engine coolant pressure (outlet)
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1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. 3. Check Status Screen Group 2 on Cat ET. Look for a valid signal.
B. Insert two 7X-1710 Multimeter Probes into the terminals that are appropriate for the suspect sensor.
It is possible that the actual air inlet pressure is less than the pressure that can be measured by the sensor during low idle operation (26.7 kPa (3.87 psi)). This causes the ECM to set the 106-03 diagnostic code although there is no short circuit to the +Battery side. In this case, adjust the derivative gain and the fuel quality in order to make the engine more stable at low idle. Refer to Troubleshooting, System Configuration Parameters. Otherwise, verify that the ECM is receiving the correct voltage. Refer to Troubleshooting, Electrical Power Supply. If the condition is not resolved, install a known good ECM according to Troubleshooting, Replacing the ECM. Verify that the problem is resolved. STOP.
Not OK The duty cycle or the frequency is

incorrect. The sensor is producing a valid signal but the signal does not reach the ECM. There is a problem in the harness between the sensor and the ECM. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP.
i01748742
Throttle Actuator Solenoid

SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) controls the throttle actuator by adjusting current flow through the actuators solenoid. The 1440-05 diagnostic code is probably caused by a problem with an electrical connector or an open circuit in a harness. Under certain circumstances, the 1440-05 diagnostic code can occur if the low side wire is shorted to ground. The next likely cause is an open circuit inside the actuator solenoid. The least likely cause is a problem with the ECM. The 1440-06 diagnostic code is probably caused by a short circuit in a harness or a problem with an electrical connector. The next likely cause is a short circuit inside the actuator solenoid. The least likely cause is a problem with the ECM.
Illustration 249 Schematic of the circuit for the throttle actuator
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Note: This Test Step is important for troubleshooting a problem with instability. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Note: For the following steps, refer to Troubleshooting, Inspecting Electrical Connectors.
Illustration 251 Harness side of the ECM P2 connector Illustration 250

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(1) ECM connectors J2/P2 (2) J10/P10 connector for the harness from the throttle actuator (3) 16 amp circuit breaker
(63) High side wire for the throttle actuator (64) Low side wire for the throttle actuator
J2/P2 ECM connectors J10/P10 connectors on the terminal box

Test Step 2. Check the Solenoid and Harnesses for an Open Circuit
A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. B. Disconnect connector P2 from the ECM.
Illustration 252 Harness side of the P10 connector (C) High side wire for the throttle actuator (D) Low side wire for the throttle actuator
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b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the throttle actuator.
Illustration 254 ECM side of connector P2 (P2-63) High side wire for the throttle actuator (P2-64) Low side wire for the throttle actuator
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Illustration 253 (4) Throttle actuator (5) J518/P518 connectors for the throttle actuator
c. Thoroughly inspect the connectors (J518/P518) for the throttle actuator for moisture and contamination. Check the harness and wiring for abrasion and pinch points from the throttle actuator to the ECM. Expected Result: All of the connectors and terminals are connected properly. The connectors are free of moisture and corrosion. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results:
C. Measure the resistance between P2 terminal (63) and terminal (64). During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result: The resistance is between 5.0 and 20.6 ohms. Results:
OK The resistance is between 5.0 and 20.6
ohms. The solenoid and wiring appear to be OK. The low side wire may have a short to ground, or the ECM may have a problem. Proceed to Test Step 3. ohms. There is a problem with a connector and/or the wiring for the solenoid, or the solenoid may have a problem. Proceed to Test Step 6.
Not OK The resistance is higher than 20.6
proper connections. If you are troubleshooting a 1440-05 diagnostic code, proceed to Test Step 2. If you are troubleshooting a 1440-06 diagnostic code, proceed to Test Step 8.
Test Step 3. Check All of the Low Side Wiring for a Short to Ground
A. Verify that harness connector P2 is disconnected from the ECM.
Test Step 4. Check the Low Side Wiring inside the Engine Harness for a Short to Ground
Illustration 256
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(1) P10 connector for the harness from the throttle actuator
A. Disconnect connector P10 from the terminal box.
Illustration 255 ECM side of connector P2 (1) Ground strap for the ECM (P2-64) Low side wire for the throttle actuator
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B. Measure the resistance between the ground strap for the ECM and P2 terminal (64). During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result: The resistance is greater than 20,000 ohms. Results:
OK The resistance measurement is greater than

20,000 ohms. The low side wire for the throttle actuator appears to be OK. Proceed to Test Step 12.
Not OK The resistance measurement is less

than 20,000 ohms. There is a problem with the low side wire for the throttle actuator. Proceed to Test Step 4.
Not OK The resistance measurement is less
than 20,000 ohms. The low side wire inside the engine harness may have a problem, or there may be a problem with the solenoid. Proceed to Test Step 5.
Test Step 5. Check the Solenoid for an Internal Short Circuit

A. Disconnect connector P518 from the throttle actuator.
Illustration 258 Throttle actuator (1) Shell (2) J518-B
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B. Measure the resistance between terminal J518-B and the connectors shell.
Illustration 257 Harness connector P10 (1) Ground Strap for the ECM (P10-D) Low side wire for the throttle actuator
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Expected Result: The resistance is greater than 20,000 ohms. Results:
B. Measure the resistance between the ground strap for the ECM and terminal P10-D. During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result: The resistance is greater than 20,000 ohms. Results:
OK The resistance is greater than 20,000
ohms. The solenoid does not have an internal short circuit. The low side wire inside the engine harness has a short to ground. Repair: Repair the engine harness or connectors, when possible. Replace the harness, if necessary. STOP.

ohms. The solenoid has an internal short circuit. Repair: Replace the solenoid. Refer to Operation and Maintenance Manual, Electrohydraulic Actuator - Recondition. STOP.
OK The resistance measurement is greater
than 20,000 ohms. The low side wire inside the engine harness appears to be OK. The low side wire inside the terminal box may have a problem. There may be a problem with a connector. Repair: Repair the harness and/or the connector, when possible. Replace the harness, if necessary. STOP.
Test Step 6. Check the Engine Harness and the Solenoid for an Open Circuit
Illustration 259 Harness connector P10 (P10-C) High side wire for the throttle actuator (P10-D) Low side wire for the throttle actuator
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Illustration 260 Throttle actuator (1) J518-A (2) J518-B
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B. Measure the resistance between P10 terminal (C) and terminal (D). During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result: The resistance is between 5.0 and 20.6 ohms. Results:
B. Measure the resistance between terminals (A) and (B) on the throttle actuators connector. Expected Result: The resistance is between 5.0 and 10.3 ohms. Results:
OK The resistance of the solenoid is between

5.0 and 10.3 ohms. The solenoid does not have an open circuit. There is an open circuit in the engine harness. There may be a problem with a connector. Repair: Repair the engine harness or connectors, when possible. Replace the harness, if necessary. STOP.
ohms. The engine harness and the solenoid appear to be OK. The wiring inside the terminal box or the terminal boxs connectors may have a problem. Repair: Repair the wiring and/or connectors, when possible. Replace the wiring, if necessary. STOP.
Not OK The resistance of the solenoid is higher

than 10.3 ohms. The resistance of the solenoid is incorrect. The solenoid has an open circuit. Repair: Replace the solenoid. Refer to Operation and Maintenance Manual, Electrohydraulic Actuator - Recondition. STOP.
Not OK The resistance is greater than 20.6

ohms. There is a problem with the engine harness or the solenoid. Proceed to Test Step 7.
Test Step 7. Check the Solenoid for an Open Circuit

Test Step 8. Check all of the Wiring and the Solenoid for a Short Circuit
A. Disconnect connector P2 from the ECM.
Illustration 261 ECM side of connector P2 (P2-63) High side wire for the throttle actuator (P2-64) Low side wire for the throttle actuator
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Illustration 262 Harness connector P10 (P10-C) High side wire for the throttle actuator (P10-D) Low side wire for the throttle actuator
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B. Measure the resistance between P2 terminal (63) and terminal (64). During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result: The resistance is between 5.0 and 20.6 ohms. Results:
B. Measure the resistance between harness connector P10 terminal (C) and terminal (D). During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result: The resistance is between 5.0 and 20.6 ohms. Results:

ohms. The solenoid and wiring do not have a short circuit. Proceed to Test Step 11.
Not OK The resistance is less than 5.0 ohms.

There is a problem with a connector and/or the wiring, or the solenoid has a problem. Proceed to Test Step 9.
ohms. The engine harness and the solenoid appear to be OK. The wiring inside the terminal box has a problem. There may be a problem with a connector. Repair: Repair the wiring and/or the connector, when possible. Replace the harness, if necessary. STOP.
Test Step 9. Check the Engine Harness and the Solenoid for a Short Circuit
Not OK The resistance is lower than 5.0 ohms.

There is a problem with the engine harness or the solenoid. Proceed to Test Step 10.
Test Step 10. Check the Solenoid for a Short Circuit

Illustration 263 Throttle actuator (1) J518-A (2) J518-B
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B. Measure the resistance between terminals (A) and (B) on the throttle actuators connector. Expected Result: The resistance is between 5.0 and 10.3 ohms. Results:
Illustration 264
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OK The resistance of the solenoid is between

5.0 and 10.3 ohms. The solenoid does not have a problem. The engine harness appears to have a short circuit. Repair: Repair the engine harness or connectors, when possible. Replace the harness, if necessary. STOP.
Harness side of the ECM P2 connector (63) High side wire for the throttle actuator (64) Low side wire for the throttle actuator
C. Use a 151-6320 Wire Removal Tool to remove terminal (63) and terminal (64) from harness connector P2. This will replace the wiring for the throttle actuator with an open circuit. D. Switch the 16 amp circuit breaker for the ECM ON. E. If a 1440-05 diagnostic code and/or a 1440-06 diagnostic code is logged, clear the code. F. Turn the engine control switch to the START position and crank the engine. Allow a minimum of 30 seconds for the generation of any codes. Then turn the engine control switch to the STOP position. G. Observe the Active Diagnostic screen on the Caterpillar Electronic Technician (ET). Look for a 1440-05 diagnostic code. Expected Result:
Not OK The resistance of the solenoid is lower

than 5.0 ohms. The resistance of the solenoid is incorrect.
Repair: Replace the solenoid. Refer to Operation and Maintenance Manual, Electrohydraulic Actuator - Recondition. STOP.
Test Step 11. Create an Open Circuit and Check the Operation of the ECM
A. Prevent fuel from entering the engine. Verify that the gas supply to the engine is OFF. B. Verify that the engine control switch is in the OFF/RESET position. Verify that the 16 amp circuit breaker for the ECM is OFF.
A 1440-05 diagnostic code is activated.
Results:
OK When an open circuit was created, a

1440-05 diagnostic code was activated. The ECM is operating correctly. The problem appears to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Perform the following procedure: Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM OFF. Reinstall the terminals that were removed from connector P2. Pull on the wires in order to verify proper installation of the terminals. Reconnect all of the connectors. Verify that the problem is resolved. STOP.
Not OK When an open circuit was created, a

1440-05 diagnostic code was not activated. The ECM may have a problem. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following procedure: Temporarily install a new ECM. Refer to Troubleshooting, Replacing the ECM. If the problem is resolved with a 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 original ECM. Follow the instructions in Troubleshooting, Replacing the ECM. STOP.
Illustration 265 Harness side of the ECM P2 connector (63) High side wire for the throttle actuator (64) Low side wire for the throttle actuator
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C. Use a 151-6320 Wire Removal Tool to remove terminal (63) and terminal (64) from harness connector P2. D. Fabricate a jumper wire with Deutsch sockets on the ends. Insert one end of the jumper wire into the open terminal 63 of the P2 connector. Verify that the socket is making contact with pin 63 in the J2 connector. E. Insert the other end of the jumper wire into the open terminal 64 of the P2 connector. Verify that the socket is making contact with pin 64 in the J2 connector. This will replace the wiring for the throttle actuator with a short circuit. F. Switch the 16 amp circuit breaker for the ECM ON. G. If a 1440-05 diagnostic code and/or a 1440-06 diagnostic code is logged, clear the code. H. Turn the engine control switch to the START position and crank the engine. Allow a minimum of 30 seconds for the generation of any codes. Then turn the engine control switch to the STOP position. I. Observe the Active Diagnostic screen on Cat ET. Look for a 1440-06 diagnostic code.
Test Step 12. Create a Short Circuit and Check the Operation of the ECM
A. Prevent fuel from entering the engine. Verify that the gas supply to the engine is OFF. B. Verify that the engine control switch is in the OFF/RESET position. Verify that the 16 amp circuit breaker for the ECM is OFF.
Expected Result: A 1440-06 diagnostic code is activated. Results:
OK When the wiring for the throttle actuator
was replaced with a short circuit, a 1440-06 diagnostic code was activated by the ECM. The ECM is operating correctly. The problem appears to be resolved. The initial diagnostic code was probably caused by a poor electrical connection. Repair: Perform the following procedure: Turn the engine control switch to the OFF position. Switch the 16 amp circuit breaker for the ECM OFF. Remove the jumper wire from the P2 connector. Reinstall the terminals that were removed from connector P2. Pull on the wires in order to verify proper installation of the terminals. Reconnect all of the connectors. Verify that the problem is resolved. STOP.
Not OK When the wiring for the throttle actuator

is replaced with a short circuit, a 1440-06 diagnostic code is not activated by the ECM. The ECM may have a problem. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following procedure: Temporarily install a new ECM. Refer to Troubleshooting, Replacing the ECM. If the problem is resolved with a 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 original ECM. Follow the instructions in Troubleshooting, Replacing the ECM. STOP.
Calibration Procedures
i01746763
Engine Speed/Timing Sensor Calibrate

SMCS Code: 1912-038 System Operation Description: The Electronic Control Module (ECM) has the ability to calibrate the mechanical differences between the Top Center (TC) of the flywheel and the TC of the timing gear on the left rear camshaft gear. A magnetic transducer signals the TC of the flywheel to the ECM when the TC hole on the flywheel passes beneath the transducer. The engine speed/timing sensor signals the TC of the timing gear to the ECM. Any offset between the TC of the flywheel and the TC of the timing gear is stored into memory. Calibration of the timing is required only after the following circumstances:
The ECM has been replaced. The speed/timing sensor has been replaced. The timing gear and/or the rear gear train have
been adjusted.
The timing gear and/or the rear gear train have

been replaced. Note: The 261-13 Engine Timing calibration required diagnostic code is generated only for an ECM that has never performed a timing calibration. The calibration procedure is initiated with the Caterpillar Electronic Technician (ET).
Test Step 1. Install the Transducer
Illustration 266 (1) P50 connector (2) 6V-3093 Transducer Adapter (3) 6V-2197 Magnetic Transducer (4) 7X-1695 Cable
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A. Turn the engine control switch to the OFF position. Remove the timing calibration plug from either the left side or the right side of the flywheel housing. Install the 6V-3093 Transducer Adapter into the hole. NOTICE The timing hole in the flywheel must not be aligned with the hole for the transducer. The transducer will be damaged on engine start-up if the transducer is installed through both holes. Rotate the flywheel for more than 10 degrees before or after the TC position in order to move the flywheel hole away from the hole for the transducer. Always confirm that the holes are not aligned.
B. Make sure that the hole in the flywheel housing for the transducer is not aligned with the timing hole in the flywheel. Remove the protective end cap from the 6V-2197 Magnetic Transducer. Insert the transducer into the adapter until the transducer contacts the surface of the flywheel. Move the transducer 1 mm (0.04 inch) away from the surface of the flywheel. Tighten the nut on the adapter in order to secure the transducer in place. C. Connect the one end of the 7X-1695 Cable to the transducer. Connect the other end of the cable to connector P50 inside of the terminal box. D. Turn the engine control switch to the STOP position.
E. Connect Cat ET to the service tool connector on the terminal box. For instructions, refer to Troubleshooting, Electrical Connectors and Functions. Start Cat ET. Continue to the next test step.
Repair: If the calibration failed in the first step, verify that the engine rpm was stable during the calibration ( 50 rpm). Verify that there are no active diagnostic codes which can prevent the calibration. Repeat the calibration procedure. If the calibration is still unsuccessful, check the installation of the tools and check the operation of the tools. Check the 7X-1695 Cable for continuity. Verify that the transducer is not bent, open, or shorted internally. Repeat the calibration procedure. Excessive backlash in the gear train will cause inconsistent timing. Refer to Disassembly and Assembly for identifying and repairing a gear train problem. STOP.
Test Step 2. Calibration

Note: A two-step process is used to calibrate the signal for the speed/timing sensor. The new timing reference is calculated first. The reference is based on the signals from the transducer and the speed/timing sensor. Next, the new timing reference is programmed into the permanent memory of the ECM. A. Start the engine. Operate the engine at the rated speed and load. B. Select Service from the main menu on Cat ET. Select Calibrations from the menu. Select Timing Calibration. C. Use either of the following methods in order to initiate the calculation of the new timing reference:
Not OK The calibration was completed

successfully. However, the 261-13 Engine Timing calibration required diagnostic code is still active. Repair: Replace the ECM according to the instructions in Troubleshooting, Replacing the ECM. STOP.
i01746774
Press the space bar on the keyboard of the

PC.
Click the left mouse button on the Continue

button in the lower left corner of the Cat ET screen. Cat ET will indicate Please wait...Calculating the new Timing Reference. After a few moments, Cat ET will display The ECM has calculated the Timing Reference and Choose the Continue button to program the Timing Reference. D. Use either of the following methods in order to program the new timing reference:
Oxygen Sensor - Calibrate

SMCS Code: 1901-038 System Operation Description: Periodic calibration of the oxygen sensor is required in order to ensure accurate readings and optimum engine performance. See the Operation And Maintenance Manual for the maintenance interval schedule. The engine must be stopped and the sensor must be removed. The sensor must be placed in uncontaminated air in order to calibrate the sensor. The air must be free of exhaust. During the calibration, the Electronic Control Module (ECM) first establishes the reference for zero percent of oxygen by reading the sensor after the sensor has cooled for two minutes. The ECM energizes the heater in the sensor for five minutes. Last, the ECM reads the percent of oxygen in the surrounding air. The surrounding air is assumed to be clean with approximately 20.95 percent oxygen. The calibration offset and the calibration range are determined from these two points.
Press the space bar on the keyboard of the

PC.
Click the left mouse button on the Continue

button in the lower left corner of the Cat ET screen. Expected Result: After a few moments, Cat ET will display CALIBRATION SUCCESSFUL. Results:
OK The timing calibration was successful.

STOP.
Not OK Cat ET displayed COULD NOT

CALIBRATE. The calibration was unsuccessful.
Illustration 267 Schematic of the circuit for the oxygen sensor and the oxygen buffer
g00894265
During operation, the oxygen sensor may reach temperatures that exceed 700 C (1292 F). Severe personal injury and property damage will result from contact with a hot oxygen sensor. Do not touch the sensor during engine operation, calibration, or testing. Allow the sensor to cool before moving the sensor. Wear gloves that resist heat. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures. A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF.
Illustration 268
g00894279
(1) ECM connectors J2/P2 (2) J10/P10 connectors for the harness from the oxygen buffer

Illustration 269
g00894288
Illustration 271 (A) VH+ (B) VH (C) IP+ (D) IP (E) VS+ (F) VS+
g00720459
Terminals of the circuit for the oxygen buffer on the harness side of the ECM P2 connector (13) +24 Volt supply for the buffer (23) Return (53) Return for the shield (67) Oxygen signal (PWM)
J652/P652 connectors for the oxygen sensor to the oxygen buffer
b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the oxygen buffer.
Illustration 270 Harness side of the P10 connector (H) Return for the shield (K) +24 Volt supply for the buffer (L) Oxygen signal (PWM) (M) Return
g00894295
Illustration 272
g00894309
(1) Oxygen sensor (2) Oxygen buffer (3) J651/P651 connectors for the harness from the terminal box (4) J652/P652 connectors for the oxygen sensor
c. Check the harness and wiring for abrasion and pinch points from the oxygen sensor to the ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points.
Results:


or sockets are not connected properly. At least one of the connectors or the wiring has corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP.
Test Step 2. Check the Atmospheric Conditions

A. Determine the ambient temperature, relative humidity, and barometric pressure. B. Use Table 36 to determine whether your relative humidity is within the permissible range for calibration of the oxygen sensor. a. Find the row for your ambient temperature. If the temperature is less than 12 C (54 F), use the 12 C (54 F) row. If the temperature is more than 38 C (100 F), do not calibrate the sensor. b. Find the column for your barometric pressure. c. Find the relative humidity in the cell that intersects your column and your row. If your relative humidity is equal to the humidity or greater than the humidity that is listed in the Table, do not calibrate the sensor. If the humidity is 90 percent or more, do not calibrate the sensor.
Table 36
Ambient Temperature, Barometric Pressure, and Relative Humidity for Calibration of the Oxygen Sensor Ambient Temperature Barometric Pressure 96 kPa (13.9 psi) 97 kPa (14.7 psi) 99 kPa (14.4 psi) 101 kPa (14.6 psi) 102 kPa (14.8 psi) 104 kPa (15 psi) 105 kPa (15.2 psi) 107 kPa (15.5 psi) 109 kPa (15.8 psi) 110 kPa (16 psi) 112 kPa (16.2 psi) 113 kPa (16.4 psi)
Relative Humidity 12 C (54 F) 14 C (57 F) 16 C (61 F) 18 C (64 F) 20 C (68 F) 22 C (72 F) 24 C (75 F) 26 C (79 F) 28 C (82 F) 30 C (86 F) 32 C (90 F) 34 C (93 F) 36 C (97 F) 38 C (100 F)

90 85 75 65 60 50 45 40 35 35 30 25 25 20
90 85 75 65 60 50 45 40 35 35 30 25 25 25
90 85 75 65 60 55 45 40 40 35 30 30 25 25
90 85 75 70 60 55 50 45 40 35 30 30 25 25
90 90 80 70 60 55 50 45 40 35 30 30 25 25
90 90 80 70 65 55 50 45 40 35 30 30 25 25
90 90 80 70 65 55 50 45 40 35 35 30 25 25
90 90 80 75 65 60 50 45 40 35 35 30 25 25
90 90 85 75 65 60 50 45 40 35 35 30 25 25
90 90 85 75 65 60 55 45 40 40 35 30 30 25
90 90 85 75 65 60 55 50 45 40 35 30 30 25
90 90 85 75 70 60 55 50 45 40 35 30 30 25
Expected Result: The temperature is less than 38 C (100 F). The ambient relative humidity is within the permissible range for calibration of the oxygen sensor. Results:
1086-13 Oxygen Sensor Element calibration

required
1087-03 Oxygen Buffer Module short to +batt 1087-08 Oxygen Buffer Module noisy signal
OK The ambient conditions are acceptable. Proceed to Test Step 3. Not OK The humidity is not acceptable.
Repair: Do not calibrate the sensor until the humidity is acceptable. STOP.
1088-05 Oxygen Sensor Power Supply open

circuit

to ground C. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. D. Turn ON the Oxygen Sensor Override.

A. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. B. Access the Logged Diagnostic Codes screen on the Caterpillar Electronic Technician ET. If the following codes are logged, clear the codes: E. Allow a minimum of 90 seconds for any diagnostic codes to be generated. F. Access the Logged Diagnostic Codes screen again. Look for the following diagnostic codes again: 1086-09, 1086-13, 1087-03, 1087-08, 1088-05, and 1088-06. Expected Result:
1086-09 Oxygen Sensor Element not

communicating on link None of the above diagnostic codes are logged.
Results:
Expected Result: Successful calibration is indicated by Cat ET. Results:
No Codes The circuit for the oxygen sensor is

OK. Proceed to test Step 4.
Logged 1086-09, 1087-03 or 1087-08 A 1086-09

1087-03 or 1087-08 diagnostic code is active. Repair: Refer to Troubleshooting, Oxygen Sensor Signal. STOP.
OK The calibration was successful. Proceed

to Test Step 5.
Not OK The calibration was not successful. Cat

ET will display a diagnostic code. Repair: Troubleshoot the diagnostic code. Check the connectors for the oxygen sensor and the oxygen buffer. Repeat the calibration procedure. If the procedure is not successful after three attempts, obtain a new oxygen sensor and repeat the calibration procedure. STOP.

There is a problem with the supply voltage for the oxygen buffer. Repair: Refer to Troubleshooting, Oxygen Sensor Buffer Supply. STOP.
Test Step 4. Calibrate the Oxygen Sensor

A. Turn the engine control switch to the OFF/RESET position. Switch the circuit breaker for the ECM OFF.
Test Step 5. Verify the Calibration of the Sensor

A. Access the Diagnostic Override screen of Cat ET. Select Diagnostics/Diagnostic Tests/Override Parameters. B. Turn ON the Oxygen Sensor Override parameter.
During operation, the oxygen sensor may reach temperatures that exceed 700 C (1292 F). Severe personal injury and property damage will result from contact with a hot oxygen sensor. Do not touch the sensor during engine operation, calibration, or testing. Allow the sensor to cool before moving the sensor. Wear gloves that resist heat. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures. B. Disconnect the oxygen sensor from the oxygen buffer. C. Allow the sensor to cool sufficiently for removal. Then remove the sensor from the exhaust system. D. Connect the oxygen sensor to the oxygen buffer. Suspend the sensor in uncontaminated air. E. Switch the circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. F. Access the Service/Calibrations/Oxygen Sensor screen of Cat ET. Use Cat ET to start the calibration. Approximately 12 minutes are required for the calibration.
Expected Result: The Actual Oxygen reading stabilizes to approximately 20.95 percent in about 30 seconds. Results:
OK The calibration of the oxygen sensor is

verified. Allow the sensor to cool before you install the sensor. STOP.
Not OK The calibration of the oxygen sensor

is not verified. Repair: Repeat the calibration procedure. STOP.
383 Index Section
Index
Numerics +5V Sensor Voltage Supply................................. 193 +8V Sensor Voltage Supply................................. 204 A Analog Sensor Signal .......................................... 213 C Calibration Procedures ........................................ 375 Customer Passwords............................................. 28 D Desired Speed Input (4 - 20 mA)......................... 222 Detonation ............................................................. 41 Probable Causes ............................................... 41 Recommended Repairs ..................................... 42 Detonation Sensors ............................................. 228 Diagnostic Codes .................................................. 70 Active Diagnostic Codes .................................... 71 Logged Diagnostic Codes.................................. 71 Diagnostic Functional Tests................................. 193 Driven Equipment .................................................. 43 Probable Causes ............................................... 43 Recommended Repairs ..................................... 43 E E004 Engine Overspeed Shutdown .................... E015 High Engine Coolant Temperature Derate.. E016 High Engine Coolant Temperature Shutdown........................................................... E017 High Engine Coolant Temperature Warning ............................................................. E019 High Engine Oil Temperature Shutdown .... E020 High Engine Oil Temperature Warning....... E025 High Inlet Air Temperature Derate.............. E026 High Inlet Air Temperature Shutdown ........ E027 High Inlet Air Temperature Warning ........... E038 Low Engine Coolant Temperature Warning ............................................................. E040 Low Engine Oil Pressure Shutdown........... E042 Low System Voltage Shutdown.................. E043 Low System Voltage Warning .................... E050 High System Voltage Warning ................... E053 Low Fuel Pressure Warning ....................... E096 High Fuel Pressure .................................... E100 Low Engine Oil Pressure Warning ............. E127 Engine Oil Filter Diff Pressure Low Warning ............................................................. E128 Engine Oil Filter Diff Pressure Low Shutdown........................................................... 149 149 149 150 150 150 151 151 151 151 152 152 152 153 153 153 153 154 154 E129 Engine Oil Filter Diff Pressure High Warning ............................................................. E130 Engine Oil Filter Diff Pressure High Shutdown........................................................... E135 Low Jacket Water Pressure Shutdown....... E223 High Gas Temperature ............................... E224 High Jacket Water Inlet Pressure............... E225 Engine Overcrank ...................................... E226 Driven Equipment Not Ready..................... E229 Fuel Energy Content Setting Low .............. E230 Fuel Energy Content Setting High.............. E231 Fuel Quality Out of Range.......................... E233 Low Engine Pre-Lube Pressure ................. E242 Engine Overload ........................................ E243 High Left Turbo Turbine Outlet Temperature....................................................... E244 High Right Turbo Turbine Outlet Temperature....................................................... E245 High Right Turbo Turbine Inlet Temperature....................................................... E246 High Left Turbo Turbine Inlet Temperature.. E247 Low Left Turbo Turbine Outlet Temperature....................................................... E248 Low Right Turbo Turbine Outlet Temperature....................................................... E249 Low Right Turbo Turbine Inlet Temperature....................................................... E250 Low Left Turbo Turbine Inlet Temperature .. E253 Detonation Derate Requested.................... E254 No Detonation Derate Action Taken........... E264 Emergency Stop Activated ......................... E266 Low Hydrax Oil Pressure ........................... E268 Unexpected Engine Shutdown ................... E269 Customer Shutdown Requested ................ E270 Driven Equipment Shutdown Requested ... E337 High Engine Oil to Engine Coolant Diff Temp .................................................................. E401 Cylinder #1 Detonation............................... E402 Cylinder #2 Detonation............................... E403 Cylinder #3 Detonation............................... E404 Cylinder #4 Detonation............................... E405 Cylinder #5 Detonation............................... E406 Cylinder #6 Detonation............................... E407 Cylinder #7 Detonation............................... E408 Cylinder #8 Detonation............................... E409 Cylinder #9 Detonation............................... E410 Cylinder #10 Detonation............................. E411 Cylinder #11 Detonation............................. E412 Cylinder #12 Detonation............................. E413 Cylinder #13 Detonation............................. E414 Cylinder #14 Detonation............................. E415 Cylinder #15 Detonation............................. E416 Cylinder #16 Detonation............................. E421 Cylinder #1 Detonation Shutdown.............. E422 Cylinder #2 Detonation Shutdown.............. E423 Cylinder #3 Detonation Shutdown.............. E424 Cylinder #4 Detonation Shutdown.............. E425 Cylinder #5 Detonation Shutdown.............. E426 Cylinder #6 Detonation Shutdown.............. E427 Cylinder #7 Detonation Shutdown.............. 154 155 155 155 155 156 156 156 156 157 157 157 157 158 158 159 159 159 160 160 161 161 161 161 162 162 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 168 168 168 169
384 Index Section
E428 Cylinder #8 Detonation Shutdown.............. E429 Cylinder #9 Detonation Shutdown.............. E430 Cylinder #10 Detonation Shutdown............ E431 Cylinder #11 Detonation Shutdown............ E432 Cylinder #12 Detonation Shutdown............ E433 Cylinder #13 Detonation Shutdown............ E434 Cylinder #14 Detonation Shutdown............ E435 Cylinder #15 Detonation Shutdown............ E436 Cylinder #16 Detonation Shutdown............ E801 Cylinder #1 High Exhaust Port Temp ......... E802 Cylinder #2 High Exhaust Port Temp ......... E803 Cylinder #3 High Exhaust Port Temp ......... E804 Cylinder #4 High Exhaust Port Temp ......... E805 Cylinder #5 High Exhaust Port Temp ......... E806 Cylinder #6 High Exhaust Port Temp ......... E807 Cylinder #7 High Exhaust Port Temp ......... E808 Cylinder #8 High Exhaust Port Temp ......... E809 Cylinder #9 High Exhaust Port Temp ......... E810 Cylinder #10 High Exhaust Port Temp ....... E811 Cylinder #11 High Exhaust Port Temp ....... E812 Cylinder #12 High Exhaust Port Temp ....... E813 Cylinder #13 High Exhaust Port Temp ....... E814 Cylinder #14 High Exhaust Port Temp ....... E815 Cylinder #15 High Exhaust Port Temp ....... E816 Cylinder #16 High Exhaust Port Temp ....... E821 Cyl #1 Exhaust Port Temp Deviating High.. E822 Cyl #2 Exhaust Port Temp Deviating High.. E823 Cyl #3 Exhaust Port Temp Deviating High.. E824 Cyl #4 Exhaust Port Temp Deviating High.. E825 Cyl #5 Exhaust Port Temp Deviating High.. E826 Cyl #6 Exhaust Port Temp Deviating High.. E827 Cyl #7 Exhaust Port Temp Deviating High.. E828 Cyl #8 Exhaust Port Temp Deviating High.. E829 Cyl #9 Exhaust Port Temp Deviating High.. E830 Cyl #10 Exhaust Port Temp Deviating High ................................................................... E831 Cyl #11 Exhaust Port Temp Deviating High ................................................................... E832 Cyl #12 Exhaust Port Temp Deviating High ................................................................... E833 Cyl #13 Exhaust Port Temp Deviating High ................................................................... E834 Cyl #14 Exhaust Port Temp Deviating High ................................................................... E835 Cyl #15 Exhaust Port Temp Deviating High ................................................................... E836 Cyl #16 Exhaust Port Temp Deviating High ................................................................... E841 Cyl #1 Exhaust Port Temp Deviating Low .. E842 Cyl #2 Exhaust Port Temp Deviating Low .. E843 Cyl #3 Exhaust Port Temp Deviating Low .. E844 Cyl #4 Exhaust Port Temp Deviating Low .. E845 Cyl #5 Exhaust Port Temp Deviating Low .. E846 Cyl #6 Exhaust Port Temp Deviating Low .. E847 Cyl #7 Exhaust Port Temp Deviating Low .. E848 Cyl #8 Exhaust Port Temp Deviating Low .. E849 Cyl #9 Exhaust Port Temp Deviating Low .. E850 Cyl #10 Exhaust Port Temp Deviating Low.. E851 Cyl #11 Exhaust Port Temp Deviating Low.. E852 Cyl #12 Exhaust Port Temp Deviating Low.. E853 Cyl #13 Exhaust Port Temp Deviating Low..
169 169 169 170 170 170 171 171 171 171 172 172 173 173 173 174 174 174 175 175 176 176 176 177 177 178 178 179 179 179 180 180 181 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188 188 189 189
E854 Cyl #14 Exhaust Port Temp Deviating Low.. 189 E855 Cyl #15 Exhaust Port Temp Deviating Low.. 190 E856 Cyl #16 Exhaust Port Temp Deviating Low.. 190 E864 Low Gas Fuel Differential Pressure ........... 191 E865 High Gas Fuel Differential Pressure........... 191 E866 Low Gas Fuel Flow Rate ............................ 191 E867 Improper Gas Flow Control Valve Response........................................................... 191 E868 Gas Flow Control Valve Malfunction .......... 192 ECM Output Circuit (Fuel Control)....................... 236 ECM Output Circuit (Prelubrication Oil Pump) .... 247 ECM Output Circuit (Starting Motor) ................... 258 ECM Status Indicator Output............................... 268 ECM Will Not Accept Factory Passwords.............. 43 Probable Causes ............................................... 43 Recommended Repairs ..................................... 43 Electrical Connectors and Functions..................... 11 Harness Wire Identification ................................ 11 Sensors.............................................................. 13 Terminal Box ...................................................... 12 Electrical Power Supply....................................... 274 Electrohydraulic System Oil Pressure (Low) ......... 43 Probable Causes ............................................... 43 Recommended Repairs ..................................... 44 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With the Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM))...................................... 45 Probable Causes ............................................... 45 Recommended Repairs ..................................... 45 Electronic Service Tools ........................................ 18 Caterpillar Electronic Technician (ET)................ 20 Electronic Troubleshooting ...................................... 9 Engine Coolant Temperature (High) ...................... 45 Probable Causes ............................................... 45 Recommended Repairs ..................................... 46 Engine Coolant Temperature (Low) ....................... 47 Probable Causes ............................................... 47 Recommended Repairs ..................................... 47 Engine Cranks but Will Not Start ........................... 47 Probable Causes ............................................... 47 Recommended Repairs ..................................... 47 Engine Misfires, Runs Rough or Is Unstable ......... 48 Probable Causes ............................................... 48 Recommended Repairs ..................................... 48 Engine Monitoring System .................................... 21 Changing the Settings of the Monitoring System ............................................................. 21 Default Settings of the Monitoring System......... 23 Engine Power Derating ...................................... 23 Monitoring Parameters....................................... 22 Programmable Parameters of the Integrated Temperature Sensing Module .......................... 26 Engine Oil Filter Differential Pressure ................... 50 Probable Causes ............................................... 50 Recommended Repairs ..................................... 50 Engine Oil Pressure (Low)..................................... 50 Probable Causes ............................................... 50 Recommended Repairs ..................................... 50
385 Index Section
Engine Oil Temperature (High) .............................. 51 Probable Causes ............................................... 51 Recommended Repairs ..................................... 51 Engine Overcrank.................................................. 51 Probable Causes ............................................... 51 Recommended Repairs ..................................... 52 Engine Overload.................................................... 52 Probable Causes ............................................... 52 Recommended Repairs ..................................... 53 Engine Overspeed................................................. 53 Probable Causes ............................................... 53 Recommended Repairs ..................................... 53 Engine Pre-Lube Pressure (Low) .......................... 53 Probable Causes ............................................... 53 Recommended Repairs ..................................... 54 Engine Shutdown .................................................. 54 Probable Causes ............................................... 54 Recommended Repairs ..................................... 54 Engine Shutdown (Unexpected)............................ 55 Probable Causes ............................................... 55 Recommended Repair ....................................... 55 Engine Shutdown without a Diagnostic Code........ 56 Probable Causes ............................................... 56 Recommended Repairs ..................................... 57 Engine Speed/Timing Sensor.............................. 281 Engine Speed/Timing Sensor - Calibrate ............ 375 Engine Starts but Stalls Immediately..................... 57 Probable Causes ............................................... 57 Recommended Repairs ..................................... 57 Engine Timing Does Not Match Programmed Timing .................................................................. 58 Probable Causes ............................................... 58 Recommended Repairs ..................................... 58 Engine Will Not Crank ........................................... 59 Probable Causes ............................................... 59 Recommended Repairs ..................................... 59 Event Codes ........................................................ 147 Active Event Codes.......................................... 148 Diagnostic Codes and Event Codes ................ 148 Logged Event Codes ....................................... 149 Operator Information........................................ 148 Other Symptoms .............................................. 148 Troubleshooting................................................ 148 Exhaust Port Temperature (High) .......................... 60 Probable Causes ............................................... 60 Recommended Repairs ..................................... 60 Exhaust Port Temperature (Low) ........................... 61 Probable Causes ............................................... 61 Recommended Repairs ..................................... 61 F
Fuel Pressure ........................................................ 62 Probable Causes ............................................... 62 Recommended Repairs ..................................... 62 G Gas Fuel Differential Pressure (High).................... Probable Causes ............................................... Recommended Repairs ..................................... Gas Fuel Differential Pressure (Low) .................... Probable Causes ............................................... Recommended repairs....................................... Gas Fuel Flow Rate (Low) ..................................... Probable Causes ............................................... Recommended Repairs ..................................... Gas Temperature (High) ........................................ Probable Causes ............................................... Recommended Repairs ..................................... I Ignition Transformers Primary Circuit .................. 303 Ignition Transformers Secondary Circuit and Spark Plugs.................................................................. 314 Important Safety Information ................................... 2 Inlet Air Temperature (High) .................................. 64 Probable Causes ............................................... 64 Recommended Repairs ..................................... 65 Inspecting Electrical Connectors ......................... 320 Integrated Temperature Sensing Module (ITSM)................................................................ 325 Intermittent Engine Shutdown ............................... 65 Probable Causes ............................................... 65 Recommended Repairs ..................................... 65 J Jacket Water Inlet Pressure (High)........................ 66 Probable Causes ............................................... 66 Recommended Repairs ..................................... 66 Jacket Water Pressure (Low)................................. 67 Probable Causes ............................................... 67 Recommended Repairs ..................................... 67 Jacket Water to Engine Oil Differential Temperature (Low).................................................................... 67 Probable Causes ............................................... 67 Recommended Repairs ..................................... 67 M 62 62 62 63 63 63 63 63 63 64 64 64
Factory Passwords ................................................ 29 Factory Passwords Worksheet .............................. 29 Flash Programming ............................................... 29 Flash Programming............................................ 30 Fuel Energy Content.............................................. 61 Probable Causes ............................................... 61 Recommended Repairs ..................................... 61 Fuel Metering Valve............................... 62, 287, 295 Probable Causes ............................................... 62 Recommended Repairs ..................................... 62
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Value open circuit .......................................................... 71 MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground.............................................................. 72 MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction .......................................................... 72 MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt................................................................. 72
386 Index Section
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground.............................................................. 73 MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt .............................................. 73 MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground .................................................... 74 MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt ........................................... 74 MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal.............................................. 74 MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt .............................................. 75 MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal .............................. 75 MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt ......................... 75 MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground ............................... 76 MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt ........................................... 76 MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground ........................................ 76 MID 036 - CID 0168 - FMI 02 System Voltage intermittent/erratic................................................ 77 MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt..................................... 77 MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground........................................... 78 MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt .............................................. 78 MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground .................................................... 79 MID 036 - CID 0261 - FMI 13 Engine Timing calibration required .............................................. 79 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt ........................................... 79 MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground ........................................ 80 MID 036 - CID 0301 - FMI 05 Cylinder 1 - Transformer Primary open circuit............................................. 80 MID 036 - CID 0301 - FMI 06 Cylinder 1 - Transformer Primary short ....................................................... 81 MID 036 - CID 0302 - FMI 05 Cylinder 2 - Transformer Primary open circuit............................................. 81 MID 036 - CID 0302 - FMI 06 Cylinder 2 - Transformer Primary short ....................................................... 81 MID 036 - CID 0303 - FMI 05 Cylinder 3 - Transformer Primary open circuit............................................. 82 MID 036 - CID 0303 - FMI 06 Cylinder 3 - Transformer Primary short ....................................................... 82 MID 036 - CID 0304 - FMI 05 Cylinder 4 - Transformer Primary open circuit............................................. 82 MID 036 - CID 0304 - FMI 06 Cylinder 4 - Transformer Primary short ....................................................... 83 MID 036 - CID 0305 - FMI 05 Cylinder 5 - Transformer Primary open circuit............................................. 83 MID 036 - CID 0305 - FMI 06 Cylinder 5 - Transformer Primary short ....................................................... 84 MID 036 - CID 0306 - FMI 05 Cyinder 6 - Transformer Primary open circuit............................................. 84
MID 036 - CID 0306 - FMI 06 Cylinder 6 - Transformer Primary short ....................................................... 84 MID 036 - CID 0307 - FMI 05 Cylinder 7 - Transformer Primary open circuit............................................. 85 MID 036 - CID 0307 - FMI 06 Cylinder 7 - Transformer Primary short ....................................................... 85 MID 036 - CID 0308 - FMI 05 Cylinder 8 - Transformer Primary open circuit............................................. 85 MID 036 - CID 0308 - FMI 06 Cylinder 8 - Transformer Primary short ....................................................... 86 MID 036 - CID 0309 - FMI 05 Cylinder 9 - Transformer Primary open circuit............................................. 86 MID 036 - CID 0309 - FMI 06 Cylinder 9 - Transformer Primary short ....................................................... 87 MID 036 - CID 0310 - FMI 05 Cylinder 10 Transformer Primary open circuit......................... 87 MID 036 - CID 0310 - FMI 06 Cylinder 10 Transformer Primary short ................................... 87 MID 036 - CID 0311 - FMI 05 Cylinder 11 Transformer Primary open circuit......................... 88 MID 036 - CID 0311 - FMI 06 Cylinder 11 Transformer Primary short ................................... 88 MID 036 - CID 0312 - FMI 05 Cylinder 12 Transformer Primary open circuit......................... 88 MID 036 - CID 0312 - FMI 06 Cylinder 12 Transformer Primary short ................................... 89 MID 036 - CID 0313 - FMI 05 Cylinder 13 Transformer Primary open circuit......................... 89 MID 036 - CID 0313 - FMI 06 Cylinder 13 Transformer Primary short ................................... 90 MID 036 - CID 0314 - FMI 05 Cylinder 14 Transformer Primary open circuit......................... 90 MID 036 - CID 0314 - FMI 06 Cylinder 14 Transformer Primary short ................................... 90 MID 036 - CID 0315 - FMI 05 Cylinder 15 Transformer Primary open circuit......................... 91 MID 036 - CID 0315 - FMI 06 Cylinder 15 Transformer Primary short ................................... 91 MID 036 - CID 0316 - FMI 05 Cylinder 16 Transformer Primary open circuit......................... 91 MID 036 - CID 0316 - FMI 06 Cylinder 16 Transformer Primary short ................................... 92 MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt ....................................................... 92 MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................... 93 MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt................................................................. 93 MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt..................................................................... 93 MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs ................................................................... 94 MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open circuit ................................................................... 94 MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short to ground.............................................................. 94 MID 036 - CID 0339 - FMI 05 Engine Pre-lube Pressure Switch open circuit ............................... 95 MID 036 - CID 0401 - FMI 05 Cylinder 1 - Transformer Secondary open circuit ........................................ 95
387 Index Section
MID 036 - CID 0401 - FMI 06 Cylinder 1 - Transformer Secondary short to ground .................................. 95 MID 036 - CID 0402 - FMI 05 Cylinder 2 - Transformer Secondary open circuit ........................................ 96 MID 036 - CID 0402 - FMI 06 Cylinder 2 - Transformer Secondary short to ground .................................. 96 MID 036 - CID 0403 - FMI 05 Cylinder 3 - Transformer Secondary open circuit ........................................ 97 MID 036 - CID 0403 - FMI 06 Cylinder 3 - Transformer Secondary short to ground .................................. 97 MID 036 - CID 0404 - FMI 05 Cylinder 4 - Transformer Secondary open circuit ........................................ 97 MID 036 - CID 0404 - FMI 06 Cylinder 4 - Transformer Secondary short to ground .................................. 98 MID 036 - CID 0405 - FMI 05 Cylinder 5 - Transformer Secondary open circuit ........................................ 98 MID 036 - CID 0405 - FMI 06 Cylinder 5 - Transformer Secondary short to ground .................................. 99 MID 036 - CID 0406 - FMI 05 Cylinder 6 - Transformer Secondary open circuit ........................................ 99 MID 036 - CID 0406 - FMI 06 Cylinder 6 - Transformer Secondary short to ground .................................. 99 MID 036 - CID 0407 - FMI 05 Cylinder 7 - Transformer Secondary open circuit ...................................... 100 MID 036 - CID 0407 - FMI 06 Cylinder 7 - Transformer Secondary short to ground ................................ 100 MID 036 - CID 0408 - FMI 05 Cylinder 8 - Transformer Secondary open circuit ...................................... 100 MID 036 - CID 0408 - FMI 06 Cylinder 8 - Transformer Secondary short to ground ................................ 101 MID 036 - CID 0409 - FMI 05 Cylinder 9 - Transformer Secondary open circuit ...................................... 101 MID 036 - CID 0409 - FMI 06 Cylinder 9 - Transformer Secondary short to ground ................................ 102 MID 036 - CID 0410 - FMI 05 Cylinder 10 Transformer Secondary open circuit .................. 102 MID 036 - CID 0410 - FMI 06 Cylinder 10 Transformer Secondary short to ground ............ 103 MID 036 - CID 0411 - FMI 05 Cylinder 11 Transformer Secondary open circuit .................. 103 MID 036 - CID 0411 - FMI 06 Cylinder 11 Transformer Secondary short to ground ............ 103 MID 036 - CID 0412 - FMI 05 Cylinder 12 Transformer Secondary open circuit .................. 104 MID 036 - CID 0412 - FMI 06 Cylinder 12 Transformer Secondary short to ground ............ 104 MID 036 - CID 0413 - FMI 05 Cylinder 13 Transformer Secondary open circuit .................. 104 MID 036 - CID 0413 - FMI 06 Cylinder 13 Transformer Secondary short to ground ............ 105 MID 036 - CID 0414 - FMI 05 Cylinder 14 Transformer Secondary open circuit .................. 105 MID 036 - CID 0414 - FMI 06 Cylinder 14 Transformer Secondary short to ground ............ 106 MID 036 - CID 0415 - FMI 05 Cylinder 15 Transformer Secondary open circuit .................. 106 MID 036 - CID 0415 - FMI 06 Cylinder 15 Transformer Secondary short to ground ............ 107 MID 036 - CID 0416 - FMI 05 Cylinder 16 Transformer Secondary open circuit .................. 107 MID 036 - CID 0416 - FMI 06 Cylinder 16 Transformer Secondary short to ground ............ 107
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt ..................................................... 108 MID 036 - CID 0444 - FMI 05 Start Relay open circuit ................................................................. 108 MID 036 - CID 0444 - FMI 06 Start Relay short to ground................................................................ 108 MID 036 - CID 0445 - FMI 03 Run Relay short to +batt................................................................... 109 MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt ......................................... 109 MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground ...................................... 109 MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt ............................. 110 MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground ................................... 110 MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM........................................................... 110 MID 036 - CID 1086 - FMI 09 Oxygen Sensor Element not communicating on link ................... 111 MID 036 - CID 1086 - FMI 13 Oxygen Sensor Element calibration required .............................. 111 MID 036 - CID 1087 - FMI 03 Oxygen Sensor Buffer Module short to +batt......................................... 112 MID 036 - CID 1087 - FMI 08 Oxygen Sensor Buffer Module noisy signal ........................................... 112 MID 036 - CID 1088 - FMI 05 Oxygen Sensor Power Supply open circuit ............................................ 112 MID 036 - CID 1088 - FMI 06 Oxygen Sensor Power Supply short to ground ...................................... 113 MID 036 - CID 1440 - FMI 05 Throttle Actuator Driver open circuit ........................................................ 113 MID 036 - CID 1440 - FMI 06 Throttle Actuator Driver short to ground .................................................. 113 MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit ........................................................ 114 MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module ................................ 114 MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction ........................................................ 114 MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required ............................................ 115 MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction............................................ 115 MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt ................................ 115 MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground ...................................... 116 MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Sensor open/short to +batt ................................ 116 MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Sensor short to ground ...................................... 116 MID 036 - CID 1505 - FMI 03 Cylinder #5 Detonation Sensor open/short to +batt ................................ 117 MID 036 - CID 1505 - FMI 04 Cylinder #5 Detonation Sensor short to ground ...................................... 117 MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ................................ 117 MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Sensor short to ground ...................................... 118 MID 036 - CID 1509 - FMI 03 Cylinder #9 Detonation Sensor open/short to +batt ................................ 118
388 Index Section
MID 036 - CID 1509 - FMI 04 Cylinder #9 Detonation Sensor short to ground ...................................... 118 MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt ................................ 119 MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground ...................................... 119 MID 036 - CID 1513 - FMI 03 Cylinder #13 Detonation Sensor open/short to +batt ................................ 119 MID 036 - CID 1513 - FMI 04 Cylinder #13 Detonation Sensor short to ground ...................................... 120 MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt ................................ 120 MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground ...................................... 120 MID 036 - CID 1758 - FMI 03 Specific Humidity Sensor open/short to +batt ................................ 121 MID 036 - CID 1758 - FMI 08 Specific Humidity Sensor signal abnormal..................................... 121 MID 036 - CID 1759 - FMI 03 Exhaust Back Pressure Sensor open/short to +batt ................................ 122 MID 036 - CID 1759 - FMI 08 Exhaust Back Pressure Sensor signal abnormal..................................... 122 MID 111 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed............................ 122 MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt................................... 123 MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sens short to ground ............................... 123 MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sens open circuit ..................................... 123 MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt................................... 124 MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sens short to ground ............................... 124 MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sens open circuit ..................................... 124 MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sens short to +batt................................... 125 MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sens short to ground ............................... 125 MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sens open circuit ..................................... 125 MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sens short to +batt................................... 126 MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sens short to ground ............................... 126 MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sens open circuit ..................................... 126 MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt ............................... 127 MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground ............................ 127 MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit .................................. 128 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt ............................... 128 MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground ............................ 128 MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit .................................. 129
MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt ............................... 129 MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground ............................ 130 MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit .................................. 130 MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt ............................... 130 MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground ............................ 131 MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit .................................. 131 MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ............................... 132 MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ............................ 132 MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit .................................. 132 MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt ............................... 133 MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground ............................ 133 MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit .................................. 133 MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt ............................... 134 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ............................ 134 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit .................................. 135 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ............................... 135 MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground ............................ 135 MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit .................................. 136 MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt ............................... 136 MID 111 - CID 1539 - FMI 04 CYL #9 Exhaust Port Temp Sensor short to ground ............................ 137 MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit .................................. 137 MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt ............................... 137 MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground ............................ 138 MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit .................................. 138 MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ............................... 139 MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ............................ 139 MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit .................................. 139 MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ............................... 140 MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground ............................ 140 MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit .................................. 141
389 Index Section
MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ............................... 141 MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground ............................ 141 MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit .................................. 142 MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ............................... 142 MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground ............................ 143 MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit .................................. 143 MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ............................... 143 MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ............................ 144 MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit .................................. 144 MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt ............................... 145 MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground ............................ 145 MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit .................................. 145 O Oxygen Sensor - Calibrate .................................. 377 Oxygen Sensor Buffer Supply ............................. 333 Oxygen Sensor Signal......................................... 342 P Prelubrication System ......................................... 354 Programming Parameters...................................... 28 PWM Sensor ....................................................... 358 R Replacing the ECM................................................ 36 Replacing the ITSM ............................................... 38 S Self-Diagnostics..................................................... Symptoms.............................................................. Diagnostic Codes and Event Codes .................. Operator Information.......................................... Other Symptoms ................................................ System Configuration Parameters......................... Air/Fuel Ratio Control......................................... Information for the Electronic Control Module (ECM)............................................................... Monitoring and Protection ............................... Override Parameters.......................................... Speed Control .................................................... Start/Stop Control Parameters........................... Timing Control.................................................... 10 41 41 41 41 30 32 31 36 36 33 35 32
System Overview..................................................... 9 Air/Fuel Ratio Control........................................... 9 Engine Monitoring and Protection...................... 10 Engine Speed Governing..................................... 9 Ignition Control..................................................... 9 Introduction .......................................................... 9 Start/Stop Sequencing....................................... 10 System Voltage...................................................... 68 Probable Causes ............................................... 68 Recommended Repairs ..................................... 68 T Table of Contents..................................................... 3 Throttle Actuator Solenoid ................................... 365 Troubleshooting Data Sheet .................................. 39 Report the Service Information.......................... 40 Troubleshooting Section .......................................... 9 Troubleshooting with a Diagnostic Code ............... 70 Troubleshooting with an Event Code ................... 147 Troubleshooting without a Diagnostic Code .......... 41 Turbocharger Turbine Temperature (High)............. 68 Probable Causes ............................................... 68 Recommended Repairs ..................................... 68 Turbocharger Turbine Temperature (Low).............. 69 Probable Causes ............................................... 69 Recommended Repairs ..................................... 69
390 Index Section
391 Index Section
2002 Caterpillar All Rights Reserved
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RENR2270-02 June 2002

Important Safety Information

Troubleshooting Section Electronic Troubleshooting

Engine Speed Governing

Air/Fuel Ratio Control

Desired engine speed Actual engine speed

Calculated engine load

Engine Monitoring and Protection

Electrical Connectors and Functions

Harness Wire Identification

(5) Engine coolant temperature sensor

Electronic Service Tools

Integrated Temperature Sensing Module

Illustration 7 Integrated temperature sensing module

The temperature is higher than the limit that is

The temperature is lower than the limit that is

The temperature of a cylinder deviates

Personal Computer (PC)

Software Communication Adapter II (1) Serial Cable As Serial Cable As

Caterpillar Electronic Technician (ET)

Diagnostic tests Sensor calibration

Connecting Cat ET with the 7X-1701 Communication Adapter

1. Turn the engine control switch to the OFF position.

Engine Monitoring System

Changing the Settings of the Monitoring System

High Jacket Water to the Engine Oil Temperature Differential

Low Gas Fuel Differential Pressure

High Engine Coolant Temperature

High Gas Fuel Differential Pressure

Low Engine Coolant Temperature

High System Voltage

High Engine Oil Temperature

High Oil Filter Differential Pressure

Low Oil Filter Differential Pressure

High Inlet Air Temperature at Low Engine Load

High Fuel Temperature

Low Fuel Pressure

High Inlet Air Temperature at High Engine Load

Default Settings of the Monitoring System

High Fuel Pressure

Engine Power Derating

E025 High Inlet Air Temperature at High Engine

E242 Engine Overload

System Response Warning Shutdown Warning Shutdown Derating Warning

Trip Point 20 volts

Security Level Password

Range of the Delay in Seconds

18 volts 113 C 111 C 109 C 5 C 1770 rpm 102 C 104 C

This item cannot be programmed.

80 to 129 C 20 Customer 5 to 80 C 1200 to 2125 rpm 85 to 102 C 85 to 104 C 80 to 138 kPa 1 to 60

Shutdown Warning Shutdown Warning Shutdown Warning Shutdown On

Factory Customer Factory Customer Factory Customer Factory

103 kPa 138 kPa 35 kPa 7 kPa 60 C 20 10 10

On E053 (1) E123 (1) On E124 (3) Shutdown

100 to 135 kPa 0 to 20 C

E864 (1) On E865 (1) Warning On

5 kPa 10 35 kPa Customer 0 to 35 kPa

34 volts 69 C 100 C 73 C 53 C 100 C 57 C 135 kPa

This item cannot be programmed. 32 to 85 C

100 to 135 kPa

This parameter is permanently active. This parameter cannot be turned off.

Conditions for Parameters

Programmable Parameters of the Integrated Temperature Sensing Module

High Exhaust Temperature

18 volts 113 C 111 C 109 C 5 C 1770 rpm 102 C 104 C

80 to 129 C 20 Customer 5 to 80 C 1200 to 2125 rpm 85 to 102 C 85 to 104 C 80 to 138 kPa 1 to 60

103 kPa 138 kPa 35 kPa 7 kPa 60 C 20 10 10

100 to 135 kPa 0 to 20 C

34 volts 69 C 100 C 73 C 53 C 100 C 57 C 135 kPa

This item cannot be programmed. 32 to 85 C