RENR5979-03 March 2004

Troubleshooting
G3520C and G3520E Engines
GDB1-Up (Engine) GHC1-Up (Engine) GHE1-Up (Engine) GHM1-Up (Engine) GHR1-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.

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Table of Contents
Troubleshooting Section
Electronic Troubleshooting System Overview .................................................. 10 Self-Diagnostics ..................................................... 11 Location of Components ....................................... 12 Electrical Connectors and Functions .................... 16 Electronic Service Tools ........................................ 18 Engine Monitoring System .................................... 20 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 ................................. 27 27 27 28 29 29 30 32 34

Inlet Air Temperature (High) .................................. 59 Intermittent Engine Shutdown ............................... 60 Jacket Water Inlet Pressure (High) ....................... 60 Jacket Water Pressure (Low) ................................ 61 Jacket Water to Engine Oil Differential Temperature (Low) ................................................................... 61 System Voltage ..................................................... 62 Turbocharger Turbine Temperature (High) ........... 62 Turbocharger Turbine Temperature (Low) ............ 63 Troubleshooting with a Diagnostic Code Diagnostic Codes .................................................. 65 MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt ................................................................ 66 MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short to ground ............................................................. 67 MID 033 - CID 0168 - FMI 02 System Voltage intermittent/erratic ............................................... 67 MID 033 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit ....................................... 67 MID 033 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short .................................................. 68 MID 033 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit ....................................... 68 MID 033 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short .................................................. 68 MID 033 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit ....................................... 69 MID 033 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short .................................................. 69 MID 033 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit ....................................... 69 MID 033 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short .................................................. 70 MID 033 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit ....................................... 70 MID 033 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short .................................................. 71 MID 033 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit ..................................... 71 MID 033 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short ................................................ 71 MID 033 - CID 0313 - FMI 05 Ignition Transformer Primary #13 open circuit ..................................... 72 MID 033 - CID 0313 - FMI 06 Ignition Transformer Primary #13 short ................................................ 72 MID 033 - CID 0315 - FMI 05 Ignition Transformer Primary #15 open circuit ..................................... 72 MID 033 - CID 0315 - FMI 06 Ignition Transformer Primary #15 short ................................................ 73 MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt ....................................................... 73 MID 033 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................... 74 MID 033 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit .................................. 74 MID 033 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground ............................. 74 MID 033 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit .................................. 75 MID 033 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground ............................. 75

Troubleshooting without a Diagnostic Code Symptoms ............................................................. 36 Detonation ............................................................ 36 Driven Equipment ................................................. 38 ECM Will Not Accept Factory Passwords ............. 38 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With an Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)) ..................................... 38 Engine Coolant Temperature (High) ..................... 39 Engine Coolant Temperature (Low) ...................... 41 Engine Cranks but Will Not Start .......................... 41 Engine Misfires, Runs Rough or Is Unstable ........ 42 Engine Oil Filter Differential Pressure ................... 44 Engine Oil Pressure (Low) .................................... 44 Engine Oil Temperature (High) ............................. 45 Engine Overcrank ................................................. 46 Engine Overload ................................................... 47 Engine Overspeed ................................................ 47 Engine Shutdown .................................................. 48 Engine Shutdown (Unexpected) ........................... 48 Engine Shutdown without a Diagnostic Code ....... 50 Engine Starts but Stalls Immediately .................... 51 Engine Timing Does Not Match Programmed Timing ................................................................. 51 Engine Will Not Crank ........................................... 52 Exhaust Port Temperature (High) ......................... 53 Exhaust Port Temperature (Low) .......................... 54 Fuel Energy Content ............................................. 55 Fuel Metering Valve .............................................. 55 Fuel Pressure ....................................................... 55 Gas Fuel Differential Pressure (High) ................... 55 Gas Fuel Differential Pressure (Low) .................... 56 Gas Fuel Flow Rate (Low) .................................... 56 Gas Temperature (High) ....................................... 57 Generator Output Power Readings Do Not Match .................................................................. 58

4 Table of Contents

MID 033 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit .................................. 75 MID 033 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground ............................. 76 MID 033 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit .................................. 76 MID 033 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground ............................. 77 MID 033 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit .................................. 77 MID 033 - CID 0409 - FMI 06 Ignition Transformer Secondary #9 short to ground ............................. 77 MID 033 - CID 0411 - FMI 05 Ignition Transformer Secondary #11 open circuit ................................. 78 MID 033 - CID 0411 - FMI 06 Ignition Transformer Secondary #11 short to ground ........................... 78 MID 033 - CID 0413 - FMI 05 Ignition Transformer Secondary #13 open circuit ................................ 79 MID 033 - CID 0413 - FMI 06 Ignition Transformer Secondary #13 short to ground ........................... 79 MID 033 - CID 0415 - FMI 05 Ignition Transformer Secondary #15 open circuit ................................ 79 MID 033 - CID 0415 - FMI 06 Ignition Transformer Secondary #15 short to ground ........................... 80 MID 033 - CID 0590 - FMI 09 Unable to communicate with Engine ECM ................................................ 80 MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt ................................. 81 MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground ....................................... 81 MID 033 - CID 1505 - FMI 03 Cylinder #5 Detonation Sensor open/short to +batt ................................. 81 MID 033 - CID 1505 - FMI 04 Cylinder #5 Detonation Sensor short to ground ....................................... 82 MID 033 - CID 1509 - FMI 03 Cylinder #9 Detonation Sensor open/short to +batt ................................. 82 MID 033 - CID 1509 - FMI 04 Cylinder #9 Detonation Sensor short to ground ....................................... 82 MID 033 - CID 1513 - FMI 03 Cylinder #13 Detonation Sensor open/short to +batt ................................. 83 MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation Sensor short to ground ....................................... 83 MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation Sensor open/short to +batt ................................. 83 MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation Sensor short to ground ....................................... 84 MID 033 - CID 1748 - FMI 05 Ignition Transformer Secondary #17 open circuit ................................ 84 MID 033 - CID 1748 - FMI 06 Ignition Transformer Secondary #17 short to ground ........................... 84 MID 033 - CID 1750 - FMI 05 Ignition Transformer Secondary #19 open circuit ................................ 85 MID 033 - CID 1750 - FMI 06 Ignition Transformer Secondary #19 short to ground ........................... 85 MID 033 - CID 1752 - FMI 05 Ignition Transformer Primary #17 open circuit ..................................... 85 MID 033 - CID 1752 - FMI 06 Ignition Transformer Primary #17 short to ground ............................... 86 MID 033 - CID 1754 - FMI 05 Ignition Transformer Primary #19 open circuit ..................................... 86

MID 033 - CID 1754 - FMI 06 Ignition Transformer Primary #19 short to ground ............................... 87 MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open circuit ................................................................... 87 MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground ............................................................. 87 MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction .......................................................... 88 MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt ................................................................ 88 MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground ............................................................. 88 MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt .............................................. 89 MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground .................................................... 89 MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt .......................................... 90 MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal ............................................. 90 MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt .............................................. 90 MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal ............................. 91 MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt ......................... 91 MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground ............................... 91 MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt ........................................... 92 MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground ........................................ 92 MID 036 - CID 0168 - FMI 02 System Voltage intermittent/erratic ............................................... 92 MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt .................................... 93 MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground .......................................... 93 MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt .............................................. 93 MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground .................................................... 94 MID 036 - CID 0261 - FMI 13 Engine Timing calibration required ............................................. 94 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt ................................ 95 MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground ............................. 95 MID 036 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit ....................................... 96 MID 036 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short .................................................. 96 MID 036 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit ....................................... 96 MID 036 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short .................................................. 97 MID 036 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit ....................................... 97 MID 036 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short .................................................. 97

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MID 036 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit ....................................... 98 MID 036 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short .................................................. 98 MID 036 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit ..................................... 98 MID 036 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short ................................................ 99 MID 036 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit ..................................... 99 MID 036 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short .............................................. 100 MID 036 - CID 0314 - FMI 05 Ignition Transformer Primary #14 open circuit ................................... 100 MID 036 - CID 0314 - FMI 06 Ignition Transformer Primary #14 short .............................................. 100 MID 036 - CID 0316 - FMI 05 Ignition Transformer Primary #16 open circuit ................................... 101 MID 036 - CID 0316 - FMI 06 Ignition Transformer Primary #16 short .............................................. 101 MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt ..................................................... 101 MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................. 102 MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt .............................................................. 102 MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt .................................................................. 102 MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs ................................................................ 103 MID 036 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit ................................ 103 MID 036 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground ........................... 103 MID 036 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit ................................ 104 MID 036 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground ........................... 104 MID 036 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit ................................ 105 MID 036 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground ........................... 105 MID 036 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit ................................ 105 MID 036 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground ........................... 106 MID 036 - CID 0410 - FMI 05 Ignition Transformer Secondary #10 open circuit .............................. 106 MID 036 - CID 0410 - FMI 06 Ignition Transformer Secondary #10 short to ground ......................... 107 MID 036 - CID 0412 - FMI 05 Ignition Transformer Secondary #12 open circuit .............................. 107 MID 036 - CID 0412 - FMI 06 Ignition Transformer Secondary #12 short to ground ......................... 107 MID 036 - CID 0414 - FMI 05 Ignition Transformer Secondary #14 open circuit .............................. 108 MID 036 - CID 0414 - FMI 06 Ignition Transformer Secondary #14 short to ground ......................... 108 MID 036 - CID 0416 - FMI 05 Ignition Transformer Secondary #16 open circuit .............................. 108 MID 036 - CID 0416 - FMI 06 Ignition Transformer Secondary #16 short to ground ......................... 109

MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt ..................................................... 109 MID 036 - CID 0444 - FMI 05 Start Relay open circuit .................................................................. 110 MID 036 - CID 0444 - FMI 06 Start Relay short to ground ................................................................ 110 MID 036 - CID 0445 - FMI 03 Run Relay short to +batt ................................................................... 110 MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt ......................................... 111 MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground ...................................... 111 MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt ............................. 111 MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground ................................... 112 MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM ........................................................... 112 MID 036 - CID 1440 - FMI 09 Unable to communicate with Throttle Actuator Drv .................................. 113 MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit ......................................................... 113 MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module ................................. 113 MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction ......................................................... 114 MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required ............................................ 114 MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction ............................................ 114 MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Sensor open/short to +batt ................................ 114 MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Sensor short to ground ...................................... 115 MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ................................ 115 MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Sensor short to ground ...................................... 115 MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt ................................ 116 MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground ...................................... 116 MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt ................................ 116 MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground ...................................... 117 MID 036 - CID 1518 - FMI 03 Cylinder #18 Detonation Sensor open/short to +batt ................................ 117 MID 036 - CID 1518 - FMI 04 Cylinder #18 Detonation Sensor short to ground ...................................... 117 MID 036 - CID 1636 - FMI 09 Loss of Communication with Engine #2 (Slave) ....................................... 118 MID 036 - CID 1719 - FMI 03 Generator Output Power Sensor open/short to +batt ..................... 118 MID 036 - CID 1719 - FMI 04 Generator Output Power Sensor short to ground ........................... 118 MID 036 - CID 1719 - FMI 12 Generator Output Power Sensor malfunction ................................. 119 MID 036 - CID 1720 - FMI 09 Turbocharger Compressor Bypass Valve Actuator not communicating on link ....................................... 119 MID 036 - CID 1749 - FMI 05 Ignition Transformer Secondary #18 open circuit ............................... 119

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MID 036 - CID 1749 - FMI 06 Ignition Transformer Secondary #18 short to ground ......................... 120 MID 036 - CID 1751 - FMI 05 Ignition Transformer Secondary #20 open circuit .............................. 120 MID 036 - CID 1751 - FMI 06 Ignition Transformer Secondary #20 short to ground ......................... 120 MID 036 - CID 1753 - FMI 05 Ignition Transformer Primary #18 open circuit ................................... 121 MID 036 - CID 1753 - FMI 06 Ignition Transformer Primary #18 short to ground ............................. 121 MID 036 - CID 1755 - FMI 05 Ignition Transformer Primary #20 open circuit ................................... 121 MID 036 - CID 1755 - FMI 06 Ignition Transformer Primary #20 short to ground ............................. 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 .................................. 122 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 .................................. 123 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 .................................. 124 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 .................................. 125 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 ............................... 126 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 ................................. 127 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt ............................... 127 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 ................................. 128 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 ............................ 129 MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit ................................. 129 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 ............................ 130 MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit ................................. 130 MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ............................... 131 MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ............................ 131 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 ............................... 132 MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground ............................ 132 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 ............................... 133 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ............................ 133 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit ................................. 134 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ............................... 134 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 ................................. 135 MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt ............................... 135 MID 111 - CID 1539 - FMI 04 Cyl #9 Exhaust Port Temp Sensor short to ground ............................ 136 MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit ................................. 136 MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt ............................... 136 MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground ............................ 137 MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit ................................. 137 MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ............................... 138 MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ............................ 138 MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit ................................. 138 MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ............................... 139 MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground ............................ 139 MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit ................................. 139 MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ............................... 140 MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground ............................ 140 MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit ................................. 141 MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ............................... 141

7 Table of Contents

MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground ............................ 141 MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit ................................. 142 MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ............................... 142 MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ............................ 142 MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit ................................. 143 MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt ............................... 143 MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground ............................ 144 MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit ................................. 144 MID 111 - CID 1547 - FMI 03 Cyl #17 Exhaust Port Temp Sensor short to +batt ............................... 144 MID 111 - CID 1547 - FMI 04 Cyl #17 Exhaust Port Temp Sensor short to ground ............................ 145 MID 111 - CID 1547 - FMI 05 Cyl #17 Exhaust Port Temp Sensor open circuit ................................. 145 MID 111 - CID 1548 - FMI 03 Cyl #18 Exhaust Port Temp Sensor short to +batt ............................... 145 MID 111 - CID 1548 - FMI 04 Cyl #18 Exhaust Port Temp Sensor short to ground ............................ 146 MID 111 - CID 1548 - FMI 05 Cyl #18 Exhaust Port Temp Sensor open circuit ................................. 146 MID 111 - CID 1549 - FMI 03 Cyl #19 Exhaust Port Temp Sensor short to +batt ............................... 147 MID 111 - CID 1549 - FMI 04 Cyl #19 Exhaust Port Temp Sensor short to ground ............................ 147 MID 111 - CID 1549 - FMI 05 Cyl #19 Exhaust Port Temp Sensor open circuit ................................. 147 MID 111 - CID 1550 - FMI 03 Cyl #20 Exhaust Port Temp Sensor short to +batt ............................... 148 MID 111 - CID 1550 - FMI 04 Cyl #20 Exhaust Port Temp Sensor short to ground ............................ 148 MID 111 - CID 1550 - FMI 05 Cyl #20 Exhaust Port Temp Sensor open circuit ................................. 148 Troubleshooting with an Event Code Event Codes ...................................................... E004 Engine Overspeed Shutdown .................... E016 High Engine Coolant Temperature Shutdown .......................................................... E017 High Engine Coolant Temperature Warning ............................................................. E019 High Engine Oil Temperature Shutdown ... E020 High Engine Oil Temperature Warning ...... 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 ............................................................. 150 152 152 153 153 153 153 154 154 154 155 155 155 155 156 156 156

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 ......................... 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 ...................................................... E264 Emergency Stop Activated ........................ 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 ............................ E417 Cylinder #17 Detonation ............................ E418 Cylinder #18 Detonation ............................ E419 Cylinder #19 Detonation ............................ E420 Cylinder #20 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 ............. 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 ...........

156 157 157 157 158 158 158 158 159 159 159 159 160 160 161 161 161 161 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 167 168 168 168 168 169 169 169 169 170 170 170 171 171 171 171

....... E820 Cylinder #20 High Exhaust Port Temp ..................................................... E805 Cylinder #5 High Exhaust Port Temp ................................................................ 199 +8V Sensor Voltage Supply ............................................................................................ 289 Generator Output Power Sensor .................. E808 Cylinder #8 High Exhaust Port Temp ........... E868 Gas Flow Control Valve Malfunction ..................................... 257 ECM Status Indicator Output ...............................Calibrate ................................... E850 Cyl #10 Exhaust Port Temp Deviating Low ............................................................. E836 Cyl #16 Exhaust Port Temp Deviating High ........................................... E855 Cyl #15 Exhaust Port Temp Deviating Low ............ E804 Cylinder #4 High Exhaust Port Temp ........ E839 Cyl #19 Exhaust Port Temp Deviating High .......... E437 Cylinder #17 Detonation Shutdown ........................................................................................... E854 Cyl #14 Exhaust Port Temp Deviating Low .. E852 Cyl #12 Exhaust Port Temp Deviating Low ................ E840 Cyl #20 Exhaust Port Temp Deviating High ............................................ E830 Cyl #10 Exhaust Port Temp Deviating High ............................... E837 Cyl #17 Exhaust Port Temp Deviating High .................................. E813 Cylinder #13 High Exhaust Port Temp ..... E826 Cyl #6 Exhaust Port Temp Deviating High ................................................................. 316 Inspecting Electrical Connectors ........... 223 Compressor Bypass ..... 269 Electrical Power Supply ............ E811 Cylinder #11 High Exhaust Port Temp ............................................. E847 Cyl #7 Exhaust Port Temp Deviating Low ..... E866 Low Gas Fuel Flow Rate .......................... E822 Cyl #2 Exhaust Port Temp Deviating High ........................................... E802 Cylinder #2 High Exhaust Port Temp ..... E844 Cyl #4 Exhaust Port Temp Deviating Low ... E851 Cyl #11 Exhaust Port Temp Deviating Low . E828 Cyl #8 Exhaust Port Temp Deviating High ... E816 Cylinder #16 High Exhaust Port Temp ........... E812 Cylinder #12 High Exhaust Port Temp .............. 305 Ignition Transformers Secondary Circuit and Spark Plugs ......................... E859 Cyl #19 Exhaust Port Temp Deviating Low .......................................... 282 Fuel Metering Valve .......... 191 191 192 192 193 193 193 194 194 195 195 195 196 196 197 197 197 197 198 198 Diagnostic Functional Tests +5V Sensor Voltage Supply ..... 172 172 172 173 173 173 173 174 174 175 175 175 176 176 177 177 177 178 178 179 179 179 180 180 180 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188 188 189 189 189 190 190 191 E846 Cyl #6 Exhaust Port Temp Deviating Low ....... 322 Integrated Temperature Sensing Module (ITSM) ..... E842 Cyl #2 Exhaust Port Temp Deviating Low .............. E834 Cyl #14 Exhaust Port Temp Deviating High .... E821 Cyl #1 Exhaust Port Temp Deviating High .. E867 Improper Gas Flow Control Valve Response ...... E853 Cyl #13 Exhaust Port Temp Deviating Low ........8 Table of Contents E436 Cylinder #16 Detonation Shutdown .................. E838 Cyl #18 Exhaust Port Temp Deviating High ...... 206 Analog Sensor Signal ...... E824 Cyl #4 Exhaust Port Temp Deviating High .......... E439 Cylinder #19 Detonation Shutdown ......................... E841 Cyl #1 Exhaust Port Temp Deviating Low .............................................. E827 Cyl #7 Exhaust Port Temp Deviating High ........................................ E843 Cyl #3 Exhaust Port Temp Deviating Low ..................................... E823 Cyl #3 Exhaust Port Temp Deviating High ................................................. 298 Ignition Transformers Primary Circuit ...................... E835 Cyl #15 Exhaust Port Temp Deviating High ................................................... 327 PWM Sensor .......... E438 Cylinder #18 Detonation Shutdown .................................... 275 Engine Speed/Timing Sensor . 239 ECM Output Circuit (Fuel Control) .............. E803 Cylinder #3 High Exhaust Port Temp ............................ E832 Cyl #12 Exhaust Port Temp Deviating High ........................... 342 Calibration Procedures Engine Speed/Timing Sensor ................. 235 Detonation Sensors ................ 349 Generator Output Power Sensor ........................ E807 Cylinder #7 High Exhaust Port Temp .................................... E810 Cylinder #10 High Exhaust Port Temp ..............................Calibrate .......... 248 ECM Output Circuit (Starting Motor) ......................... E819 Cylinder #19 High Exhaust Port Temp ................ E440 Cylinder #20 Detonation Shutdown ............. E857 Cyl #17 Exhaust Port Temp Deviating Low ................................................................................. E818 Cylinder #18 High Exhaust Port Temp ........................................................................................ E815 Cylinder #15 High Exhaust Port Temp ....... E809 Cylinder #9 High Exhaust Port Temp .. E817 Cylinder #17 High Exhaust Port Temp ........ E849 Cyl #9 Exhaust Port Temp Deviating Low ........................... E825 Cyl #5 Exhaust Port Temp Deviating High ...................................... E858 Cyl #18 Exhaust Port Temp Deviating Low .........................20 mA) ................................... E845 Cyl #5 Exhaust Port Temp Deviating Low ................................................................... E856 Cyl #16 Exhaust Port Temp Deviating Low ....................................... E860 Cyl #20 Exhaust Port Temp Deviating Low ................ E833 Cyl #13 Exhaust Port Temp Deviating High .......................... E801 Cylinder #1 High Exhaust Port Temp ............. 229 Desired Speed Input (4 ........................... 214 CAT Data Link ....................................................... E814 Cylinder #14 High Exhaust Port Temp ........................ 335 Throttle Actuator .... E806 Cylinder #6 High Exhaust Port Temp ........................................ E864 Low Gas Fuel Differential Pressure .................. E865 High Gas Fuel Differential Pressure ...................................................................................... E848 Cyl #8 Exhaust Port Temp Deviating Low ........ 351 .................................. E829 Cyl #9 Exhaust Port Temp Deviating High .......................................................................................................... E831 Cyl #11 Exhaust Port Temp Deviating High .....................

......9 Table of Contents Index Section Index ........................................................... 355 ...

System Overview SMCS Code: 1900 Air/Fuel Ratio Control The master ECM provides control of the air/fuel mixture for performance and for efficiency at low emission levels. The following steps describe the basic operation: 1. and maps in the master ECM. The command for the flow of the fuel is sent to the electronic fuel metering valve via the CAN data link. Engine Speed Governing The master ECM maintains the desired engine speed by controlling the actuator for the throttle. • Engine speed governing • Air/fuel ratio control • Start/stop sequencing • Engine monitoring and protection • Control of the ignition and detonation of the left cylinder bank The slave ECM primarily supports the control of ignition and of detonation of the right cylinder bank. The master ECM issues a throttle command that represents a percent of the level of electrical current. output drivers in the master ECM. The system consists of an electronic fuel metering valve. The master ECM removes the voltage when the programmable crank terminate speed is reached or when a programmable cycle crank time has expired.10 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i02072648 Desired engine speed is determined by the status of the idle/rated switch. One module is the master ECM and the other module is the slave ECM. When the programmable logic determines that it is necessary to crank the engine. The master ECM determines the desired flow rates for the air and for the fuel. The master ECM controls most of the functions of the engine. remote start switch. This process is repeated continuously during engine operation. . The customer programmable logic responds to signals from the following components: engine control. the master ECM supplies +Battery voltage to the relay for the starting motor. The master ECM monitors various inputs from sensors in order to activate relays. Actual engine speed is detected via a signal from the speed/timing sensor. The output can be viewed on the Caterpillar Electronic Technician (ET). Each module is an environmentally sealed unit that is mounted in a terminal box on the engine. The control compensates for changes in the BTU of the fuel in order to maintain desired emission levels. the desired speed input (analog voltage or 4 to 20 mA). etc at the appropriate levels. and parameters such as maximum engine high idle speed that are programmed into the software. Parameters such as governor gain can be programmed with Cat ET. data link. emergency stop switch. The master ECM supports the following five primary functions: • Desired engine speed • Actual engine speed • Calculated engine load 2. The actuator is located at the inlet to the aftercooler. Start/Stop Sequencing The master ECM contains the logic and the outputs for control of starting and of shutdown. and other inputs. The actuator is electrically controlled and electrically actuated. solenoids. The flow rates are determined by these factors: Introduction Two Electronic Control Modules (ECM) are used to control the engine.

Logged codes may not indicate that a repair is needed. Diagnostic codes can have two different states: • Active • Logged Active Code – An active diagnostic code indicates that an active problem has been detected. see Troubleshooting. The master ECM can issue a warning or a shutdown. an ECM will detect the problem. The ECM will generate an active diagnostic code for the problem. the master ECM supplies +Battery voltage to the GSOV whenever the programmable logic determines that fuel is required to operate the engine. For example. The GSOV may be energized by the customer’s equipment or by the engine’s control system. The transformer steps up the voltage in order to create a spark across the spark plug electrode. For more information.11 Troubleshooting Section The engine must be equipped with an energize-to-run type of gas shutoff valve (GSOV). the ECM generates a code. if the system is powered and a sensor is disconnected. The code is logged. To initiate combustion. If retarding the timing does not limit detonation to an acceptable level. see Troubleshooting. The source of the voltage to the GSOV depends on the engine’s configuration. For more information. Logged codes may be useful to help troubleshoot intermittent problems. Problems with engine operation such as low oil pressure produce an event code. an ECM sends a pulse of approximately 100 volts to the primary coil of an ignition transformer at the appropriate time and for the appropriate duration. “Troubleshooting With A Diagnostic Code”. see Troubleshooting. the master ECM shuts down the engine. A code is cleared from memory when one of the following conditions occur: Ignition Control Each ECM provides variable ignition timing that is sensitive to detonation. the active code will disappear. When an ECM detects a problem. i01804722 Self-Diagnostics SMCS Code: 1901 Each Electronic Control Module (ECM) has the ability to detect problems with the electronic system and with engine operation. Problems with the electronic system such as an open circuit produce a diagnostic code. This depends on the severity of the condition. Each ECM can store a maximum of ten different codes at one time. An alarm may also be generated. The master ECM also provides a switch for ignition timing in order to allow operation with alternate fuels such as propane that require a timing offset. The logged code will remain in the memory of the ECM until the code is cleared. The problem may have been resolved since the logging of the code. Logged Code – Every generated code is stored in the memory of the ECM that detected the problem. The problem may have been temporary. The master ECM and the slave ECM provide extensive diagnostics for the ignition system. “Troubleshooting With An Event Code”. When the sensor is connected. If the engine’s control system controls the GSOV. . Each cylinder has an ignition transformer that is located under the valve cover for the cylinder. Active codes require immediate attention. the appropriate ECM retards the ignition timing of the affected cylinder or cylinders. The ECM will also log the code. Each sensor monitors two adjacent cylinders. The G3520C Engine has ten detonation sensors. For more information on programmable parameters. The code indicates the specific problem with the circuitry. “Programming Parameters”. Detonation sensors monitor the engine for excessive detonation. The sensors generate data on vibration that is processed by each ECM in order to determine detonation levels. the master ECM or the slave ECM generates a diagnostic code. Always service active codes prior to servicing logged codes. Logged codes can also be used to review the performance of the engine and the electronic system. If detonation reaches an unacceptable level. • Diagnostic • Event Diagnostic Code – When a problem with the electronic system or a component is detected. There are two types of codes: Engine Monitoring and Protection The master ECM monitors both the engine operation and the electronic system. Logged codes remain in the memory of the ECM even if the power is removed from the ECM.

Actuators Event Code – An event code is generated when an ECM detects an abnormal engine operating condition. • A new code is logged and there are already ten codes in memory. an event code will be generated if the oil pressure is too low. The 50 Hz configuration is similar. Illustration 1 g01016786 Top view of the engine. In this case. Illustrations 3. The information enables the modules to control the engine as efficiently as possible over a wide range of operating conditions. The sensors also enable the activation of alarms and of shutoffs in response to abnormal operation. Sensors Sensors provide information to the electronic control modules. The fuel metering valve is electrically controlled and electrically actuated. 4. Refer to Systems Operation/Testing and Adjusting. The 60 Hz configuration is shown. The fuel metering valve and the master Electronic Control Module (ECM) communicate via the CAN data link. “Engine Sensors” for the descriptions of the sensors. the oldest code is cleared. the event code indicates the symptom of a problem. • The code does not recur for 1000 hours. i02087842 Location of Components SMCS Code: 1900 Fuel Metering Valve Illustration 2 Right side view (1) Throttle actuator (2) Actuator for the compressor bypass valve g01012402 Throttle actuator (1) and the actuator for the compressor bypass valve (2) are electrically controlled and electrically actuated. The master ECM issues commands to the actuators via the CAN data link. The information is used for monitoring engine operation. For example. In this case. and 5 show the locations of the sensors. .12 Troubleshooting Section • The service technician manually clears the code.

13 Troubleshooting Section Illustration 3 Right side view (1) Engine oil temperature sensor (2) Pressure switch for the coolant pump (inlet) (3) Pressure sensor for unfiltered oil (4) Pressure sensor for filtered oil g01064731 Illustration 4 Top view (5) Engine coolant temperature sensor (6) Engine coolant pressure sensor (outlet) (7) Inlet air temperature sensor (8) Inlet air pressure sensor g01064733 .

“Integrated Temperature Sensing Module” for the descriptions of the thermocouples. Illustration 6 shows the locations of the thermocouples. The thermocouples also enable alarms and shutoffs to be activated. Refer to Systems Operation/Testing and Adjusting.14 Troubleshooting Section Illustration 5 Left side view (9) Detonation sensor (10) Speed/timing sensor g01064734 Thermocouples Thermocouples provide information to the Integrated Temperature Sensing Module (ITSM). . The information is used to monitor engine operation.

The ITSM broadcasts the temperature readings of the thermocouples over the CAT data link for use by other modules. Refer to Systems Operation/Testing and Adjusting.15 Troubleshooting Section Illustration 6 Locations of the thermocouples (1) Thermocouple for the temperature of a cylinder exhaust port (2) Thermocouple for the temperature of an exhaust inlet to a turbocharger turbine (3) Thermocouples for the temperature of the turbocharger exhaust outlets (4) Thermocouple for the temperature of the turbocharger exhaust outlet g01064747 Integrated Temperature Sensing Module The Integrated Temperature Sensing Module (ITSM) (5) monitors all of the thermocouples. Illustration 7 shows the location of the ITSM. “Integrated Temperature Sensing Module” for the description of the ITSM. Illustration 7 g01066046 Integrated temperature sensing module on the left side of the engine .

For example. The terminal box contains the master Electronic Control Module (ECM) and the slave ECM. . For all Caterpillar engine harnesses with electronic ignition systems. a code of J011-RD on the schematic identifies a red wire that is stamped with the circuit number J011. Unless the schematic specifies a different size. 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 schematic also identifies the size of the wire. you may assume that the wire is 16 AWG. This particular wire is the engine harness wire for the primary signal of the transformer in the number one cylinder. The electrical connectors for the terminal box are located between the terminal box and the engine. 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 Illustration 8 Rear view (1) Terminal box (2) Emergency stop button g01064774 In addition to the color. Table 1 lists the color codes of the wiring. the code of J011-RD identifies the wire for the primary signal of the transformer in the number one cylinder. The actual wires are identified on the schematic. The size or gauge of the wire is called the American Wire Gauge (AWG).16 Troubleshooting Section i02088018 Terminal Box Electrical Connectors and Functions SMCS Code: 7553-WW Harness Wire Identification Caterpillar identifies different wires with eleven different solid colors.

17 Troubleshooting Section Illustration 9 Components inside the terminal box (3) Master ECM (4) Slave ECM (5) Ground strap for the master ECM (6) P3 connector for the slave ECM (7) Master ECM connector P2 (8) P4 connector for the slave ECM (9) Master ECM connector P1 (10) Ignition harness for the left bank (11) Ground strap for the slave ECM (12) Ignition harness for the right bank (13) Service tool connector J5 for the Caterpillar Electronic Technician (ET) g01064776 (14) J10/P10 connector for the terminating resistor for the CAN data link (15) J6 connector for the customer (16) J9 connector (17) J7 connector (18) J8 connector for the detonation sensors .

• Read parameters. • Diagnose problems. • Calibrate sensors.5 amp circuit breaker for the start command from the master ECM (6) Positive terminal for the connection of the engine’s power supply (7) Negative terminal for the connection of the engine’s power supply g01059145 The junction box contains all of the circuit breakers for the engine. The junction box also contains the magnetic switches for the electric starting motors. • Program parameters. (1) Junction box (2) 2.5 amp circuit breaker for the engine control (3) 10 amp circuit breaker for the customer (4) 35 amp circuit breaker for the engine (5) 2.18 Troubleshooting Section Junction Box Illustration 10 The junction box is located on left side of the engine. Electronic Service Tools SMCS Code: 0785 Caterpillar Electronic Service Tools are designed to help the service technician perform the following functions: • Obtain data. . i02088034 The tools that are listed in Table 2 are required in order to enable a service technician to perform the procedures.

This cable connects to the USB port on computers that are not equipped with a serial port. 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 • Flash downloading • Set parameters . Data subscription for all engines This group provides the communication between the PC and the engine.19 Troubleshooting Section Table 2 Service Tools Pt. N/A “JERD2124” “JERD2129” 171-4400 7X-1414 237-7547 8T-8726 151-6320 1U-5804 146-4080 7X-1710 (1) (1) Description Personal Computer (PC) Software Software Communication Adapter Gp Data Link Cable As Adapter Cable As Adapter Cable As Wire Removal Tool Crimp Tool Digital Multimeter Multimeter Probes Functions The PC is required for the use of Cat ET. No. This tool is used for work with CE electrical connectors. This cable connects the communication adapter to the service tool connector on the engine. The multimeter is used for the testing and for the adjusting of electronic circuits. Set the engine control to the OFF/RESET mode. Single user license for Caterpillar Electronic Technician (ET) Use the most recent version of the software. The 7X-1700 Communication Adapter Gp may also be used. Caterpillar Electronic Technician (ET) The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. refer to the documentation that accompanies your Cat ET software. Connecting Cat ET with the 171-4401 Communication Adapter II The engine’s power supply supplies the communication adapter with 24 VDC. Note: For more information regarding the use of Cat ET and of the PC requirements for Cat ET. This tool is used for the removal of pins and of sockets from Deutsch connectors and AMP connectors. Use the following procedure to connect Cat ET and the communication adapter to the engine. The probes are used with the multimeter to measure voltage in wiring harnesses without disconnecting the harnesses. 1. This breakout harness is for use between the jacks and the plugs of the sensors.

“Electronic Service Tool Will Not Communicate With ECM”. Use the Caterpillar Electronic Technician (ET) to perform the following activities: • Select the available responses. . The ECM that is connected to the harness reads the harness code. Note: If your PC is not equipped with a serial port. • Program delay times for each response. 3. i02088048 Engine Monitoring System SMCS Code: 7490 Illustration 11 Right side view (1) (2) (3) (4) (5) (6) PC 196-0055 Serial Cable 171-4401 Communication Adapter II 207-6845 Adapter Cable 7X-1414 Data Link Cable Terminal box g01059043 Note: Items (2). The master ECM can initiate responses if a specific engine parameter exceeds an acceptable range. use the 237-7547 Adapter Cable As in order to connect to the USB port. The screens of Cat ET provide guidance for the changing of trip points. • Program the level for monitoring. Connect one end of the adapter to the end of cable (2). Make repairs.20 Troubleshooting Section 6. Some of the responses are not available for some of the parameters. If Cat ET and the communication adapter do not communicate with the ECM. The jumper wire must be connected in order for the engine to crank. Two possible responses may be available for each parameter: “WARNING” and “SHUTDOWN”. Other parameters can be changed with customer passwords. Connect cable (4) to communication adapter (3). If Cat ET displays “Duplicate Type on data link. and (4) are part of the 171-4400 Communication Adapter Gp. Note: Some of the parameters are protected by factory passwords. 7. This allows the ECM to operate as the slave ECM. The jumper wire must remain connected in order for the engine to run. Set the engine control to the STOP mode. 4. 2. Unable to Service”. The engine should be OFF. To accommodate unique applications and sites. Connect cable (5) to the service tool connector on terminal box (6). Connect cable (2) to communication adapter (3). refer to Troubleshooting. as needed. The harness inside the terminal box for the slave ECM has a jumper wire (harness code) that connects terminals J3-29 and J3-60. Check the continuity between terminals J3-29 and J3-60. The jumper wire must be connected in order for the Cat ET to communicate with the modules. The default settings for the parameters are programmed at the factory. Verify that the jumper wire is in good condition. The master Electronic Control Module (ECM) monitors the operating parameters of the engine. Connect the other end of the adapter to a USB port on the PC. Connect cable (4) to cable (5). check the harness code for the slave ECM. 5. the parameters may be reprogrammed with Cat ET. (3). Connect cable (2) to the RS232 serial port of PC (1).

“High Engine Oil Temperature” The trip point for a warning for this parameter can be programmed by the customer. This parameter cannot be turned off. If the engine oil temperature increases to the trip point or if the engine oil temperature exceeds the trip point. The trip point for a shutdown is set at the factory. “High Fuel Temperature” The trip point for this parameter can be programmed by the customer. “Low Engine Coolant Temperature” The trip point for this parameter can be programmed by the customer. Then click on the “Change” button in the lower left corner of the screen. If the engine coolant temperature increases to the trip point or if the engine coolant temperature exceeds the trip point. The shutdown response cannot be turned off. This parameter is always ON. Highlight the desired parameter. The shutdown response is always ON.21 Troubleshooting Section Changing the Settings of the Monitoring System Use the following procedure to change settings of the parameters: 1. If the fuel pressure decreases to the trip point or if the fuel pressure goes below the trip point. the ECM will activate an engine shutdown. the ECM will generate a warning. The trip point for a shutdown for this parameter is set at the factory. A typical trip point is 118 percent of the engine’s rated speed for generator set applications. 3. The trip point cannot be changed. This parameter cannot be turned off. Change the “State” to “On” or “Off”. The new settings will be effective immediately. This parameter is always ON. The “Change Monitor System” screen will appear. “Low Fuel Pressure” The trip point for this parameter can be programmed by the customer. If the fuel temperature increases to the trip point or if the fuel temperature exceeds the trip point. the ECM will generate a warning. the “Enter Passwords” screen will appear. the ECM will generate a warning. If the system voltage decreases to the trip point or if the system voltage goes below the trip point. Set the “Trip Point” and the “Delay Time” according to the “Allowed Values” in the lower half of the screen. If the engine oil filter differential pressure increases to the trip point or if the engine oil filter differential pressure exceeds the trip point. If the engine oil filter differential pressure decreases to the trip point or if the engine oil filter differential pressure goes below the trip point. the ECM will generate a warning or a shutdown. “Engine Overspeed” The trip point for this parameter is set at the factory. This parameter cannot be turned off. This parameter is always ON. the ECM will generate a warning or a shutdown. If the engine speed increases to the trip point or if the engine speed exceeds the trip point. If the engine coolant temperature decreases to the trip point or if the engine coolant temperature goes below the trip point. . 5. Use Cat ET and select the “Service/Monitoring System” screen. 2. the ECM will generate a warning or a shutdown. “High Oil Filter Differential Pressure” The trip point for a warning for this parameter can be programmed by the customer. This parameter cannot be turned off. This parameter is always ON. 4. Enter the correct passwords and then click the “OK” button. Click the “OK” button. “Low Oil Filter Differential Pressure” The trip point for a warning for this parameter can be programmed by the customer. The trip point for a shutdown is set at the factory. This parameter cannot be turned off. the ECM will generate a warning or a shutdown. Monitoring Parameters “Low System Voltage” The trip point for this parameter is set at the factory. the ECM will generate a warning or a shutdown. If a password is required. “High Engine Coolant Temperature” The trip points for this parameter can be programmed by the customer. This parameter is always ON.

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 system voltage increases to the trip point or if the system voltage exceeds the trip point. Use the Cat ET to determine the programming for your engine. “High Fuel Pressure” The trip point for this parameter can be programmed by the customer. The shutdown response cannot be turned off. 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. “Low Gas Fuel Differential Pressure” The trip point for this parameter can be programmed by the customer. This feature provides a trip point between high engine load and low engine load. The trip point for a shutdown for this parameter is set at the factory. the ECM will generate a warning. The trip point is used for events that involve high inlet air temperature. the ECM will generate a warning or a shutdown. The ECM can activate a warning or a shutdown if the inlet air temperature increases to the trip point or if the inlet air temperature exceeds the trip point during the high load operation that is defined. “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”. Many of the items can be reprogrammed in order to accommodate the requirements of individual sites.22 Troubleshooting Section “High Engine Oil to Engine Coolant Differential Temperature” The trip point for a warning for this parameter can be programmed by the customer. The possible responses of the system include a warning or a shutdown. If the fuel differential pressure increases to the trip point or if the fuel differential pressure exceeds the trip point. the ECM will generate a warning. This parameter is always ON. The ECM can activate a warning or a shutdown if the inlet air temperature increases to the trip point or if the inlet air temperature exceeds the trip point during the low load operation that is defined. If the load is greater than the trip point. This parameter cannot be turned off. If the load is less than the trip point. The trip point cannot be changed. “High System Voltage” The trip point for this parameter is set at the factory. The trip point for the events is based on the engine load. The shutdown response is always ON. . “High Gas Fuel Differential Pressure” The trip point for this parameter can be programmed by the customer. The ECM will activate a warning if the fuel pressure increases to the trip point or if the fuel pressure exceeds the trip point. The values may have changed. If the fuel differential pressure decreases to the trip point or if the fuel differential pressure goes below the trip point. “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 shutdown response cannot be turned off. Default Settings of the Monitoring System Examples of the default settings for the parameters are listed in Table 3. Trip Points of the Engine Load for High Inlet Air Temperature The trip points for these parameters can be programmed by the customer. If the differential temperature of the jacket water and the engine oil increases to the trip point or if the differential temperature of the jacket water and the engine oil exceeds the trip point. The shutdown response is always ON. the ECM will generate a warning.

On On (1) 80 to 129 °C 20 Customer 5 to 80 °C 0 20 Factory Customer Factory Customer 10 Factory Customer Factory 20 10 Customer 1200 to 2125 rpm 85 to 102 °C 85 to 104 °C 80 to 138 kPa 0 1 to 60 E038 (1) E004 (3) E020 (1) E019 (3) E129 (1) E130 (3) E127 (1) E128 (3) E223 (1) E053 (1) E337 (1) E337 (3) Warning Shutdown Warning Shutdown Warning Shutdown Warning Shutdown On 5 °C 1770 rpm 102 °C 104 °C On (1) 103 kPa 138 kPa 35 kPa 5 kPa 60 °C 5 to 80 kPa 0 to 60 °C 100 to 135 kPa 0 to 20 °C 1 to 60 Warning On 105 kPa 14 °C Shutdown On (1) 20 °C 20 Factory E864 (1) On E865 (1) E050 (1) E027 (1) E026 (3) E027 (1) E026 (3) E096 (1) Shutdown Warning Shutdown Warning Warning On (1) 5 kPa 10 35 kPa 34 volts 69 °C 73 °C 53 °C 57 °C 135 kPa 10 100 to 135 kPa 20 Customer 32 to 100 °C 1 to 60 20 This item cannot be programmed. 32 to 85 °C Customer 0 to 35 kPa On On (1) On On (1) On This parameter is permanently active. The parameter cannot be turned off. .23 Troubleshooting Section Table 3 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 Engine Oil to Engine Coolant Differential Temperature” “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)” System Response Warning Shutdown Warning Shutdown State Trip Point 20 volts 18 volts 109 °C 113 °C Delay in Seconds 20 10 Security Level Password Range Range of the Delay in Seconds On (1) This item cannot be programmed.

Some parameters are not dependent upon any conditions. None The crank terminate relay is energized for more than 30 seconds. The fuel control relay is energized. For example. If a trip point is exceeded. the warning for “High Engine Coolant Temperature E017 (1)” can be set to 95 °C with a five second delay. The crank terminate relay is energized for more than 30 seconds. None The crank terminate relay is energized for more than 30 seconds. The timer starts counting if the coolant temperature exceeds 95 °C. The conditions are designed to eliminate false events during start-up if the customer has programmed a delay time to zero. Some of the parameters are allowed to function after the crank terminate relay has been energized for more than 30 seconds. None None The crank terminate relay is energized for more than 30 seconds. Condition . If the temperature is not reduced to less than 95 °C within five seconds. The fuel control relay is energized. Table 4 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 Engine Oil to Engine Coolant Differential Temperature” “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. the event becomes active and the event is logged. The conditions are listed in Table 4.24 Troubleshooting Section Separate timers are used in the master ECM for each response that is associated with a parameter. the timer for that event is started. Other parameters are allowed to function after the output for the fuel control relay is energized. Conditions for Parameters Some of the programmable parameters are dependent on the status of a master ECM output before the parameters are allowed to function.

the engine will shut down and the warning will not be activated. and of the outlets of the turbocharger turbines. If the connection between the ITSM and the master ECM is not correct. of the inlets of the turbocharger turbine. . Use Cat ET to determine the programming for your engine. The monitoring system will accept any settings within the ranges. Ensure that the response of the ITSM is correct for the application. Note: To initiate the responses. the ITSM can initiate a “WARNING” or “SHUTDOWN”. If a temperature exceeds an acceptable range. The items can be reprogrammed in order to accommodate the requirements of individual sites. Use Cat ET to perform the following activities: • Select the available responses. the ITSM cannot initiate any response.25 Troubleshooting Section Use care when you program the trip points and the delay times. Ensure that the response of the master ECM is correct for the application. • Program delay times for each response. If the trip point for a shutdown is programmed to activate before the trip point for a warning. • Program the level for monitoring. However. To accommodate unique applications and sites. the engine will shut down and the warning will not be activated. the ITSM sends commands to the master ECM via the Cat Data Link. The screens of Cat ET provide guidance for changing trip points. The monitoring system will accept any setting within the ranges. Table 5 lists default examples of the values for the parameters. the values may have changed. The default settings for the parameters are programmed at the factory. If the trip point for a shutdown is programmed to activate before the trip point for a warning. the parameters may be reprogrammed with Cat ET. Use care when you program the trip points and the delay times. Programmable Parameters of the Integrated Temperature Sensing Module The Integrated Temperature Sensing Module (ITSM) monitors the temperatures of the cylinder exhaust ports. Both of the responses are available for all of the parameters.

. the event becomes active and the event is logged. For example.26 Troubleshooting Section Table 5 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 E820 (1) E801 (3) through E820 (3) Warning 655 °C 30 100 to 665 °C 1 to 60 Shutdown 665 °C “Exhaust Port Temperature High Deviation” E821 (1) through E840 (1) E821 (3) through E840 (3) Warning 50 °C 60 10 to 50 °C 100 to 200 °C Customer 10 to 50 °C 10 to 200 °C 100 to 710 °C 100 to 730 °C 100 to 625 °C 1 to 60 Shutdown 200 °C 10 1 to 10 “Exhaust Port Temperature Low Deviation” E841 (1) through E860 (1) E841 (3) through E860 (3) Warning On 50 °C 60 1 to 60 Shutdown Warning Shutdown Warning Shutdown 200 °C 710 °C 10 1 to 10 “High Turbo Turbine Inlet Temperature” E245 (1) E246 (1) E245 (3) E246 (3) E243 (1) E244 (1) E243 (3) E244 (3) 30 730 °C 615 °C 60 625 °C 1 to 60 “High Turbo Turbine Outlet Temperature” 1 to 60 Separate timers are used in the ITSM for each response that is associated with a parameter. If the temperature is not reduced to less than 655 °C within 30 seconds. the timer for that event is started. If a trip point is exceeded. the warning for the “High Exhaust Temperature” (E801 (1)) can be set to 655 °C with a 30 second delay. The timer starts counting if the exhaust port temperature of the number 1 cylinder reaches 655 °C.

5. Highlight the “Customer Password #1” parameter. If an Electronic Control Module (ECM) is replaced. Because of the passwords. This can cause engine damage.27 Troubleshooting Section Programming Parameters i01829539 Programming Parameters SMCS Code: 1901 Programmable parameters enable the engine to be configured in order to meet the requirements of the application. Enter the password in the “Change Parameter Value” dialog box and click on the “OK” button. If the customer passwords are not programmed. After the customer passwords are entered. Highlight the “Customer Password #2” parameter. Use the following procedure to program the passwords. Table 6 Customer Passwords i01902441 Customer Passwords SMCS Code: 0785 Certain monitoring system parameters and system configuration parameters may be protected with customer passwords. 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. This feature is enabled by programming two customer passwords. Perform this programming before the initial engine start-up. and start/stop control. Make a copy of Table 6 and record your passwords. 3. The system configuration parameters must be programmed when the application is installed. timing control. Click on the “Change” button in the lower right corner of the screen. Enter the password in the “Change Parameter Value” dialog box and click on the “OK” button. NOTICE Changing the parameters during engine operation can cause the engine to operate erratically. Click on the “Change” button in the lower right corner of the screen. air/fuel ratio control. speed control. if necessary. The passwords are case sensitive. This can be done with the “Copy Configuration” feature of the Caterpillar Electronic Technician (ET). Store the passwords securely. only authorized personnel can make changes to some of the programmable items in an Electronic Control Module (ECM). the passwords are required in order to change certain parameters. Once the passwords are entered successfully. Alternatively. the changes are programmed into the master ECM. . The customer passwords can be changed. Incorrect programming of parameters may lead to complaints about performance and/or to engine damage. Note: Be sure to record the customer passwords. all of the parameters are unprotected. 2. 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 fuel control. Store the passwords securely. Use of the passwords helps to prevent free access to the modification of the parameters. The same procedure is used to change the passwords: 1. Programmable parameters can be classified into the following types: engine identification. The passwords can have a maximum of eight characters. Alphanumeric characters may be used. the appropriate parameters must be copied from the old ECM. The passwords are now programmed into the memory of the Master Electronic Control Module (ECM). the passwords are not requested again until another screen is accessed or the data link is interrupted. the settings can be recorded on paper and then programmed into the new module. Access the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). Only change the settings of the parameters when the engine is STOPPED. When the correct passwords are entered. 4. Customer Password #1 Customer Password #2 i01865997 Factory Passwords SMCS Code: 0785 Factory level security passwords are required for clearing certain logged events and for changing certain programmable parameters.

Table 7 • Current master ECM • Serial number of the service tool • Serial number of the engine • Serial number of the master ECM • Diagnostic clock • Total Tattletale • Reason The old interlock code is required to change the interlock code on a used ECM. After you exit the “Enter Factory Passwords” screen on Cat ET. a different set of passwords will be required before you can program the master ECM. factory passwords are required for some of the programming. 2) . Factory passwords are not required for the first hour of operation for a new master ECM. The passwords may only be used for one programming session. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. The passwords are controlled by Caterpillar. To obtain the proper passwords. Factory Passwords Worksheet Dealer Code Customer’s Name Address Telephone Number Information from the “Enter Factory Passwords” Screen on the Caterpillar Electronic Technician (Cat ET) Serial Number for Cat ET Engine Serial Number ECM Serial Number Total Tattletale Reason Code Factory Passwords Factory Password (No. After the hour expires.28 Troubleshooting Section Factory passwords are required to program the following shutdowns: i02089534 Factory Passwords Worksheet SMCS Code: 0785 • “Engine Overspeed” • “High Engine Oil Temperature” • “High Oil Filter Differential Pressure” • “Low Oil Filter Differential” • “High Engine Oil to Engine Coolant Differential Temperature” The “Enter Factory Passwords” screen on Cat ET will display the following parameters. 1) Factory Password (No. the information must be given to an authorized Caterpillar dealer: The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Note: A mistake in recording this information will result in incorrect passwords. The passwords may only be obtained by an authorized Caterpillar dealer.

JERD2129 is used. Refer to Troubleshooting. Access the “Configuration” screen under the “Service” menu in order to determine the parameters that require programming. The values of the parameters can be viewed on the “Configuration” screen of Cat ET. If a diagnostic code of 268-02 “Check Programmable Parameters” is generated. 3. 8. Connect Cat ET to the service tool connector. the “ECM Selector” window will appear. b. 5. 6. use the “Utilities/Preferences” option on the Cat ET. If a parameter has a tattletale of 0. The Caterpillar Electronic Technician (ET) can be used to flash new software into an ECM or the ITSM. flash programming can last up to 15 minutes. “Electronic Service Tools”. Cat ET will not flash if the engine control is in the OFF/RESET or START mode. When the flash is completed. This is the only method for updating the software. Select the correct disk drive and the directory from “Drives” and “Directories” on Cat ET. program any parameters that were not in the original software. Allow a few moments for “WinFlash” to detect the electronic control modules and connect to the electronic control modules. Start the engine and check for proper operation. i01945454 System Configuration Parameters SMCS Code: 1901 Certain parameters are unique for each engine application. Access the information about the “ECM Summary” under the “Information” menu. Set the engine control to the STOP mode.. The “Flash File Selection” window will appear. Read the “Description” and the “File Info” in order to verify that the correct file is selected. a. the slave ECM. Flash Programming SMCS Code: 1901-591 Software is located in the flash memory of the master Electronic Control Modules (ECM). When an ECM has been detected. “WinFlash” will try to detect an ECM. To select the baud rate. Select the appropriate ECM and then select “OK”. All of the parameters should have a tattletale of 1 or more. This eliminates the risk of moisture entry into a module due to improper seal installation. Select “WinFlash” from the “Utilities” menu on the Cat ET. 4. click on the “Cancel” button in order to stop the process. The component that contains the software cannot be physically removed from the module. Then select the baud rate from the “Advanced Communication Settings” menu and click the “OK” button. Select “Open”. “System Configuration Parameters”. Refer to Troubleshooting. 2. The parameters are programmed into the Electronic Control Module (ECM) via the Caterpillar Electronic Technician (Cat ET). this message will appear: “Flash Completed Successfully”. program that parameter. Flash Programming If the slowest baud rate of Cat ET is selected. “WinFlash” Error Messages If you receive any error messages during flash programming. Select the “Communications” tab and click on “Advanced. 9. . If a communication error occurs. select a slower baud rate in order to improve the reliability. 1. The flash files are located on a disk drive and in a directory. JERD2124 or Software.. Select the “Begin Flash” button in order to program the personality module. The parameters must be programmed in order to ensure proper engine operation.”.29 Troubleshooting Section i01866010 A list of flash files will appear. Table 8 is a list of the parameters that can be configured for G3520C Engines. 7. Make sure that you are flashing the correct file for your engine. Program the configuration parameters and the monitoring system parameters. The Software. “Engine Monitoring System” and Troubleshooting. and the Integrated Temperature Sensing Module (ITSM). Look under the “Tattletale” column. Select the correct file from the list of flash files. Be sure to set the baud rate to the fastest rate for your PC. The flash is accomplished by transferring the data from Cat ET to the module via data link wiring.

Install a test ECM in place of the suspect ECM. contd) Configuration Parameters for G3520C Engines Power Monitoring “Generator Output Power Sensor Scale Factor” “Generator Output Power Sensor Offset” “Engine Output Power Configuration” “Engine Driven Accessory Load Configuration” Information for the ECM “Engine Serial Number” “Equipment ID” “Customer Password #1” “Customer Password #2” “Total Tattletale” Configuration Parameters for G3520C Engines Timing Control “First Desired Timing” “Second Desired Timing” Air/Fuel Ratio Control “Fuel Quality” “Gas Specific Gravity” “Fuel Specific Heat Ratio” “Desired Emission Gain Adjustment” “Air/Fuel Proportional Gain” “Air/Fuel Integral Gain” Speed Control “Low Idle Speed” “Minimum High Idle Speed” “Maximum High Idle Speed” “Engine Accel. replace the suspect ECM with the test ECM. follow the troubleshooting procedures in this manual in order to be sure that replacement of the ECM will correct the problem. the parameters must be obtained from records or from the factory. Rate” “Desired Speed Input Configuration” “Governor Type Setting” “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 Load Set Point” (continued) i02088063 Replacing the ECM SMCS Code: 1901-510 Electronic control modules contain no moving parts. Note: If the parameters cannot be read from the suspect ECM.30 Troubleshooting Section Refer to Systems Operation/Testing and Adjusting. The appropriate configuration data must then be re-entered into the appropriate ECM. Transfer the software from the suspect ECM to the test ECM. Before you replace an ECM. Refer to the following test steps for details on programming the parameters. . reconnect the suspect ECM. Program all the parameters for the test ECM in order to match the parameters of the suspect ECM. Table 8 (Table 8. If the master ECM and the slave ECM are interchanged. Replacement of an Electronic Control Module (ECM) can consume much time. If the problem recurs. Verify that the problem recurs. Failure to program each ECM correctly may result in improper engine operation. The parameters must match. all of the configuration data for each ECM must be transferred into the Caterpillar Electronic Technician (ET). “Electronic Control System Parameters” for the descriptions of the parameters. Verify that the suspect ECM is the cause of the problem. If the test ECM resolves the problem. Note: The master ECM and the slave ECM should not be interchanged in order to determine if an ECM is faulty.

1. Select the suspect ECM and select “OK”. Remove mounting nut (2) in order to disconnect the ground strap. Note: Before you replace an ECM. b. You may also select the “Print” function in order to obtain a paper copy of the parameter settings. Note: Do not terminate the Cat ET. Save the file. Replace the ECM.31 Troubleshooting Section Perform the following procedure to replace the ECM. Select “File/Disconnect F8” from the drop-down menu. record all of the logged events. a. You can select “Load from ECM”. Note: This procedure describes replacement of the master ECM. a. Select “OK”. Use the “Service/Copy Configuration/ECM Replacement” function of the Caterpillar Electronic Technician (ET). d. Illustration 13 g01064809 The master ECM is on the left side of the terminal box. 2. Use a 4 mm allen wrench to disconnect connectors (3) and (4). . the Cat ET will display this message: “The data has been successfully loaded from the ECM”. The slave ECM is on the right side of the terminal box. (2) Mounting nut (3) P2 connector (4) P1 connector c. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Cat ET will load the configuration parameters and the monitoring system parameters of the suspect ECM. Illustration 12 Junction box (1) 35 amp circuit breaker g01054206 b. Remove the three remaining mounting nuts. After the loading is complete. Select “Load from ECM” in the lower left corner of the Cat ET screen. c. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu on Cat ET. Replacement of the slave ECM is similar. Connect the Cat ET with the communications adapter.

A window with the message “Program ECM Results” will appear. The parameters must match. factory passwords are not required for the first hour of operation. Connect Cat ET with the communications adapter. a. Note: Before you replace an ITSM. factory passwords are required for changing the parameters that are normally protected with factory passwords. The grommets help to reduce vibration. Then install the other three mounting nuts. Click “OK” on the window. After one hour. e. follow the troubleshooting procedures in this manual in order to be sure that replacement of the ITSM will correct the problem. spacers. 5. 4. The grommets may fall when the ECM is removed. Switch 35 amp circuit breaker (1) to the ON position. replace the suspect ITSM with the test ITSM.Calibrate”. Check the mounting hardware and the ECM for correct installation. Use a 4 mm allen wrench to connect the P1 and P2 connectors to the ECM. “Engine Speed/Timing Sensor . e. Use a mounting nut to fasten the ground strap for the ECM to the upper left mounting stud. Use the mounting hardware to install the new ECM. Select the replacement ECM and click “OK”. 1. Replacement of the ITSM can consume much time. i02088110 Replacing the ITSM SMCS Code: 1901-510 The Integrated Temperature Sensing Module (ITSM) contains no moving parts. h. the parameters must be obtained from records or from the factory. b. If the test ITSM resolves the problem. reconnect the suspect ITSM. Be sure not to lose the grommets. . Note: When you program a new ECM. d. Select “OK”. Refer to the following steps for details on programming the parameters. f. g. Select the replacement ECM and click “OK”. If the correct ECM is shown. Verify that the problem recurs. c. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu. You may also select the “Print” function in order to obtain a paper copy of the parameter settings. After the loading is complete. If the ECM cannot move slightly on the grommets. a. Cat ET will load the configuration parameters and the monitoring parameters from the ECM. Select “OK”.32 Troubleshooting Section Note: Rubber grommets behind the ECM are held in place by the mounting studs. Tighten the screws to a torque of 6 ± 1 N·m (55 ± 9 lb in). A correctly installed ECM will move slightly on the rubber grommets. Program all the parameters for the test ITSM in order to match the parameters of the suspect ITSM. b. Transfer the software from the suspect ITSM to the test ITSM. See Troubleshooting. and grommets are positioned correctly. Remove the ECM from the terminal box. select “Yes”. Program the configuration parameters and the monitoring system parameters into the replacement ECM. Use the “Service/Copy Configuration/ECM Replacement” function of the Caterpillar Electronic Technician (ET) in order to transfer the software from the suspect ITSM. a window with the message “Programming Conflict Warning” will appear. If the problem recurs. check that the washers. Calibrate the speed/timing sensor. 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. Install the replacement ECM. Select “Program ECM” from the lower left corner of the screen. record all of the logged events. 3. Before you replace an ITSM. Set the engine control to the “STOP” mode. a. Select “File/Select ECM” from the drop-down menu. Use the following procedure to replace the ITSM: Note: If the parameters cannot be read from the suspect ITSM.

Ground strap (5) must also be lifted from one of the studs. c. Select “Load from ECM” in the lower left corner of the screen. Note: Do not exit from Cat ET. Switch 35 amp circuit breaker (1) to the OFF position. a. Select “OK”. .33 Troubleshooting Section b. e. Select the suspect ITSM and select “OK”. Remove four nuts (4) and washers (6) from mounting flanges (7) of the ITSM. Set the engine control to the OFF/RESET mode. Remove the ITSM from the engine. Illustration 16 Mounting hardware for the ITSM (4) (5) (6) (7) Nut Ground strap Washer Mounting flange on the ITSM g01064841 d. Illustration 14 Junction box (1) 35 amp circuit breaker g01054206 b. Replace the ITSM. Cat ET will display this message: “The data has been successfully loaded from the ECM”. Select “File/Disconnect F8” from the drop-down menu. Illustration 15 Rear view g01064840 (2) Connectors for the harness to the thermocouples (3) Connectors for the harness to the terminal box for the master ECM c. After the loading is complete. Disconnect connectors (2) and (3) from the ITSM. 2.

d. i02089781 Troubleshooting Data Sheet SMCS Code: 0785 To help troubleshoot a gas engine. check that the mounting hardware is installed correctly. Be sure to include the units of measurement. Select “Service/Copy Configuration/ECM Replacement” from the drop-down menu. Select “OK”. the ITSM does not require calibration. Set the engine control to the STOP mode. factory passwords are not required. Orient the 54-pin connector toward the bottom of the engine. Click “OK” on the window. Install the replacement ITSM. A properly installed ITSM will move slightly on the rubber grommets. b. e. g. .34 Troubleshooting Section 3. Program the configuration parameters and the monitoring system parameters into the replacement ITSM. Select the “Replacement ITSM” and click “OK”. a window with the message “Programming Complete” will appear. Switch 35 amp circuit breaker (1) to the ON position. Select the replacement ITSM and click “OK”. b. Be sure to install the lock washer between ground strap (5) and mounting flange (7). f. Note: When you program a new ITSM. Connect connectors (2) and (3) to the ITSM. After the loading is complete. complete the information in Illustration 17. 4. Select “Program ECM” from the lower left corner of the screen. a. Select “File/Select ECM” from the drop-down menu of Cat ET. Also. a. If the ITSM cannot move slightly on the grommets. Use the mounting hardware to install the new ITSM. Check the mounting hardware and the ITSM for correct installation. Note: One of the washers is a lock washer. c. The lock washer improves the electrical conductivity between the ground strap and the mounting flange. Be sure to install ground strap (5) between one of the washers on the mounting flange and the nut.

You may have replaced the ignition transformer per instructions from the factory. include all of the codes and the status of the codes. Repair – Explain your repair of the problem. If diagnostic codes or event codes were generated. a visual inspection revealed abrasion of a wire in a harness. For example. Be specific: dynamometer testing of the engine produced power below specifications at 1800 rpm due to the loss of an ignition transformer. The following topics are recommended for your report: Complaint – Include a description of the customer’s complaint in the report. The providing of complete. you may have installed a new wiring harness. For example. . For example. Indicate your determination of the problem. Cause – Provide a specific description of the cause of the failure. Include the method that was used in order to diagnose the problem. it is important to provide good information about the repair. if you performed a diagnostic functional test. identify the test procedure. accurate information will help Caterpillar to provide better service to you and to the customer.35 Troubleshooting Section Illustration 17 Data sheet for troubleshooting g01013492 Report the Service Information After you have successfully repaired the engine.

Operator Information Obtain the following information from the operator: Symptoms SMCS Code: 1000-035 Some engine symptoms can be unrelated to the electronic control system. happened in addition to the symptom. 3. and the history of the engine. The • Determine if there are any systems that were conditions will include the engine rpm and the load.36 Troubleshooting Section Troubleshooting without a Diagnostic Code i01970297 Narrow the probable cause. Consider the operator information. 1. “Inspecting Electrical Connectors”. Refer to Troubleshooting. “Troubleshooting With an Event Code”. Check the diagnostic codes and event codes. Inspect the following items: • The occurrence and the time of the occurrence • Determine the conditions for the occurrence. “Troubleshooting With A Diagnostic Code” or refer to Troubleshooting. perform the following steps first in order to diagnose a malfunction. Perform a visual inspection. This is specially true for problems that are intermittent. Repair any active codes. If these inspections do not reveal any problems. Verify that the complaint is not due to error of the operator. Be sure to check the connectors. • Determine whether any other occurrences Diagnostic Codes and Event Codes Examine the following information regarding any codes: • The probable cause of the symptom is correlated to the code. occurred. identify the probable causes with the procedures in this manual that best describe the symptoms. • Fuel supply • Oil level • Oil supply • Coolant level • Wiring • Connectors 4. 2. Check each probable cause according to the tests that are recommended. Verify that the complaint is not due to normal engine operation. For basic troubleshooting of the engine. installed by the dealer or by the customer that could cause the symptom. Refer to Troubleshooting. • The symptoms have a probable cause that is common. i02064369 Detonation SMCS Code: 1000-035 Probable Causes • Excessive load • Excessive inlet manifold air pressure • High inlet air temperature . Gather information about the complaint from the operator. the conditions of operation. • The code was generated when the symptom • Codes that are repeatedly logged • The complaint is not due to normal engine operation. This section is for troubleshooting problems that have symptoms without active diagnostic codes. Other Symptoms If other occurrences happened in addition to the symptom. investigate the following conditions: • The other occurrences are related to the symptom. Conditions such as poor fuel quality or improperly adjusted valves can cause some engine symptoms.

Also. 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. and excessive detonation. . Note: Excessive deposits contribute to guttering of the valves. • “E229 (1) Fuel Energy Content Setting Low” (warning) (warning) • “E230 (1) Fuel Energy Content Setting High” • “E231 (3) Fuel Quality Out Of Range” (shutdown) Refer to Troubleshooting. Look for the following event codes: • “E026 (3) High Inlet Air Temperature” (shutdown) • “E027 (1) High Inlet Air Temperature” (warning) Refer to Troubleshooting. Check the Inlet Manifold Air Pressure The calculated engine load increases when the inlet manifold air pressure increases.Adjust”. “Inlet Air Temperature (High)”. blue smoke. Make sure that the engine oil level is correct. “Detonation Sensors”. “Air/Fuel Ratio Control . The fuel supply pressure must be adequate and stable.37 Troubleshooting Section • Incorrect air/fuel ratio • Incorrect base timing • Changes in the fuel quality • The engine speed/timing sensor is not calibrated. Check for Event Codes Regarding the Fuel Check for the following event codes: Recommended Repairs Excessive Load Make sure that the load is not excessive. A change in the fuel energy content will change the air/fuel ratio. For specific data on the engine. Measure the inlet manifold air pressure during engine operation with a load. Verify that the exhaust emissions are correct. Refer to Systems Operation/Testing and Adjusting. refer to the engine Technical Marketing Information. Check the inlet air temperature. “Engine Speed/Timing Sensor Calibrate”. • Faulty circuit for the detonation sensor(s) • Excessive deposits in the combustion chamber Check the Base Timing Verify that the base timing is correct. Check the Inlet Air Temperature High inlet air temperature can cause detonation. disengage the driven equipment and test the engine. Refer to Troubleshooting. Check for Deposits in the Cylinders Overfilling of engine oil can lead to deposits. Calibrate the engine speed/timing sensor. Look for the following conditions: Air/Fuel Ratio An air/fuel mixture that is too rich will cause detonation.Adjust”. Obtain a fuel analysis. Make sure that the fuel metering valve is operating correctly. If necessary. “Ignition Timing . Refer to Systems Operation/Testing and Adjusting. • 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 • Signs of internal leaks Signs of internal leaks include excessive consumption of engine oil. Use a borescope to inspect the cylinders. Reduce the load. perform this procedure if the engine speed/timing sensor has not been calibrated. Check the Detonation Sensors Troubleshoot the detonation sensors.

Recommended Repairs Check the Driven Equipment Determine whether the driven equipment has generated a “Start Inhibit” or “Shutdown” request.38 Troubleshooting Section If excessive deposits and/or signs of internal leaks are found. as needed. Verify that Cat ET is on the “Factory Password” screen. locate the source of the excessive resistance. Repair the wiring. Verify that the correct passwords were entered. Check the wiring between the driven equipment and the ECM connector for damage and/or corrosion. Verify that the following information from Cat ET has been recorded correctly: Driven Equipment SMCS Code: 1400-035 Probable Causes • The master Electronic Control Module (ECM) has received a “Start Inhibit” or a “Shutdown” signal. 3. Set the engine control to the OFF/RESET mode for 30 seconds and then retry. investigate the cause of the condition. as needed. 2. Check every character in each password. • The circuit for the signal is faulty. Check the resistance of the circuit between terminals P1-21 and P1-31 at the master ECM. • Serial Number of the engine • Serial Number of the Electronic Control Module (ECM) • Serial Number of the Cat ET • Total Tattletale • Reason Code • Diagnostic Clock i01804831 Check the Circuit for the Switch The circuit for the switch must remain closed in order to allow the engine to run. Make repairs. as needed. Make repairs. Service the driven equipment according to the recommendations of the OEM of the equipment. Determine the cause for the request. The correct resistance of the circuit is 5 Ohms or less. i01804809 ECM Will Not Accept Factory Passwords SMCS Code: 1901-035 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With an Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)) SMCS Code: 0785-035 Probable Causes • Electrical power supply • Electrical connectors • Communication adapter and/or cables • Electronic service tool • A problem with the harness code for the slave ECM Probable Causes One of the following items may not be recorded correctly on the Caterpillar Electronic Technician (ET): • Passwords • Serial Numbers . Refer to Troubleshooting. i02088119 • Total Tattletale • Reason Code Recommended Repairs 1. If the resistance is greater than 5 Ohms. “Inspecting Electrical Connectors”.

Set the engine control to the OFF/RESET mode. 3. 2. “Inlet Air Temperature (High)”. . the display will be blank. If the communication adapter is not receiving power. Probable Causes • High ambient temperature and/or high inlet air temperature Communication Adapter and/or Cables 1. “Communication Adapter II User’s Manual”. Verify that power supply voltage is present between terminals A and B of the J5 service tool connector. when possible. If you are using the 171-4401 Communication Adapter II. Make repairs. If the jumper wire is disconnected.39 Troubleshooting Section Recommended Repairs Electrical Power Supply Check power to the module. “Inspecting Electrical Connectors”. Then reconnect the communication adapter. If the same problem occurs with a different engine. the slave ECM will assume the function of a master ECM. The ECM that is connected to the harness reads the harness code. Check for high inlet air temperature. refer to Manual. Unable to Service”. Cat ET will display “Duplicate Type on data link. check Cat ET and the related equipment in order to determine the cause of the problem. 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. “Electrical Power Supply”. Note: If a module is not receiving power. as needed. Cat ET will not communicate with any of the modules. Check the condition of the fuse for the communication adapter. Switch the 35 amp circuit breaker OFF. Check the Harness Code for the Slave ECM The harness inside the terminal box has a jumper wire (harness code) that connects terminals J3-29 and J3-60. • Low coolant level and/or coolant leakage • Insufficient flow of air or coolant through the radiator or heat exchanger • Faulty water temperature regulators • Faulty coolant temperature sensor and/or circuit • Insufficient flow of coolant through the engine • Exhaust restriction • Excessive load • Incorrect base timing • Incorrect air/fuel ratio Electronic Service Tool In order to eliminate Cat ET as the problem. Refer to Troubleshooting. connect Cat ET to a different engine. Disconnect the communication adapter and the cables from the service tool connector. i01974132 Electrical Connectors Check the following components: • Power supply connections and ground to the module module Engine Coolant Temperature (High) SMCS Code: 1395-035 • Wiring harnesses and the connectors for the Refer to Troubleshooting. the module will not communicate. Make corrections. Refer to Troubleshooting. Verify that the jumper wire is in good condition. This allows the ECM to operate as the slave ECM. Determine the cause of the high air temperature. Check the continuity between terminals J3-29 and J3-60.

troubleshoot the circuit and the coolant temperature sensor. Refer to Systems Operation/Testing and Adjusting.40 Troubleshooting Section Check for a Low Coolant Level and/or Coolant Leakage Note: Low coolant level can be the effect of overheating rather than the cause. Ensure that the temperature is reasonable. “Analog Sensor Signal”. If the flow of cooling water through the heat exchanger is insufficient. Check the fan for proper operation. “Air Inlet and Exhaust System”. Obtain a fuel analysis. Reduce the load. Inspect the cooling system for leaks. If the temperature of the cooling water is too high. The temperature should rise steadily as the engine is warmed. A change in the fuel energy content will change the air/fuel ratio. The fuel supply pressure must be adequate and stable. disengage the driven equipment and test the engine. If the radiator fins are obstructed. 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. Refer to Systems Operation/Testing and Adjusting. Refer to Systems Operation/Testing and Adjusting. Check the Water Temperature Regulators Check the water temperature regulators for proper operation. determine the cause. make the necessary repairs. Make necessary repairs. If the fan does not operate properly. If leaking is found. determine the location of the obstruction. Check the coolant level. Refer to Systems Operation/Testing and Adjusting. Heat Exchanger Check for sufficient flow and temperature of the cooling water through the heat exchanger. “Ignition Timing . determine the cause of the excessive back pressure. Air/Fuel Ratio An air/fuel mixture that is too rich will cause overheating.Adjust”. Check for Insufficient Flow of Air and Coolant Through the Radiator or Heat Exchanger Radiator Check the fins of the radiator for obstructions.Adjust”. make the necessary repairs. Verify that the exhaust emissions are correct. Check the Flow of Coolant Through the Engine During normal operation. Add coolant. Check the Coolant Temperature Sensor and/or the Circuit Check the reading of the coolant temperature on the Caterpillar Electronic Technician (ET). Run the engine to operating temperature. “Testing the Cooling System”. Check the Exhaust Restriction Check the back pressure of the exhaust system. Excessive Load Make sure that the load is not excessive. Replace the water temperature regulators. if necessary. . determine the cause of the obstruction. If necessary. “Air/Fuel Ratio Control . Refer to Troubleshooting. Make the necessary repairs. Determine whether the leak occurs before the engine overheats. Check the Base Timing Verify that the base timing is correct. Make the necessary repairs. if necessary. clean the fins. If the reading on Cat ET for the coolant temperature is not reasonable. If the back pressure exceeds the specifications for the engine.

inspect the internal parts of the gas pressure regulator for wear. Make sure that the valve moves freely. interview the operator in order to determine if fuel quality is in question. Make the necessary repairs. “Testing the Cooling System”. gas shutoff valve. If the reading on Cat ET for the coolant temperature is not reasonable. Replace the water temperature regulators. When possible. and fuel metering valve. Make sure that the size of the fuel line is sufficient. If the engine speed changes. 1400-035 Engine Coolant Temperature (Low) SMCS Code: 1395-035 Probable Causes • Fuel supply • Electrical connectors or power supply • No signal from the speed/timing sensor • Ignition system • Incorrect base timing • 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. Check the Water Temperature Regulators The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. “Analog Sensor Signal”. determine the cause of the malfunction of the heaters. check the water temperature regulators according to Systems Operation/Testing and Adjusting. Check the hose at the outlet for the jacket water. troubleshoot the circuit and the coolant temperature sensor. Inspect the fuel system components: fuel filter. Inspect the fuel system for leaks. Try to determine if the source of the fuel was changed. If the jacket water heaters are not functioning properly. Verify that the system’s components are operating correctly. a regulator may be stuck open. The temperature should rise steadily as the engine is warmed. Refer to Troubleshooting. if necessary. Allow the engine to cool and then start the engine. i02088134 Engine Cranks but Will Not Start SMCS Code: 1000-035. • Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. Replace the fuel filter. if necessary. . Ensure that the fuel metering valve is operating correctly. gas pressure regulator. 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).41 Troubleshooting Section Strike the gas pressure regulator with a soft hammer. Ensure that the temperature is reasonable. Inspect the gas pressure regulator’s diaphragm for leaks. i01727368 If the water temperature regulators are malfunctioning. Recommended Repairs Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. If the hose is warm and normal operating temperature is not achieved yet. The valve must seat correctly.

Check the power and ground connections. Refer to Troubleshooting. Cat ET will display a graph of the cylinder’s exhaust gas temperature. 2. test the engine under the conditions. Inspect the wiring from the power supply to the master ECM and to the slave ECM. engine operating temperature.Replace”. extender. ignition transformer. Probable Causes • Cold cylinder . Excessive Load Make sure that the load is not excessive. and the desired engine speed are also displayed. Use the “Data Link/Select ECM” option on the Cat ET to select the ITSM. “Ignition System Spark Plugs . full load. Refer to Systems Operation/Testing and Adjusting. “Ignition Transformers Secondary Circuit and Spark Plugs”. Check the wiring harnesses and the connectors. Inspect the extenders for signs or pin holes and arcing. Troubleshooting the symptom under other conditions can give misleading results. short circuits. Ignition System Inspect the ignition transformers for loose connections. the engine speed. The Caterpillar Electronic Technician (ET) and the Integrated Temperature Sensing Module (ITSM) can be used to detect a misfiring cylinder. Refer to Troubleshooting. Inspect the extender for signs of pin holes and/or arcing. Inspect the power supply connections and the ground. Reduce the load. The output voltage of the transformer’s secondary circuit. If necessary. Inspect the primary wiring and the secondary electrical connections. Check the following components for failure: spark plug. Select “Diagnostics/Diagnostic Tests”. “Electrical Power Supply”.Adjust”. Runs Rough or Is Unstable SMCS Code: 1000-035 Cold Cylinder Locate the misfiring cylinder. and primary wiring.42 Troubleshooting Section Electrical Connectors or Power Supply There may be an intermittent interruption of power. Make sure that the timing wheel is correctly installed. Inspect the connectors in the terminal box. Make sure that the correct transformers and spark plugs are installed. i02085470 Engine Misfires. disengage the driven equipment and test the engine. Recommended Repairs Note: If the symptom only occurs under certain operating conditions (high idle. Select the suspect cylinder and click the “Start” button in the lower left corner of the screen. “Ignition Timing . moisture. • Electrical connectors or power supply • Ignition system • Fuel supply • Incorrect air/fuel ratio • Incorrect governor adjustment • Compressor bypass valve • Air inlet restriction • Exhaust restriction • Binding of the throttle actuator • 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. “Engine Speed/Timing Sensor”. Refer to Troubleshooting. etc). and open circuits. Maintain the spark plug according to Operation and Maintenance Manual. Use the following procedure: 1. 3. Check the Base Timing Verify that the base timing is correct.

Make sure that the correct transformers and spark plugs are installed. if necessary. Make the necessary repairs. Maintain the spark plug according to the engine’s Operation and Maintenance Manual. “Air/Fuel Ratio Control . Obtain a fuel analysis. Refer to Systems Operation/Testing and Adjusting. “Electrical Power Supply”. Inspect the wiring from the power supply to the control modules. Check the wiring harnesses and the connectors. refer to Systems Operation/Testing and Adjusting. Inspect the power supply connections and the ground. Verify that the system’s components are operating correctly. “Engine Governing .Adjust”. Move the throttle plate while you feel the motion. The following conditions can cause the engine to malfunction: • Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. inspect the air inlet piping for obstructions. Switch the 35 amp circuit breaker OFF. Refer to Disassembly and Assembly. . Testing And Adjusting.Adjust”. clean the filter element or install a new filter element. Verify that the exhaust emissions are correct. A change in the fuel energy content will change the air/fuel ratio. Check for Binding of the Throttle Actuator Set the engine control to the OFF/RESET mode. Refer to Systems Operation/Testing and Adjusting. moisture. If the indication is higher than the maximum permissible restriction.43 Troubleshooting Section Electrical Connectors or Power Supply There may be an intermittent interruption of power. short circuits.Install”. Air Inlet Restriction High inlet air restriction adversely affects engine performance. If the motion is sticky and/or rough. Air/Fuel Ratio An air/fuel mixture that is too rich or too lean will have an adverse effect on engine operation. “Actuator Bypass Valve (Variable) . Inspect the primary wiring and the secondary electrical connections. The fuel supply pressure must be adequate and stable. Inspect the fuel system for leaks. Refer to Troubleshooting. Make sure that the size of the fuel line is sufficient. interview the operator in order to determine if fuel quality is in question. Refer to the applicable Gas Engine Technical Data Sheet for additional information. When possible. For more information. Refer to Systems Operation. Check the restriction again. “Restriction of Air Inlet and Exhaust”. “Valve Lash and Valve Bridge Adjustment”. Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. Exhaust Restriction Check for restriction in the exhaust system. Compressor Bypass Valve The actuator for the compressor bypass valve must be installed properly in order to provide stable operation. Try to determine if the source of the fuel was changed. gas shutoff valve. Incorrect Valve Lash Check the valve lash. Governor Adjustment The governor’s parameters must be programmed with the values that provide stable operation. Ignition System Inspect the ignition transformers for the following items: loose connections. Replace the fuel filter. Inspect the extenders for signs of pin holes and of arcing. The maximum allowable air inlet restriction is 3. and open circuits. Inspect the connectors in the terminal boxes. Refer to Systems Operation/Testing and Adjusting. “Restriction of Air Inlet and Exhaust”. investigate the cause of the binding. Inspect the fuel system components: fuel filter. If the restriction remains too high. and fuel metering valve. gas pressure regulator.75 kPa (15 inches of H2O). Make sure that the ignition timing is correct.

Refer to the engine’s Operation and Maintenance Manual. “Engine Oil”. Do not allow the differential pressure to exceed 103 kPa (15 psi). Make sure that the sensors are correctly wired. Recommended Repairs Low Engine Oil Level Check the oil level. Inspect the oil filters for good condition. “Cylinder Pressure . repair the valve. the sensors are wired improperly. Add oil. refer to Operation and Maintenance Manual. If the oil filter bypass valve is faulty. i01727473 Engine Oil Pressure (Low) SMCS Code: 1348-035-PX Engine Oil Filter Differential Pressure SMCS Code: 1308-035 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. . Check for signs of damage and/or wear to the valves. “Engine Oil”. as needed. when possible. For more information. if necessary. Refer to Troubleshooting. For the correct engine oil to use. new valve lifters must be installed. Replace any suspect oil filter. i01727510 Throttle Make sure that the throttle actuator is operating properly. If the readings are not approximately zero for both of the sensors. Change the engine oil and the engine oil filter. Contaminated Engine Oil Engine oil that is contaminated with another liquid will cause low engine oil pressure. Inspect the condition of the camshafts. Troubleshoot the sensor circuit(s). cylinder head gasket. “Measuring Engine Oil Pressure”. refer to Operation and Maintenance Manual.44 Troubleshooting Section Cylinder Head and Related Components Measure the cylinder compression. If the oil filter differential pressure is too high. Obtain an analysis of the 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. Incorrect Viscosity Make sure that the engine is supplied with the correct engine oil. High engine oil level can be an indication of contamination. etc.Measure/Record”. 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. Replace the valve. If the motion of the actuator is sticky and/or rough. 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. Inspect the components of the valve train for good condition. For the correct engine oil to use. “Analog Sensor Signal”. Check the operation of the oil filter bypass valve. service the actuator. If a camshaft is replaced. see Systems Operation/Testing and Adjusting. change the oil filter elements. Determine the reason for contamination of the engine oil and make the necessary repairs.

If a reading is significantly different from zero.45 Troubleshooting Section 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. if necessary. a restriction. Thoroughly clean • There is a problem with a piston cooling jet. • An engine oil line or a passage for engine oil is disconnected or broken. 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. Make the necessary repairs. oil pump can have a restriction. For comparative data. • The engine oil filter is clogged. Replace the engine oil filter. troubleshoot the circuit for the oil temperature sensor. The temperature should rise steadily as the engine is warmed. • The engine oil cooler is clogged. This restriction will cause cavitation and a loss of engine oil pressure. the engine oil cooler. Determine the pressure differential between the inlet and the outlet of the oil cooler. or incorrect installation of a piston cooling jet will cause seizure of the piston. • The engine oil pump’s pressure regulating valve or a bypass valve is stuck in the open position. Refer to Troubleshooting. Clean the valve. Replace parts. Ensure that the temperature is reasonable. Investigate the cause of the obstruction. “Analog Sensor Signal”. Worn Components Excessive clearance at the crankshaft or camshaft bearings will cause low engine oil pressure. Refer to Troubleshooting. of the tube for cracks or a damaged O-ring seal. inspect the clearance between the rocker arm shafts and the rocker arms. Check the joints • There is a problem with the engine oil pump. Check the Flow of Oil Through the Oil Cooler Run the engine at normal operating temperature. • The inlet screen of the suction tube for the engine Check the Flow of Coolant Through the Oil Cooler Oil Coolers that are Cooled with Jacket Water Check for “High Engine Coolant Temperature” events. Check the inlet screen on the suction tube and remove any material that may be restricting engine oil flow. If the reading on Cat ET for the oil temperature is not reasonable. • The suction tube is drawing in air. check the temperature of the coolant at the outlet of the oil cooler. refer to the Technical Marketing Information for the engine. Both readings should be close to zero pressure. If the inlet temperature is OK. Check the gears of the engine oil pump for excessive wear. Breakage. “Engine coolant Temperature (High)”. . SMCS Code: 1348-035 i01727521 Engine Oil Temperature (High) 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 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). replace the suspect engine oil pressure sensor. Check the analysis for the level of wear metals in the engine oil. Obtain an analysis of the engine oil. Check the engine components for excessive clearance. Also. Engine oil pressure is reduced by gears that have too much wear. A high temperature difference indicates an insufficient flow rate.

“Ignition Timing . Check the Engine Speed The master ECM must detect a minimum of 50 rpm before the gas and the ignition are supplied to the engine. check the engine rpm. • The quality of the gas does not match the parameter for “Fuel Quality”. “Fuel Pressure”. i01974116 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. Refer to Systems Operation/Testing and Adjusting. If the engine should crank and cranking occurs. Make the necessary repairs. Use Cat ET to monitor the engine speed while you crank the engine. troubleshoot the diagnostic code. Recommended Repairs Check the Gas Supply to the Engine Check for low gas pressure. there is an insufficient flow of oil through the oil cooler. troubleshoot the speed/timing sensor. If no engine speed is displayed on Cat ET or if the engine speed is not stable. If the throttle does not open. Correct the cause of the active code. “Engine Speed/Timing Sensor”. refer to Troubleshooting. Check the Base Timing Verify that the base timing is correct. If the LHV of the fuel does not match the “Fuel Quality” parameter that is programmed into the master ECM. If the gas pressure is low. Before the engine can be started. “Air/Electric Starting System”. you must recycle the power to the engine. Refer to Systems Operation/Testing and Adjusting.Adjust”. Engine Overcrank SMCS Code: 1400-035 Probable Causes • The gas supply to the engine is insufficient. If the motion is sticky and/or rough. The master ECM uses the setting for start-up and for air/fuel ratio control at low loads. Check for Diagnostic Codes Check for active diagnostic codes that relate to the ignition system. . 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 master ECM. Then set the control to the STOP mode. • A feature for engine protection prevents the engine from starting. If there is at least one active diagnostic code that relates to the ignition system. investigate the cause of the binding. 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. Set the engine control to the OFF/RESET mode. • The ignition system is not functioning.46 Troubleshooting Section If the pressure differential between the inlet and the outlet of the oil cooler exceeds the data that is published for the engine. • The starting motor circuit is faulty. • There is no engine speed signal to the master Electronic Control Module (ECM). Make the necessary repairs. troubleshoot the starting circuit. program the master ECM with the correct setting for the “Fuel Quality” parameter. Refer to Troubleshooting. Move the throttle plate while you feel the motion. • The base timing is incorrect. Determine the cause of the obstruction. If the status of the relay for the starting motor indicates that the engine should crank but no cranking occurs. check for binding of the throttle actuator.

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. For specific data on the engine. Check for Diagnostic Codes that Relate to the Signal from the Signal Driver in the Master ECM Check for diagnostic codes that relate to the actuator of the throttle. Program the “Fuel Quality” configuration parameter to the average value of the LHV. Check for Slow Governor Response Observe the “Speed Governor Adjustment” screen on the Caterpillar Electronic Technician (ET). Recommended Repairs Check the Inlet Manifold Air Pressure The calculated engine load increases when the inlet manifold air pressure increases. Look for the engine response to the worst cases for step-loading and unloading. If the LHV of the gas does not match the “Fuel Quality” parameter value that is programmed into the ECM. refer to the engine Technical Marketing Information. Change the trip point to an acceptable speed.47 Troubleshooting Section i01804844 • Binding of the throttle actuator Engine Overload SMCS Code: 1000-035 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. Verify that the trip point for the engine overspeed is properly programmed. investigate the cause of the binding. Probable Causes • Low trip point for engine overspeed • Signal from the signal driver in the master Electronic Control Module (ECM) for the actuator of the throttle • Energy of the driven equipment • Slow governor response . The trip point or engine overspeed may be too low. program the master ECM with the correct value for the “Fuel Quality” parameter by selecting the “Change” button in the lower left corner of the screen. If the motion is sticky and/or rough. Make corrections to the installation in order to prevent the overspeed from recurring. this parameter is set at 118 percent of rated speed. Make the necessary repairs. Program the correct LHV for the “Fuel Quality” configuration parameter. i01804850 Check the Driven Equipment Determine if the driven equipment has additional inputs of energy that could drive the engine beyond the rated rpm. Type the correct value and then select “OK”. Engine Overspeed SMCS Code: 1000-035 Check for Binding of the Throttle Actuator Set the engine control to the OFF/RESET mode. This parameter requires a factory password in order to change the trip point. Obtain a Fuel Analysis and Program the Fuel Energy Content Obtain an analysis of the gas in order to determine the LHV. Make the necessary repairs. Move the throttle plate while you feel the motion. Typically. Switch the 35 amp circuit breaker OFF. obtain several analyses over a period of time. If the quality of the gas is not consistent. Investigate the diagnostic code(s). Measure the inlet manifold air pressure during engine operation with a load.

Reset the control system. as needed. Use an ohmmeter and toggle the switches in order to check for proper electrical operation. 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. Refer to Troubleshooting. • Either switch is activated by excessive vibration. If the resistance is greater than 5 Ohms. • Incorrect input(s) for the mode of operation to the master Electronic Control Module (ECM) relay. Probable Causes • There is a problem with the Gas Shutoff Valve (GSOV). • The normal stop switch that is installed by the customer is activated. Replace any faulty components. close the switch and check the resistance between terminals 23 and 31 of the P1 connector. Make repairs. The correct resistance between the terminals is less than 5 Ohms. • There is a problem with the “Run” relay. • A shutdown has been requested by the driven equipment. Recommended Repair Check the Circuit for the GSOV Troubleshoot for the following diagnostic codes: • 17-05 Fuel Shutoff Valve open circuit . For the emergency stop switch. cracks. “Inspecting Electrical Connectors”. • The delay time for the driven equipment is • There is a problem with the harness code for the slave ECM. and abrasion. locate the source of the excessive resistance. i01804861 Engine Shutdown SMCS Code: 1400-035 Probable Causes • The “Emergency Stop” button is pressed. Look for damage and/or corrosion. reset the control system. Engine Shutdown (Unexpected) SMCS Code: 1400-035 Recommended Repairs Talk to the operator Ask the operator if the stop was intentional. close the switch and check the resistance between terminals 22 and 31 of the P1 connector. For the normal stop switch. Disassemble the switches. • The circuit for the normal stop switch is faulty. Resume normal operation. Make sure that the reason for the stop has been corrected.48 Troubleshooting Section i02052150 Inspect the Stop Switches Inspect the stop switches for evidence of damage that has been caused by vibration. • The “Crank Terminate Speed” is incorrectly programmed. Inspect the wiring between the switches and the connector of the electronic control module. Inspect the components for looseness. excessive. • The “Engine Overcrank Time” is incorrectly programmed. Resume normal operation. • The circuit for the emergency stop is faulty. If the stop was accidental. • There is a problem with the “Crank Terminate” • There is a problem with the relay for the starting motor. • The “Cycle Crank Time” is incorrectly programmed.

the attempt to start is terminated. program the delay time to zero. Use Cat ET to increase the “Engine Overcrank Time”. Check the “Crank Terminate Speed” The “Crank Terminate Speed” is a parameter that can be configured.49 Troubleshooting Section • 17-06 Fuel Shutoff Valve short to ground • 17-12 Fuel Shutoff Valve malfunction Refer to Troubleshooting. Check the “Start” Relay Troubleshoot for the following diagnostic codes: • 444-05 Start Relay open circuit • 444-06 Start Relay short to ground Refer to Troubleshooting. “ECM Output Circuit (Starting Motor)”. Make repairs. An event code is generated if the “Driven Equipment Delay Time” elapses without closure of the switch input. the engine will shut down. Check the “Driven Equipment Delay Time” The “Driven Equipment Delay Time” is a parameter that can be configured. Use Cat ET to check the “Engine Overcrank Time”. “ECM Status Indicator Output”. as needed. as needed. Check the “Engine Overcrank Time” The “Engine Overcrank Time” is a parameter that can be configured. “Driven Equipment”. Use Cat ET to check the “Driven Equipment Delay Time”. the “Engine Overcrank Time” can elapse before the engine is able to start. The master Electronic Control Module (ECM) disengages the starting motor when the engine exceeds the programmed “Crank Terminate Speed”. “ECM Output Circuit (Fuel Control)”. If the engine does not start within the programmed “Engine Overcrank time”. Make repairs. Use Cat ET to adjust the “Crank Terminate Speed”. If the “Cycle Crank Time” is insufficient. Check the “Run” Relay Troubleshoot for the “445-03 Run Relay short to +batt” diagnostic code. If the engine does not start within the programmed “Cycle Crank Time”. This parameter determines the length of time for the crank cycle. If the “Crank Terminate Speed” is too slow. The master 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. the “Engine Overcrank Time” can elapse before the engine is able to start. Make repairs. If the programmed delay time is too long. . The master ECM provides a switch input for the driven equipment in order to delay engine start-up until the driven equipment is ready. Check the “Cycle Crank Time” The “Cycle Crank Time” is a parameter that can be configured. To disable this feature. Use Cat ET to check the “Cycle Crank Time”. as needed. Refer to Troubleshooting. Make repairs. as needed. Make repairs. An “E225 (3) Engine Overcrank” event is generated. Make corrections. Check for a Request for a Shutdown by the Driven Equipment Determine whether a shutdown for the driven equipment has been requested. Check the “Crank Terminate” Relay Troubleshoot for the “443-03 Crank Terminate Relay short to +batt” diagnostic code. Refer to Troubleshooting. if necessary. if necessary. Use the Caterpillar Electronic Technician (ET) to check the programmed “Crank Terminate” speed. as needed. Use Cat ET to increase the time. Refer to Troubleshooting. Use Cat ET to program the delay time to a reasonable amount of time. Check the Inputs for the Mode of Operation to the Master ECM Troubleshoot for the “336-02 Incorrect ECS Switch inputs” diagnostic code. “Electrical Power Supply”. Refer to Troubleshooting. if necessary. If the “Cycle Crank Time” is insufficient. This parameter determines the time for engagement of the starting motor and the gas shutoff valve during the crank cycle. “ECM Status Indicator Output”. the engine may not start. as needed. the attempt to start is suspended for an equal “Rest” cycle. The default value of 250 rpm should be sufficient for all applications.

Use the “Data Link/Select ECM” screen on Cat ET to select the ITSM. “Electrical Power Supply”. • The master Electronic Control Module (ECM) has • There is a problem with the fuel supply. “Engine Speed/Timing Sensor”. the engine speed. Refer to Troubleshooting. ignition transformer. Verify that the jumper wire is in good condition. Misfiring Cylinders For a shutdown that is due to misfiring cylinders. The jumper wire must remain connected in order for the engine to run. the shutdown is likely to occur only when the engine is operating under a load. The Caterpillar Electronic Technician (ET) and the ITSM can be used to detect a misfiring cylinder. and the desired engine speed are also displayed. Check the wiring connections to the 35 amp circuit breaker for proper installation. Power Supply to the Engine Control System 1. Check the continuity between terminals J3-29 and J3-60. Locate the misfiring cylinder. . 2. Engine Shutdown without a Diagnostic Code SMCS Code: 1400-035 • Inspect the fuel lines for foreign objects and for obstructions that can block the fuel supply. extender. Inspect the electronic control modules and the terminal box for proper installation of the connectors. “Ignition Transformers Secondary Circuit and Spark Plugs”. 2. Fuel Supply • Check the fuel supply pressure. 3. Speed/Timing Sensor A loss of supply voltage to the speed/timing sensor will cause a shutdown. Cat ET will display a graph of the cylinder’s exhaust gas temperature. This allows the ECM to operate as the slave ECM. Refer to Troubleshooting. Inspect the ground strap and the power supply for connections that are loose and/or corroded. The transformer’s secondary circuit. The ECM that is connected to the harness reads the harness code. Probable Causes • An external shutdown or a customer shutdown was requested. Use the following procedure: 1. Inspect the extender for signs of pin holes and/or arcing. Check the following components for failure: spark plug. • The power supply becomes disconnected from the engine control system. The engine will shut down if the jumper wire becomes disconnected during engine operation. 4. Make repairs. Check the 35 amp circuit breaker on the power distribution box. i01804877 3.50 Troubleshooting Section Check the Harness Code for the Slave ECM The harness inside the terminal box has a jumper wire (harness code) that connects terminals J3-29 and J3-60. lost the supply voltage for the speed/timing sensor. • A cylinder or cylinders are misfiring. Refer to Troubleshooting. and primary wiring. Select the suspect cylinder and click the “Start” button in the lower left corner of the screen. Select “Diagnostics/Diagnostic Tests”. Recommended Repairs External Shutdown or Customer Shutdown Check the master ECM and the Integrated Temperature Sensing Module (ITSM) for logged codes of events that are shutdowns. as needed.

The following conditions can cause the engine to malfunction: Excessive Load Make sure that the load is not excessive. Make sure that the correct transformers and spark plugs are installed. “Inspecting Electrical Connectors”. Engine Speed/Timing Sensor Make sure that the speed/timing sensor is installed correctly. Electrical Connectors or Power Supply 1. moisture. Check the wiring harnesses and the connectors from the power supply to the power distribution box. Check the wiring harnesses and the connectors from the power distribution box to the terminal box. • The input for the selection of the base timing may Recommended Repairs Note: If the symptom only occurs under certain operating conditions (high idle. • The timing may be retarded due to the selection of the map for speed or the map for load. Refer to Troubleshooting. Inspect the fuel system components: fuel filter. Engine Timing Does Not Match Programmed Timing SMCS Code: 1000-035. “Engine Speed/Timing Sensor”. Reduce the load. See Troubleshooting. if necessary. 1400-035 Probable Causes • The timing may be retarded due to detonation. etc). engine operating temperature. Recommended Repairs Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. i01804902 • Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. . and open circuits.51 Troubleshooting Section i01804883 Engine Starts but Stalls Immediately SMCS Code: 1250-035. If this diagnostic code is logged. Make sure that the timing wheel is correctly installed. full load. Try to determine if the source of the fuel was changed. Verify that the system’s components are operating correctly. Probable Causes • Fuel supply • Electrical connectors or power supply • Engine speed/timing sensor • Ignition system • Excessive load Ignition System Inspect the ignition transformers for the following items: loose connections. proceed to Troubleshooting. Inspect the primary wiring and the secondary electrical connections. test the engine under the conditions. Maintain the spark plug according to the engine’s Operation and Maintenance Manual. Inspect the power supply connections and the ground. Inspect the connectors in the terminal box. and actuator for the throttle. Inspect the fuel system for leaks. fuel metering valve. Make sure that the size of the fuel line is sufficient. Inspect the extenders for signs of pin holes and of arcing. “Electrical Power Supply”. be incorrect. gas pressure regulator. disengage the driven equipment and test the engine. If necessary. Troubleshooting the symptom under other conditions can give misleading results. 1400-035 2. Use the Caterpillar Electronic Technician (ET) to check for the 168-02 diagnostic code for “System Voltage intermittent/erratic”. Replace the fuel filter. interview the operator in order to determine if fuel quality is in question. When possible. short circuits. gas shutoff valve.

2. turn the crankshaft by hand. Load test the batteries. Refer to the topic in Troubleshooting for the particular event code. If the battery cables are corroded. a. the clutch jaws may be broken. Charge the batteries. Tighten any loose connections. i01822829 Starting Motor or Flywheel Ring Gear If the pinion engages the flywheel but the flywheel does not turn. Inspect the air lines for leaks. If the starting motor does not turn the crankshaft. Refer to the schematic diagram in Troubleshooting. “Battery Test Procedure”. Engine Will Not Crank SMCS Code: 1000-035. . Refer to Special Instruction. there may be a problem with the starting motor. Repair the starting motor or replace the starting motor. If the crankshaft will turn by hand. the “Second Desired Timing”. If the pinion does not engage correctly with the flywheel. SEHS9249. and battery cables for loose connections and corrosion. replace the parts. Before you remove the starting motor. try the starting motor again. “Programming Parameters”. and the “Desired Timing” parameters. Low Air Pressure Determine the cause of the low air pressure. Grease the splines of the drive shaft and the pinion. Starting Circuit Check the starting circuit. SEHS7633. “Use of 4C-4911 Battery Load Tester for 6. If the starting motor turns but the flywheel does not turn. If the pinion does not engage the flywheel. inspect the gear teeth. A short circuit between terminals J1-20 and J1-31 selects the “Second Desired Timing”. Refer to Special Instruction. “ECM Output Circuit (Starting Motor)”. 1400-035 Probable Causes • Batteries and/or battery cables • Starting circuit • Starter motor pinion or flywheel ring gear • Low air pressure • Static load • Internal mechanical problem • There is a problem with the harness code for the slave Electronic Control Module (ECM). Inspect the pinion and the flywheel ring gear for damage. Map Use the “Service/Configuration” screen of Cat ET in order to verify the value that is programmed for the timing. Inspect the main power switch. Recommended Repairs Batteries and/or Battery Cables 1. disengage the driven equipment and test the engine. Try to turn the crankshaft by hand. the clutch jaws. Ensure that a mechanical failure inside the engine is not preventing the crankshaft from turning. If necessary. remove the starting motor. the pinion shaft may be stuck. Check the “First Desired Timing”. Look for codes “E401-1” through “E416-1”. b. An open circuit between terminals J1-20 and J1-31 selects the “First Desired Timing”.52 Troubleshooting Section Detonation Use the Caterpillar Electronic Technician (ET) to review the logged codes. Timing Selection Verify that the input for the selection of the base timing is correct. or other parts. 8 and 12 Volt Lead Acid Batteries”. If the teeth of the pinion and/or of the flywheel ring gear are worn or broken. Remove the pinion. Inspect the batteries. remove the battery cables and clean the battery cables. Static Load Make sure that the driven equipment is not preventing the crankshaft from turning. Repair any leaks in the air lines. battery posts. Refer to Troubleshooting.

Adjust”. i02085826 Inlet Air Restriction High inlet air restriction adversely affects engine performance. Check the inlet air temperature. Refer to Systems Operation/Testing and Adjusting. Obtain a fuel analysis. disengage the driven equipment and test the engine. as needed. . clean the filter element or install a new filter element. Reduce the load.Adjust”. Refer to Troubleshooting. “Air/Fuel Ratio Control . Verify that the exhaust emissions are correct. Air/Fuel Ratio An air/fuel mixture that is too rich will increase the exhaust temperature. If this is not the problem. Perform adjustments and/or make repairs. If necessary. the engine must be disassembled in order to investigate internal mechanical problems. • Bearing seizure • Piston seizure • Valve and piston contact Check the Harness Code for the Slave ECM The harness inside the terminal box for the slave ECM has a jumper wire (harness code) that connects terminals J3-29 and J3-60. The fuel supply pressure must be adequate and stable. Refer to Systems Operation/Testing and Adjusting. This allows the ECM to operate as the slave ECM. Possible internal problems include the following conditions: Recommended Repairs Check the Inlet Air Temperature High inlet air temperature can cause detonation. Investigate the cause of the exhaust restriction. Measure the Exhaust Restriction Measure the exhaust restriction during engine operation with a load. Check the Base Timing Verify that the base timing is correct. The ECM that is connected to the harness reads the harness code. Check the continuity between terminals J3-29 and J3-60. Make repairs. “Inlet Air Temperature (High)”. as needed. A change in the fuel energy content will change the air/fuel ratio.75 kPa (15 inches of H2O). Check for fluid in the cylinders. For data that is specific to the engine. remove the spark plugs. Verify that the jumper wire is in good condition. The jumper wire must remain connected in order for the engine to run. Check the restriction again. Exhaust Port Temperature (High) SMCS Code: 1059-035 Probable Causes • High inlet air temperature • Inlet air restriction • Air/fuel ratio • Excessive load • Incorrect base timing • Exhaust restriction • A buildup of deposits in the cylinder or internal oil leaks Excessive Load Make sure that the load is not excessive. The maximum allowable inlet air restriction is 3.53 Troubleshooting Section Internal Mechanical Problem If the crankshaft will not turn and the driven equipment is disengaged. If the indication is higher than the maximum permissible restriction. “Ignition Timing . inspect the air inlet piping before the air cleaner for obstructions. The jumper wire must be connected in order for the engine to crank. Refer to the applicable Gas Engine Technical Data Sheet for additional information. If the restriction remains too high. refer to the Technical Marketing Information.

investigate the cause of the condition. If no logged diagnostic codes are present for the suspect cylinder. the temperatures from similar locations are reduced at a similar rate. Refer to Troubleshooting. Make repairs. • 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 Check for Suspect Thermocouples Observe the temperatures from the thermocouples after the engine is shut off. “Engine Misfires. replace the thermocouple. Refer to Troubleshooting. If excessive deposits and/or signs of internal oil leaks are found. When the engine is operating properly. If the temperature problem follows the thermocouple. Note: Excessive deposits contribute to guttering of the valves. Look for the following conditions: 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. Recommended Repairs Check for Misfire Operation with a low load can result in low exhaust temperatures. Troubleshoot the code.Runs Rough or Is Unstable”. “Ignition Transformers Secondary Circuit and Spark Plugs”. Probable Causes • Operation with a light load • Active diagnostic code from the Integrated Temperature Sensing Module (ITSM) • A faulty thermocouple • Insufficient ignition • Low cylinder compression Check the Cylinder Compression Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression. . investigate the cause for the low temperature. If any discrepancies are found. Make repairs. investigate the cause of the low compression. switch the suspect thermocouple for another thermocouple. Operate the engine at low idle or near low idle in order to identify a misfire problem.54 Troubleshooting Section Check for Deposits in the Cylinder and Check for Internal Oil Leaks Use a borescope to inspect the cylinders. If low compression is found. Refer to Troubleshooting. If the temperature problem stays at the original location of the suspect thermocouple. “Ignition Transformers Primary Circuit”. • Signs of internal oil leaks Other signs of internal oil leaks include high oil consumption and blue smoke. as needed. as needed. inspect the components of the ignition system for the cylinder. Troubleshoot the cause of the misfire. Also. Troubleshoot the code. i01727687 Exhaust Port Temperature (Low) SMCS Code: 1059-035 Check for Insufficient Ignition Use Cat ET to check for logged diagnostic codes that relate to the ignition system. the temperatures from similar locations are comparable.

i01804920 Fuel Metering Valve SMCS Code: 1274-035 Probable Causes • Low operating voltage for the fuel metering valve • Internal binding of the fuel metering valve Recommended Repairs Check the Operating Voltage for the Fuel Metering Valve Check the operating voltage for the fuel metering valve. Clean the valve. Visually inspect the internal mechanism of the valve. adjust the gas pressure regulator in order to achieve the correct pressure. Check for binding due to dirt and/or contamination. Make repairs. Check for binding due to wear of internal components. Verify that the emissions are within specifications. Recommended Repairs Obtain a Fuel Analysis and Program the “Fuel Quality” Parameter Obtain an analysis of the gas in order to determine the LHV. Gas Fuel Differential Pressure (High) SMCS Code: 1250-035 Probable Causes • Excessive fuel supply pressure • Leaks in the piping after the fuel metering valve . i01727704 Fuel Energy Content SMCS Code: 1250-035 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. Program the “Fuel Quality” parameter to the actual value of the LHV. If the valve is binding due to wear of internal components. Refer to Troubleshooting.55 Troubleshooting Section i01804917 Check the Fuel Metering Valve Shut OFF the fuel supply. “Electrical Power Supply”. 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. if necessary. • Condensation is forming in the gas. obtain several analyses over a period of time.5 to 5 psi). Program the “Fuel Quality” parameter to the average value of the LHV. repair the regulator or replace the regulator. as needed. refer to the literature that is provided by the OEM of the valve. The fuel metering valve requires a gas supply that is regulated to a pressure between 10 to 35 kPa (1. Disconnect the fuel lines from the fuel metering valve. i01369481 Check the Dryer for the Gas Check the dryer for the gas for proper operation. If the quality of the gas is not consistent. Repair the dryer. If the fuel pressure is not within the acceptable range. if necessary. If the gas pressure regulator cannot be adjusted to the correct setting.

Check the Gas Shutoff Valve (GSOV) for proper operation. Replace the fuel filter. • Obstructions in the fuel supply • Inadequate fuel energy content or moisture in the gas Check the Gas Pressure Regulator The fuel metering valve requires a minimum pressure of 10 kPa (1. Adjust the gas pressure regulator in order to achieve the correct pressure. Replace the GSOV. Ensure that the fuel metering valve is installed properly. Clean the piping and make repairs. if necessary. Verify that the valve is fully open when the valve is energized. if necessary. i01804929 Gas Fuel Differential Pressure (Low) SMCS Code: 1250-035 Check the Fuel Outlet for Obstructions Inspect the piping for obstructions between the fuel metering valve and the inlet to the turbocharger compressor. repair the regulator or replace the regulator.5 psi) for the gas supply. if necessary. Clean the lines and make repairs. If the gas pressure regulator cannot be adjusted to the correct setting. Check the outlet pressure from the gas pressure regulator. as needed. Inspect the fuel supply lines to the fuel metering valve for obstructions. Adjust the gas pressure regulator in order to achieve the correct pressure. If the gas pressure regulator cannot be adjusted to the correct setting. as needed. Probable Causes • Improper installation of the fuel metering valve • Low fuel supply pressure • Obstructed fuel supply • Obstructed fuel outlet i01727721 Gas Fuel Flow Rate (Low) SMCS Code: 1250-035 Probable Causes • High fuel temperature • Faulty gas pressure regulator or low fuel supply pressure 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. Repair the GSOV. if necessary. 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. Verify that the GSOV does not stick in a partially open position.56 Troubleshooting Section Recommended Repairs Check the Fuel Supply Pressure Check the pressure of the fuel supply to the fuel metering valve for high pressure. repair the regulator or replace the regulator. Check the Fuel Supply for Obstructions Check the fuel filter for restriction. The maximum allowable pressure to the fuel metering valve is 35 kPa (5 psi). Clean the screen. Inspect the screen inside the inlet of the fuel metering valve for cleanliness.

Program the Fuel Energy Content to the average value of the LHV. “Fuel Energy Content”. determine the reason for the faulty signal from the fuel metering valve.5 psi) for the gas supply. Make repairs. If the measurement for the temperature is significantly different from the reading on Cat ET. Clean the screen. refer to Troubleshooting. Inspect the screen inside the inlet of the fuel metering valve for cleanliness. if necessary. Verify that the GSOV does not stick in a partially open position. Compare the measurement to the reading for the temperature on the Caterpillar Electronic Technician (ET). refer to Troubleshooting. If the temperature on Cat ET is different.57 Troubleshooting Section Recommended Repairs Check the Fuel Temperature Measure the temperature of the gas that is entering the fuel metering valve. Check the Gas Shutoff Valve (GSOV) for proper operation. If the pressure of the gas supply is too low. the fuel metering valve could demand an excessive supply of fuel. determine the cause of the high fuel temperature. repair the equipment. Verify that the valve is fully open when the valve is energized. Check Cat ET for a “E230 (1) Fuel Energy Content Setting High” event code. • The fuel metering valve has sent faulty data to the master Electronic Control Module. . If the fuel temperature is high. repair the regulator or replace the regulator. as needed. Check the Dryer for the Gas Check the dryer for the gas for proper operation. adjust the gas pressure regulator in order to achieve the correct pressure. Program the Fuel Energy Content to the actual value of the LHV. determine the reason for the faulty data from the fuel metering valve. Inspect the fuel supply lines to the fuel metering valve for obstructions. if necessary. If there is an active “E223 High Gas Temperature” event code. if necessary. Make repairs. The fuel metering valve requires a minimum pressure of 10 kPa (1. as needed. Check the Gas Pressure Regulator Check the outlet pressure from the gas pressure regulator. If the quality of the gas is not consistent. Recommended Repairs Investigate the Cause of the High Temperature Check for proper operation of the equipment that treats the gas prior to the engine. Obtain a Fuel Analysis If the fuel energy content is too low. If the code is present. Check the Data from the Fuel Metering Valve Measure the temperature of the gas that is entering the fuel metering valve. Replace the fuel filter. “Gas Temperature (High)”. as needed. obtain several analyses over a period of time. if necessary. If the gas pressure regulator cannot be adjusted to the correct setting. Clean the lines and make repairs. Repair the dryer. Compare the measurement to the reading for the fuel temperature on the Caterpillar Electronic Technician (ET). Check the Fuel Supply for Obstructions Check the fuel filter for restriction. Replace the GSOV. i01758553 Gas Temperature (High) SMCS Code: 1250-035 Probable Causes • The temperature of the gas is too high. as needed. Repair the GSOV. If a problem is found for the equipment that treats the gas prior to the engine. Obtain an analysis of the gas in order to determine the LHV. Check Cat ET for a “E223 High Gas Temperature” event code. Check for proper operation of the equipment that treats the gas prior to the engine.

“Inspecting Electrical Connectors”. • A potential transformer in the ATB+ is faulty. Verify that the values for the “Air/Fuel Ratio Control” configuration parameters are correct. Refer to the service literature for the power sensor. Probable Causes The following probable causes apply if the generator is equipped with the EMCP II+: • There is an incorrect calibration value for the AC Transformer Box + (ATB+). “Electronic Control System Parameters”. • The ATB+ is faulty. “Electronic Control System Parameters”. Verify that the values for the “Air/Fuel Ratio Control” configuration parameters are correct. The following probable causes apply if the generator is equipped with a power sensor: • There is a faulty potential transformer for the power sensor. Refer to Troubleshooting. • There is an incorrect value for one or more of the “Power Monitoring” parameters.01 VDC. “Power Monitoring” parameters. Perform this procedure before you adjust the “Power Monitoring” parameters. Refer to the appropriate service literature for the EMCP II+. “Electronic Control System Parameters”. • A current transformer in the ATB+ is faulty. Refer to Troubleshooting. Refer to Troubleshooting. If the voltage is not accurate. Refer to Troubleshooting. Refer to the service literature for the power sensor. • There is a faulty current transformer for the power • The power sensor is faulty. This voltage is called the offset voltage. parameters for the fuel. Generators that are Equipped with a Power Sensor Verify that the transformers for the power sensor are operating correctly. Use the following procedure in order to determine if the offset voltage is too high. sensor. Verify that the power sensor is operating correctly. • There is an incorrect value for one or more of the .58 Troubleshooting Section i02089727 • The offset voltage at the input to the master ECM from the power sensor is too high. The master ECM must receive an accurate voltage from the power sensor. Generator Output Power Readings Do Not Match SMCS Code: 5574-035-PWR The master Electronic Control Module (ECM) monitors the generator’s output power in order to accurately control the air/fuel ratio. the voltage from the power sensor must be less than 0. When the generator’s output is zero. Verify that the values for the “Power Monitoring” configuration parameters are correct. • There is a problem with the wiring between the power sensor and the master ECM. the master ECM may not accurately control the air/fuel ratio. • There is an incorrect value for one or more of the parameters for the fuel. The master ECM uses an output from one of the following sources in order to monitor the generator’s output power: • There is an incorrect value for one or more of the Read the rest of this procedure before you adjust the “Power Monitoring” parameters. Recommended Repairs Generators that are Equipped with EMCP II+ Verify that the transformers and the ATB+ are operating correctly. Check the wiring between the power sensor and the master ECM for corrosion and for pinch points. • Electronic Modular Control Panel II+ (EMCP II+) • Programmable Logic Controller (PLC) • Wattmeter The PLC and the wattmeter are also called power sensors.

Make corrections.01 VDC. Verify that the probes are making good contact with the terminals inside the connector. Refer to Troubleshooting. If the sensor is OK. Measure the DC voltage at the terminals. “Engine Coolant Temperature (High)”. “Electronic Control System Parameters”. Inlet Air Temperature (High) SMCS Code: 1087-035 Check the Temperature Sensor and/or the Circuit Allow the sensor to cool and remove the sensor. For specific data. perform the following procedures: • 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. High Altitude Make sure that the settings for the engine are correct for the altitude. switch the sensor with a sensor that is known to be good. If the engine is running. If the voltage is less than ±0. The engine must be stopped. the circuit between the power sensor and the master ECM must be calibrated. Refer to Systems Operation/Testing and Adjusting. .01 VDC. 2. when possible. Check for obstructions to the air inlet. refer to the Technical Marketing Information for the engine.Calibration”. If there is a high differential between the inlet temperature and the outlet temperature of the coolant for the aftercooler. i01623042 Coolant Temperature Refer to Troubleshooting. Check the reading for the inlet air temperature. If the temperature is OK. Measure the inlet air pressure while the engine is operating under load. Verify that the problem is solved. Replace the air filters and/or remove the obstruction from the air inlet. If the voltage is greater than ±0. 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 for Sufficient Flow of Cooling Water Through the Aftercooler Check the inlet temperature of the coolant for the aftercooler. 1. Insert 7X-1710 Multimeter Probes into terminals P1-19 and P1-25. Determine the cause of the high air temperature. Inlet Air Restriction Check for plugged air filters. If the reading is not correct. • Check the water circuit of the aftercooler for obstructions. Connect a digital voltmeter to the probes.01 VDC. the values for the “Power Monitoring” parameters may be incorrect. the reading and the ambient temperature are approximately equal. if necessary. Check for High Inlet Air Restriction and/or High Altitude When inlet air pressure is low. The polarity of the connections is not important. Compare the reading to the regulated temperature. stop the engine. • Make repairs. check the outlet temperature of the coolant. the turbocharger works harder in order to achieve the desired inlet manifold pressure. “Generator Output Power Sensor . This increases inlet air temperature. • Check the pump for proper operation.59 Troubleshooting Section Note: This measurement must be taken at the master ECM P1 connector. A high temperature differential indicates an insufficient flow rate. 3. The voltage is acceptable if the voltage is less than ±0.

set the engine control to the OFF/RESET mode for at least 15 seconds before you try to restart the engine. If problems are found with the fuel lines. repair the lines and/or replace the lines. Inspect the connectors in the terminal boxes. replace the fuel filter. Check the restriction of the fuel filter. If the fuel pressure is still low. . Circuit Breakers Check the 35 amp circuit breaker on the power distribution box. “Fuel System” for the correct pressure values. Reset the circuit breaker if the circuit breaker is tripped. Probable Causes • Active engine shutdown • Electrical connectors • Circuit breaker • Engine speed/timing signal • Fuel supply • Spark plug Fuel Supply 1. Check the fuel quality. 2. After correcting the problem. “Electrical Power Supply” for more information. “Electrical Power Supply”. 3. Recommended Repairs Active Engine Shutdown Use the Caterpillar Electronic Technician (ET) to check for any active engine shutdowns and/or logged engine shutdowns. 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. For specific data.60 Troubleshooting Section Check for Sufficient Flow of Air Through the Aftercooler Determine the pressure differential of the inlet air across the aftercooler. and pinched lines. 4. Refer to Troubleshooting. Check the wiring harnesses and the connectors. Check the fuel pressure. Inspect the wiring from the power supply to the power distribution box. If this diagnostic code is logged. Check the power and ground connections at each electronic control module. 2. “Engine Speed/Timing Sensor”. Determine the reason for the shutdown. refer to Troubleshooting. Refer to Troubleshooting. The circuit breaker may exceed the trip point due to overheating. i01368495 Electrical Connectors 1. “Ignition Transformers Secondary Circuit and Spark Plugs”. For more information. If the pressure differential of the air across the aftercooler does not match the specifications. Use Cat ET to check for logged diagnostic codes. Inspect the wiring from the power distribution box to the electronic control modules. proceed to Troubleshooting. Inspect the power supply connections and the ground. Use Cat ET to check for the 168-02 diagnostic code for “System Voltage Intermittent”. Check the fuel lines for the following problems: restrictions. check the gas regulator and the fuel metering valve. “Inspecting Electrical Connectors”. Jacket Water Inlet Pressure (High) SMCS Code: 1350-035 Probable Causes • The circuit for the engine coolant pump pressure switch (inlet) is OPEN. Refer to Troubleshooting. clean the aftercooler. Engine Speed/Timing Signal Loss of the signal from the speed/timing sensor will cause a shutdown. If the fuel pressure is low. Intermittent Engine Shutdown SMCS Code: 1400-035 Note: Use this procedure only if the engine shuts down completely and the engine must be restarted. obstructions. Refer to Systems Operation/Testing and Adjusting. collapsed lines. refer to the Technical Marketing Information for the engine. i01804935 3.

“Inspecting Electrical Connectors”. • Check for plugging of the radiator or the heat exchanger. i01727750 • Check the water temperature regulators for proper operation. 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. The “Engine Coolant Outlet Pressure Sensor noisy signal” diagnostic will be generated although there is no malfunction in the electrical circuit. Check the Flow of Coolant Use the Caterpillar Electronic Technician (ET) to observe the pressure at the jacket water outlet with the engine OFF. Make repairs. Inspect the system for restrictions. If the reading is not reasonable or if the reading is not within specifications. a 109-08 diagnostic code will be generated. reduce the pressure. This will prevent a false 109-08 from being logged. i01866678 Jacket Water to Engine Oil Differential Temperature (Low) SMCS Code: 1350-035 Jacket Water Pressure (Low) SMCS Code: 1350-035 Probable Causes • High engine oil temperature or low engine coolant temperature Probable Causes • Low coolant level • Insufficient flow of coolant • Faulty temperature sensor and/or circuit • Faulty water temperature regulators . • Inspect the jacket water pump for damage to the Make the necessary repairs. check the following components: 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). inspect the cooling system for leaks. replace the pressure switch at the inlet for the jacket water. “PWM Sensor”. Compare the gauge reading with the reading from Cat ET. the high pressure may be caused by a restriction in the jacket water system. as needed. If the coolant level is low. install a pressure gauge near the pressure sensor at the jacket water outlet. If the readings from the comparative gauge agree approximately with Cat ET. Note: If the outlet pressure of the coolant is greater than approximately 444 kPa (64 psi). verify the actual outlet pressure of the coolant with a pressure gauge. Check wiring for damage or corrosion. troubleshoot the circuit for the pressure sensor at the jacket water outlet. make the necessary repairs. impeller. Refer to Troubleshooting.61 Troubleshooting Section • The pressure at the inlet for the jacket water is excessive. as needed. repair the wiring. Then observe the reading during engine operation. If the readings from the comparative gauge do not agree approximately with Cat ET. Refer to Troubleshooting. If leaks are found. Recommended Repairs Check the Coolant Level and Inspect the Cooling System for Leaks Check coolant level. If a pressure of at least 462 ± 41 kPa (67 ± 6 psi) is measured at the inlet for the jacket water. If a problem with the wiring for the circuit is found. 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. If the coolant level is low. If this code is generated. fill the cooling system. If the actual pressure is greater than approximately 444 kPa (64 psi).

Turbocharger Turbine Temperature (High) SMCS Code: 1052-035 Probable Causes • High inlet manifold temperature • Incorrect base timing • Exhaust restriction • A buildup of deposits in the cylinder or internal oil leaks Check the Temperature Sensors and/or Circuits Use a separate device to measure the temperatures of the engine oil and the engine coolant. troubleshoot the circuit(s). Replace the water temperature regulators. 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: • E026 (3) High Inlet Air Temperature (shutdown) • E027 (1) High Inlet Air Temperature (warning) If one or more of the codes is active. If one or both of the readings are incorrect. Refer to Troubleshooting.62 Troubleshooting Section Recommended Repairs Check for Event Codes for the Engine Oil and for the Engine Coolant Use the Caterpillar Electronic Technician (ET) to check for the following event codes: Check the water temperature regulators according to Systems Operation/Testing and Adjusting. Check the tube at the outlet for the jacket water. refer to Troubleshooting. refer to Troubleshooting. Refer to Troubleshooting. “Engine Oil Temperature (High)”. Check the Water Temperature Regulators The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. if necessary. If the temperature of the engine coolant is low. Allow the engine to cool and then start the engine. . refer to Troubleshooting. i01368006 System Voltage SMCS Code: 1400-035 • E019 (3) High Engine Oil Temperature (shutdown) • E020 (1) High Engine Oil Temperature (warning) • E038 (1) Low Engine Coolant Temperature (warning) Probable Causes There is a problem with the electrical system. i02064382 • E337 (3) High Engine Oil to Engine Coolant Diff Temp (shutdown) If one or more of the codes is active. “Electrical Power Supply”. “Troubleshooting with an Event Code”. If the tube is warm and normal operating temperature is not achieved yet. Check the Engine Oil Temperature and the Engine Coolant Temperature Use the Caterpillar Electronic Technician (ET) to check the temperature of the engine oil and the engine coolant. • E337 (1) Hign Engine Oil to Engine Coolant Diff Temp (warning) Recommended Repairs Troubleshoot the electrical system. Refer to Troubleshooting. a regulator may be stuck open. troubleshoot the code. If the engine oil temperature is high. “Testing the Cooling System”. “Inlet Air Temperature (High)”. “Analog Sensor Signal”. Compare the measured temperatures to the readings on Cat ET. “Engine Coolant Temperature (Low)”.

Adjust”. the temperatures from similar locations are comparable. If the temperature problem follows the thermocouple. Troubleshoot the code. • Signs of internal oil leaks Other signs of internal oil leaks include high oil consumption and blue smoke. Look for the following conditions: 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. Turbocharger Turbine Temperature (Low) SMCS Code: 1052-035 Probable Causes • Operation with a light load • Diagnostic code from the Integrated Temperature Sensing Module (ITSM) Check for Diagnostic Codes that Relate to Ignition Use Cat ET to check for diagnostic codes that relate to the ignition system. as needed. investigate the cause for the low temperature. the temperatures from similar locations are reduced at a similar rate. Investigate the cause of the exhaust restriction. For data that is specific to the engine. “Ignition Timing . If the temperature problem stays at the original location of the thermocouple. Measure the Exhaust Restriction Measure the exhaust restriction during engine operation with a load. replace the thermocouple. Make repairs. as needed. • Low temperature from the cylinder exhaust ports • A faulty temperature sensor • Faulty ignition . Troubleshoot the cause of the misfire. “Engine Misfires. i01804955 Check for Suspect Thermocouples Observe the temperatures from the thermocouples for the turbocharger(s) after the engine is shut off. Refer to Systems Operation/Testing and Adjusting. refer to the Technical Marketing Information. Troubleshoot the code. Check for Deposits in the Cylinder and Check for Internal Oil Leaks Use a borescope to inspect the cylinders. When the engine is operating properly. Also. If excessive deposits and/or signs of internal oil leaks are found. • Low cylinder compression Recommended Repairs Check for Misfire Operation with a low load can result in low exhaust temperatures. Note: Excessive deposits contribute to guttering of the valves. Make repairs. • 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 Check the Temperatures of the Cylinder Exhaust Ports Observe the temperatures for the exhaust ports of the cylinders in the suspect bank. If any discrepancies are found. Perform adjustments and/or make repairs. switch the suspect thermocouple for another thermocouple. investigate the cause of the condition. determine the reason for the difference in the exhaust port temperatures. Refer to Troubleshooting. If any of the temperatures for the exhaust ports are significantly different. Runs Rough or Is Unstable”. Operate the engine at low idle or near low idle in order to identify a misfire problem. as needed.63 Troubleshooting Section Check the Base Timing Verify that the base timing is correct.

Make repairs. . as needed. Check the Cylinder Compression Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression. If low compression is found. as needed. Make repairs. Refer to Troubleshooting. investigate the cause of the low compression. “Ignition Transformers Secondary Circuit and Spark Plugs”.64 Troubleshooting Section Check the Ignition System Inspect the components of the ignition system for the suspect cylinder bank.

Some electronic displays do not display the MID because the module which generates the code is obvious. Do not use the diagram to troubleshoot the oil temperature sensor. The MID for the master Electronic Control Module (ECM) is 36. The MID for the Integrated Temperature Sensing Module (ITSM) is 111. Note: Do not confuse diagnostic codes with event codes. and the failure mode identifier (FMI). see Troubleshooting. the CID number 0017 identifies the fuel shutoff valve. The master ECM will generate all of the diagnostic codes that are applicable to G3500 engines that have a single ECM. For information on event codes. The MID for the slave ECM is 33. For example. The Caterpillar Electronic Technician (ET) is a software program that is designed to run on a personal computer. Failure Mode Identifier (FMI) – The FMI is a two digit code that indicates the type of failure. pulse. 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. All of the diagnostic codes that are pertinent to the slave ECM have the same setting conditions and the same conditions for clearing as the master ECM. . Component Identifier (CID) – The CID is a number with three or four digits. “Troubleshooting with an Event Code”. Diagnostic codes also indicate the nature of the problem to the service technician. 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. Table 9 is a list of the failure mode identifiers that are adapted from the “SAE J1587” standard. Illustration 18 represents the operating range of an oil temperature sensor. The CID indicates the component that generated the code.65 Troubleshooting Section Troubleshooting with a Diagnostic Code i01875210 Table 9 Failure Mode Identifiers FMI 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 Description of Failure “Data valid but above normal operating range” “Data valid but below normal operating range” “Data erratic. The diagram is a reference. Diagnostic codes may be viewed on a personal computer that has Cat ET software. the component identifier (CID). The diagnostic codes that are generated by the slave ECM are a subset of the diagnostic codes that are generated by the master ECM. Diagnostic codes consist of the module identifier (MID). Module Identifier (MID) – The MID is a code with two or three digits that indicates the electronic module which generated the diagnostic code.

(2) In this area. The fuel is shut off. the oil temperature above 102 °C (216 °F) is higher than the normal range. The electronic problem will generate a diagnostic code. The next likely cause is a component failure. Active Diagnostic Codes An active diagnostic code represents a problem with the electronic control system. The diagnostic code becomes logged. or a shutdown for high oil temperature.2 and 4.66 Troubleshooting Section This information is a valuable indicator for troubleshooting intermittent problems. If the condition that generated the code is momentary. the “Active Alarm” indicator (“Engine Control Alarm Status” on Cat ET) is activated in order to alert the operator. the message disappears from the list of active diagnostic codes. The least likely cause is the failure of an electronic module. A code is cleared from memory when one of the following conditions occur: • The service technician manually clears the code. • A new code is logged and there are already ten codes in memory. a derating. the output voltage of the sensor is too high or too low.1 volts. the engine is shut down. Each ECM has an internal diagnostic clock. The shutdown output is activated. The normal output voltage of the sensor is between 0.FMI 03 8 Volt DC Supply short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code: The voltage supply from the slave Electronic Control Module (ECM) to the detonation sensors on the right side of the engine has exceeded the normal range. (3) This area represents the normal operating temperature for the engine oil. All of the diagnostic codes for the detonation sensors on the right side of the engine are disabled while this code is active. i01775013 (1) In these areas. In this case. Possible Performance Effect: Since the engine protection is disabled. Logged Diagnostic Codes When an ECM generates a diagnostic code. System Response: Default values are assumed for the inputs to the slave ECM from all of the detonation sensors on the right side of the engine. Some diagnostic codes may log occurrences that did not result in complaints. The sensor does not have an electronic problem. Each ECM will record the following information when a code is generated: • 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 . Illustration 18 Typical operating range of an oil temperature sensor g00791619 Some diagnostic codes may be easily triggered. The most likely cause of an intermittent problem is a faulty connection or damaged wiring. the ECM logs the code in permanent memory. Note: Always clear logged diagnostic codes after investigating and correcting the problem which generated the code. When an active diagnostic code is generated. The output is outside of the normal range. The code is logged. The output voltage of the sensor will generate an event code for a warning. MID 033 . Diagnostic codes that are logged repeatedly may indicate a problem that needs special investigation. Correct the problem as soon as possible.CID 0041 . • The code does not recur for 1000 hours. the oldest code is cleared.

Either of the following conditions occur: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer . The code is logged. The power supply voltage returns to the normal range within 0. Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results: The alarm output is activated. The fuel is shut off. The code is logged. the engine may experience speed burps. The shutdown output is activated. All of the diagnostic codes for the detonation sensors on the right side of the engine are disabled while this code is active. However. i01769134 MID 033 .CID 0041 . Perform the following diagnostic procedure: “Electrical Power Supply” Results: • OK – STOP. Possible Performance Effect: The intermittent problem may not affect engine operation. The code is logged. The engine will shut down.CID 0168 FMI 02 System Voltage intermittent/erratic SMCS Code: 1408-038 Conditions Which Generate This Code: The slave Electronic Control Module (ECM) has been powered for at least 5 seconds.CID 0301 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . Possible Performance Effect: Since the engine protection is disabled. the slave ECM will not log this diagnostic code. • There are three voltage readings of less than 6 System Response: i01775014 • OK – STOP.060 seconds. System Response: Default values are assumed for the inputs to the slave ECM from all of the detonation sensors on the right side of the engine. System Response: The alarm output is activated.67 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results: • The power supply voltage is less than 6 VDC for a minimum of 0. intermittent shutdowns. the engine is shut down. VDC within 7 seconds. i01935325 Possible Performance Effect: The cylinder will misfire. Note: If power supply voltage is lost and the voltage does not return. The engine has been running.015 seconds.FMI 05 Ignition Transformer Primary #1 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. • OK – STOP. and/or complete shutdowns. MID 033 .FMI 04 8 Volt DC Supply short to ground SMCS Code: 5574-038 Conditions Which Generate This Code: The voltage supply from the slave Electronic Control Module (ECM) to the detonation sensors on the right side of the engine is below the normal range.

CID 0303 .CID 0303 . i01758841 • A short circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 033 . System Response: The alarm output is activated. The code is logged. The code is logged.FMI 06 Ignition Transformer Primary #1 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.CID 0301 . Possible Performance Effect: The cylinder will misfire. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . . Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A short circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • OK – STOP.68 Troubleshooting Section • An open circuit within the primary winding of the transformer i01758839 • An internal failure of the slave electronic control module (ECM) Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 033 . • OK – STOP.FMI 06 Ignition Transformer Primary #3 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.FMI 05 Ignition Transformer Primary #3 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. • OK – STOP. i01758737 System Response: The alarm output is activated.

FMI 05 Ignition Transformer Primary #7 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.CID 0305 .FMI 06 Ignition Transformer Primary #5 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.CID 0305 . The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • A short circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. i01758852 • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer MID 033 . System Response: The alarm output is activated. Possible Performance Effect: • A short circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.69 Troubleshooting Section Possible Performance Effect: The cylinder will misfire. i01758846 The cylinder will misfire.CID 0307 . Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: Results: • OK – STOP. • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” .FMI 05 Ignition Transformer Primary #5 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. i01758849 • A short circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer MID 033 . System Response: The alarm output is activated. The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 .

FMI 06 Ignition Transformer Primary #7 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Possible Performance Effect: The cylinder will misfire. • OK – STOP. The code is logged. Possible Performance Effect: The cylinder will misfire. i01758853 MID 033 .FMI 05 Ignition Transformer Primary #9 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.70 Troubleshooting Section System Response: The alarm output is activated.CID 0309 . • A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer . The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: Possible Performance Effect: The cylinder will misfire. i01758859 • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 033 . The code is logged.CID 0307 . System Response: The alarm output is activated. System Response: The alarm output is activated. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the primary winding of the transformer • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.

Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 .CID 0311 . The code is logged. • A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the . i01758872 Possible Performance Effect: The cylinder will misfire.FMI 05 Ignition Transformer Primary #11 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.FMI 06 Ignition Transformer Primary #11 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated.FMI 06 Ignition Transformer Primary #9 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated.CID 0311 . Possible Performance Effect: The cylinder will misfire. • OK – STOP. System Response: The alarm output is activated.CID 0309 . The code is logged.71 Troubleshooting Section i01758861 Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. i01758875 • A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 033 .

The code is logged. Possible Performance Effect: The cylinder will misfire. The code is logged.FMI 05 Ignition Transformer Primary #15 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.FMI 06 Ignition Transformer Primary #13 short SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. System Response: The alarm output is activated. . Possible Performance Effect: The cylinder will misfire. i01758886 MID 033 .CID 0313 . The code is logged.CID 0313 . i01758898 MID 033 . System Response: The alarm output is activated.FMI 05 Ignition Transformer Primary #13 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. • OK – STOP.72 Troubleshooting Section • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: i01758889 MID 033 .CID 0315 .

03 12 Volt DC Power Supply short to +batt • 145 . The shutdown output is activated. all of the following conditions must occur: The slave Electronic Control Module (ECM) has been powered for at least one second.03 code is set after the pattern of the timing reference gear is lost for more than one second. Possible Performance Effect: If the engine is running.CID 0320 . The engine speed is greater than 150 rpm.04 12 Volt DC Power Supply short to ground Note: The 0320 . the engine will not start. If the engine is not running. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: • A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • OK – STOP. The code is logged. i01775725 • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 033 . the engine will be shut down. . System Response: If the engine is running. System Response: The alarm output is activated. Neither of the following diagnostic codes are active: • OK – STOP.04 is activated during the 1. Troubleshooting: One of the following conditions is the source of the diagnostic code: • 145 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.5 seconds before the code is activated.FMI 06 Ignition Transformer Primary #15 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. If a 145 .03 or 145 . the logic hesitates for 1. i01758902 MID 033 . Possible Performance Effect: The cylinder will misfire. the ignition signals stop.CID 0315 . The code is logged. then the 0320 03 code is deactivated.5 seconds.FMI 03 Speed/Timing Sensor short to +batt SMCS Code: 1912-038 Conditions Which Generate This Code: To activate this code. The pattern of the timing reference gear is lost for more than one second. However.73 Troubleshooting Section Possible Performance Effect: The cylinder will misfire.

CID 0401 .CID 0401 . i01864730 MID 033 . The alarm output is activated and the code is logged. The alarm output is activated and the code is logged.FMI 05 Ignition Transformer Secondary #1 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. • OK – STOP. i01864793 MID 033 . the engine will be shut down. reverse rotation is detected. Possible Performance Effect: The cylinder will misfire. System Response: The status of the transformer’s secondary output is set to zero percent. less than one second.FMI 06 Ignition Transformer Secondary #1 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . One of the following two conditions occurs: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • An invalid pattern for the timing reference gear is detected. The shutdown output is activated. • The pattern for the timing reference gear is lost for System Response: If the engine is running. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Possible Performance Effect: If the engine is running.CID 0320 . the ignition signals stop. The engine speed is greater than 150 rpm. System Response: The status of the transformer’s secondary output is set to 120 percent. For example. If the engine is not running. the engine will not start.FMI 08 Engine Speed/Timing signal abnormal SMCS Code: 1912-038 Conditions Which Generate This Code: The slave Electronic Control Module (ECM) must be powered for at least one second.74 Troubleshooting Section i01775729 Possible Performance Effect: The cylinder will misfire.

FMI 06 Ignition Transformer Secondary #3 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP.CID 0403 .CID 0403 . System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit.CID 0405 . The alarm output is activated and the code is logged. i01864798 • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide.FMI 05 Ignition Transformer Secondary #3 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. Possible Performance Effect: The cylinder will misfire. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 033 .FMI 05 Ignition Transformer Secondary #5 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. i01864795 The transformer’s secondary circuit is diagnosed with a short circuit.75 Troubleshooting Section • The spark plug is fouled. System Response: The status of the transformer’s secondary output is set to 120 percent. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: i01864797 MID 033 . . • OK – STOP. • The spark plug gap is closed. • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled.

However.FMI 06 Ignition Transformer Secondary #5 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. The alarm output is activated and the code is logged. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” . the engine will probably misfire. • OK – STOP.FMI 05 Ignition Transformer Secondary #7 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled. Possible Performance Effect: The cylinder will misfire. • The spark plug gap is closed. The alarm output is activated and the code is logged.CID 0405 .76 Troubleshooting Section Possible Performance Effect: Generation of the diagnostic code does not affect engine performance. i01864802 • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. This will cause the engine to run rough. i01864800 MID 033 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 033 . The engine may shut down. Troubleshooting: One of the following conditions is the source of the diagnostic code: • OK – STOP. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. System Response: The status of the transformer’s secondary output is set to zero percent.CID 0407 . System Response: The status of the transformer’s secondary output is set to 120 percent.

Possible Performance Effect: The cylinder will misfire. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Possible Performance Effect: The cylinder will misfire.CID 0409 . System Response: The status of the transformer’s secondary output is set to zero percent. i01864806 MID 033 . .CID 0409 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 033 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. The alarm output is activated and the code is logged.FMI 06 Ignition Transformer Secondary #9 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. • OK – STOP.FMI 05 Ignition Transformer Secondary #9 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. i01864809 MID 033 . Possible Performance Effect: The cylinder will misfire.FMI 06 Ignition Transformer Secondary #7 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. The alarm output is activated and the code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: • OK – STOP. System Response: The status of the transformer’s secondary output is set to zero percent.77 Troubleshooting Section Results: System Response: The status of the transformer’s secondary output is set to 120 percent. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A short circuit within the secondary winding of the transformer • OK – STOP.CID 0407 . The alarm output is activated and the code is logged. i01864812 • The spark plug is fouled.

• The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A short circuit within the secondary winding of the transformer • The spark plug is fouled. Troubleshooting: One of the following conditions is the source of the diagnostic code: The transformer’s secondary circuit is diagnosed with a short circuit. Possible Performance Effect: The cylinder will misfire. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.78 Troubleshooting Section Troubleshooting: One of the following conditions is the source of the diagnostic code: • The spark plug gap is too wide. System Response: The status of the transformer’s secondary output is set to 120 percent. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled.CID 0411 .FMI 06 Ignition Transformer Secondary #11 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP. i01864821 MID 033 . i01864818 MID 033 . The alarm output is activated and the code is logged. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP.CID 0411 .FMI 05 Ignition Transformer Secondary #11 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to zero percent. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open .

• A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 .CID 0413 .79 Troubleshooting Section i01864822 System Response: The status of the transformer’s secondary output is set to zero percent. • OK – STOP. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 033 . • The spark plug gap is closed. The alarm output is activated and the code is logged. The alarm output is activated and the code is logged. The alarm output is activated and the code is logged. System Response: The status of the transformer’s secondary output is set to 120 percent. System Response: The status of the transformer’s secondary output is set to 120 percent. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled.CID 0415 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP.FMI 05 Ignition Transformer Secondary #13 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.FMI 06 Ignition Transformer Secondary #13 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.FMI 05 Ignition Transformer Secondary #15 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . Possible Performance Effect: The cylinder will misfire. • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer . i01864826 • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. i01864824 Possible Performance Effect: The cylinder will misfire.CID 0413 .

. Neither ECM is being flashed. Alternatively. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 033 . Note: If Cat ET cannot communicate with the master ECM. and two-thirds of the messages have not been received by the slave ECM. • The spark plug gap is too wide. the master ECM has sent messages to the slave ECM over a period of time. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • OK – STOP. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. The alarm output is activated and the code is logged. • The spark plug gap is closed. • The spark plug is fouled. None of the messages have been received by the slave ECM. i01864829 MID 033 . Possible Performance Effect: The engine is shut down. System Response: The alarm output is activated. The code is logged by the slave ECM. Note: Although there is a failure to communicate with the slave ECM.CID 0590 .FMI 06 Ignition Transformer Secondary #15 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. Possible Performance Effect: The cylinder will misfire.80 Troubleshooting Section • A problem with the connection to the spark plug’s terminal post i01796190 • The spark plug has internal damage or an open circuit.CID 0415 .FMI 09 Unable to communicate with Engine ECM SMCS Code: 1901-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has sent ten consecutive messages to the slave ECM via the Cat data link. Engine ignition is terminated. System Response: The status of the transformer’s secondary output is set to zero percent. Perform the following diagnostic procedure: “Cat Data Link” Results: • OK – STOP. the values will display “Unavailable”. the master ECM may still be able to communicate with the Caterpillar Electronic Technician (ET).

The code is logged. System Response: The shutdown output is activated. • 0041 .CID 1505 . Possible Performance Effect: The engine is shut down.03 8 Volt DC Supply short to +batt • 0041 . The signal from the detonation sensor for cylinders 1 and 3 to the slave Electronic Control Module (ECM) is less than 1.CID 1501 .81 Troubleshooting Section i01761131 System Response: The shutdown output is activated. The signal from the detonation sensor for cylinders 1 and 3 to the slave Electronic Control Module (ECM) is greater than 4.0 VDC for ten seconds. The signal from the detonation sensor for cylinders 5 and 7 to the slave Electronic Control Module (ECM) is greater than 4.FMI 03 Cylinder #5 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 .04 8 Volt DC Supply short to ground i01761136 • OK – STOP. Possible Performance Effect: The engine is shut down.03 8 Volt DC Supply short to +batt • 0041 . Neither of the following diagnostic codes are active: • OK – STOP.FMI 04 Cylinder #1 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. i01761195 • 0041 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 . The code is logged. Possible Performance Effect: The engine is shut down.8 VDC for ten seconds.04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.8 VDC for ten seconds.04 8 Volt DC Supply short to ground .03 8 Volt DC Supply short to +batt • 0041 . The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 . Neither of the following diagnostic codes are active: • 0041 . Neither of the following diagnostic codes are active: • OK – STOP.CID 1501 .FMI 03 Cylinder #1 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.

Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 . The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 .04 8 Volt DC Supply short to ground i01761212 • OK – STOP. Possible Performance Effect: The engine is shut down.CID 1509 .FMI 04 Cylinder #5 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Neither of the following diagnostic codes are active: • OK – STOP.82 Troubleshooting Section i01761200 System Response: The shutdown output is activated.04 8 Volt DC Supply short to ground . The signal from the detonation sensor for cylinders 9 and 11 to the slave Electronic Control Module (ECM) is less than 1.04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.03 8 Volt DC Supply short to +batt • 0041 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 . The signal from the detonation sensor for cylinders 9 and 11 to the slave Electronic Control Module (ECM) is greater than 4. Neither of the following diagnostic codes are active: • OK – STOP.0 VDC for ten seconds. The signal from the detonation sensor for cylinders 5 and 7 to the slave Electronic Control Module (ECM) is less than 1. i01761215 • 0041 . System Response: The shutdown output is activated.CID 1509 . The code is logged. Neither of the following diagnostic codes are active: • 0041 . The code is logged.FMI 03 Cylinder #9 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. • 0041 .FMI 04 Cylinder #9 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.8 VDC for ten seconds. Possible Performance Effect: The engine is shut down.03 8 Volt DC Supply short to +batt • 0041 .0 VDC for ten seconds.03 8 Volt DC Supply short to +batt • 0041 .CID 1505 .

FMI 04 Cylinder #13 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. • 0041 . Neither of the following diagnostic codes are active: • OK – STOP.8 VDC for ten seconds.04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.03 8 Volt DC Supply short to +batt • 0041 .04 8 Volt DC Supply short to ground i01761234 • OK – STOP. i01761242 • 0041 .CID 1517 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 .04 8 Volt DC Supply short to ground . The code is logged. The code is logged. System Response: The shutdown output is activated. Possible Performance Effect: The engine is shut down. The signal from the detonation sensor for cylinders 17 and 19 to the slave Electronic Control Module (ECM) is greater than 4.FMI 03 Cylinder #17 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 033 .03 8 Volt DC Supply short to +batt • 0041 .83 Troubleshooting Section i01761230 System Response: The shutdown output is activated.CID 1513 . The signal from the detonation sensor for cylinders 13 and 15 to the slave Electronic Control Module (ECM) is greater than 4.FMI 03 Cylinder #13 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Possible Performance Effect: The engine is shut down.03 8 Volt DC Supply short to +batt • 0041 . Possible Performance Effect: The engine is shut down. Neither of the following diagnostic codes are active: • 0041 .CID 1513 . Neither of the following diagnostic codes are active: • OK – STOP.8 VDC for ten seconds. The signal from the detonation sensor for cylinders 13 and 15 to the slave Electronic Control Module (ECM) is less than 1. The code is logged.0 VDC for ten seconds.

The transformer’s secondary circuit is diagnosed with a short circuit.84 Troubleshooting Section i01761245 Possible Performance Effect: The cylinder will misfire. The code is logged.04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.CID 1517 . Possible Performance Effect: The engine is shut down. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • 0041 .0 VDC for ten seconds. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: • OK – STOP.03 8 Volt DC Supply short to +batt • 0041 . The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.CID 1748 . The alarm output is activated and the code is logged. The signal from the detonation sensor for cylinders 17 and 19 to the slave Electronic Control Module (ECM) is less than 1. System Response: The status of the transformer’s secondary output is set to zero percent.FMI 06 Ignition Transformer Secondary #17 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: i01760803 • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . System Response: The status of the transformer’s secondary output is set to 120 percent.FMI 05 Ignition Transformer Secondary #17 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.CID 1748 . i01760914 MID 033 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer .FMI 04 Cylinder #17 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. MID 033 . Neither of the following diagnostic codes are active: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit.

The alarm output is activated and the code is logged. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. System Response: The status of the transformer’s secondary output is set to zero percent. • The spark plug gap is closed.FMI 06 Ignition Transformer Secondary #19 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP.FMI 05 Ignition Transformer Primary #17 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled.85 Troubleshooting Section • The spark plug is fouled. System Response: The status of the transformer’s secondary output is set to 120 percent. . • OK – STOP. i01760805 The transformer’s secondary circuit is diagnosed with a short circuit. The code is logged. i01760301 • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Possible Performance Effect: The cylinder will misfire.CID 1752 .CID 1750 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 033 .FMI 05 Ignition Transformer Secondary #19 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.CID 1750 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. • OK – STOP. System Response: The alarm output is activated. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: i01760949 MID 033 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . • The spark plug gap is closed.

FMI 05 Ignition Transformer Primary #19 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.CID 1754 . The code is logged.FMI 06 Ignition Transformer Primary #17 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. The code is logged. i01760305 The alarm output is activated. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 033 . System Response: • OK – STOP. Possible Performance Effect: The cylinder will misfire. i01760309 • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 033 .86 Troubleshooting Section Possible Performance Effect: The cylinder will misfire.CID 1752 . System Response: The alarm output is activated. • A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the . Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the slave Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.

FMI 05 Fuel Shutoff Valve open circuit SMCS Code: 1259-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has detected a positive voltage source on the output for the fuel shutoff valve. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the harness or in the fuel control relay • A short circuit in the wiring between the slave Electronic Control Module (ECM) and the transformer transformer • 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: • A short circuit within the primary winding of the • An internal failure of the slave ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. The output is normally ON when the engine control is in the START mode and the engine RPM is greater than zero. The code is logged.CID 0017 . • The wiring harness has an open circuit. i01805813 • OK – STOP. . The most likely cause is one of the following conditions: • The output for the fuel control relay is ON. Possible Performance Effect: The engine will not start due to the lack of fuel.FMI 06 Fuel Shutoff Valve short to ground SMCS Code: 1259-038 Conditions Which Generate This Code: MID 036 . System Response: The alarm output is activated. The alarm output is activated.CID 1754 . The output is normally OFF when the engine control is in the STOP mode. System Response: No fuel is provided to the engine.87 Troubleshooting Section i01760311 • There is a short circuit to the +Battery in the wiring for the fuel control relay. Troubleshooting: The most likely cause is one of the following conditions: MID 033 . • The fuel control relay has an open coil. Possible Performance Effect: The cylinder will misfire.CID 0017 .FMI 06 Ignition Transformer Primary #19 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. The code is logged. Note: This condition cannot be detected by the master ECM when the output for the fuel control relay is OFF. i02088213 MID 036 . • The master Electronic Control Module (ECM) detects excessive current on the output for the fuel control relay. Note: This code cannot be detected by the master ECM when the output for the fuel control relay is ON.

Troubleshooting: Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” Results: Since the engine protection is disabled. The shutdown output is activated.FMI 12 Fuel Shutoff Valve malfunction SMCS Code: 1259-038 Conditions Which Generate This Code: The driver in the master Electronic Control Module (ECM) for the gas shutoff valve is OFF but the engine still runs. .CID 0041 . All of the diagnostic codes for the 8 volt sensors to the ECM are disabled while this code is active. The code is logged. The code is logged. the engine is shut down. i01914068 MID 036 . i01758598 MID 036 . The code is logged. System Response: The master ECM will disable the ignition system and the gas shutoff valve in order to shut down the engine. System Response: Default values are assumed for the inputs to the master ECM from all of the 8 volt sensors.CID 0017 . The fuel is shut off. • OK – STOP.88 Troubleshooting Section System Response: The master ECM will continue attempting to energize the relay.CID 0041 . All of the diagnostic codes for the 8 volt sensors to the ECM are disabled while this code is active.FMI 03 8 Volt DC Supply short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code: The voltage supply from the master Electronic Control Module (ECM) for the 8 volt sensors has exceeded the normal range. The shutdown output is activated. Troubleshooting: The condition is probably caused by a short circuit in the harness or by an internal short circuit in the fuel control relay. The fuel is shut off. The alarm output is activated. The shutdown output is activated. Possible Performance Effect: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results: • OK – STOP. The code is logged. Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” Results: i01914066 MID 036 . Possible Performance Effect: The engine will not start due to the lack of fuel. System Response: Default values are assumed for the inputs to the master ECM from all of the 8 volt sensors. The engine may shut down due to a lack of fuel.FMI 04 8 Volt DC Supply short to ground SMCS Code: 5574-038 Conditions Which Generate This Code: The voltage supply from the master Electronic Control Module (ECM) for the 8 volt sensors is below the normal range. Possible Performance Effect: The engine is shut down.

FMI 04 Engine Oil Pressure short to ground SMCS Code: 1924-038 Conditions Which Generate This Code: • OK – STOP. The shutdown output is activated. i01758623 MID 036 .CID 0100 . The monitoring of the oil pressure is disabled.03 5 Volt Sensor DC Power Supply short to +batt • 262 . This disables the engine protection for low oil pressure and for excessive oil pressure.CID 0100 .03 5 Volt Sensor DC Power Supply short to +batt • 262 .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 master Electronic Control Module (ECM) is greater than 4. neither of the following diagnostic codes are active: The signal from the filtered oil pressure sensor to the master Electronic Control Module (ECM) is less than 0. Perform the following diagnostic procedure: “Analog Sensor Signal” • OK – STOP. Additionally. The fuel is shut off.8 VDC for at least five seconds. This disables the engine protection for low oil pressure and for excessive oil pressure. the engine is shut down. Troubleshooting: This condition indicates an open circuit or a short circuit to a positive voltage source.04 5 Volt Sensor DC Power Supply short to ground System Response: The master ECM assumes the last valid value for the engine oil pressure. . Possible Performance Effect: Since the engine protection is disabled. The code is logged. the engine is shut down. The shutdown output is activated.04 5 Volt Sensor DC Power Supply short to ground System Response: The master ECM assumes the last valid value for the engine oil pressure. Possible Performance Effect: Since the engine protection is disabled.2 VDC for at least five seconds. The code is logged. neither of the following diagnostic codes are active: • 262 . Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • 262 . Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results: Results: • OK – STOP. the engine is shut down. The monitoring of the oil pressure is disabled.89 Troubleshooting Section Possible Performance Effect: Since the engine protection is disabled. The fuel is shut off. i01758614 MID 036 . Additionally.

neither of the following diagnostic codes are active: The alarm output is activated. Perform the following diagnostic procedure: “PWM Sensor” Results: • 41 . Additionally. Perform the following diagnostic procedure: “PWM Sensor” Results: • OK – STOP.FMI 03 Coolant Outlet Pressure open/short to +batt SMCS Code: 5574-038-PX 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. neither of the following diagnostic codes are active: • 41 . MID 036 . Troubleshooting: This condition indicates a possible open circuit or a possible short circuit.03 8 Volt DC Supply short to +batt • OK – STOP. Additionally.03 8 Volt DC Supply short to +batt • 41 . The shutdown output is activated.CID 0106 . Troubleshooting: The condition indicates a possible open circuit or a short circuit. Possible Performance Effect: The engine performance is not affected. . The code is logged.04 8 Volt DC Supply short to ground System Response: The fuel is shut off.CID 0109 . The code is logged.90 Troubleshooting Section i01780399 • 41 . The code is logged.CID 0106 . Possible Performance Effect: The engine is shut down. Possible Performance Effect: The engine is shut down.FMI 03 Air Inlet Pressure Sensor short to +batt SMCS Code: 5574-038-PX Conditions Which Generate This Code: The duty cycle for the inlet manifold pressure sensor is greater than the maximum value. The shutdown output is activated.03 8 Volt DC Supply short to +batt • 41 . Troubleshooting: Perform the following diagnostic procedure: “PWM Sensor” Results: MID 036 . i01793903 MID 036 . Additionally. neither of the following diagnostic codes are active: • 41 .04 8 Volt DC Supply short to ground System Response: i01636377 • OK – STOP.04 8 Volt DC Supply short to ground System Response: The fuel is shut off.FMI 08 Air Inlet Pressure Sensor noisy signal SMCS Code: 5574-038-PX Conditions Which Generate This Code: The duty cycle or the frequency for the inlet manifold pressure sensor is out of range.

CID 0110 . . The shutdown output is activated.91 Troubleshooting Section i01691110 MID 036 . This disables the engine protection for low coolant temperature and for high coolant temperature. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP. The shutdown output is activated.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 master Electronic Control Module (ECM) is less than 0. The fuel is shut off. Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • 41 . i01758638 MID 036 . This disables the engine protection for low coolant temperature and for high coolant temperature. The code is logged. The monitoring of the coolant temperature is disabled. Possible Performance Effect: Since the engine protection is disabled. Possible Performance Effect: Since the engine protection is disabled.2 VDC for at least five seconds. The code is logged.04 8 Volt DC Supply short to ground System Response: The alarm output is activated.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 master Electronic Control Module (ECM) is greater than 4. Additionally. Troubleshooting: Perform the following diagnostic procedure: “PWM Sensor” Results: • OK – STOP. The code is logged. Possible Performance Effect: The engine performance is not affected.CID 0110 .CID 0109 . neither of the following diagnostic codes are active: The fuel is shut off.FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal SMCS Code: 5574-038-PX Conditions Which Generate This Code: The duty cycle or the frequency of the signal from the pressure sensor for the outlet of the engine coolant is out of range. System Response: The master ECM assumes the last valid value for engine coolant temperature. The monitoring of the coolant temperature is disabled. Troubleshooting: This condition indicates a possible open circuit or a possible short circuit. System Response: The master ECM assumes the last valid value for the engine coolant temperature.8 VDC for at least five seconds. • OK – STOP.03 8 Volt DC Supply short to +batt • 41 . i01758632 MID 036 . the engine is shut down. the engine is shut down.

However. and/or complete shutdowns.060 seconds. • OK – STOP. i01866808 MID 036 . The code is logged. The 12 volt sensor supply voltage becomes greater than 14.015 seconds. The shutdown output is activated. System Response: If the engine is running. the fuel is shut off. The voltage returns to the normal range within 0. . The shutdown output is activated.2 V for at least one second. Note: If power supply voltage is lost and the voltage does not return. The code is logged.CID 0168 FMI 02 System Voltage intermittent/erratic SMCS Code: 1408-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered for at least 5 seconds. Possible Performance Effect: The engine is shut down or the engine will not start.FMI 04 12 Volt DC Power Supply short to ground SMCS Code: 5574-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered for at least five seconds.CID 0145 .92 Troubleshooting Section i01866770 Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: MID 036 . VDC within 7 seconds. the fuel is shut off. the master ECM will not log this diagnostic code. The code is logged. Possible Performance Effect: The intermittent problem may not affect engine operation. the engine may experience speed burps.CID 0145 . i01921808 The master Electronic Control Module (ECM) has been powered for at least five seconds. Troubleshooting: Perform the following diagnostic procedure: “Electrical Power Supply” Results: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: MID 036 . Either of the two following conditions occur: • The power supply voltage is less than 6 VDC for a minimum of 0. Possible Performance Effect: The engine is shut down or the engine will not start.FMI 03 12 Volt DC Power Supply short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code: • OK – STOP. The engine is running. intermittent shutdowns. The 12 volt sensor supply voltage becomes less than 11 VDC for at least one second. System Response: If the engine is running. • There are three voltage readings of less than 6 System Response: The alarm output is activated. The engine will shut down.

The monitoring of the inlet manifold air temperature is disabled.03 5 Volt Sensor DC Power Supply short to +batt • 262 .CID 0172 .03 5 Volt Sensor DC Power Supply short to +batt • 262 . neither of the following diagnostic codes are active: MID 036 .CID 0175 . neither of the following diagnostic codes are active: • 262 .8 VDC for at least five seconds.CID 0172 . The air/fuel ratio control cannot compensate for the inlet air temperature. Troubleshooting: The condition indicates a possible open circuit or a short circuit to a positive voltage source.8 VDC for at least five seconds.FMI 03 Intake Manifold Air Temp open/short to +batt SMCS Code: 5574-038-TA Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered for at least five seconds. Possible Performance Effect: The engine is shut down. i01758680 • OK – STOP. Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • 262 .93 Troubleshooting Section i01875963 i01758674 MID 036 . The fuel is shut off. Additionally. The code is logged. The air/fuel ratio control cannot compensate for the inlet air temperature.04 5 Volt Sensor DC Power Supply short to ground System Response: The master ECM assumes the last valid value for the inlet manifold air temperature. The fuel is shut off. This disables the engine protection for high inlet manifold air temperature. . Additionally. The signal from the inlet manifold temperature sensor to the master ECM is greater than 4.04 5 Volt Sensor DC Power Supply short to ground System Response: The master ECM assumes the last valid value for the inlet manifold air temperature.FMI 03 Engine Oil Temperature open/short to +batt SMCS Code: 5574-038-TA Conditions Which Generate This Code: The signal from the engine oil temperature sensor to the master Electronic Control Module (ECM) is greater than 4. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP.2 VDC for at least five seconds. The monitoring of the inlet manifold air temperature is disabled. Possible Performance Effect: The engine is shut down.FMI 04 Intake Manifold Air Temp short to ground SMCS Code: 5574-038-TA Conditions Which Generate This Code: The signal from the inlet manifold temperature sensor to the master Electronic Control Module (ECM) is less than 0. The code is logged. MID 036 . The shutdown output is activated. The shutdown output is activated. This disables the engine protection for high inlet manifold air temperature.

Possible Performance Effect: Since engine protection is disabled. monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled. Either condition will result in reduced engine performance. This disables the engine protection for both parameters. The code is logged. The shutdown output is activated. the monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled.CID 0261 . neither of the following diagnostic codes are active: System Response: The master ECM assumes the last valid value for the engine oil temperature. neither of the following diagnostic codes are active: System Response: The alarm output is activated. This disables the engine protection for both parameters.94 Troubleshooting Section Additionally. Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP.03 5 Volt Sensor DC Power Supply short to +batt • 262 . The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • 262 .04 5 Volt Sensor DC Power Supply short to ground • OK – STOP.03 5 Volt Sensor DC Power Supply short to +batt • 262 . Also. engine damage will result. Additionally. The code is logged. If the condition is not corrected. Possible Performance Effect: Since engine protection is disabled.FMI 04 Engine Oil Temperature short to ground SMCS Code: 5574-038-TA Conditions Which Generate This Code: The signal from the engine oil temperature sensor to the master Electronic Control Module (ECM) is less than 0. .04 5 Volt Sensor DC Power Supply short to ground System Response: The master ECM assumes the last valid value for the engine oil temperature. i01758708 MID 036 . The monitoring of the engine oil temperature is disabled. The monitoring of the engine oil temperature is disabled. The shutdown output is activated. the engine is shut down. Troubleshooting: Calibrate the engine speed/timing sensor. Also.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: The timing will be advanced or the timing will be retarded. the engine is shut down. Troubleshooting: The condition indicates a possible open circuit or a short circuit to a positive voltage source.Calibrate” Results: • 262 .2 VDC for at least five seconds. i01636386 MID 036 .CID 0175 . Perform the following diagnostic procedure: “Engine Speed/Timing Sensor . • OK – STOP.

The code is logged. Possible Performance Effect: Since engine protection is disabled. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) indicates a “Sensor Supply Fault” for each sensor. Perform the following diagnostic procedure: “+5V Sensor Voltage Supply” Results: • OK – STOP. System Response: All of the inputs to the master ECM for the 5 volt sensors assume default values. a short circuit in the signal wire for the desired speed potentiometer can generate this code. 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. All other diagnostic codes for the 5 volt sensors are disabled while this diagnostic code is active. Troubleshooting: The condition indicates a possible short circuit to ground or a short circuit between the sensor supply and the return.CID 0262 . the engine is shut down.FMI 04 5 Volt Sensor DC Power Supply short to ground SMCS Code: 5574-038 Conditions Which Generate This Code: The supply voltage from the master Electronic Control Module (ECM) to the sensors for the following parameters is less than the normal level: • Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure If the engine is equipped with a desired speed potentiometer. . the engine is shut down.95 Troubleshooting Section i01805835 i01805855 MID 036 . • OK – STOP. The shutdown indicator is activated. Troubleshooting: Perform the following diagnostic procedure: “+5V Sensor Voltage Supply” Results: • Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure If the engine is equipped with a desired speed potentiometer. Possible Performance Effect: Since engine protection is disabled. All other diagnostic codes for the 5 volt sensors are disabled while this diagnostic code is active. This indicates that the sensors are not operating due to an active diagnostic code. System Response: All of the inputs to the master ECM for the 5 volt sensors assume default values.FMI 03 5 Volt Sensor DC Power Supply short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code: The supply voltage from the master Electronic Control Module (ECM) to the sensors for the following parameters is exceeding the normal level: MID 036 . The shutdown output is activated.CID 0262 . a short circuit in the signal wire for the desired speed potentiometer can generate this code.

Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . System Response: The alarm output is activated. • OK – STOP. i01758836 MID 036 . System Response: The alarm output is activated.FMI 05 Ignition Transformer Primary #2 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.CID 0302 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the .96 Troubleshooting Section i01758830 Possible Performance Effect: The cylinder will misfire.FMI 05 Ignition Transformer Primary #4 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Possible Performance Effect: The cylinder will misfire.CID 0304 .FMI 06 Ignition Transformer Primary #2 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. i01758842 • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 . Possible Performance Effect: The cylinder will misfire. The code is logged. The code is logged. The code is logged. System Response: The alarm output is activated.CID 0302 .

CID 0304 .CID 0306 . Troubleshooting: One of the following conditions is the source of the diagnostic code: The primary circuit of the transformer is diagnosed with an open circuit.97 Troubleshooting Section • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: i01758850 MID 036 . System Response: The alarm output is activated. i01758843 MID 036 . The code is logged.FMI 06 Ignition Transformer Primary #4 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.CID 0306 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Possible Performance Effect: The cylinder will misfire. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. i01758851 MID 036 .FMI 05 Ignition Transformer Primary #6 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP. . • OK – STOP. Possible Performance Effect: The cylinder will misfire.FMI 06 Ignition Transformer Primary #6 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged.

System Response: The alarm output is activated. i01758862 • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” MID 036 .CID 0308 . i01758856 • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 .CID 0308 .FMI 05 Ignition Transformer Primary #10 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. System Response: The alarm output is activated.FMI 05 Ignition Transformer Primary #8 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: Possible Performance Effect: The cylinder will misfire. i01758855 MID 036 .FMI 06 Ignition Transformer Primary #8 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Possible Performance Effect: The cylinder will misfire. The code is logged. • OK – STOP.CID 0310 . .98 Troubleshooting Section Troubleshooting: One of the following conditions is the source of the diagnostic code: Results: • OK – STOP.

The code is logged. Possible Performance Effect: • An open circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. The code is logged.CID 0312 . The code is logged. i01758879 • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer MID 036 . System Response: The alarm output is activated.99 Troubleshooting Section System Response: The alarm output is activated. Possible Performance Effect: The cylinder will misfire.CID 0310 .FMI 06 Ignition Transformer Primary #10 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. i01758867 MID 036 . • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the . System Response: The alarm output is activated.FMI 05 Ignition Transformer Primary #12 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.

System Response: The alarm output is activated. System Response: The alarm output is activated. Possible Performance Effect: • A short circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Possible Performance Effect: The cylinder will misfire.CID 0312 . The code is logged. The cylinder will misfire.CID 0314 .100 Troubleshooting Section i01758881 Possible Performance Effect: The cylinder will misfire.FMI 06 Ignition Transformer Primary #14 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the . The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 .CID 0314 . i01758891 MID 036 .FMI 06 Ignition Transformer Primary #12 short SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. i01758894 • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer MID 036 . The code is logged. System Response: The alarm output is activated.FMI 05 Ignition Transformer Primary #14 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.

FMI 06 Ignition Transformer Primary #16 short SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP.CID 0316 . Possible Performance Effect: The cylinder will misfire. Possible Performance Effect: The cylinder will misfire.CID 0316 . . i01760423 Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 .FMI 03 Speed/Timing Sensor short to +batt SMCS Code: 1912-038 Conditions Which Generate This Code: To activate this code. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit in the wiring between the master Electronic Control Module (ECM) and the transformer transformer • A short circuit within the primary winding of the • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • An open circuit in the wiring from the master Electronic Control Module (ECM) to the transformer transformer • An open circuit within the primary winding of the • An internal failure of the master ECM • OK – STOP. Neither of the following diagnostic codes are active: • OK – STOP. The pattern of the timing reference gear is lost for more than one second. The code is logged.FMI 05 Ignition Transformer Primary #16 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: The path for the circuit driver of the transformer is diagnosed with a short circuit. i01758906 MID 036 . The code is logged.CID 0320 . all of the following conditions must occur: The master Electronic Control Module (ECM) has been powered for at least one second.101 Troubleshooting Section • An internal failure of the master ECM Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: i01758913 MID 036 . System Response: The alarm output is activated. System Response: The alarm output is activated. The engine speed is greater than 150 rpm.

CID 0324 . However.04 is activated during the 1. For example. The shutdown output is activated.04 12 Volt DC Power Supply short to ground Note: The 0320 . Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: MID 036 . Note: This diagnostic condition cannot be detected when the shutdown output is OFF. • OK – STOP. The engine speed is greater than 150 rpm. the logic hesitates for 1. the engine will not start. i01760427 MID 036 . The code is logged.CID 0323 . the engine will be shut down. the ignition signals stop. The shutdown output is activated.03 code is set after the pattern of the timing reference gear is lost for more than one second. then the 0320 03 code is deactivated.CID 0320 .FMI 03 Warning Lamp short to +batt SMCS Code: 7400-038-IND Conditions Which Generate This Code: The master Electronic Control Module (ECM) detects excessive current for the alarm output.3 amperes. i01760426 System Response: The master ECM limits the current for the shutdown output to 0. If the engine is not running. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: Possible Performance Effect: If the engine is running. MID 036 . The code is logged. the ignition signals stop.102 Troubleshooting Section • 145 . less than one second.FMI 03 Shutdown Lamp short to +batt SMCS Code: 7400-038-IND Conditions Which Generate This Code: The master Electronic Control Module (ECM) detects excessive current for the shutdown output.03 12 Volt DC Power Supply short to +batt • 145 . If the engine is not running. . System Response: If the engine is running.FMI 08 Engine Speed/Timing signal abnormal SMCS Code: 1912-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) must be powered for at least one second. The code is logged. If a 145 . i01760430 • The pattern for the timing reference gear is lost for System Response: If the engine is running. • OK – STOP.03 or 145 . reverse rotation is detected. Possible Performance Effect: The engine operation is not affected.5 seconds. the engine will not start. Possible Performance Effect: If the engine is running. the engine will be shut down. One of the following two conditions occurs: • An invalid pattern for the timing reference gear is detected.5 seconds before the code is activated. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: • OK – STOP.

Troubleshooting: Perform the following diagnostic procedure: “Electrical Power Supply” Results: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit.FMI 02 Incorrect ECS Switch inputs SMCS Code: 7332-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) detects an invalid combination on these inputs from the Engine Control Switch (ECS): “Switched +Battery”.3 amperes. System Response: The master ECM limits the current for the alarm output to 0. i01760434 The cylinder will misfire. . The alarm output is activated and the code is logged. i01864834 • OK – STOP.CID 0402 .FMI 06 Ignition Transformer Secondary #2 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. The code is logged. System Response: The status of the transformer’s secondary output is set to 120 percent. the engine will be shut down.CID 0402 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. “Stop”. The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . “Start”. System Response: The shutdown output is activated.FMI 05 Ignition Transformer Secondary #2 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. and “Auto”.103 Troubleshooting Section Note: This diagnostic condition cannot be detected when the alarm output is OFF. Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: i01864831 MID 036 . Possible Performance Effect: If the engine is running.CID 0336 . MID 036 . Possible Performance Effect: The engine operation is not affected. Possible Performance Effect: • OK – STOP.

The alarm output is activated and the code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled. Possible Performance Effect: The cylinder will misfire.CID 0404 . Possible Performance Effect: The cylinder will misfire. .FMI 06 Ignition Transformer Secondary #4 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . The alarm output is activated and the code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: • An open circuit within the secondary winding of the transformer terminal post circuit. i01864835 MID 036 .FMI 05 Ignition Transformer Secondary #4 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.104 Troubleshooting Section System Response: The status of the transformer’s secondary output is set to zero percent. Possible Performance Effect: The cylinder will misfire. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A short circuit within the secondary winding of the transformer • OK – STOP. • The spark plug gap is closed. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. System Response: The status of the transformer’s secondary output is set to 120 percent. • The spark plug gap is closed. i01864836 • The spark plug is fouled. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A problem with the transformer’s ground • OK – STOP.CID 0404 . Troubleshooting: One of the following conditions is the source of the diagnostic code: The transformer’s secondary circuit is diagnosed with a short circuit.

FMI 05 Ignition Transformer Secondary #6 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.FMI 05 Ignition Transformer Secondary #8 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. The alarm output is activated and the code is logged.CID 0406 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . The alarm output is activated and the code is logged. i01864848 • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. Possible Performance Effect: The cylinder will misfire. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . System Response: The status of the transformer’s secondary output is set to 120 percent.105 Troubleshooting Section i01864837 System Response: The status of the transformer’s secondary output is set to zero percent. • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer . Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled. • OK – STOP. • The spark plug gap is closed. The alarm output is activated and the code is logged. System Response: The status of the transformer’s secondary output is set to 120 percent. i01864842 Possible Performance Effect: The cylinder will misfire.FMI 06 Ignition Transformer Secondary #6 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 .CID 0406 .CID 0408 .

Possible Performance Effect: The cylinder will misfire. • OK – STOP. The alarm output is activated and the code is logged. System Response: • OK – STOP.CID 0408 .FMI 05 Ignition Transformer Secondary #10 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.FMI 06 Ignition Transformer Secondary #8 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide.106 Troubleshooting Section • A problem with the connection to the spark plug’s terminal post i01864850 • The spark plug has internal damage or an open circuit. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A short circuit within the secondary winding of the transformer • The spark plug is fouled. . System Response: The status of the transformer’s secondary output is set to zero percent. • The spark plug gap is closed. Troubleshooting: One of the following conditions is the source of the diagnostic code: The status of the transformer’s secondary output is set to 120 percent. Possible Performance Effect: The cylinder will misfire. • The spark plug gap is too wide.CID 0410 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. The alarm output is activated and the code is logged. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . i01864849 MID 036 .

• A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . System Response: The status of the transformer’s secondary output is set to 120 percent. • The spark plug gap is closed.FMI 06 Ignition Transformer Secondary #10 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.FMI 05 Ignition Transformer Secondary #12 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . • A short circuit within the secondary winding of the transformer • The spark plug is fouled. i01864861 • A short circuit within the secondary winding of the transformer • The spark plug is fouled. Possible Performance Effect: The cylinder will misfire. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. System Response: The status of the transformer’s secondary output is set to zero percent. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP.CID 0410 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit.FMI 06 Ignition Transformer Secondary #12 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.CID 0412 . The alarm output is activated and the code is logged. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.CID 0412 .107 Troubleshooting Section i01864851 Possible Performance Effect: The cylinder will misfire. . i01864860 • OK – STOP.

The alarm output is activated and the code is logged. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 .CID 0416 . . Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: i01864863 MID 036 .108 Troubleshooting Section • The spark plug gap is closed.FMI 06 Ignition Transformer Secondary #14 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: The transformer’s secondary circuit is diagnosed with a short circuit.FMI 05 Ignition Transformer Secondary #16 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.CID 0414 . Possible Performance Effect: The cylinder will misfire. • OK – STOP. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit. Possible Performance Effect: The cylinder will misfire. i01864862 MID 036 . The alarm output is activated and the code is logged.FMI 05 Ignition Transformer Secondary #14 open circuit SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. • The spark plug gap is closed.CID 0414 . • OK – STOP. i01864864 • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. System Response: The status of the transformer’s secondary output is set to 120 percent. System Response: The status of the transformer’s secondary output is set to zero percent.

Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • A problem with the transformer’s ground • An open circuit within the secondary winding of the transformer terminal post circuit.FMI 06 Ignition Transformer Secondary #16 short to ground SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.3 amperes. The output is normally OFF when the engine control is in the STOP mode. • OK – STOP. • OK – STOP. i01864865 MID 036 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . • The spark plug gap is closed. Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: • OK – STOP. The alarm output is activated. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Note: This diagnostic condition cannot be detected when the output for the crank terminate relay is OFF.CID 0443 . . Possible Performance Effect: The cylinder will misfire.109 Troubleshooting Section System Response: The status of the transformer’s secondary output is set to 120 percent. Troubleshooting: One of the following conditions is the source of the diagnostic code: Troubleshooting: One of the following conditions is the source of the diagnostic code: • A short circuit within the secondary winding of the transformer • The spark plug is fouled. i01866568 • A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide. The alarm output is activated and the code is logged.CID 0416 . System Response: The status of the transformer’s secondary output is set to zero percent.FMI 03 Crank Terminate Relay short to +batt SMCS Code: 4493-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) detects excessive current for the crank terminate relay. System Response: The master ECM will limit the current for the crank terminate relay to 0. The code is logged.

The output is ON until the crank terminate relay is energized.110 Troubleshooting Section i01866572 System Response: The master ECM will continue to attempt to energize the relay. The alarm output is activated. Troubleshooting: The harness or the relay probably has an open circuit. Perform the following diagnostic procedure: “ECM Output Circuit (Starting Motor)” Results: MID 036 . Note: This diagnostic condition cannot be detected when the output for the “Run” relay is OFF. The “Status” screen of the Caterpillar Electronic Technician (ET) will display “Relay Fault”. Note: This diagnostic condition can only be detected by the master ECM when the output for the starting motor relay is OFF. The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. System Response: An internal resistor rises to the +Battery side when no electrical load is present.FMI 05 Start Relay open circuit SMCS Code: 1426-038 Conditions Which Generate This Code: The output from the master Electronic Control Module (ECM) for the starting motor relay is OFF. An open circuit or a short circuit to the +Battery is detected. Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: • OK – STOP. The output is normally ON when the engine control is changed from the STOP mode to the START mode.FMI 06 Start Relay short to ground SMCS Code: 1426-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) detects excessive current for the output of the starting motor relay.CID 0444 . The code is logged.3 amperes.FMI 03 Run Relay short to +batt SMCS Code: 4493-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) detects excessive current for the run relay. The alarm output is activated. The output is normally OFF when the engine control is in the STOP mode. Possible Performance Effect: The engine will probably be unable to crank. Troubleshooting: This condition indicates an short circuit in the harness or the relay. i01866579 MID 036 . . Note: This diagnostic condition can only be detected by the master ECM when the output for the starting motor relay is ON. System Response: • OK – STOP. The code is logged.CID 0445 . The code is logged. The master ECM will limit the current to 0. Possible Performance Effect: The engine will be unable to crank. Perform the following diagnostic procedure: “ECM Output Circuit (Starting Motor)” Results: • OK – STOP.CID 0444 . i01866577 MID 036 .

FMI 03 Unfiltered Engine Oil Pressure open/short to +batt SMCS Code: 1924-038 Conditions Which Generate This Code: The signal to the master Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is greater than 4. The alarm output is activated. System Response: When the “Idle/Rated” switch is in the “Rated” position. • 262 .FMI 04 Desired Engine Speed Sensor short to ground SMCS Code: 5574-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered up for at least five seconds.CID 0524 . 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).8 VDC for at least five seconds.20 mA)” Results: • OK – STOP. i01761094 The diagnostic code is generated by one of the following conditions: • A short circuit to the +Battery side • A short circuit to ground Perform the following diagnostic procedure: “Desired Speed Input (4 . . Troubleshooting: • 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 .04 5 Volt Sensor DC Power Supply short to ground System Response: The master ECM assumes the last valid value for unfiltered engine oil pressure. The code is logged. Troubleshooting: The diagnostic code is generated by one of the following conditions: MID 036 .20 mA)” Results: MID 036 . Monitoring for restriction of the oil filters is disabled. Also.FMI 03 Desired Engine Speed Sensor short to +batt SMCS Code: 5574-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered up for at least five seconds. The alarm output is activated.CID 0524 . The alarm output is activated. i01761093 MID 036 . 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). the master ECM assumes a default value for the desired engine speed.111 Troubleshooting Section i01761091 System Response: When the “Idle/Rated” switch is in the “Rated” position. The code is logged. The current to the master ECM for the desired speed input is less than 2 mA for more than five seconds. The current to the master ECM for the desired speed input is greater than 22 mA for more than five seconds. neither of the following diagnostic codes are active: • OK – STOP. the master ECM assumes a default value for the desired engine speed.03 5 Volt Sensor DC Power Supply short to +batt • 262 .CID 0542 .

112 Troubleshooting Section Possible Performance Effect: Engine operation is not affected.2 VDC for at least five seconds. Note: This diagnostic code is logged by the master ECM only. If the engine is running. The alarm output is activated. The Integrated Temperature Sensing Module (ITSM) has sent ten consecutive messages to the master ECM via the CAT Data Link. The code is logged.03 5 Volt Sensor DC Power Supply short to +batt • 262 . Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: i01946568 MID 036 . neither of the following diagnostic codes are active: • 262 . Note: If Cat ET cannot communicate with the ITSM. Possible Performance Effect: If the engine is not running. • OK – STOP. None of the messages have been received by the master ECM.CID 0542 .FMI 09 Unable to communicate with ITSM SMCS Code: 1901-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered up for at least five seconds.CID 1042 . . System Response: The alarm output is activated. the engine will not start. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP. the ITSM may still be able to communicate with the Caterpillar Electronic Technician (ET). Also. i01761095 MID 036 .04 5 Volt Sensor DC Power Supply short to ground System Response: The master ECM assumes the last valid value for unfiltered engine oil pressure. Monitoring for restriction of the oil filters is disabled. Troubleshooting: Perform the following diagnostic procedure: “CAT Data Link” Results: • OK – STOP.FMI 04 Unfiltered Engine Oil Pressure short to ground SMCS Code: 1924-038 Conditions Which Generate This Code: The signal to the master Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is less than 0. the engine is shut down. Although there is a failure to communicate with the master ECM. This code is not activated or logged by the ITSM. the values for the ITSM “Status Parameter” will display “Unavailable”.

Messages on the CAN data link between the master ECM and the throttle actuator have been lost for 0. The “Status Parameter” for “Fuel Valve Position”. The shutdown output is activated. i01884041 MID 036 . Possible Performance Effect: Engine performance is affected. The code is logged. .CID 1440 . the engine will not start. System Response: The “Alarm Status” is activated. The alarm output is activated.CID 1446 . The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Throttle Actuator” Results: X = 3. The calculation for “X” is given in Table 10.0 V − [ ( G · 1. System Response: The “Status Parameter” for “Fuel Valve Position” will display “0 %” on the Caterpillar Electronic Technician (ET). The code is logged. System Response: The fuel is shut off. • The voltage of the signal is less than “X” for 5 seconds.75 V ) ÷ 300 CFM ] G is the flow of the fuel in CFM. “Fuel Pressure (abs)”. None of the messages have been received by the master ECM. The alarm output is activated. Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” • The master Electronic Control Module (ECM) has been powered up for more than 5 seconds.CID 1446 . • The battery voltage is greater than 20 VDC. • The flow rate of the fuel is less than 8497 L/min (300 CFM). Possible Performance Effect: If the engine is not running. Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” Results: • OK – STOP.113 Troubleshooting Section i01830219 Table 10 MID 036 .FMI 05 Fuel Metering Module open circuit SMCS Code: 1741-038 Conditions Which Generate This Code: To generate this diagnostic code. indicating a short circuit or an open circuit on one of the wires or both of the wires for the CAN data link. If the engine is running. and “Fuel Temperature” are frozen on the Caterpillar Electronic Technician (ET). the engine is shut down. all of the following conditions must occur: The master Electronic Control Module (ECM) has been powered up for more than 5 seconds.FMI 09 Unable to communicate with Fuel Metering Module SMCS Code: 1741-038 Conditions Which Generate This Code: • OK – STOP. i01761115 MID 036 . Possible Performance Effect: Engine performance is affected.48 seconds. Ten consecutive messages have been sent from the fuel metering valve to the master ECM via the CAN Data Link. “Fuel Valve Differential Pressure”.FMI 09 Unable to communicate with Throttle Actuator Drv SMCS Code: 1716-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has been powered for at least five seconds.

FMI 13 Fuel Metering Module calibration required SMCS Code: 1741-038 Conditions Which Generate This Code: The “Gas Fuel Properties” have not been programmed for the fuel metering valve. The alarm output is activated. System Response: The code is logged. Possible Performance Effect: The fuel metering valve is shutdown. The shutdown output is activated.FMI 12 Fuel Metering Sensor Module malfunction SMCS Code: 1741-038 Conditions Which Generate This Code: The fuel metering valve sends a signal to the master Electronic Control Module (ECM) via the CAN data link. Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” Results: Results: • OK – STOP.CID 1446 . Possible Performance Effect: The engine is shut down. MID 036 . Possible Performance Effect: The engine is shut down. The signal from the detonation sensor for cylinders 2 and 4 to the master Electronic Control Module (ECM) is greater than 4. • OK – STOP. The shutdown output is activated.CID 1502 . Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” Results: • OK – STOP.FMI 12 Fuel Metering Module malfunction SMCS Code: 1741-038 Conditions Which Generate This Code: The fuel metering valve sends a signal to the master Electronic Control Module (ECM) via the CAN data link. System Response: The code is logged. i01761169 MID 036 .8 VDC for ten seconds. i01761123 MID 036 .114 Troubleshooting Section Results: Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” i01761117 • OK – STOP. This prevents the engine from running. i01619975 MID 036 . The signal indicates that there is a problem with the fuel metering valve’s sensor module.FMI 03 Cylinder #2 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal indicates that there is a problem with the fuel metering valve.CID 1447 . System Response: The code is logged. Neither of the following diagnostic codes are active: .CID 1446 .

CID 1502 .04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.FMI 04 Cylinder #2 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.0 VDC for ten seconds. The code is logged. Neither of the following diagnostic codes are active: • OK – STOP.FMI 04 Cylinder #6 Detonation Sensor short to ground SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Possible Performance Effect: The engine is shut down. Neither of the following diagnostic codes are active: • OK – STOP. The signal from the detonation sensor for cylinders 2 and 4 to the master Electronic Control Module (ECM) is less than 1.04 8 Volt DC Supply short to ground . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .115 Troubleshooting Section • 0041 .0 VDC for ten seconds.CID 1506 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . Possible Performance Effect: The engine is shut down.04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.03 8 Volt DC Supply short to +batt • 0041 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: i01761203 MID 036 . i01761191 • 0041 .04 8 Volt DC Supply short to ground System Response: The shutdown output is activated. The code is logged. The signal from the detonation sensor for cylinders 6 and 8 to the master Electronic Control Module (ECM) is greater than 4. The code is logged.CID 1506 .8 VDC for ten seconds. Neither of the following diagnostic codes are active: • OK – STOP. Possible Performance Effect: The engine is shut down.03 8 Volt DC Supply short to +batt • 0041 .03 8 Volt DC Supply short to +batt • 0041 . i01761210 • 0041 . • 0041 . The signal from the detonation sensor for cylinders 6 and 8 to the master Electronic Control Module (ECM) is less than 1.FMI 03 Cylinder #6 Detonation Sensor open/short to +batt SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.03 8 Volt DC Supply short to +batt • 0041 .

116 Troubleshooting Section

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:

i01761225

MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground
SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 10 and 12 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:

• OK – STOP.
i01761217

MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt
SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 10 and 12 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds. Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground
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:

• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground

• OK – STOP.
i01761236

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 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt
SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 14 and 16 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds. Neither of the following diagnostic codes are active:

• OK – STOP.

• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground

117 Troubleshooting Section

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:

i01761250

MID 036 - CID 1518 - FMI 03 Cylinder #18 Detonation Sensor open/short to +batt
SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 18 and 20 to the master Electronic Control Module (ECM) is greater than 4.8 VDC for ten seconds. Neither of the following diagnostic codes are active:

• OK – STOP.
i01761239

MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground
SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 14 and 16 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:

• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground
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:

• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground
System Response:

• OK – STOP.
i01761252

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 1518 - FMI 04 Cylinder #18 Detonation Sensor short to ground
SMCS Code: 1559-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The signal from the detonation sensor for cylinders 18 and 20 to the master Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active:

• OK – STOP.

• 0041 - 03 8 Volt DC Supply short to +batt • 0041 - 04 8 Volt DC Supply short to ground

118 Troubleshooting Section

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:

i02088242

MID 036 - CID 1719 - FMI 03 Generator Output Power Sensor open/short to +batt
SMCS Code: 5574-038-PWR Conditions Which Generate This Code: One of the following conditions has occurred:

• The load signal from the Electronic Modular Control
Panel II+ (EMCP II+) is missing.

• OK – STOP.
i01796209

• The load signal from the power sensor to the
master Electronic Control Module (ECM) is missing. master ECM is greater than 4.8 VDC.

MID 036 - CID 1636 - FMI 09 Loss of Communication with Engine #2 (Slave)
SMCS Code: 1901-038 Conditions Which Generate This Code: The slave Electronic Control Module (ECM) has sent ten consecutive messages to the master ECM via the Cat data link. None of the messages have been received by the master ECM. Note: Although there is a failure to communicate with the master ECM, the slave ECM may still be able to communicate with the Caterpillar Electronic Technician (ET). System Response: The alarm output is activated. The code is logged by the master ECM. Engine ignition is terminated. Note: If Cat ET cannot communicate with the slave ECM, the values will display “Unavailable”. Possible Performance Effect: The engine is shut down. Perform the following diagnostic procedure: “Cat Data Link” Results:

• The load signal from the power sensor to the
System Response: The diagnostic code is logged and the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Generator Output Power Sensor” Results:

• OK – STOP.
i02088252

MID 036 - CID 1719 - FMI 04 Generator Output Power Sensor short to ground
SMCS Code: 5574-038-PWR Conditions Which Generate This Code: This diagnostic code is not applicable to generators that are equipped with the Electronic Modular Control Panel II+ (EMCP II+). Both of the following conditions occur:

• The engine load is greater than 20 percent. • The signal from the power sensor to the master
Electronic Control Module (ECM) is less than 0.2 VDC.

• OK – STOP.

119 Troubleshooting Section

System Response: The diagnostic code is logged and the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Generator Output Power Sensor” Results:

System Response: The fuel is shut off. The shutdown output is activated. The code is logged. Possible Performance Effect: If the engine is not running, the engine will not start. If the engine is running, the engine is shut down. Perform the following diagnostic procedure: “Bypass Valve” Results:
i02088262

• OK – STOP.

MID 036 - CID 1719 - FMI 12 Generator Output Power Sensor malfunction
SMCS Code: 5574-038-PWR Conditions Which Generate This Code: This diagnostic code is applicable to generators that are equipped with the Electronic Modular Control Panel II+ (EMCP II+) only. The master Electronic Control Module (ECM) has determined that the load signal from the EMCP II+ may be invalid. System Response: The diagnostic code is logged and the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Generator Output Power Sensor” Results:

• OK – STOP.
i01760808

MID 036 - CID 1749 - FMI 05 Ignition Transformer Secondary #18 open circuit
SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s 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 diagnostic code:

• OK – STOP.
i01904169

• A problem with the transformer’s ground • An open circuit within the secondary winding of
the transformer terminal post circuit.

MID 036 - CID 1720 - FMI 09 Turbocharger Compressor Bypass Valve Actuator not communicating on link
SMCS Code: 1052-038-BV Conditions Which Generate This Code: The master Electronic Control Module (ECM) cannot communicate with the actuator for the bypass valve.

• A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide.
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs”

120 Troubleshooting Section

Results:

System Response: The status of the transformer’s 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 diagnostic code:

• OK – STOP.
i01760946

MID 036 - CID 1749 - FMI 06 Ignition Transformer Secondary #18 short to ground
SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s 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 diagnostic code:

• A problem with the transformer’s ground • An open circuit within the secondary winding of
the transformer terminal post circuit.

• A problem with the connection to the spark plug’s • The spark plug has internal damage or an open • The spark plug gap is too wide.
Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results:

• A short circuit within the secondary winding of the
transformer

• OK – STOP.
i01760951

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

MID 036 - CID 1751 - FMI 06 Ignition Transformer Secondary #20 short to ground
SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire.

• OK – STOP.
i01760821

MID 036 - CID 1751 - FMI 05 Ignition Transformer Secondary #20 open circuit
SMCS Code: 1561-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.

121 Troubleshooting Section

Troubleshooting: One of the following conditions is the source of the diagnostic code:

i01760307

• A short circuit within the secondary winding of the
transformer

MID 036 - CID 1753 - FMI 06 Ignition Transformer Primary #18 short to ground
SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect:

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

• OK – STOP.
i01760306

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

MID 036 - CID 1753 - FMI 05 Ignition Transformer Primary #18 open circuit
SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

• A short circuit in the wiring between the master
Electronic Control Module (ECM) and the transformer transformer

• A short circuit within the primary winding of the • An internal failure of the master ECM
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:

• OK – STOP.
i01760312

• An open circuit in the wiring from the master

Electronic Control Module (ECM) to the transformer transformer

MID 036 - CID 1755 - FMI 05 Ignition Transformer Primary #20 open circuit
SMCS Code: 1561-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. System Response: The alarm output is activated. The code is logged.

• An open circuit within the primary winding of the • An internal failure of the master ECM
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:

• OK – STOP.

122 Troubleshooting Section

Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

• An internal failure of the master ECM
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:

• OK – STOP.
i01636449

• An open circuit in the wiring from the master

Electronic Control Module (ECM) to the transformer transformer

• An open circuit within the primary winding of the • An internal failure of the master ECM
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results:

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:

• OK – STOP.
i01760313

MID 036 - CID 1755 - FMI 06 Ignition Transformer Primary #20 short to ground
SMCS Code: 1561-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated. The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code:

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:

• OK – STOP.
i01728761

MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt
SMCS Code: 5574-038 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.

• A short circuit in the wiring between the master
Electronic Control Module (ECM) and the transformer transformer

• A short circuit within the primary winding of the

i01728782 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. 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. protection for the port is lost.FMI 05 Left Turbo Turbine Out Temp Sens open circuit SMCS Code: 5574-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. The code is logged.FMI 04 Left Turbo Turbine Out Temp Sens short to ground SMCS Code: 5574-038 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: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” MID 111 .CID 1490 . protection for the port is lost. i01728785 • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost.123 Troubleshooting Section System Response: Monitoring of the temperature for the port of the turbine is lost. Also. System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Also. Also. Also. protection for the port is lost. .CID 1489 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Results: • OK – STOP. protection for the port is lost.CID 1489 . i01728777 MID 111 . Possible Performance Effect: Engine operation is not affected.FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt SMCS Code: 5574-038 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. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Possible Performance Effect: Engine operation is not affected. The code is logged. System Response: Monitoring of the temperature for the port of the turbine is lost. This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine.

i01728791 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. . protection for the port is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. Also. Also.FMI 04 Rt Turbo Turbine Out Temp Sens short to ground SMCS Code: 5574-038 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: Monitoring of the exhaust temperature for the port of the turbine is lost.124 Troubleshooting Section This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728794 MID 111 .CID 1490 . i01728795 MID 111 . protection for the port is lost.CID 1491 . Possible Performance Effect: Engine operation is not affected.FMI 05 Rt Turbo Turbine Out Temp Sens open circuit SMCS Code: 5574-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. The code is logged. Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.CID 1490 . Possible Performance Effect: Engine operation is not affected.FMI 03 Rt Turbo Turbine In Temp Sens short to +batt SMCS Code: 5574-038 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. The code is logged. The code is logged. protection for the port is lost. System Response: • OK – STOP.

System Response: • OK – STOP. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost. protection for the port is lost.CID 1492 .FMI 05 Rt Turbo Turbine In Temp Sens open circuit SMCS Code: 5574-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. i01728804 MID 111 . System Response: Monitoring of the temperature for the port of the turbine is lost. Possible Performance Effect: Engine operation is not affected. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. Also. protection for the port is lost.FMI 04 Rt Turbo Turbine In Temp Sens short to ground SMCS Code: 5574-038 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: Monitoring of the exhaust temperature for the port of the turbine is lost.125 Troubleshooting Section This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine.FMI 03 Left Turbo Turbine In Temp Sens short to +batt SMCS Code: 5574-038 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. • OK – STOP. Also. i01728797 MID 111 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728800 MID 111 . Possible Performance Effect: Engine operation is not affected.CID 1491 . This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. . Also. protection for the port is lost. Possible Performance Effect: Engine operation is not affected.CID 1491 . The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine.

i01728806 • OK – STOP. protection for the port is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728813 MID 111 . System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. protection for the port is lost.CID 1531 . Possible Performance Effect: Engine operation is not affected. . Also. The code is logged. MID 111 . Also. The code is logged. protection for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine.FMI 04 Left Turbo Turbine In Temp Sens short to ground SMCS Code: 5574-038 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: System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. Also.CID 1492 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost.CID 1492 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.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. Possible Performance Effect: Engine operation is not affected. i01728819 MID 111 .126 Troubleshooting Section Possible Performance Effect: Engine operation is not affected.FMI 05 Left Turbo Turbine In Temp Sens open circuit SMCS Code: 5574-038 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.

CID 1531 . Monitoring of the exhaust temperature for the cylinder is lost. i01728826 MID 111 . System Response: • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. The thermocouple is removed from the calculation for the average temperature of the engine. . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.127 Troubleshooting Section The code is logged. protection for the cylinder is lost.CID 1531 . Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. i01728828 MID 111 . The code is logged. i01728833 MID 111 .CID 1532 . Also. protection for the cylinder is lost.FMI 03 Cyl #2 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. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost.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. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.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. Possible Performance Effect: Engine operation is not affected. Possible Performance Effect: Engine operation is not affected. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Results: • OK – STOP.

The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. i01728835 MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.FMI 05 Cyl #2 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.128 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The code is logged. Possible Performance Effect: Engine operation is not affected. • OK – STOP. protection for the cylinder is lost. . protection for the cylinder is lost. Also.CID 1532 .FMI 04 Cyl #2 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. The code is logged.CID 1532 . Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. i01728837 MID 111 . Possible Performance Effect: Engine operation is not affected. protection for the cylinder is lost. The code is logged. Also. Possible Performance Effect: Engine operation is not affected. The thermocouple is removed from the calculation for the average temperature of the engine. System Response: Monitoring of the exhaust temperature for the cylinder is lost.

Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . Also. 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.FMI 05 Cyl #3 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. i01728915 MID 111 . The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. The code is logged. Also. The thermocouple is removed from the calculation for the average temperature of the engine.CID 1533 . The thermocouple is removed from the calculation for the average temperature of the engine. protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The code is logged.CID 1533 . Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. • A short circuit to the −Battery side • A short circuit to the ground . i01728912 • OK – STOP. protection for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Possible Performance Effect: Engine operation is not affected.CID 1533 . System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.FMI 03 Cyl #3 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.FMI 04 Cyl #3 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. protection for the cylinder is lost.129 Troubleshooting Section i01728852 System Response: Monitoring of the exhaust temperature for the cylinder is lost.

. i01728928 • OK – STOP. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. MID 111 . Also. protection for the cylinder is lost. The code is logged. Also.FMI 03 Cyl #4 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. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.FMI 05 Cyl #4 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.130 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728923 MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: • OK – STOP. The code is logged. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected. i01728917 MID 111 .CID 1534 . System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Possible Performance Effect: Engine operation is not affected. protection for the cylinder is lost.CID 1534 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.CID 1534 .

Possible Performance Effect: Engine operation is not affected. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.131 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Possible Performance Effect: Engine operation is not affected. • A short circuit to the −Battery side • A short circuit to the ground i01728934 • OK – STOP. The code is logged.CID 1535 . Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The code is logged. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged.FMI 03 Cyl #5 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. i01728940 MID 111 . System Response: Monitoring of the exhaust temperature for the cylinder is lost. • OK – STOP.FMI 04 Cyl #5 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. protection for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Also. Possible Performance Effect: Engine operation is not affected. .CID 1535 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. 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. The thermocouple is removed from the calculation for the average temperature of the engine. Also. protection for the cylinder is lost. protection for the cylinder is lost.

Possible Performance Effect: Engine operation is not affected.132 Troubleshooting Section i01728953 System Response: Monitoring of the exhaust temperature for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.FMI 04 Cyl #6 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. Also.FMI 05 Cyl #5 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. protection for the cylinder is lost.CID 1535 . i01728968 MID 111 . The code is logged. The code is logged. The thermocouple is removed from the calculation for the average temperature of the engine. Also. Also. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected.FMI 03 Cyl #6 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. protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine. MID 111 . . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . protection for the cylinder is lost. The code is logged.CID 1536 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.CID 1536 . i01728959 • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.

FMI 05 Cyl #6 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. Also. i01728976 MID 111 . Also.FMI 03 Cyl #7 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. The thermocouple is removed from the calculation for the average temperature of the engine. i01728999 MID 111 . 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. • A short circuit to the −Battery side • A short circuit to the ground . The code is logged. protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. protection for the cylinder is lost.CID 1537 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.CID 1536 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728993 MID 111 . • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.CID 1537 .FMI 04 Cyl #7 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. The code is logged.133 Troubleshooting Section The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. System Response: • OK – STOP. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.

134 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. The code is logged. System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1537 .FMI 05 Cyl #7 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. • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The code is logged. System Response: Monitoring of the exhaust temperature for the cylinder is lost. i01729015 MID 111 . The thermocouple is removed from the calculation for the average temperature of the engine.CID 1538 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. protection for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The code is logged. i01729006 • OK – STOP. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Possible Performance Effect: Engine operation is not affected. Also. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . Possible Performance Effect: Engine operation is not affected. . Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.FMI 03 Cyl #8 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. The thermocouple is removed from the calculation for the average temperature of the engine. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. protection for the cylinder is lost. protection for the cylinder is lost.

CID 1538 .CID 1538 . Also. . The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected. protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. i01729025 MID 111 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The code is logged. The code is logged. i01729257 MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.CID 1539 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. protection for the cylinder is lost. protection for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . The code is logged.FMI 04 Cyl #8 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. The thermocouple is removed from the calculation for the average temperature of the engine.135 Troubleshooting Section i01729019 System Response: Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Also.FMI 05 Cyl #8 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.FMI 03 Cyl #9 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. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected.

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. . Possible Performance Effect: Engine operation is not affected. System Response: Monitoring of the exhaust temperature for the cylinder is lost.FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: • OK – STOP. The code is logged. Also. 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. Also. i01761374 MID 111 . The thermocouple is removed from the calculation for the average temperature of the engine. The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.FMI 04 Cyl #9 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.136 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01729264 MID 111 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.CID 1540 . The code is logged. protection for the cylinder is lost.CID 1539 . The thermocouple is removed from the calculation for the average temperature of the engine.FMI 03 Cyl #10 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. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. • OK – STOP. i01729267 MID 111 .CID 1539 . protection for the cylinder is lost.

Also. System Response: Monitoring of the exhaust temperature for the cylinder is lost.137 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected.CID 1540 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. 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. protection for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Possible Performance Effect: Engine operation is not affected. The code is logged. • OK – STOP.FMI 05 Cyl #10 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. The code is logged.FMI 04 Cyl #10 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. Also. i01729270 • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. protection for the cylinder is lost. i01729271 MID 111 .CID 1540 . protection for the cylinder is lost. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 .

Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Possible Performance Effect: Engine operation is not affected. The thermocouple is removed from the calculation for the average temperature of the engine. i01729277 MID 111 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.138 Troubleshooting Section i01729273 System Response: Monitoring of the exhaust temperature for the cylinder is lost.FMI 04 Cyl #11 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. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. System Response: Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The code is logged.CID 1541 . System Response: Monitoring of the exhaust temperature for the cylinder is lost. protection for the cylinder is lost. Also.FMI 05 Cyl #11 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.CID 1541 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. MID 111 . i01729275 • OK – STOP.FMI 03 Cyl #11 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. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. protection for the cylinder is lost. Also. Possible Performance Effect: Engine operation is not affected.CID 1541 . protection for the cylinder is lost. The code is logged. • A short circuit to the −Battery side • A short circuit to the ground .

Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01729281 MID 111 . protection for the cylinder is lost. .CID 1542 . The thermocouple is removed from the calculation for the average temperature of the engine.FMI 05 Cyl #12 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.CID 1542 . Possible Performance Effect: Engine operation is not affected. Also.FMI 04 Cyl #12 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. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1542 . • OK – STOP.FMI 03 Cyl #12 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. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. i01729278 • 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. The thermocouple is removed from the calculation for the average temperature of the engine. MID 111 . The code is logged. i01729284 MID 111 . System Response: Monitoring of the exhaust temperature for the cylinder is lost. The code is logged.139 Troubleshooting Section Possible Performance Effect: Engine operation is not affected. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. protection for the cylinder is lost.

Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Possible Performance Effect: Engine operation is not affected. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. . Also. The thermocouple is removed from the calculation for the average temperature of the engine. • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Also. The thermocouple is removed from the calculation for the average temperature of the engine. protection for the cylinder is lost. protection for the cylinder is lost.CID 1543 . The code is logged. i01729291 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The code is logged. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.FMI 03 Cyl #13 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. Also. Possible Performance Effect: Engine operation is not affected.140 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1543 . i01729287 • OK – STOP. Possible Performance Effect: Engine operation is not affected. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.FMI 04 Cyl #13 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. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.

CID 1543 . Monitoring of the exhaust temperature for the cylinder is lost.CID 1544 .FMI 05 Cyl #13 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. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. protection for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. . System Response: Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. protection for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. protection for the cylinder is lost. Possible Performance Effect: Engine operation is not affected.141 Troubleshooting Section i01729294 MID 111 .FMI 04 Cyl #14 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. Also.FMI 03 Cyl #14 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. MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. i01729303 MID 111 . The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. • A short circuit to the −Battery side • A short circuit to the ground System Response: i01729297 • OK – STOP.CID 1544 . Also. The code is logged. The code is logged. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.

CID 1545 . The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.FMI 04 Cyl #15 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. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. i01729306 MID 111 . • A short circuit to the −Battery side • A short circuit to the ground . Also. • OK – STOP. protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.CID 1544 . Possible Performance Effect: Engine operation is not affected. protection for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. Possible Performance Effect: Engine operation is not affected. The code is logged.FMI 05 Cyl #14 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. i01729310 MID 111 . 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.142 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01729307 MID 111 .FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: • OK – STOP.CID 1545 . The thermocouple is removed from the calculation for the average temperature of the engine.

Also. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.FMI 03 Cyl #16 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.FMI 05 Cyl #15 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. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Possible Performance Effect: Engine operation is not affected. 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. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. • OK – STOP. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. The code is logged. i01729314 MID 111 . protection for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Also.CID 1545 . i01729312 MID 111 . System Response: Monitoring of the exhaust temperature for the cylinder is lost.143 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The code is logged. Possible Performance Effect: Engine operation is not affected. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. protection for the cylinder is lost. protection for the cylinder is lost.CID 1546 . .

FMI 04 Cyl #16 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. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. protection for the cylinder is lost. Also. Possible Performance Effect: Engine operation is not affected. The code is logged. 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. The thermocouple is removed from the calculation for the average temperature of the engine.FMI 03 Cyl #17 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919-038 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. System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1546 . The code is logged. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. protection for the cylinder is lost. protection for the cylinder is lost. i01729319 MID 111 . . Also. The thermocouple is removed from the calculation for the average temperature of the engine. Also. i01761434 MID 111 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.CID 1547 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. • OK – STOP.CID 1546 .144 Troubleshooting Section i01729316 System Response: Monitoring of the exhaust temperature for the cylinder is lost.

The thermocouple is removed from the calculation for the average temperature of the engine. Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.CID 1547 . protection for the cylinder is lost. protection for the cylinder is lost. protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01761455 MID 111 .CID 1548 . . The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.FMI 04 Cyl #17 Exhaust Port Temp Sensor short to ground SMCS Code: 1919-038 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. i01761436 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The code is logged. i01761445 • 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. • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.FMI 05 Cyl #17 Exhaust Port Temp Sensor open circuit SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. MID 111 . System Response: Monitoring of the exhaust temperature for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also.CID 1547 .FMI 03 Cyl #18 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919-038 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. Also. Possible Performance Effect: Engine operation is not affected. The thermocouple is removed from the calculation for the average temperature of the engine.145 Troubleshooting Section Possible Performance Effect: Engine operation is not affected.

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. Also. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.CID 1548 . i01761457 MID 111 . i01761446 • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The code is logged.146 Troubleshooting Section The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected. protection for the cylinder is lost. protection for the cylinder is lost.FMI 05 Cyl #18 Exhaust Port Temp Sensor open circuit SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine.FMI 04 Cyl #18 Exhaust Port Temp Sensor short to ground SMCS Code: 1919-038 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.CID 1548 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The code is logged. The code is logged. System Response: Monitoring of the exhaust temperature for the cylinder is lost. MID 111 . Possible Performance Effect: Engine operation is not affected.

The code is logged.FMI 05 Cyl #19 Exhaust Port Temp Sensor open circuit SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. protection for the cylinder is lost.FMI 03 Cyl #19 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919-038 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. Possible Performance Effect: Engine operation is not affected. The code is logged. Also. MID 111 . i01761447 • OK – STOP.FMI 04 Cyl #19 Exhaust Port Temp Sensor short to ground SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. • A short circuit to the −Battery side • A short circuit to the ground . System Response: Monitoring of the exhaust temperature for the cylinder is lost.147 Troubleshooting Section i01761437 System Response: Monitoring of the exhaust temperature for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. System Response: Monitoring of the exhaust temperature for the cylinder is lost. i01761460 MID 111 . Also. protection for the cylinder is lost. Possible Performance Effect: Engine operation is not affected.CID 1549 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine. protection for the cylinder is lost.CID 1549 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . The code is logged. Also.CID 1549 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.

The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. System Response: Monitoring of the exhaust temperature for the cylinder is lost.FMI 04 Cyl #20 Exhaust Port Temp Sensor short to ground SMCS Code: 1919-038 Conditions Which Generate This Code: • OK – STOP. protection for the cylinder is lost. i01761438 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Possible Performance Effect: Engine operation is not affected.FMI 03 Cyl #20 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919-038 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.148 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01761449 MID 111 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. . The thermocouple is removed from the calculation for the average temperature of the engine. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.CID 1550 . MID 111 . i01761461 • OK – STOP. Possible Performance Effect: Engine operation is not affected.CID 1550 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.FMI 05 Cyl #20 Exhaust Port Temp Sensor open circuit SMCS Code: 1919-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine. Also. protection for the cylinder is lost. The code is logged.CID 1550 . • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.

The code is logged. Also. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. protection for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. .149 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected.

the oil temperature above 102 °C (216 °F) is higher than normal. The sensor does not have an electronic problem. The master ECM will diagnose all of the events that are applicable to G3500 engines that have a single ECM. Any generated code becomes logged in the permanent memory of the Electronic Control Module (ECM) that detected the event. The fourth “(X)” represents a numeric identifier for the severity of the code. Illustration 19 represents the operating range of an oil temperature sensor. The events that are diagnosed by the slave ECM are a subset of the events that are diagnosed by the master ECM. The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. the engine is shut down in order to help prevent possible engine damage. Shutdown (3) – For this condition. Event codes may be viewed on a personal computer that has the Cat ET software. Events do not indicate problems with the electronic system. The following format is used for event codes: • “EXXX (X) Description of the code” The “E” means that the code is an event code. Do not use the diagram to troubleshoot the oil temperature sensor.2 and 4. (2) In this area.1 volts. All of the events that are pertinent to the slave ECM have the same setting conditions and the same conditions for clearing as the master ECM. The “XXX” represents a numeric identifier for the event code. When the event code is generated. this condition does not require a shutdown. Illustration 19 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. Both the master ECM and the slave ECM can indicate active events. The normal output voltage of the sensor is between 0. This is followed by a description of the code. The output voltage of the sensor will generate an event code for a warning or a shutdown for high oil temperature. . the event is active. Event codes also indicate the nature of the problem. Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high coolant temperature has been detected. Refer to 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. (3) This area represents the normal operating temperature for the engine oil. The diagram is a reference. The output is outside of the normal range. However. The electronic problem will generate a diagnostic code.150 Troubleshooting Section Troubleshooting with an Event Code i02088275 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.

Correct the problem as soon as possible. 3. installed by the dealer or the customer that could cause the symptom. 2. Consider the operator information. Active Event Codes An active event code represents a problem with engine operation. If the responses are programmed. see Troubleshooting. See • Determine whether any other occurrences Troubleshooting. Diagnostic Codes and Event Codes Examine the following information regarding any codes: Troubleshooting For basic troubleshooting of the engine. identify the probable causes with the procedures in this manual that best describe the symptoms. Verify that the complaint is not due to normal engine operation. “Inspecting Electrical Connectors”. See Troubleshooting. Cat ET can display the event. The • Determine if there are any systems that were conditions will include the engine rpm and the load. “Troubleshooting with a Diagnostic Code”. • The code was generated when the symptom • Codes that are repeatedly logged • The complaint is not due to normal engine operation. Other Symptoms If other occurrences happened in addition to the symptom. • The symptoms have a probable cause that is common. If these inspections do not reveal any problems. Note: Do not confuse event codes with diagnostic codes. investigate the following conditions: • The other occurrences are related to the symptom. “Troubleshooting With A Diagnostic Code”. However. occurred. Repair any active codes. Perform a visual inspection. the display will not appear. perform the following steps first in order to diagnose a malfunction. Perform the following tasks before you troubleshoot the event code: Be sure to check the connectors.151 Troubleshooting Section These responses to certain events may be programmed into the ECM. Narrow the probable cause. engine operation. • Verify that the complaint is not due to normal • Repair all active diagnostic codes. and the history of the engine. This is specially true for problems that are intermittent. For information on diagnostic codes. Check the diagnostic codes and event codes. • Gather enough information about the complaint in order to describe the symptom(s) adequately. • Fuel supply • Oil level • Oil supply • Wiring • Connectors 4. Inspect the following items: • The probable cause of the symptom is correlated to the code. the conditions of operation. . happened in addition to the symptom. Operator Information Obtain the following information from the operator: • The occurrence and the time of the occurrence • Determine the conditions for the occurrence. Gather information about the complaint from the operator. If the responses are not programmed. Verify that the complaint is not due to error of the operator. Check each probable cause according to the tests that are recommended. the occurrence of any event will cause the event code to be logged in the ECM that detected the event. 1.

The most recent event code is listed first. When an event code is active. System Response: The gas shutoff valve and the ignition are shut off. Logged events are listed in chronological order. Troubleshooting: Refer to Troubleshooting. The shutdown output is activated. The master ECM has determined that the detected speed is accurate. Active event codes are listed in ascending numerical order on Cat ET. Logged codes can also be used to review the performance of the engine.152 Troubleshooting Section Both the master ECM and the slave ECM can indicate active events. A code is cleared from memory when one of the following conditions occur: • OK – STOP. The code with the lowest number is listed first. the oldest code is cleared. Note: Always clear logged event codes after investigating and correcting the problem which generated the code. The code is logged. Each ECM will record the following information when a code is generated: • 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. The engine coolant temperature has exceeded the trip point and the delay time has expired. . Possible Performance Effect: The engine is shut down. In this case. No other codes for the engine coolant are active. the message disappears. Results: Logged Event Codes The master ECM and the slave ECM can log events. E016 High Engine Coolant Temperature Shutdown SMCS Code: 1395-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. i01633543 • The service technician manually clears the code. The shutdown output is activated. Each ECM has an internal diagnostic clock. • The code does not recur for 1000 hours. System Response: The fuel is shut off. Possible Performance Effect: The engine is shut down. the “Active Alarm” indicator (“Engine Control Alarm Status” on Cat ET) is activated in order to alert the operator. The event code will be logged in the memory of the ECM that detected the event. Troubleshooting: Refer to Troubleshooting. The code is logged. If the condition that generated the code is momentary. “Engine Coolant Temperature (High)”. “Engine Overspeed”. When an ECM generates an event code the ECM logs the code in permanent memory. i01761523 E004 Engine Overspeed Shutdown SMCS Code: 1348-038 Conditions Which Generate This Code: The engine rpm has exceeded the trip point that is programmed into the master Electronic Control Module (ECM) and the delay time has expired. • A new code is logged and there are already ten codes in memory.

if the coolant temperature continues to rise. “Engine Coolant Temperature (High)”. System Response: The alarm output is activated. . Troubleshooting: Refer to Troubleshooting. i01633755 E026 High Inlet Air Temperature Shutdown SMCS Code: 1050-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. However. The inlet air temperature has exceeded the trip point and the delay time has expired. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. Troubleshooting: Refer to Troubleshooting. i01633605 E020 High Engine Oil Temperature Warning SMCS Code: 1348-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. However. • OK – STOP. if the engine oil temperature continues to rise. The engine coolant temperature has exceeded the trip point and the delay time has expired. No other codes for the inlet air temperature are active. Results: Results: • OK – STOP. The code is logged. “Engine Oil Temperature (High)”. The code is logged. The engine oil temperature has exceeded the trip point and the delay time has expired. Results: • OK – STOP. No other codes for the engine coolant are active. No other codes for the engine oil temperature are active. No other codes for the engine oil temperature are active. the engine can be shut down. i01633603 E019 High Engine Oil Temperature Shutdown SMCS Code: 1348-038 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. The shutdown output is activated. System Response: The alarm output is activated. Possible Performance Effect: The engine is shut off. i01633545 • OK – STOP. E017 High Engine Coolant Temperature Warning SMCS Code: 1395-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds.153 Troubleshooting Section Results: Troubleshooting: Refer to Troubleshooting. “Engine Oil Temperature (High)”. Possible Performance Effect: The engine operation is not immediately affected. System Response: The fuel is shut off. the engine will be shut down.

Possible Performance Effect: The engine is shut down. “Engine Coolant Temperature (Low)”. No other codes for the coolant temperature are active. The code is logged. The temperature of the engine coolant is less than the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. “Engine Oil Pressure (Low)”.154 Troubleshooting Section System Response: The fuel is shut off. . 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. Results: • OK – STOP. • OK – STOP. System Response: The alarm output is activated. The shutdown output is activated. System Response: The alarm output is activated. i01633762 E040 Low Engine Oil Pressure Shutdown SMCS Code: 1348-038-PX Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 10 seconds. “Inlet Air Temperature (High)”. However. Possible Performance Effect: The engine operation is not immediately affected. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. i01633756 E027 High Inlet Air Temperature Warning SMCS Code: 1050-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. System Response: The fuel is shut off. The code is logged. Troubleshooting: Refer to Troubleshooting. “Inlet Air Temperature (High)”. The code is logged. • OK – STOP. The shutdown output is activated. the engine may be shut down. 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. Troubleshooting: Refer to Troubleshooting. Results: Possible Performance Effect: The engine operation is not immediately affected. if the inlet air temperature continues to rise. Results: i01633757 E038 Low Engine Coolant Temperature Warning SMCS Code: 1395-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds.

if the fuel pressure continues to be reduced. the engine will be shut down. System Response: The alarm output is activated. The code is logged. “System Voltage”. the supply may become inadequate for the fuel metering valve. Troubleshooting: Refer to Troubleshooting. if the system voltage continues to be reduced. . “System Voltage”. The code is logged. i01877738 E042 Low System Voltage Shutdown SMCS Code: 1400-038 Conditions Which Generate This Code: The voltage is less than the trip point and the delay time has expired. E053 Low Fuel Pressure Warning SMCS Code: 1250-038 Conditions Which Generate This Code: The fuel pressure is less than the trip point and the delay time has expired. System Response: The shutdown output is activated. However. Possible Performance Effect: The engine operation is not immediately affected. engine components could be damaged if the system voltage continues to increase. i01637578 E043 Low System Voltage Warning SMCS Code: 1400-038 Conditions Which Generate This Code: The voltage is less than the trip point and the delay time has expired.155 Troubleshooting Section Results: Results: • OK – STOP. However. No other codes for the system voltage are present. Troubleshooting: Refer to Troubleshooting. System Response: The alarm output is activated. However. No other codes for the system voltage are present. The code is logged. System Response: The alarm output is activated. • OK – STOP. Results: i01633765 • OK – STOP. No other codes for the system voltage are present. The code is logged. “System Voltage”. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. Results: E050 High System Voltage Warning SMCS Code: 1400-038 Conditions Which Generate This Code: The voltage is greater than the trip point and the delay time has expired. Possible Performance Effect: The engine operation is not immediately affected. Possible Performance Effect: The engine operation is not immediately affected. i01633763 • OK – STOP. “Fuel Pressure”. Troubleshooting: Refer to Troubleshooting.

The engine oil filter differential pressure is less than the trip point and the delay time has expired. “Fuel Pressure”. i01633787 E100 Low Engine Oil Pressure Warning SMCS Code: 1348-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least ten seconds. Results: Results: • OK – STOP. There are no active codes for the oil pressure sensors. The engine oil pressure is less than the trip point and the delay time has expired. The code is logged. The code is logged. E096 High Fuel Pressure SMCS Code: 1250-038 Conditions Which Generate This Code: The fuel pressure is higher than the trip point and the delay time has expired. “Engine Oil Pressure (Low)”. if the engine oil filter differential pressure continues to be reduced. However. Possible Performance Effect: The engine operation is not immediately affected. The oil filter differential pressure is less than the trip point and the delay time has expired. the engine may be shut down. Results: • OK – STOP. System Response: The alarm output is activated. However. the supply may exceed the maximum limit for the fuel metering valve. System Response: The alarm output is activated. i01633814 E128 Engine Oil Filter Diff Pressure Low Shutdown SMCS Code: 1308-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The code is logged. System Response: The alarm output is activated. if the oil pressure continues to be reduced. • OK – STOP. Possible Performance Effect: The engine operation is not immediately affected. if the fuel pressure continues to increase. Possible Performance Effect: The engine operation is not immediately affected. . There are no active codes for the oil pressure sensors.156 Troubleshooting Section Results: Troubleshooting: Refer to Troubleshooting. Troubleshooting: Refer to Troubleshooting. i01637590 • OK – STOP. i01633790 E127 Engine Oil Filter Diff Pressure Low Warning SMCS Code: 1308-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. the engine may be shut down. There are no active codes for the engine oil pressure sensor. Troubleshooting: Refer to Troubleshooting. However. “Engine Oil Filter Differential Pressure”.

157 Troubleshooting Section

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:

i01633832

E130 Engine Oil Filter Diff Pressure High Shutdown
SMCS Code: 1308-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil filter differential pressure is greater than the trip point and the delay time has expired. There are no active codes for the oil pressure sensors. 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.
i01633828

E129 Engine Oil Filter Diff Pressure High Warning
SMCS Code: 1308-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The 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. Troubleshooting: Refer to Troubleshooting, “Engine Oil Filter Differential Pressure”. Results:

• OK – STOP.
i01633833

E135 Low Jacket Water Pressure Shutdown
SMCS Code: 1350-038 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.

158 Troubleshooting Section

Results:

Troubleshooting: Refer to Troubleshooting, “Jacket Water Inlet Pressure (High)”.
i01633954

• OK – STOP.

E223 High Gas Temperature
SMCS Code: 1250-038 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)”. Results:

Results:

• OK – STOP.
i01633959

E225 Engine Overcrank
SMCS Code: 1400-038 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:

• OK – STOP.
i01633956

• OK – STOP.
i01761561

E224 High Jacket Water Inlet Pressure
SMCS Code: 1350-038 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.

E226 Driven Equipment Not Ready
SMCS Code: 1404-038 Conditions Which Generate This Code: The engine is ready to start. However, the master 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.

159 Troubleshooting Section

Troubleshooting: Refer to Troubleshooting, “Driven Equipment”. Results:

Troubleshooting: Refer to Troubleshooting, “Fuel Energy Content”. Results:

• OK – STOP.
i01633972

• OK – STOP.
i01746483

E229 Fuel Energy Content Setting Low
SMCS Code: 1250-038 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:

E231 Fuel Quality Out of Range
SMCS Code: 1250-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The Low Heat 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 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:

• OK – STOP.
i01633976

• OK – STOP.
i01634015

E230 Fuel Energy Content Setting High
SMCS Code: 1250-038 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.

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)

160 Troubleshooting Section

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:

Troubleshooting: Refer to Troubleshooting, “Turbocharger Turbine Temperature (High)”. Results:

• OK – STOP.
i01634041

E245 High Right Turbo Turbine Inlet Temperature
SMCS Code: 1052-038 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.

• OK – STOP.
i01634039

System Response: The following event codes are logged according to the trip points for the temperature:

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:

• E245 (1) High Right Turbo Turbine Inlet
Temperature (warning)

• 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
Temperature (warning)

• 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: 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.

161 Troubleshooting Section

i01634043

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:

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:

• OK – STOP.
i01634063

• 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:

E268 Unexpected Engine Shutdown
SMCS Code: 1400-038 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:

• OK – STOP.
i01634059

• OK – STOP.
i01634093

E264 Emergency Stop Activated
SMCS Code: 1400-038 Conditions Which Generate This Code: The input for the emergency stop is activated.

E269 Customer Shutdown Requested
SMCS Code: 1400-038 Conditions Which Generate This Code: The engine is either cranking or running. The input for the stop is set for 200 ms.

162 Troubleshooting Section

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 Shutdown”. Results:

i01864896

E337 High Engine Oil to Engine Coolant Diff Temp
SMCS Code: 1350-038 Conditions Which Generate This Code: 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:

• OK – STOP.
i01634097

E270 Driven Equipment Shutdown Requested
SMCS Code: 1400-038 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:

• E337 (1) High Engine Oil to Engine Coolant Diff
Temp (warning)

• E337 (3) High Engine Oil to Engine Coolant Diff
Temp (shutdown) If a warning is activated, the alarm output is activated. If a shutdown is activated, the shutdown output is activated. 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: Refer to Troubleshooting, “Jacket Water to Engine Oil Differential Temperature (Low)”. Results:

• OK – STOP.

• OK – STOP.

163 Troubleshooting Section

i01637607

i01637627

E401 Cylinder #1 Detonation
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s 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:

E403 Cylinder #3 Detonation
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s 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.
i01637623

• OK – STOP.
i01637634

E402 Cylinder #2 Detonation
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s 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:

E404 Cylinder #4 Detonation
SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s 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.

• OK – STOP.

i01637651 E406 Cylinder #6 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. i01637646 • OK – STOP. There is no active diagnostic code for the cylinder’s detonation sensor. • OK – STOP. The code is logged. Results: • OK – STOP. Troubleshooting: Refer to Troubleshooting. . Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. System Response: The alarm output is activated. “Detonation”. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Results: • OK – STOP. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. The code is logged. Results: E407 Cylinder #7 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Results: E408 Cylinder #8 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Detonation”. Troubleshooting: Refer to Troubleshooting.164 Troubleshooting Section i01637642 i01637648 E405 Cylinder #5 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. System Response: The alarm output is activated. Troubleshooting: Refer to Troubleshooting. The code is logged. System Response: The alarm output is activated. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. Troubleshooting: Refer to Troubleshooting. “Detonation”. System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor.

Results: E412 Cylinder #12 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. i01637657 • OK – STOP. The code is logged. The code is logged. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”.165 Troubleshooting Section i01637653 i01637663 E409 Cylinder #9 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. Results: • OK – STOP. “Detonation”. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. System Response: The alarm output is activated. . System Response: The alarm output is activated. • OK – STOP. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. Troubleshooting: Refer to Troubleshooting. System Response: The alarm output is activated. System Response: The alarm output is activated. i01637665 E410 Cylinder #10 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The code is logged. Results: E411 Cylinder #11 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. “Detonation”. Results: • OK – STOP.

• OK – STOP. The code is logged. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. i01637706 E414 Cylinder #14 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Results: E416 Cylinder #16 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. System Response: The alarm output is activated. Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. The code is logged. Results: • OK – STOP. Results: E415 Cylinder #15 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point.166 Troubleshooting Section i01637696 i01637702 E413 Cylinder #13 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The code is logged. “Detonation”. The code is logged. System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. . Troubleshooting: Refer to Troubleshooting. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. System Response: The alarm output is activated. i01637699 • OK – STOP. System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. 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. i01762527 E418 Cylinder #18 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The code is logged.167 Troubleshooting Section i01762523 i01762525 E417 Cylinder #17 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. i01762524 • OK – STOP. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. . Results: E419 Cylinder #19 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. System Response: The alarm output is activated. Results: • OK – STOP. The code is logged. Troubleshooting: Refer to Troubleshooting. Results: E420 Cylinder #20 Detonation SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. 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”. • OK – STOP. “Detonation”. The code is logged. System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Troubleshooting: Refer to Troubleshooting. System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. 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”.

Possible Performance Effect: The engine is shut down. Possible Performance Effect: The engine is shut down. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The shutdown output is activated. The shutdown output is activated. . Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Results: • OK – STOP. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. i01634838 E423 Cylinder #3 Detonation Shutdown SMCS Code: 1000-038 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. “Detonation”. i01635415 E424 Cylinder #4 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine is shut down. System Response: The fuel is shut off. “Detonation”. The shutdown output is activated. “Detonation”. • OK – STOP. The code is logged. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The shutdown output is activated. Results: E422 Cylinder #2 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The fuel is shut off.168 Troubleshooting Section i01634664 Results: E421 Cylinder #1 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. i01634746 • OK – STOP. System Response: The fuel is shut off. System Response: The fuel is shut off.

Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed.169 Troubleshooting Section Troubleshooting: Refer to Troubleshooting. System Response: The fuel is shut off. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The shutdown output is activated. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine is shut down. i01635417 • OK – STOP. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. . The code is logged. The shutdown output is activated. • OK – STOP. i01635421 E428 Cylinder #8 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The code is logged. i01635420 E427 Cylinder #7 Detonation Shutdown SMCS Code: 1000-038 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. “Detonation”. System Response: The fuel is shut off. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine is shut down. Results: E425 Cylinder #5 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Results: Possible Performance Effect: The engine is shut down. The shutdown output is activated. System Response: The fuel is shut off. “Detonation”. Results: • OK – STOP. Results: E426 Cylinder #6 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. i01635416 • OK – STOP.

. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. The code is logged. Possible Performance Effect: The engine is shut down. i01635423 E429 Cylinder #9 Detonation Shutdown SMCS Code: 1000-038 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. Results: i01635424 E430 Cylinder #10 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Possible Performance Effect: The engine is shut down. The shutdown output is activated. System Response: The fuel is shut off. “Detonation”. System Response: • OK – STOP. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. The shutdown output is activated. i01635428 E431 Cylinder #11 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. The shutdown output is activated. “Detonation”.170 Troubleshooting Section System Response: The fuel is shut off. There is no active diagnostic code for the cylinder’s detonation sensor. • OK – STOP. Troubleshooting: Refer to Troubleshooting. Results: The fuel is shut off. The shutdown output is activated. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Troubleshooting: Refer to Troubleshooting. “Detonation”. Possible Performance Effect: The engine is shut down. System Response: The fuel is shut off. The code is logged.

There is no active diagnostic code for the cylinder’s detonation sensor. Results: • OK – STOP. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The code is logged. System Response: The fuel is shut off. i01635435 E435 Cylinder #15 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine is shut down. Possible Performance Effect: The engine is shut down. The shutdown output is activated. The shutdown output is activated. “Detonation”. The shutdown output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. System Response: The fuel is shut off. • OK – STOP. “Detonation”. i01635433 E434 Cylinder #14 Detonation Shutdown SMCS Code: 1000-038 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. i01635431 • OK – STOP. “Detonation”. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Troubleshooting: Refer to Troubleshooting. The shutdown output is activated.171 Troubleshooting Section Results: Troubleshooting: Refer to Troubleshooting. There is no active diagnostic code for the cylinder’s detonation sensor. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. System Response: The fuel is shut off. The code is logged. i01635429 • OK – STOP. System Response: The fuel is shut off. Results: E433 Cylinder #13 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The code is logged. Results: E432 Cylinder #12 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Possible Performance Effect: The engine is shut down.

The code is logged. “Detonation”. “Detonation”. The shutdown output is activated. The code is logged. The shutdown output is activated. The shutdown output is activated. i01635436 • OK – STOP. i01762528 E437 Cylinder #17 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. “Detonation”. Results: • OK – STOP. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Results: System Response: The fuel is shut off. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. System Response: The fuel is shut off. There is no active diagnostic code for the cylinder’s detonation sensor. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Troubleshooting: Refer to Troubleshooting. “Detonation”. Possible Performance Effect: The engine is shut down. . System Response: The fuel is shut off. Possible Performance Effect: The engine is shut down. Results: Results: • OK – STOP. The code is logged. E436 Cylinder #16 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. i01762529 E438 Cylinder #18 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. • OK – STOP.172 Troubleshooting Section Possible Performance Effect: The engine is shut down.

The shutdown output is activated. . System Response: The fuel is shut off. Possible Performance Effect: If a warning is generated. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine is shut down. System Response: The fuel is shut off. i01635494 E801 Cylinder #1 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. Troubleshooting: Refer to Troubleshooting. i01635500 E802 Cylinder #2 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. If a shutdown is generated. “Detonation”. The shutdown output is activated. Results: • OK – STOP. E440 Cylinder #20 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. “Detonation”. 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) • E801 (3) Cylinder #1 High Exhaust Port Temp (shutdown) If a warning is generated. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. the shutdown output is activated and the fuel is shut off. The code is logged. the alarm output is activated. Possible Performance Effect: The engine is shut down. The code is logged. i01762532 • OK – STOP.173 Troubleshooting Section i01762530 Results: E439 Cylinder #19 Detonation Shutdown SMCS Code: 1000-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Exhaust Port Temperature (High)”. There is no active diagnostic code for the cylinder’s detonation sensor. Results: • OK – STOP. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The engine will be shut down if the trip point for the shutdown is exceeded.

“Exhaust Port Temperature (High)”.174 Troubleshooting Section System Response: The following event codes are logged according to the trip points for the temperature: If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off. the shutdown output is activated and the fuel is shut off. i01635505 E804 Cylinder #4 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. • E803 (1) Cylinder #3 High Exhaust Port Temp (warning) • E803 (3) Cylinder #3 High Exhaust Port Temp (shutdown) If a warning is generated. Results: • E802 (1) Cylinder #2 High Exhaust Port Temp (warning) • E802 (3) Cylinder #2 High Exhaust Port Temp (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated. the alarm output is activated. System Response: • OK – STOP. 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: • E804 (1) Cylinder #4 High Exhaust Port Temp (warning) • E804 (3) Cylinder #4 High Exhaust Port Temp (shutdown) If a warning is generated. the engine performance is not immediately affected. the engine performance is not immediately affected. If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. the engine performance is not immediately affected. If a shutdown is generated. . the alarm output is activated. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Results: • OK – STOP. i01635503 E803 Cylinder #3 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting.

the alarm output is activated. . Possible Performance Effect: If a warning is generated. “Exhaust Port Temperature (High)”. System Response: The following event codes are logged according to the trip points for the temperature: • E806 (1) Cylinder #6 High Exhaust Port Temp (warning) • E806 (3) Cylinder #6 High Exhaust Port Temp (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. “Exhaust Port Temperature (High)”. Troubleshooting: Refer to Troubleshooting. i01635508 E805 Cylinder #5 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. If a shutdown is generated. “Exhaust Port Temperature (High)”. Results: • E805 (1) Cylinder #5 High Exhaust Port Temp (warning) • E805 (3) Cylinder #5 High Exhaust Port Temp (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. i01635512 E807 Cylinder #7 High Exhaust Port Temp SMCS Code: 1059-038 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: • OK – STOP. the shutdown output is activated and the fuel is shut off. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. the alarm output is activated. Results: • OK – STOP. the engine performance is not immediately affected.175 Troubleshooting Section Troubleshooting: Refer to Troubleshooting. Results: i01635511 E806 Cylinder #6 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: • OK – STOP.

If a shutdown is generated. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. The engine will be shut down if the trip point for the shutdown is exceeded. System Response: The following event codes are logged according to the trip points for the temperature: System Response: The following event codes are logged according to the trip points for the temperature: • E809 (1) Cylinder #9 High Exhaust Port Temp (warning) • E809 (3) Cylinder #9 High Exhaust Port Temp (shutdown) If a warning is generated.176 Troubleshooting Section • E807 (1) Cylinder #7 High Exhaust Port Temp (warning) Possible Performance Effect: If a warning is generated. “Exhaust Port Temperature (High)”. . Troubleshooting: Refer to Troubleshooting. the shutdown output is activated and the fuel is shut off. the alarm output is activated. “Exhaust Port Temperature (High)”. Results: • OK – STOP. • E808 (1) Cylinder #8 High Exhaust Port Temp (warning) • E808 (3) Cylinder #8 High Exhaust Port Temp (shutdown) If a warning is generated. If a shutdown is generated. i01635513 E808 Cylinder #8 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. 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 will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. the engine performance is not immediately affected. • OK – STOP. i01635546 E809 Cylinder #9 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Results: • E807 (3) Cylinder #7 High Exhaust Port Temp (shutdown) If a warning is generated. “Exhaust Port Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. the engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting. the alarm output is activated.

the shutdown output is activated and the fuel is shut off. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (High)”. Results: • E810 (1) Cylinder #10 High Exhaust Port Temp (warning) • E810 (3) Cylinder #10 High Exhaust Port Temp (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • E811 (1) Cylinder #11 High Exhaust Port Temp (warning) • E811 (3) Cylinder #11 High Exhaust Port Temp (shutdown) If a warning is generated. Results: • OK – STOP. “Exhaust Port Temperature (High)”. the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off.177 Troubleshooting Section Results: System Response: The following event codes are logged according to the trip points for the temperature: i01635549 • OK – STOP. the engine performance is not immediately affected. the alarm output is activated. the alarm output is activated. the alarm output is activated. • E812 (1) Cylinder #12 High Exhaust Port Temp (warning) • E812 (3) Cylinder #12 High Exhaust Port Temp (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. E810 Cylinder #10 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. . If a shutdown is generated. If a shutdown is generated. i01635568 E812 Cylinder #12 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. i01635556 E811 Cylinder #11 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. If a shutdown is generated.

The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off. i01635577 E814 Cylinder #14 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. i01635570 System Response: The following event codes are logged according to the trip points for the temperature: E813 Cylinder #13 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. If a shutdown is generated. Results: Results: • OK – STOP. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. . • OK – STOP. • OK – STOP. System Response: The following event codes are logged according to the trip points for the temperature: • E814 (1) Cylinder #14 High Exhaust Port Temp (warning) • E814 (3) Cylinder #14 High Exhaust Port Temp (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting. the alarm output is activated.178 Troubleshooting Section Possible Performance Effect: If a warning is generated. the alarm output is activated. Results: • E813 (1) Cylinder #13 High Exhaust Port Temp (warning) • E813 (3) Cylinder #13 High Exhaust Port Temp (shutdown) If a warning is generated. the engine performance is not immediately affected. “Exhaust Port Temperature (High)”. Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (High)”. If a shutdown is generated. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (High)”. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected.

the shutdown output is activated and the fuel is shut off. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (High)”. “Exhaust Port Temperature (High)”. If a shutdown is generated. System Response: The following event codes are logged according to the trip points for the temperature: • E817 (3) Cylinder #17 High Exhaust Port Temp (shutdown) If a warning is generated. i01635584 • E817 (1) Cylinder #17 High Exhaust Port Temp (warning) E816 Cylinder #16 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Results: • E815 (1) Cylinder #15 High Exhaust Port Temp (warning) • E815 (3) Cylinder #15 High Exhaust Port Temp (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. Possible Performance Effect: If a warning is generated. . If a shutdown is generated. the shutdown output is activated and the fuel is shut off. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • E816 (3) Cylinder #16 High Exhaust Port Temp (shutdown) If a warning is generated. i01762533 E817 Cylinder #17 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. Results: • OK – STOP. the alarm output is activated. the engine performance is not immediately affected.179 Troubleshooting Section i01635578 • E816 (1) Cylinder #16 High Exhaust Port Temp (warning) E815 Cylinder #15 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.

the shutdown output is activated and the fuel is shut off. Results: • OK – STOP. . “Exhaust Port Temperature (High)”. System Response: The following event codes are logged according to the trip points for the temperature: • E819 (1) Cylinder #19 High Exhaust Port Temp (warning) • E819 (3) Cylinder #19 High Exhaust Port Temp (shutdown) If a warning is generated. the engine performance is not immediately affected. • OK – STOP. the engine performance is not immediately affected. If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (High)”. Troubleshooting: Refer to Troubleshooting. i01762534 System Response: The following event codes are logged according to the trip points for the temperature: E818 Cylinder #18 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.180 Troubleshooting Section The engine will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. Results: • E818 (1) Cylinder #18 High Exhaust Port Temp (warning) • E818 (3) Cylinder #18 High Exhaust Port Temp (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. Results: i01762535 E819 Cylinder #19 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. i01762536 E820 Cylinder #20 High Exhaust Port Temp SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. • OK – STOP. “Exhaust Port Temperature (High)”. the alarm output is activated. If a shutdown is generated. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off.

181 Troubleshooting Section System Response: The following event codes are logged according to the trip points for the temperature: If a shutdown is generated. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. • OK – STOP. the alarm output is activated. the engine performance is not immediately affected. • E821 (1) Cyl #1 Exhaust Port Temp Deviating High (warning) • E821 (3) Cyl #1 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. i01635593 E822 Cyl #2 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the alarm output is activated. i01635587 E821 Cyl #1 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the alarm output is activated. If a shutdown is generated. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. The amount of deviation has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off. The engine will be shut down if the trip point for the shutdown is exceeded. Results: • OK – STOP. Possible Performance Effect: If a warning is generated. “Exhaust Port Temperature (High)”. If a shutdown is generated. . Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: System Response: The following event codes are logged according to the trip points for the temperature: • E822 (1) Cyl #2 Exhaust Port Temp Deviating High (warning) • E822 (3) Cyl #2 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. The amount of deviation has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. Results: • E820 (1) Cylinder #20 High Exhaust Port Temp (warning) • E820 (3) Cylinder #20 High Exhaust Port Temp (shutdown) If a warning is generated. “Exhaust Port Temperature (High)”.

182 Troubleshooting Section

Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:

i01635604

E824 Cyl #4 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code:

• OK – STOP.
i01635600

E823 Cyl #3 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

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:

• E824 (1) Cyl #4 Exhaust Port Temp Deviating High
(warning)

• E824 (3) Cyl #4 Exhaust Port Temp Deviating 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:

• E823 (1) Cyl #3 Exhaust Port Temp Deviating High
(warning)

• E823 (3) Cyl #3 Exhaust Port Temp Deviating 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.

183 Troubleshooting Section

i01635605

System Response: The following event codes are logged according to the trip points for the temperature:

E825 Cyl #5 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• E826 (1) Cyl #6 Exhaust Port Temp Deviating High
(warning)

• E826 (3) Cyl #6 Exhaust Port Temp Deviating 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:

• E825 (1) Cyl #5 Exhaust Port Temp Deviating High
(warning)

• E825 (3) Cyl #5 Exhaust Port Temp Deviating 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

E827 Cyl #7 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.

• OK – STOP.
i01635612

System Response: The following event codes are logged according to the trip points for the temperature:

E826 Cyl #6 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.

• E827 (1) Cyl #7 Exhaust Port Temp Deviating High
(warning)

• E827 (3) Cyl #7 Exhaust Port Temp Deviating High
(shutdown) If a warning is generated, the alarm output is activated.

184 Troubleshooting Section

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:

Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:

• OK – STOP.
i01635618

E829 Cyl #9 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• OK – STOP.
i01635616

E828 Cyl #8 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• E829 (1) Cyl #9 Exhaust Port Temp Deviating High
(warning)

• E829 (3) Cyl #9 Exhaust Port Temp Deviating 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:

• E828 (1) Cyl #8 Exhaust Port Temp Deviating High
(warning)

• E828 (3) Cyl #8 Exhaust Port Temp Deviating 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.

185 Troubleshooting Section

i01635634

System Response: The following event codes are logged according to the trip points for the temperature:

E830 Cyl #10 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• E831 (1) Cyl #11 Exhaust Port Temp Deviating
High (warning)

• E831 (3) Cyl #11 Exhaust Port Temp Deviating
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:

• E830 (1) Cyl #10 Exhaust Port Temp Deviating
High (warning)

• E830 (3) Cyl #10 Exhaust Port Temp Deviating
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.
i01635645

E832 Cyl #12 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.

• OK – STOP.
i01635641

System Response: The following event codes are logged according to the trip points for the temperature:

E831 Cyl #11 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.

• E832 (1) Cyl #12 Exhaust Port Temp Deviating
High (warning)

• E832 (3) Cyl #12 Exhaust Port Temp Deviating
High (shutdown) If a warning is generated, the alarm output is activated.

186 Troubleshooting Section

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:

Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:

• OK – STOP.
i01635656

E834 Cyl #14 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• OK – STOP.
i01635653

E833 Cyl #13 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• E834 (1) Cyl #14 Exhaust Port Temp Deviating
High (warning)

• E834 (3) Cyl #14 Exhaust Port Temp Deviating
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:

• E833 (1) Cyl #13 Exhaust Port Temp Deviating
High (warning)

• E833 (3) Cyl #13 Exhaust Port Temp Deviating
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.

187 Troubleshooting Section

i01635658

System Response: The following event codes are logged according to the trip points for the temperature:

E835 Cyl #15 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• E836 (1) Cyl #16 Exhaust Port Temp Deviating
High (warning)

• E836 (3) Cyl #16 Exhaust Port Temp Deviating
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:

• E835 (1) Cyl #15 Exhaust Port Temp Deviating
High (warning)

• E835 (3) Cyl #15 Exhaust Port Temp Deviating
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.
i01762537

E837 Cyl #17 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.

• OK – STOP.
i01635661

System Response: The following event codes are logged according to the trip points for the temperature:

E836 Cyl #16 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired.

• E837 (1) Cyl #17 Exhaust Port Temp Deviating
High (warning)

• E837 (3) Cyl #17 Exhaust Port Temp Deviating
High (shutdown) If a warning is generated, the alarm output is activated.

188 Troubleshooting Section

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:

Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature (High)”. Results:

• OK – STOP.
i01762539

E839 Cyl #19 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• OK – STOP.
i01762538

E838 Cyl #18 Exhaust Port Temp Deviating High
SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature:

• E839 (1) Cyl #19 Exhaust Port Temp Deviating
High (warning)

• E839 (3) Cyl #19 Exhaust Port Temp Deviating
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:

• E838 (1) Cyl #18 Exhaust Port Temp Deviating
High (warning)

• E838 (3) Cyl #18 Exhaust Port Temp Deviating
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.

Results: • OK – STOP. The engine will be shut down if the trip point for the shutdown is exceeded. The amount of deviation has exceeded the trip point and the delay time has expired. i01635667 E842 Cyl #2 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. If a shutdown is generated. the engine performance is not immediately affected. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. The amount of deviation has exceeded the trip point and the delay time has expired. the alarm output is activated. Possible Performance Effect: If a warning is generated. “Exhaust Port Temperature (Low)”. . If a shutdown is generated. • OK – STOP.189 Troubleshooting Section i01762540 System Response: The following event codes are logged according to the trip points for the temperature: E840 Cyl #20 Exhaust Port Temp Deviating High SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. i01635664 System Response: The following event codes are logged according to the trip points for the temperature: E841 Cyl #1 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Troubleshooting: Refer to Troubleshooting. • E842 (1) Cyl #2 Exhaust Port Temp Deviating Low (warning) • E841 (3) Cyl #2 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. the alarm output is activated. “Exhaust Port Temperature (High)”. the engine performance is not immediately affected. 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) • E841 (3) Cyl #1 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. The amount of deviation has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. Results: • E840 (1) Cyl #20 Exhaust Port Temp Deviating High (warning) • E840 (3) Cyl #20 Exhaust Port Temp Deviating High (shutdown) If a warning 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. System Response: The following event codes are logged according to the trip points for the temperature: • E844 (1) Cyl #4 Exhaust Port Temp Deviating Low (warning) • E844 (3) Cyl #4 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Results: • OK – STOP. . Possible Performance Effect: If a warning is generated. The amount of deviation has exceeded the trip point and the delay time has expired. i01635668 E843 Cyl #3 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. i01635670 E844 Cyl #4 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. • OK – STOP.190 Troubleshooting Section If a shutdown is generated. If a shutdown is generated. The amount of deviation has exceeded the trip point and the delay time has expired. Results: Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (Low)”. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (Low)”. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting. If a shutdown is generated. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. Results: • E843 (1) Cyl #3 Exhaust Port Temp Deviating Low (warning) • E843 (3) Cyl #3 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (Low)”. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected.

the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. The amount of deviation has exceeded the trip point and the delay time has expired. Possible Performance Effect: If a warning is generated. the alarm output is activated. 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: • E846 (1) Cyl #6 Exhaust Port Temp Deviating Low (warning) • E846 (3) Cyl #6 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. If a shutdown is generated. If a shutdown is generated. The amount of deviation has exceeded the trip point and the delay time has expired. i01635677 E847 Cyl #7 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. “Exhaust Port Temperature (Low)”. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. “Exhaust Port Temperature (Low)”. • E847 (1) Cyl #7 Exhaust Port Temp Deviating Low (warning) • E847 (3) Cyl #7 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. • OK – STOP. Results: • E845 (1) Cyl #5 Exhaust Port Temp Deviating Low (warning) • E845 (3) Cyl #5 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. Results: • OK – STOP. .191 Troubleshooting Section i01635672 System Response: The following event codes are logged according to the trip points for the temperature: E845 Cyl #5 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. i01635673 System Response: The following event codes are logged according to the trip points for the temperature: E846 Cyl #6 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected.

Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. “Exhaust Port Temperature (Low)”. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. System Response: The following event codes are logged according to the trip points for the temperature: • E849 (1) Cyl #9 Exhaust Port Temp Deviating Low (warning) • E849 (3) Cyl #9 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. i01635680 E848 Cyl #8 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. the shutdown output is activated and the fuel is shut off. The amount of deviation has exceeded the trip point and the delay time has expired. Results: • OK – STOP. the alarm output is activated. . the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. the engine performance is not immediately affected. • OK – STOP. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (Low)”. Results: • E848 (1) Cyl #8 Exhaust Port Temp Deviating Low (warning) • E848 (3) Cyl #8 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated.192 Troubleshooting Section If a shutdown is generated. Results: Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. i01635683 E849 Cyl #9 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. “Exhaust Port Temperature (Low)”. The amount of deviation has exceeded the trip point and the delay time has expired.

i01635688 E852 Cyl #12 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. • E852 (1) Cyl #12 Exhaust Port Temp Deviating Low (warning) • E852 (3) Cyl #12 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • E851 (1) Cyl #11 Exhaust Port Temp Deviating Low (warning) • E851 (3) Cyl #11 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. the alarm output is activated. The amount of deviation has exceeded the trip point and the delay time has expired. The amount of deviation has exceeded the trip point and the delay time has expired. If a shutdown is generated. Results: • E850 (1) Cyl #10 Exhaust Port Temp Deviating Low (warning) • E850 (3) Cyl #10 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. the alarm output is activated. “Exhaust Port Temperature (Low)”. the engine performance is not immediately affected. i01635685 System Response: The following event codes are logged according to the trip points for the temperature: E851 Cyl #11 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. • OK – STOP. If a shutdown is generated. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. The amount of deviation has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off.193 Troubleshooting Section i01635684 System Response: The following event codes are logged according to the trip points for the temperature: E850 Cyl #10 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Results: • OK – STOP. the engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (Low)”. .

If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. Results: Troubleshooting: Refer to Troubleshooting. the alarm output is activated.194 Troubleshooting Section If a shutdown is generated. “Exhaust Port Temperature (Low)”. 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 amount of deviation has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. i01635692 E854 Cyl #14 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Troubleshooting: Refer to Troubleshooting. • OK – STOP. The engine will be shut down if the trip point for the shutdown is exceeded. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. Results: • E853 (1) Cyl #13 Exhaust Port Temp Deviating Low (warning) • E853 (3) Cyl #13 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. i01635691 E853 Cyl #13 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (Low)”. 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: • E854 (1) Cyl #14 Exhaust Port Temp Deviating Low (warning) • E854 (3) Cyl #14 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. the engine performance is not immediately affected. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. . If a shutdown is generated. “Exhaust Port Temperature (Low)”. Results: • OK – STOP.

Results: • E855 (1) Cyl #15 Exhaust Port Temp Deviating Low (warning) • E855 (3) Cyl #15 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. i01635695 System Response: The following event codes are logged according to the trip points for the temperature: E856 Cyl #16 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders.195 Troubleshooting Section i01635694 System Response: The following event codes are logged according to the trip points for the temperature: E855 Cyl #15 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 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. the alarm output is activated. Possible Performance Effect: If a warning is generated. • E857 (1) Cyl #17 Exhaust Port Temp Deviating Low (warning) • E857 (3) Cyl #17 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • E856 (1) Cyl #16 Exhaust Port Temp Deviating Low (warning) • E856 (3) Cyl #16 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Results: • OK – STOP. . i01762541 E857 Cyl #17 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. the shutdown output is activated and the fuel is shut off. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (Low)”. The engine will be shut down if the trip point for the shutdown is exceeded. The amount of deviation has exceeded the trip point and the delay time has expired. Possible Performance Effect: If a warning is generated. • OK – STOP. “Exhaust Port Temperature (Low)”. If a shutdown is generated. If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. The amount of deviation has exceeded the trip point and the delay time has expired. the engine performance is not immediately affected.

the engine performance is not immediately affected. . i01762545 E859 Cyl #19 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the shutdown output is activated and the fuel is shut off. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. If a shutdown is generated. the alarm output is activated. i01762544 E858 Cyl #18 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. If a shutdown is generated.196 Troubleshooting Section If a shutdown is generated. the engine performance is not immediately affected. • OK – STOP. Possible Performance Effect: If a warning is generated. Results: • OK – STOP. System Response: The following event codes are logged according to the trip points for the temperature: • E859 (1) Cyl #19 Exhaust Port Temp Deviating Low (warning) • E859 (3) Cyl #19 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. Results: • E858 (1) Cyl #18 Exhaust Port Temp Deviating Low (warning) • E858 (3) Cyl #18 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. “Exhaust Port Temperature (Low)”. Troubleshooting: Refer to Troubleshooting. The amount of deviation has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. Results: Troubleshooting: Refer to Troubleshooting. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. The amount of deviation has exceeded the trip point and the delay time has expired. “Exhaust Port Temperature (Low)”. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (Low)”. Troubleshooting: Refer to Troubleshooting.

However. System Response: The alarm output is activated. Possible Performance Effect: The engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. i01637712 • OK – STOP. “Gas Fuel Differential Pressure (Low)”. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. If a shutdown is generated. Troubleshooting: Refer to Troubleshooting.197 Troubleshooting Section i01762546 System Response: The alarm output is activated. Results: E860 Cyl #20 Exhaust Port Temp Deviating Low SMCS Code: 1059-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Results: • E860 (3) Cyl #20 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. The code is logged. The code is logged. i01637716 • E860 (1) Cyl #20 Exhaust Port Temp Deviating Low (warning) E865 High Gas Fuel Differential Pressure SMCS Code: 1250-038 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. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. The delay time has expired. the engine performance is not immediately affected. The difference in fuel pressure between the outlet and the inlet of the fuel metering valve is less than the trip point. Possible Performance Effect: The engine performance is not immediately affected. The delay time has expired. “Gas Fuel Differential Pressure (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. i01637720 E864 Low Gas Fuel Differential Pressure SMCS Code: 1250-038 Conditions Which Generate This Code: The gas shutoff valve (GSOV) is energized. the flow rate that is computed by the valve does not match the fuel demand for a delay time of 5 seconds. “Exhaust Port Temperature (Low)”. E866 Low Gas Fuel Flow Rate SMCS Code: 1250-038 Conditions Which Generate This Code: The fuel metering valve is fully open. Results: • OK – STOP. The amount of deviation has exceeded the trip point and the delay time has expired. .

The code is logged. The code is logged. Results: • OK – STOP. Troubleshooting: Refer to Troubleshooting. i01761860 • OK – STOP. The code is logged. System Response: The alarm output is activated. Possible Performance Effect: The engine performance is not immediately affected. Possible Performance Effect: The engine performance is not immediately affected. Results: • OK – STOP. Possible Performance Effect: The engine performance is not immediately affected.198 Troubleshooting Section System Response: The alarm output is activated. E867 Improper Gas Flow Control Valve Response SMCS Code: 1741-038 Conditions Which Generate This Code: The fuel metering valve is not responding correctly to the master Electronic Control Module (ECM) and the delay time has expired. Troubleshooting: Refer to Troubleshooting. “Fuel Metering Valve”. Troubleshooting: Refer to Troubleshooting. “Fuel Metering Valve”. “Gas Fuel Flow Rate (Low)”. . Results: System Response: The alarm output is activated. i01761863 E868 Gas Flow Control Valve Malfunction SMCS Code: 1741-038 Conditions Which Generate This Code: The master Electronic Control Module (ECM) has detected a malfunction for the fuel metering valve and the delay time has expired.

• The “DESIRED SPEED” potentiometer is near the maximum desired speed or at the maximum desired speed. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This troubleshooting procedure may generate additional diagnostic codes.199 Troubleshooting Section Diagnostic Functional Tests i02088364 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. Before you begin this procedure. The least likely cause is a problem with the master ECM. A “5 Volt Sensor DC Power Supply short to +batt” diagnostic code will be activated if both of these conditions occur: • The desired speed signal wire is shorted to a voltage source that is greater than +5 volts. A short circuit on one of these terminals will cause a short circuit on the other terminal. “DESIRED SPEED” Potentiometer (if equipped) The master ECM also provides 5. . The next likely cause is a sensor problem. +5V Sensor Voltage Supply SMCS Code: 5574-038 System Operation Description: The master Electronic Control Module (ECM) supplies 5. A “+5 V sensor supply” diagnostic code is probably caused by a short circuit or an open circuit in a harness.0 ± 0. Keep your mind on correcting the cause of the original diagnostic code.5 VDC to the “DESIRED SPEED” potentiometer (if equipped). Clear the diagnostic codes after the problem is resolved. • The “DESIRED SPEED” potentiometer is near the maximum desired speed or at the maximum desired speed.5 VDC to the sensors for these parameters: • Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure Terminals J1-2 and J1-18 are connected together inside the master ECM. Logged diagnostic codes provide a historical record.0 ± 0.

200 Troubleshooting Section Illustration 20 Schematic for the 5 V supply g01065037 .

Inspect the Electrical Connectors and Wiring • J1/P1 connectors • J6/P6. Note: For the following steps. Illustration 22 Terminal box g01065031 (2) J1/P1 connectors for the master ECM (3) J6/P6 connectors for the customer (4) J7/P7 connectors for the harness from the 5 volt sensors Illustration 24 Harness side of the J6 connector (J6-5) 5 volt supply (J6-15) Return (J6-25) Signal for desired speed (J6-35) Shield g00929111 B. b. Check the torque of the allen head screws for the ECM connectors. “Inspecting Electrical Connectors”. refer to Troubleshooting.25 N·m (20 ± 2 lb in). Set the engine control to the OFF/RESET mode. Illustration 21 Junction box (1) 35 amp circuit breaker g01054206 Illustration 23 Harness side of the P1 connector (P1-2) 5 volt supply (P1-3) Return (P1-14) Signal for the inlet manifold air temperature (P1-16) Signal for the desired speed (P1-17) Signal for the engine oil temperature (P1-18) 5 volt supply (P1-24) Signal for the filtered engine oil pressure (P1-26) Signal for the unfiltered engine oil pressure (P1-35) Return g01053671 A. Thoroughly inspect each of the following connectors: .25 ± 0.201 Troubleshooting Section Test Step 1. Switch 35 amp circuit breaker (1) to the OFF position. and J7/P7 connectors a. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.

or pinch points. . Expected Result: All connectors. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 5 V sensors. pins. Check the harness and wiring for corrosion. abrasion and pinch points from the 5 volt sensors to the master ECM.202 Troubleshooting Section Illustration 26 Right side view (5) Engine oil temperature sensor (6) Unfiltered oil pressure sensor (7) Filtered oil pressure sensor Illustration 25 Harness side of the J7 connector (J7-3) Signal for the inlet manifold air temperature (J7-4) Signal for the filtered engine oil pressure (J7-5) Signal for the engine oil temperature (J7-6) Signal for the unfiltered engine oil pressure (J7-17) Return for the inlet manifold air temperature (J7-18) Return for the filtered engine oil pressure (J7-19) Return for the engine oil temperature (J7-20) Return for the unfiltered engine oil pressure (J7-31) Shield for the inlet manifold air temperature (J7-32) Shield for the filtered engine oil pressure (J7-33) Shield for the engine oil temperature (J7-34) Shield for the unfiltered engine oil pressure (J7-45) 5 volt supply for the inlet manifold air temperature (J7-46) 5 volt supply for the filtered engine oil pressure (J7-47) 5 volt supply for the engine oil temperature (J7-48) 5 volt supply for the unfiltered engine oil pressure g00929117 g01065032 c. Illustration 27 Top view (8) Inlet air temperature sensor g01065033 d. abrasion. The connectors and the wiring do not have corrosion. and sockets are connected properly.

A. STOP. Refer to Troubleshooting. Expected Result: The resistance is greater than 20.203 Troubleshooting Section Results: • OK – All connectors. Proceed to Test Step 4.000 Ohms. Check the Analog Speed Circuit Note: If the engine is not equipped with a “DESIRED SPEED” potentiometer. . Proceed to Test Step 2. Results: Test Step 4. there is at least one logged code for the 5 volt sensor supply. or pinch points. The connectors and the wiring do not have corrosion. The wiring for the “DESIRED SPEED” potentiometer appears to be OK. and/or pinch points. Results: Test Step 2. Proceed to Test Step 3. B. Connect Cat ET to the service tool connector. Refer to Troubleshooting. Rotate the “DESIRED SPEED” potentiometer (if equipped) counterclockwise to the minimum speed position. • OK – The resistance is greater than 20. STOP. Disconnect the P1 connector from the master ECM. pins. There is a problem with the analog speed circuit. • Logged code – The 262-03 code or the 262-04 code is not active. if necessary. potentiometer clockwise to the maximum speed position caused an active code. Proceed to Test Step 5.000 Ohms. Expected Result: The 262-03 code or the 262-04 code is not active or logged. The components are in good condition with proper connections. Switch the 35 amp circuit breaker ON. Measure the resistance between terminals P1-16 and P1-69. sockets are not connected properly. D. Repair: There may be a problem with the wiring and/or a connector. abrasion. D. • Active code – Rotating the “DESIRED SPEED” • 262-03 5 Volt Sensor DC Power Supply short to +batt • 262-04 5 Volt Sensor DC Power Supply short to ground E. The +5 V sensor voltage supply is operating correctly at this time. C. Check for diagnostic codes again. Check the Wiring for the “DESIRED SPEED” Potentiometer A. Disconnect the wiring from the “DESIRED SPEED” potentiometer. At least one of the connectors and the wiring has corrosion. Look for these codes: • No codes – Rotating the “DESIRED SPEED” potentiometer clockwise to the maximum speed position did not cause an active code. Repair: Perform the necessary repairs and/or replace parts. abrasion. Set the engine control to the OFF/RESET mode. “Inspecting Electrical Connectors”. or Test Step 3. Observe the “Active Diagnostic” screen on Cat ET. B. Label the wiring that is connected to the “DESIRED SPEED” potentiometer. pins. if necessary. Switch the 35 amp circuit breaker OFF. Set the engine control to the STOP mode. Rotate the “DESIRED SPEED” potentiometer (if equipped) clockwise to the maximum speed position. Resume normal operation. Expected Result: The 262-03 code or the 262-04 code is not active. Wait at least 30 seconds so that any codes may become activated. and sockets are connected properly. • Not OK – At least one of the connectors. Look for the same codes. • Active code – The 262-03 code or the 262-04 code is active. C. However. Results: • No codes – There are no active codes or logged codes. “Electronic Service Tools”. Proceed to Test Step 3. Observe the “Logged Diagnostic” screen on Cat ET. Verify that the wiring and/or connectors are OK. proceed to Test Step 9. Check for Diagnostic Codes A.

if necessary. Replace the “DESIRED SPEED” potentiometer. replace the original ECM. Insert terminal P1-18 into the P1 connector. Use Cat ET to look for diagnostic codes. Pull on the wire in order to verify that the terminal is fully inserted into the connector. There is a problem with the wiring for the “DESIRED SPEED” potentiometer. Refer to Troubleshooting. Use Cat ET to look for diagnostic codes. “Replacing the ECM”. Refer to Troubleshooting. D. E. 4. Isolate the Wiring Harnesses from the Master ECM A. Reconnect the P1 connector to the master ECM. Switch the 35 amp circuit breaker ON. C. Test Step 6. Connect the 5 Volt Wiring for the Analog Speed Circuit to the Master ECM A. This will disconnect all of the +5 V wiring from the master ECM. Exit this procedure and perform this procedure again. Expected Result: No active codes Test Step 5. Reconnect the wiring to the “DESIRED SPEED” potentiometer. Alternatively. If the new ECM operates correctly and the original ECM does not operate correctly. Set the engine control to the STOP mode.000 Ohms. Expected Result: No active codes . If the problem is resolved with the new ECM. Switch the 35 amp circuit breaker OFF. Set the engine control to the OFF/RESET mode. D. perform the following steps: Temporarily install a new master ECM. STOP. 2. • Not OK – The resistance is less than 20. Be sure to connect the wires to the appropriate terminals. Perform the following procedure: 1. Verify that the original problem is resolved. C. Rotate the “DESIRED SPEED” potentiometer clockwise to the maximum speed position. Use a 151-6320 Wire Removal Tool to remove terminals P1-2 and P1-18. Disconnecting all of the +5 V wiring from the master ECM eliminated the active “5 Volt Sensor Supply” diagnostic code. install the original ECM and verify that the problem returns. if necessary. “Replacing the ECM”. Set the engine control to the STOP mode. The problem could be between the P1 connector and the J6 connector. E. Continue with this procedure when the “DESIRED SPEED” potentiometer is operating correctly. Set the engine control to the OFF/RESET mode. Perform this entire procedure again. • Active code – The 262-03 code or the 262-04 code is active. B. Repair: It is unlikely that the master ECM has failed. Switch the 35 amp circuit breaker OFF. Proceed to Test Step 6. Repair: Perform any necessary repairs or replace parts. Disconnecting all of the 5 volt wiring from the master ECM did not eliminate the active “5 Volt Sensor Supply” diagnostic code. 3. STOP.204 Troubleshooting Section Repair: The “DESIRED SPEED” potentiometer may have a problem. Reconnect the P1 connector to the master ECM. If the problem is not resolved. the problem could be in the P6 connector or the wiring that is connected to the P6 connector. B. There may be a problem with the master ECM. STOP. Check the “DESIRED SPEED” potentiometer in order to ensure that the potentiometer does not have an internal short circuit. Switch the 35 amp circuit breaker ON. There is a problem with a connector and/or the wiring in a harness. Results: • No codes – The 262-03 code or the 262-04 code is not active.

C. Set the engine control to the OFF/RESET mode. If these conditions are true. Note: An “Open Circuit” code will be generated for each sensor that is disconnected. wait for at least 30 seconds and then observe the “Active Diagnostic” screen on Cat ET. Switch the 35 amp circuit breaker ON. Switch the 35 amp circuit breaker OFF. Pull on the wire in order to verify that the terminal is fully inserted into the connector. 5. B. Set the engine control to the OFF/RESET mode. 2. A. Use Cat ET to clear the logged 262-03 or 262-04 code. Repair: Perform the following procedure: 1. Insert terminal P1-2 into the P1 connector. code is active. 4. Use Cat ET to look for diagnostic codes. After you reconnect each sensor. Set the engine control to the STOP mode. Clear the codes after you complete this procedure. • Active code – The 262-03 code or the 262-04 code is active. Set the engine control to the STOP mode. Switch the 35 amp circuit breaker OFF. Expected Result: No active codes Results: • Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure Expected Result: The original “5 Volt Sensor” diagnostic code is activated when a particular sensor is disconnected.205 Troubleshooting Section Results: • Unfiltered engine oil pressure • Filtered engine oil pressure C. This is normal. Disconnect the sensors for the following parameters: • Inlet air temperature • Engine oil temperature . Resume normal operation. E. Set the engine control to the STOP mode. STOP. Observe the “Active Diagnostic” screen on Cat ET. Proceed to Test Step 7. D. Clear all of the diagnostic codes. Verify that the 262-03 code or the 262-04 code is not active. Verify that the diagnostic code recurs. Disconnect the 5 Volt Sensors and Look For Active Diagnostic Codes. Connecting the 5 VDC for the sensors caused a diagnostic code. Test Step 8. Verify that the problem is eliminated. Reconnect the suspect sensor. 3. Results: • No codes – The 262-03 code or the 262-04 code is not active. • No codes – The 262-03 code or the 262-04 code is not active. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker ON. Disconnect the suspect sensor. Repair: The initial diagnostic code was probably caused by a poor electrical connection. Connecting the wiring for the analog speed circuit to the master ECM did not cause a diagnostic code. Connect the 5 Volt Wiring for the Sensors to the Master ECM A. Proceed to Test Step 4. • Yes – The original “5 Volt Sensor” diagnostic code is activated when a particular sensor is reconnected. Connecting the 5 VDC for the sensors did not cause a diagnostic code. D. • Active codes – The 262-03 code or the 262-04 Test Step 7. replace the sensor. The sensor and/or the wiring for the sensor has a short circuit. The problem appears to be resolved. STOP. Connecting the wiring for the analog speed circuit to the master ECM caused a diagnostic code. B. Proceed to Test Step 8. The wiring for the analog speed circuit appears to be OK. Reconnect the sensors for the following parameters one at a time.

wiggle the harnesses in order to check for an intermittent problem with the harness.000 Ohms. • Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure C.0 ± 0. The initial diagnostic code was probably caused by a poor electrical connection. The problem appears to be resolved. Proceed to Test Step 9. Switch the 35 amp circuit breaker OFF. A short circuit on one of these terminals will cause a short circuit on the other terminal. B. Check the Harnesses A. A “+8 V sensor supply” diagnostic code is probably caused by a short circuit or an open circuit in a harness. STOP. Verify that all of the sensors for the following parameters are disconnected from the engine harness: than 20. . when possible.000 Ohms.8 VDC to the detonation sensors for the right side of the engine. Disconnect the P1 connector. Verify that the problem is resolved. Replace parts. Repair: The problem may be between the P1 connector and the P7 connector. The least likely cause is a problem with an ECM. if necessary. The next likely cause is a sensor problem. Measure the resistance between terminal P1-2 and the points that are listed in Table 11. Results: • OK – Each check of the resistance is greater Test Step 9. wiggle the harness at the P7 connector. Set the engine control to the OFF/RESET mode. Repair: Reconnect all of the connectors. Do not reconnect the sensors. Connector and Terminal P1-2 5 volt 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) P1-3 (analog return) Ground strap for the engine P1-69 (−Battery terminal) P1-57 (unswitched +Battery) P1-70 (switched +Battery) +8V Sensor Voltage Supply SMCS Code: 5574-038 System Operation Description: The master Electronic Control Module (ECM) supplies 8. i02088517 Measure the Resistance for the Engine Harness. The 5 volt wires in the engine harnesses do not have a problem.206 Troubleshooting Section • No – The original “5 Volt Sensor” diagnostic code was still active while all of the 5 volt sensors were disconnected. During each measurement. Table 11 • Not OK – At least one check of the resistance is less than 20. Resume normal operation. Expected Result: Each check of the resistance is greater than 20. There is a problem with a connector and/or at least one of the 5 volt wires in a harness.8 VDC to these sensors: • Sensor for engine coolant pressure (outlet) • Sensor for inlet air pressure • The detonation sensors for the left side of the engine Terminals J1-4 and J2-56 are connected together inside the master ECM.000 Ohms. The slave ECM supplies 8.0 ± 0. STOP. the problem may be in the engine harness that is connected to the J7 connector. Also. Repair the connection and/or the wire. Alternatively. Be sure to wiggle the harnesses near each of the connectors for the disconnected sensors.

use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Clear the diagnostic codes after the problem is resolved. . This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Before you begin this procedure.207 Troubleshooting Section Logged diagnostic codes provide a historical record.

208 Troubleshooting Section Illustration 28 g01065067 .

Illustration 29 Junction box (1) 35 amp circuit breaker g01054206 A. b. “Inspecting Electrical Connectors”. Check the torque of the allen head screws for the ECM connectors. Illustration 31 Harness side of the P1 connector (P1-4) 8 volt supply for the pressure sensors (P1-5) Return for the pressure sensors (P1-10) Signal for the inlet air pressure g01065914 Illustration 30 Terminal box g01065068 (2) J2/P2 connectors for the master ECM (3) J1/P1 connectors for the master ECM (4) J7/P7 connectors for the harness from the 8 volt sensors (5) J8/P8 connectors for the detonation sensors (6) J4/P4 connectors for the slave ECM . Check the torque of the allen head screws for the connectors on the terminal box. refer to Troubleshooting. Inspect the Electrical Connectors and Wiring B.25 ± 0. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Thoroughly inspect each of the following connectors: • J1/P1 and J2/P2 connectors for the master ECM • J4/P4 connectors for the slave ECM • J7/P7 and J8/P8 connectors on the terminal box a.25 N·m (20 ± 2 lb in). Switch the 35 amp circuit breaker OFF.209 Troubleshooting Section Schematic for the 8 V supply Test Step 1. The proper torque is 2. Set the engine control to the OFF/RESET mode. Note: For the following steps.

210 Troubleshooting Section Illustration 32 Harness side of the P2 connector (P2-36) (P2-37) (P2-38) (P2-39) (P2-44) (P2-54) (P2-55) (P2-56) (P2-57) (P2-68) g01065070 Detonation sensor signal for cylinders 2 and 4 Detonation sensor signal for cylinders 6 and 8 Detonation sensor signal for cylinders 10 and 12 Detonation sensor signal for cylinders 14 and 16 Detonation sensor signal for cylinders 18 and 20 Return for the detonation sensors Return for the detonation sensors 8 volt supply for the detonation sensors 8 volt supply for the detonation sensors Signal for the engine coolant pressure Illustration 34 Harness side of the J7 connector (J7-1) Signal for the inlet air pressure (J7-2) Signal for the engine coolant pressure (J7-15) Return for the inlet air pressure (J7-16) Return for the engine coolant pressure (J7-29) Shield for the inlet air pressure (J7-30) Shield for the engine coolant pressure (J7-43) 8 volt supply for the inlet air pressure (J7-44) 8 volt supply for the engine coolant pressure g00929364 Illustration 33 Harness side of the P4 connector (P4-36) (P4-37) (P4-38) (P4-39) (P4-44) (P4-54) (P4-55) (P4-56) (P4-57) g01065071 Detonation sensor signal for cylinders 1 and 3 Detonation sensor signal for cylinders 5 and 7 Detonation sensor signal for cylinders 9 and 11 Detonation sensor signal for cylinders 13 and 15 Detonation sensor signal for cylinders 17 and 19 Return for the detonation sensors Return for the detonation sensors 8 volt supply for the detonation sensors 8 volt supply for the detonation sensors .

and sockets are c. abrasion. pins. connected properly. or pinch points.211 Troubleshooting Section Illustration 36 Top view (7) Engine coolant pressure sensor (8) Inlet air pressure sensor g01065072 Illustration 35 Harness side of the J8 connector g00929380 (J8-1) 8 V Supply for the detonation sensor for cylinders 2 and 4 (J8-2) 8 V Supply for the detonation sensor for cylinders 6 and 8 (J8-3) 8 V Supply for the detonation sensor for cylinders 10 and 12 (J8-4) 8 V Supply for the detonation sensor for cylinders 14 and 16 (J8-5) 8 V Supply for the detonation sensor for cylinders 18 and 20 (J8-6) 8 V Supply for the detonation sensor for cylinders 1 and 3 (J8-7) 8 V Supply for the detonation sensor for cylinders 5 and 7 (J8-8) 8 V Supply for the detonation sensor for cylinders 9 and 11 (J8-9) 8 V Supply for the detonation sensor for cylinders 13 and 15 (J8-10) 8 V Supply for the detonation sensor for cylinders 17 and 19 (J8-11) Return for the detonation sensor for cylinders 2 and 4 (J8-12) Return for the detonation sensor for cylinders 6 and 8 (J8-13) Return for the detonation sensor for cylinders 10 and 12 (J8-14) Return for the detonation sensor for cylinders 14 and 16 (J8-15) Return for the detonation sensor for cylinders 18 and 20 (J8-16) Return for the detonation sensor for cylinders 1 and 3 (J8-17) Return for the detonation sensor for cylinders 5 and 7 (J8-18) Return for the detonation sensor for cylinders 9 and 11 (J8-19) Return for the detonation sensor for cylinders 13 and 15 (J8-20) Return for the detonation sensor for cylinders 17 and 19 (J8-21) Signal from the detonation sensor for cylinders 2 and 4 (J8-22) Signal from the detonation sensor for cylinders 6 and 8 (J8-23) Signal from the detonation sensor for cylinders 10 and 12 (J8-24) Signal from the detonation sensor for cylinders 14 and 16 (J8-25) Signal from the detonation sensor for cylinders 18 and 20 (J8-26) Signal from the detonation sensor for cylinders 1 and 3 (J8-27) Signal from the detonation sensor for cylinders 5 and 7 (J8-28) Signal from the detonation sensor for cylinders 9 and 11 (J8-29) Signal from the detonation sensor for cylinders 13 and 15 (J8-30) Signal from the detonation sensor for cylinders 17 and 19 (J8-31) Shield for the detonation sensor for cylinders 2 and 4 (J8-32) Shield for the detonation sensor for cylinders 6 and 8 (J8-33) Shield for the detonation sensor for cylinders 10 and 12 (J8-34) Shield for the detonation sensor for cylinders 14 and 16 (J8-35) Shield for the detonation sensor for cylinders 18 and 20 (J8-36) Shield for the detonation sensor for cylinders 1 and 3 (J8-37) Shield for the detonation sensor for cylinders 5 and 7 (J8-38) Shield for the detonation sensor for cylinders 9 and 11 (J8-39) Shield for the detonation sensor for cylinders 13 and 15 (J8-40) Shield for the detonation sensor for cylinders 17 and 19 Illustration 37 Detonation sensors g01065074 d. pins. or pinch points. Expected Result: All connectors. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 8 volt sensors. and sockets are connected properly. Check the harness and wiring for abrasion and pinch points from the 8 volt sensors to the electronic control modules. The connectors and the wiring do not have corrosion. Proceed to Test Step 2. abrasion. The components are in good condition with proper connections. The connectors and the wiring do not have corrosion. . Results: • OK – All connectors.

Clear the codes after you complete this procedure. Test Step 4. B. Note: An “Open Circuit” code will be generated for each sensor that is disconnected. “Electronic Service Tools”. Disconnect the 8 Volt Sensors and Look for Active Diagnostic Codes. STOP. Proceed to Test Step 3. wait for at least 30 seconds and then observe the “Active Diagnostic” screen on Cat ET. Wait at least 30 seconds so that any codes may become activated. Check for diagnostic codes again. Proceed to Test Step 4. • No – The original “8 Volt DC Supply” diagnostic code is still active when a particular sensor is disconnected. Switch the 35 amp circuit breaker OFF. • 41-03 8 Volt DC Supply short to +batt • 41-04 8 Volt DC Supply short to ground D. Check for Diagnostic Codes A. Verify that the diagnostic code is deactivated. Repair: There may be a problem with the wiring and/or a connector. is active. 3. However. The sensor and/or the wiring for the sensor has a short circuit. B. Verify that the problem is eliminated. there is at least one logged code for the 8 volt sensor supply. Refer to Troubleshooting. Isolate the Wiring Harnesses from the Electronic Control Modules A. Set the engine control to the OFF/RESET mode. Set the engine control to the STOP mode. Observe the “Active Diagnostic” screen on Cat ET. Repair: Perform the necessary repairs and/or replace parts. Look for the same codes. • Active code – The 41-03 code or the 41-04 code • Logged code – The 41-03 code or the 41-04 code is not active. Refer to Troubleshooting. STOP. Connect Cat ET to the service tool connector. Verify that the wiring and/or connectors are OK. If these conditions are true. A. After you disconnect each sensor. Disconnect each 8 volt sensor one at a time. This is normal. Reconnect the suspect sensor. If you are troubleshooting an 8 volt problem with the master ECM. Results: Test Step 2. Disconnect the suspect sensor. Turn on the “Active Diagnostic” screen on Cat ET. The 8 volt sensor supply is operating correctly at this time. if necessary.212 Troubleshooting Section • Not OK – At least one of the connectors. if necessary. Results: • No codes – The 41-03 code or the 41-04 code is not active. • P1-4 • P2-56 • P2-57 . Verify that the diagnostic code recurs. and/or pinch points. Replace parts. Observe the “Logged Diagnostic” screen on Cat ET. Expected Result: The 41-03 code or the 41-04 code is not active. Expected Result: The original “8 Volt DC Supply” diagnostic code is deactivated when a particular sensor is disconnected. 2. “Inspecting Electrical Connectors”. B. Proceed to Test Step 3. C. At least one of the connectors and/or the wiring has corrosion. Verify that the “41-03” or “41-04” code is active. Do not reconnect the sensors. Repair: Perform the following procedure: 1. use a 151-6320 Wire Removal Tool to remove the wires from the following terminals: Test Step 3. if necessary. Clear all of the diagnostic codes. Switch the 35 amp circuit breaker ON. abrasion. Look for these codes: • Yes – The original “8 Volt DC Supply” diagnostic code is deactivated when a particular sensor is disconnected. repair the sensor or the sensor’s harness. STOP. and sockets are not connected properly. pins.

wiggle the harnesses in order to check for an intermittent problem. It is unlikely that the ECM has failed. Measure the resistance between the terminals that are listed in Table 12. perform the following steps: Temporarily install a new ECM. Switch the 35 amp circuit breaker ON. Determine if a 41-03 code or a 41-04 code is active.213 Troubleshooting Section C. If the problem is resolved with the new ECM. Exit this procedure and perform this procedure again. . Switch the 35 amp circuit breaker OFF. Pull on the wires in order to verify that the terminals are fully inserted into the connector. C. install the original ECM and verify that the problem returns. Disconnecting all of the 8 volt wiring from the ECM eliminated the active “8 Volt DC Supply” diagnostic code. “Replacing the ECM”. Pull on the wires in order to verify that the terminals are fully inserted into the connector. If you are troubleshooting an 8 volt problem with the slave ECM. use a 151-6320 Wire Removal Tool to remove the wires from the following terminals: Test Step 5. E. “Replacing the ECM”. Disconnecting all of the 8 volt wiring from the ECM did not eliminate the active “8 Volt DC Supply” diagnostic code. Table 12 • P4-56 • P4-57 D. If the new ECM operates correctly and the original ECM does not operate correctly. Refer to Troubleshooting. Insert all of the terminals that were removed.000 Ohms.000 Ohms. During each measurement. D. • Not OK – At least one check of the resistance is less than 20. Results: • OK – Each check of the resistance is greater than 20. Proceed to Test Step 5. Set the engine control to the STOP mode. Proceed to Test Step 6. B. replace the original ECM. Set the engine control to the OFF/RESET mode. There is a problem with a connector and/or at least one of the 8 volt wires in a harness.000 Ohms. Expected Result: Each check of the resistance is greater than 20. E. Insert all of the terminals that were removed. If the problem is not resolved. There may be a problem with an ECM. There is a problem in a connector and/or the wiring in a harness. Wait for at least 30 seconds and then observe the “Active Diagnostics” screen on Cat ET. STOP. The 8 volt wires and connectors on the left side of the engine do not have a short circuit. Disconnect the P1 connector and the P2 connector for the master ECM. code. Expected Result: No active codes Results: • No codes – The 41-03 code or the 41-04 code is not active. Check the Wiring Harnesses on the Left Side of the Engine A. Be sure to wiggle the wires near each of the connectors. Refer to Troubleshooting. Disconnect all of the 8 volt sensors. Switch the 35 amp circuit breaker OFF. Points for the Measurement of Resistance for the Left Side of the Engine Connector and Terminal P1-4 (8 volt supply) Connector and Terminal All of the remaining terminals on the P1 connector All of the terminals on the P2 connector P2-56 (8 volt supply) All of the remaining terminals on the P2 connector All of the terminals on the P1 connector P2-57 (8 volt supply) All of the remaining terminals on the P2 connector All of the terminals on the P1 connector • Active code – There is an active 41-03 or 41-04 Repair: Set the engine control to the OFF/RESET mode.

000 Ohms. Repair: Reconnect all of the connectors and resume normal operation. Be sure to wiggle the wires near each of the connectors. if necessary. when possible. Repair the connection and/or the wire. when possible. The -03 code is probably caused by a problem in an engine harness. The problem seems to be resolved. The engine coolant temperature sensor is a passive sensor of the analog type. STOP. or a short circuit to a positive voltage source in a harness. During each measurement. There are no diagnostic codes for the circuit of the “DESIRED SPEED” potentiometer. STOP. if necessary.000 Ohms. Results: • Potentiometer • 4-20 ma The “DESIRED SPEED” potentiometer (if equipped) must be supplied with +5 VDC from the master ECM. If the “DESIRED SPEED” potentiometer has a short circuit or the potentiometer’s wiring has a short circuit. Alternatively. The master ECM can be configured for one of these types of speed control: Points for the Measurement of Resistance for the Right Side of the Engine Connector and Terminal P4-56 (8 volt supply) Connector and Terminal All of the remaining terminals on the P4 connector All of the remaining terminals on the P4 connector P4-57 (8 volt supply) Expected Result: Each check of the resistance is greater than 20.000 Ohms. the problem may be in an engine harness. The next likely cause is a sensor problem. the problem may be in an engine harness. • OK – Each check of the resistance is greater than 20. Replace parts. a 262-03 or 262-04 diagnostic code may be activated. wiggle the harnesses in order to check for an intermittent problem. Table 13 Analog Sensor Signal SMCS Code: 5574-038 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 master Electronic Control Module (ECM). Disconnect the P3 connector and the P4 connector for the slave ECM. The 8 volt wires and connectors on the right side of the engine do not have a short circuit. The initial diagnostic code was probably caused by a poor electrical connection. STOP.214 Troubleshooting Section Repair: The problem may be inside the terminal box. Repair: The problem could be inside the terminal box. The sensor operates without a voltage supply from the master ECM. There may be an open circuit in a harness. Measure the resistance between the terminals that are listed in Table 13. The least likely cause is a problem with the master ECM. Repair the connection and/or the wire. . • Not OK – At least one check of the resistance is less than 20. i02088679 Test Step 6. Alternatively. B. Check the Wiring Harnesses on the Right Side of the Engine A. Replace parts. There is a problem with a harness on the right side of the engine.

Before you begin this procedure. Logged diagnostic codes provide a historical record. This troubleshooting procedure may generate additional diagnostic codes. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Clear the diagnostic code after the problem is resolved. The least likely cause is a problem with the master ECM. Keep your mind on correcting the cause of the original diagnostic code. The next likely cause is a sensor problem. .215 Troubleshooting Section The -04 code is probably caused by a short circuit to ground in an engine harness.

216 Troubleshooting Section Illustration 38 Schematic for the analog sensors g01065103 .

b. Switch 35 amp circuit breaker (1) to the OFF position.217 Troubleshooting Section Test Step 1. Check the torque of the allen head screws for the terminal box’s connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Thoroughly inspect each of the following connectors: . Check the torque of the allen head screws for the ECM connectors.25 ± 0. The proper torque is 2. Illustration 39 Junction box (1) 35 amp circuit breaker g01054206 Illustration 41 Harness side of the P1 connector (P1-2) 5 volt supply (P1-3) Return (P1-14) Signal for the inlet manifold air temperature (P1-16) Signal for the desired speed (P1-17) Signal for the engine oil temperature (P1-18) 5 volt supply (P1-24) Signal for the filtered engine oil pressure (P1-26) Signal for the unfiltered engine oil pressure (P1-27) Signal for the engine coolant temperature (P1-35) Return g01065104 A.25 N·m (20 ± 2 lb in). Note: For the following steps. refer to Troubleshooting. Set the engine control to the OFF/RESET mode. Illustration 40 Terminal box g01065031 (2) J1/P1 connectors for the master ECM (3) J6/P6 connectors for the customer (4) J7/P7 connectors for the harness from the 5 volt sensors B. and J7/P7 connectors a. Inspect the Electrical Connectors and Wiring • J1/P1 connectors • J6/P6. “Inspecting Electrical Connectors”.

Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the analog sensors. .218 Troubleshooting Section Illustration 42 Harness side of the J6 connector (J6-5) 5 volt supply (J6-15) Return (J6-25) Signal for desired speed (J6-35) Shield g00929111 Illustration 43 Harness side of the J7 connector g00929594 (J7-3) Signal for the inlet manifold air temperature (J7-4) Signal for the filtered engine oil pressure (J7-5) Signal for the engine oil temperature (J7-6) Signal for the unfiltered engine oil pressure (J7-7) Signal for the engine coolant temperature (J7-17) Return for the inlet manifold air temperature (J7-18) Return for the filtered engine oil pressure (J7-19) Return for the engine oil temperature (J7-20) Return for the unfiltered engine oil pressure (J7-21) Return for the engine coolant temperature (J7-31) Shield for the inlet manifold air temperature (J7-32) Shield for the filtered engine oil pressure (J7-33) Shield for the engine oil temperature (J7-34) Shield for the unfiltered engine oil pressure (J7-35) Shield for the engine coolant temperature (J7-45) 5 volt supply for the inlet manifold air temperature (J7-46) 5 volt supply for the filtered engine oil pressure (J7-47) 5 volt supply for the engine oil temperature (J7-48) 5 volt supply for the unfiltered engine oil pressure c.

STOP. and sockets are connected properly. Expected Result: All connectors. If necessary. abrasion. Check the harness and wiring for abrasion and for pinch points from the analog sensors to the master ECM. Switch the 35 amp circuit breaker ON. The connectors and the wiring do not have corrosion. Look for these codes: • 262-03 5 Volt Sensor DC Power Supply short to +batt • 262-04 5 Volt Sensor DC Power Supply short to ground Expected Result: There are no active “5 Volt Sensor DC Power Supply” diagnostic codes. if necessary. and sockets are connected properly. At least one of the connectors and/or the wiring has corrosion. Proceed to Test Step 3. Connect Cat ET to the service tool connector. B. Repair: Refer to Troubleshooting. or pinch points. pins. and/or sockets are not connected properly. C. Allow a minimum of 30 seconds for any codes to activate. d. abrasion. Refer to Troubleshooting. “+5V Sensor Supply”. Observe the “Active Diagnostic” screen on ET. Check for Diagnostic Codes for the Power Supply Illustration 44 Right side view (5) Engine oil temperature sensor (6) Unfiltered oil pressure sensor (7) Filtered oil pressure sensor g01065032 A. The components are in good condition with proper connections. Test Step 2. . STOP. Proceed to Test Step 2. return to this functional test in order to troubleshoot the analog sensor after the “+5 V Sensor Supply” diagnostic code has been resolved. pins. The connectors and the wiring do not have corrosion. • Active code – There is an active “5 Volt Sensor DC Power Supply” diagnostic code. or pinch points. Set the engine control to the STOP mode. Results: • No codes – There are no active “5 Volt Sensor DC Illustration 45 Top view (8) Engine coolant temperature sensor (9) Engine coolant pressure sensor (outlet) g01065110 Power Supply” diagnostic codes. or pinch points.219 Troubleshooting Section Results: • OK – All connectors. • Not OK – At least one of the connectors. pins. This procedure will not work when this type of code is active. “Electronic Service Tools”. abrasion. Repair: Perform the necessary repairs and/or replace parts.

replace the original sensor. STOP. Expected Result: There is an active “open/short to +batt” diagnostic code for the disconnected sensor. Proceed to Test Step 4. If the engine is running properly at this time. D. Look for an active “open/short to +batt” diagnostic code. If you are troubleshooting the sensor for engine coolant temperature. • No active codes – None of the above codes are active. there was an active “short to ground” diagnostic code for the sensor. Set the engine control to the OFF/RESET mode. Create an Open Circuit for the Sensor A. 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). “Troubleshooting Without a Diagnostic Code”. If the active “short to ground” diagnostic code recurs. After the suspect sensor was disconnected. refer to Troubleshooting. Observe the “Active Diagnostic” screen on Cat ET. there may be an intermittent problem in the harness that is causing the codes to be logged. proceed to Test Step 6.220 Troubleshooting Section Test Step 3. Wait at least 30 seconds so that any codes may become activated. . Expected Result: None of the above codes are active. • No – Before the suspect sensor was disconnected. there was an active “short to ground” diagnostic code for the sensor. Results: disconnected. “Inspecting Electrical Connectors”. Repair: Reconnect the sensor. If you are troubleshooting the sensor for engine coolant temperature. • Active “open/short to +batt” (FMI 03) – There is an active “open/short to +batt” diagnostic code. Allow a minimum of 30 seconds for any codes to activate. Verify that the code does not activate when the new sensor is installed. Look for the codes that are listed in Table 14: Table 14 • Active “short to ground” (FMI 04) – There is an active “short to ground” diagnostic code. Repair: If any of the above codes are logged and the engine is not running properly. If one of the above codes is active. B. Set the engine control to the STOP mode. After the suspect sensor was disconnected. proceed to Test Step 6. Test Step 4. Otherwise. Refer to Troubleshooting. proceed to Test Step 5. Test Step 5. Results: 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 • Yes – Before the suspect sensor was B. Check the Supply Voltage at the Sensor Connector A. Clear the logged diagnostic code from the master ECM. Verify that the suspect sensor is disconnected from the engine harness. there was an active “open/short to +batt” diagnostic code for the sensor. Otherwise. the active “open/short to +batt” diagnostic code remained. proceed to Test Step 5. Observe the “Active Diagnostic” screen on Cat ET. Disconnect the sensor that has the “short to ground” diagnostic code. C. STOP. Check for Active Analog Sensor Diagnostic Codes A.

5 VDC and 5. Set the engine control to the OFF/RESET mode. Check the Pull-Up Voltage at the Master ECM A. The 5 volt supply is present at the sensor connector.0 VDC and 7.0 VDC. STOP.5 VDC and 5. . Set the engine control to the STOP mode. insert a 7X-1710 Multimeter Probe along terminal 3. Expected Result: The voltage is between 6. Test Step 6.0 VDC and 7. or between terminals 1 and 2. when possible.5 VDC and 5.0 VDC and 7. B. Results: • OK – The voltage between terminals A and B is between 4. and the return terminal is not between 6. Results: B. At the harness side of the P1 connector. Proceed to Test Step 6. Replace parts. measure the voltage between terminals B and C. E. Refer to Troubleshooting. At the harness connector for the suspect sensor. • OK – The voltage between the signal terminal and the return terminal is between 6. The pull-up voltage that is created by the master ECM is not present at the sensor connector. Check the Pull-Up Voltage at the Sensor A.0 VDC. Expected Result: The voltage is between 4. The 5 volt supply is not present at the sensor connector.221 Troubleshooting Section Illustration 46 Harness connectors for the various sensors (A) 5 volt supply (B) Return (C) Signal g00889729 Illustration 47 Harness connectors for the various sensors (A) 5 volt supply (B) Return (C) Signal (1) Signal (2) Return g00889801 B. • Not OK – The voltage between the signal terminal Test Step 7. “Inspecting Electrical Connectors”. The pull-up voltage that is created by the master ECM is present at the sensor connector. Switch the 35 amp circuit breaker OFF. The signal wire and the return wire for the suspect sensor appear to be OK. Connect the other multimeter lead to the probe. or in the engine harness. D.5 VDC. Repair: Verify that the wiring and/or connectors are OK.0 VDC. Proceed to Test Step 7. G.5 VDC. At the harness connector for the suspect sensor. if necessary. Insert one end of the jumper wire into the open terminal of the P1 connector. measure the voltage between terminals A and B. Repair any faulty wiring and/or connectors. Proceed to Test Step 8. The 5 volts must be present at the sensor in order to continue this procedure. • Not OK – The voltage between terminals A and terminal B is not between 4. Switch the 35 amp circuit breaker ON. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P1 connector. The 5 volt wiring problem may be inside the terminal box. F. Use a jumper wire with Deutsch terminals on the ends. Verify that the suspect sensor’s connector is disconnected from the engine harness.5 VDC. Connect a multimeter lead to the end of the jumper wire that is not inserted into the connector. C. Check for diagnostic codes again.

Repair: Perform the following procedure: Set the engine control to the OFF/RESET mode. Connecting a new sensor resolved the problem. Reconnect the suspect sensor. . Verify that no diagnostic codes are activated. Allow a minimum of 30 seconds for any codes to activate. • Not OK – The active “open/short to +batt” code remains. Verify that the problem has been resolved. Measure the pull-up voltage at the master ECM. Replace any wiring and/or connectors. “Inspecting Electrical Connectors”. 4. Observe the “Active Diagnostic” screen on ET. Clear any existing diagnostic codes.0 VDC and 7. For the proper torque value for the new sensor. Switch the 35 amp circuit breaker ON. Verify that the “open/short to +batt” diagnostic code is deactivated. Expected Result: The voltage is between 6. There is a problem with the signal wire between P1 and the harness connector for the sensor. Results: Results: • OK – No diagnostic codes are activated when a good sensor is temporarily installed. Check the Operation of the Master ECM A. There may be a problem with a connector. C. if necessary. Expected Result: No diagnostic codes are activated. Install one end of the jumper wire into the terminal for the signal wire that was removed from the P1 connector. B. Install the other end of the jumper wire into terminal 19 of the P1 connector. Allow a minimum of 30 seconds for any codes to activate. STOP. Switch the 35 amp circuit breaker ON. An active “open/short to +batt” diagnostic code is generated for the sensor. Reinstall the terminal that was removed from the P1 connector. C. when possible.222 Troubleshooting Section H. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Check the Sensor sensor at the master ECM is not between 6. Verify that the signal wire for the suspect sensor has been removed from the P1 connector. Observe the “Active Diagnostic” screen on Cat ET. Verify that the wiring and/or connectors are OK. • Not OK – The pull-up voltage for the suspect Test Step 8. Proceed to Test Step 9. Test Step 9. Verify that the “open/short to +batt” diagnostic code recurs. Set the engine control to the STOP mode. Switch the 35 amp circuit breaker OFF. 3. Repair: Perform the following procedure: 1.0 VDC. A. This will replace the sensor circuit with a short circuit. Proceed to Test Step 9. • OK – The pull-up voltage for the suspect sensor at the master ECM is between 6.0 VDC. STOP. 2. Pull on the wire in order to verify proper installation of the terminal. replace the faulty sensor with the new sensor. E. Use a jumper wire that is the appropriate length with Deutsch terminals on the ends. If these conditions are true.0 VDC and 7. Set the engine control to the OFF/RESET mode. Temporarily connect a sensor that is known to be good to the engine harness. F. Clear all of the diagnostic codes. Set the engine control to the STOP mode.0 VDC. Refer to Troubleshooting. Connect the new connector. Switch the 35 amp circuit breaker OFF. B. Connecting a new sensor did not resolve the problem.0 VDC and 7. Disconnect the multimeter leads. Repair any faulty wiring and/or connectors. refer to the Specifications manual. D. Disconnect the suspect sensor. The master ECM is producing a pull-up voltage that is valid.

Results: i02088853 CAT Data Link SMCS Code: 1901-038 System Operation Description: The CAT data link is used to share information between the following components: • Master Electronic Control Module (ECM) • Slave ECM • Integrated Temperature Sensing Module (ITSM) • Service tool • Customer installed components Illustration 48 shows the information that is shared between the master ECM and the slave ECM via the CAT data link. Repair: Perform the following procedure: Set the engine control to the OFF/RESET mode. If the problem is not resolved. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Allow a minimum of 30 seconds for any codes to activate. Exit this procedure and perform this entire procedure again. Switch the 35 amp circuit breaker OFF.223 Troubleshooting Section G. “Replacing the ECM”. . Refer to Troubleshooting. Pull on the wire in order to verify proper installation of the terminal. Refer to Troubleshooting. Observe the “Active Diagnostic” screen on Cat ET. perform the following steps: Temporarily install a new master ECM. • Not OK – No active “open/short to +batt” and “short to ground” diagnostic codes were generated. STOP. “Replacing the ECM”. Reinstall the terminal that was removed from the P1 connector. If the new ECM operates correctly and the original ECM does not operate correctly. replace the ECM. STOP. Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Resume normal operation. An active “short to ground” diagnostic code is generated. • OK – Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. The initial diagnostic code was probably caused by a poor electrical connection. install the original ECM and verify that the problem returns. If the problem is resolved with the new ECM. Repair: It is unlikely that the master ECM has failed. The master ECM is operating correctly. The master ECM is not operating correctly.

The signals cannot be measured with common service tools. The signals operate at a very high frequency. If the jumper wire is disconnected. The CAT data link consists of two wires that are twisted together. Be careful not to interchange the + wire and the . or if a module has not been programmed with a flash file.wire in a connector. The most likely cause of a diagnostic code for the CAT data link are an open circuit or a short circuit. Perform this procedure for all problems that are associated with the CAT data link. the slave ECM will assume the function of a master ECM. The signals on the data link wires are a square wave type signal. Connector terminals that are not fully seated in the connector body can create an open circuit condition. The ECM that is connected to the harness reads the harness code.wire are interchanged in a connector. The CAT data link can fail if a module is not receiving power.224 Troubleshooting Section Illustration 48 Information that is shared between the master ECM and the slave ECM g00951847 Each ECM and the ITSM communicate with the Caterpillar Electronic Technician Cat ET via the CAT data link. When the suspect transformer is removed. This allows the ECM to operate as the slave ECM. Therefore. The other wire is designated as -. the engine will not start. Temporarily install a transformer that is known to be good into a cylinder. Cat ET will not communicate with any of the modules. If the engine is running. the ECM also generates a diagnostic code for the CAT data link. This can happen if there is a problem with the wiring that provides power to the module. the engine will shut down. . Unable to Service”. Harness Code for the Slave ECM The harness inside the terminal box has a jumper wire (harness code) that connects terminals J3-29 and J3-60. One wire is designated as +. If the engine is not running. A faulty ignition transformer can cause the ECM to reset. The CAT data link can fail if a module is programmed with the wrong flash file. only continuity measurements can be made on the wires for the CAT data link. Cat ET will display “Duplicate Type on data link. Verify that all modules have been programmed with the proper flash file. If this procedure does not solve the problem. the ECM will not reset. If the code is still active. there may be a faulty ignition transformer. install the good transformer into a different cylinder. When the reset occurs. The CAT data link will not operate if the + wire and the . Then check for the diagnostic code.

Set the engine control to the OFF/RESET mode. Illustration 50 Junction Box (1) 35 amp circuit breaker g01054206 Illustration 51 Terminal box (2) (3) (4) (5) (6) (7) Ground strap J5 connector for Cat ET J1/P1 connectors for the master ECM J6 connector for the customer J9/P9 connectors for the CAT data link J3/P3 connectors for the slave ECM g01065143 A. refer to Troubleshooting.225 Troubleshooting Section Illustration 49 Schematic of the CAT data link g01065141 Test Step 1. Switch 35 amp circuit breaker (1) to the OFF position. Inspect the Electrical Connectors and Wiring Note: For the following steps. . “Inspecting Electrical Connectors”.

Check the torque of the allen head screw for the ECM connectors. or pinch points. Thoroughly inspect each of the following connectors: • J1/P1 connectors • J3/P3 connectors • J5. and J9/P9 connectors • 14-pin connectors for the ITSM a. pins. d. and sockets are connected properly.25 ± 0. The connectors and the wiring do not have corrosion. Illustration 54 Harness side of the P3 connector (P3-8) CAT data link + (P3-9) CAT data link − (P3-29) Harness code (P3-60) harness code g01065147 c. b. abrasion.25 N·m (20 ± 2 lb in). The proper torque is 2. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the CAT data link. Check the torque of the allen head screws for the connectors on the terminal box. Check the harness and wiring for abrasion and for pinch points from the slave ECM to the master ECM. Expected Result: The connectors. e. J6. Check the harnesses and wiring for abrasion and for pinch points from the ITSM to the master ECM. .226 Troubleshooting Section Illustration 53 Harness side of the P1 connector (P1-8) CAT data link + (P1-9) CAT data link − g01065145 Illustration 52 g01065149 (8) ITSM (9) 14-pin connectors for the harness to the terminal box for the master ECM B. The proper torque is 6 ± 1 N·m (53 ± 9 lb in).

STOP. Verify that the engine control is in the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Refer to Troubleshooting. wiggle the wires in the harness in order to check for an intermittent problem. If any of the above codes are logged and the engine is running properly. as needed. Switch the 35 amp circuit breaker OFF. Check the continuity between terminals J3-29 and J3-60. Measure the resistance between the points that are listed in Table 15. condition and/or at least one connection is improper. there may be an intermittent problem in a connector or a wiring harness. Test Step 3. Connect Cat ET to the service tool connector. Disconnect the following connectors: • P1 connector from the master ECM • P3 connector from the slave ECM • P6 connector (if equipped) • 14-pin connector from the ITSM D. . Unable to Service”. Make repairs. Check the Wiring for the CAT Data Link A. Refer to Troubleshooting. Proceed to Test Step 2. • Not OK – At least one of the modules is not displayed on the “ECM Selector” screen. The problem seems to be resolved. B. There may be an active diagnostic code for the CAT data link. C. There are no active diagnostic codes for the CAT data link. “Electronic Service Tools”. Set the engine control to the OFF/RESET mode. There are no active diagnostic codes for the CAT data link. Test Step 2. if necessary. Verify that the jumper wire is in good condition. During each measurement. refer to Troubleshooting. Set the engine control to the STOP mode. Switch the 35 amp circuit breaker ON. B. • 0590-09 Unable to communicate with Engine ECM • 1636-09 Loss of communication with Engine #2 (Slave) • 1042-09 Unable to communicate with ITSM Note: If Cat ET displays “Duplicate Type on data link. Be sure to wiggle the wires near each of the connectors. D. Verify that the 35 amp circuit breaker is OFF. there may be a problem with the harness inside the terminal box. STOP. Expected Result: All of the modules are displayed on the “ECM Selector” screen. Set the engine control to the OFF/RESET mode. Check the CAT Data Link A. Disconnect Cat ET from the service tool connector. C. “Troubleshooting Without a Diagnostic Code”. Select the “File/Select ECM” menu on the Cat ET. “Inspecting Electrical Connectors”. Verify that all of the modules are displayed on the “ECM Selector” screen. Proceed to Test Step 3. • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts. Verify that the following diagnostic codes are not activated. Repair: If any of the above codes are logged and the engine is not running properly.227 Troubleshooting Section Results: • OK – The components are in good condition with proper connections. Results: • OK – All of the modules are displayed on the “ECM Selector” screen.

5. STOP. there may be a problem with the module that is not communicating with Cat ET. Refer to Troubleshooting. If the problem is resolved with the new module. “Electrical Power Supply”. “Replacing the ITSM”. reinstall the original module and verify that the problem returns. Refer to Troubleshooting. • P1 connector to the master ECM • P3 connector to the slave ECM • P6 connector (if equipped) • 14-pin connector to the ITSM 2. Repair: Perform the following procedure: 1.000 Ohms. It is unlikely that a module has failed. Verify that Cat ET is able to communicate with each of the modules. “Replacing the ECM” or Troubleshooting. STOP. temporarily replace the module that is not communicating. replace the original module. Expected Result: Each check of the resistance between the connectors is less than 5 Ohms.228 Troubleshooting Section Table 15 Resistance Measurements for the CAT Data Link Connector and Terminal P1-8 Connector and Terminal P3-8 J5-D J6-7 Terminal J of the 14-pin connector on the ITSM P3-8 P1-9 J5-D P3-9 J5-E J6-17 Terminal N of the 14-pin connector on the ITSM P3-9 P1-34 P1-50 J5-E Ground strap for the master ECM Ground strap for the master ECM 4. If Cat ET is unable to communicate with a module. The wiring for the CAT data link appears to be OK. Connect Cat ET to the service tool connector. Verify that the problem is resolved. Set the engine control to the STOP mode. If the problem is not resolved. Exit this procedure and perform this procedure again. If the problem is not resolved. Verify that the wiring for the CAT data link between the J6 connector and the customer’s equipment is working properly. Repair: Repair the connection and/or the wire. Refer to Troubleshooting. “Electronic Service Tools”. Each check of the resistance between the connector and the ground strap is greater than 20. there may be a problem with the supply voltage to the module. if necessary. “Replacing the ECM” or Troubleshooting. there may be a problem with the wiring for the CAT data link between the J6 connector and the customer’s equipment. 6. Refer to Troubleshooting. If the problem is not resolved. when possible. Results: • OK – Each check of the resistance for the CAT data link is within the specification. “Replacing the ITSM”. Switch the 35 amp circuit breaker ON. Connect the following connectors: • Not OK – At least one check of the resistance for the CAT data link is incorrect. If the new module works correctly and the original module does not work correctly. There is a problem with the wiring for the CAT data link. Verify that the problem is resolved. . 7. 3. Replace parts.

be sure to check the terminating resistor that is inside the terminal box. Identification on the CAN Data Link When the actuator for the bypass valve is powered up. the master ECM will activate a 1720-09 diagnostic code. The electrical connector for the actuator is designed so that the terminals for electrical power are connected before terminal N. the actuator looks for a ground on terminal N. For this reason. If there is no ground on terminal N and the actuator is powered up. CCM heartbeat. The least likely cause is a problem with the master ECM. The master ECM sends a command signal to the actuator. This scavenges any unburned gases in the components of the system during engine shutdown. Replace parts. The bypass valve is activated by an actuator. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link. The actuator opens the valve. The engine will not start. This reduces the boost pressure in the air inlet manifold. The increased speed of the engine causes the turbochargers to overspeed temporarily. If there is a ground on terminal N. The master ECM responds to a rapid increase in the speed of the engine by activating the actuator for the bypass valve. and internal fault diagnosis. Instead. Terminating resistors must be connected to each end of the CAN data link. The master Electronic Control Module (ECM) activates the actuator for the bypass valve during these conditions: If the master ECM cannot communicate with the actuator. The terminating resistors improve the communication between the devices. . The master ECM will not communicate with the actuator for the bypass valve. the actuator will have a unique identification on the CAN data link.229 Troubleshooting Section i02088898 Compressor Bypass SMCS Code: 1052-038-BV System Operation Description: A bypass valve is connected between the outlets for the turbocharger compressors and the inlets for the turbocharger compressors. the actuator for the bypass valve and the throttle actuator will have the same identification. Surging can damage the turbochargers. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve. The next likely cause is a problem with the actuator. The master ECM continuously monitors the speed of the engine. Make repairs. when possible. This is called a turbocharger surge. Engine Shutdown Engine shutdown occurs when the output for the fuel control relay is OFF and the engine RPM is above 100. The valve allows the compressed air/fuel mixture in the aftercooler’s inlet to flow into the intake of the turbocharger’s compressor. if necessary. A 1720-09 diagnostic code is probably caused by a problem with an electrical connector or a harness. software version. The actuator sends the following information to the master ECM: actuator position. • Turbocharger surge • Engine shutdown Turbocharger Surge A rapid drop in the output power of the generator can cause the engine’s speed to quickly increase. the master ECM activates a 1720-09 diagnostic code and the engine is shut down. The master ECM activates the actuator for the bypass valve until the engine RPM drops to zero. CAN Data Link The master ECM and the actuator communicate via the CAN data link. electrical power must be removed before the connector for the actuator is connected.

230 Troubleshooting Section Illustration 55 Schematic for the circuit of the actuator for the bypass valve g01065173 .

Set the engine control to the OFF/RESET mode. Illustration 58 g01065176 Note: For the following steps. The proper torque is 2. b.231 Troubleshooting Section Test Step 1. Harness side of the P1 connector (P1-34) CAN data link − (P1-42) CAN shield (P1-50) CAN data link + Illustration 57 Terminal box (2) (3) (4) (5) g01065175 g00934039 Ground strap J1/P1 connectors for the master ECM J9/P9 connectors for the CAN data link J10/P10 connectors for the terminating resistor for the CAN data link Illustration 59 Harness side of the J9 connector (J9-6) CAN data link + (J9-12) CAN data link − (J9-18) CAN shield . Check the torque of the allen head screw for the ECM connectors. Thoroughly inspect each of the following connectors: • J1/P1 connectors • J9/P9 connectors • Connectors on the actuator for the bypass valve a. Inspect the Electrical Connectors and Wiring B. Illustration 56 Junction box (1) 35 amp circuit breaker g01054206 A. “Inspecting Electrical Connectors”. Check the torque of the allen head screws for the connectors on the terminal box.25 ± 0. refer to Troubleshooting.25 N·m (20 ± 2 lb in). The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Switch 35 amp circuit breaker (1) to the OFF position.

However. Illustration 60 Right side views g00935459 d. Expected Result: The 1720-09 code is not active. Switch the 35 amp circuit breaker ON. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the actuator for the bypass valve. Ensure that the connectors are properly engaged. Use Cat ET in order to determine if a 1720-09 diagnostic code is active. Set the engine control to the STOP mode.232 Troubleshooting Section c. Proceed to Test Step 2. diagnostic codes may be logged. abrasion. Expected Result: All of the connectors. or pinch points. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. . C. Test Step 2. Repair: If you are troubleshooting an intermittent problem. if necessary. Verify that the repair has eliminated the original problem. pins. and sockets are connected properly. STOP. refer to Troubleshooting. Results: • OK – The components are in good condition with proper connections. The • Not OK – The components are not in good communication between the master ECM and the actuator for the bypass valve appears to be OK at this time. Results: B. Repair: Perform the necessary repairs and/or replace parts. “Inspecting Electrical Connectors”. The connectors and the wiring do not have corrosion. Check for a Diagnostic Code A. • OK – The 1720-09 code is not active. Ensure that all of the seals are properly installed. Check the wiring for abrasion and for pinch points from the actuator for the bypass valve to the master ECM. condition and/or at least one connection is improper.

STOP. Table 17 Points to Check for Continuity Connector and Terminal P1-34 P1-50 P1-42 Harness Connector for the Actuator for the Bypass Valve Terminal “B” (CAN data link −) Terminal “A” (CAN data link +) Terminal “M” (CAN shield) Points to Check for Continuity Connector and Terminal P1-34 (CAN data link −) Connector and Terminal P1-50 (CAN data link +) P1-42 (CAN shield) P1-52 (+ Battery) Ground strap for the ECM P1-42 (CAN shield) P1-52 (+ Battery) Ground strap for the ECM P1-52 (+ Battery) Ground strap for the ECM Expected Result: The continuity of the circuits between the terminals is good. Set the engine control to the OFF/RESET mode. STOP. if necessary. . the open circuit could be caused by one of the following components: • The harness inside the terminal box • The harness between the terminal box and the fuel metering valve • The harness between the fuel metering valve and the throttle actuator • Not OK (Active 1720-09) – The master ECM has detected a problem with the communication between the master ECM and the actuator for the bypass valve. Be sure to wiggle the harness near each of the connectors. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link. wiggle the harnesses in order to check for an intermittent problem with the harness. Alternatively. • The harness between the throttle actuator and the actuator for the bypass valve • The fuel metering valve • The throttle actuator Make repairs. The terminating resistors improve the communication between the devices. Switch the 35 amp circuit breaker OFF. when possible. There is an open circuit for the CAN data link between the actuator for the bypass valve and the master ECM. Repair: The open circuit could be caused by a poor electrical connection in a connector. During each measurement. C. if necessary. Be sure to wiggle the harness near the fuel metering valve and the throttle actuator. Test Step 3. Expected Result: All of the measurements indicate an open circuit. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve. when possible. B. Disconnect the P1 connector. Check the CAN Data Link for a Short Circuit A. be sure to check the terminating resistor that is inside the terminal box.233 Troubleshooting Section Terminating resistors must be connected to each end of the CAN data link. Disconnect the connector for the actuator for the bypass valve. Replace parts. Table 16 Test Step 4. Be sure to wiggle the harness near the fuel metering valve and the throttle actuator. Use a multimeter to check for continuity between the points that are listed in Table 16. Results: P1-50 (CAN data link +) P1-42 (CAN shield) • OK – The continuity of the circuits between the terminals is good. wiggle the harnesses in order to check for an intermittent problem with the harness. • OK – All of the measurements indicate an open circuit. Make repairs. The CAN data link does not have a short circuit. Use a multimeter to check for continuity between the points that are listed in Table 17. Check the CAN Data Link for Continuity Between the Actuator for the Bypass Valve and the Master ECM A. Proceed to Test Step 4. During each measurement. Be sure to wiggle the harness near each of the connectors. Proceed to Test Step 3. B. Results: • Not OK – At least one of the continuity checks indicates an open circuit. Replace parts. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF.

3. Temporarily install a new master ECM. Check for a Diagnostic Code A. Temporarily install a new actuator for the bypass valve. If the problem is not resolved with a new ECM. Results: • OK – The 1720-09 code is not active. the problem is resolved. If the new throttle actuator operates correctly. Refer to Troubleshooting. If the new actuator for the bypass valve operates correctly. the problem is resolved. install the original ECM. Temporarily install a new fuel metering valve. “Inspecting Electrical Connectors”. Repair: If there is an intermittent problem that is causing the code to be logged.234 Troubleshooting Section Repair: Reconnect the P1 connector. If the new throttle actuator does not operate correctly. If the 1720-09 code remains active. STOP. install the original ECM and verify that the problem returns. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. If the new fuel metering valve does not operate correctly. Reconnect the connector for the actuator for the bypass valve. Continue with this procedure. install the original fuel metering valve. The problem seems to be resolved. Use Cat ET in order to determine if a 1720-09 diagnostic code is active. Test Step 5. Exit this procedure and perform this procedure again. If the new actuator for the bypass valve does not operate correctly. Alternatively. when possible. Repair: The active 1720-09 code could be caused by one of the following components: • The master ECM • The throttle actuator • The actuator for the bypass valve • The fuel metering valve It is unlikely that any of the components that are listed above have failed. “Replacing the ECM”. Expected Result: The 1720-09 code is not active. “Replacing the ECM”. Refer to Troubleshooting. B. “Inspecting Electrical Connectors”. 4. Repair: The short circuit could be caused by a poor electrical connection in a connector. if necessary. Replace parts. Temporarily install a new actuator for the throttle actuator. If the problem is resolved with the new ECM. Refer to Troubleshooting. the short circuit could be caused by one of the following components: • The harness inside the terminal box • The harness between the terminal box and the fuel metering valve • The harness between the fuel metering valve and the throttle actuator • The harness between the throttle actuator and the actuator for the bypass valve • The fuel metering valve • The throttle actuator Make repairs. If the new fuel metering valve operates correctly. If the new ECM operates correctly and the original ECM does not operate correctly. replace the original ECM. The initial diagnostic code was probably caused by a poor electrical connection. perform the following procedure: 1. STOP. Proceed to Test Step 5. • Not OK – The 1720-09 code is active. refer to Troubleshooting. install the original throttle actuator and continue with this procedure. STOP. install the original actuator for the bypass valve and continue with this procedure. . the problem is resolved. 2. • Not OK – At least one of the measurements indicate a short circuit.

Clear the diagnostic codes after the problem is resolved. Current values that are greater than 22. The master Electronic Control Module (ECM) cannot be configured to accept a PWM input signal for control of the engine speed. If the “Desired Speed Input” is set to “0-5 VDC Input”. The value of the current corresponds to a range of desired engine speeds between minimum high idle and maximum high idle. The least likely cause is a problem with the master ECM. Before you begin this procedure. The next likely cause is a problem with a component.0 mA will activate the “524-04 Desired Engine Speed Sensor short to ground” diagnostic code. When the desired speed input is correspondingly configured. Current values that are less than 2. Keep your mind on correcting the cause of the original diagnostic code. The selection of the “4-20 mA Input” setting requires a 4 to 20 mA signal for regulation of the desired engine speed. Illustration 61 Schematic of the 4 to 20 mA desired speed input g01065191 Test Step 1. The troubleshooting procedure may generate additional diagnostic codes. The “Minimum Engine High Idle Speed” and the “Maximum Engine High Idle Speed” are set with the “Service/Configuration” screen of ET. 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).0 mA corresponds to “Maximum Engine High Idle Speed”. For more information. do not use this procedure to troubleshoot the circuit. When the “Idle/Rated” switch is in the Rated position. refer to Troubleshooting.0 mA will activate the “524-03 Desired Engine Speed Sensor short to +batt” diagnostic code. “Electronic Control System Parameters”. Set the engine control to the OFF/RESET mode. the master ECM controls the engine speed according to the 4 to 20 mA current. use ET to print the logged codes to a file.235 Troubleshooting Section i02088933 Desired Speed Input (4 . A current value of 20. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. a current value of 4. refer to Systems Operation/Testing and Adjusting.20 mA) SMCS Code: 1901-038 System Operation Description: Note: For this troubleshooting procedure. 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”. Note: For the following steps. Inspect the Electrical Connectors and Wiring Illustration 62 Junction box (1) 35 amp circuit breaker g01054206 A. Do not select “PWM”. Logged diagnostic codes provide a historical record.0 mA corresponds to the programmed “Minimum Engine High Idle Speed”. . “Inspecting Electrical Connectors”. Switch 35 amp circuit breaker (1) to the OFF position.

The proper torque is 2. Check the torque of the allen head screw for the ECM connectors. or pinch points. pins.25 N·m (20 ± 2 lb in). Expected Result: All connectors. Thoroughly inspect the following components: • J1/P1 connectors • J6/P6 connectors • Wiring and the connections between the terminal box and the device that supplies the 4 to 20 mA signal a.Signal g00929720 c. . d. Check the torque of the allen head screws for the terminal box’s connectors.25 ± 0.Signal g00905060 Illustration 63 Terminal box (2) Ground strap (3) J1/P1 connectors for the master ECM (4) J6/P6 connectors for the customer g01065192 B. and sockets are connected properly. Illustration 65 Harness side of the J6 connector (J6-37) + Signal (J6-27) . b. Check the harness and wiring for abrasion and for pinch points between the device that supplies the 4 to 20 mA signal and the master ECM. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the 4 to 20 mA circuit. The connectors and the wiring do not have corrosion. The proper torque is 6 ± 1 N·m (55 ± 9 lb in).236 Troubleshooting Section Illustration 64 Harness side of the P1 connector (P1-36) + Signal (P1-37) . abrasion.

Use an ohmmeter to measure the resistance between terminals P1-36 and P1-57 on the ECM side of the P1 connector. proceed to Test Step 5. . Repair the connection and/or the wire. Use an ohmmeter to measure the resistance between the ground strap for the master ECM and terminal P1-37. Disconnect the P1 connector from the master ECM. Make sure that the leads of the wires for the 4 to 20 mA signal do not create a short circuit. Repair: Remove the jumper wire. Remove the two wires (“+” and “-”) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal. The circuit is not open. the problem may be between the P6 connector and the device that provides the 4 to 20 mA signal. Install a jumper wire between the two wires (“+” and “-”) that were removed from the device that supplies the 4 to 20 mA signal. Use an ohmmeter to measure the resistance between terminals P1-36 and P1-37 on the ECM side of the P1 connector. Check for a Short Circuit to the +Battery at Terminal P1-36 A. C. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. if necessary. If you are troubleshooting a “524-03 Desired Engine Speed Sensor short to +batt” diagnostic code. if necessary. • No – The resistance is less than 20.000 Ohms. Expected Result: The resistance is greater than 20. Verify that the problem is resolved. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal. Alternatively. Repair: The problem may be between the P1 connector and the J6 connector. B. STOP. C. D. Expected Result: The resistance is greater than 20. The wiring from terminal P1-36 is not shorted to the +Battery side. Verify that the problem is resolved. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. B. Test Step 4. Repair: The problem may be between the P1 connector and the J6 connector. if necessary. There is a problem with a connector and/or the wiring from the P1 connector. There is a problem with a connection and/or the wiring from terminal P1-36. C. Test Step 3. Test Step 2. when possible. Replace parts. B. Replace parts. proceed to Test Step 2. Check for an Open Circuit A.000 Ohms.000 Ohms. Proceed to Test Step 3. Repair the connection and/or the wire. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. Proceed to Test Step 4. Alternatively. • OK – The resistance is less than 5 Ohms.000 Ohms. Do not reconnect any connectors. Check for a Short to Ground at Terminal P1-37 A. the problem may be between the J6 connector and the device that provides the 4 to 20 mA signal. • Not OK – The resistance is greater than 5 Ohms. STOP. Expected Result: The resistance is less than 5 Ohms. STOP. If you are troubleshooting a “524-04 Desired Engine Speed Sensor short to ground” diagnostic code. condition and/or at least one connection is improper. when possible.237 Troubleshooting Section Results: • OK – The components are in good condition with proper connections. Results: • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts. Results: • Yes – The resistance is greater than 20.

Proceed to Test Step 6. STOP.000 Ohms. Repair the connection and/or the wire. Results: Test Step 5. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF.000 Ohms. D. • No – The resistance is less than 20. B.000 Ohms. Verify that the problem is resolved. Verify that the problem is resolved. Verify that the problem is resolved. Repair: The problem may be between the P1 connector and the J6 connector.000 Ohms. when possible. the problem may be between the P6 connector and the device that provides the 4 to 20 mA signal. E. if necessary. STOP. Replace parts. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. Proceed to Test Step 7. Alternatively. The wiring from terminal P1-37 is not shorted to the +Battery side. Expected Result: The resistance is greater than 20. Repair: The problem may be between the P1 connector and the J6 connector. There is a problem with a connection and/or the wiring that is connected to P1-37. C. • Yes – The resistance is greater than 20. Expected Result: The resistance is greater than 20. Test Step 7. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal. Repair the connection and/or the wire. . • No – The resistance is less than 20. Reconnect the two wires (“+” and “-”) for the 4 to 20 mA signal to the device that supplies the 4 to 20 mA signal. Check for a Short Circuit to the +Battery Side at Terminal P1-37 A. Verify that the correct signal is provided to the master ECM. Remove the two wires (“+” and “-”) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal. if necessary. 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. Use an ohmmeter to measure the resistance between ground strap (2) and terminal P1-36. • No – The resistance is less than 20. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. C.238 Troubleshooting Section Results: • Yes – The resistance is greater than 20. Repair: Reconnect the P1 connector. B. Alternatively. Replace parts. Results: • Yes – The resistance is greater than 20. Do not reconnect any connectors. There is a problem with a connection and/or the wiring from terminal P1-36. Alternatively. There is a problem with a connection and/or the wiring from terminal P1-37.000 Ohms.000 Ohms. Check for a Short Circuit to Ground at Terminal P1-36 A. the problem may be between the J6 connector and the device that provides the 4 to 20 mA signal. Verify the correct 4 to 20 mA signal at terminals P1-36 and P1-37. Test Step 6. the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. The wiring from terminal P1-36 appears to be OK. Use an ohmmeter to measure the resistance between terminals P1-37 and P1-57. Repair: The problem may be between the P1 connector and the J9 connector. Disconnect the P1 connector from the master ECM.000 Ohms. STOP.000 Ohms. Locate the wire with the short circuit and replace the wire. The wiring from terminal P1-37 appears to be OK. Do not reconnect any connectors. Proceed to Test Step 7. when possible. Make sure that the ends of the wires for the 4 to 20 mA signal do not create a short circuit.

• No – The master ECM is not receiving the correct 4 to 20 mA signal. Detonation protection is disabled when the engine speed is less than 250 rpm. Each sensor monitors two adjacent cylinders. if necessary. The master ECM monitors the detonation sensors on the left side of the engine. The signal is amplified and the signal is filtered. The rate of advance is based upon the level of detonation. There is probably a problem with the device that provides the 4 to 20 mA. Repair: It is unlikely that the master ECM is faulty. The fastest rate of proportional timing advance is one degree per minute. to the +Battery side. Repair: Service the device that provides the 4 to 20 mA according to the literature that is provided by the OEM of the device. STOP. The timing can be retarded up to six degrees for severe detonation. An input from a detonation sensor that is diagnosed by an ECM as “open/shorted to +battery” may measure 0 VDC on a voltmeter. The timing may be retarded for a single cylinder or for more than one cylinder. Therefore. Exit this procedure and perform this procedure again. The rate is faster for lighter detonation. Each ECM will diagnose the detonation sensors for a signal that is shorted to the −Battery side. If the timing has been retarded by the maximum amount and the level of detonation remains high. Verify that the problem is resolved. The master ECM can retard the timing of the cylinders on the left side of the engine in order to limit detonation levels. Results: • Yes – The correct 4 to 20 mA signal is provided to the master ECM. replace the master ECM according to Troubleshooting. the master ECM will shut down the engine. A proportional strategy is used for advancing the timing after the timing has been retarded. If retardation of the timing does not sufficiently limit the detonation. Verify that the problem is resolved. or for an open circuit. each ECM only monitors a detonation sensor when one of the pistons that is monitored by that sensor is between top center and 40 degrees after top center on the power stroke. The slave ECM can retard the timing of the cylinders on the right side of the engine in order to limit detonation levels. If the problem is not resolved. The frequency of the signal corresponds to the mechanical frequency of the vibrations. the “Block Tap” method of testing the detonation sensors does not work for the G3500C Engine. i02089065 Detonation Sensors SMCS Code: 1559-038 System Operation Description: Detonation sensors are located on the upper cylinder block between every two cylinders. the minimum allowable actual timing is ten degrees BTC (five degrees BTC for propane operation). STOP. However. The master Electronic Control Module (ECM) and the slave ECM supply 8 VDC in order to power the sensors. the master ECM is not responding correctly to the signal. An ECM can retard timing by as few as three degrees for light detonation levels. one sensor monitors cylinders 1 and 3 and one sensor monitors cylinders 2 and 4. For example. There may be a problem with the master ECM. Each sensor outputs an electrical signal. To avoid detecting vibrations that are not related to detonation. Each ECM monitors the signals in order to determine the presence and the severity of the detonation. The slave ECM monitors the detonation sensors on the right side of the engine. This is caused by the lack of pull up resistors in the detonation sensor’s circuits inside the ECM. For most applications. The timing may be retarded for all of the cylinders. the master ECM will shut down the engine.239 Troubleshooting Section Expected Result: The correct 4 to 20 mA signal is provided to the master ECM. “Replacing the ECM”. The amplitude of the signal is proportional to the intensity of the vibrations. Each ECM also supports related event codes when the levels of detonation warrant a reaction from the ECM. The detonation sensors provide electrical signals to the modules that indicate mechanical engine vibrations. Illustration 66 Arrangement of the detonation sensors g00951975 .

use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Before you begin this procedure. Keep your mind on correcting the cause of the original diagnostic code. The troubleshooting procedure may generate additional diagnostic codes. The least likely cause is a problem with an ECM. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. Clear the diagnostic codes after the problem is resolved. The next likely cause is a problem with a sensor.240 Troubleshooting Section Logged diagnostic codes provide a historical record. .

241 Troubleshooting Section Illustration 67 Schematic for the detonation sensors g01065289 .

Illustration 70 Harness side of the side of the P2 connector (P2-36) Detonation sensor signal for cylinders 2 and 4 (P2-37) Detonation sensor signal for cylinders 6 and 8 (P2-38) Detonation sensor signal for cylinders 10 and 12 (P2-39) Detonation sensor signal for cylinders 14 and 16 (P2-44) Detonation sensor signal for cylinders 18 and 20 (P2-54) Return for the detonation sensors (P2-55) Returnfor the detonation sensors (P2-56) +8 V supplyfor the detonation sensors (P2-57) +8 V supplyfor the detonation sensors g01065071 Illustration 69 Terminal box (2) J2/P2 connectors for the master ECM (3) J8/P8 connectors for the detonation sensors (4) J4/P4 connectors for the slave ECM g01065290 .25 N·m (20 ± 2 lb in).25 ± 0. refer to Troubleshooting. Switch 35 amp circuit breaker (1) to the OFF position. The proper torque is 2. Thoroughly inspect each of the following connectors: • J2/P2 connectors • J8/P8 connectors • J4/P4 connectors • Connectors for each of the detonation sensors a. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Set the engine control to the OFF/RESET mode. Check the torque of the allen head screw for the ECM connectors. Note: For the following steps. Check the torque of the allen head screws for the connectors on the terminal box. b. “Inspecting Electrical Connectors”.242 Troubleshooting Section Test Step 1. Inspect the Electrical Connectors and Wiring B. Illustration 68 Junction box (1) 35 amp circuit breaker g01054206 A.

or pinch points. Expected Result: All connectors. Check the harness and wiring for abrasion and for pinch points from the detonation sensors to each ECM. Make sure that the detonation sensors are properly installed according to the torque in Specifications. “Detonation Sensors”. pins. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the detonation sensors.243 Troubleshooting Section Illustration 72 Harness side of the P4 connector for the slave ECM g01065071 Illustration 71 Harness side of the J8 connector g00929380 (J8-1) 8 V Supply for the detonation sensor for cylinders 2 and 4 (J8-2) 8 V Supply for the detonation sensor for cylinders 6 and 8 (J8-3) 8 V Supply for the detonation sensor for cylinders 10 and 12 (J8-4) 8 V Supply for the detonation sensor for cylinders 14 and 16 (J8-5) 8 V Supply for the detonation sensor for cylinders 18 and 20 (J8-6) 8 V Supply for the detonation sensor for cylinders 1 and 3 (J8-7) 8 V Supply for the detonation sensor for cylinders 5 and 7 (J8-8) 8 V Supply for the detonation sensor for cylinders 9 and 11 (J8-9) 8 V Supply for the detonation sensor for cylinders 13 and 15 (J8-10) 8 V Supply for the detonation sensor for cylinders 17 and 19 (J8-11) Return for the detonation sensor for cylinders 2 and 4 (J8-12) Return for the detonation sensor for cylinders 6 and 8 (J8-13) Return for the detonation sensor for cylinders 10 and 12 (J8-14) Return for the detonation sensor for cylinders 14 and 16 (J8-15) Return for the detonation sensor for cylinders 18 and 20 (J8-16) Return for the detonation sensor for cylinders 1 and 3 (J8-17) Return for the detonation sensor for cylinders 5 and 7 (J8-18) Return for the detonation sensor for cylinders 9 and 11 (J8-19) Return for the detonation sensor for cylinders 13 and 15 (J8-20) Return for the detonation sensor for cylinders 17 and 19 (J8-21) Signal from the detonation sensor for cylinders 2 and 4 (J8-22) Signal from the detonation sensor for cylinders 6 and 8 (J8-23) Signal from the detonation sensor for cylinders 10 and 12 (J8-24) Signal from the detonation sensor for cylinders 14 and 16 (J8-25) Signal from the detonation sensor for cylinders 18 and 20 (J8-26) Signal from the detonation sensor for cylinders 1 and 3 (J8-27) Signal from the detonation sensor for cylinders 5 and 7 (J8-28) Signal from the detonation sensor for cylinders 9 and 11 (J8-29) Signal from the detonation sensor for cylinders 13 and 15 (J8-30) Signal from the detonation sensor for cylinders 17 and 19 (J8-31) Shield for the detonation sensor for cylinders 2 and 4 (J8-32) Shield for the detonation sensor for cylinders 6 and 8 (J8-33) Shield for the detonation sensor for cylinders 10 and 12 (J8-34) Shield for the detonation sensor for cylinders 14 and 16 (J8-35) Shield for the detonation sensor for cylinders 18 and 20 (J8-36) Shield for the detonation sensor for cylinders 1 and 3 (J8-37) Shield for the detonation sensor for cylinders 5 and 7 (J8-38) Shield for the detonation sensor for cylinders 9 and 11 (J8-39) Shield for the detonation sensor for cylinders 13 and 15 (J8-40) Shield for the detonation sensor for cylinders 17 and 19 (P4-36) Detonation sensor signal for cylinders 1 and 3 (P4-37) Detonation sensor signal for cylinders 5 and 7 (P4-38) Detonation sensor signal for cylinders 9 and 11 (P4-39) Detonation sensor signal for cylinders 13 and 15 (P4-44) Detonation sensor signal for cylinders 17 and 19 (P4-54) Return for the detonation sensors (P4-55) Return for the detonation sensors (P4-56) 8 volt supply for the detonation sensors (P4-57) 8 volt supply for the detonation sensors c. The connectors and the wiring do not have corrosion. e. abrasion. Illustration 73 Detonation sensors g00929792 d. . and sockets are connected properly. All of the detonation sensors are properly installed.

STOP. Switch the 35 amp circuit breaker ON. Proceed to Test Step 3. Allow a minimum of 30 seconds for any diagnostic codes to become active. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. Test Step 3. Connect Cat ET to the service tool connector. the engine must be running. Observe the “Active Diagnostic” screen of Cat ET. Observe the “Active Diagnostic” screen of Cat ET and look for the diagnostic codes that are listed in Table 18: • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts. B. Refer to Troubleshooting. 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. STOP. Proceed to Test Step 2. C. • Not OK – At least one of the “8 Volt DC Supply” Repair: The “8 Volt DC Supply” diagnostic code must be resolved before you can proceed with this functional test. B. Results: • OK – Neither of the “8 Volt DC Supply” diagnostic codes are active. Set the engine control to the STOP mode.244 Troubleshooting Section Results: • OK – The components are in good condition with proper connections. Therefore. “Electronic Service Tools”. Exit this procedure and refer to Troubleshooting. Check for Diagnostic Codes for the 8 Volt DC Supply A. “+8V Sensor Voltage Supply”. Look for these codes: • “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. return to this functional test in order to troubleshoot the detonation sensor after the “8 Volt DC Supply” diagnostic code has been resolved. A. Test Step 2. . condition and/or at least one connection is improper. If necessary. diagnostic codes is active. if necessary. Start the engine and run the engine. Wait at least 30 seconds so that any codes may become activated.

there may be an intermittent problem in a connector or a wiring harness. The original diagnostic code was probably caused by a poor electrical connection in one of the harness connectors. Set the engine control to the STOP mode. Switch the 35 amp circuit breaker OFF. STOP. Disconnect the detonation sensor with the diagnostic code. 17 and 19 18 and 20 Illustration 74 Harness connector for the detonation sensors (A) 8 volt supply (B) Return (C) Signal g00890518 Note: A “short to ground” diagnostic code can indicate either an actual short to ground or an open circuit. Set the engine control to the OFF/RESET mode. D. Refer to Troubleshooting. 2 and 4 5 and 7 6 and 8 • Not OK (Active Code) – A “short to +batt” or “short to ground” diagnostic code was activated. refer to Troubleshooting. Measure the voltage between terminals A and B on the harness connector for the sensor. Verify the Presence of the Supply Voltage at the Sensor A. “Troubleshooting Without a Diagnostic Code”. Switch the 35 amp circuit breaker ON. 13 and 15 14 and 16 C. 10 and 12 Test Step 4. Repair: If any of the above codes are logged and the engine is not running properly.245 Troubleshooting Section Table 18 Results: Description Cylinder #1 Detonation Sensor short to +batt Cylinder #1 Detonation Sensor short to ground Cylinder #2 Detonation Sensor short to +batt 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 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 Cylinder #17 Detonation Sensor short to +batt Cylinder #17 Detonation Sensor short to ground Cylinder #18 Detonation Sensor short to +batt Cylinder #18 Detonation Sensor short to ground Cylinders Code 1501-03 1501-04 1502-03 1502-04 1505-03 1505-04 1506-03 1506-04 1509-03 1509-04 1510-03 1510-04 1513-03 1513-04 1514-03 1514-04 1517-03 1517-04 1518-03 1518-04 • OK (No active codes) – None of the above codes 1 and 3 are active at this time.6 VDC and 8. Expected Result: The voltage is between 7. If any of the above codes are logged and the engine is running properly. “Inspecting Electrical Connectors”. 9 and 11 Repair: Note the diagnostic code and note the location of the suspect detonation sensor. Expected Result: None of the above diagnostic codes are active. The problem seems to be resolved.4 VDC. . B. Proceed to Test Step 4.

Verify that the problem is resolved. Tighten the detonation sensor according to the torque in Specifications. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P2 connector. Check the Operation of the Master ECM A. Test Step 6.6 VDC and 8. STOP. Start the engine.4 VDC. Observe the “Active Diagnostic” screen on Cat ET. • Not OK – The voltage is not between 7. Therefore. E. if necessary.6 VDC. Expected Result: The voltage is between 0.4 VDC and 0. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. Measure the voltage between terminals B and C on the harness connector for the suspect sensor. Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated.4 VDC. STOP. Replace the harness. If you are troubleshooting a detonation sensor for the master ECM. Test Step 5. there is probably a short circuit to a +Battery source between the connector for the detonation sensor and the ECM. Repair: Reconnect the suspect sensor. The correct voltage is available to the sensor. Results: • Yes – The voltage is between 0. If you are troubleshooting a detonation sensor for the slave ECM. Proceed to Test Step 5. D. there is probably a short to ground or an open circuit between the connector for the detonation sensor and the ECM. 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.4 VDC. Start the engine again and check for the diagnostic code.246 Troubleshooting Section Results: • No – The voltage is not between 0. the engine must be running. replace the detonation sensor with a known good detonation sensor. Set the engine control to the STOP mode. Set the engine control to the OFF/RESET mode.8 VDC.6 VDC. proceed to Test Step 6. Do not reconnect the sensor. Switch the 35 amp circuit breaker OFF.4 VDC and 0. . Repair the electrical connection and/or the wiring. Allow a minimum of 30 seconds for any codes to activate. If the voltage is less than 0. There is probably an open circuit in the 8 volt supply or in the return for the sensor. Measure the Voltage of the Signal Wire at the Sensor Illustration 75 Harness connector for the detonation sensors (A) 8 volt supply (B) Return (C) Signal g00890518 A. If the voltage is greater than 4.6 • OK – The voltage is between 7. B. when possible. The correct voltage is not available to the sensor. C. proceed to Test Step 7. An active “open/short to +batt” diagnostic code is generated for the sensor. Switch the 35 amp circuit breaker ON.4 VDC and 0. “Detonation Sensor”.6 VDC and VDC. 8. If the diagnostic code recurs. Set the engine control to the OFF/RESET mode. This will replace the sensor circuit with an open circuit.

D. Set the engine control to the STOP mode.247 Troubleshooting Section Repair: Remove the jumper wire. Illustration 76 Master ECM with jumper wire (1) P2 connector (2) P1 connector (3) Jumper wire g01065294 If the problem is resolved with the new ECM. Exit this procedure and perform this procedure again. Fabricate a jumper wire that is long enough to reach between the P1 connector and the P2 connector. when possible. the engine must be running. Refer to Troubleshooting. Start the engine. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. E. F. perform the following steps: Temporarily install a new master ECM. “Replacing the ECM”. Pull on the wire in order to verify that the terminal is fully inserted into the connector. install the original ECM and verify that the problem returns. replace the original ECM. • OK – Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. G. Therefore. If the new ECM operates correctly and the original ECM does not operate correctly. Insert the terminal that was removed from the P2 connector. Refer to Troubleshooting. STOP. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P4 connector. Allow a minimum of 30 seconds for any codes to activate. An active “short to ground” diagnostic code is generated for the sensor. There is probably an open circuit in a harness between the master ECM and the connector for the sensor. Start the engine. “Replacing the ECM”. Observe the “Active Diagnostic” screen on Cat ET. Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. The master ECM is operating correctly. C. The master ECM is not operating correctly. Switch the 35 amp circuit breaker OFF. Install the other end of the jumper wire into terminal 19 of the P1 connector (2). if necessary. Set the engine control to the OFF/RESET mode. Allow a minimum of 30 seconds for any codes to activate. This will replace the sensor circuit with an open circuit. Set the engine control to the OFF/RESET mode. This will replace the sensor circuit with a short circuit to ground. STOP. Repair the harness. Observe the “Active Diagnostic” screen on Cat ET. Repair: It is unlikely that the master ECM has failed. B. An active “open/short to +batt” diagnostic code is generated for the sensor. If the problem is not resolved. Install Deutsch terminals on the ends. Install one end of jumper wire (3) into the terminal for the signal wire that was removed from the P2 connector (1). Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Check the Operation of the Slave ECM A. Replace the harness. • Not OK – No active “open/short to +batt” and “short to ground” diagnostic codes were generated. . Results: Test Step 7. Switch the 35 amp circuit breaker ON.

• Not OK – No active “open/short to +batt” and “short to ground” diagnostic codes were generated. If the new ECM operates correctly and the original ECM does not operate correctly. Refer to Troubleshooting. Exit this procedure and perform this procedure again. the relay for the Gas Shutoff Valve (GSOV) must be energized. This stops the fuel flow. Install the other end of the jumper wire into terminal 19 of the P3 connector (2). when possible. The logic for starting and stopping is customer programmable. Insert the terminal that was removed from the P4 connector. and other inputs. “Replacing the ECM”. install the original ECM and verify that the problem returns. i02089084 F. . • OK – Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. perform the following steps: Temporarily install a new slave ECM. STOP. STOP. Repair the harness. replace the original ECM. if necessary. To enable fuel flow to the engine. remote start switch. The slave ECM is not operating correctly. Results: ECM Output Circuit (Fuel Control) SMCS Code: 1901-038 System Operation Description: The master Electronic Control Module (ECM) contains the logic and the outputs for starting and stopping the engine. Refer to Troubleshooting. Replace the harness. The master ECM provides +Battery voltage to the relay for the GSOV when the logic determines that fuel is required for engine operation. The slave ECM is operating correctly. If the problem is not resolved. This will replace the sensor circuit with a short circuit to ground. Start the engine. Pull on the wire in order to verify that the terminal is fully inserted into the connector. Install one end of jumper wire (3) into the terminal for the signal wire that was removed from the P4 connector (1). The fuel control relay is energize-to-run. data link. emergency stop switch.248 Troubleshooting Section Repair: Remove the jumper wire. There is probably an open circuit in the harness between the slave ECM and the connector for the sensor. Illustration 77 Slave ECM with jumper wire (1) P4 connector (2) P3 connector (3) Jumper wire g01065295 If the problem is resolved with the new ECM. Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Repair: It is unlikely that the slave ECM has failed. the master ECM removes the voltage from the fuel control relay. Observe the “Active Diagnostic” screen on Cat ET. G. Allow a minimum of 30 seconds for any codes to activate. The logic responds to inputs from the following components: engine control switch. An active “short to ground” diagnostic code is generated for the sensor. For engine shutdown. Install Deutsch terminals on the ends. Fabricate a jumper wire that is long enough to reach between the P4 connector and the P3 connector. “Replacing the ECM”.

use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. terminals P6-21 and P6-24 are used. The troubleshooting procedure may generate additional diagnostic codes. This procedure may be used to troubleshoot either configuration. The jumper wire must be connected in order for the engine to start. The least likely cause is a problem with the master ECM. The next likely cause is a problem with the GSOV. The jumper wire must remain connected in order for the engine to run. The voltage will be removed from the fuel control relay if the jumper wire is not connected. Refer to Illustration 78 for the schematic diagram. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. . Before you begin this procedure.249 Troubleshooting Section The output circuit for the relay for the GSOV includes the J6 connector. a jumper wire must be connected between terminals 21 and 31. If the J6 connector is not used. Clear the diagnostic codes after the problem is resolved. Connections for the Fuel Control Relay The fuel control relay may be connected to either of the following connectors: • P6 via wiring that is provided by the customer • P7 via the engine harness If the fuel control relay is connected to P6. If the fuel control relay is connected to P7. a jumper wire must be connected between terminals P6-21 and P6-31. Keep your mind on correcting the cause of the original diagnostic code. Logged diagnostic codes provide a historical record.

250 Troubleshooting Section Illustration 78 Optional connections for the fuel control relay g01065314 .

“Inspecting Electrical Connectors”. Note: For the following steps. Illustration 82 Harness side of the J6 connector (J6-21) Circuit driver for the fuel control relay (J6-24) Return (J6-31) Circuit for the fuel control relay g00952066 . Set the engine control to the OFF/RESET mode. Check the torque of the allen head screw for the ECM connectors. and J7/P7 connectors • Connectors for the fuel control relay a. The proper torque is 2. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Check the torque of the allen head screws for the connectors on the terminal box.25 ± 0. Switch 35 amp circuit breaker (1) to the OFF position. refer to Troubleshooting. Illustration 79 Junction box (1) 35 amp circuit breaker g01054206 A. Inspect the Electrical Connectors and Wiring C.25 N·m (20 ± 2 lb in).251 Troubleshooting Section Test Step 1. b. Illustration 81 Harness side of the P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return g00930126 Illustration 80 Terminal box g01065317 (2) J2/P2 connectors for the master ECM (3) J6/P6 connector for the customer (4) J7/P7 connectors for the harness from the fuel control relay B. Thoroughly inspect the following connectors and the wiring harnesses for the connectors: • J2/P2 connectors • J6/P6.

or pinch points. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel control relay. C. proceed to the “Results” for this Test Step. The connectors and the wiring do not have corrosion. If there is a “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code. Note: This diagnostic condition cannot be detected by the master ECM when the output for the fuel control relay is OFF. D. Results: • OK – The components are in good condition with proper connections. abrasion. Otherwise. If there is an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Connect Cat ET to the service tool connector. continue this procedure. . Wait for 30 seconds and use Cat ET to check for an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Proceed to Test Step 2. condition and/or at least one connection is improper. if necessary. Check for Diagnostic Codes A. Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code cannot be detected when the output for the fuel control relay is ON. • Not OK – The components are not in good Repair: Perform the necessary repairs. Illustration 83 Harness side of the J7 connector (J7-50) Circuit driver for the fuel control relay (J7-64) Return g00929957 c. The output is ON when the engine control is in the START mode and the engine speed is not zero. Test Step 2. STOP. Refer to Troubleshooting. pins. shut the gas supply OFF. E. To prevent the engine from starting. Illustration 84 Typical fuel control relay g00869737 d. Set the engine control to the STOP mode. “Electronic Service Tools”. Check the harness and wiring for abrasion and pinch points from the fuel control relay to the master ECM. when possible. Switch the 35 amp circuit breaker ON. The output is OFF when the engine control is in the STOP mode. and sockets are connected properly. B. clear the code. Replace parts. Use Cat ET to check the logged diagnostic codes.252 Troubleshooting Section Expected Result: All connectors.

• Not OK (“17-05 Fuel Shutoff Valve open circuit” diagnostic code) – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was activated. The master ECM disabled the ignition. After the engine was cranked. Then reconnect the connector.253 Troubleshooting Section Note: To provide the output for the fuel control relay. there was no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. F. Set the engine control to the START mode for at least 30 seconds. diagnostic code) – After the engine was cranked. Verify that the engine control is in the STOP mode. Results: • OK – No diagnostic codes were generated. when the relay is disconnected and connected. refer to Troubleshooting. • OK – There is no audible click and/or vibration when the relay is disconnected and connected. Proceed to Test Step 4. G. A. Repair: Set the engine control to the OFF/RESET mode. If the ambient noise is too loud. This can be caused by an actual open circuit or by a short circuit to the +Battery side. There is an open circuit. The output for the fuel control relay seems to be OK at this time. 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. there was no logged “17-06 Fuel Shutoff Valve short to ground” or “17-12 Fuel Shutoff Valve malfunction” diagnostic code. a “17-06 Fuel Shutoff Valve short to ground” diagnostic code was generated. Otherwise. B. touch the relay when the relay is reconnected in order to feel the vibration. Contact you local gas provider immediately for assistance in the event of a leak. . The initial diagnostic code was probably caused by a poor electrical connection. Expected Result: When the engine control was in the STOP mode. Then set the engine control to the STOP mode. STOP. Results: Test Step 3. the sequence for engine start-up must be initiated. Proceed to Test Step 5. Replace the fuel control relay. a “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code cannot be generated. Note: Open sparks can be generated during this test. “Inspecting Electrical Connectors”. Repair: If there is an intermittent problem that is causing the codes to be logged. STOP. The relay is not energized when the engine control is in the STOP mode. The relay is receiving power when the engine control is in the STOP mode. Listen for an audible click from the relay. Switch the 35 amp circuit breaker OFF. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. a “17-12 Fuel Shutoff Valve malfunction” diagnostic code was generated. There is probably a short circuit to the +Battery side in a connector or a wiring harness. Proceed to Test Step 3. Proceed to Test Step 7. There is no short circuit to the +Battery side. • Not OK (“17-06 Fuel Shutoff Valve short to ground” • Not OK – There is an audible click and/or vibration • Not OK (“17-12 Fuel Shutoff Valve malfunction” diagnostic code) – After the engine was cranked. C. Disconnect the connector from the fuel control relay. Check for a Short Circuit to the +Battery Side Gaseous fuel is present. The relay will vibrate when the relay is de-energized and energized. Make sure that no combustible gas is present in the surrounding atmosphere. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire.

Create a Short Circuit in order to Check for an Open Circuit A. Replace parts. Then reconnect the connector. Switch the 35 amp circuit breaker OFF. Determine the Cause of the Energized Relay 4. Disconnect the connector from the fuel control relay. perform the following steps: Temporarily install a new master ECM. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. touch the relay when the relay is reconnected in order to feel the vibration. Refer to Troubleshooting. If the relay is energized. Refer to Troubleshooting. Set the engine control to the OFF/RESET mode. The relay will vibrate when the relay is de-energized and energized. Then reconnect the connector. when possible. Repair: Repair the wiring and/or the connector. install the original ECM and verify that the problem returns. Contact you local gas provider immediately for assistance in the event of a leak. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. Switch the 35 amp circuit breaker OFF. If the ambient noise is too loud. 3. STOP. The relay is not energized when the wiring is removed from the P2 connector. • OK – There is no audible click and/or vibration when the solenoid is disconnected and reconnected. The relay will vibrate when the relay is de-energized and energized. STOP. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. A. there is an intermittent problem with a connector and/or the wiring. B. If the ambient noise is too loud. “Inspecting Electrical Connectors”. Listen for an audible click from the relay. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Use a 151-6320 Wire Removal Tool to remove terminals P2-11 and P2-21. if necessary. Disconnect the connector from the fuel control relay. The relay is energized when the wiring is removed from the P2 connector. Test Step 5. It is unlikely that the master ECM has failed. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. touch the relay when the relay is reconnected in order to feel the vibration. Pull on the wires in order to verify proper installation of the terminals. Disconnect the fuel control relay’s connector. . C. Exit this procedure and perform this procedure again. Reinstall terminals P2-11 and P2-21. Set the engine control to the STOP mode. If the problem is resolved with the new ECM. If the problem is not resolved. D. “Replacing the ECM”. Refer to Troubleshooting. If the relay is not energized. Set the engine control to the OFF/RESET mode. Note: Open sparks can be generated during this test. there may be a problem with the master ECM. replace the original ECM. There is a short circuit to the +Battery side in a harness. The relay is not energized when the wiring is removed from the P2 connector. B. “Replacing the ECM”.254 Troubleshooting Section Test Step 4. Results: • Not OK – There is an audible click and/or vibration when the relay is disconnected and reconnected. 2. Switch the 35 amp circuit breaker ON. Gaseous fuel is present. Listen for an audible click from the relay. Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty: 1. If the new ECM operates correctly and the original ECM does not operate correctly.

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. There may be an open circuit in a harness. Pull on the jumper wire in order to verify proper installation. Switch the 35 amp circuit breaker OFF. The output is OFF when the engine control is in the STOP mode and the engine is not running. Set the engine control to the OFF/RESET mode. The output is OFF when the engine control is in the STOP mode and the engine is not running. Inspect the relay’s connector for damage. 2. Make repairs. Switch the 35 amp circuit breaker ON. E. . Repair: Perform the following procedure: 1. D. Set the engine control to the STOP mode.255 Troubleshooting Section If the problem is not resolved. Switch the 35 amp circuit breaker ON. 4. C. E. and for corrosion. Test Step 6. • Not OK – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was generated when the jumper wire was installed. Check the Master ECM A. replace the fuel control relay. STOP. 3. C. for moisture. Install a jumper wire (2) into the two terminals of the relay’s connector (1) on the engine harness. Expected Result: 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. Remove the jumper wire from the relay’s connector on the engine harness. Illustration 85 (1) Connector for the fuel control relay (2) Jumper wire g01065318 B. There is a problem with the relay. 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. Install a jumper wire (1) into terminals P2-11 and P2-21. Proceed to Test Step 6. Results: Illustration 86 P2 connector with jumper wire (1) Jumper wire (2) P2 connector g01065319 • OK – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was not generated when the jumper wire was installed. Use the 151-6320 Wire Removal Tool to remove terminals P2-11 and P2-21. Set the engine control to the OFF/RESET mode. as needed. D. Switch the 35 amp circuit breaker OFF. 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. 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. Set the engine control to the STOP mode.

Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Expected Result: A “17-06 Fuel Shutoff Valve short to ground” was not generated. Set the engine control to the OFF/RESET mode. Verify that the problem is resolved. Inspect the relay’s connectors for damage and/or for corrosion. the sequence for engine start-up must be initiated. STOP. Pull on the wires in order to verify proper installation of the terminals. G. 3. There is a problem between the P2 connector and the connector for the fuel control relay.256 Troubleshooting Section Expected Result: There is no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code again. as needed. F. the master ECM did not detect the jumper wire at the connector for the fuel control relay. Note: To provide the output for the fuel control relay. Switch the 35 amp circuit breaker OFF. replace the relay. shut OFF the main gas supply. no “short to ground” diagnostic code was generated. Pull on the wires in order to verify proper installation of the terminals. Use Cat ET to clear the logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code. The master ECM did not detect the jumper wire. . Make repairs. Create an Open Circuit in order to Check for a Short Circuit to Ground A. 3. Inspect the wiring that is connected to terminals J6-21 and J6-31. If the problem is not resolved. Reinstall the terminals into P2-11 and P2-21. Thoroughly inspect the J6/P6 and J7/P7 connectors. there was no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. When the relay was disconnected. Set the engine control to the STOP mode. 2. STOP. Repair: Perform the following procedure: 1. • OK – When the relay was connected. C. 4. E. Set the engine control to the START mode for at least 30 seconds. However. Results: • OK – When the jumper wire was installed. Set the engine control to the OFF/RESET mode. Proceed to Test Step 8. Make repairs. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Disconnect the connector from the fuel control relay. D. Set the engine control to the OFF/RESET mode. There is a problem with the wiring or with the ECM. Repair: Perform the following procedure: 1. Replace the master ECM according to Troubleshooting. There is a problem with the relay. a “17-06 Fuel Shutoff Valve short to ground” diagnostic code cannot be generated. • Not OK – A “short to ground” diagnostic code was generated when the relay was disconnected. 3. Results: Test Step 7. if necessary. Then set the engine control to the STOP mode. 4. 2. Otherwise. • Not OK – When the jumper wire was installed. Switch the 35 amp circuit breaker OFF. a “short to ground” diagnostic code was generated. Set the engine control to the OFF/RESET mode. a “17-05 Fuel Shutoff Valve open circuit” diagnostic code was activated. Reinstall the terminals into P2-11 and P2-21. The master ECM detects the jumper wire at the P2 connector. 5. There is a problem with the master ECM. B. To prevent the engine from starting. STOP. “Replacing the ECM”. Switch the 35 amp circuit breaker OFF. Repair: Perform the following procedure: 1.

Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code again. Set the engine control to the START mode for at least 30 seconds. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. when possible. F. 3. Exit this procedure and perform this procedure again. Expected Result: The “17-06 Fuel Shutoff Valve short to ground” diagnostic code was not generated. STOP. G. Reinstall the terminal that was removed from P2-11. B. data link. Use the 151-6320 Wire Removal Tool to remove terminal P2-11. The logic responds to inputs from the following components: engine control switch. “Replacing the ECM”. If the problem is not resolved. Note: To provide the output for the fuel control relay. Results: • 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 P2 connector. Set the engine control to the OFF/RESET mode. Use Cat ET to clear the logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code.257 Troubleshooting Section Test Step 8. The next likely cause is a problem with a magnetic switch or with a relay. 3. Set the engine control to the OFF/RESET mode. the sequence for engine start-up must be initiated. If the new ECM operates correctly and the original ECM does not operate correctly. Reinstall the terminal that was removed from P2-11. Refer to Troubleshooting. 2. E. Switch the 35 amp circuit breaker OFF. Pull on the wire in order to verify proper installation of the terminal. remote start switch. if necessary. and other inputs. Refer to Troubleshooting. Replace the harness. Switch the 35 amp circuit breaker OFF. Set the engine control to the STOP mode. STOP. Switch the 35 amp circuit breaker OFF. Switch the 35 amp circuit breaker ON. perform the following steps: Temporarily install a new master ECM. Before you begin this procedure. Pull on the wire in order to verify proper installation of the terminal. D. There is a problem in the wiring between the P2 connector and the connector for the fuel control relay. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. disconnected from the P2 connector. a “17-06 Fuel Shutoff Valve short to ground” diagnostic code cannot be generated. i02089116 • OK – When the output to the relay was ECM Output Circuit (Starting Motor) SMCS Code: 1901-038 System Operation Description: The master Electronic Control Module (ECM) contains the logic and the outputs for starting the engine. . The least likely cause is a problem with the master ECM. Set the engine control to the OFF/RESET mode. shut OFF the main gas supply. There may be a problem with the master ECM. However. a “short to ground” diagnostic code was generated when the connector was disconnected from the fuel control relay. emergency stop switch. Check the Master ECM A. The logic for starting is customer programmable. Then set the engine control to the STOP mode. Repair: Perform the following procedure: 1. Repair the harness. If the problem is resolved with the new ECM. install the original ECM and verify that the problem returns. “Replacing the ECM”. To prevent the engine from starting. Otherwise. Logged diagnostic codes provide a historical record. Repair: Perform the following procedure: 1. C. It is unlikely that the master ECM has failed. 2. replace the original ECM. the “17-06 Fuel Shutoff Valve short to ground” diagnostic code was not generated.

258 Troubleshooting Section The troubleshooting procedure may generate additional diagnostic codes. Each magnetic switch provides +Battery voltage to a solenoid on an electric starting motor. Keep your mind on correcting the cause of the original diagnostic code. The master ECM removes the voltage when the crank terminate relay is energized. Electric Start The master ECM supplies +Battery voltage to two magnetic switches when the logic determines that it is necessary. Clear the diagnostic codes after the problem is resolved. The voltage is also removed if the customer programmable “Overcrank Time” has expired. . The voltage is also removed if the customer programmable “Overcrank Time” has expired. Air Start The master ECM supplies +Battery voltage to the air start relay when the logic determines that it is necessary. The master ECM removes the voltage when the crank terminate relay is energized.

259 Troubleshooting Section Illustration 87 Schematic for the electric starting system g01065332 Illustration 88 Schematic for the air starting system g01065333 .

Thoroughly inspect the following connectors and the wiring harnesses for the connectors: • J2/P2 connectors • J7/P7 connectors a. Check the torque of the allen head screw for the ECM connectors. Illustration 89 Junction box (1) 35 amp circuit breaker g01054206 A.25 ± 0. refer to Troubleshooting. Check the torque of the allen head screws for the connectors on the terminal box. Inspect the Electrical Connectors and Wiring B. Illustration 91 Harness side of the P2 connector (P2-10) Start command (P2-20) Return for the start command g01055043 Illustration 90 Terminal box g01065334 (2) J2/P2 connectors for the master ECM (3) J7/P7 connectors for the wiring from the starting system . Switch 35 amp circuit breaker (1) to the OFF position. “Inspecting Electrical Connectors”. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Note: For the following steps. Set the engine control to the OFF/RESET mode.25 N·m (20 ± 2 lb in). b. The proper torque is 2.260 Troubleshooting Section Test Step 1.

Then set the engine control to the STOP mode. Results: • OK – The components are in good condition with proper connections. The connectors and the wiring do not have corrosion. or pinch points. Illustration 92 Harness side of the J7 connector (J7-28) Start command (J7-56) Return for the start command g00931050 E. F. To prevent the engine from starting. . The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. The output for the start command seems to be OK at this time.261 Troubleshooting Section Test Step 2. Otherwise. continue this procedure. Connect Cat ET to the service tool connector. After the engine was cranked. B. Wait for 30 seconds and use Cat ET to check for an active “444-05 Start Relay open circuit” diagnostic code. Results: c. Expected Result: All connectors. The initial diagnostic code was probably caused by a poor electrical connection. shut the gas supply OFF. Check the harness and wiring for abrasion and for pinch points from the starter motor relay to the master ECM. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the starter motor relay. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Expected Result: When the engine control was in the STOP mode. Replace parts. there was no active “444-05 Start Relay open circuit” diagnostic code. The output is normally ON when the engine control is set from the STOP mode to the START mode. • Not OK – The components are not in good Repair: Perform the necessary repairs. Refer to Troubleshooting. If there is a logged “444-06 Start Relay short to ground” diagnostic code. Use Cat ET to check the logged diagnostic codes. clear the code. d. pins. “Electronic Service Tools”. Set the engine control to the START mode for at least six seconds. G. If there is an active “444-05 Start Relay open circuit” diagnostic code. Switch the 35 amp circuit breaker ON. condition and/or at least one connection is improper. and sockets are connected properly. Check for Diagnostic Codes A. • OK – No diagnostic codes were activated. STOP. D. Note: The “444-05 Start Relay open circuit” diagnostic code can only be detected when the output for the start command is OFF. Proceed to Test Step 2. The output remains ON until the crank terminate relay is energized. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. when possible. if necessary. proceed to the “Results” for this Test Step. Set the engine control to the STOP mode. abrasion. C. there was no logged “444-06 Start Relay short to ground” diagnostic code.

for moisture. There is an open circuit. Remove the jumper wire from the harness connector. C. The master ECM detected the short circuit. Proceed to Test Step 4. C. as needed. touch the air start relay when the relay is reconnected in order to feel the vibration. STOP. Repair: Perform the following procedure: 1. The harness and the master ECM are OK. Make repairs. Set the engine control to the OFF/RESET mode.262 Troubleshooting Section Repair: If there is an intermittent problem that is causing the codes to be logged. Make sure that no combustible gas is present in the surrounding atmosphere. Disconnect the harness connector from the air start relay. Results: • OK – There is no audible click and/or vibration • Not OK (“444-05 Start Relay open circuit” when the air start relay is disconnected and connected. • Not OK – There is an audible click and/or vibration • Not OK (“444-06 Start Relay short to ground” Test Step 4. refer to Troubleshooting. There is no short circuit to the +Battery side. The relay will vibrate when the relay is de-energized and energized. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. a “444-06 Start Relay short to ground” diagnostic code was activated. Expected Result: There is no audible click and/or vibration when the air start relay is disconnected and reconnected. Set the engine control to the STOP mode. Expected Result: A “444-05 Start Relay open circuit” diagnostic code was not activated when the jumper wire was installed. proceed to Test Step 3. D. proceed to Test Step 10. If the engine is equipped with an electric starting system. “Inspecting Electrical Connectors”. B. proceed to Test Step 7. Contact you local gas provider immediately for assistance in the event of a leak. Install a jumper wire into the two terminals of the harness connector for the air start relay. The relay is receiving power when the engine control is in the STOP mode. 4. Check for damage. Inspect the relay’s connector and the harness connector for the relay. 3. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Results: Test Step 3. If the engine is equipped with an air starting system. If the engine is equipped with an air starting system. 2. Switch the 35 amp circuit breaker OFF. Disconnect the connector from the air start relay. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Create a Short Circuit in order to Check for an Open Circuit A. proceed to Test Step 9. when the air start relay is disconnected and connected. Set the engine control to the OFF/RESET mode. If the engine is equipped with an electric starting system. Then reconnect the connector. • OK – A “444-05 Start Relay open circuit” diagnostic code was not activated when the jumper wire was installed. There is a problem with the air start relay. If the ambient noise is too loud. Switch the 35 amp circuit breaker OFF. B. Switch the 35 amp circuit breaker ON. Note: Open sparks can be generated during this test. diagnostic code) – A “444-05 Start Relay open circuit” diagnostic code was activated. Proceed to Test Step 6. Check for a Short Circuit to the +Battery Side Gaseous fuel is present. Ensure that the engine control is in the STOP mode. diagnostic code) – After the engine was cranked. 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. and for corrosion. Listen for an audible click from the relay. A. E. The relay is not energized when the engine control is in the STOP mode. .

. However. B. If the problem is resolved with the new ECM. Switch the 35 amp circuit breaker ON. STOP. Exit this procedure and perform this procedure again. Pull on the wires in order to verify proper installation of the terminals. Repair: Perform the following procedure: 1. Set the engine control to the OFF/RESET mode. STOP. “Replacing the ECM”. Check the Master ECM A. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Set the engine control to the OFF/RESET mode. there was no active “444-05 Start Relay open circuit” diagnostic code. Pull on the wires in order to verify proper installation of the terminals. • No – When the jumper wire was installed. replace the air start relay. Alternatively. Reinstall terminals P2-10 and P2-20. Repair the harness. It is unlikely that the master ECM has failed. 4. Install a jumper wire into terminals P2-10 and P2-20. Ensure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. Use a 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20. “Replacing the ECM”. If the problem is not resolved. the master ECM did not detect the jumper wire at the relay’s connector. perform the following steps: Temporarily install a new master ECM. Use a 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20. Set the engine control to the START mode for at least six seconds. C. Pull on the jumper wire in order to verify proper installation. E. Switch the 35 amp circuit breaker OFF. 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. shut OFF the main gas supply. Refer to Troubleshooting. 3. If the new ECM operates correctly and the original ECM does not operate correctly. when possible. Set the engine control to the STOP mode. Create an Open Circuit in order to Check for a Short Circuit A. Switch the 35 amp circuit breaker OFF. The problem could be between the P2 connector and the J7 connector. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. the problem could be in the P7 connector or the wiring that is connected to the P7 connector. Then set the engine control to the STOP mode. 2. install the original ECM and verify that the problem returns. • Not OK – A “444-05 Start Relay open circuit” diagnostic code was activated when the jumper wire was installed. Proceed to Test Step 5. replace the original ECM. There is a problem with the wiring. a Test Step 5. To prevent the engine from starting. C. Set the engine control to the STOP mode. 2. Test Step 6. E. if necessary. The master ECM did not detect the jumper wire. Reinstall terminals P2-10 and P2-20. Switch the 35 amp circuit breaker ON. D. D. • OK – When the jumper wire was installed. STOP. The master ECM did not detect the short circuit. Set the engine control to the OFF/RESET mode. There is a problem with the master ECM. Replace the harness. 3. Results: “444-05 Start Relay open circuit” diagnostic code was activated. Switch the 35 amp circuit breaker OFF.263 Troubleshooting Section If the problem is not resolved. The master ECM detects the jumper wire at the P2 connector. B. Expected Result: There is no active “444-05 Start Relay open circuit” diagnostic code. Repair: Perform the following procedure: 1. Refer to Troubleshooting.

• Not OK – A “444-06 Start Relay short to ground” Test Step 7.264 Troubleshooting Section Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. the relay was receiving power. Make repairs. Then set the engine control to the STOP mode. Disconnect the harness connector from the air start relay. replace the air start relay. Proceed to Test Step 8. The problem could be between the P2 connector and the J7 connector. • OK – A “444-06 Start Relay short to ground” diagnostic code was not activated when the air start relay was disconnected. Exit this procedure and perform this procedure again. To prevent the engine from starting. Inspect the connectors for the air start relay. Replace the harness. Refer to Troubleshooting. C. the relay was not receiving power. replace the original ECM. install the original ECM and verify that the problem returns. It is unlikely that the master ECM has failed. Set the engine control to the STOP mode. diagnostic code was activated when the air start relay was disconnected. Expected Result: A “444-06 Start Relay short to ground” was not activated. Pull on the wires in order to verify proper installation of the terminals. STOP. The output is normally ON when the engine control is set from the STOP mode to the START mode. if necessary. for moisture. If the new ECM operates correctly and the original ECM does not operate correctly. 3. when possible. Set the engine control to the OFF/RESET mode. Repair: Perform the following procedure: 1. Switch the 35 amp circuit breaker OFF. 2. There may be a problem with the master ECM. Create an Open Circuit at the Air Start Relay A. • Not OK – When the master ECM was connected. When the master ECM was not connected. F. as needed. the problem could be in the P7 connector or the wiring that is connected to the P7 connector. “Replacing the ECM”. Set the engine control to the OFF/RESET mode. Check for damage. Alternatively. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Repair: Perform the following procedure: 1. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. The output remains ON until the crank terminate relay is energized. shut OFF the main gas supply. Switch the 35 amp circuit breaker ON. and for corrosion. Results: B. The air start relay is OK. Refer to Troubleshooting. Switch the 35 amp circuit breaker OFF. perform the following steps: Temporarily install a new master ECM. There is a problem with the air start relay. E. 4. When the master ECM was not connected. Repair: Repair the harness. Remove the jumper wire from the connector. If the problem is not resolved. There is a problem with the wiring. If the problem is resolved with the new ECM. 2. The relay is not energized when the engine control is in the STOP mode. Reinstall terminals P2-10 and P2-20. STOP. Switch the 35 amp circuit breaker OFF. the relay was still receiving power. . Set the engine control to the START mode for at least six seconds. D. If the problem is not resolved. Results: • OK – When the master ECM was connected. the relay was receiving power. STOP. Set the engine control to the OFF/RESET mode. “Replacing the ECM”.

Set the engine control to the START mode for at least six seconds. There is a problem with the wiring. Test Step 9.5 amp) g01055051 A. replace the original ECM. Pull on the wires in order to verify proper installation of the terminals. Reinstall terminals P2-10 and P2-20. Pull on the wires in order to verify proper installation of the terminals. Set the engine control to the OFF/RESET mode. Then set the engine control to the STOP mode.265 Troubleshooting Section Test Step 8. It is unlikely that the master ECM has failed. • Not OK – When the wiring was disconnected from the master ECM. Set the engine control to the OFF/RESET mode. The output is normally ON when the engine control is set from the STOP mode to the START mode. “Replacing the ECM”. There seems to be a problem with the master ECM. Alternatively. The problem could be between the P2 connector and the J7 connector. 2. perform the following steps: Temporarily install a new master ECM. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. if necessary. shut OFF the main gas supply. the problem could be in the P7 connector or the wiring that is connected to the P7 connector. If the new ECM operates correctly and the original ECM does not operate correctly. Use the 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20. Check the Master ECM A. Repair: Perform the following procedure: 1. Switch the 35 amp circuit breaker OFF. Set the engine control to the STOP mode. when possible. STOP. Illustration 93 “SM” circuit breaker (2. STOP. Switch the 35 amp circuit breaker ON. 3. Results: Repair: Perform the following procedure: 1. Expected Result: The “444-06 Start Relay short to ground” diagnostic code was not activated. D. Reinstall terminals P2-10 and P2-20. a “444-06 Start Relay short to ground” diagnostic code was activated. Replace the harness. B. Expected Result: The “SM” circuit breaker is in the ON position. 2. . The output remains ON until the crank terminate relay is energized. If the problem is not resolved. a “444-06 Start Relay short to ground” diagnostic code was not activated. E. Check the “SM” Circuit Breaker • OK – When the wiring was disconnected from the master ECM. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. Exit this procedure and perform this procedure again. Refer to Troubleshooting. C. Set the engine control to the OFF/RESET mode. Repair the harness. “Replacing the ECM”. Verify that the “SM” circuit breaker is in the ON position. Switch the 35 amp circuit breaker OFF. install the original ECM and verify that the problem returns. If the problem is resolved with the new ECM. To prevent the engine from starting. F. Switch the 35 amp circuit breaker OFF. Refer to Troubleshooting.

Remove seven bolts and nuts. ON position. Disconnect the +24 V power supply from the engine. If there is an active “444-05 Start Relay open circuit” diagnostic code. proceed to Test Step 10. The voltage on the terminals should be zero VDC. Verify that the 35 amp circuit breaker is ON. the problem appears to be resolved.266 Troubleshooting Section Results: • OK – The “SM” circuit breaker is in the ON position. The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. Verify that each electrical connection inside the junction box is securely connected. Resume normal operation. Open the junction box. Proceed to Test Step 10. Illustration 94 Terminals on the junction box g00931289 B. • Not OK – The “SM” circuit breaker is not in the Repair: Switch the “SM” circuit breaker to the ON position. Check for moisture and for corrosion. Inspect the Inside of the Junction Box A. D. the problem may be resolved. Illustration 95 Fasteners for the junction box g00931303 C. If there is no active “444-05 Start Relay open circuit” diagnostic code. Set the engine control to the STOP mode. Perform the following procedure: 1. Note: The “444-05 Start Relay open circuit” diagnostic code can only be detected when the output for the start command is OFF. Wait for 30 seconds and use Cat ET to check for an active “444-05 Start Relay open circuit” diagnostic code. 2. Test Step 10. . Verify that the power is disconnected by checking for voltage at the “+” and “-” terminals on the junction box. Inspect the inside of the junction box. If the circuit breaker remains in the ON position.

STOP. Repair: Repair the wiring and/or the connection. open circuit. if necessary. B. • OK – The inside of the junction box does not have moisture or corrosion. Proceed to Test Step 12. Use a multimeter to check for a short circuit between the points that are listed in Table 20: Note: Refer to Illustration 87. Replace parts. There is a short circuit to the +Battery. Proceed to Test Step 11. • Not OK – At least one measurement is more than two Ohms. There is not a short circuit to the +Battery. when possible. Test Step 12. Points to Check for a Short Circuit Point P2-10 Point The connection for the “SM”circuit breaker that is connected to wire “P6B0A-RD” The other connection for the “SM” circuit breaker The coil terminal of each magnetic switch that is connected to wire “C990-RD” P2-20 One of the connections for the “SM” circuit breaker The connection for the “SM” circuit breaker that is connected to wire “P6B0B-RD” The coil terminal of each magnetic switch that is connected to wire “C991-BK” Illustration 96 Section view of the junction box (1) Coil terminals on the magnetic switches (2) Terminals on the “SM” circuit breaker g01055064 B. Verify that the “SM” circuit breaker is in the ON position.267 Troubleshooting Section Expected Result: The inside of the junction box does not have moisture or corrosion. moisture or corrosion and/or there is a loose electrical connection. All of the electrical connections inside the junction box are securely connected. There is not an open circuit. Results: Expected Result: All of the measurements are an open circuit. Check for an Open Circuit A. There is a problem with the wiring or with the “SM” circuit breaker. when possible. STOP. Results: • OK – All of the measurements are an open circuit. Results: P2-20 P2-10 Each coil terminal (1) on each magnetic switch Each terminal (2) on the “SM” circuit breaker • OK – All of the measurements are less than two Ohms. . Use a 151-6320 Wire Removal Tool to remove terminals P2-10 and P2-20. if necessary. Check for a Short Circuit A. All of the electrical connections inside the junction box are securely connected. Proceed to Test Step 13. • Not OK – At least one measurement is not an • Not OK – The inside of the junction box has Repair: Perform the necessary repairs. Table 20 Test Step 11. Use a multimeter to check for an open circuit between the points that are listed in Table 19: Table 19 Expected Result: Points to Check for an Open Circuit Point Point “+” terminal on the junction box “+” terminal on the junction box “+” terminal on the junction box “+” terminal on the junction box All of the measurements are less than two Ohms. if necessary. Replace parts.

Verify that terminals P2-10 and P2-20 are removed from the P2 connector. STOP. STOP. replace the original ECM. “Replacing the ECM”. Refer to Troubleshooting. perform the following steps: Temporarily install a new master ECM. If the problem is resolved with the new ECM. Expected Result: The resistance of each coil is between 16 and 20 Ohms. B. The • Not OK – The resistance of a coil is not between initial diagnostic code was probably caused by a poor electrical connection. The output remains ON until the crank terminate relay is energized. when possible. D. Exit this procedure and perform this procedure again. 2. Set the engine control to the OFF/RESET mode.268 Troubleshooting Section Repair: Repair the wiring and/or the connection. Set the engine control to the STOP mode. A “444-05 Start Relay open circuit” diagnostic code should not be activated. Results: Test Step 13. “Inspecting Electrical Connectors”. Use a multimeter to measure the resistance of the coil for each magnetic switch. F. Repair: If there is an intermittent problem that is causing the codes to be logged. The output is normally ON when the engine control is set from the STOP mode to the START mode. Reinstall terminals P2-10 and P2-20. if necessary. Reconnect the +24 V power supply to the engine. Check the Operation of the Master ECM A. Verify that the 35 amp circuit breaker is ON. Pull on the wires in order to verify proper installation of the terminals. C. Results: • OK – The resistance of each coil is between 16 Ohms and 20 Ohms. Set the engine control to the START mode. Repair: 1. STOP. G. Install the seven bolts and nuts for the junction box. Test Step 14. A “444-06 Start Relay short to ground” diagnostic code should not be activated. Verify that the “SM” circuit breaker is ON. Replace parts. E. Repair: Replace the magnetic switch. If the new ECM operates correctly and the original ECM does not operate correctly. If the problem is not resolved. The coil resistance for each magnetic switch is correct. • Not OK – A diagnostic code was activated. Look for a “444-06 Start Relay short to ground” diagnostic code. Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the output for the start command is ON. Verify that the original problem is resolved. Note: The “444-05 Start Relay open circuit” diagnostic code can only be detected when the output for the start command is OFF. install the original ECM and verify that the problem returns. • OK – No diagnostic codes were activated. Switch the 35 amp circuit breaker OFF. Proceed to Test Step 14. Switch the 35 amp circuit breaker ON. Repair: It is unlikely that the master ECM has failed. The output is normally OFF when the engine control is in the STOP mode or when the crank terminate relay is energized. refer to Troubleshooting. There may be a problem with the master ECM. The resistance of a coil for a magnetic switch is incorrect. Expected Result: No diagnostic codes were activated. Check the Coils for the Magnetic Switches A. “Replacing the ECM”. 16 Ohms and 20 Ohms. Refer to Troubleshooting. STOP. .

a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. “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. The master ECM has shut down the engine. Note: These circuits do not sink enough current for illumination of standard incandescent lights. This output indicates that a potentially damaging operating condition was detected by the master ECM. The troubleshooting procedure may generate additional diagnostic codes. replace the lamp with the lamp that is specified in the engine’s Parts Manual. The engine will start soon or the engine is running. The ECM closes the circuit in order to set the output to ON. If a lamp is burned out. The master ECM cannot diagnose this output while the output is OFF. While this output is energized. and “Fault Relay”. While this output is energized. “Troubleshooting with an Event Code” or Troubleshooting. Refer to Troubleshooting. The next likely cause is a problem with an indicator. This output indicates that the master ECM has detected an electrical problem or an abnormal operating condition. “Crank Terminate Relay”. 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. a diagnostic code is generated. Keep your mind on correcting the cause of the original diagnostic code. If excessive current flows through the circuit. the ECM allows a maximum current of 0.269 Troubleshooting Section i02089153 ECM Status Indicator Output SMCS Code: 7400-038-IND System Operation Description: The master Electronic Control Module (ECM) has four outputs in order to indicate the status of engine operation: “Run Relay”. “Fault Relay” – This is the shutdown output.3 amperes to flow through the circuit to a ground that is inside the ECM. When the circuit is closed and the output is ON. A short circuit to the +battery side will also activate a diagnostic code. The ECM opens an internal circuit in order to set an output to OFF. a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. The most likely causes of a diagnostic code for a status indicator is a poor electrical connection or a problem in a wiring harness. 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. The least likely cause is a problem with the master ECM. These outputs can be used to energize indicator lamps or the outputs can be used to interface with other controls. Logged diagnostic codes provide a historical record. use ET to print the logged codes to a file. The master ECM cannot diagnose this output while the output is OFF. The master ECM cannot diagnose this output while the output is OFF. Before you begin this procedure. While this output is energized. “Troubleshooting with a Diagnostic Code”. The master ECM cannot diagnose this output while the output is OFF. Clear the diagnostic codes after the problem is resolved. a short circuit to a positive voltage source or excessive current through the circuit will cause a diagnostic code to become activated. “Engine Control Alarm Status”. . While this output is energized. “Run Relay” – This output indicates that the engine is in the “Run” status. Failure to correct these serious conditions can result in engine damage. “Engine Control Alarm Status” – This is the alarm output.

The proper torque is 6 ± 1 N·m (55 ± 9 lb in).25 ± 0. Switch 35 amp circuit breaker (1) to the OFF position. b. Note: Some indicators may obtain the status of the engine via a data link. Thoroughly inspect each of the following connectors: • J2/P2 connectors • J6/P6 connectors a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 2. If all of the status indicators are not directly controlled by the master ECM.25 N·m (20 ± 2 lb in). Check the torque of the allen head screws for the connectors on the terminal box. Set the engine control to the OFF/RESET mode. B. Inspect the Electrical Connectors and Wiring Illustration 99 Terminal box Illustration 98 Junction box (1) 35 amp circuit breaker g01054206 g01065355 (2) J2/P2 connectors for the master ECM (3) J6/P6 connectors for the customer A. do not proceed with this test. .270 Troubleshooting Section Illustration 97 Schematic for the status indicators g01065354 Test Step 1.

Expected Result: All connectors.271 Troubleshooting Section e. The “Active Alarm” indicator and the “Engine Failure” indicator did not illuminate. Inspect the wiring and the receptacles for the status indicators. Allow a minimum of 30 seconds for any diagnostic codes to activate. abrasion. Use the “Active Diagnostic” screen on Cat ET to look for the codes that are listed in Table 21: Table 21 Diagnostic Codes and Descriptions with Corresponding ECM Outputs Illustration 101 Harness side of the J6 connector (J6-22) (J6-23) (J6-32) (J6-33) Run Relay Fault Relay Crank Terminate Relay Engine Control Alarm Status g00930208 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” c. Switch the 35 amp circuit breaker ON. Test Step 2. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the status indicators. or pinch points. if necessary. and sockets are connected properly. Note: These outputs do not provide enough current for illumination of standard incandescent lights. C. The connectors and the wiring do not have corrosion. replace the lamp with the lamp that is specified in the engine’s Parts Manual. B. pins. Proceed to Test Step 2. 445-03 Expected Result: There are no active diagnostic codes. Illustration 100 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 g01055309 • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts. Results: • OK – The components are in good condition with proper connections. The “Engine On” indicator and the “Crank Terminate” indicator (if equipped) illuminated normally. Connect Cat ET to the service tool connector on the terminal box. If a lamp is burned out. Refer to Troubleshooting. . “Electronic Service Tools”. d. STOP. condition and/or at least one connection is improper. Check for Diagnostic Codes A. Attempt to start the engine and observe the status indicators. Check the harness and wiring for abrasion and for pinch points from the customer’s equipment to the master ECM.

There must be an alarm condition before a 324-03 diagnostic code can be generated. There are no active diagnostic codes. Operate the engine under low load. Proceed to Test Step 4. Repair: The outputs for the status indicators seem to be operating correctly at this time. Observe the “Engine Control Alarm Status” indicator on the control panel (if equipped). If there is an intermittent problem that is causing the codes to be logged. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. The original diagnostic code was probably caused by a poor electrical connection. refer to Troubleshooting. “Troubleshooting with a Diagnostic Code”. Both of these conditions are serious. • Not OK (Active 323-03 or 324-03 Diagnostic Code) – There is an active “323-03 Shutdown Lamp short to +batt” or “324-03 Warning Lamp short to +batt”. • Not OK (Active 443-03 or 445-03 Diagnostic Code) – When the engine was started. Illustration 102 Right side view (1) Unfiltered engine oil pressure sensor (2) Filtered engine oil pressure sensor g01065357 A. STOP. “Troubleshooting with an Event Code” or Troubleshooting. There must be a shutdown condition before a 323-03 diagnostic code can be generated. Repair: Use Cat ET to determine the event code or the diagnostic code that corresponds to the 323-03 or 324-03 diagnostic code.272 Troubleshooting Section 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”. There is a problem with the output for the “Run Relay” indicator and/or the “Crank Terminate Relay” indicator (if equipped). The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. . “Inspecting Electrical Connectors”. • 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”. There may still be a problem with the output for the alarm indicator or the shutdown indicator. A 443-03 or 445-03 diagnostic code was activated. When the engine was started. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. the “Run Relay” indicator and the “Crank Terminate Relay” indicator (if equipped) illuminated normally. Allow the engine operation to continue. Exit this procedure. During engine operation. Allow the engine operation to continue for this procedure. Proceed to Test Step 3. Test Step 3. STOP. disconnect the connector for the unfiltered engine oil pressure sensor (1). After you have resolved the condition. Repair: The 323-03 and 324-03 diagnostic codes can only be activated when the corresponding indicator is activated. return to this procedure in order to troubleshoot the 323-03 and/or 324-03 diagnostic code. There are no active diagnostic codes. Refer to Troubleshooting. the “Run Relay” indicator and the “Crank Terminate Relay” indicator (if equipped) illuminated normally. Check for Proper Operation of the Status Indicators for the Alarm and Shutdown Note: All active diagnostic codes and active event codes must be cleared in order for the “Engine Control Alarm Status” indicator to be OFF. When the engine was started. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-03 or 324-03 diagnostic code. The alarm and/or the shutdown must be activated. the “Run Relay” indicator and/or the “Crank Terminate Relay” indicator (if equipped) did not illuminate normally. if necessary.

C. proceed to the “Expected Result”. Disconnect the connector for the filtered engine oil pressure sensor (2). G. The original problem seems to be resolved. A “323-03 Shutdown Lamp short to +batt” and/or a “324-03 Warning Lamp short to +batt” diagnostic code was generated. and shutdown were activated according to the “Expected Result”. Connect the positive lead of a voltmeter to the end of the 7X-1710 Multimeter Probe. Illustration 103 Terminal box (1) Ground strap for the master ECM (P2-28) Run Relay (P2-29) Crank Terminate Relay (P2-30) Fault Relay (P2-31) Engine Control Alarm Status g00930238 A. The engine was shut down. Switch the 35 amp circuit breaker OFF. Measure the Voltage of the Suspect Indicator at the P2 Connector • OK – The indicators. Observe the “Fault Relay” indicator on the control panel (if equipped). Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. disconnect one wire from the suspect indicator. Set the engine control to the OFF/RESET mode. Connect the voltmeter’s negative lead to ground strap (1). The engine was shut down. C. 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.273 Troubleshooting Section If you are only troubleshooting a “324-03 Warning Lamp short to +batt”. Note: When the filtered engine oil pressure sensor is disconnected. the engine will shut down. The outputs for the status indicators seem to be operating correctly at this time. Be sure to disconnect the wire that comes from the master ECM. Repair: The original diagnostic code was probably caused by a poor electrical connection. refer to Troubleshooting. . D. Insert a 7X-1710 Multimeter Probe into the suspect control terminal in the P2 connector. B. diagnostic codes. If there is an intermittent problem that is causing the codes to be logged. The “542-03” and the “100-03” diagnostic codes were generated. E. If the customer has equipment for the status indicators. Use the “Diagnostics” screen on Cat ET to look for active diagnostic codes. Note the voltage that is displayed on the voltmeter. Results: Test Step 4. Switch the 35 amp circuit breaker ON. STOP. There is a problem with the output for the status indicators. F. • Not OK – The “Engine Control Alarm Status” indicator and/or the “Fault Relay” indicator did not illuminate normally when the sensors were disconnected. Set the engine control to the STOP mode. B. Proceed to Test Step 4. “Inspecting Electrical Connectors”. 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.

Set the engine control to the OFF/RESET mode. temporarily install a known good indicator for the suspect indicator. After the suspect indicator was disconnected. voltage was displayed on the voltmeter. Switch the 35 amp circuit breaker ON. F. when possible. Repair: The problem could be caused by a poor electrical connection. Results: • Yes – Before the suspect indicator was disconnected. or a component in the customer’s equipment. the voltmeter displayed approximately zero volts. Repair the connection and/or the wiring. • No – Before the suspect indicator was disconnected. Pull on the wire in order to verify that the terminal is fully inserted into the connector. STOP. when possible. the voltmeter displayed approximately zero volts. if necessary. G. After the suspect indicator was disconnected. After the suspect indicator was disconnected. I. Expected Result: Before the suspect indicator was disconnected. Set the engine control to the STOP mode. Use a 151-6320 Wire Removal Tool to remove the suspect terminal from the ECM P2 connector. if necessary. Switch the 35 amp circuit breaker OFF. Switch the 35 amp circuit breaker ON. Results: C. There may be a problem with the master ECM. 3. Test Step 5. . Proceed to Test Step 5. Replace parts. STOP. Thoroughly inspect all wiring and all connectors in the customer’s equipment. Connect the other lead of the voltmeter to the ground strap for the master ECM. Expected Result: The voltmeter displays approximately zero volts. Set the engine control to the OFF/RESET mode. • The voltage is approximately zero – After the suspect terminal was removed from connector P2. J. the reading on the voltmeter was approximately zero. a wire. Set the engine control to the STOP mode. Check the Master ECM A. Disconnect the voltmeter leads and remove the 7X-1710 Multimeter Probe from the P2 connector. There is a problem in the customer’s equipment. B. Make the necessary repairs. Verify that the problem is resolved. Test the indicator. D. H. • The voltage remained – After the suspect terminal was removed from the P2 connector. Repair: Perform the following procedure: 1. 4. Connect a voltmeter lead to the end of the jumper wire that is not inserted into the connector. E. 2.274 Troubleshooting Section H. Insert the terminal for the output wire into the P2 connector. Set the engine control to the OFF/RESET mode. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the ECM P2 connector. Switch the 35 amp circuit breaker OFF. Note the voltage that is displayed on the voltmeter. Replace parts. “Inspecting Electrical Connectors”. the voltage was still displayed on the voltmeter. voltage was displayed on the voltmeter. Disconnect the voltmeter leads. If you suspect that the indicator has an internal short circuit. Insulate the terminal with electrical tape in order to ensure that the terminal does not create a short circuit. There is a problem with a connection and/or the wiring between the customer’s equipment and the ECM. voltage was still displayed on the voltmeter. voltage was displayed on the voltmeter. Observe the voltage reading on the voltmeter. Insulate the end of the wire with electrical tape in order to ensure that the wire does not create a short circuit. Refer to Troubleshooting. Insert one end of the jumper wire into the open terminal of the P2 connector. Fabricate a jumper wire with Deutsch terminals on the ends. Switch the 35 amp circuit breaker OFF.

If the supply voltage drops to zero and stays at zero. i02089172 For the slave ECM. The “336-02” diagnostic code indicates that the master ECM has detected a problem with the circuit for the engine control. When the master ECM detects battery voltage at this input. If the problem is not resolved. Clear the diagnostic codes after the problem is resolved.275 Troubleshooting Section Repair: It is unlikely that the master ECM has failed. in the STOP mode. the master ECM will power up. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. the maximum allowable AC ripple is 150 mV AC peak to peak. “Replacing the ECM”. Refer to Troubleshooting. or in the AUTO mode. Keep your mind on correcting the cause of the original diagnostic code. replace the original ECM. The 24 VDC power supply for the engine can be provided by a battery or by an electrical power supply. . the slave ECM will power up. If the power is provided by an electrical power supply. Electrical Power Supply SMCS Code: 1408-038 System Operation Description: Electrical power is supplied to the following components: • Master Electronic Control Module (ECM) • Slave ECM • Integrated Temperature Sensing Module (ITSM) • Fuel metering valve • Actuator for the throttle • Actuator for the compressor bypass group The cause of an intermittent power supply can occur on either the positive side or the negative side of the power supply. in the STOP mode. or in the AUTO mode. The wiring from the power supply to the ECM must provide a maximum voltage drop of 1. The engine will shut down. the input at terminal 70 of the P3 connector (“Switched +Battery”) receives battery voltage from the engine control when the control is in the START mode. The master ECM input at terminal 70 of the P1 connector (“Switched +Battery”) receives battery voltage from the engine control when the control is in the START mode. perform the following steps: Temporarily install a new master ECM. “Replacing the ECM”. When the slave ECM detects battery voltage at this input. neither ECM will log this code. The minimum requirement for the power supply is 22 VDC at 30 amperes. Refer to Troubleshooting. If the new ECM operates correctly and the original ECM does not operate correctly. Before you begin this procedure. install the original ECM and verify that the problem returns. the master ECM will power down after the engine has shut down.0 VDC. When battery voltage is removed from this input. Exit this procedure and perform this procedure again. If the problem is resolved with the new ECM. The “168-02” diagnostic code indicates that the voltage of the power supply is intermittent or low while the engine is running. STOP. This procedure may generate additional diagnostic codes. Logged diagnostic codes provide a historical record.

276 Troubleshooting Section Illustration 104 g01065369 .

Thoroughly inspect each of the following connectors: A. The proper torque is 2. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). “Inspecting Electrical Connectors”. .5 ampere) (2) Circuit breaker for the customer (10 ampere) (3) Circuit breaker for the engine (35 ampere) (4) Circuit breaker for the master ECM output for the electrical starting motor (2. Inspect the Electrical Connectors and Wiring Illustration 106 Terminal box Illustration 105 Junction box (1) Circuit breaker for the engine control (2. Note: For the following steps. refer to Troubleshooting. Switch 35 amp circuit breaker (3) to the OFF position. J6/P6 and J7/P7 connectors • Connectors for the 24 VDC power supply • Connectors for the engine control a. b.25 ± 0. Set the engine control to the OFF/RESET mode. • J1/P1 connectors • J3/P3 connectors • J5. Check the torque of the allen head screw for the ECM connectors.25 N·m (20 ± 2 lb in).277 Troubleshooting Section Schematic for the electrical power Test Step 1. Check the torque of the allen head screws for the connectors on the terminal box.5 ampere) g01055400 g01065370 (5) J5 connector for the service tool (6) J1/P1 connectors for the master ECM (7) J6/P6 connectors for the customer (8) J7/P7 connectors for the harness for electrical power (9) J3/P3 connectors for the slave ECM B.

condition and/or at least one connection is improper. d. • Not OK – The components are not in good . Check the harness and wiring for abrasion and for pinch points from the power supply to the master ECM and from the engine control to the master ECM. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply. Proceed to Test Step 2. abrasion. Results: • OK – The components are in good condition with proper connections. The connectors and the wiring do not have corrosion.278 Troubleshooting Section Illustration 107 Harness side of connectors P1 and P3 (P1-31) (P1-52) (P1-53) (P1-55) (P1-57) (P1-61) (P1-62) (P1-63) (P1-64) (P1-65) (P1-67) (P1-69) (P1-70) Digital return Unswitched +Battery Unswitched +Battery Unswitched +Battery Unswitched +Battery Stop (Master ECM) Start (Master ECM) -Battery Auto (Master ECM) -Battery -Battery -Battery Switched +Battery g01055407 Illustration 109 Harness side of the J7 connector (J7-57) (J7-58) (J7-60) (J7-61) (J7-62) (J7-65) (J7-70) Unswitched +Battery Unswitched +Battery Power for the engine control Switched +Battery Switched +Battery Power for the customer -Battery g00931545 c. Expected Result: g00952120 Illustration 108 Harness side of the J6 connector (J6-1) +Battery for the customer (10 amperes) (J6-4) Power for the engine control (J6-14) Switched +Battery (J6-19) Stop command (J6-29) Start command (J6-36) Digital return (J6-39) Auto command The connectors. and sockets are connected properly. pins. or pinch points.

wiggle the harness in order to check for an intermittent problem. • Not OK – An ECM is not receiving the correct voltage. Ensure that all of the seals are properly installed. clear the events from the “Logged Events” screen of Cat ET. The voltage measurements are constant. Test Step 3. Make sure that the connectors are properly fastened. C. Measure the power supply voltage at the P3 connector. For an engine with an electric starting motor. “Electronic Service Tools”. Locate the source of the voltage drop. Record the measurement. Troubleshoot the power supply if the voltage is less than 22 VDC or more than 29 VDC. Make sure that the engine will not crank during this procedure. Refer to Troubleshooting. Insert the first probe into terminal 52. D. Switch the 35 amp circuit breaker ON. I. Insert the second probe into terminal 63. Switch the 35 amp circuit breaker OFF. Record the measurement. Make sure that the air is purged from the system. Insert the second probe into terminal 63. After you have completed this step. Check the Voltage at the Power Supply. as needed. Measure the power supply voltage at the P1 connector. Note: If a power supply is used instead of batteries. C. Refer to the schematic for the electrical system. . Be sure to wiggle the harness near each of the connections. Results: Test Step 2. Repair: Perform the following procedure: 1. Remove the probes from the P1 connector. STOP. Expected Result: The voltage that is measured at the terminals for the power supply is at least 22 VDC. During the measurement. For an engine with an electric starting motor. F. Be sure to wiggle the harness near each of the connections. For an engine with an air starting motor. 4. Make repairs. H. Check the Engine Control Switch A. G. Make sure that the air is purged from the system. Repair: Perform the following procedure: Switch the 35 amp circuit breaker OFF. Switch the 35 amp circuit breaker ON. Connect a multimeter to the probes. B. E. at the Master ECM. • OK – Each ECM is receiving the correct voltage. Make sure that the engine will not crank during this procedure. Switch the 35 amp circuit breaker ON. For an engine with an air starting motor. During the measurement. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. the minimum voltage for the power supply is 22 VDC. Connect Cat ET to the service tool connector. Use a voltmeter to check the wiring. Note: An “E225 Engine Overcrank” and/or an “E233 Low Engine Prelube Pressure” event code may be generated during this step. Insert two 7X-1710 Multimeter Probes into the harness side of the P3 connector. 3. Proceed to Test Step 3. Measure the voltage at the terminals for the power supply. Verify that the repair has eliminated the problem. wiggle the harness in order to check for an intermittent problem. make sure that the pressurized air supply is OFF. and at the Slave ECM A. STOP. Connect a multimeter to the probes. make sure that the pressurized air supply is OFF. make sure that the battery cables are disconnected from the motor. B. Remove the probes from the P3 connector.279 Troubleshooting Section Repair: Perform the necessary repairs and/or replace parts. if necessary. Insert the first probe into terminal 52. The voltage that is measured at the P1 connector and at the P3 connector is within one volt of the voltage that was measured at the terminals for the power supply. Record the measurement. Remove the probes from the P3 connector. Switch the 35 amp circuit breaker OFF. 2. make sure that the battery cables are disconnected from the motor.

“Inspecting Electrical Connectors”. Make sure that the air is purged from the system. Set the engine control to the STOP mode and measure the voltage between terminals P1-69 and P1-70 connector. The correct voltage measurement is less than one volt. Look for an active “336-02 Incorrect ECS Switch inputs” diagnostic code. Insert the first probe into terminal 31. M. Results: Note: During these measurements. After you have completed the test. STOP. Remove the probes from the P1 connector. The inputs from the engine control are correct. Expected Result: The voltage checks are within the specifications. Set the engine control to the STOP mode and measure the voltage between terminals P1-31 and P1-61. Make sure that the engine will not crank during this procedure. H. For an engine with an air starting motor. K. Set the engine control to the AUTO mode and measure the voltage between terminals P1-69 and P1-70. Refer to Troubleshooting. B. the START mode. Repeat this step several times. Observe the “Active Diagnostic” screen on Cat ET and set the engine control to the STOP mode. Insert the second probe into terminal 61. • Not OK – A “336-02 Incorrect ECS Switch inputs” diagnostic code was activated. Remove the probe from terminal 31 and insert the probe into terminal 69. I. The correct voltage measurement is at least +20 VDC. C. The master ECM has detected an invalid pattern of inputs from the engine control switch. Repair: It is unlikely that the master ECM has failed.280 Troubleshooting Section D. Test Step 4. clear the events from the “Logged Events” screen of Cat ET. the START mode. F. wiggle the harness in order to check for an intermittent problem. and the AUTO mode. Proceed to Test Step 4. Switch the 35 amp circuit breaker ON. Perform the following procedure: . E. Remove the probe from terminal 64 and insert the probe into terminal 70. D. Be sure to wiggle the harness near each of the connections. • OK – The voltage checks are within the specifications. The correct voltage measurement is at least 20 VDC. make sure that the pressurized air supply is OFF. Switch the 35 amp circuit breaker OFF. Note: An “E225 Engine Overcrank” and/or an “E233 Low Engine Prelube Pressure” event code may be generated during the test. G. The problem seems to be resolved. Set the engine control to the AUTO mode and measure the voltage between terminals P1-31 and P1-64. Connect a multimeter to the probes. Set the engine control to the START mode and measure the voltage between terminals P1-31 and P1-62. The correct voltage measurement is less than one volt. the master ECM may have a problem. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. If the original problem is not resolved. J. L. make sure that the battery cables are disconnected from the motor. Remove the probe from terminal 62 and insert the probe into terminal 64. Results: • OK – A “336-02 Incorrect ECS Switch inputs” diagnostic code was not activated. Set the engine control to the OFF/RESET mode. For an engine with an electric starting motor. Expected Result: A “336-02 Incorrect ECS Switch inputs” diagnostic code was not activated when the engine control was set to the STOP mode. and the AUTO mode. The correct voltage measurement is less than one volt. Remove the probe from terminal 61 and insert the probe into terminal 62. Repair: The problem may be intermittent. Set the engine control to the START mode and measure the voltage between terminals P1-69 and P1-70. The correct voltage measurement is at least 20 VDC. Check the Circuit of the Engine Control Switch A. Start the engine and run the engine.

and AUTO modes from the device that provides engine control. 4. “Replacing the ECM”. 2. when possible. Verify that the correct signals are generated by the electronic control. Repair: Perform the following steps: 1. If an electronic control provides engine control. STOP. 3. replace the ECM. If the problem is not resolved. STOP. Disconnect the wires for the STOP. check the control according to the literature that is provided by the OEM of the control.281 Troubleshooting Section Temporarily install a new master ECM. use an ohmmeter to check the contacts for the switch. Refer to Troubleshooting. If the problem is resolved with the new ECM. If the engine control is faulty. • Not OK – The P1 connector does not have the correct voltage. Refer to Troubleshooting. . install the original ECM and verify that the problem returns. The device may be a mechanical switch or an electronic control. Set the engine control to the OFF/RESET mode. “Replacing the ECM”. Switch the 35 amp circuit breaker OFF. Set the switch to each position in order to check the contacts. If the new ECM operates correctly and the original ECM does not operate correctly. If a mechanical switch provides engine control. if necessary. START. Replace the harness. repair the harness. replace the control.

each ECM is able to calculate the positions of the pistons in the cylinders. The timing ring is mounted on the rear of the left camshaft. The ECM that detected the problem with the signal will activate the corresponding diagnostic code. The engine will not start. The timing ring has a special tooth pattern that indicates the position of the camshaft and the direction of rotation. If detonation is detected in any of the cylinders. the master ECM will not initiate the ignition. the sensor generates a signal that matches the pattern of the teeth. • 1 wide slot • 3 narrow slots • 2 wide slots • 18 narrow slots . 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. During engine operation. Three of the slots are about 2.5 times wider than the rest of the slots. If there is a problem with the engine speed/timing sensor’s signal during start-up but no corresponding diagnostic code is active. the master ECM will shut down the engine if either ECM detects a problem with the signal from the speed/timing sensor.282 Troubleshooting Section i02089204 Engine Speed/Timing Sensor SMCS Code: 1912-038 System Operation Description: Illustration 110 Speed/Timing sensor and timing ring g00893441 The speed/timing sensor provides information about engine speed and the position of the crankshaft to the master Electronic Control Module (ECM) and the slave ECM. Each ECM determines the desired ignition timing according to the engine speed and load. The timing ring has 24 slots in the outer diameter. All 24 teeth pass the sliphead during one revolution of the camshaft or two revolutions of the crankshaft. When the engine rotates in the normal direction. The sensor is powered by the sensor supply (12 VDC) from the master ECM. Twenty one of the slots are narrow. With the information from the engine speed/timing sensor. the appropriate ECM retards the timing of the affected cylinders. Each ECM sends voltage pulses to the ignition transformers for firing the spark plugs according to the desired timing. As the teeth of the ring rotate past the sliphead of the sensor. The corresponding diagnostic code is not activated. A magnetic pickup is located underneath the plastic sliphead of the sensor.

The next likely cause is a problem with the engine speed/timing sensor. Clear the diagnostic codes after the problem is resolved. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The least likely cause is a problem with an ECM.283 Troubleshooting Section The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. Before you begin this procedure. Keep your mind on correcting the cause of the original diagnostic code. Logged diagnostic codes provide a historical record. Illustration 111 Schematic for the circuit of the speed/timing sensor g01065386 . The troubleshooting procedure may generate additional diagnostic codes.

Note: For the following steps. Thoroughly inspect the following connections: • J1/P1 connectors • J3/P3 connectors • J7/P7 connectors a. “Inspecting Electrical Connectors”. Set the engine control to the OFF/RESET mode. Illustration 114 Harness side of the master ECM P1 connector (P1-33) Signal (P1-43) 12 volt supply (P1-51) Return g01055533 Illustration 115 Harness side of the slave ECM P3 connector (P3-33) Signal g01065390 Illustration 113 Terminal box g01065389 (2) J1/P1 connectors for the master ECM (3) J7/P7 connectors for the harness from the speed/timing sensor (4) J3/P3 connectors for the slave ECM . Inspect the Electrical Connectors and Wiring B. The proper torque is 2.25 ± 0. Illustration 112 Junction box (1) 35 amp circuit breaker g01054206 A. refer to Troubleshooting. Switch 35 amp circuit breaker (1) to the OFF position.284 Troubleshooting Section Test Step 1. Check the torque of the allen head screws for the connectors on the terminal box.25 N·m (20 ± 2 lb in). b. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Check the torque of the allen head screw for the ECM connectors.

Clean any debris from the plastic sliphead. • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts. Test Step 2. Switch the 35 amp circuit breaker OFF. Look for signs of wear and for contaminants. Check the tension of the plastic sliphead. B. Check the harness and wiring for abrasion and for pinch points from the speed/timing sensor to each ECM. and sockets are connected properly. abrasion. Gently extend the plastic sliphead for a minimum of 4 mm (0. pins. Remove the speed/timing sensor. At least 22 N (5 lb) of force is required to push in the plastic sliphead from the extended position.16 inch). Illustration 118 Plastic sliphead for the speed/timing sensor g00931748 C. Results: • OK – The components are in good condition with proper connections. if necessary. Expected Result: The sensor is in good condition. or pinch points. Inspect the condition of the plastic sliphead. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the speed/timing sensor. STOP. condition and/or at least one connection is improper. Repair: Install the sensor. The connectors and the wiring do not have corrosion. Check the Sensor g00931722 Illustration 116 Harness side of the P7 connector (P7-9) Signal (P7-23) Return (P7-37) Shield (P7-51) 12 volt supply A. Proceed to Test Step 2. . D. Results: • OK – The sensor is not damaged. Expected Result: The connectors. The tension of Illustration 117 Left side view (5) Speed/timing sensor g01065391 the plastic sliphead is correct. Then push back the plastic sliphead. c. Set the engine control to the OFF/RESET mode.285 Troubleshooting Section d.

the speed decreases back to “0”. Use Cat ET to Check the Engine RPM A. Expected Result: Before the engine is cranked. Refer to Troubleshooting. Damage to the plasic sliphead will result. However. Look for the following codes: • 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. c. STOP. • Not OK – The engine cranked. 1. The engine speed increases until the speed stabilizes at the normal cranking speed. Check for Active Diagnostic Codes for the 12 Volt Sensor Supply A. Repair: Install a new sensor. b. B. Calibrate the sensor. If the condition is not resolved. Before installing the sensor.5 mm (0. Note: The plastic sliphead is designed to contact the tooth of the timing ring during installation.Group 1” screen in order to observe “Engine Speed”. Use the following steps to install the speed/timing sensor: a. The maximum allowable clearance between the sliphead and a tooth on the timing ring is 0. d. Observe the “Engine Speed” parameter on the screen and set the engine control to the START mode. Connect Cat ET to the service tool connector. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. When the engine is stopped. Fully extend the sliphead. Do not install the sensor’s plastic sliphead between the teeth of the timing ring. • Active code – One of the above codes is active. Refer to Troubleshooting. • OK – The engine started and the engine ran properly. As the timing ring begins to turn. Set the engine control to the STOP mode.Calibrate”. Proceed to Test Step 5. Results: • No active codes – None of the above codes are active. Crank the engine. ensure that a tooth of the ring is visible in the mounting hole for the sensor. The speed/timing sensor is operating properly. at least one of the codes is logged. Continue to observe the screen and allow the engine rpm to stabilize at the normal cranking speed. Switch the 35 amp circuit breaker ON.286 Troubleshooting Section 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. Use the “Status . A 320-03 diagnostic code or a 320-08 diagnostic code are not activated. ET did not display the correct engine speed or a 320-03 or a 320-08 diagnostic code was activated. If the correct clearance is not maintained. Proceed to Test Step 4. B. Repair: Clear the logged codes. Use the “Active Diagnostic” screen on Cat ET. the engine speed is “0”. the signal from the sensor will not be generated. Proceed to Test Step 5. proceed to Test Step 3. Set the engine control to the STOP mode. C. Proceed to Test Step 3. the radial runout of the timing ring will push the plastic sliphead into the sensor body slightly.02 inch). Coat the threads of the sensor with 4C-5597 Anti-Seize Compound. Ensure that a tooth on the timing ring is visible in the mounting hole for the sensor. Test Step 4. “Electronic Service Tools”. Test Step 3. Tighten the sensor to 40 ± 5 N·m (30 ± 4 lb ft). Cat . C. Install the sensor. However. Results: • Not OK – The plastic sliphead is damaged and/or the tension of the sliphead is insufficient. This provides the plastic sliphead’s air gap with a self-adjusting function. “Engine Speed/Timing Sensor .

Cat ET displayed the correct engine speed. Set the engine control to the OFF/RESET mode. Make repairs. B. Install a new speed/timing sensor. E. Calibrate the sensor. Remove the breakout t from the connectors for the speed/timing sensor. Proceed to Test Step 6.0 VDC. If you are troubleshooting the speed/timing sensor’s signal for the master ECM. the voltage is less than 3. Set the engine control to the START mode.287 Troubleshooting Section • Not OK – The engine cranked but the engine did not start. Refer to Troubleshooting. Set the engine control to the STOP mode. Crank the engine and measure the signal voltage between terminals “B” and “C”. proceed to Test Step 8. Switch the 35 amp circuit breaker OFF.5 VDC. Repair: Remove the breakout t from the connectors for the speed/timing sensor. • Not OK – The sensor is not producing the correct output signal. “Engine Speed/Timing Sensor . Set the engine control to the STOP mode. Measure the Sensor Supply Voltage at the Sensor A. Each ECM is receiving a valid signal.5 VDC and 13. Measure the signal voltage between terminals “B” and “C”. STOP. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. as needed. Measure the supply voltage between terminals “A” and “B” of the breakout t. C.0 VDC or the voltage is greater than 10. Repair: Set the engine control to the OFF/RESET mode.5 VDC and 13. “Engine Cranks But Will Not Start”. B. • Not OK – The sensor is not receiving correct Test Step 7. B.5 VDC. Reconnect the connectors for the speed/timing sensor. • OK – The sensor is receiving correct supply voltage.Calibrate”. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Measure the Sensor Supply Voltage at the Master ECM A. Set the engine control to the OFF mode. Results: Repair: Refer to Troubleshooting. Results: • OK – The sensor is producing the correct output signal. If you are troubleshooting the speed/timing sensor’s signal for the slave ECM. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. C. The voltage varied between 2. Remove the breakout t. Expected Result: The voltage is between 11.0 VDC and 4.0 VDC during cranking. Set the engine control to the STOP mode. Remove the wire from terminal “C” of the breakout t in order to isolate the sensor signal wire. Proceed to Test Step 7. Install a 8T-8726 Adapter Cable As (Three-Pin Breakout) in series with the connectors for the speed/timing sensor. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Set the engine control to the OFF/RESET mode. C. Leave the breakout t connected. supply voltage or a 145-03 diagnostic code or a 145-04 diagnostic code is active. Expected Result: The voltage is between 11. Test Step 5. Insert the probes into terminals P1-33 and P1-51. Test Step 6. STOP. D. . Expected Result: When the engine control is in the STOP mode. Measure the supply voltage at the master ECM. Isolate the Signal Voltage at the Sensor A. Ensure that the breakout t is connected in series with the connectors for the speed/timing sensor. Use two 7X-1710 Multimeter Probes. proceed to Test Step 9.

. Repair: Refer to Troubleshooting. replace the ECM. Refer to Troubleshooting. Connect the other lead of the multimeter to the terminal that was removed from the P1 connector. Isolate the Sensor Signal at the Slave ECM and Measure the Sensor Signal Voltage at the Slave ECM A. Record the measurement. the voltage is less than 3. Record the measurement. B.5 VDC and 13. Measure the signal voltage between the terminals. replace the ECM. The voltage varied between 2.0 VDC or the voltage is greater than 10. If the condition is not resolved. Test Step 8. perform the following steps: Temporarily install a new master ECM. Connect one lead of a multimeter to the terminal that was removed from the P3 connector. The wiring and/or the connectors between the sensor and the master ECM has an open circuit or the circuit has excessive resistance. If the problem is resolved with the new ECM. STOP. STOP. the master ECM is not reading the signal. If the condition is not resolved. However. install the original ECM and verify that the problem returns. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. Connect the leads of a multimeter to the terminals that were removed from the P1 connector. “Replacing the ECM”. Crank the engine and measure the signal voltage between the terminals again. Refer to Troubleshooting. There is an intermittent problem in the circuit for the speed/timing sensor. “Replacing the ECM”.0 VDC and 4. Record the measurement. Exit this procedure and perform this procedure again. Set the engine control to the OFF/RESET mode. STOP. • Not OK – The signal voltage is not correct. as needed. There may be a problem with the master ECM. Remove terminal 51 from the P1 connector from the master ECM. Make repairs. Measure the signal voltage between the terminals. Repair: It is unlikely that the master ECM has failed. D. There may be a problem with the master ECM. “Inspecting Electrical Connectors”. If the new ECM operates correctly and the original ECM does not operate correctly.5 VDC. Make the necessary repairs to the harness and/or connectors. Repair: Set the engine control to the OFF/RESET mode. perform the following steps: Temporarily install a new master ECM. Refer to Troubleshooting. D. Results: • Yes – The sensor supply voltage at the ECM is between 11. Isolate the Sensor Signal at the Master ECM and Measure the Sensor Signal Voltage at the Master ECM A.288 Troubleshooting Section Results: Expected Result: When the engine control is in the STOP mode. Refer to Troubleshooting. Repair: It is unlikely that the master ECM has failed.0 VDC during cranking. install the original ECM and verify that the problem returns. Test Step 9. • No – The master ECM is not producing the correct sensor supply voltage or a 145-03 or a 145-04 diagnostic code is active. Set the engine control to the STOP mode. “Replacing the ECM”. C. If the new ECM operates correctly and the original ECM does not operate correctly. Set the engine control to the OFF/RESET mode.0 VDC. E. Use a 151-6320 Wire Removal Tool to remove terminal 33 from the P3 connector on the slave ECM. Use a 151-6320 Wire Removal Tool to remove terminals P1-33 and P1-51. C. B. • OK – Both of the measurements are correct. “Replacing the ECM”. Switch the 35 amp circuit breaker OFF. Set the engine control to the START mode. Exit this procedure and perform this procedure again. STOP. Set the engine control to the STOP mode. If the problem is resolved with the new ECM.

289 Troubleshooting Section E. If the new ECM operates correctly and the original ECM does not operate correctly. If the problem is resolved with the new ECM. Engine performance will be affected. Exit this procedure and perform this procedure again. Refer to Troubleshooting. “Replacing the ECM”.0 VDC during cranking. 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 master ECM. STOP. STOP. The ECM will activate a 1446-05 diagnostic code. Status Indicator for the Fuel Metering Valve • OK – Both of the measurements are correct. Repair: Refer to Troubleshooting. differential pressure of the valve. The valve converts the command signal and the information into a valve position that directly corresponds to the desired gas flow. as needed. If the digital signal is not available. Engine performance will be affected. If the PWM signal is not available. The ECM will activate a 1446-09 diagnostic code.0 VDC and 4. . Refer to Troubleshooting. Results: The master ECM sends a command signal for the flow of fuel and information about the specific gravity of the gas to the fuel metering valve. The position of the valve is compensated by these additional factors that are internal to the valve: absolute fuel pressure.0 VDC or the voltage is greater than 10. and fuel temperature. The voltage varied between 2. Record the measurement. absolute fuel pressure. “Replacing the ECM”. install the original ECM and verify that the problem returns. the valve will use the PWM signal.0 VDC. the valve will continue to use the digital signal. • Not OK – The signal voltage is not correct. The valve will use the digital signal when both signals are available. Information about the specific gravity of the gas is sent to the fuel metering valve via the CAN Data Link. and fuel temperature. Set the engine control to the START mode. There may be a problem with the slave ECM. The fuel metering valve sends information to the master ECM via the CAN Data Link. The command signal is a 180 hertz PWM signal. One of the signals is a digital signal that is received via the CAN data link. If the condition is not resolved. Repair: It is unlikely that the slave ECM has failed. the slave ECM is not reading the signal. differential pressure of the valve. Expected Result: When the engine control is in the STOP mode. Make repairs. The valve works with the master Electronic Control Module (ECM) in order to ensure the correct flow of fuel in all conditions of engine operation. the valve receives two command signals from the ECM. The other signal is a pulse width modulated signal (PWM) that is received via a pair of wires. During normal operation. However. Crank the engine and measure the signal voltage between the terminals again. replace the ECM. There is an intermittent problem in the circuit for the speed/timing sensor. perform the following steps: Temporarily install a new slave ECM. the voltage is less than 3. This procedure also tests whether the following information is properly sent to the master ECM by the fuel metering valve: position of the fuel valve. “Inspecting Electrical Connectors”. i02089347 Fuel Metering Valve SMCS Code: 1741-038 System Operation Description: The fuel metering valve is an electronic gas valve that controls the flow of fuel to the engine.

The color of the indicator indicates the severity of the problem. observe the status indicator. the status indicator will flash one of the following colors: Green – Normal operation Orange – The valve has detected a problem and the valve continues to operate. Refer to Installation and Operation Manual.290 Troubleshooting Section Illustration 119 Status indicator for the fuel metering valve g00996218 The fuel metering valve contains a status indicator. During operation. Before performing maintenance on the valve. Red – The valve has detected a serious problem. The indicator flashes in order to indicate the status of the valve. The valve has shut down. SEBU7630 for additional information. The flash code indicates the particular error that has been detected by the valve. .

291 Troubleshooting Section

Illustration 120 Schematic for the circuit of the fuel metering valve

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292 Troubleshooting Section

Test Step 1. Inspect the Electrical Connectors and Wiring

Illustration 122 Terminal box Illustration 121 Junction box (1) 35 amp circuit breaker
g01054206

g01065454

A. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”.

(2) Ground strap (3) J1/P1 connectors for the master ECM (4) J6/P6 connectors for the customer (5) J7/P7 connectors for the harness from the fuel metering valve (6) J9/P9 connectors for the harness for the CAN data link (7) J10/P10 connectors for the terminating resistor for the CAN data link

B. Thoroughly inspect each of the following connectors:

• J1/P1 connectors • J6/P6, J7/P7, and J9/P9 connectors • Connectors on the fuel metering valve
a. Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). b. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).

293 Troubleshooting Section

Illustration 123 Harness side of the P1 connector (P1-34) (P1-42) (P1-50) (P1-58) (P1-60) CAN Data Link − CAN shield CAN Data Link + Signal for the fuel flow Return for the signal for the fuel flow

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Illustration 125 (P24-C) CAN Data Link + (P24-D) CAN Data Link + to the throttle actuator (P24-E) CAN Data Link − to the throttle actuator (P24-F) CAN Data Link − (P24-K) Unswitched +Battery (P24-L) −Battery (P24-M) Switched +Battery (P24-S) Signal for the fuel flow (P24-T) Return for the signal for the fuel flow

g00952267

Harness side of the P24 connector for the fuel metering valve

c. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel metering valve.

Illustration 124 Harness side of the J7 connector (J7-11) Signal for the fuel flow (J7-25) Return for the signal for the fuel flow (J7-39) Shield (J7-61) Switched +Battery

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294 Troubleshooting Section

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.

Test Step 2. Check for Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. 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”

• 1446-12 “Fuel Metering Module malfunction” • 1446-13 “Fuel Metering Module calibration
required”

• 1447-12 “Fuel Metering Sensor Module
malfunction” Expected Result:
Illustration 126
g01065457

There are no active diagnostic codes. Results:

Top view of the engine. The 60 Hz configuration is shown. The 50 Hz configuration is similar. (8) Fuel metering valve (9) P24/J24 connectors for the fuel metering valve

• OK – There are no active diagnostic codes. The

d. Check the wiring for abrasion and for pinch points from the fuel metering valve to the master ECM. Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. Results:

signal and the communication between the master 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.

• Not OK (Active 1446-05) – The master ECM has

• OK – The components are in good condition with
proper connections. Proceed to Test Step 2. condition and/or at least one connection is improper.

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. detected an open circuit or a short circuit for the circuit of the CAN Data Link between the master ECM and the fuel metering valve. Proceed to Test Step 4.

• Not OK – The components are not in good

• Not OK (Active 1446-09) – The master ECM has

295 Troubleshooting Section

• Not OK (Active 1446-12) – The fuel metering valve
has detected an internal malfunction. Repair: Refer to Installation and Operation Manual, SEBU7630, “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. STOP.

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

• Not OK (Active 1446-13) – The fuel metering valve
requires calibration. Repair: Refer to Installation and Operation Manual, SEBU7630, “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. STOP.

frequency of the signal for the fuel flow is not correct at the master ECM P1 connector. Proceed to Test Step 5.

Test Step 4. Check the Continuity of the Wiring Harness for the CAN Data Link
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the master ECM J1/P1 connectors. Disconnect the harness connector for the fuel metering valve.

• Not OK (Active 1447-12) – There is a malfunction
of the sensor module in the fuel metering valve. Repair: Refer to Installation and Operation Manual, SEBU7630, “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. STOP.

Test Step 3. Check the Signal for the Fuel Flow
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. 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 35 amp circuit breaker ON. Set the engine control to the STOP mode. 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 127 Connections for the circuit for the fuel metering valve (P1) Connector for the ECM (P24) Connector 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 +
g01065458

C. Use a multimeter to check for continuity between the points that are listed in Table 22.
Table 22

Points to Check for Continuity Connector and Terminal P1-34 P1-50 P1-34 P1-50 Connector and Terminal P24-F P24-C Ground strap for the ECM Ground strap for the ECM

• OK – The voltage, the duty cycle, and the

frequency of the signal for the fuel flow is correct at the master ECM P1 connector. There is a problem with the fuel metering valve.

Expected Result: The continuity of the circuits between the terminals is good.

296 Troubleshooting Section

The continuity between the terminals and the ground strap is open. Results:

• OK – The continuity of the circuits is good. The

continuity of the circuit between the master ECM and the ground strap is open. Repair: Perform the following steps: 1. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. 2. Observe the “Active Diagnostic Codes” screen of Cat ET. If a “1446-09 Unable to communicate with Fuel Metering Module” diagnostic code is activated, troubleshoot the CAN data link. Refer to the engine’s schematic diagram. If a 1446-09 diagnostic code is not activated, proceed to Test Step 6.
Illustration 128 Connections for the circuit for the fuel metering valve (P1) Connector for the ECM (P24) Connector for the fuel metering valve (P1-58) Signal for the fuel flow (P1-60) Return for the signal for the fuel flow (P24-S) Signal for the fuel flow (P24-T) Return for the signal for the fuel flow
g01012855

• Not OK – At least one of the following conditions

D. Use a multimeter to check the continuity of the following circuits:

is found: There is an open circuit between the plug for the master ECM and the plug for the fuel metering valve. There is a short circuit between the plug for the master ECM and a component that is at ground potential. 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.

• P1-58 and P24-S • P1-58 and the ground strap for the ECM • P1-60 and P24-T
Expected Result: The continuity of the circuits between the terminals is good. The continuity between the terminal and the ground strap is open. Results:

Test Step 5. Check the Continuity of the Circuit for the Fuel Flow
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. B. Disconnect the J1/P1 connector. C. Disconnect the fuel metering valve J24/P24 connector.

• OK – The continuity of the circuit between the

master ECM and the fuel metering valve is good. The continuity of the circuit between the master ECM and the ground strap is open. Proceed to Test Step 6. found: There is an open circuit between the master ECM and the fuel metering valve. There is a short circuit between the master 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.

• Not OK – One or both of the following conditions is

297 Troubleshooting Section

Test Step 6. Check the Resistance of the Internal Circuit of the Fuel Metering Valve
A. Ensure the following conditions:

• The fuel metering valve J24/P24 connectors
are disconnected. B. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Note: The “1446-05 Fuel Metering Module open circuit” and “1446-09 Unable to communicate with Fuel Metering Module” diagnostic codes will be activated.

• The engine control is in the OFF/RESET mode. • The 35 amp circuit breaker in the terminal box
is OFF.

• The fuel metering valve J24/P24 connectors
are disconnected.

Illustration 130 Illustration 129 J24 connector on the fuel metering valve (J24-S) Signal for the fuel flow (J24-T) Return for the signal for the fuel flow
g00952241

g00952242

P24 plug on the harness for the fuel metering valve (P24-K) Unswitched +Battery (P24-L) −Battery (P24-M) Switched +Battery

B. Measure the resistance between terminals J24-S and J24-T. Expected Result: The resistance is between 315,000 Ohms and 325,000 Ohms. Results:

C. Use a multimeter to measure the voltage between the following terminals of the harness connector for the fuel metering valve:

• P24-M and P24-L • P24-K and P24-L
Expected Result: The voltage between terminals P24-M and P24-L is between 22.0 VDC and 24.0 VDC. The voltage between terminals P24-K and P24-L terminals is 22.0 VDC and 24.0 VDC. Results:

• OK – The resistance is between 315,000 Ohms
and 325,000 Ohms. Proceed to Test Step 7. Ohms and 325,000 Ohms.

• Not OK – The resistance is not between 315,000
Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.

• OK – The voltage is correct at the P24 plug for the
fuel metering valve. However, the fuel metering valve is not communicating with the master ECM.

Test Step 7. Check the Supply Voltage to the Fuel Metering Valve
A. Ensure the following conditions:

Repair: Replace the fuel metering valve. Verify that the repair has eliminated the original problem. STOP.

• The engine control is in the OFF/RESET mode. • The 35 amp circuit breaker in the terminal box
is OFF.

• Not OK – The voltage is not correct at the P24

plug for the fuel metering valve. There is an open circuit or a short circuit in the harness to the fuel metering valve.

If the generator is not equipped with the EMCP II+. the engine will shut down. The master ECM uses a load signal from one of the following sources in order to monitor the generator’s output power: • The value of the “Fuel Quality” parameter • Inlet air temperature and pressure • Other factors The master ECM compares the two values. A 1719-03 diagnostic code is also generated if the voltage on terminal J1-25 ever exceeds 4. the master ECM will start requesting information on the generator’s load from the GSC+ via the CAT data link. • Electronic Modular Control Panel II+ (EMCP II+) • Programmable Logic Controller (PLC) • Wattmeter The PLC and the wattmeter are also called power sensors. i02089358 1719-04 Diagnostic Code This code only applies to engines that are equipped with a power sensor. the master ECM receives the load signal from a power sensor via terminal J1-25. . If two seconds elapse and the master ECM does not receive a response from the GSC+. the master ECM will look for a load signal on terminal J1-25. 1719-03 Diagnostic Code On powerup. If the value that is calculated by using the information from the GSC+ is not within 20 percent of the other value. if necessary. the engine will shut down. If the engine is running. STOP. the engine will shut down. If the engine is running. Only one load signal is connected to the master ECM. One value is calculated by using the information on the generator’s load from the GSC+. The other value is calculated from the following inputs: Generator Output Power Sensor SMCS Code: 5574-038-PWR System Operation Description: The master ECM monitors the generator’s output power in order to accurately control the air/fuel ratio.8 VDC as the generator’s output increases to the maximum output. If there is no load signal on terminal J1-25. If the engine is running.298 Troubleshooting Section Repair: Perform the necessary repairs for the wiring and/or the connectors.8 VDC. the master ECM receives the load signal from the Generator Set Control + (GSC+) via the CAT data link. 1719-12 Diagnostic Code This code only applies to engines that are equipped with the EMCP II+. The load signal from the power sensor is an analog voltage. the engine will shut down.2 VDC. the master ECM will generate a 1719-03 diagnostic code. Replace parts. Verify that the repair has eliminated the original problem. the master ECM will generate a 1719-12 diagnostic code. If the generator is equipped with the EMCP II+. If the engine load is greater than 20 percent and the voltage on terminal J1-25 is less than 0. Ensure that all of the seals are properly installed. The load signal increases from 0 VDC to 4. If the engine is running. Ensure that the connectors are properly engaged. The master ECM calculates two values that represent the engine’s load. the master ECM will generate a 1719-04 diagnostic code.

For the actual wiring. . refer to the generator’s schematic diagram.299 Troubleshooting Section Illustration 131 Schematic of the power sensor’s input with EMCP II+ g01065476 Illustration 132 g01065477 Schematic of the power sensor’s input with a power sensor For the actual wiring.Calibrate”. refer to Troubleshooting. For further information. refer to the generator’s schematic diagram. The potentiometer is optional. “Generator Output Power Sensor .

Illustration 133 Junction box (1) 35 amp circuit breaker g01054206 A. Illustration 135 Harness side of the P1 connector (P1-8) Cat data link + (P1-9) Cat data link − (P1-19) Load signal + (P1-25) Load signal − g01065479 Illustration 134 Terminal box g01065478 (2) J1/P1 connectors (3) J6/P6 connectors for the wiring from the power sensor . “Inspecting Electrical Connectors”. Set the engine control to the OFF/RESET mode. The proper torque is 2. Thoroughly inspect the following components: • J1/P1 connectors • J6/P6 connectors • The wiring and the connections between the master ECM and the GSC+ (if equipped) • The wiring and the connections between the master ECM and the power sensor (if equipped) a.25 ± 0.25 N·m (20 ± 2 lb in). b. refer to Troubleshooting. Switch 35 amp circuit breaker (1) to the OFF position.300 Troubleshooting Section Test Step 1. Check the torque of the allen head screw for the ECM connectors. Inspect the Electrical Connectors and Wiring B. Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Note: For the following steps.

Test Step 2. B. Attempt to apply at least a 30 percent load to the generator. Repair: Perform the necessary repairs and/or replace parts. Results: • Active 1719-03 code – There is an active 1719-03 code. Results: Illustration 136 Harness side of the J6 connector (J6-3) Load signal + (J6-7) Cat data link + (J6-13) Load signal − (J6-17) Cat data link − g00952302 • No active codes – There are no active codes for the generator output power sensor. Refer to Troubleshooting. Disconnect the P1 connector from the master ECM. code. d. Proceed to Test Step 2. if necessary. Expected Result: Each continuity check indicates an open circuit. . D. Expected Result: There are no active codes for the generator output power sensor. • Not OK – The components are not in good condition and/or at least one connection is improper. Disconnect the “load signal” wires from the power sensor. c. Allow a minimum of 30 seconds for any codes to activate. Repair: If there is a logged code for the generator output power sensor. Check the “Load Signal” Wiring for a Short Circuit A. Connect the Cat Electronic Technician (ET) to the service tool connector. STOP. Refer to Troubleshooting. Check the harness and wiring for abrasion and for pinch points between the power sensor and the master ECM. • OK – The components are in good condition with proper connections. Look for these codes: • 1719-03 • 1719-04 • 1719-12 D. STOP. Proceed to Test Step 7. Observe the “Active Diagnostic” screen on ET. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the power sensor.301 Troubleshooting Section B. C. Start the engine and run the engine. Otherwise. proceed to Test Step 3. or pinch points. • Active 1719-04 code – There is an active 1719-04 • Active 1719-12 code – There is an active 1719-12 Test Step 3. abrasion. “Inspecting Electrical Connectors”. and sockets are connected properly. Check for continuity between P1-19 and all the other terminals on the P1 connector. “Electronic Service Tools”. there may be a problem with the wiring and/or a connector. Proceed to Test Step 5. Expected Result: All connectors. Check for continuity between P1-25 and all the other terminals on the P1 connector. Check for a Diagnostic Code A. C. proceed to Test Step 7. Stop the engine. There may be a logged code for the generator output power sensor. pins. If the generator is equipped with EMCP II+. The connectors and the wiring do not have corrosion. code.

Verify that the problem is resolved. Proceed to Test Step 6. Check the continuity of the wiring between P1-25 and the power sensor. Reconnect the “load signal +” wire to the power sensor. There is a short circuit in a harness or in a connector. Results: • Not OK – At least one continuity check indicates a short circuit. the problem may be between the J6 connector and the power sensor. and the Current Transformers Verify that the power sensor. Repair: Reconnect the P1 connector. Replace parts. Repair: The problem may be between the P1 connector and the J6 connector. Check for continuity between P1-25 and all the other terminals on the P1 connector. Proceed to Test Step 4. the potential transformers. A high resistance reading may be caused by the potentiometer. in a connector. if necessary. Test Step 4. Repair the harness or the connection. Repair: The problem may be between the P1 connector and the J6 connector. • Not OK – The “load signal” wiring has an open circuit. Repair: Reconnect the P1 connector. • OK – The “load signal” wiring has continuity. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. C. if necessary. Results: circuit. Expected Result: Each continuity check indicates an open circuit. Refer to the appropriate service literature for the components. Be sure to observe the correct polarity. Replace parts. • OK – Each continuity check indicates an open circuit. Check the “Load Signal” Wiring for Continuity Note: A potentiometer may be installed in the “load signal” wiring. the problem may be between the J6 connector and the generator output power sensor. Verify that the problem is resolved. Check the “Load Signal +” Wire for a Short Circuit A. or in the potentiometer. Verify that the original problem is resolved. D. B. when possible. STOP. Alternatively.302 Troubleshooting Section Results: • OK – Each continuity check indicates an open Test Step 5. Alternatively. The “load signal +” wire does not have a short circuit. Disconnect the P1 connector from the master ECM. Test Step 6. the Potential Transformers. and the current transformers are operating correctly. . Replace parts. Repair the harness or the connection. if necessary. • Not OK – At least one continuity check indicates a short circuit. The “load signal” wiring does not have a short circuit. Expected Result: The components are operating correctly. when possible. Disconnect the “load signal +” wire from the power sensor. Expected Result: The “load signal” wiring has continuity. STOP. Proceed to Test Step 6. STOP. B. Reconnect the “load signal” wires to the power sensor. when possible. A. Check the Power Sensor. The open circuit may be in a wire. Check the continuity of the wiring between P1-19 and the power sensor. Repair: Repair the component.

000 Ohms. Disconnect the wiring for the Cat data link from the GSC+. Disconnect the P1 connector from the master ECM. • Not OK – At least one check of the resistance for the Cat data link is incorrect. • OK – The components are operating correctly. STOP. operating correctly. when possible. Refer to the appropriate service literature for the EMCP II+. Disconnect Cat ET from the service tool connector. Verify that the original problem is resolved. Proceed to Test Step 8. Reconnect the P1 connector.303 Troubleshooting Section Results: 2. E. B. STOP. Be sure to connect each wire to the appropriate terminal. Switch the 35 amp circuit breaker OFF. Verify that the original problem is resolved. Refer to the appropriate service literature for the EMCP II+. Check the “Fuel Quality” parameter Verify that the value of the “Fuel Quality” parameter is correct. Be sure to wiggle the wires near each of the connectors. Repair: Perform the following procedure: 1. Verify that the original problem is resolved. Results: • OK – The value of the “Fuel Quality” parameter is correct. when possible. wiggle the wires in the harness in order to check for an intermittent problem. The wiring for the Cat data link appears to be OK. “Methane Number Program”. is not correct. • Not OK – The GSC+ is not operating correctly. • Not OK – At least one of the components is not Repair: Repair the component. Check the Continuity of the Cat Data Link A. Use the value that is obtained from the Caterpillar Software. There is a problem with the wiring for the Cat data link. Each check of the resistance between the terminals and the ground strap is greater than 20. Proceed to Test Step 13. C. Expected Result: The GSC+ is operating correctly. Replace the component. During each measurement. Results: The value of the “Fuel Quality” parameter is correct. Repair: Repair the connection and/or the wire. Replace parts. • Not OK – The value of the “Fuel Quality” parameter Repair: Enter the correct value for the parameter. STOP. Measure the resistance between the points that are listed in Table 23. • OK – Each check of the resistance for the Cat data link is within the specification. if necessary. Proceed to Test Step 10. Verify that the original problem is resolved. Proceed to Test Step 13. Set the engine control to the OFF/RESET mode. STOP. LEKQ6378. Reconnect the wiring to the GSC+. Resistance Measurements for the Cat Data Link Connector and Terminal P1-8 P1-9 P1-8 P1-9 Connector and Terminal Terminal 19 on the GSC+ Terminal 20 on the GSC+ Ground strap for the ECM Ground strap for the ECM Test Step 9. D. Results: • OK – The GSC+ is operating correctly. Repair: Repair the GSC+. . if necessary. Test Step 7. Check the GSC+ Verify that the GSC+ is operating correctly. Table 23 Test Step 8. Expected Result: Expected Result: Each check of the resistance between the terminals is less than 5 Ohms.

Proceed to Test Step 13. Refer to the appropriate service literature for the EMCP II+. Expected Result: The GSC+ is operating correctly. If the new ECM operates correctly and the original ECM does not operate correctly. Repair: Install the original ECM and verify that the problem returns. STOP. B. • Not OK – One or both of the values of the parameters are incorrect. Results: • OK – The problem is resolved when a new master ECM is installed. Verify that the original problem is resolved. Connect a pressure gauge and a temperature sensor to the air inlet manifold. “Generator Output Power Readings Do Not Match”. • OK – The GSC+ is operating correctly. • Not OK – The problem is not resolved when a new ECM is installed. Repair: Replace the appropriate sensor. Verify that the Output Power Reading is Correct Operate the generator at various loads. If the engine is running.304 Troubleshooting Section Test Step 10. Repair: Repair the GSC+. temporarily install a new master ECM. Results: • OK – The value of the “Generator Real kW” parameter is correct. parameter is incorrect. If the problem is not resolved. Results: • “Inlet manifold air pressure (abs)” • “Inlet air temperature” Expected Result: The values of the parameters are correct. Results: Test Step 11. Proceed to Test Step 8. Expected Result: The value of the “Generator Real kW” parameter is correct. STOP. Check the Master ECM It is unlikely that the master ECM has failed. Exit this procedure and perform this procedure again. C. Refer to the appropriate service literature for the EMCP II+. replace the ECM. Repair: Reinstall the original ECM. View the Status Group 1 on Cat ET. Test Step 13. Proceed to Test Step 12. Verify that the value of the “Generator Real kW” parameter in Status Group 1 is within 1 percent of the generator’s output power. . • Not OK – The GSC+ is not operating correctly. Verify that the original problem is resolved. STOP. stop the engine. Compare the values on the instruments with the following parameters: Test Step 12. Expected Result: The problem is resolved when a new master ECM is installed. • OK – The values of the parameters are correct. STOP. Check the Sensors for the Air Inlet Manifold A. Refer to Troubleshooting. STOP. Consult with Caterpillar customer service for large gas engines. • Not OK – The value of the “Generator Real kW” Repair: Refer to Troubleshooting. “Replacing the ECM”. Check the GSC+ Verify that the GSC+ is operating correctly.

8. The ignition wiring is continuous from the master ECM P2 connector to the individual transformers for the cylinders with an even number. 11. The next likely cause is a problem with an ignition transformer. 17.305 Troubleshooting Section i02089430 Table 24 Ignition Transformers Primary Circuit SMCS Code: 1561-038 System Operation Description: The master Electronic Control Module (ECM) has internal circuit drivers for the ignition transformers on the left side of the engine. 19. The least likely cause is a problem with an ECM. 4 and 6 13 and 15 14 and 16 1. A high side short circuit will affect only that cylinder. 9. Circuit Drivers Some circuit drivers send signals to a single cylinder. 6. 10. or 14 Cylinder 3 or 5 Circuit driver’s side short to +Battery Cylinder 4 or 6 Circuit driver’s side short to +Battery Cylinder 13 or 15 Circuit driver’s side short to +Battery Cylinder 14 or 16 Circuit driver’s side short to +Battery Return side short to +Battery 3 and 5 Cylinders Only one cylinder is affected. The slave ECM has internal returns for the ignition transformers on the right side of the engine. and 19 2.000 volts) to the spark plugs. The ignition wiring is continuous from the P4 connector on the slave ECM to the individual transformers for the cylinders with an odd number. Some circuit drivers send signals to more than one cylinder. and 10 12. 9. This means that a return short circuit to the +Battery will simultaneously affect all of the cylinders that are grouped. a high side short circuit will affect more than one cylinder. 18. The signal goes to the high side of the primary circuits of the ignition transformers. or 20 Circuit driver’s side short to ground for cylinders 1. 12. 2. Some of the returns consist of groups of terminals that are connected via diodes inside the master ECM. 2. Each circuit driver creates a signal of +108 volts. Diagnostic Conditions and the Combinations of Cylinders that are Affected Condition Circuit driver’s side open Return side open Return side short to ground Circuit driver’s side short to +Battery for cylinders 1. For this reason. 11. Logged diagnostic codes provide a historical record. Return Side The master ECM has internal returns for the ignition transformers on the left side of the engine. and 20 Because the circuits are in pairs or groups. 15. 4. a single problem will activate either only one diagnostic code or multiple codes. If multiple diagnostic codes are active for the primary ignition. For the combinations of cylinders that can be affected by a condition. and 9 11. troubleshooting the circuits one at a time is an effective way to find the root cause. 19. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. . Some of the returns consist of groups of terminals that are connected via diodes inside the slave ECM. Some circuit drivers and returns are shared. multiple diagnostic codes can be activated for a single problem. 16. Therefore. 18. 3. 8. The transformers deliver high voltage (8000 to 37. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. 12. Each circuit driver creates a signal of +108 volts. 7. 17. The transformers deliver high voltage (8000 to 37. 7. 7. or 20 Return side short to +Battery for cylinders 5. The slave ECM has internal circuit drivers for the ignition transformers on the right side of the engine. 18. Before you begin this procedure.000 volts) to the spark plugs. 17. 10. 13. The signal goes to the high side of the primary circuits of the ignition transformers. refer to Table 24. 8. This means that a return short circuit to the +Battery will simultaneously affect all of the cylinders that are grouped.

306 Troubleshooting Section Illustration 137 Schematic for the primary ignition on the left side of the engine g01065514 .

307 Troubleshooting Section Illustration 138 Schematic for the primary ignition on the right side of the engine g01065515 .

Switch 35 amp circuit breaker (1) to the OFF position. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). (2) Harness for the primary ignition from the master ECM to the left bank (3) J2/P2 connectors for the master ECM (4) J4/P4 connectors for the slave ECM (5) Harness for the primary ignition from the slave ECM to the right bank B. Inspect the Electrical Connectors and Wiring Illustration 140 Terminal box Illustration 139 Junction box (1) 35 amp circuit breaker g01054206 g01065516 A. Note: For the following steps. “Inspecting Electrical Connectors”. refer to Troubleshooting. Thoroughly inspect the following connectors: • J2/P2 connectors • J4/P4 connectors a. . Set the engine control to the OFF/RESET mode.308 Troubleshooting Section Test Step 1. Check the torque of the allen head screw for the ECM connectors.

condition and/or at least one connection is improper. and sockets are connected properly. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit of the ignition system. STOP. or pinch points. . C. Expected Result: All connectors. pins.309 Troubleshooting Section Illustration 141 Harness side of the P2 connector (P2-1) Number 2 transformer’s circuit driver (P2-2) Number 2 transformer’s return (P2-3) Number 12 transformer’s circuit driver (P2-4) Number 12 transformer’s return (P2-14) Number 4 transformer’s circuit driver (P2-15) Number 4 transformer’s return (P2-16) Number 16 transformer’s circuit driver (P2-17) Number 16 transformer’s return (P2-24) Number 8 transformer’s circuit driver (P2-25) Number 8 transformer’s return (P2-26) Number 20 transformer’s circuit driver (P2-27) Number 20 transformer’s return (P2-32) Number 10 transformer’s circuit driver (P2-33) Number 10 transformer’s return (P2-34) Number 18 transformer’s circuit driver (P2-35) Number 18 transformer’s return (P2-48) Number 6 transformer’s circuit driver (P2-49) Number 6 transformer’s return (P2-50) Number 14 transformer’s circuit driver (P2-51) Number 14 transformer’s return g01066020 Illustration 142 Harness side of the P4 connector (P4-1) Number 1 transformer’s circuit driver (P4-2) Number 1 transformer’s return (P4-3) Number 11 transformer’s circuit driver (P4-4) Number 11 transformer’s return (P4-14) Number 3 transformer’s circuit driver (P4-15) Number 3 transformer’s return (P4-16) Number 15 transformer’s circuit driver (P4-17) Number 15 transformer’s return (P4-24) Number 7 transformer’s circuit driver (P4-25) Number 7 transformer’s return (P4-26) Number 19 transformer’s circuit driver (P4-27) Number 19 transformer’s return (P4-32) Number 9 transformer’s circuit driver (P4-33) Number 9 transformer’s return (P4-34) Number 17 transformer’s circuit driver (P4-35) Number 17 transformer’s return (P4-48) Number 5 transformer’s circuit driver (P4-49) Number 5 transformer’s return (P4-50) Number 13 transformer’s circuit driver (P4-51) Number 13 transformer’s return g01066020 b. Results: • OK – The components are in good condition with proper connections. abrasion. Check the ignition harnesses and wiring for abrasion and for pinch points from each ignition transformer to each ECM. Proceed to Test Step 2. The connectors and the wiring do not have corrosion. if necessary. • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts.

Do not attempt to remove the valve covers when the engine is operating. Results: Illustration 143 Section view of a cylinder (1) Cover (2) Transformer (3) 3-pin connector g01057615 • Active “open circuit” – There is an open in the primary circuit. 3. Remove cover (1) for the suspect cylinder. Connect Cat ET to the service tool connector. and for pinch points. Switch the 35 amp circuit breaker ON. “Inspecting Electrical Connectors”. Check for Diagnostic Codes for the Primary Circuit A. Proceed to Test Step 6. B. The engine will not operate without the valve covers. The transformers are grounded to the valve covers. Use Cat ET in order to determine if the following codes are active or logged: Ignition systems can cause electrical shocks. . • 301-05 Ignition Transformer Primary #1 open circuit through 316-05 Ignition Transformer Primary #16 open circuit • 1752-05 Ignition Transformer Primary #17 open circuit through 1755-05 Ignition Transformer Primary #20 open circuit • 301-06 Ignition Transformer Primary #1 short through 316-06 Ignition Transformer Primary #16 short • 1752-06 Ignition Transformer Primary #17 short through 1755-06 Ignition Transformer Primary #20 short Note: If a diagnostic code for the primary circuit is logged but not currently active. • Active “short” – There is a short in the primary • Logged only – There may be an intermittent problem in the ignition harness. “Electronic Service Tools”. Refer to Troubleshooting. attempt to repeat the condition that activated the code. for abrasion.310 Troubleshooting Section Test Step 2. Repair: Perform the following steps: 2. 1. Attempt to start the engine. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. Proceed to Test Step 3. Inspect the harness and 3-pin connector (3) of transformer (2). Reconnect the connectors. Set the engine control to the OFF/RESET mode. Run the engine to full operating temperature. refer to Troubleshooting. Avoid contacting the ignition system components and wiring. Check for corrosion. and reinstall the cover. circuit. If the problem persists. Switch the 35 amp circuit breaker OFF. C. STOP. Expected Result: None of the above diagnostic codes are active.

A. The engine will not operate without the valve covers. The transformers are grounded to the valve covers. Visually inspect the 3-pin connectors for corrosion and/or for damage. D. Illustration 145 (4) 3-pin connector for the transformer (5) Terminal A (6) Terminal B (7) Blocking diode (8) Flyback diode (9) Primary coil of the transformer (10) Secondary coil of the transformer (11) Resistor (12) Spark plug gap g01057616 Schematic for the primary circuit and for the secondary circuit E. . Avoid contacting the ignition system components and wiring. C. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. Do not attempt to remove the valve covers when the engine is operating.311 Troubleshooting Section Test Step 3. Remove cover (1) for the suspect cylinder. Disconnect 3-pin connector (3). Illustration 144 Section view of a cylinder (1) Cover (2) Transformer (3) 3-pin connector g01057615 B. Remove transformer (2) from the cylinder head. Set the engine control to the OFF/RESET mode. Check the Transformer’s Primary Circuit and the Secondary Circuit Ignition systems can cause electrical shocks. Switch the 35 amp circuit breaker OFF. Measure the primary circuit by checking the voltage of the blocking diode.

b. Operate the engine. the resistance between the screw for the ground spring and the connector for the spark plug is within the acceptable tolerance. the correct resistance is between 21.450 VDC. Install the spark plug according to the instructions in Operation and Maintenance Manual. Restart the engine. if the transformer’s temperature is 60 °C (140 °F).000 and 23. Measure the voltage between the terminals again. For the secondary circuit. F. Reverse the multimeter leads. 3. Illustration 147 demonstrates the relationship between the secondary coil’s resistance and the temperature. 2. Install the valve covers. Note: The resistance of the secondary coil will vary with the temperature. Measure the resistance of the secondary circuit.000 Ohms.000 Ohm scale. A reading that is within 1000 Ohms is acceptable. Check for a recurrence of the problem. Set the multimeter to the 40. Connect the multimeter leads to terminals (A) and (B) of the 3-pin connector. For example. Reset the control system. Measure the resistance between mounting flange (13) and the extension’s internal terminal (14) for the spark plug.Terminal (13) Mounting flange (14) Connector for the spark plug g01057618 a. The polarity of the leads is not important. Clear any logged codes. Set the multimeter to the diode scale. Measure the voltage between the terminals. one of the voltage measurements is approximately 0. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Repair: Perform the following steps: 1.312 Troubleshooting Section Illustration 147 Resistance versus temperature (Y) Resistance in Ohms (X) Temperature in degrees celsius (degrees fahrenheit) g00863850 Illustration 146 Ignition transformer (A) + Terminal (B) . The other voltage measurement indicates an open circuit. “Ignition System Spark Plugs Check/Adjust/Replace”. Record the measurement. Record the measurement. • OK – All three of the measurements are correct. Install the transformers. Results: a. . Expected Result: For the primary circuit. 4.

Turn OFF the gas supply before you perform this step. Look for a “short circuit” code. Resume normal operation. A. Switch the 35 amp circuit breaker OFF. proceed to Test Step 4. Expected Result: The “short” code is active when the transformer’s connector is disconnected. the ignition system is disabled. If the original “short circuit” code does not return. C. NOTICE The air inlet. Connect the ignition harness to the transformer. and the engine is cranked. STOP. The unburned fuel can ignite unexpectedly and cause damage. A. • Not OK – At least one of the three measurements is incorrect. Repair: Perform the following procedure: 1. 2. and the exhaust system can be filled with fuel when the gas supply is ON. Replace the transformer if the original “short circuit” code is activated. Results: 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. Shut OFF the fuel supply. B. and the engine is cranked. Disconnect the 3-pin connector for the suspect transformer.313 Troubleshooting Section If the problem stays with the suspect transformer. replace the transformer. and the exhaust system can be filled with fuel when the gas supply is ON. Proceed to Test Step 5. Disconnect the Wiring From the ECM and Check for a Short Circuit There is a strong electrical shock hazard when the crankshaft is rotating. P2 or P4 connector . the ignition system is disabled. The unburned fuel can ignite unexpectedly and cause damage. the cylinders. • Yes – The “short” code was activated after the transformer’s connector was disconnected. Illustration 148 g01065517 • No – The original “short” code was not activated after the transformer’s connector was disconnected. Test Step 4. If the problem stays with the suspect cylinder. Check for a Short Circuit Between the ECM and the Transformer Test Step 5. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Make sure that you use the correct transformer for the G3520C Engine. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Set the engine control to the OFF mode. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. Set the engine control to the OFF/RESET mode. the problem appears to be resolved. NOTICE The air inlet. Turn OFF the gas supply before you perform this step. the cylinders. Repair: Replace the ignition transformer. STOP.

Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Table 25 Repair: Set the engine control to the OFF/RESET mode. Follow the instructions in Troubleshooting. and the exhaust system can be filled with fuel when the gas supply is ON. Disconnect the 3-pin connector for the transformer. and the engine is cranked. Verify that the connectors do not have damage or corrosion. Verify that the harness does not have damage or corrosion. Set the engine control to the STOP mode. D. Remove the valve cover for the suspect cylinder. Switch the 35 amp circuit breaker ON. Avoid contacting the ignition system components and wiring. Set the engine control to the OFF/RESET mode. Expected Result: An “open circuit” diagnostic code is activated for the circuit after removal of the wire for the circuit driver. NOTICE The air inlet. D. Install a jumper wire into terminals A and B of the 3-pin connector on the ignition harness. The engine will not operate without the valve covers. Shut OFF the fuel supply. Inspect the harness. Create a Short Circuit in the Ignition Harness Ignition systems can cause electrical shocks. A. B. STOP. Test Step 6. C. There is a short circuit in the wiring. the ignition system is disabled. The unburned fuel can ignite unexpectedly and cause damage.314 Troubleshooting Section B. Use a 151-6320 Wire Removal Tool to remove the terminal for the circuit driver of the suspect cylinder from the ECM connector. if necessary. Cylinder and Corresponding Terminal of the ECM Connector for the Ignition Harness Cylinder 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Terminal for the Circuit Driver P4-1 P2-1 P4-14 P2-14 P4-48 P2-48 P4-24 P2-24 P4-32 P2-32 P4-3 P2-3 P4-50 P2-50 P4-16 P2-16 P4-34 P2-34 P4-26 P2-26 • No – The ECM continued to activate a “short circuit” diagnostic code after the wire was disconnected from the ECM. Results: • Yes – The ECM detected an open circuit after the wire was disconnected from the ECM. “Replacing the ECM”. There is a problem with the ECM. refer to Illustration 148 and Table 25. Repair: Replace the ECM that is appropriate for the suspect cylinder. Replace the harness. Do not attempt to remove the valve covers when the engine is operating. STOP. the cylinders. For identification of the appropriate terminal. C. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. Inspect the connectors. The transformers are grounded to the valve covers. Turn OFF the gas supply before you perform this step. . when possible. Switch the 35 amp circuit breaker OFF. Repair the harness.

The ECM did not detect the jumper wire. Reconnect the ignition harness to the transformer. Proceed to Test Step 7. Turn OFF the gas supply before you perform this step. The unburned fuel can ignite unexpectedly and cause damage. Look for the original “open circuit” code. A. NOTICE The air inlet. the ignition system is disabled. the ignition system is disabled. For identification of the appropriate terminals. If the original “open circuit” code is activated. STOP. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. Set the engine control to the OFF/RESET mode. Remove the jumper wire from the 3-pin connector of the ignition harness. 2. Expected Result: The original “open circuit” code is active. 5. Test Step 7. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker to the OFF position. the cylinders. Use a 151-6320 Wire Removal Tool to remove two terminals for the circuit driver of the suspect cylinder from the ECM connector.315 Troubleshooting Section E. and the exhaust system can be filled with fuel when the gas supply is ON. 1. 7. the cylinders. NOTICE The air inlet. and the engine is cranked. Check the Engine Harness for an Open Circuit • Yes – The original “open circuit” code was activated after a short circuit was created in the ignition harness. 4. Shut OFF the fuel supply. Results: 6. Illustration 149 P2 or P4 connector g01013288 B. Reconnect the ignition harness to the transformer. . • No – Cat ET displayed an active “short” diagnostic There is a strong electrical shock hazard when the crankshaft is rotating. Turn OFF the gas supply before you perform this step. The unburned fuel can ignite unexpectedly and cause damage. Switch the 35 amp circuit breaker OFF. Replace the transformer. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Clear all of the logged diagnostic codes. and the exhaust system can be filled with fuel when the gas supply is ON. 3. set the engine control to the OFF/RESET mode. The harness and the ECM are OK. code after a short circuit was created in the ignition harness. Make sure that you use the correct transformer for the G3520C Engine. and the engine is cranked. Set the engine control to the START mode and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. Look for the original “open circuit” code. Switch the 35 amp circuit breaker OFF. refer to Illustration 149 and Table 26. Repair: Perform the following steps: There is a strong electrical shock hazard when the crankshaft is rotating.

3. Switch the 35 amp circuit breaker OFF. The ECM did not detect the jumper wire. 1561-038 System Operation Description: The ignition transformers initiate combustion by providing high voltage to the spark plugs. Set the engine control to the START mode. STOP. a “short circuit” diagnostic code was activated for the suspect cylinder. Ignition Transformers Secondary Circuit and Spark Plugs SMCS Code: 1555-038. The original “open circuit” diagnostic code was not active. Switch the 35 amp circuit breaker to the ON position. This will replace the wiring with a short circuit. i02089548 C. The transformers are located underneath covers at the top of each cylinder. E. . 2. There is an open circuit in the wiring harness for the suspect cylinder. • No – When the jumper wire was installed into the connector. Install the ends of a jumper wire into the terminals for the removed wires. There is a problem with the ECM. Repair: Perform the following steps: 1. Expected Result: A “short circuit” diagnostic code is activated for the suspect cylinder. Each transformer is grounded to the cylinder head via a mounting flange. The original “open circuit” diagnostic code is not active. when possible. Pull on the wires in order to verify that the terminals are fully inserted into the connector. 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. Replace the harness. Remove the jumper wire and reinstall the terminals that were removed from the connector. Set the engine control to the OFF/RESET mode. Observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Look for a “short circuit” diagnostic code. D. if necessary. Repair: Replace the ECM that is appropriate for the suspect cylinder.316 Troubleshooting Section Table 26 Results: Cylinders and Corresponding Terminals of the ECM Connectors for the Ignition Harnesses Cylinder 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Terminals for the Cylinder P4-1 and P4-2 P2-1 and P2-2 P4-14 and P4-15 P2-14 and P2-15 P4-48 and P4-49 P2-48 and P2-49 P4-24 and P4-25 P2-24 and P2-25 P4-32 and P4-33 P2-32 and P2-33 P4-3 and P4-4 P2-3 and P2-4 P4-50 and P4-51 P2-50 and P2-51 P4-16 and P4-17 P2-16 and P2-17 P4-34 and P4-35 P2-34 and P2-35 P4-26 and P4-27 P2-26 and P2-27 • Yes – When the jumper wire was installed into the connector. Follow the instructions in Troubleshooting. Repair the harness. “Replacing the ECM”. a “Short circuit” diagnostic code was not activated. STOP.

a megohmmeter must be used. Switch the 35 amp circuit breaker ON. Test Step 1. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The total duration of the spark is approximately 400 microseconds. Secondary open circuits and short circuits will not directly shut down the engine. Each Electronic Control Module (ECM) can diagnose the primary circuit of the ignition transformers for open circuits and/or for short circuits.317 Troubleshooting Section Note: Ignition transformers from Electronic Ignition Systems (EIS) are not interchangeable with the transformers in this engine. Connect Cat ET to the service tool connector. Logged diagnostic codes provide a historical record.000 to 37. If a measurement of the resistance is desired. Most ignition systems are not affected by resistance in the secondary circuit. Set the engine control to the STOP mode.000 volts. Refer to Troubleshooting. Set the engine control to the OFF/RESET mode. Lugging of the engine can cause a shutdown. Check the Status Screen of Cat ET for the Output of the Secondary Circuits of the Transformers Illustration 150 Ignition transformer and spark plug (1) Mounting flange (2) 3-pin connector (3) Transformer (4) Extension (5) Secondary spark plug terminal (6) O-ring seal (7) Hole in the spark plug’s precombustion chamber g01057652 Illustration 151 Junction box (1) 35 amp circuit breaker g01054206 The secondary circuit of the transformer provides an initial 8. C. A. This voltage is then reduced to about 1000 volts. D. A low voltage multimeter will not provide a reliable reading of the resistance because oxidation of the spark plug’s internal components will affect the readings of those meters. B. Set up two status screens for Cat ET. Before you begin this procedure. However. The spark plugs operate at a voltage that is greater than 5.000 volts to the spark plug. Caterpillar spark plugs are high voltage devices with internal resistors. This voltage ionizes the spark plug gap. these conditions may lead to misfire which can cause lugging of the engine. Use eight of the following labels for parameters on each status screen: . “Electronic Service Tools”. Switch 35 amp circuit breaker (1) to the OFF position.

Results: Illustration 152 Section view of a cylinder (1) Cover (2) Transformer (3) 3-pin connector g01057615 • OK – The displayed value of the output for the secondary circuit of each transformer is between 1 and 90 percent. Proceed to Test Step 2. Allow the engine to warm up to normal operating temperature. The transformers are grounded to the valve covers. Remove cover (1) for the suspect cylinder. Switch the 35 amp circuit breaker OFF. A. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. Refer to Troubleshooting. Test Step 2. The engine will not operate without the valve covers. Troubleshoot the symptom. Set the engine control to the OFF/RESET mode. Apply the normal load at rated speed. F. Observe the value of the output for the secondary circuit of each transformer. Do not attempt to remove the valve covers when the engine is operating. Expected Result: The displayed value of the output for the secondary circuit of each transformer is between 1 and 90 percent.318 Troubleshooting Section Table 27 Parameters for the Status Screens on Cat ET Screen 1 Group 8 “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” “Cylinder #17 Transformer Secondary Output Voltage Percentage” “Cylinder #19 Transformer Secondary Output Voltage Percentage” 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” “Cylinder #18 Transformer Secondary Output Voltage Percentage” “Cylinder #20 Transformer Secondary Output Voltage Percentage” Repair: Investigate other possible root causes of the problem. Avoid contacting the ignition system components and wiring. • Not OK – At least one of the outputs displayed a value of 0 percent or a value that is greater than 90 percent. Start the engine. E. STOP. The ignition system components are operating properly. . Inspect the Transformer Ignition systems can cause electrical shocks. B. “Troubleshooting Without A Diagnostic Code”. The ignition system components require maintenance.

Inspect internal O-ring seal (7) for damage. Expected Result: The transformer is in good condition. Proceed to Test Step 3. G. The extension has an internal terminal for the spark plug.319 Troubleshooting Section NOTICE Pulling on the wiring harness may break the wires. Illustration 153 Ignition transformer and spark plug (4) (5) (6) (7) Transformer Extension Secondary terminal for the spark plug O-ring seal g01057657 D. Restart the engine. Inspect the terminal for looseness. Reset the control system. Inspect the body of transformer (4) and extension (5) for corrosion and/or for damage. Insert a spark plug into the extension and check the terminal for spring pressure. NOTICE The extension can be scratched and damaged with a wire brush. Do not use a wire brush on the extension. Clean any deposits from the inside of the extension. Clear the logged codes. Results: • OK – The transformer appears to be in good condition. Be sure to use the correct transformer for the G3520C Engine. if necessary. E. and/or for damage. • Not OK – An inspection found a problem with the Repair: Repair the transformer. STOP. Replace the transformer. F. transformer. Use a 6V-7093 Brush with isopropyl alcohol. when possible. . C. Remove transformer (2) from the engine. Disconnect the ignition harness from 3-pin connector (3). Do not pull on the wiring harness. for corrosion.

Measure the primary circuit by checking the voltage of the blocking diode. Measure the resistance of the secondary circuit. Set the multimeter to the diode scale. The polarity of the leads is not important. Illustration 156 demonstrates the relationship between the secondary coil’s resistance and the temperature.320 Troubleshooting Section Test Step 3. B. Note: The resistance of the secondary coil will vary with the temperature. Check the Primary Circuit and the Secondary Circuit Illustration 155 Ignition transformer (A) + Terminal (B) . b. the correct resistance is between 21. Connect the multimeter leads to the terminal (A) and terminal (B) of the 3-pin connector. Reverse the multimeter leads. Measure the voltage between the terminals again. Record the measurement. For example. .000 and 23.Terminal (10) Mounting flange (11) Connector for the spark plug g01057660 Illustration 154 (1) (2) (3) (4) (5) (6) (7) (8) (9) 3-pin connector for the transformer Terminal A Terminal B Blocking diode Flyback diode Primary coil of the transformer Secondary coil of the transformer Resistor Spark plug gap g01057676 Schematic for the primary circuit and for the secondary circuit a. if the transformer’s temperature is 60 °C (140 °F). A. Measure the voltage between the terminals. Record the measurement.000 Ohms. A reading that is within 1000 Ohms is acceptable.

Reset the control system.000 Ohm scale. C. • Not OK – At least one of the measurements is Repair: Make sure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. Test Step 5. STOP. Make sure that you use the correct transformer for the G3520C Engine. Repair: Discard the spark plug. Results: • OK – All three of the measurements are correct. Perform the following procedures according to the instructions in the engine’s Operation and Maintenance Manual. Illustration 156 Resistance versus temperature (Y) Resistance in Ohms (X) Temperature in degrees celsius (degrees fahrenheit) g00863850 a. B.450 VDC. the resistance cannot be measured. Note: For a spark plug with a precombustion chamber. Install a new spark plug according to the instructions in the engine’s Operation and Maintenance Manual. Expected Result: The spark plug is in good condition. Proceed to Test Step 4. Clear any logged diagnostic codes. the resistance between the mounting flange and the secondary terminal for the spark plug is within the acceptable tolerance. incorrect. For the secondary circuit. The spark plug may be good for a considerable period beyond 3000 service hours. D. Proceed to Test Step 5. Replace the ignition transformer. Expected Result: For the primary circuit. Set the multimeter to the 40. Measure the resistance between mounting flange (10) and the extension’s internal terminal (11) for the spark plug. • OK – The spark plug is in good condition. • Not OK – The spark plug is not in good condition. STOP. Install the transformer and the cover.321 Troubleshooting Section Illustration 157 Spark plug that has a precombustion chamber g01057662 B. Reset the control system. Restart the engine. c. Remove the spark plug from the cylinder head. Switch the 35 amp circuit breaker OFF. Check the Spark Plug A. . one of the voltage measurements is approximately 0. The other voltage measurement indicates an open circuit. Operate the Engine A. The minimum service life of a spark plug with a precombustion chamber is approximately 3000 service hours. Install the spark plug according to the instructions in the engine’s Operation and Maintenance Manual. Test Step 4. Clean the spark plug. Experience at the particular site will help to determine the proper interval for replacement of the spark plug. Start the engine and operate the engine in order to generate the diagnostic code again. b. Inspect the spark plug. Clear the logged codes. Results: a.

Install the covers. The solder connections are usually protected by a chemical potting which prevents access to the solder point. repair the connector and verify that the problem is corrected. Install the transformers.Check/Adjust/Replace”. Proceed with normal operation. B. Repair: Make sure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. to Test Step 6. C. STOP. Make sure that you use the correct transformer for the G3520C Engine. Sometimes. Start the engine and operate the engine in order to generate the diagnostic code again. Use the following test steps to help determine whether the connector is the cause of the problem. Immediately after you reconnect the connector. Reset the control system. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Install a new spark plug according to the instructions in Operation and Maintenance Manual. Reset the control system. STOP. Clear any logged diagnostic codes. Reset the control system. • Not OK – A diagnostic code is generated. Results: • Loose terminals • Bent terminals • Improperly crimped terminals • Improperly mated connectors • Moisture • Corrosion • Yes – The diagnostic code is generated for the suspect transformer. • No – The diagnostic code is generated for the original cylinder. Proceed Test Step 6. STOP. . Repair: Make sure that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. If this occurs. Expected Result: The diagnostic code is generated for the suspect transformer. Isolate the Spark Plug and the Transformer A. Always check for an active diagnostic code before you open any connection. check for codes again. Replace the faulty transformer. the following conditions are likely causes: • OK – A diagnostic code is not generated. Intermittent electrical problems are often caused by poor connections. simply disconnecting a connector and then reconnecting the connector can solve a problem. If a problem is found in a connector. The pins and the sockets are soldered to the electrical wires. Results: i01811734 Inspecting Electrical Connectors SMCS Code: 7553-040-WW System Operation Description: Many of the troubleshooting procedures direct you to a specific electrical connector. Illustration 158 g00700045 The MS connectors have a metal housing. Clear any logged diagnostic codes.322 Troubleshooting Section Expected Result: A diagnostic code is not generated. “Ignition System Spark Plugs . Clear any logged diagnostic codes.

The connector has a locking mechanism in order to hold the pins and the sockets. Check the Connectors. Always set the engine control to the OFF/RESET mode before you inspect electrical conductors. Test Step 1. B. . Check that the threading is properly aligned and securely mated. Illustration 160 g00928006 Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem. Switch the 35 amp circuit breaker OFF.323 Troubleshooting Section Illustration 159 g00700064 Deutsch connectors have a plastic housing. The pins and the sockets are crimped onto the electrical wires. These connectors are repairable without cutting the wires. For the MS connectors. make sure that the receptacle is turned fully in the clockwise direction. A.

When you connect a rectangular connector to the terminal box.324 Troubleshooting Section C. Switch the 35 amp circuit breaker OFF. C. • Not OK Repair: Repair the connector or replace the connector. If there is an active diagnostic code that pertains to the circuit. For the Deutsch DT style. Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. do not exceed 2.25 N·m (20 ± 2 lb in) of torque on the screw. Expected Result: Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body. Verify that the receptacle is clicked into the locked position. When you connect a 70-pin connector to an Electronic Control Module (ECM). For the Deutsch HD connectors. STOP. A. Test Step 3. Results: Verify that the repair eliminates the problem. Be careful not to overtighten the screw and break the screw. Make sure that the two halves cannot be pulled apart. as required. Verify that the repair eliminates the problem. Test Step 4. The DT connectors use an orange wedge to lock the terminals in place.25 ± 0. Check that the receptacle has clicked into the locked position. do not exceed 6 ± 1 N·m (55 ± 9 lb in) of torque on the screw. B. Use the 1U-5804 Crimp Tool. Check the Allen Head Screw on the Rectangular Connectors A. STOP. Note: Terminals should ALWAYS be crimped onto the wires with a crimp tool. STOP. Reconnect all of the connectors. Perform a Pull Test on Each Wire Connection. Do not touch wires that are associated with the ignition transformer circuit when the engine is cranking or running. Make sure that the two halves cannot be pulled apart. D. Set the engine control to the OFF/RESET mode. Do not solder terminals. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors. • OK – Proceed to Test Step 3. • Not OK Repair: Repair the connectors and/or replace the connectors. Test Step 2. Ensure that each allen head screw is properly tightened. perform the following steps: a. Expected Result: Each rectangular connector is secure and the allen head screw is properly torqued. B. Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled. Expected Result: All connectors are properly mated and free of damage. Make sure that the receptacle is turned fully in the clockwise direction. A. . This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector. Results: • OK – Proceed to Test Step 2. make sure that the plug and the receptacle are aligned properly with the index markings. • Not OK Repair: Repair the circuit. There is a strong electrical shock hazard when the crankshaft is rotating. Results: • OK – Proceed to Test Step 4. make sure that the orange wedge is used in order to lock the pins.

Results: • OK – Proceed to Test Step 6. . If there are no active diagnostic codes that pertain to the circuit. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. there is a problem in the wiring or the connector. If the harness is being pulled and the engine has a speed burp or a power cutout. nicks. B. Set the engine control to the STOP mode. • OK – Proceed to Test Step 5. STOP. Expected Result: The wires do not have abrasion. If the harness is being pulled and the reading changes erratically. d. Run the engine under normal operating conditions. there could be a problem in the wiring or the connector. or cuts and the harness is properly clamped. B. Test Step 5. of nicks. Set the engine control to the STOP mode. Monitor the “Display Status” screen on Cat ET while you pull on all harnesses and connectors for the circuit. c. check all of the hold down clamps in order to verify that the harness is not compressed by the clamps. If the harness is being pulled and the active diagnostic code disappears. Expected Result: The problem appears to be external to the harnesses and connectors. Also. there is a problem in the wiring or the connector. Check Wires for Nicks or Abrasion in the Insulation. b. Switch the 35 amp circuit breaker OFF. Listen for speed burps or power cutouts while the wiring and/or the connectors are pulled. perform the following test: a. Results: Verify that the repair eliminates the problem. C. Verify that the repair eliminates the problem. or engine performance. b. Pull back the harness sleeves in order to check for flattening of the wires by the clamps. Then start the engine. Carefully inspect each wire for signs of abrasion. Set the engine control to the OFF/RESET mode. If there are no active diagnostic codes and there are complaints about intermittent changes in speed or power cutouts. component status. Allow the engine to coast to a stop. Repair the circuit.325 Troubleshooting Section b. Run the engine under normal operating conditions. The following areas are likely locations: • Places with exposed insulation • Points with wiring that rubs against the engine • Places with wiring that rubs against a sharp point D. perform the following test: a. Run the engine under normal operating conditions. as required. STOP. C. Switch the 35 amp circuit breaker OFF. • Not OK Repair: Set the engine control to the OFF/RESET mode. or of cuts. Pulling on the harness and on the connectors does not affect the active diagnostic code. • Not OK Repair: Repair the wires or replace the wires. Monitor the “Active Diagnostic Code” screen on Cat ET while you pull on all harnesses and connectors for the circuit with the active code. A. Switch the 35 amp circuit breaker ON.

The harness and the wiring does not have corrosion. abrasion. Do not use any cleaners that contain 1.1. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. This will deform the connector seal and this will create a path for the entrance of moisture. replace the connector. Note: If corrosion is evident on the pins. replace the seal or plug.1 trichloro-ethylene because 1. If any of the seals or plugs are missing. The following list includes likely paths for the entrance of moisture: • 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 an ECM connector. Results: Illustration 161 g00690571 A.326 Troubleshooting Section Test Step 6. If the repair is not made. the problem will recur. use only denatured alcohol to remove the corrosion. Check the Connectors for Moisture or Corrosion. the source of the moisture entry must be found and the source of the moisture entry must be repaired. The ECM is not the source of the moisture. Minor seal abrasion will not allow the entry of moisture. Do not replace an ECM if moisture is found in either ECM connector. Note: It is normal to see some minor seal abrasion on the ECM connector seals. Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. • Not OK Repair: Repair the circuit. sockets or the connector.1 trichloro-ethylene may damage the connector. . If moisture or corrosion is evident in the connector. Use a cotton swab or a soft brush to remove the corrosion. Ensure that the connector seals and the white sealing plugs are in place. thoroughly check all connectors and wires on the harness that connects to the ECM. Illustration 162 g00690568 B. If necessary. • OK – Proceed to Test Step 7. Expected Result: All of the connectors are completely coupled and all of the seals are completely inserted. If moisture is found in an ECM connector. Thoroughly inspect each ECM connector for evidence of moisture entry. Simply drying the connector will not fix the problem.1. or pinch points.

One at a time. if necessary. Repair: Repair any bad pins and sockets. Verify that the socket holds the pin when the connector hangs freely. it may be necessary to replace the wires that have moisture. i02089552 • OK – Proceed to Test Step 7. Expected Result: Each socket firmly grips each pin. Replace the wiring. Expected Result: The terminals are properly aligned and the terminals appear undamaged. Verify that the repair eliminates the problem. One at a time. Make sure that the pin is properly gripped by the socket. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector. The temperatures can be viewed on the Caterpillar Electronic Technician (ET). as required. B. Inspect the Connector Terminals. STOP. insert a new pin into each socket. Make sure that the pin is properly gripped by the socket. STOP. Temperature readings of the thermocouples are available over the CAT data link for use by each Electronic Control Module (ECM) and other modules. If moisture reappears. Replace the connectors. Check the Individual Retention of the Pins and Sockets. insert a new socket onto each pin. the moisture is wicking into the connector. • High exhaust temperature • High deviation of an exhaust port temperature • Low deviation of an exhaust port temperature Illustration 163 g00690572 • High inlet temperature to the turbocharger turbine . • Not OK Repair: Repair the terminals and/or replace the terminals.327 Troubleshooting Section Verify that the repair eliminates the problem by running the engine for several minutes and by checking again for moisture. The ITSM generates event codes for each of the following programmable conditions: Test Step 8. Verify that the repair eliminates the problem. Results: • OK – The pins and sockets mate properly. Note: This is especially important for intermittent problems. A. These wires may have moisture that is trapped inside the insulation. Integrated Temperature Sensing Module (ITSM) SMCS Code: 1901-038 System Operation Description: The Integrated Temperature Sensing Module (ITSM) monitors type K thermocouples at each cylinder exhaust port and at the inlets and outlets for both turbochargers. Even if the moisture entry path is repaired. Verify that the terminals are not damaged. The ITSM can also calculate the average temperature for each cylinder bank (left and right). • Not OK – The pins and sockets do not mate properly. Verify that the repair eliminates the problem. Results: Test Step 7. STOP. if necessary. STOP.

or open. shorted to ground. use Cat ET to print the logged codes to a file. . Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved. Before you begin this procedure.328 Troubleshooting Section • 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. Logged diagnostic codes provide a historical record. This troubleshooting procedure may generate additional diagnostic codes.

329 Troubleshooting Section Illustration 164 Schematic for the circuit of the ITSM for 1500 RPM engines g01065625 .

330 Troubleshooting Section Illustration 165 g01065626 .

25 N·m (20 ± 2 lb in). b. refer to Troubleshooting.331 Troubleshooting Section Schematic for the circuit of the ITSM for 1800 RPM engines Test Step 1. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the ITSM. Check the torque of the allen head screw for the ECM connectors.25 ± 0. Illustration 168 g01065145 Note: For the following steps. Thoroughly inspect each of the following connectors: • Master ECM J1/P1 connectors • J3/P3 connectors for the slave ECM • J7/P7 and J9/P9 connectors on the terminal box a. Harness side of the P1 connector (P1-8) CAT data link + (P1-9) CAT data link − c. Illustration 166 Junction box (1) 35 amp circuit breaker g01054206 A. Check the torque of the allen head screws for the connectors on the terminal box. Illustration 167 Terminal box (2) J1/P1 connectors for the master EM (3) J7/P7 connectors for the harness from the ITSM (4) J9/P9 connectors for the CAT Data Link (5) J3/P3 connectors for the slave ECM g01065628 . The proper torque is 2. Inspect the Electrical Connectors and Wiring B. Set the engine control to the OFF/RESET mode. Switch 35 amp circuit breaker (1) to the OFF position. “Inspecting Electrical Connectors”. The proper torque is 6 ± 1 N·m (53 ± 9 lb in).

332 Troubleshooting Section Illustration 169 Thermocouples (6) Thermocouple for the temperature of a cylinder exhaust port (7) Thermocouple for the temperature of the exhaust inlet to the turbocharger turbine (8) Thermocouples for the temperature of the turbocharger exhaust outlets (9) Thermocouple for the temperature of the turbocharger exhaust outlet g01065630 d. Check the harnesses and wiring for abrasion and for pinch points from each thermocouple to the ITSM. Carefully inspect the connectors for each of the thermocouples. .

Proceed to Test Step 2. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Results: • No Active Codes – None of the above diagnostic codes for the thermocouples are active. Check the harnesses and wiring for abrasion and for pinch points from the ITSM to the master ECM. abrasion. refer to Troubleshooting. • Active “open circuit” – At least one “open circuit” Test Step 3. Create an Open Circuit • Not OK – The components are not in good A. pins. Switch the 35 amp circuit breaker OFF. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Verify the Active Diagnostic Codes A. Results: • Active “short to ground” or “short to +batt” – At least one “short to ground” or “short to +batt” diagnostic code is active. Switch the 35 amp circuit breaker ON. diagnostic code is active. The connectors and the wiring do not have corrosion. there may be an intermittent condition that is causing the codes to be generated. Repair: If any of the codes are logged. B. Determine if any of the following diagnostic codes for the thermocouples are active: • 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 1550-03 (“short to +batt”) • 1531-04 through 1550-04 (“short to ground”) • 1531-05 through 1550-05 (“open circuit”) Expected Result: Illustration 170 ITSM (10) 54-pin connectors for the harness to the thermocouples (11) ITSM (12) 14-pin connectors for the harness to the terminal box for the master ECM g01065631 None of the above diagnostic codes for the thermocouples are active. STOP.333 Troubleshooting Section Test Step 2. Disconnect the connector for the thermocouple with the short circuit diagnostic code. If the wiring harness from the thermocouples to the ITSM requires repair. Proceed to Test Step 3. Set the engine control to the STOP mode. . Expected Result: All of the connectors. D. Proceed to Test Step 4. C. Thoroughly inspect 54-pin connectors (10) and 14-pin connectors (12) for ITSM (11). If the engine is not running properly. replace the harness in order to ensure reliable operation. Repair: Perform the necessary repairs and/or replace parts. and sockets are connected properly. The polarity of the wires from each thermocouple to the ITSM must be maintained in order for the ITSM to read the correct temperatures. if necessary. Access the “Active Diagnostic” screen for the ITSM on Cat ET. STOP. Expected Result: There is an active “open circuit” diagnostic code for the disconnected thermocouple. • OK – The components are in good condition with proper connections. “Troubleshooting Without a Diagnostic Code”. Set the engine control to the OFF/RESET mode. or pinch points. e. condition and/or at least one connection is improper. All of the wiring from the thermocouples to the ITSM must be type K.

5. When the jumper wire was removed. 5. 4. Reconnect the thermocouple’s connectors and check for an active open circuit diagnostic code. STOP. there is a problem with the thermocouple. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Ensure that the connectors and the seals are in good condition. Check for an active open circuit diagnostic code. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. Proceed to Test Step 5. Results: • Yes – When the jumper wire was installed. Check the ITSM A. 3. E. Repair: Perform the following procedure: 1. Observe the “Active Diagnostic” screen. • No – When the jumper wire was installed. • No – There is not an active “open circuit” diagnostic code for the disconnected thermocouple. the “open circuit” diagnostic code recurred. Disconnect the connector for the thermocouple with the open circuit diagnostic code. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. Repair: Perform the following procedure: 1. The ITSM and the harness are OK. Allow a minimum of 30 seconds for any diagnostic codes to be generated. F. 2. If the short circuit diagnostic code becomes active again. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. Remove the jumper wire and observe the “Active Diagnostic” screen. Create a Short Circuit A. 2. remove the suspect thermocouple from the engine. the “open circuit” diagnostic code recurred. Expected Result: When the jumper wire was installed. . STOP. Set the engine control to the STOP mode. Set the engine control to the OFF/RESET mode. Check for an active short circuit diagnostic code. Install a jumper wire into terminals A and B on the harness connector for the suspect thermocouple. Repair: Remove the jumper wire. If the diagnostic code is not generated with the good thermocouple. Clear the logged diagnostic codes. Ensure that the connectors and the seals are in good condition. If the diagnostic code is not generated with the good thermocouple. If the open circuit diagnostic code becomes active again. remove the suspect thermocouple from the engine. Switch the 35 amp circuit breaker OFF. B. Do not install the good thermocouple into the engine yet.334 Troubleshooting Section Results: • Yes – There is an active “open circuit” diagnostic code for the disconnected thermocouple. There is probably an open circuit in the harness between the ITSM and the connector for the thermocouple. Reconnect the thermocouple’s connectors and check for an active short circuit diagnostic code. D. there is a problem with the thermocouple. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Switch the 35 amp circuit breaker ON. Proceed to Test Step 5. a “short circuit” diagnostic code was generated. 3. Thoroughly inspect the thermocouple’s connectors. When the jumper wire was removed. Install the good thermocouple. The ITSM and the harness are OK. 4. Thoroughly inspect the thermocouple’s connectors. a “short circuit” diagnostic code was generated. There is a short circuit between the harness for the thermocouple and the ITSM. C. Test Step 4. Install the good thermocouple. Test Step 5. Do not install the thermocouple into the engine yet. Clear the logged diagnostic codes. the “open circuit” diagnostic code recurred.

STOP. Results: • No – Either of the following results or both of the results occurred: When the 54-pin connectors were disconnected. 3. Observe the “Active Diagnostic” screen. install the original ITSM and verify that the problem returns. a “short circuit” diagnostic code was generated. C. Set the engine control to the STOP mode. Remove the jumper wire from the connector on the ITSM. Replace the harness in order to ensure reliable operation. All of the wiring from the thermocouples to the ITSM must be K type. Access the “Active Diagnostic” screen for the ITSM on Cat ET. i02089570 PWM Sensor SMCS Code: 5574-038 System Operation Description: The engine contains the following Pulse Width Modulated sensors (PWM): • Yes – When the 54-pin connectors were disconnected. D. Switch the 35 amp circuit breaker OFF. Refer to Troubleshooting. Only pay attention to the diagnostic codes for the suspect thermocouple. Set the engine control to the OFF/RESET mode. STOP. Set the engine control to the OFF/RESET mode. Disconnect the 54-pin connector from the ITSM. In a digital signal. a “short circuit” diagnostic code was generated. There is a problem in the harness between the ITSM and the connector for the suspect thermocouple. 4. Repair: Remove the jumper wire. Exit this procedure and perform this procedure again. refer to Illustration 164 or 165. Allow a minimum of 30 seconds for any diagnostic codes to be generated. . Refer to Illustration 171. Set the engine control to the STOP mode. “Replacing the ITSM”. If the new ITSM operates correctly and the original ITSM does not operate correctly. Refer to Troubleshooting. F. the duty cycle varies as the input condition changes. replace the original ITSM. If the problem is resolved with the new ITSM. Clear the logged diagnostic codes and verify that the problem is resolved. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Switch the 35 amp circuit breaker ON. For identification of the terminals. E. an “open circuit” diagnostic code was generated for the suspect sensor. Repair: It is unlikely that the ITSM has failed. • Engine coolant pressure (outlet) • Inlet manifold air pressure A PWM sensor produces a digital signal. a “short circuit” diagnostic code was not generated.335 Troubleshooting Section B. “Replacing the ITSM”. 2. G. The polarity of the wires from each thermocouple to the ITSM must be maintained in order for the ITSM to read the correct temperatures. There may be a problem with the ITSM. Temporarily install a new ITSM. Observe the “Active Diagnostic” screen. The ITSM is OK. Thoroughly inspect the 54-pin connectors. When the jumper wire was installed. If the problem is not resolved. Switch the 35 amp circuit breaker ON. perform the following steps: 1. Ensure that the connectors are in good condition. When the jumper wire was installed. an active “open circuit” diagnostic code will be generated for all of the thermocouples. Switch the 35 amp circuit breaker OFF. Install a jumper wire into the terminals for the suspect sensor on the 54-pin connector on the ITSM. Note: When the 54-pin connectors are disconnected. The frequency remains constant. Expected Result: When the 54-pin connectors were disconnected. This is normal. When the jumper wire was installed. an “open circuit” diagnostic code was generated for the suspect sensor. an “open circuit” diagnostic code was not generated for the suspect sensor.

medium. measure the absolute pressure with a pressure gauge before you troubleshoot the sensor. the code will be generated. . print the logged codes to a file. Clear the diagnostic codes after the problem is resolved. reduce the pressure in order to avoid activation of false diagnostic codes. 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. Before you begin this procedure. Although there is not a problem with the sensor. and high g01065665 The master Electronic Control Module (ECM) supplies 8. If the pressure is actually too high. Keep your mind on correcting the cause of the original diagnostic code. If a “106-08” or “109-08” diagnostic code is generated. the code will be generated. Illustration 171 Duty cycles that are low. Note: Excessive pressure can generate false “noisy signal” diagnostic codes.8 VDC to each PWM sensor.0 ± 0. If the actual inlet manifold air pressure is greater than approximately 338 kPa (49 psi).336 Troubleshooting Section This troubleshooting procedure may generate additional diagnostic codes. a “106-08 Air Inlet Pressure Sensor noisy signal” diagnostic code will be generated. Logged diagnostic codes provide a historical record.

Thoroughly inspect the following connectors: • J1/P1 connectors • J2/P2 connectors • J7/P7 connectors • The connectors for each PWM sensor .337 Troubleshooting Section Illustration 172 Schematic for the PWM sensors g01065666 Test Step 1. Note: For the following steps. Switch 35 amp circuit breaker (1) to the OFF position. “Inspecting Electrical Connectors”. B. refer to Troubleshooting. Inspect the Electrical Connectors and Wiring Illustration 174 Terminal box Illustration 173 Junction box (1) 35 amp circuit breaker g01054206 g01065667 (2) J2/P2 connectors for the master ECM (3) J1/P1 connectors for the master ECM (4) J7/P7 connectors for the PWM sensors A. Set the engine control to the OFF/RESET mode.

Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the PWM sensors.25 N·m (20 ± 2 lb in). Check the torque of the allen head screws for the connectors on the terminal box. The proper torque is 6 ± 1 N·m (55 ± 9 lb in).25 ± 0. Illustration 176 Harness side of the P2 connector (P2-68) Signal for engine coolant pressure (outlet) g01057771 .338 Troubleshooting Section a. The proper torque is 2. b. Check the torque of the allen head screw for the ECM connectors. Illustration 175 Harness side of the P1 connector (P1-4) 8 volt supply (P1-5) Return (P1-10) Signal for inlet manifold air pressure g01057769 Illustration 177 Harness side of the P7 connector g00933045 (P7-1) Signal for inlet manifold air pressure (P7-2) Signal for engine coolant pressure (outlet) (P7-15) Return for inlet manifold air pressure (P7-16) Return for engine coolant pressure (outlet) (P7-29) Shield (P7-30) Shield (P7-43) 8 volt supply for the inlet manifold air pressure (P7-44) 8 volt supply for the engine coolant pressure (outlet) c.

Repair: Refer to Troubleshooting. Test Step 3. and sockets are connected properly. Test Step 2. condition and/or at least one connection is improper. pins. Look for these codes: • 41-03 8 Volt DC Supply short to +batt • 41-04 8 Volt DC Supply short to ground Expected Result: There are no active “8 Volt DC Supply” diagnostic codes. Proceed to Test Step 2. or pinch points. Determine if any of these diagnostic codes are active: • 106-03 Air Inlet Pressure Sensor open/short to +batt . • Active code – There is an active diagnostic code for the 8 volt power supply. Observe the “Active Diagnostic” screen on Cat ET. Check for Active “8 Volt DC Supply” Diagnostic Codes A. • Not OK – The components are not in good • No codes – There are no active diagnostic codes for the power supplies. Allow a minimum of thirty seconds for any codes to activate. abrasion. Refer to Troubleshooting. This procedure will not work when this type of code is active. B. Expected Result: The connectors. if necessary. STOP. “Electronic Service Tools”. Repair: Perform the necessary repairs and/or replace parts. Check the harness and wiring for abrasion and for pinch points from each of the PWM sensors to the master ECM. Set the engine control to the STOP mode. Switch the 35 amp circuit breaker ON.339 Troubleshooting Section Illustration 178 Top view (5) Sensor for engine coolant pressure (outlet) (6) Sensor for inlet manifold air pressure g01065668 d. STOP. Results: • OK – The components are in good condition with proper connections. Check for Active Diagnostic Codes for the PWM Sensors A. Turn on the “Active Diagnostic” screen on Cat ET. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. “+8 V Sensor Voltage Supply”. Results: C. Proceed to Test Step 3. The connectors and the wiring do not have corrosion.

The battery voltage is not present in the signal wire. At the harness connector for the suspect sensor. Results: • OK – The voltage is between 7. Refer to Troubleshooting. Proceed to Test Step 6. • Not OK – The voltage is not within the specification. Replace the harness. Refer to Troubleshooting.0 Illustration 179 Harness connector for the PWM sensors (A) 8 volt supply (B) Return g00896288 VDC. there may be an intermittent problem in the harness that is causing the codes to be logged. the battery voltage.340 Troubleshooting Section • 106-08 Air Inlet Pressure Sensor noisy signal • 109-03 Engine Coolant Outlet Pressure open/short to +batt signal Results: • OK – The voltage is within the specification. Repair any faulty wiring and/or connectors. B. Verify that +Battery Voltage is Not Present in the Signal Wire Illustration 180 Harness connector for the PWM sensors (B) Return (C) Signal g00896299 Test Step 4.0 VDC and 8. Verify the Supply Voltage to the Sensor A. The • 109-08 Engine Coolant Outlet Pressure noisy Expected Result: One of the above codes is active. The signal wire is probably shorted to the battery between the sensor and the master ECM. Set the engine control to the STOP mode. STOP. STOP. • No – None of the above codes are active. “Troubleshooting Without a Diagnostic Code”. measure the voltage between terminal (B) and terminal (C). Proceed to Test Step 5. Repair: Verify that the wiring and/or connectors are OK. A. STOP.0 VDC and 8. refer to Troubleshooting.6 VDC and 8. Proceed to Test Step 4. • Yes – At least one of the above diagnostic codes is active. Repair: Set the engine control to the OFF/RESET mode. if necessary. Repair: If any of the above codes are logged and the engine is not running properly. Expected Result: The voltage is between 7. when possible. “Inspecting Electrical Connectors”.0 VDC. • Not OK – The voltage is approximately equal to D. measure the voltage between terminals (A) and (B). Switch the 35 amp circuit breaker OFF. . Repair the harness. Set the engine control to the OFF/RESET mode. C. if necessary. Results: correct voltage is present at the sensor connector. If the engine is running properly at this time. The correct voltage is not present at the sensor connector. Test Step 5.4 VDC. Expected Result: The voltage is between 7. Replace any faulty wiring and/or connectors. when possible. Disconnect the suspect sensor. At the harness connector for the suspect sensor. “Inspecting Electrical Connectors”. The correct voltage must be present at the sensor connector in order to continue this procedure.

Connect a sensor that is known to be good. Check for an active diagnostic code. incorrect. Replace the harness. Set the engine control to the OFF/RESET mode. Repair: Set the engine control to the OFF/RESET mode. Check the Signal at the Sensor A. Measure the duty cycle and the frequency of the suspect sensor. Measure the duty cycle and the frequency of the suspect sensor. Do not install the new sensor into the engine yet. Set the engine control to the STOP mode. If the duty cycle and the frequency of the sensor signal are incorrect. install the sensor into the engine. Connect the multimeter to the probes. The sensor is receiving the correct supply voltage but the sensor is not producing a valid signal. The ECM is receiving a valid signal from the sensor. 3. Switch the 35 amp circuit breaker ON. Repair the harness. Use a multimeter that is capable of measuring both the duty cycle and the frequency. D. B. C. Results: Test Step 7. A valid signal is produced by the sensor. when possible. The terminals for the connection of the probes are identified in Table 28. STOP. Disconnect the sensor.341 Troubleshooting Section • Not OK – The voltage is approximately 0 volts. C. STOP. 5. E. Thoroughly inspect the connector for the sensor according to Troubleshooting. Check the duty cycle and the frequency of the sensor signal again. The frequency is between 400 and 600 Hz. if necessary. The frequency is between 400 and 600 Hz. Set the engine control to the STOP mode. B. 6. Switch the 35 amp circuit breaker OFF. Proceed to Test Step 7. Results: • Not OK – The duty cycle or the frequency is • OK – The duty cycle is between 5 percent and 95 percent. Expected Result: The duty cycle is between 5 percent and 95 percent. Install a 8T-8726 Adapter Cable As (Three-Pin Breakout) at the harness connector for the suspect sensor. set the engine control to the OFF/RESET mode. Insert two 7X-1710 Multimeter Probes into the terminals that are appropriate for the suspect sensor. “Inspecting Electrical Connectors”. Set the engine control to the OFF/RESET mode. Clear any logged diagnostic codes. Repair: Perform the following steps: . Allow a minimum of 30 seconds for any codes to activate. Switch the 35 amp circuit breaker OFF. Expected Result: The duty cycle is between 5 percent and 95 percent. Set the engine control to the STOP mode. The frequency is between 400 and 600 Hz. Test Step 6. Table 28 Terminals for the Connection of the Probes Suspect Sensor Engine coolant pressure (outlet) Inlet manifold air pressure Connector and Terminals J2-68 and J1-5 J1-10 and J1-5 • OK – The duty cycle is between 5 percent and 95 percent. The frequency is between 400 and 600 Hz. D. If the code is not active for the new sensor. Connect the multimeter to terminal B and terminal C of the breakout t. The signal wire is probably shorted to ground between the sensor and the master ECM. 4. Check the Signal at the Master ECM A. Use a multimeter that is capable of measuring both the duty cycle and the frequency. Repair: Perform the following steps: 1. E. 2.

In this case. adjust the derivative gain and the fuel quality in order to make the engine more stable at low idle. If the problem is resolved with the new ECM.87 psi)). Refer to Troubleshooting. If the new ECM operates correctly and the original ECM does not operate correctly. the master ECM activates a 1440-09 diagnostic code and the engine is shut down. replace the original ECM. Otherwise. The actuator sends the following information to the master ECM: actuator position. This troubleshooting procedure may generate additional diagnostic codes. software version. “System Configuration Parameters”. If the condition is not resolved. Repair: Repair the harness. Look for a valid signal. The sensor is producing a valid signal but the signal does not reach the master ECM. • Not OK – The duty cycle or the frequency is incorrect. 3. . Refer to Troubleshooting. Check “Status Screen Group 2” on Cat ET. STOP. Before you begin this procedure. “Electrical Power Supply”. and internal fault diagnosis. The terminating resistors improve the communication between the devices. “Replacing the ECM”. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link. Set the engine control to the STOP mode. CCM heartbeat. verify that the master ECM is receiving the correct voltage. when possible. Clear the diagnostic codes after the problem is resolved. Keep your mind on correcting the cause of the original diagnostic code. If the master ECM cannot communicate with the throttle actuator. when possible. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF. The master ECM sends a command signal to the actuator. Terminating resistors must be connected to each end of the CAN data link. Replace the harness. 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. temporarily install a new master ECM. be sure to check the terminating resistor that is inside the terminal box. Refer to Troubleshooting. if necessary. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Logged diagnostic codes provide a historical record. The next likely cause is a problem with the actuator. install the original ECM and verify that the problem returns. i02089593 Throttle Actuator SMCS Code: 1716-038 System Operation Description: The throttle actuator is an electronic actuator that works with the master Electronic Control Module (ECM) in order to ensure the correct throttle position in all conditions of engine operation. This causes the master ECM to set the 106-03 diagnostic code although there is no short circuit to the +Battery side. “Replacing the ECM”. Make repairs.342 Troubleshooting Section 1. The least likely cause is a problem with the master ECM. if necessary. The master ECM and the throttle actuator communicate via the CAN data link. There is a problem in the harness between the sensor and the master ECM. Replace parts. 2. A 1440-09 diagnostic code is probably caused by a problem with an electrical connector or a harness. Switch the 35 amp circuit breaker ON. Refer to Troubleshooting. STOP. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve.7 kPa (3.

343 Troubleshooting Section Illustration 181 Schematic for the circuit of the throttle actuator g01065716 .

B. . Thoroughly inspect each of the following connectors: • J1/P1 connectors • J9/P9 connectors • Connectors on the throttle actuator a.344 Troubleshooting Section Test Step 1. Check the torque of the allen head screw for the ECM connectors.25 N·m (20 ± 2 lb in). Switch 35 amp circuit breaker (1) to the OFF position. b. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Inspect the Electrical Connectors and Wiring Illustration 183 Terminal box Illustration 182 Junction box (1) 35 amp circuit breaker g01054206 g01065717 (2) (3) (4) (5) Ground strap J1/P1 connectors for the master ECM J9/P9 connectors for the CAN data link J10/P10 connectors for the terminating resistor for the CAN data link A. “Inspecting Electrical Connectors”. Note: For the following steps.25 ± 0. Set the engine control to the OFF/RESET position. The proper torque is 2. Check the torque of the allen head screws for the connectors on the terminal box. refer to Troubleshooting.

Ensure that the connectors are properly engaged. Ensure that all of the seals are properly installed. • Not OK – The components are not in good Illustration 185 Harness side of the J9 connector (J9-6) CAN data link + (J9-12) CAN data link − (J9-18) CAN shield g00934039 c. B. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. Results: • OK – The components are in good condition with proper connections. C. Expected Result: All of the connectors. or pinch points. if necessary. Use Cat ET in order to determine if a 1440-09 diagnostic code is active.345 Troubleshooting Section Illustration 184 Harness side of the P1 connector (P1-34) CAN data link − (P1-42) CAN shield (P1-50) CAN data link + g01054209 Illustration 186 Right side view with the throttle actuator g01065718 d. Verify that the repair has eliminated the original problem. Set the engine control to the STOP mode. Proceed to Test Step 2. Check for Diagnostic Codes A. Check the wiring for abrasion and for pinch points from the throttle actuator to the master ECM. Switch the 35 amp circuit breaker ON. condition and/or at least one connection is improper. and sockets are connected properly. pins. Test Step 2. Repair: Perform the necessary repairs and/or replace parts. abrasion. . STOP. The connectors and the wiring do not have corrosion. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the throttle actuator.

if necessary. Results: Expected Result: The continuity of the circuits between the terminals is good. The communication between the master ECM and the throttle actuator appears to be OK at this time. Replace parts. Switch the 35 amp circuit breaker OFF. the open circuit could be caused by one of the following components: • The harness inside the terminal box • The harness between the terminal box and the fuel metering valve • The harness between the fuel metering valve and the throttle actuator • Not OK (Active 1440-09) – The master ECM has detected a problem with the communication between the master ECM and the throttle actuator. if necessary. diagnostic codes may be logged. C. Be sure to wiggle the harness near the fuel metering valve. Check the CAN Data Link for a Short Circuit A. Use a multimeter to check for continuity between the points that are listed in Table 29. Be sure to wiggle the harness near each of the connectors. • The fuel metering valve Make repairs. refer to Troubleshooting. Make repairs. “Inspecting Electrical Connectors”. Table 29 Test Step 4. Disconnect the P1 connector. Terminating resistors must be connected to each end of the CAN data link. Repair: The open circuit could be caused by a poor electrical connection in a connector. • Not OK – At least one of the continuity checks indicates an open circuit. Verify that the engine control is in the OFF/RESET mode and that the 35 amp circuit breaker is OFF. B. Points to Check for Continuity Connector and Terminal P1-34 P1-50 P1-42 Harness Connector for the Throttle Actuator Terminal B (CAN data link −) Terminal A (CAN data link +) Terminal M (CAN shield) . Replace parts. Set the engine control to the OFF/RESET mode. There is an open circuit for the CAN data link between the throttle actuator and the master ECM. Results: • OK – The 1440-09 code is not active. Proceed to Test Step 4. Test Step 3. During each measurement. Also check the jumper wire that is connected between terminals J and K on the actuator for the bypass valve. Be sure to wiggle the harness near each of the connectors. STOP. when possible. when possible. During each measurement. wiggle the harnesses in order to check for an intermittent problem with the harness. be sure to check the terminating resistor that is inside the terminal box. Be sure to wiggle the harness near the fuel metering valve.346 Troubleshooting Section Expected Result: The 1440-09 code is not active. If there is an intermittent diagnostic code for any of the devices that are connected to the CAN data link. wiggle the harnesses in order to check for an intermittent problem with the harness. • OK – The continuity of the circuits between the terminals is good. The terminating resistors improve the communication between the devices. STOP. Repair: If you are troubleshooting an intermittent problem. Proceed to Test Step 3. B. However. Use a multimeter to check for continuity between the points that are listed in Table 30. Alternatively. Check the CAN Data Link for Continuity Between the Throttle Actuator and the Master ECM A. Disconnect the connector for the throttle actuator.

Repair: The active 1440-09 code could be caused by one of the following components: • OK – All of the measurements indicate an open circuit. Repair: If there is an intermittent problem that is causing the code to be logged. The problem seems to be resolved. Refer to Troubleshooting. Exit this procedure and perform this procedure again. Temporarily install a new master ECM. STOP. the problem is resolved. If the new actuator for the bypass valve does not operate correctly. the problem is resolved. Repair: The short circuit could be caused by a poor electrical connection in a connector. “Replacing the ECM”. . • Not OK – At least one of the measurements indicate a short circuit. Switch the 35 amp circuit breaker ON. install the original actuator for the bypass valve and continue with this procedure. Use Cat ET in order to determine if a 1440-09 diagnostic code is active. the short circuit could be caused by one of the following components: • The harness inside the terminal box • The harness between the terminal box and the fuel metering valve • The harness between the fuel metering valve and the throttle actuator • The fuel metering valve Make repairs. 3. Replace parts. Repair: Reconnect the P1 connector. If the new actuator for the bypass valve operates correctly. when possible. Results: • OK – The 1440-09 code is not active. • The master ECM • The throttle actuator • The actuator for the bypass valve • The fuel metering valve It is unlikely that any of the components that are listed above have failed. Refer to Troubleshooting. if necessary. 2. If the new throttle actuator does not operate correctly. Alternatively. “Replacing the ECM”. P1-50 (CAN Data Link +) P1-42 (CAN Shield) Expected Result: All of the measurements indicate an open circuit. If the new ECM operates correctly and the original ECM does not operate correctly. Test Step 5. Temporarily install a new throttle actuator. If the new throttle actuator operates correctly. Set the engine control to the STOP mode. STOP. perform the following procedure: 1. If the 1440-09 code remains active. Check for Diagnostic Codes A. B. install the original ECM. Continue with this procedure. “Inspecting Electrical Connectors”. The initial diagnostic code was probably caused by a poor electrical connection. refer to Troubleshooting. replace the original ECM. Results: • Not OK – The 1440-09 code is active. Proceed to Test Step 5. install the original throttle actuator and continue with this procedure. Temporarily install a new actuator for the bypass valve. If the problem is not resolved with a new ECM. Reconnect the connector for the throttle actuator.347 Troubleshooting Section Table 30 Expected Result: Points to Check for Continuity Connector and Terminal P1-50 (CAN Data Link +) P1-42 (CAN Shield) P1-52 (+ Battery) Ground strap for the ECM P1-42 (CAN Shield) P1-52 (+ Battery) Ground strap for the ECM P1-52 (+ Battery) Ground strap for the ECM Connector and Terminal P1-34 (CAN Data Link −) The 1440-09 code is not active. install the original ECM and verify that the problem returns. If the problem is resolved with the new ECM. The CAN data link does not have a short circuit.

. STOP. Temporarily install a new fuel metering valve. the problem is resolved. install the original fuel metering valve. “Inspecting Electrical Connectors”.348 Troubleshooting Section 4. Refer to Troubleshooting. If the new fuel metering valve does not operate correctly. If the new fuel metering valve operates correctly.

A magnetic transducer signals the TC of the flywheel to the master ECM when the TC hole on the flywheel passes beneath the transducer. Note: The “261-13 Engine Timing calibration required” diagnostic code is generated only for a master ECM that has never performed a timing calibration. Calibration of the timing is required only after the following circumstances: • The master ECM has been replaced. • The timing gear and/or the rear gear train have been replaced. The master ECM communicates the information from the calibration to the slave ECM via the CAT data link. The engine speed/timing sensor signals the TC of the timing gear to the master ECM. Any offset between the TC of the flywheel and the TC of the timing gear is stored into memory.349 Troubleshooting Section Calibration Procedures i02089646 Engine Speed/Timing Sensor Calibrate SMCS Code: 1912-524 System Operation Description: The master 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. • The timing gear and/or the rear gear train have been adjusted. The calibration procedure is initiated with the Caterpillar Electronic Technician (ET). .

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. Remove the protective end cap from 6V-2197 Magnetic Transducer (2). Insert the transducer into the adapter until the transducer contacts the surface of the flywheel. NOTICE The timing hole in the flywheel must not be aligned with the hole for the transducer. . the new timing reference is programmed into the permanent memory of the master ECM. The reference is based on the signals from the transducer and the speed/timing sensor. Calibration Note: A two-step process is used to calibrate the signal for the speed/timing sensor. Install the Transducer Illustration 187 Right side view (1) 6V-3093 Transducer Adapter (2) 6V-2197 Magnetic Transducer (3) Connector for the 7X-1695 cable (4) 7X-1695 Cable g01065745 A. Select “Calibrations” from the menu. Next. The new timing reference is calculated first. Start the engine. Always confirm that the holes are not aligned. Select “Timing Calibration”. The transducer will be damaged on engine start-up if the transducer is installed through both holes. A. D. Operate the engine at the rated speed and load. Test Step 2. • Click the left mouse button on the “Continue” button in the lower left corner of the Cat ET screen. Set the engine control to the OFF/RESET mode. “Electronic Service Tools”. Select “Service” from the main menu on Cat ET. B.04 inch) away from the surface of the flywheel. Start Cat ET. Make sure that the hole in the flywheel housing for the transducer is not aligned with the timing hole in the flywheel. Tighten the nut on the adapter in order to secure the transducer in place. Use either of the following methods in order to initiate the calculation of the new timing reference: • Press the space bar on the keyboard of the PC. C. Remove the timing calibration plug from either the left side or the right side of the flywheel housing. Continue to the next test step.350 Troubleshooting Section Test Step 1. Move the transducer 1 mm (0. E. Install 6V-3093 Transducer Adapter (1) into the hole. C. Connect the other end of the cable to connector (3) on the side of the engine. Connect the one end of 7X-1695 Cable (4) to the transducer. Connect Cat ET to the service tool connector on the terminal box. Set the engine control to the STOP mode. B. For instructions. refer to Troubleshooting.

• Not OK – Cat ET displayed “COULD NOT • Not OK – The calibration was completed successfully. Disconnect the transducer and the cable. • Press the space bar on the keyboard of the PC.351 Troubleshooting Section Cat ET will indicate “Please wait. Refer to Disassembly and Assembly for identifying and repairing a gear train problem. . Repair: If the calibration failed in the first step. Repair: Replace the master ECM according to the instructions in Troubleshooting. the “261-13 Engine Timing calibration required” diagnostic code is still active. Cat ET will display “The ECM has calculated the Timing Reference” and “Choose the Continue button to program the Timing Reference”. D.. “Replacing the ECM”. Verify that the transducer is not bent. STOP. Use either of the following methods in order to program the new timing reference: i02089716 Generator Output Power Sensor . After a few moments.Calculating the new Timing Reference”. Repeat the calibration procedure. verify that the engine rpm was stable during the calibration (± 50 rpm).01 VDC.Calibrate SMCS Code: 5574-524-PWR System Operation Description: The master Electronic Control Module (ECM) must receive an accurate signal that indicates the power output of the generator. Test Step 1. or shorted internally. The offset voltage is the voltage level of the signal when the generator is stopped. Results: • OK – The timing calibration was successful. STOP.. the signal must be less than 0. Remove the adapter and reinstall the timing calibration plug. Remove the electrical power from the engine. CALIBRATE”. However. STOP. • Click the left mouse button on the “Continue” button in the lower left corner of the Cat ET screen. An offset voltage above 0. The following steps describe the procedure for adding the correct amount of resistance to the circuit in order to reduce the offset voltage to an acceptable level.01 VDC can be reduced by adding resistance to the circuit. Excessive backlash in the gear train will cause inconsistent timing. The calibration was unsuccessful. When the generator is stopped. Expected Result: After a few moments. Repeat the calibration procedure. Check the 7X-1695 Cable for continuity. open. If the calibration is still unsuccessful. Cat ET will display “CALIBRATION SUCCESSFUL”. Replace the protective cover on the transducer. Identify the Configuration of the Wiring A. Verify that there are no active diagnostic codes which can prevent the calibration. check the installation of the tools and the operation of the tools.

Test Step 3.352 Troubleshooting Section Illustration 188 Schematic for the wiring between the generator output power sensor and the ECM g01065858 B. Adjust the Potentiometer to the Minimum Value A. Measure the resistance between the end terminals. . Test Step 2. Connect an ohmmeter to the end terminals of the potentiometer. Use a piece of 16 gauge wire in order to make the connection. You may connect the potentiometer to the positive terminal or to the negative terminal of the generator output power sensor. Refer to Illustration 188. properly. A. Determine if a potentiometer has been connected to the wiring. Proceed to Test Step 3. 122-9457 Potentiometer meets these specifications. D. Connect the potentiometer to the wiring. • Not OK – The potentiometer is not connected Repair: Make repairs to the installation. Adjust the potentiometer in order to create the minimum resistance across the terminals. Results: B. Expected Result: A potentiometer is connected to the wiring. Proceed to Test Step 2. Expected Result: The potentiometer is connected correctly. Use 16 gauge wire in order to make the connections. Disconnect one of the wires that is used to connect the potentiometer to the circuit. • 5000 Ohms • Linear taper • 10 turns The wattage rating of the potentiometer is not important. Proceed to Test Step 4. as needed. Connect the terminal for the wiper to an end terminal. Carefully inspect the wiring between the generator output power sensor and the ECM. Results: • Yes – A potentiometer is connected to the wiring. • No – A potentiometer is not connected to the wiring. Install a Potentiometer The potentiometer must have the following characteristics: • OK – The potentiometer is connected properly. Refer to Illustration 188. C. STOP.

Set the engine control to the STOP position. Adjust the Potentiometer Note: The multimeter must be connected to the P1 connector. Measure the DC voltage at the terminals. continue with this procedure. The voltage reading will decrease as you increase the resistance. D. C. Results: • OK – The potentiometer is set to the minimum value. The adjustment is correct when the voltage reading is between ±0. Verify that the probes are making good contact with the terminals inside the connector. Adjust the potentiometer in order to create the minimum resistance across the terminals. Connect a digital voltmeter to the probes. When the potentiometer is set to the minimum value. Test Step 4. Reconnect the wire to the circuit. STOP. C. slowly adjust the potentiometer. minimum value. Connect an ohmmeter to the end terminals of the potentiometer. A reading of zero VDC is ideal. Restore the electrical power to the engine. Expected Result: The potentiometer is set to the minimum value. D. . Perform this Test Step again. Insert 7X-1710 Multimeter Probes into terminals P1-19 and P1-25. While you are measuring the voltage at the terminals of the master ECM. Illustration 189 Terminal box g01066039 (P1-19) Return for the input from the generator output power sensor (P1-25) Input from the generator output power sensor A. Proceed to Test Step 4.00 VDC and ±0.353 Troubleshooting Section B. • Not OK – The potentiometer is not set to the Repair: The potentiometer must be set to the minimum value before you continue with this procedure. B. The polarity of the connections is not important.01 VDC.

Results: • OK – The voltage is between ±0.01 VDC.354 Troubleshooting Section Expected Result: The voltage decreases as the potentiometer is adjusted. Refer to Systems Operation/Testing and Adjusting.01 VDC. • Not OK – The potentiometer cannot be adjusted in order to attain a DC voltage between ±0.01 VDC.0 VDC and ±0.0 VDC and ±0. STOP. . Repair: Replace the potentiometer and perform this entire procedure again. The calibration procedure has been completed successfully. “Electronic Control System Parameters”. Repair: Adjust the “Power Monitoring” parameters. STOP. The final voltage is between ±0.0 VDC and ±0.

......... 235 Detonation .............................................................................................. E435 Cylinder #15 Detonation Shutdown. 152 152 153 153 153 153 154 154 154 155 155 155 155 156 156 156 156 E129 Engine Oil Filter Diff Pressure High Warning ......................................................... E427 Cylinder #7 Detonation Shutdown............ E050 High System Voltage Warning ................................... 36 Recommended Repairs ...... E422 Cylinder #2 Detonation Shutdown............................................ 38 Recommended Repairs ........................ E405 Cylinder #5 Detonation............................................... E128 Engine Oil Filter Diff Pressure Low Shutdown..... E226 Driven Equipment Not Ready..................................................................................... 38 E E004 Engine Overspeed Shutdown ................................................................................................................... 239 Diagnostic Codes ......... E424 Cylinder #4 Detonation Shutdown................ E053 Low Fuel Pressure Warning.... E019 High Engine Oil Temperature Shutdown ........................ E016 High Engine Coolant Temperature Shutdown................... E418 Cylinder #18 Detonation............................. E423 Cylinder #3 Detonation Shutdown........................... E020 High Engine Oil Temperature Warning..................................................................... E406 Cylinder #6 Detonation..................................... 214 C Calibration Procedures ............................................................. 38 Probable Causes ......................................................................................................... E417 Cylinder #17 Detonation................................................................................ E042 Low System Voltage Shutdown......................... E420 Cylinder #20 Detonation..... E402 Cylinder #2 Detonation........................................................ E027 High Inlet Air Temperature Warning ................ E409 Cylinder #9 Detonation............................. 66 Logged Diagnostic Codes.. 37 Detonation Sensors ......................................................................................................... E135 Low Jacket Water Pressure Shutdown ........................................................ E426 Cylinder #6 Detonation Shutdown........ 36 Probable Causes ........ E413 Cylinder #13 Detonation................................ 65 Active Diagnostic Codes ............. E040 Low Engine Oil Pressure Shutdown.................................. E428 Cylinder #8 Detonation Shutdown...... E434 Cylinder #14 Detonation Shutdown................................................................ E404 Cylinder #4 Detonation.................................. E223 High Gas Temperature ................. E230 Fuel Energy Content Setting High............. E270 Driven Equipment Shutdown Requested ............................... E127 Engine Oil Filter Diff Pressure Low Warning ......................................... E229 Fuel Energy Content Setting Low .................................... E408 Cylinder #8 Detonation...... E416 Cylinder #16 Detonation...................................... E431 Cylinder #11 Detonation Shutdown.......................... E269 Customer Shutdown Requested ..... E401 Cylinder #1 Detonation...20 mA)............... E038 Low Engine Coolant Temperature Warning ......................... 27 D Desired Speed Input (4 ....................... E411 Cylinder #11 Detonation ..................... E337 High Engine Oil to Engine Coolant Diff Temp . E419 Cylinder #19 Detonation... E407 Cylinder #7 Detonation.......... 199 Driven Equipment . E414 Cylinder #14 Detonation....... E017 High Engine Coolant Temperature Warning ....................... E425 Cylinder #5 Detonation Shutdown................. E264 Emergency Stop Activated............. E245 High Right Turbo Turbine Inlet Temperature...... E415 Cylinder #15 Detonation......................................... E268 Unexpected Engine Shutdown..................... E096 High Fuel Pressure ...................... E429 Cylinder #9 Detonation Shutdown..................................... E410 Cylinder #10 Detonation............ E043 Low System Voltage Warning ................ 223 Compressor Bypass ........................... E246 High Left Turbo Turbine Inlet Temperature..... 206 A Analog Sensor Signal .................................................... E231 Fuel Quality Out of Range....... E244 High Right Turbo Turbine Outlet Temperature.................... E433 Cylinder #13 Detonation Shutdown........................... E432 Cylinder #12 Detonation Shutdown................................ 66 Diagnostic Functional Tests.....................355 Index Section Index Numerics +5V Sensor Voltage Supply.. E430 Cylinder #10 Detonation Shutdown....................................................................................................... 349 CAT Data Link .............................. E026 High Inlet Air Temperature Shutdown ................................................................... E412 Cylinder #12 Detonation........................................... 157 157 157 158 158 158 158 159 159 159 159 160 160 161 161 161 161 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 167 168 168 168 168 169 169 169 169 170 170 170 171 171 171 171 ................ 229 Customer Passwords .... E100 Low Engine Oil Pressure Warning ............................................ E130 Engine Oil Filter Diff Pressure High Shutdown............... E224 High Jacket Water Inlet Pressure............. E225 Engine Overcrank .......................... E403 Cylinder #3 Detonation...... 199 +8V Sensor Voltage Supply........ E421 Cylinder #1 Detonation Shutdown............................... E243 High Left Turbo Turbine Outlet Temperature.........................

.... E838 Cyl #18 Exhaust Port Temp Deviating High ...................................................... E826 Cyl #6 Exhaust Port Temp Deviating High................................................. 197 E864 Low Gas Fuel Differential Pressure .................................. 269 ECM Will Not Accept Factory Passwords.............. E823 Cyl #3 Exhaust Port Temp Deviating High................... E440 Cylinder #20 Detonation Shutdown................ E836 Cyl #16 Exhaust Port Temp Deviating High ................................................................... E841 Cyl #1 Exhaust Port Temp Deviating Low ................................................ E842 Cyl #2 Exhaust Port Temp Deviating Low ........................................................................................... 195 E857 Cyl #17 Exhaust Port Temp Deviating Low ...... E840 Cyl #20 Exhaust Port Temp Deviating High .............................................................................. E805 Cylinder #5 High Exhaust Port Temp ................................................................. 18 Terminal Box ............................................ E813 Cylinder #13 High Exhaust Port Temp ........................... E812 Cylinder #12 High Exhaust Port Temp .................................. E839 Cyl #19 Exhaust Port Temp Deviating High ......................................... E837 Cyl #17 Exhaust Port Temp Deviating High .......................... E807 Cylinder #7 High Exhaust Port Temp ....... 38 Probable Causes ............. E829 Cyl #9 Exhaust Port Temp Deviating High.......... 197 E867 Improper Gas Flow Control Valve Response............ 193 E851 Cyl #11 Exhaust Port Temp Deviating Low.... E845 Cyl #5 Exhaust Port Temp Deviating Low ......... E817 Cylinder #17 High Exhaust Port Temp ............................ E834 Cyl #14 Exhaust Port Temp Deviating High ..................... E802 Cylinder #2 High Exhaust Port Temp ....................... E831 Cyl #11 Exhaust Port Temp Deviating High ..................... E832 Cyl #12 Exhaust Port Temp Deviating High ................................................................ 39 Engine Coolant Temperature (Low)................... E828 Cyl #8 Exhaust Port Temp Deviating High..... E809 Cylinder #9 High Exhaust Port Temp ...... E439 Cylinder #19 Detonation Shutdown.......... 194 E854 Cyl #14 Exhaust Port Temp Deviating Low ........... 38 Probable Causes ... E810 Cylinder #10 High Exhaust Port Temp .......................... E819 Cylinder #19 High Exhaust Port Temp ...... E822 Cyl #2 Exhaust Port Temp Deviating High................................................... 38 Recommended Repairs ................. 196 E860 Cyl #20 Exhaust Port Temp Deviating Low ........... 16 Junction Box ......... E804 Cylinder #4 High Exhaust Port Temp ................................. E824 Cyl #4 Exhaust Port Temp Deviating High..... E827 Cyl #7 Exhaust Port Temp Deviating High....................356 Index Section E436 Cylinder #16 Detonation Shutdown................................................................. 191 E847 Cyl #7 Exhaust Port Temp Deviating Low ..... 39 Electronic Service Tools .............................................................................................................................. 38 Electrical Connectors and Functions ............ 19 Electronic Troubleshooting ............. E806 Cylinder #6 High Exhaust Port Temp ....................... 10 Engine Coolant Temperature (High) ................ 192 E850 Cyl #10 Exhaust Port Temp Deviating Low .............. E821 Cyl #1 Exhaust Port Temp Deviating High..................... 195 E858 Cyl #18 Exhaust Port Temp Deviating Low ......... 193 E853 Cyl #13 Exhaust Port Temp Deviating Low ............. E835 Cyl #15 Exhaust Port Temp Deviating High .................................. 39 Probable Causes .......... 18 Caterpillar Electronic Technician (ET)........ E808 Cylinder #8 High Exhaust Port Temp ............................................ E438 Cylinder #18 Detonation Shutdown................ E801 Cylinder #1 High Exhaust Port Temp ............ 41 Engine Cranks but Will Not Start ........ 38 Recommended Repairs ................................................. 198 ECM Output Circuit (Fuel Control)................................................ 41 Probable Causes ......................... 16 Electrical Power Supply............. 275 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With an Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)). 192 E849 Cyl #9 Exhaust Port Temp Deviating Low ........... 257 ECM Status Indicator Output........................................................................................................ 39 Recommended Repairs ........................................ 172 172 172 173 173 173 173 174 174 175 175 175 176 176 177 177 177 178 178 179 179 179 180 180 180 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188 188 189 189 189 190 190 191 E846 Cyl #6 Exhaust Port Temp Deviating Low ............ E843 Cyl #3 Exhaust Port Temp Deviating Low ................................................................. 198 E868 Gas Flow Control Valve Malfunction ................ 41 Recommended Repairs ........................... 194 E855 Cyl #15 Exhaust Port Temp Deviating Low ............................................ E815 Cylinder #15 High Exhaust Port Temp ........ E811 Cylinder #11 High Exhaust Port Temp......................................................... 197 E866 Low Gas Fuel Flow Rate................................................ E814 Cylinder #14 High Exhaust Port Temp .................................... 41 Probable Causes .......... 195 E856 Cyl #16 Exhaust Port Temp Deviating Low .............. 196 E859 Cyl #19 Exhaust Port Temp Deviating Low .. E816 Cylinder #16 High Exhaust Port Temp ................................... 248 ECM Output Circuit (Starting Motor)........................................ 41 ................... E818 Cylinder #18 High Exhaust Port Temp ........... 16 Harness Wire Identification ...................................................... E844 Cyl #4 Exhaust Port Temp Deviating Low ....................................................................................... 197 E865 High Gas Fuel Differential Pressure............................. 41 Recommended Repairs .......................................................................... E825 Cyl #5 Exhaust Port Temp Deviating High.... E820 Cylinder #20 High Exhaust Port Temp ........ 193 E852 Cyl #12 Exhaust Port Temp Deviating Low ................................... E830 Cyl #10 Exhaust Port Temp Deviating High ................. E803 Cylinder #3 High Exhaust Port Temp ............. 191 E848 Cyl #8 Exhaust Port Temp Deviating Low ... E833 Cyl #13 Exhaust Port Temp Deviating High ............................ E437 Cylinder #17 Detonation Shutdown.......

............................................ 316 Important Safety Information ..................... 52 Event Codes ................................................................ 57 Recommended Repairs ............ 51 Engine Timing Does Not Match Programmed Timing ................... 57 Gas Temperature (High) ............ 45 Recommended Repairs ...... 54 Recommended Repairs ........................................................... 25 Engine Oil Filter Differential Pressure ..................................................................... 152 Operator Information.... 47 Recommended Repairs .. 51 Recommended Repairs .................................. 151 Other Symptoms ..................................................... 29 Fuel Energy Content............................... 55 Probable Causes ................................................. 42 Recommended Repairs .......... 47 Probable Causes ................... 48 Recommended Repair .... 20 Changing the Settings of the Monitoring System ............. 59 Recommended Repairs ............. 47 Probable Causes ................................ 56 Gas Fuel Flow Rate (Low).......................... 46 Probable Causes ............ 55 Recommended Repairs ... 53 Exhaust Port Temperature (Low)................................. 151 Troubleshooting .................................. 60 Probable Causes ................ 58 Generator Output Power Sensor ..................................................... 53 Probable Causes ....................... 52 Probable Causes ........................................................... 55 Recommended Repairs .......................... 298 Generator Output Power Sensor .............................................. 60 Recommended Repairs ............ 48 Probable Causes ................................ 48 Engine Shutdown (Unexpected)..... 55 Probable Causes ........................ 42 Probable Causes ........................................................................ 28 Flash Programming ................................................ 51 Probable Causes .......... 151 Exhaust Port Temperature (High) ............Calibrate ........................................................................... 57 Generator Output Power Readings Do Not Match ........... 45 Engine Overcrank........... 46 Recommended Repairs ............................................................................................... 55 Probable Causes ....................................................................................... 50 Probable Causes ....................................................................................................................................... 322 Integrated Temperature Sensing Module (ITSM)........................... 56 Recommended repairs.................................................................................. 48 Probable Causes ...................................... 44 Recommended Repairs .................................................................... 60 Probable Causes ........................................... 22 Monitoring Parameters...................................................................................... 55 Recommended Repairs ................ 48 Recommended Repairs ................................................................ 150 Active Event Codes............................................. 151 Logged Event Codes ... 282 Engine Speed/Timing Sensor .............................................................................................................. 50 Recommended Repairs ........................... 57 Probable Causes .............. 47 Engine Shutdown ....................... 56 Recommended Repairs ......................Calibrate .................................................................................... 53 Recommended Repairs ... 42 Engine Monitoring System.... 54 Probable Causes .................. 51 Probable Causes .......................................................................................357 Index Section Engine Misfires...... 44 Probable Causes . 55.......... 55 Fuel Metering Valve............... 289 Probable Causes ........... 51 Engine Will Not Crank .............................................................................................................. 56 Probable Causes ............................................................. 27 Factory Passwords Worksheet..... 60 Recommended Repairs ..................................................................................... 59 Inspecting Electrical Connectors .................................................... 327 Intermittent Engine Shutdown ................................................................................................................................. 21 Default Settings of the Monitoring System......................... 51 Recommended Repairs ................ 59 Probable Causes ................................................................................ 54 F Factory Passwords ................................................. 47 Recommended Repairs ............................ 29 Flash Programming... 55 Fuel Pressure ......................................................................... 48 Engine Shutdown without a Diagnostic Code.......................................... 21 Programmable Parameters of the Integrated Temperature Sensing Module ................................. 46 Engine Overload......... 56 Probable Causes .................... 44 Probable Causes ..................... 44 Recommended Repairs ........................................... 47 Engine Overspeed..... 44 Engine Oil Temperature (High) ............... 349 Engine Starts but Stalls Immediately.......... 58 Probable Causes .................................................................... 58 Recommended Repairs ..................................................................................... 305 Ignition Transformers Secondary Circuit and Spark Plugs. Runs Rough or Is Unstable................................................................................. 50 Engine Speed/Timing Sensor ........................... 56 Gas Fuel Differential Pressure (Low) ...... 55 G Gas Fuel Differential Pressure (High).................................................. 55 Recommended Repairs .... 45 Probable Causes ......... 2 Inlet Air Temperature (High) ................................... 351 I Ignition Transformers Primary Circuit ..... 52 Recommended Repairs ..................................................................................................................... 151 Diagnostic Codes and Event Codes ................................................. 61 . 44 Engine Oil Pressure (Low)............................................................................................ 60 J Jacket Water Inlet Pressure (High)..................................................

...CID 0411 ...FMI 06 Ignition Transformer Secondary #1 short to ground ...CID 0301 .........CID 0415 ...........................CID 1748 ...................CID 0307 ...FMI 05 Ignition Transformer Primary #13 open circuit ........ 72 MID 033 ......FMI 05 Ignition Transformer Secondary #1 open circuit .............................. 62 L Location of Components...........................FMI 06 Ignition Transformer Primary #3 short .... 69 MID 033 .................................................................................CID 0320 ............... 71 MID 033 .. 71 MID 033 .............FMI 06 Ignition Transformer Secondary #9 short to ground ...........................................................CID 1501 .... 61 Recommended Repairs ............ 73 MID 033 ....... 72 MID 033 ................ 78 MID 033 ..................CID 0415 ..............FMI 06 Ignition Transformer Secondary #5 short to ground ..................................CID 0409 .....CID 0301 ............. 71 MID 033 ........CID 0309 .......... 61 Probable Causes .............................. 79 MID 033 ..................................CID 1509 . 77 MID 033 ....................... 67 MID 033 .......CID 1748 ................ 74 MID 033 ..... 77 MID 033 .......................................................... 84 MID 033 ................................FMI 05 Ignition Transformer Secondary #7 open circuit ........ 82 MID 033 ..............................................FMI 05 Ignition Transformer Primary #3 open circuit .....CID 0405 .........FMI 06 Ignition Transformer Primary #13 short ................FMI 03 Cylinder #5 Detonation Sensor open/short to +batt ................. 74 MID 033 .CID 0403 .....CID 0305 ...........FMI 04 Cylinder #1 Detonation Sensor short to ground .......... 78 MID 033 ............FMI 05 Ignition Transformer Secondary #11 open circuit .....................CID 1509 ...............................CID 0315 .....CID 0315 .................FMI 06 Ignition Transformer Secondary #15 short to ground ....FMI 04 8 Volt DC Supply short to ground...................... 84 MID 033 ...............CID 0311 .....................................CID 0313 ..... 75 MID 033 ...... Integrated Temperature Sensing Module........FMI 05 Ignition Transformer Primary #11 open circuit .CID 0590 .......................................... 83 MID 033 ........................ 83 MID 033 ..........FMI 06 Ignition Transformer Secondary #17 short to ground ........ 61 Recommended Repairs ..............................CID 0401 ..FMI 06 Ignition Transformer Primary #5 short .............................CID 1501 .............................CID 1513 .......................... 69 MID 033 ...... 77 MID 033 .....CID 0409 .......................................................... Thermocouples .................. 66 MID 033 ........FMI 03 Cylinder #1 Detonation Sensor open/short to +batt .......................CID 0309 ..CID 0041 .......... 81 MID 033 ..................CID 1513 .... 76 MID 033 ...........CID 0407 .............................FMI 06 Ignition Transformer Primary #11 short......FMI 05 Ignition Transformer Primary #15 open circuit .............................CID 0405 ...................... 80 MID 033 ............... 67 MID 033 ........ 83 MID 033 ........CID 0313 ....FMI 06 Ignition Transformer Primary #1 short .......FMI 06 Ignition Transformer Secondary #3 short to ground ............. Fuel Metering Valve .... 81 MID 033 ........................................CID 1517 ...............FMI 05 Ignition Transformer Secondary #15 open circuit .........................FMI 05 Ignition Transformer Primary #9 open circuit .......FMI 03 Cylinder #17 Detonation Sensor open/short to +batt ..FMI 04 Cylinder #9 Detonation Sensor short to ground ........CID 0307 ........... M MID 033 . 67 MID 033 ...........FMI 09 Unable to communicate with Engine ECM ...................FMI 02 System Voltage intermittent/erratic ................ 79 MID 033 .CID 1505 .FMI 03 8 Volt DC Supply short to +batt..............FMI 06 Ignition Transformer Secondary #7 short to ground .............FMI 05 Ignition Transformer Secondary #5 open circuit ..........................FMI 04 Cylinder #17 Detonation Sensor short to ground ...................................................... 68 MID 033 ........................ 68 MID 033 ......................... 61 Probable Causes ......................CID 0401 ..........CID 0403 ................ Sensors........FMI 05 Ignition Transformer Secondary #3 open circuit ........................FMI 05 Ignition Transformer Secondary #9 open circuit ....CID 0413 ...................................................... 69 MID 033 ........ Actuators.........................CID 0168 ... 74 MID 033 ............FMI 05 Ignition Transformer Primary #1 open circuit ................ 82 MID 033 ........................... 84 ........................FMI 04 Cylinder #5 Detonation Sensor short to ground ... 81 MID 033 ............................................................. 73 12 12 12 15 12 14 MID 033 ..CID 0413 ............... 82 MID 033 ................................................... 70 MID 033 ............ 61 Jacket Water to Engine Oil Differential Temperature (Low)....FMI 08 Engine Speed/Timing signal abnormal .FMI 06 Ignition Transformer Primary #7 short ... 75 MID 033 . 79 MID 033 ... 72 MID 033 ..............CID 0320 ...........CID 0041 ..............................................FMI 05 Ignition Transformer Primary #5 open circuit ......FMI 06 Ignition Transformer Primary #9 short ...............FMI 06 Ignition Transformer Primary #15 short ...............................CID 0303 ......CID 0305 ... 75 MID 033 .........FMI 05 Ignition Transformer Primary #7 open circuit ...................CID 0303 ... 76 MID 033 .FMI 05 Ignition Transformer Secondary #17 open circuit .................................................. 70 MID 033 ....................358 Index Section Jacket Water Pressure (Low) ...CID 1517 ..............FMI 03 Speed/Timing Sensor short to +batt.........................CID 0311 ....CID 0411 ...CID 1505 ...........CID 0407 ....FMI 03 Cylinder #9 Detonation Sensor open/short to +batt ......FMI 06 Ignition Transformer Secondary #13 short to ground ...........FMI 04 Cylinder #13 Detonation Sensor short to ground ................ 68 MID 033 .........FMI 05 Ignition Transformer Secondary #13 open circuit ............FMI 03 Cylinder #13 Detonation Sensor open/short to +batt ..................FMI 06 Ignition Transformer Secondary #11 short to ground............ 80 MID 033 .......................

...............FMI 03 Shutdown Lamp short to +batt.......CID 0310 .....................FMI 03 Coolant Outlet Pressure open/short to +batt......CID 0410 .......... 95 MID 036 ................CID 0408 . 102 MID 036 ............. 97 MID 036 ...... 94 MID 036 ..CID 0145 ..................CID 0402 ......FMI 03 8 Volt DC Supply short to +batt.......... 91 MID 036 .FMI 05 Ignition Transformer Secondary #8 open circuit ............ 87 MID 036 ....CID 0017 .... 102 MID 036 .. 97 MID 036 ..... 104 MID 036 .......... 85 MID 033 ..................................................... 92 MID 036 . 98 MID 036 ..........................................CID 0336 .........FMI 03 Speed/Timing Sensor short to +batt........................... 97 MID 036 ....... 92 MID 036 .................CID 0109 ..........FMI 08 Engine Speed/Timing signal abnormal ..........FMI 06 Ignition Transformer Secondary #8 short to ground ......CID 0110 ................ 100 MID 036 ..........CID 0320 ........CID 0100 ........... 90 MID 036 .. 96 MID 036 .FMI 05 Ignition Transformer Primary #4 open circuit .CID 0109 .....FMI 08 Air Inlet Pressure Sensor noisy signal.........................CID 0262 .................................................................CID 0312 .... 107 MID 036 ....CID 0406 ....CID 0402 ......FMI 12 Fuel Shutoff Valve malfunction ..FMI 05 Ignition Transformer Primary #16 open circuit ..........................................................................FMI 05 Fuel Shutoff Valve open circuit ................FMI 03 Air Inlet Pressure Sensor short to +batt ...FMI 06 Ignition Transformer Secondary #10 short to ground ..CID 0100 ........CID 0304 ..........CID 0316 .................CID 0106 ............CID 0017 ..............................FMI 06 Ignition Transformer Secondary #6 short to ground ...............................FMI 05 Ignition Transformer Secondary #2 open circuit .......................FMI 04 Engine Oil Pressure short to ground..CID 0412 .............................FMI 05 Ignition Transformer Secondary #4 open circuit ...........................................CID 0316 ...........CID 0168 ....FMI 03 5 Volt Sensor DC Power Supply short to +batt ...................CID 0314 ........... 99 MID 036 .......... 106 MID 036 .............. 93 MID 036 ...CID 0017 ...................................FMI 03 Warning Lamp short to +batt..........................FMI 04 12 Volt DC Power Supply short to ground.......................FMI 05 Ignition Transformer Primary #8 open circuit ..................................FMI 05 Ignition Transformer Primary #14 open circuit ...... 105 MID 036 ...............................CID 0320 ........................CID 0262 .........................................CID 0041 .............CID 0308 ........CID 0172 ............. 93 MID 036 ............CID 1752 ......CID 0406 ..FMI 06 Ignition Transformer Primary #4 short ....FMI 02 System Voltage intermittent/erratic ............................... 104 MID 036 ...........................................CID 0175 ....... 103 MID 036 ......................... 107 ...... 94 MID 036 ........ 101 MID 036 . 87 MID 036 ........CID 0172 .......... 101 MID 036 ...................CID 0041 ....................... 91 MID 036 ...FMI 06 Ignition Transformer Primary #12 short ...FMI 03 Engine Coolant Temperature open/short to +batt .....................................................FMI 06 Ignition Transformer Primary #19 short to ground .......CID 0310 ........................FMI 06 Ignition Transformer Primary #8 short ................... 107 MID 036 .....CID 0175 ................... 89 MID 036 ..FMI 06 Ignition Transformer Secondary #19 short to ground .CID 1752 ...................... 99 MID 036 ..........................FMI 06 Ignition Transformer Secondary #2 short to ground .....CID 0412 .....................FMI 03 12 Volt DC Power Supply short to +batt.....................CID 0324 ......... 95 MID 036 .....FMI 06 Ignition Transformer Secondary #12 short to ground .................... 93 MID 036 .FMI 04 Engine Oil Temperature short to ground. 88 MID 036 ....................................... 92 MID 036 ............. 85 MID 033 .................. 90 MID 036 .FMI 04 Engine Coolant Temperature short to ground ........FMI 05 Ignition Transformer Secondary #12 open circuit ........FMI 06 Ignition Transformer Secondary #4 short to ground ............................... 105 MID 036 ..............CID 0314 .... 103 MID 036 .. 86 MID 033 ..........................................CID 0404 ..........................................................................................CID 0323 ....FMI 03 Engine Oil Pressure open/short to +batt.CID 1750 ...............CID 0302 ................... 91 MID 036 .........FMI 06 Ignition Transformer Primary #17 short to ground .....................FMI 03 Intake Manifold Air Temp open/short to +batt......................FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal ....................................... 88 MID 036 .......FMI 13 Engine Timing calibration required .FMI 05 Ignition Transformer Primary #10 open circuit ...................CID 1750 ............................................. 103 MID 036 ..FMI 06 Ignition Transformer Primary #6 short .....................................CID 0302 ......... 90 MID 036 ........CID 0408 .......FMI 05 Ignition Transformer Primary #2 open circuit ....CID 0304 .FMI 04 8 Volt DC Supply short to ground...........FMI 06 Ignition Transformer Primary #10 short ......................CID 0306 .......FMI 05 Ignition Transformer Secondary #19 open circuit ........... 101 MID 036 .....FMI 05 Ignition Transformer Primary #6 open circuit ....... 89 MID 036 ........359 Index Section MID 033 ... 98 MID 036 ..........FMI 05 Ignition Transformer Secondary #6 open circuit ..................FMI 05 Ignition Transformer Primary #17 open circuit ................................................ 100 MID 036 .............. 100 MID 036 ...... 87 MID 036 .FMI 05 Ignition Transformer Primary #12 open circuit .......................... 98 MID 036 . 105 MID 036 ....................... 88 MID 036 ...FMI 06 Ignition Transformer Primary #16 short ... 85 MID 033 ...... 86 MID 033 .. 106 MID 036 ...CID 0106 .....FMI 03 Engine Oil Temperature open/short to +batt....CID 0312 ..........CID 0261 ........CID 0308 .........................FMI 05 Ignition Transformer Primary #19 open circuit ..................CID 0306 ......................FMI 05 Ignition Transformer Secondary #10 open circuit .........FMI 06 Fuel Shutoff Valve short to ground............ 96 MID 036 .............CID 0410 ............FMI 06 Ignition Transformer Primary #14 short ...........................FMI 04 Intake Manifold Air Temp short to ground.....................FMI 04 5 Volt Sensor DC Power Supply short to ground ....................................FMI 02 Incorrect ECS Switch inputs .................CID 0145 ..CID 0404 ..............CID 1754 ............FMI 06 Ignition Transformer Primary #2 short .....CID 1754 .. 102 MID 036 .................. 96 MID 036 ...............................CID 0110 ...........

............... 119 MID 036 ........CID 1506 ..CID 1491 ...............FMI 05 Fuel Metering Module open circuit .FMI 04 Desired Engine Speed Sensor short to ground . 111 MID 036 .................................................................CID 1518 .......................CID 1514 ... 115 MID 036 .......................FMI 04 Cylinder #2 Detonation Sensor short to ground .......CID 1532 ...CID 1531 .... 124 MID 111 .... 113 MID 036 .CID 1490 ................ 108 MID 036 ........ 119 MID 036 ....CID 1492 .CID 1447 ... 123 MID 111 .CID 0416 ... 110 MID 036 ........... 122 MID 111 ...... 116 MID 036 ........CID 1489 ........................FMI 05 Ignition Transformer Secondary #20 open circuit .................................................CID 1506 ..................CID 1510 ..............................CID 1753 .................................FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground ....................... 126 MID 111 ............................CID 1636 ....FMI 06 Ignition Transformer Secondary #16 short to ground . 123 MID 111 ............................................... 112 MID 036 ..........................................CID 1719 .......................... 114 MID 036 . 128 .......FMI 04 Rt Turbo Turbine In Temp Sens short to ground......................................... 111 MID 036 .................... 109 MID 036 ..................CID 1749 ......... 118 MID 036 ...FMI 06 Ignition Transformer Secondary #18 short to ground ....... 124 MID 111 ........FMI 03 Rt Turbo Turbine In Temp Sens short to +batt.... 109 MID 036 ..........................................CID 1719 ..... 127 MID 111 .. 108 MID 036 ..................FMI 03 Unfiltered Engine Oil Pressure open/short to +batt ....... 111 MID 036 ...FMI 03 Generator Output Power Sensor open/short to +batt ..... 120 MID 036 ...FMI 09 Turbocharger Compressor Bypass Valve Actuator not communicating on link .CID 0524 .FMI 04 Unfiltered Engine Oil Pressure short to ground ...FMI 12 EEPROM checksum fault or ECM not programmed .....................FMI 05 Left Turbo Turbine In Temp Sens open circuit .....FMI 09 Unable to communicate with Throttle Actuator Drv .......................... 117 MID 036 ...........CID 1042 ..........CID 0444 ....CID 1502 .....FMI 09 Unable to communicate with Fuel Metering Module......FMI 04 Cylinder #10 Detonation Sensor short to ground ........................CID 1719 ....FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt...........CID 0542 .......... 127 MID 111 ...........................FMI 04 Generator Output Power Sensor short to ground .................. 120 MID 036 .................... 121 MID 036 ..........FMI 03 Crank Terminate Relay short to +batt......CID 1755 .................. 108 MID 036 ...CID 1755 .... 110 MID 036 ................CID 1753 ..................FMI 03 Left Turbo Turbine Out Temp Sens short to +batt.......FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit .................... 117 MID 036 ..CID 1531 ....... 127 MID 111 ... 126 MID 111 ....FMI 05 Ignition Transformer Secondary #14 open circuit ...... 118 MID 036 .......FMI 06 Start Relay short to ground..................... 122 MID 111 ....FMI 12 Fuel Metering Sensor Module malfunction.............CID 0414 .. 126 MID 111 ............ 124 MID 111 ..........................CID 1446 . 113 MID 036 .................................................................FMI 04 Cylinder #18 Detonation Sensor short to ground .........................FMI 03 Desired Engine Speed Sensor short to +batt ........CID 1489 ................FMI 03 Cylinder #10 Detonation Sensor open/short to +batt .... 117 MID 036 ...........................FMI 03 Run Relay short to +batt.....CID 1531 ........FMI 04 Cylinder #6 Detonation Sensor short to ground ..................CID 0524 ...........FMI 05 Left Turbo Turbine Out Temp Sens open circuit ... 116 MID 036 ................................ 112 MID 036 ......CID 1532 ...FMI 05 Ignition Transformer Secondary #18 open circuit .............360 Index Section MID 036 .......CID 1510 ................FMI 04 Left Turbo Turbine Out Temp Sens short to ground...........CID 0416 ........... 125 MID 111 ...... 115 MID 036 .......................CID 1492 .......... 114 MID 036 ................CID 0591 ...FMI 05 Rt Turbo Turbine Out Temp Sens open circuit ...............................FMI 05 Ignition Transformer Primary #18 open circuit ..FMI 06 Ignition Transformer Secondary #14 short to ground ........CID 1490 .........FMI 03 Left Turbo Turbine In Temp Sens short to +batt.......................................FMI 03 Cylinder #18 Detonation Sensor open/short to +batt ............CID 1518 ....FMI 13 Fuel Metering Module calibration required . 123 MID 111 ...... 118 MID 036 ................. 125 MID 111 ............ 115 MID 036 .................FMI 05 Rt Turbo Turbine In Temp Sens open circuit .........FMI 06 Ignition Transformer Primary #18 short to ground ......FMI 05 Start Relay open circuit ................................. 125 MID 111 .......CID 0445 ................................... 114 MID 036 ........CID 0443 .............FMI 09 Loss of Communication with Engine #2 (Slave)...........................FMI 06 Ignition Transformer Primary #20 short to ground ......FMI 09 Unable to communicate with ITSM..........................CID 0414 .................CID 1502 ..CID 1490 .... 119 MID 036 .............................. 114 MID 036 ...CID 0444 ..............................CID 1489 .FMI 05 Ignition Transformer Primary #20 open circuit ..........CID 1491 ... 116 MID 036 .....CID 1751 ....FMI 12 Generator Output Power Sensor malfunction..................CID 1749 .....FMI 05 Ignition Transformer Secondary #16 open circuit ...........CID 1492 ......CID 1751 ..............CID 0542 .......FMI 04 Rt Turbo Turbine Out Temp Sens short to ground.........CID 1446 ... 121 MID 036 ....... 120 MID 036 .FMI 03 Cylinder #14 Detonation Sensor open/short to +batt .........FMI 06 Ignition Transformer Secondary #20 short to ground ............. 121 MID 036 .............FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt .......FMI 04 Cylinder #14 Detonation Sensor short to ground ..........FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ................................CID 1720 ................CID 1446 ....CID 1440 ....FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt .................................... 122 MID 111 ...........CID 1491 ........CID 1446 .... 113 MID 036 ........FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground .........FMI 04 Left Turbo Turbine In Temp Sens short to ground..............................FMI 03 Cylinder #2 Detonation Sensor open/short to +batt ........CID 1514 .. 110 MID 036 ........................................FMI 12 Fuel Metering Module malfunction ....................

..... 136 MID 111 ......FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt .CID 1535 ..............................CID 1533 .............CID 1550 ................................CID 1549 ...................CID 1537 .....FMI 05 Cyl #20 Exhaust Port Temp Sensor open circuit ......CID 1540 ................ 146 MID 111 ...................CID 1535 .......FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit .........CID 1537 ............. 138 MID 111 ......FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ......FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ........................CID 1532 ......... 135 MID 111 ........................................ 147 MID 111 ....FMI 03 Cyl #17 Exhaust Port Temp Sensor short to +batt ........... 146 MID 111 ..CID 1542 ...... 32 ..FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground .......................CID 1536 .........CID 1540 ..CID 1545 ..........CID 1544 ....CID 1534 .............. 335 R Replacing the ECM.CID 1541 ..............FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit ...... 131 MID 111 ......... 27 PWM Sensor ............................................ 142 MID 111 .FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ..........................................................CID 1540 .CID 1533 ........ 144 MID 111 .CID 1548 ..CID 1541 ............ 129 MID 111 ....................FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground . 142 MID 111 ...........CID 1550 .. 132 MID 111 ......... 133 MID 111 ..FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ...............................CID 1536 ...........FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt .........CID 1539 ...........CID 1542 ...CID 1543 ...................FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground ....FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ..........................FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit ..........................FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt ............. 129 MID 111 .CID 1550 .....FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ......... 143 MID 111 ..... 132 MID 111 ........ 137 MID 111 ................. 30 Replacing the ITSM ............................................. 135 MID 111 ....FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground .............FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ................ 148 P Programming Parameters ........CID 1547 .................... 139 MID 111 ........... 139 MID 111 ..............CID 1544 ...........FMI 04 Cyl #20 Exhaust Port Temp Sensor short to ground ....FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground ..... 133 MID 111 ..FMI 05 Cyl #19 Exhaust Port Temp Sensor open circuit .FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ...CID 1546 .....FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit .CID 1546 ...................................................... 145 MID 111 .......FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt ...CID 1549 .......... 147 MID 111 ... 130 MID 111 . 140 MID 111 ..... 140 MID 111 . 145 MID 111 .............FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ....CID 1545 .............FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground .........FMI 05 Cyl #18 Exhaust Port Temp Sensor open circuit ......CID 1549 ....... 134 MID 111 ........FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ...............CID 1539 ....... 130 MID 111 .FMI 04 Cyl #9 Exhaust Port Temp Sensor short to ground .........................CID 1545 ......FMI 03 Cyl #19 Exhaust Port Temp Sensor short to +batt ... 147 MID 111 ...FMI 05 Cyl #17 Exhaust Port Temp Sensor open circuit ..........CID 1539 .... 145 MID 111 .....FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit .361 Index Section MID 111 .......CID 1548 ............ 137 MID 111 .........................................CID 1536 .............. 144 MID 111 ........................................CID 1547 ...............FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground .................. 139 MID 111 ..CID 1548 ...FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit ......... 131 MID 111 ...........FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt ......FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit .....FMI 04 Cyl #17 Exhaust Port Temp Sensor short to ground ..... 130 MID 111 .....CID 1538 ...............CID 1543 .... 148 MID 111 .....FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt ............ 141 MID 111 ................... 148 MID 111 ......FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit ............. 136 MID 111 ...............CID 1547 ....FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit .........FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ............................CID 1537 .....CID 1541 ..............FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit .............. 129 MID 111 ....................... 138 MID 111 ............................................ 138 MID 111 ........... 142 MID 111 .........FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground .........FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit ............FMI 03 Cyl #18 Exhaust Port Temp Sensor short to +batt ................................................CID 1538 ......CID 1534 . 128 MID 111 ..................................FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit ... 135 MID 111 .................CID 1538 ............CID 1533 ....................... 133 MID 111 ................ 136 MID 111 ..........CID 1534 ..........CID 1542 ........CID 1546 .. 132 MID 111 .......CID 1535 ..................FMI 03 Cyl #20 Exhaust Port Temp Sensor short to +batt ..FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit .........CID 1543 ..... 143 MID 111 ..........FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground ..........................FMI 04 Cyl #18 Exhaust Port Temp Sensor short to ground .........................................FMI 04 Cyl #19 Exhaust Port Temp Sensor short to ground . 141 MID 111 ......... 141 MID 111 ...FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt ... 144 MID 111 ............................................CID 1544 ..... 134 MID 111 .................FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit ..FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit ..........

............................... 63 Probable Causes ............................ 10 System Voltage............................................................................... 36 System Configuration Parameters.. 342 Troubleshooting Data Sheet........ 36 Diagnostic Codes and Event Codes .................. 11 Symptoms............................... 10 Air/Fuel Ratio Control............ 36 Turbocharger Turbine Temperature (High) ...................................... 10 Engine Monitoring and Protection.............. 11 Engine Speed Governing........................................................................................................................................................................................ 62 Recommended Repairs ...... 65 Troubleshooting with an Event Code... 36 Operator Information............................................. 35 Troubleshooting Section...... 63 Recommended Repairs .. 62 Turbocharger Turbine Temperature (Low)............. 62 Probable Causes ..................................................................... 150 Troubleshooting without a Diagnostic Code ......... 10 Troubleshooting with a Diagnostic Code .... 63 ........ 62 Probable Causes ....... 62 T Table of Contents...................................................................... 62 Recommended Repairs ........................................................................................... 11 Introduction .......................................................... 34 Report the Service Information ........................................ 3 Throttle Actuator ............................................................................ 10 Start/Stop Sequencing ....................................................... 10 Ignition Control.............. 36 Other Symptoms ...........362 Index Section S Self-Diagnostics.................................................................................... 29 System Overview.........

363 Index Section .

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