RENR5910-00 - (Troubleshooting) G3612 - G3616 Engines PDF

RENR5910
February 2002
Troubleshooting
G3612 and G3616 Engines
BLB1-Up (Engine)
BKE1-Up (Engine)
i01658146
Important Safety Information

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

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

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents Noise Coming from Cylinder (Noisy Cylinder

Head) .................................................................. 60
Poor Coolant Flow ................................................ 60
System Voltage ..................................................... 61
Troubleshooting Section Short Spark Plug Life ............................................ 61
Starting Motor Runs, Pinion Engages But Does Not
Electronic Troubleshooting
Turn the Flywheel ................................................ 62
System Overview .................................................. 10
Too Much Vibration ............................................... 62
Electrical Connectors and Functions .................... 12
Turbocharger Turbine Temperature (High) ............ 63
Electronic Service Tools ........................................ 18
Engine Monitoring System .................................... 21
Troubleshooting with a Diagnostic Code
Diagnostic Codes .................................................. 64
Programming Parameters
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open
Programming Parameters ..................................... 22
circuit ................................................................... 65
Customer Passwords ............................................ 22
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short
Factory Passwords ................................................ 22
to ground ............................................................. 66
Flash Programming .............................................. 23
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve
System Configuration Parameters ........................ 24
malfunction .......................................................... 66
Factory Passwords Worksheet ............................. 25
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short
Replacing the ECM ............................................... 25
to +batt ................................................................ 66
Replacing the ICSM .............................................. 26
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short
Troubleshooting Data Sheet ................................. 28
to ground ............................................................. 67
MID 036 - CID 0094 - FMI 03 Fuel Pressure
Troubleshooting without a Diagnostic Code
open/short to +batt .............................................. 67
Symptoms ............................................................. 31
MID 036 - CID 0094 - FMI 08 Fuel Pressure
Air Starting Motor .................................................. 31
Noisy ................................................................... 67
Crankcase Pressure (High) .................................. 32
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure
Detonation ............................................................ 33
Driven Equipment ................................................. 34
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure
ECM Will Not Accept Factory Passwords ............. 35
short to ground .................................................... 68
Electrohydraulic System Oil Pressure (Low) ......... 35
MID 036 - CID 0101 - FMI 03 Crankcase Pressure
Electronic Service Tool Will Not Communicate with
ECM or ICSM ...................................................... 36
MID 036 - CID 0101 - FMI 04 Crankcase Pressure
Engine Coolant Temperature (High) ..................... 37
short to ground .................................................... 69
Engine Coolant Temperature (Low) ...................... 39
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure
Engine Cranks but Will Not Start .......................... 39
Sensor short to +batt .......................................... 69
Engine Misfires, Runs Rough or Is Unstable ........ 41
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure
Engine Oil Filter Differential Pressure ................... 43
Sensor noisy signal ............................................. 70
Engine Oil Pressure (Low) .................................... 43
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure
Engine Oil Temperature (High) ............................. 44
Engine Overcrank ................................................. 45
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet
Engine Overload ................................................... 46
Pressure Sensor noisy signal ............................. 70
Engine Overspeed ................................................ 46
MID 036 - CID 0110 - FMI 03 Engine Coolant
Engine Pre-Lube Pressure (Low) ......................... 47
Temperature open/short to +batt ......................... 71
Engine Shutdown .................................................. 48
MID 036 - CID 0110 - FMI 04 Engine Coolant
Engine Shutdown (Unexpected) ........................... 48
Temperature short to ground ............................... 71
Engine Shutdown without a Diagnostic Code ....... 50
MID 036 - CID 0168 - FMI 02 System Voltage
Engine Starts but Stalls Immediately .................... 50
intermittent/erratic ............................................... 71
Excessive Engine Oil Consumption ...................... 51
MID 036 - CID 0172 - FMI 03 Intake Manifold Air
Exhaust Emission Too High/Fuel Consumption Too
Temp open/short to +batt .................................... 72
High ..................................................................... 52
MID 036 - CID 0172 - FMI 04 Intake Manifold Air
Exhaust Port Temperature (High) ......................... 53
Temp short to ground .......................................... 72
Exhaust Port Temperature (Low) .......................... 54
MID 036 - CID 0174 - FMI 03 Fuel Temperature
Fuel Energy Content ............................................. 55
Fuel Pressure ....................................................... 55
MID 036 - CID 0174 - FMI 04 Fuel Temperature short
Gas Temperature (High) ....................................... 56
to ground ............................................................. 73
Inlet Air Temperature (High) .................................. 56
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature
Intermittent Engine Shutdown ............................... 57
Jacket Water Inlet Pressure (High) ....................... 58
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature
Jacket Water Pressure (Low) ................................ 58
short to ground .................................................... 74
Jacket Water to Engine Oil Differential Temperature
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed
(Low) ................................................................... 59
signal ................................................................... 74
Mechanical Noise (Knock) in Engine .................... 59
4
Table of Contents
MID 036 - CID 0190 - FMI 08 Engine Speed signal MID 036 - CID 0314 - FMI 06 Cylinder 14 -
abnormal ............................................................. 75 Transformer Primary short .................................. 85
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power MID 036 - CID 0315 - FMI 05 Cylinder 15 -
Supply short to +batt ........................................... 75 Transformer Primary open circuit ........................ 86
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power MID 036 - CID 0315 - FMI 06 Cylinder 15 -
Supply short to ground ........................................ 75 Transformer Primary short .................................. 86
MID 036 - CID 0301 - FMI 05 Cylinder 1 - Transformer MID 036 - CID 0316 - FMI 05 Cylinder 16 -
Primary open circuit ............................................ 76 Transformer Primary open circuit ........................ 87
Primary short ...................................................... 76 Transformer Primary short .................................. 87
MID 036 - CID 0302 - FMI 05 Cylinder 2 - Transformer MID 036 - CID 0323 - FMI 03 Shutdown Lamp short
Primary open circuit ............................................ 76 to +batt ................................................................ 87
MID 036 - CID 0302 - FMI 06 Cylinder 2 - Transformer MID 036 - CID 0324 - FMI 03 Warning Lamp short to
Primary short ...................................................... 77 +batt .................................................................... 88
MID 036 - CID 0303 - FMI 05 Cylinder 3 - Transformer MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Primary open circuit ............................................ 77 inputs .................................................................. 88
MID 036 - CID 0303 - FMI 06 Cylinder 3 - Transformer MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
Primary short ...................................................... 77 circuit ................................................................... 88
MID 036 - CID 0304 - FMI 05 Cylinder 4 - Transformer MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short
Primary open circuit ............................................ 78 to ground ............................................................. 88
MID 036 - CID 0304 - FMI 06 Cylinder 4 - Transformer MID 036 - CID 0339 - FMI 05 Engine Pre-lube
Primary short ...................................................... 78 Pressure Switch open circuit ............................... 89
MID 036 - CID 0305 - FMI 05 Cylinder 5 - Transformer MID 036 - CID 0401 - FMI 05 Cylinder 1 - Transformer
Primary open circuit ............................................ 79 Secondary open circuit ....................................... 89
Primary short ...................................................... 79 Secondary short to ground ................................. 90
MID 036 - CID 0306 - FMI 05 Cyinder 6 - Transformer MID 036 - CID 0402 - FMI 05 Cylinder 2 - Transformer
MID 036 - CID 0310 - FMI 05 Cylinder 10 - MID 036 - CID 0406 - FMI 05 Cylinder 6 - Transformer
Transformer Primary open circuit ........................ 82 Secondary open circuit ....................................... 93
Transformer Primary short .................................. 82 Secondary short to ground ................................. 94
MID 036 - CID 0314 - FMI 05 Cylinder 14 - MID 036 - CID 0410 - FMI 05 Cylinder 10 -
Transformer Primary open circuit ........................ 85 Transformer Secondary open circuit ................... 96
5
Table of Contents
MID 036 - CID 0410 - FMI 06 Cylinder 10 - MID 036 - CID 1505 - FMI 03 Cylinder #5 Detonation
Transformer Secondary short to ground ............. 97 Sensor open/short to +batt ............................... 108
Transformer Secondary open circuit ................... 97 Sensor short to ground ..................................... 108
Transformer Secondary open circuit ................. 100 Sensor short to ground ..................................... 110
Transformer Secondary short to ground ........... 100 Sensor open/short to +batt ............................... 111
Transformer Secondary short to ground ........... 101 Sensor open/short to +batt ............................... 111
MID 036 - CID 0416 - FMI 06 Cylinder 16 - MID 036 - CID 1844 - FMI 05 Fuel Actuator open
Transformer Secondary short to ground ........... 102 circuit ................................................................. 112
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay MID 036 - CID 1844 - FMI 06 Fuel Actuator short to
short to +batt ..................................................... 102 ground ............................................................... 112
MID 036 - CID 0444 - FMI 05 Start Relay open MID 109 - CID 0253 - FMI 02 Personality Module
circuit ................................................................. 102 mismatch ........................................................... 113
MID 036 - CID 0444 - FMI 06 Start Relay short to MID 109 - CID 0591 - FMI 12 EEPROM checksum
ground ............................................................... 103 fault or ECM not programmed ........................... 113
MID 036 - CID 0445 - FMI 03 Run Relay short to MID 109 - CID 1040 - FMI 09 ICSM #1 not
+batt .................................................................. 103 communicating on link ...................................... 113
MID 036 - CID 0524 - FMI 03 Desired Engine Speed MID 109 - CID 1043 - FMI 02 Cylinder #1 Firing
Sensor short to +batt ........................................ 103 Signal noisy ....................................................... 113
MID 036 - CID 0524 - FMI 04 Desired Engine Speed MID 109 - CID 1043 - FMI 03 Cylinder #1 Firing
Sensor short to ground ..................................... 104 Signal open/short to +batt ................................. 114
MID 036 - CID 0525 - FMI 05 Choke Actuator open MID 109 - CID 1043 - FMI 04 Cylinder #1 Firing
circuit ................................................................. 104 Signal short to ground ....................................... 114
MID 036 - CID 0525 - FMI 06 Choke Actuator short MID 109 - CID 1043 - FMI 08 Cylinder #1 Firing
to ground ........................................................... 104 Signal abnormal signal ...................................... 114
MID 036 - CID 0526 - FMI 05 Wastegate Valve MID 109 - CID 1044 - FMI 02 All Cylinders Firing
open .................................................................. 105 Signal noisy ....................................................... 115
MID 036 - CID 0526 - FMI 06 Wastegate Valve MID 109 - CID 1044 - FMI 03 All Cylinders Firing
short .................................................................. 105 Signal open/short to +batt ................................. 115
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil MID 109 - CID 1044 - FMI 04 All Cylinders Firing
Pressure open/short to +batt ............................ 105 Signal short to ground ....................................... 115
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil MID 109 - CID 1101 - FMI 02 Cylinder #1 Combustion
Pressure short to ground .................................. 106 Probe noisy ....................................................... 116
MID 036 - CID 1040 - FMI 09 ICSM #1 not MID 109 - CID 1101 - FMI 04 Cylinder #1 Combustion
communicating on link ...................................... 106 Probe short to ground ....................................... 116
MID 036 - CID 1041 - FMI 09 ICSM #2 not MID 109 - CID 1103 - FMI 02 Cylinder #3 Combustion
communicating on link ...................................... 106 Probe noisy ....................................................... 117
MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation MID 109 - CID 1103 - FMI 04 Cylinder #3 Combustion
Sensor open/short to +batt ............................... 107 Probe short to ground ....................................... 117
Sensor short to ground ..................................... 107 Probe noisy ....................................................... 117
Sensor open/short to +batt ............................... 107 Probe short to ground ....................................... 118
Sensor short to ground ..................................... 108 Probe noisy ....................................................... 118
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Table of Contents
MID 109 - CID 1107 - FMI 04 Cylinder #7 Combustion MID 109 - CID 1541 - FMI 03 Cyl #11 Exhaust Port
Probe short to ground ....................................... 119 Temp Sensor short to +batt ............................... 128
Probe noisy ....................................................... 119 Temp Sensor short to ground ............................ 129
Probe short to ground ....................................... 119 Temp Sensor open circuit ................................. 129
MID 109 - CID 1111 - FMI 02 Cylinder #11 MID 109 - CID 1543 - FMI 03 Cyl #13 Exhaust Port
Combustion Probe noisy ................................... 120 Temp Sensor short to +batt ............................... 129
Combustion Probe short to ground ................... 120 Temp Sensor short to ground ............................ 130
Combustion Probe noisy ................................... 120 Temp Sensor open circuit ................................. 130
Combustion Probe short to ground ................... 121 Temp Sensor short to +batt ............................... 130
Combustion Probe noisy ................................... 121 Temp Sensor short to ground ............................ 130
Combustion Probe short to ground ................... 122 Temp Sensor open circuit ................................. 131
MID 109 - CID 1490 - FMI 03 Rt Turbo Turbine Out MID 110 - CID 0253 - FMI 02 Personality Module
Temp Sens short to +batt .................................. 122 mismatch ........................................................... 131
MID 109 - CID 1490 - FMI 04 Rt Turbo Turbine Out MID 110 - CID 0591 - FMI 12 EEPROM checksum
Temp Sens short to ground ............................... 122 fault or ECM not programmed ........................... 131
MID 109 - CID 1490 - FMI 05 Rt Turbo Turbine Out MID 110 - CID 1041 - FMI 09 ICSM #2 not
Temp Sens open circuit ..................................... 123 communicating on link ...................................... 132
MID 109 - CID 1491 - FMI 03 Rt Turbo Turbine In MID 110 - CID 1044 - FMI 02 All Cylinders Firing
Temp Sens short to +batt .................................. 123 Signal noisy ....................................................... 132
Temp Sens short to ground ............................... 123 Signal open/short to +batt ................................. 132
Temp Sens open circuit ..................................... 124 Signal short to ground ....................................... 133
MID 109 - CID 1531 - FMI 03 Cyl #1 Exhaust Port MID 110 - CID 1044 - FMI 08 All Cylinders Firing
Temp Sensor short to +batt ............................... 124 Signal abnormal signal ...................................... 133
MID 109 - CID 1531 - FMI 04 Cyl #1 Exhaust Port MID 110 - CID 1102 - FMI 02 Cylinder #2 Combustion
Temp Sensor short to ground ............................ 124 Probe noisy ....................................................... 133
Temp Sensor open circuit ................................. 124 Probe short to ground ....................................... 134
Temp Sensor short to +batt ............................... 125 Probe noisy ....................................................... 134
Temp Sensor short to ground ............................ 125 Probe short to ground ....................................... 135
Temp Sensor open circuit ................................. 125 Probe noisy ....................................................... 135
Temp Sensor short to +batt ............................... 126 Probe short to ground ....................................... 135
Temp Sensor short to ground ............................ 126 Probe noisy ....................................................... 136
Temp Sensor open circuit ................................. 126 Probe short to ground ....................................... 136
MID 109 - CID 1537 - FMI 03 Cyl #7 Exhaust Port MID 110 - CID 1110 - FMI 02 Cylinder #10
Temp Sensor short to +batt ............................... 127 Combustion Probe noisy ................................... 136
Temp Sensor short to ground ............................ 127 Combustion Probe short to ground ................... 137
Temp Sensor open circuit ................................. 127 Combustion Probe noisy ................................... 137
Temp Sensor short to +batt ............................... 127 Combustion Probe short to ground ................... 138
Temp Sensor short to ground ............................ 128 Combustion Probe noisy ................................... 138
Temp Sensor open circuit ................................. 128 Combustion Probe short to ground ................... 138
7
Table of Contents
Combustion Probe noisy ................................... 139 Temp Sensor open circuit ................................. 148
MID 110 - CID 1116 - FMI 04 Cylinder #16
Combustion Probe short to ground ................... 139 Troubleshooting with an Event Code
MID 110 - CID 1489 - FMI 03 Left Turbo Turbine Out Event Codes ...................................................... 149
Temp Sens short to +batt .................................. 139 E004 Engine Overspeed Shutdown .................... 151
MID 110 - CID 1489 - FMI 04 Left Turbo Turbine Out E013 High Crankcase Pressure Shutdown ........ 151
Temp Sens short to ground ............................... 140 E016 High Engine Coolant Temperature
MID 110 - CID 1489 - FMI 05 Left Turbo Turbine Out Shutdown .......................................................... 151
Temp Sens open circuit ..................................... 140 E017 High Engine Coolant Temperature
MID 110 - CID 1492 - FMI 03 Left Turbo Turbine In Warning ............................................................. 151
Temp Sens short to +batt .................................. 140 E019 High Engine Oil Temperature Shutdown ... 152
MID 110 - CID 1492 - FMI 04 Left Turbo Turbine In E020 High Engine Oil Temperature Warning ...... 152
Temp Sens short to ground ............................... 141 E026 High Inlet Air Temperature Shutdown ........ 152
MID 110 - CID 1492 - FMI 05 Left Turbo Turbine In E027 High Inlet Air Temperature Warning .......... 153
Temp Sens open circuit ..................................... 141 E038 Low Engine Coolant Temperature
MID 110 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Warning ............................................................. 153
Temp Sensor short to +batt ............................... 141 E040 Low Engine Oil Pressure Shutdown .......... 153
MID 110 - CID 1532 - FMI 04 Cyl #2 Exhaust Port E042 Low System Voltage Shutdown ................. 153
Temp Sensor short to ground ............................ 142 E043 Low System Voltage Warning .................... 154
MID 110 - CID 1532 - FMI 05 Cyl #2 Exhaust Port E050 High System Voltage Warning ................... 154
Temp Sensor open circuit ................................. 142 E096 High Fuel Pressure .................................... 154
MID 110 - CID 1534 - FMI 03 Cyl #4 Exhaust Port E100 Low Engine Oil Pressure Warning ............. 154
Temp Sensor short to +batt ............................... 142 E101 High Crankcase Pressure Warning ........... 155
MID 110 - CID 1534 - FMI 04 Cyl #4 Exhaust Port E127 Engine Oil Filter Diff Pressure Low
Temp Sensor short to ground ............................ 142 Warning ............................................................. 155
MID 110 - CID 1534 - FMI 05 Cyl #4 Exhaust Port E128 Engine Oil Filter Diff Pressure Low
Temp Sensor open circuit ................................. 143 Shutdown .......................................................... 155
MID 110 - CID 1536 - FMI 03 Cyl #6 Exhaust Port E129 Engine Oil Filter Diff Pressure High
Temp Sensor short to +batt ............................... 143 Warning ............................................................. 156
MID 110 - CID 1536 - FMI 04 Cyl #6 Exhaust Port E130 Engine Oil Filter Diff Pressure High
Temp Sensor short to ground ............................ 143 Shutdown .......................................................... 156
MID 110 - CID 1536 - FMI 05 Cyl #6 Exhaust Port E135 Low Jacket Water Pressure Shutdown ...... 156
Temp Sensor open circuit ................................. 144 E200 Continuous Cylinder Misfire ...................... 157
MID 110 - CID 1538 - FMI 03 Cyl #8 Exhaust Port E201 Cylinder #1 Intermittent Misfire .................. 157
Temp Sensor short to +batt ............................... 144 E202 Cylinder #2 Intermittent Misfire .................. 157
Temp Sensor short to ground ............................ 144 E204 Cylinder #4 Intermittent Misfire .................. 158
Temp Sensor open circuit ................................. 145 E206 Cylinder #6 Intermittent Misfire .................. 158
Temp Sensor short to +batt ............................... 145 E208 Cylinder #8 Intermittent Misfire .................. 159
Temp Sensor short to ground ............................ 145 E210 Cylinder #10 Intermittent Misfire ................ 159
MID 110 - CID 1540 - FMI 05 Cyl #10 Exhaust Port E211 Cylinder #11 Intermittent Misfire ................ 160
Temp Sensor open circuit ................................. 145 E212 Cylinder #12 Intermittent Misfire ................ 160
Temp Sensor short to +batt ............................... 146 E214 Cylinder #14 Intermittent Misfire ................ 160
Temp Sensor short to ground ............................ 146 E216 Cylinder #16 Intermittent Misfire ................ 161
MID 110 - CID 1542 - FMI 05 Cyl #12 Exhaust Port E223 High Gas Temperature .............................. 161
Temp Sensor open circuit ................................. 146 E224 High Jacket Water Inlet Pressure .............. 162
MID 110 - CID 1544 - FMI 03 Cyl #14 Exhaust Port E225 Engine Overcrank ...................................... 162
Temp Sensor short to +batt ............................... 147 E226 Driven Equipment Not Ready .................... 162
MID 110 - CID 1544 - FMI 04 Cyl #14 Exhaust Port E229 Fuel Energy Content Setting Low .............. 162
Temp Sensor short to ground ............................ 147 E230 Fuel Energy Content Setting High ............. 163
MID 110 - CID 1544 - FMI 05 Cyl #14 Exhaust Port E231 Fuel Quality Out of Range ......................... 163
Temp Sensor open circuit ................................. 147 E233 Low Engine Pre-Lube Pressure ................ 163
MID 110 - CID 1546 - FMI 03 Cyl #16 Exhaust Port E242 Engine Overload ........................................ 163
Temp Sensor short to +batt ............................... 148 E243 High Left Turbo Turbine Outlet
MID 110 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temperature ...................................................... 164
Temp Sensor short to ground ............................ 148 E244 High Right Turbo Turbine Outlet
Temperature ...................................................... 164
8
Table of Contents
E245 High Right Turbo Turbine Inlet E804 Cylinder #4 High Exhaust Port Temp ........ 181
Temperature ...................................................... 164 E805 Cylinder #5 High Exhaust Port Temp ........ 181
E246 High Left Turbo Turbine Inlet Temperature .. 165 E806 Cylinder #6 High Exhaust Port Temp ........ 182
E264 Emergency Stop Activated ........................ 165 E807 Cylinder #7 High Exhaust Port Temp ........ 182
E266 Low Hydrax Oil Pressure ........................... 165 E808 Cylinder #8 High Exhaust Port Temp ........ 183
E268 Unexpected Engine Shutdown .................. 166 E809 Cylinder #9 High Exhaust Port Temp ........ 183
E269 Customer Shutdown Requested ............... 166 E810 Cylinder #10 High Exhaust Port Temp ...... 183
E270 Driven Equipment Shutdown Requested .. 166 E811 Cylinder #11 High Exhaust Port Temp ...... 184
E337 High Engine Oil to Engine Coolant Diff E812 Cylinder #12 High Exhaust Port Temp ...... 184
Temp ................................................................. 166 E813 Cylinder #13 High Exhaust Port Temp ...... 185
E401 Cylinder #1 Detonation .............................. 167 E814 Cylinder #14 High Exhaust Port Temp ...... 185
E404 Cylinder #4 Detonation .............................. 168 E821 Cyl #1 Exhaust Port Temp Deviating High .. 186
E410 Cylinder #10 Detonation ............................ 169 E827 Cyl #7 Exhaust Port Temp Deviating High .. 189
E413 Cylinder #13 Detonation ............................ 170 E830 Cyl #10 Exhaust Port Temp Deviating
E414 Cylinder #14 Detonation ............................ 170 High ................................................................... 190
E415 Cylinder #15 Detonation ............................ 170 E831 Cyl #11 Exhaust Port Temp Deviating
E416 Cylinder #16 Detonation ............................ 171 High ................................................................... 190
E421 Cylinder #1 Detonation Shutdown ............. 171 E832 Cyl #12 Exhaust Port Temp Deviating
E422 Cylinder #2 Detonation Shutdown ............. 171 High ................................................................... 191
E430 Cylinder #10 Detonation Shutdown ........... 173 High ................................................................... 192
E431 Cylinder #11 Detonation Shutdown ........... 174 E841 Cyl #1 Exhaust Port Temp Deviating Low .. 193
E601 Cylinder #1 Continuous Misfire ................. 175 E847 Cyl #7 Exhaust Port Temp Deviating Low .. 195
E604 Cylinder #4 Continuous Misfire ................. 176 E850 Cyl #10 Exhaust Port Temp Deviating
E605 Cylinder #5 Continuous Misfire ................. 177 Low ................................................................... 196
E610 Cylinder #10 Continuous Misfire ............... 178 E853 Cyl #13 Exhaust Port Temp Deviating
E611 Cylinder #11 Continuous Misfire ............... 178 Low ................................................................... 197
E801 Cylinder #1 High Exhaust Port Temp ........ 180 Low ................................................................... 199
E802 Cylinder #2 High Exhaust Port Temp ........ 180
E803 Cylinder #3 High Exhaust Port Temp ........ 181 Diagnostic Functional Tests
9
Table of Contents
+5V Sensor Voltage Supply ................................ 200

+8V Sensor Voltage Supply ................................ 212
Air/Fuel Pressure Module ................................... 223
Analog Sensor Signal ......................................... 230
Choke Actuator Solenoid .................................... 240
Combustion Sensor ............................................ 249
Cylinder Firing Pulse ........................................... 256
Desired Speed Input (4 - 20 mA) ........................ 271
Detonation Sensors ............................................ 278
ECM Output Circuit (Fuel Control) ...................... 292
ECM Output Circuit (Prelubrication Oil Pump) .... 304
ECM Output Circuit (Starting Motor) ................... 317
ECM Status Indicator Output .............................. 327
Electrical Power Supply ...................................... 334
Engine Speed/Timing Sensor ............................. 341
Fuel Actuator Solenoid ....................................... 348
Ignition Transformers Primary Circuit .................. 357
Ignition Transformers Secondary Circuit and Spark
Plugs ................................................................. 368
Inspecting Electrical Connectors ........................ 372
Integrated Combustion Sensing Module
(ICSM) ............................................................... 377
Prelubrication System ......................................... 384
PWM Sensor ....................................................... 389
Thermocouple Test ............................................. 403
Wastegate Solenoid ............................................ 413
Index Section
Index ................................................................... 422
10
Troubleshooting Section
Troubleshooting Section Governing the Engine

Desired engine speed is determined by the status
of the idle/rated switch, the desired speed input
Electronic Troubleshooting (analog voltage or 4 to 20 mA), and parameters that
are programmed into the software. Actual engine
speed is detected via a signal from the engine
i01625280 speed/timing sensor. Parameters such as idle speed
and governor gain can be programmed with ET.
System Overview
The ECM monitors the actual engine speed. The
SMCS Code: 1901-038 ECM calculates the difference between the actual
engine speed and the desired engine speed. The
Control System ECM controls the fuel actuator in order to maintain
the desired engine speed.
The following components are included in the
control system: If the actual engine speed is less than the desired
engine speed, the ECM commands the fuel actuator
• Electronic Control Module (ECM) to move toward the open position in order to
increase the fuel flow.
• Integrated Combustion Sensing Module (ICSM)
Controlling Ignition
• Gas Shutoff Valve (GSOV)
Each cylinder has an ignition transformer. To
• Prelube pump initiate combustion, the ECM sends a pulse of
approximately 108 volts to the primary coil of each
• Electrohydraulic actuator system ignition transformer at the appropriate time and for
the appropriate duration. The transformer increases
• Starting system the voltage which creates a spark across the spark
plug electrode.
• Sensors for monitoring engine operation
The ECM provides variable ignition timing that
The Engine Control Module (ECM) controls most is sensitive to detonation. Detonation sensors
of the functions of the engine. The ECM monitors monitor the engine for excessive detonation. The
various inputs from sensors in order to activate engine has one detonation sensor for each two
relays, solenoids, etc at the appropriate levels. The adjacent cylinders. The sensors generate data on
ECM supports the following five primary functions: vibration that is processed by the ECM in order to
determine detonation levels. If detonation reaches
• Governing the engine an unacceptable level, the ECM retards the ignition
timing of the affected cylinder or cylinders. If
• Controlling ignition retarding the timing does not limit detonation to an
acceptable level, the ECM shuts down the engine.
• Controlling emissions
Levels of detonation can be displayed by the
• Start/stop control Machine Information Display System (MIDS) on the
remote control panel. Alternatively, the “Cylinder X
• Monitoring engine operation Detonation Level” screen of ET can also be used.
The “X” represents the cylinder number.
The ECM does not have a removable personality
module. The software and maps are changed by Controlling Emissions
using ET to flash program a file.
The ECM provides control of the air/fuel mixture for
performance and efficiency at low emission levels.
The system includes the following components:
combustion sensors, an Integrated Combustion
Sensing Module (ICSM) for each bank of cylinders,
maps in the ECM, output drivers in the ECM, fuel
actuator, air choke actuator, and exhaust bypass
actuator (wastegate).
11
The desired air/fuel ratio is based on maps that A command for the desired inlet manifold air
are stored in the ECM. The maps are specific for pressure is sent from the ECM to the exhaust bypass
different applications, engine speeds, and engine actuator. The actuator adjusts the inlet manifold air
loads. pressure in order to correct the combustion burn
time.
The engine load is calculated from the fuel flow. For
example, zero fuel flow is zero load and fuel flow of If the average desired combustion burn time is
100 cfm might be the rated load. too fast, the ECM commands the exhaust bypass
actuator to move toward the closed position in order
At loads that are less than 40 percent, the air/fuel to lean the air/fuel mixture. Combustion of the leaner
ratio is controlled by the air choke actuator which is air/fuel mixture reduces the combustion burn time.
trimmed by the exhaust port temperatures.
This is a continuous process during operation
Each cylinder exhaust port has a thermocouple at loads that are greater than approximately 40
that is monitored by an ICSM. The ICSM monitors percent.
the actual exhaust port temperatures for one
bank of cylinders. The ICSM calculates an Start/Stop Control
average exhaust port temperature for the bank of
cylinders. The ECM sends a map of the desired The ECM contains the logic and the outputs for
exhaust port temperature to the ICSM. The ICSM control of engine prelubrication, starting, shutdown,
calculates the difference between the average and postlube. The customer programmable logic
exhaust port temperature and the desired exhaust responds to signals from the following components:
port temperature. The ICSM communicates the mode control switch, emergency stop switch,
information to the ECM. The ECM controls the air remote start switch, data link, and other inputs.
choke actuator in order to maintain the desired
exhaust temperature. To control the engine at the appropriate times, the
ECM provides +Battery voltage to the solenoids that
If the average exhaust temperature is too low, the control the prelube pump, the starting motor, and
ECM commands the air choke actuator to move the gas shutoff valve.
toward the closed position in order to richen the
air/fuel mixture. Combustion of the richer air/fuel When the programmable logic determines that
mixture increases the exhaust port temperatures. the prelubrication function is necessary, the ECM
supplies +Battery voltage to the solenoid for the
When the load reaches approximately 40 percent, prelube pump. The system is programmed to
the air/fuel ratio is controlled by the exhaust bypass perform a postlube cycle during engine shutdown in
actuator which is trimmed by the combustion burn order to ensure that the turbocharger has adequate
time. lubrication during shutdown.
Combustion burn time – The combustion burn time When the programmable logic determines that it is
is measured in each cylinder. Each cylinder has a necessary to crank the engine, the ECM supplies
combustion sensor. The pulse of the ignition starts a +Battery voltage to the solenoid for the starting
timer in the ICSM. The flame travels in the cylinder motor. The ECM removes the voltage when the
from the spark plug to the combustion sensor. The programmable crank terminate speed is reached
ICSM monitors the voltage across the combustion or when a programmable cycle crank time has
sensor. When the flame reaches the combustion expired.
sensor, the ionization that surrounds the sensor
changes the voltage. When the ICSM detects the The engine has an energize-to-run type of gas
change of the sensor’s voltage, the ICSM stops the shutoff valve. When the programmable logic
timer. The combustion burn time is a method of determines that fuel is required to start the engine
measuring the air/fuel ratio. A rich air/fuel mixture or to run the engine, the ECM supplies +Battery
provides a faster combustion burn time. A lean voltage to the valve’s solenoid.
air/fuel mixture provides a slower combustion burn
time.
Monitoring Engine Operation
Each ICSM calculates an average combustion burn
The ECM monitors both the engine operation and
time for all of the cylinders in one bank. The ECM
the electronic system.
sends a map of the desired combustion burn time
to the ICSM. The ICSM calculates the difference
Problems with engine operation cause the ECM
between the average combustion burn time and the
to generate an event code. The ECM can issue a
desired combustion burn time. The ICSM sends a
warning or a shutdown for events. This depends on
fuel correction factor to the ECM. The ECM controls
the severity of the condition.
the exhaust bypass actuator in order to maintain
the desired combustion burn time.
12
For example, a high pressure pump provides Table 1

hydraulic pressure with oil for the electrohydraulic Color Codes for Wiring
system. The oil supply is separate from the engine
oil. The high pressure oil supply is monitored by Code Color
a pressure switch. If the pressure drops below an
BK Black
acceptable level, the ECM generates an event code
and the ECM shuts down the engine. BR Brown
BU Blue
An ICSM is installed on each side of the engine.
Each ICSM monitors the combustion sensors GN Green
and the thermocouples for the cylinders and the
GY Gray
turbocharger on that side of the engine. The ICSM
sends signals regarding the parameters to the OR Orange
ECM over the CAT Data Link. If any parameter
PK Pink
exceeds the acceptable range, the ECM can initiate
a warning or a shutdown. PU Purple
For more information on monitoring of the engine, RD Red

refer to Troubleshooting, “Troubleshooting with an WH White
Event Code” and Systems Operation, “Electronic
Control System Parameters”. YL Yellow
Problems with the electronic system such as In addition to the color, the entire length of each
an open circuit produce a diagnostic code. wire is stamped with a specific circuit number that
For more information, refer to Troubleshooting, is repeated on every 25 mm (1 inch) of the wire.
“Troubleshooting with a Diagnostic Code”. The actual wires are identified on the schematic.
For example, a code of J011-RD on the schematic

i01626552
identifies a red wire that is stamped with the
Electrical Connectors and circuit number J011. This particular wire is the
engine harness wire for the primary signal of the
Functions transformer in the number one cylinder.
SMCS Code: 1408-038 The schematic also identifies the size of the wire.
The size or gauge of the wire is called the American
Harness Wire Identification Wire Gauge (AWG). Unless the schematic specifies
a different size, the wire is 16 AWG.
Caterpillar identifies different wires with eleven
different solid colors. Table 1 lists the color codes of
the wiring.
13
Terminal Box
g00842401
Illustration 1
Inside of the terminal box
(1) 70-pin connectors (J2/P2) for the ECM (8) Ignition wiring for the left side of the (12) 47-pin connector (J4) for the customer
(2) 70-pin connectors (J1/P1) for the ECM engine or the control panel
(3) Ground strap (9) 70-pin connectors (J6/P6) for the sensors (13) Wiring for the electrical power
(4) Service tool connector (J7) on the left side of the engine
(5) 16 amp circuit breaker (CB1) (10) 70-pin connectors (J5/P5) for the
(6) 6 amp circuit breaker (CB2) sensors on the right side of the engine
(7) 70-pin connector (J3) for the customer (11) Ignition wiring for the right side of the
or the control panel engine
14
g00869099
Illustration 2
Front and bottom of the terminal box
(9) 70-pin connectors (J6/P6) for the sensors on the left side of
the engine
(10) 70-pin connectors (J5/P5) for the sensors on the right side
of the engine
(12) 47-pin connector (J4) for the customer or the control panel
(14) Emergency stop button
Sensors
Sensors provide information to the engine control
module and the integrated combustion sensing
modules. The information is used for monitoring Illustration 3 g00803846
engine operation. The information enables the Front view
modules to control the engine as efficiently as
(1) Jacket water outlet pressure sensor
possible over a wide range of operating conditions. (2) Jacket water temperature sensor
(3) Unfiltered engine oil pressure sensor
(4) Engine oil temperature sensor
(5) Filtered engine oil pressure sensor
15
g00825893
Illustration 5
The inlet manifold air temperature sensor is installed in the inlet
air manifold between the two center cylinder heads on the right
side of the engine.
(9) Inlet manifold air temperature sensor
g00825637
Illustration 4
Right side view near the front of the engine
(1) Jacket water outlet pressure sensor
(6) Detonation sensor
(7) Jacket water inlet pressure switch
(8) Crankcase pressure sensor
Note: There is one detonation sensor between each

pair or cylinders.
16
g00825717
Illustration 6
Right side view near the rear of the engine
(10) Connector for the electrohydraulic actuators’ pressure switch
(11) Prelube oil pressure switch
g00825638
Illustration 7
Rear view
(12) Fuel temperature sensor
(13) Inlet air restriction switch (left)
(14) Air/fuel pressure module
(15) Inlet air restriction switch (right)
(16) Engine speed/timing sensor
17
Integrated Combustion Sensing Module Each ICSM calculates an average combustion burn
(ICSM) time for all of the cylinders in one bank. The ECM
sends a map of the desired combustion burn time
to the ICSM. The ICSM calculates the difference
between the average combustion burn time and the
desired combustion burn time. The ICSM sends a
fuel correction factor to the ECM. The ECM controls
the exhaust bypass actuator in order to maintain
the desired combustion burn time.
g00843952
Illustration 8
Integrated Combustion Sensing Module (ICSM)
The engine has an Integrated Combustion Sensing

Module (ICSM) for each bank of cylinders. The
ICSM monitors exhaust temperature sensors
and combustion sensors. The ICSM performs
calculations with the data. The ICSM communicates
with the ECM via the CAT Data Link.
Exhaust temperatures are monitored for each

cylinder exhaust port, the inlet of the turbocharger
turbine, and the outlet of the turbocharger turbine.
At loads that are less than 40 percent, the air/fuel

ratio is controlled according to the desired exhaust
port temperature. The air choke actuator is
trimmed according to the average exhaust port
temperatures.
g00825730
Illustration 9
The ICSM monitors the actual exhaust port
temperatures for one bank of cylinders. The ICSM (17) Temperature sensor for the cylinder exhaust port
(18) Temperature sensor for the exhaust after the turbocharger
calculates an average exhaust port temperature for (19) Temperature sensor for the exhaust before the turbocharger
the bank of cylinders. The ECM sends a map of (20) Combustion sensor
the desired exhaust port temperature to the ICSM.
The ICSM calculates the difference between the Note: For each cylinder, there is one temperature
average exhaust port temperature and the desired sensor for the exhaust port (17) and one combustion
exhaust port temperature. The ICSM communicates sensor (20). For each turbocharger, there is one
the information to the ECM. The ECM controls the temperature sensor for the exhaust after the
air choke actuator in order to maintain the desired turbocharger (18) and one temperature sensor for
exhaust temperature. the exhaust before the turbocharger (19).
When the load reaches approximately 40 percent,

the air/fuel ratio is controlled by the exhaust
bypass actuator which is trimmed according to the
combustion burn time.
18
i01626171
Electronic Service Tools

SMCS Code: 1901-038
Caterpillar Electronic Service Tools are designed to

help the service technician:
• Obtain data.
• Diagnose problems.
• Read parameters.
• Program parameters.
• Calibrate sensors.
The tools that are listed in Table 2 are required in
order to enable a service technician to perform the
procedures.
19
Table 2
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) This PC configuration is recommended:
Intel Pentium II 333 mHz processor
64 megabyte of RAM
4.3 GB hard drive
14X speed CD-ROM drive
N/A Personal Computer (PC) This PC configuration has the minimum requirements:
IBM PC compatible 100 MHz processor
32 megabyte of RAM
10 MB of available hard drive space
CD-ROM drive
3.5" 1.44-MB floppy disk drive
Windows NT or Windows 95
RS232 port with 16550AF UART
VGA monitor or display
“JERD2124 Version Software Single user license for ET
2001B” If a more recent version of this software is available, the more
recent version may be used.
“JERD2129” Software Data subscription for all engines
171-4401 Communication Adapter II (1) The communication adapter is connected between the PC (ET)
and the ECM.
196-0055 Serial Cable As (1)(2) This cable connects the PC to the 171-4401 Communication
Adapter II.
160-0141 Serial Cable As (2) This cable connects the PC to the 171-4401 Communication
Adapter II.
207-6845 Adapter Cable As (1)(3) This cable connects the 171-4401 Communication Adapter II to
the 7X-1414 Data Link Cable As.
7X-1701 Communication Adapter The communication adapter is connected between the PC (ET)
and the ECM.
7X-1425 Serial Cable As This cable connects the PC (ET) to the 7X-1701 Communication
Adapter.
139-4166 Adapter Cable As This cable connects the 7X-1701 Communication Adapter to the
7X-1414 Data Link Cable As.
7X-1414 Data Link Cable As This cable connects the service tool connector on the engine
mounted terminal box to the 139-4166 Adapter Cable As.
8T-8726 Adapter Cable As This is a breakout cable for use between the jacks and the plugs
of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch
connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.
9U-7330 Digital Multimeter The multimeter is used for the testing and the adjusting of electronic
circuits.
7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage in
wiring harnesses without disconnecting the harnesses.
5P-7277 Voltage Tester The tester is used to test for voltage in circuits, relays, bulbs, wires,
and switches.
(1) This item is included in the 171-4400 Communication Adapter Gp.
(2) Either the 160-0141 or the 196-0055 cable may be used.
(3) Either the 160-0133 or the 207-6845 cable may be used.
20
Note: Either the 171-4401 Communication Adapter

II or the 7X-1700 Communication Adapter Gp can
be used. However, the 7X-1700 Communication
Adapter Gp is no longer serviced.
Electronic Technician (ET)

The Caterpillar Electronic Technician (ET) is
designed to run on a personal computer. ET can
display the following information:
• Parameters
• Diagnostic codes
• Event codes
• Engine configuration
• Status of the monitoring system
ET can perform the following functions:
• Diagnostic tests
• Sensor calibration
• Flash downloading Illustration 10 g00694774
(1) PC
• Set parameters (2) 196-0055 Serial Cable or the 160-0141 Serial Cable
(3) 171-4401 Communication Adapter II
Connecting ET with the 171-4401 (4) 207-6845 Adapter Cable
(5) 7X-1414 Data Link Cable
Communication Adapter II
2. Connect cable (2) to the RS232 serial port of
The battery supplies the communication adapter PC (1).
with 24 VDC. Use the following procedure to
connect ET and the communication adapter to the 3. Connect cable (2) to communication adapter (3).
engine.
4. Connect cable (4) to communication adapter (3).
1. Turn the engine control switch to the OFF
position. 5. Connect cable (4) to cable (5).
6. Connect cable (5) to the service tool connector

of the terminal box.
7. Turn the engine control switch to the ON position.

The engine should be OFF. If ET and the
communication adapter do not communicate with
the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate With ECM”.
Connecting ET with the 7X-1701

Communication Adapter
The battery supplies the communication adapter
with 24 VDC. Use the following procedure to
connect ET and the communication adapter to the
engine.
21
1. Turn the engine control switch to the OFF i01653858

position.
Engine Monitoring System
SMCS Code: 1901-038
The ECM monitors the operating parameters of

the engine. The ECM can initiate a warning or a
shutdown if a specific engine parameter exceeds
an acceptable range. The default settings for the
parameters are programmed at the factory.
The status of the parameters can be viewed on

the “Service/Monitoring System” screen of ET. This
screen is also used to change the settings.
To accommodate unique applications and sites,

some parameters may be reprogrammed with ET.
The screens of ET provide guidance for changing
trip points. Use ET to perform the following activities:
• Select the available responses.

• Program the level for monitoring.
• Program delay times for each response.
Note: Some parameters are protected by factory
passwords. Other parameters can be changed with
customer passwords.
g00694776
Illustration 11
For instructions on using ET, refer to User’s Manual,
(1) PC
(2) 7X-1425 Serial Cable NEHS0679, “Caterpillar Electronic Technician”.
(3) 7X-1701 Communication Adapter
(4) 139-4166 Adapter Cable For information on the warnings and shutdowns,
(5) 7X-1414 Data Link Cable refer to Troubleshooting, “Troubleshooting with an
Event Code”.
2. Connect cable (2) to the RS232 serial port of
PC (1). For detailed information on system parameters that
can be programmed and for recommendations
3. Connect cable (2) to communication adapter (3). for programming parameters, refer to Systems
Operation/Testing and Adjusting, RENR5908,
4. Connect cable (4) to communication adapter (3). “Engine Monitoring System”.
5. Connect cable (4) to cable (5).
NOTICE
6. Connect cable (5) to the service tool connector Changing the parameters during engine operation can
of the terminal box. cause the engine to operate erratically. This can cause
engine damage.
7. Turn the engine control switch to the ON position.
The engine should be OFF. If ET and the Unless the instructions are different, only change
communication adapter do not communicate with the settings of the parameters when the engine is
the ECM, refer to Troubleshooting, “Electronic STOPPED.
Service Tool Will Not Communicate With ECM”.
22
Programming Parameters Note: Be sure to record the customer passwords.

Store the passwords securely. The passwords can
have a maximum of eight characters. Alphanumeric
i01625792 characters may be used. The passwords are case
sensitive.
Programming Parameters
3. Enter the password in the “Change Parameter
SMCS Code: 1901-038 Value” dialog box and click on the “OK” button.
Programmable parameters enable the engine to 4. Highlight the “Customer Password #2” parameter.
be configured to meet the requirements of the Click on the “Change” button in the lower right
application. Two types of parameters can be corner of the screen.
programmed into the ECM: system configuration
parameters and monitoring system parameters. 5. Enter the password in the “Change Parameter
Value” dialog box and click on the “OK” button.
The CAT Electronic Technician (ET) is used
for viewing the status of parameters and for The passwords are now programmed into the
programming parameters. memory of the ECM.
For more information on parameters, refer to Make a copy of Table 3 and record your passwords.
Troubleshooting, “Sytem Configuration Parameters” Store the passwords securely.
and Troubleshooting, “Engine Monitoring System”.
Table 3
i01409654 Customer Passwords
Customer Passwords Customer Password #1

Customer Password #2
SMCS Code: 1901
Certain monitoring system parameters and system i01298784

configuration parameters may be protected with
customer passwords. Use of the passwords helps Factory Passwords
to prevent free access to the modification of the
parameters. If the customer passwords are not SMCS Code: 1901-038
programmed, all of the parameters are unprotected.
Factory level security passwords are required for
The customer passwords can be changed, if clearing certain logged events and for changing
necessary. The customer passwords or a factory certain programmable parameters. Because of the
password is needed in order to change the passwords, only authorized personnel can make
customer passwords. If the customer passwords changes to some of the programmable items in the
are forgotten, factory passwords can be acquired ECM. When the correct passwords are entered, the
from Caterpillar. changes are programmed into the ECM.
After the customer passwords are entered, the Factory passwords are required to program the
passwords are required in order to change certain following shutdowns:
parameters. Once the passwords are entered
successfully, the passwords are not requested • “Engine Overspeed”
again until another screen is accessed or the data
link is interrupted. • “High Engine Oil Temperature”
This feature is enabled by programming two • “High Oil Filter Differential Pressure”
customer passwords. Use the following procedure
to program the passwords. The same procedure is • “Low Oil Filter Differential”
used to change the passwords:
• “High Jacket Water to Engine Oil Temperature
1. Access the “Service/Configuration” screen of Differential”
the ET.
The “Enter Factory Passwords” ET screen will
2. Highlight the “Customer Password #1” parameter. display the following parameters. To obtain the
Click on the “Change” button in the lower right proper passwords, the information must be given to
corner of the screen. an authorized Caterpillar dealer:
23
• Current ECM 2. Turn the engine control switch to the STOP

position.
• Serial number of the service tool
The ET will not flash if the engine control switch
• Serial number of the engine is in the OFF or START position.
• Serial number of the ECM 3. Select “WinFlash” from the “Utilities” menu on
the ET.
• Diagnostic clock
“WinFlash” will try to detect an ECM.
• Total Tattletale
4. When an ECM has been detected, the “ECM
• Reason Selector” window will appear. Select the
appropriate ECM and then select “OK”.
The old interlock code is required to change the
interlock code on a used ECM. The passwords are The “Flash File Selection” window will appear.
controlled by Caterpillar. The passwords may only
be obtained by an authorized Caterpillar dealer. 5. The flash files are located on a disk drive and
in a directory. Select the correct disk drive and
The passwords may only be used for one the directory from “Drives” and “Directories” on
programming session. After you exit the “Enter the ET.
Factory Passwords” ET screen, a different set of
passwords will be required before you can program A list of flash files will appear.
the ECM.
6. Select the correct file from the list of flash files.
Factory passwords are not required for the first hour Read the “Description” and the “File Info” in
of operation for a new ECM. After the hour expires, order to verify that the correct file is selected.
factory passwords are required for some of the Select “Open”.
programming.
7. Select the “Begin Flash” button in order to
program the personality module.
i01626337
Flash Programming When the flash is completed, this message will

appear: “Flash Completed Successfully”.
SMCS Code: 1901-038
8. Program the configuration parameters and the
Software is located in the flash memory of the ECM monitoring system parameters.
and the Integrated Combustion Sensing Module
(ICSM). ET can be used to flash new software into The parameters must be programmed in order
the ECM and the ICSM. The flash is accomplished to ensure proper engine operation. Refer to
by transferring the data from ET to the module Troubleshooting, “Programming Parameters”.
via data link wiring. The Software, JERD2124 or
Software, JERD2129 is used. 9. Start the engine and check for proper operation.
a. If a diagnostic code of 268-02 “Check

Flash Programming Programmable Parameters” is generated,
program any parameters that were not in the
If the slowest baud rate of ET is selected, flash original software.
programming can last up to 15 minutes. Be sure to
set the baud rate to the fastest rate for your PC. b. Access the “Configuration” screen under
the “Service” menu in order to determine
To select the baud rate, use the ET the parameters that require programming.
“Utilities/Preferences”. Select the “Communications” Look under the “Tattletale” column. All of the
tab and click on “Advanced...”. Then select the parameters should have a tattletale of 1 or
baud rate from the “Advanced Communication more. If a parameter has a tattletale of 0,
Settings” menu and click the “OK” button. program that parameter.
If a communication error occurs, select a slower

baud rate in order to improve the reliability.
1. Connect the ET to the service tool connector.

24
“WinFlash” Error Messages (Table 4, contd)

Configuration Parameters for G3600 Engines
If you receive any error messages during flash
programming, click on the “Cancel” button in order “Engine Accel. Rate”
to stop the process. Access the information about “Desired Speed Input Configuration”
the “ECM Summary” under the “Information” menu.
Make sure that you are flashing the correct file for Governing
your engine. “Governor Type Setting”
“Engine Speed Droop”
i01653867
“Governor Gain”
System Configuration “Governor Stability”
Parameters “Governor Compensation”
SMCS Code: 1901-038 “Auxiliary Proportional Governor Gain 1”
“Auxiliary Integral Governor Gain 1”
The system configuration parameters must be
programmed when the application is installed. “Auxiliary Derivative Governor Gain 1”
Perform this programming before the initial engine
start-up. Incorrect programming of parameters “Choke Gain”
may lead to complaints about performance and/or “Choke Stability”
to engine damage. Data from a gas analysis is
required for determining the correct settings for the “Choke Compensation”
fuel quality and the specific gravity of the gas. “Wastegate Gain”
The status of the parameters can be viewed on the “Wastegate Stability”

“Configuration” screen of ET. “Wastegate Compensation”
If the ECM is replaced, the appropriate parameters Start/Stop Control

must be copied from the old ECM. This can be “Driven Equipment Delay Time”
done with the “Copy Configuration” feature of ET.
Alternatively, the settings can be recorded on paper “Crank Terminate Speed”
and then programmed into the new module. “Engine Purge Cycle Time”
Table 4 is a list of the parameters that can be “Engine Cooldown Duration”

configured for G3600 Engines. “Cycle Crank Time”
Table 4 “Engine Overcrank Time”
Configuration Parameters for G3600 Engines “Engine Speed Drop Time”
Information for the ECM “Engine Pre-lube Time Out Period”
“Engine Serial Number” “Engine PostLube Time Out Period”
“Equipment ID” Monitoring and Protection
“Customer Password #1” “High Inlet Air Temp Engine Load Set Point”
“Customer Password #2”
For detailed information on the configuration
“Total Tattletale”
parameters and for recommendations on
Air/Fuel Ratio Control programming of the parameters, refer to Systems
“Fuel Quality”
“Electronic Control System Parameters”.
“Gas Specific Gravity”
For instructions on using ET, refer to User’s Manual,
Speed Control NEHS0679, “Caterpillar Electronic Technician”.
“Low Idle Speed”
“Minimum Engine High Idle Speed”
“Maximum Engine High Idle Speed”
(continued)
25
Verify that the suspect ECM is the cause of the

NOTICE problem. Install a test ECM in place of the suspect
Changing the parameters during engine operation can ECM. Transfer the software from the suspect ECM
cause the engine to operate erratically. This can cause to the test ECM. Program all the parameters for
engine damage. the test ECM in order to match the parameters of
the suspect ECM. The parameters must match.
Unless the instructions are different, only change Refer to the following test steps for details on
the settings of the parameters when the engine is programming the parameters.
STOPPED.
If the test ECM resolves the problem, reconnect
the suspect ECM. Verify that the problem recurs. If
i01522611 the problem recurs, replace the suspect ECM with
the test ECM.
Factory Passwords Worksheet
Note: If the parameters cannot be read from the
SMCS Code: 1901-038 suspect ECM, the parameters must be obtained
from records or from the factory.
Note: A mistake in recording this information will
result in incorrect passwords. Perform the following procedure to replace the ECM.
Table 5 1. Use the “Service/Copy Configuration/ECM
Factory Passwords Worksheet Replacement” function of the ET.
Dealer Code Save the file. You can select “Load from ECM”.
Customer’s Name You may also select the “Print” function in order
to obtain a paper copy of the parameter settings.
Address
Note: Before you replace an ECM, record all of the
logged events.
Telephone Number a. Connect the ET with the communications

adapter. Select the ET “Service/Copy
Information from the “Enter Factory Passwords”
Screen on ET Configuration/ECM Replacement” from the
pull-down menu.
ET Serial Number
Engine Serial Number
The ET will load the configuration parameters
and the monitoring system parameters of the
ECM Serial Number suspect ECM.
Diagnostic Clock(1)
b. Select “Load from ECM” in the lower left
Total Tattletale corner of the ET screen. Select the suspect
ECM and select “OK”.
Reason Code
Factory Passwords After the loading is complete, the ET will
display this message: “The data has been
Factory Password (No. 1)
successfully loaded from the ECM”. Select
Factory Password (No. 2) “OK”.
(1) Do not obtain this information from the service meter.
c. Select “File/Disconnect F8” from the pull-down
menu.
i01626381
Note: Do not terminate the ET.
Replacing the ECM
2. Replace the ECM.
SMCS Code: 1901-038
a. Turn the engine control switch to the
The Electronic Control Module (ECM) contains no “OFF/RESET” position.
moving parts. Before you replace an ECM, follow
the troubleshooting procedures in this manual in
order to be sure that replacement of the ECM will
correct the problem.
26
b. Use a 4 mm Allen wrench to connect the P1

and P2 connectors to the ECM. Tighten the
screws to a torque of 6 ± 1 N·m (55 ± 9 lb in).
4. Program the configuration parameters and

the monitoring system parameters into the
replacement ECM.
a. Switch circuit breaker (1) to the ON position.
b. Turn the engine control switch to the “STOP”

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

menu.
d. Select the replacement ECM and click “OK”.
e. Select “Service/Copy Configuration/ECM

Replacement” from the pull-down menu. Click
“OK” on the window.
g00842215
Illustration 12
(1) ECM Connector P2
f. Select “Program ECM” from the lower left
(2) ECM Connector P1 corner of the screen. Select the replacement
(3) 16 Amp Circuit Breaker ECM and click “OK”. If the correct ECM is
(4) Mounting nut shown, select “Yes”.
(5) Ground Strap
g. After the loading is complete, a window with
b. Switch the 16 Amp circuit breaker (1) for the the message “Programming Conflict Warning”
ECM to the OFF position. will appear. Select “OK”.
c. Use a 4 mm Allen wrench to disconnect h. A window with the message “Program ECM
connectors (P1) and (P2). Results” will appear. Select “OK”.
d. Remove mounting nut (2) in order to Note: When you program a new ECM, factory
disconnect the ground strap (3). Remove the passwords are not required for the first hour of
three remaining mounting nuts. operation. After one hour, factory passwords are
required for changing the parameters that are
Note: Rubber grommets behind the ECM are held in normally protected with factory passwords.
place by the mounting studs. The grommets help to
reduce vibration. The grommets may fall when the
ECM is removed. Be sure not to lose the grommets. i01626386
e. Remove the ECM from the terminal box. Replacing the ICSM
3. Install the replacement ECM. SMCS Code: 1901-038
a. Use the mounting hardware to install the The Integrated Combustion Sensing Module (ICSM)
new ECM. Use a mounting nut to fasten the contains no moving parts. Replacement of the ICSM
ground strap for the ECM to the upper left can consume much time. Before you replace an
mounting stud. Then install the other three ICSM, follow the troubleshooting procedures in this
mounting nuts. manual in order to be sure that replacement of the
ICSM will correct the problem.
Check the mounting hardware and the
ECM for correct installation. A correctly Use the following guidelines to verify that the
installed ECM will move slightly on the rubber suspect ICSM is the cause of the problem:
grommets. If the ECM cannot move slightly
on the grommets, check that the washers,
spacers, and grommets are positioned
correctly.
27
Install a test ICSM in place of the suspect ICSM.

Transfer the software from the suspect ICSM to
the test ICSM. Program all the parameters for the
test ICSM in order to match the parameters of the
suspect ICSM. The parameters must match. Refer
to the following steps for details on programming
the parameters.
If the test ICSM resolves the problem, reconnect

the suspect ICSM. Verify that the problem recurs.
If the problem recurs, replace the suspect ICSM
with the test ICSM.
Use the following procedure to replace the ICSM:

g00842289
Note: If the parameters cannot be read from the Illustration 13
suspect ICSM, the parameters must be obtained 16 amp circuit breaker for the ECM
from records or from the factory.
b. Switch the 16 amp circuit breaker for the ECM
1. Use the “Service/Copy Configuration/ECM to the OFF position.
Replacement” function of ET in order to transfer
the software from the suspect ICSM.
You may also select the “Print” function in order

to obtain a paper copy of the parameter settings.
Note: Before you replace an ICSM, record all of the

logged events.
a. Connect ET with the communications adapter.

Select “Service/Copy Configuration/ECM
Replacement” from the pull-down menu.
ET will load the configuration parameters and

the monitoring parameters from the ECM. g00842252
Illustration 14
b. Select “Load from ECM” in the lower left (1) 20 pin P72 connector
corner of the screen. Select the suspect ICSM (2) 14 pin P73 connector
(3) Bolt
and select “OK”.
After the loading is complete, ET will c. Disconnect P72 connector (1) and P73
display this message: “The data has been connector (2) from the ICSM. Remove four
successfully loaded from the ECM”. Select bolts (3) in order to remove the cover.
“OK”.
Note: Rubber grommets for the ICSM are held in
c. Select “File/Disconnect F8” from the pull-down place on the mounting studs. The grommets help to
menu. reduce vibration. The grommets may fall when the
ICSM is removed. Be sure not to lose the grommets.
Note: Do not exit from ET.
Note: A ground strap is connected with one of the
2. Replace the ICSM. mounting bolts.

“OFF/RESET” position.
28
e. Select “Service/Copy Configuration/ECM

Replacement” from the pull-down menu. Click
“OK” on the window.
f. Select “Program ECM” from the lower left

corner of the screen. Select the replacement
ICSM and click “OK”.
g. After the loading is complete, a window with

the message “Programming Complete” will
appear. Select “OK”.
Note: When you program a new ICSM, factory

passwords are not required. Also, the ICSM does
g00842267
not require calibration.
Illustration 15
(4) Connectors for the sensors
(5) Mounting bolts i01681543
(6) Ground strap
Troubleshooting Data Sheet
d. Disconnect connectors (4) for the sensors
from the ICSM. Remove four mounting bolts SMCS Code: 1901-038
(5). Detach ground strap (6).
To help troubleshoot a gas engine, complete the
3. Install the replacement ICSM. Orient the 20 pin information in Table 6. Be sure to include the units
J72 connector to the upward position. of measurement.
a. Use the mounting hardware to install the new

ICSM. Be sure to install ground strap (6).
Check the mounting hardware and the

ICSM for correct installation. A properly
installed ICSM will move slightly on the rubber
grommets. If the ICSM cannot move slightly
on the grommets, check that the washers and
grommets are positioned correctly.
b. Connect connectors (4) for the sensors to

the ICSM.
c. Connect P72 connector (1) and P73 connector

(2) to the ICSM.
d. Install the cover and four bolts (3).
4. Program the configuration parameters and

the monitoring system parameters into the
replacement ICSM.
a. Switch the 16 amp circuit breaker for the ECM

ON.
b. Turn the engine control switch to the “STOP”

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

menu of ET.
d. Select the “Replacement ICSM” and click

“OK”.
29
Table 6
Data Sheet for Troubleshooting
Customer and installation
Engine model and driven equipment
Engine serial number Application
Service Compression Altitude “Fuel Quality”
hours ratio setting (LHV)
Fuel Fuel Fuel Pressure to the gas
LHV methane number rate regulator
Fuel Air Brand of oil
flow flow type of oil
Engine Percent Detonation Air
rpm load level restriction
Inlet manifold air pressure Inlet manifold air temperature Actual air/fuel ratio
Desired air/fuel ratio
Desired burn time
Engine oil pressure Turbocharger exhaust left Exhaust stack
temperature pressure
right
Exhaust stack % O2 PPM of NOx PPM of CO Brand of exhaust
temperature analyzer
Cylinder exhaust (1) (3) (5) (7) (9) (11) (13) (15)
port temperatures
(2) (4) (6) (8) (10) (12) (14) (16)
Needle valve (1) (3) (5) (7) (9) (11) (13) (15)
setting
(2) (4) (6) (8) (10) (12) (14) (16
Cylinder (1) (3) (5) (7) (9) (11) (13) (15)
burn time
(2) (4) (6) (8) (10) (12) (14) (16)
Aftercooler water in Jacket water in Engine oil in
temperature temperature temperature
out out out
Comments
Report the Service Information Complaint – Include a description of the customer’s

complaint in the report.
After you have successfully repaired the engine,
it is important to provide good information about
the repair. The following topics are recommended
for your report:
30
Cause – Provide a specific description of the cause

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

example, you may have installed a new wiring
harness. You may have replaced the ignition
transformer per instructions from the factory.
The providing of complete, accurate information will

help Caterpillar to provide better service to you and
to the customer.
31
Troubleshooting without a Operator Information

Diagnostic Code Obtain the following information from the operator:
• The occurrence and the time of the occurrence

i01305323
Symptoms • Determine the conditions for the occurrence. The

conditions will include the engine rpm and the
load.
SMCS Code: 1000-038; 1901-038
Some engine symptoms can be unrelated to

• Determine if there are any systems that were
installed by the dealer or the customer that could
the electronic control system. This section is for cause the symptom.
troubleshooting problems that have symptoms
without active diagnostic codes. Conditions such as
poor fuel quality or improperly adjusted valves can
• Determine whether any other occurrences
happened in addition to the symptom.
cause some engine symptoms.
For basic troubleshooting of the engine, perform Diagnostic Codes and Event Codes
the following steps first in order to diagnose a
malfunction. Examine the following information regarding any
codes:
1. Gather information about the complaint from the
operator. • The probable cause of the symptom is correlated
to the code.
2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not • The code was generated when the symptom
due to error of the operator. occurred.
3. Perform a visual inspection. Inspect the following • Codes that are repeatedly logged
items:
• The complaint is not due to normal engine
• Fuel supply operation.
• Oil level Other Symptoms

• Oil supply If other occurrences happened in addition to the
symptom, investigate the following conditions:
• Wiring
• The other occurrences are related to the
• Connectors symptom.
4. Check the diagnostic codes and event codes. • The symptoms have a probable cause that is
Repair any active codes. common.
If these inspections do not reveal any problems,
identify the probable causes with the procedures in i01643608
this manual that best describe the symptoms. See
Troubleshooting, “Troubleshooting With A Diagnostic Air Starting Motor
Code” or see Troubleshooting, “Troubleshooting
With Event Codes”. Check each probable cause SMCS Code: 1451-035
according to the tests that are recommended.
Probable Causes
Be sure to check the connectors. This is specially
true for problems that are intermittent. See The following conditions can prevent operation of
Troubleshooting, “Inspecting Electrical Connectors”. the starting motor:
Narrow the probable cause. Consider the operator • Engaged barring device
information, the conditions of operation, and the
history of the engine. • Electrical problem
• Low supply pressure
32
• Problem with the lubricator Relay Valve

• Problem with the starting motor’s control valve After the starting motor’s pinion is engaged, the
relay valve enables a large volume of supply
• Problem with the starting motor’s relay valve pressure to enter the air starting motor. Make
sure that the relay valve is not stuck. Check for
• Worn starting motor leaks. Check for debris in the supply line to the
starting motor. Make sure that the air line is properly
connected.
Recommended Repairs
Barring Device Worn Starting Motor
Before you remove the starting motor, turn the
Make sure that the barring device is fully
crankshaft by hand. Ensure that a mechanical failure
disengaged. Inspect the fittings and the air lines
of the interlock for leaks. inside the engine is not preventing the crankshaft
from turning. If the crankshaft will turn by hand, try
the starting motor again. If the starting motor does
Electrical Problem not turn the crankshaft, remove the starting motor.
Inspect the starting motor for worn parts.
There may be a problem with the starting system’s
electrical circuit. Refer to Troubleshooting, “ECM Check the starting motor for worn seals. Plug the
Start/Stop Output”. starting motor’s exhaust outlet and attach a source
of pressurized air to the inlet. Submerge the starting
Low Supply Pressure motor in water for a minimum of 30 seconds. If
bubbles rise from the starting motor, replace the
Determine the cause of the low supply pressure. seals.
Inspect the supply lines for leaks and/or
obstructions. Make the necessary repairs. If a vane is cracked or if the height of a vane is less
than 32 mm (1.25 inch), install new vanes.
Check the compressor for proper operation.
If any of the rotor bearings are loose or rough,
If a tank is used for the supply pressure, make replace the bearings.
sure that the size of the tank is sufficient. Check
the pressure in the tank. If the rotor’s body is scored, try to smooth the body
with emery cloth. If the body cannot be smoothed
Check the pressure regulator for proper adjustment. with emery cloth, replace the rotor.
Lubricator If the end plate is scored, use emery cloth to

smooth the end plate.
Check the oil level in the lubricator and adjust the
lubricator according to the engine’s Operation and If the cylinder is cracked or if the cylinder is scored
Maintenance Manual. deeply, replace the cylinder.
Inspect the fitting of the lubricator to the air line. i01654689

Make sure that the fitting is tight and free of leaks.
Crankcase Pressure (High)
Disassemble the lubricator and clean the parts.
Inspect the parts for good condition. Replace any SMCS Code: 1901-038; 1916
parts that are worn or damaged or replace the
lubricator.
Probable Causes
Control Valve • Plugged crankcase breather
Check the control valve’s solenoid for proper • Problem with the crankcase ventilation system
operation. Replace the solenoid, if necessary. (if equipped)
• Plugged port on the crankcase pressure sensor

• Faulty sensor
33
• Internal engine problem If a problem with a piston is suspected, do

not operate the engine. Remove the crankshaft
inspection covers in order to inspect the cylinder
Recommended Repairs liner for scoring and scuffing. Use the barring
device to move the piston to the uppermost position.
Crankcase Breather Replace the piston rings and the cylinder liner, if
necessary.
A plugged crankcase breather will cause excessive
crankcase pressure. Leakage of the crankshaft
seal can occur. Sealing of the piston rings can be i01635777
lost. This will enable crankcase blowby to further
increase the crankcase pressure. Detonation
Clean the crankcase breather according to SMCS Code: 1901-038
Operation and Maintenance Manual, SEBU7563,
“Engine Crankcase Breather - Clean”. Probable Causes
Crankcase Ventilation System • Excessive load
Engines that use bio-gas may have a system for • Misfire
ventilation of the crankcase. A problem with the
ventilation system can increase the crankcase • Adjustment of needle valves for the precombustion
pressure. Service the ventilation system according chamber
to the literature that is provided by the OEM of the
system. • High inlet air temperature
Plugged Port • Incorrect air/fuel ratio
The crankcase pressure sensor has a port in order • Coolant in a cylinder

to allow the ambient pressure into the sensor. The
port is enclosed under a cap. Remove the cap and • Excessive deposits in the combustion chamber
inspect the port for obstructions. Clean the port,
when possible. Otherwise, replace the sensor. • Faulty circuit for the detonation sensor(s)
Faulty Sensor Recommended Repairs

If you suspect that the crankcase pressure sensor Excessive Load
is faulty, replace the sensor with a sensor that is
known to be good. Make sure that the load is not excessive. Reduce
the load. If necessary, disengage the driven
Internal Engine Problem equipment and test the engine.
If the piston rings do not seal, blowby will increase Misfire

the crankcase pressure and the problem will
become worse. Performance will deteriorate. The If a cylinder is misfiring, the other cylinders can be
engine will have poor combustion. Deposits will overloaded. This will cause the other cylinders to
build up on the pistons, the valves, and the cylinder detonate. To eliminate the detonation, first eliminate
heads. Downward pumping of the pistons against the misfire. Refer to Troubleshooting, “Engine
the increased crankcase pressure will further Misfires, Runs Rough or is Unstable”.
reduce the performance.
Needle Valves
To determine whether the piston rings leak,
measure the crankcase blowby. Refer to Operation Misfire can occur in the precombustion chamber
and Maintenance Manual, SEBU7563, “Engine if the air/fuel mixture is too lean. If a cylinder is
Crankcase Blowby- Measure/Record”. misfiring, the other cylinders can be overloaded.
This will cause the other cylinders to detonate.
Sticking of the pistons will also increase the
crankcase pressure. If the problem is not resolved,
piston seizure will result.
34
Determine whether the adjustment of the needle Use a borescope to inspect the cylinders. Look for
valves is correct. If the needle valves require the following conditions:
adjustment, fully close all of the needle valves. Then
open all of the needle valves for four full turns. • Deposits on the valve seats
Operate the engine and use an emissions analyzer
to obtain the correct level of exhaust emissions. • Deposits on the valve faces
Check the Inlet Air Temperature • Deposits on the cylinder walls that are above the
upper limit of the piston stroke
High inlet air temperature can cause detonation.
Check the inlet air temperature. Look for the • Signs of internal leaks
following event codes:
Signs of internal leaks include excessive
• E026 High Inlet Air Temperature Shutdown consumption of engine oil, blue smoke, and
excessive detonation.
• E027 High Inlet Air Temperature Warning
If excessive deposits and/or signs of internal leaks
Refer to Troubleshooting, “Inlet Air Temperature are found, investigate the cause of the condition.
(High)”. Make repairs, as needed.
Air/Fuel Ratio Check the Detonation Sensors
An air/fuel mixture that is too rich will cause A problem with a detonation sensor or the electrical
detonation. A change in the fuel energy content circuit can cause false indications of detonation.
will change the air/fuel ratio. Obtain a fuel analysis. Troubleshoot the detonation sensors. Refer to
Enter the data into Caterpillar Software Program, Troubleshooting, “Detonation Sensors”.
LEKQ6378, “Methane Number Program”. Use ET to
program the correct LHV and specific gravity of the i01648990
fuel into the ECM.
Driven Equipment
The fuel supply pressure must be adequate and
stable. SMCS Code: 1901-038
Make sure that the electrohydraulic actuator for the

fuel is operating correctly. Probable Causes
Verify that the exhaust emissions are correct. • The ECM has received a “Start Inhibit” or a
“Shutdown” signal.
Coolant in a Cylinder • The circuit for the signal is faulty.
Under some circumstances, detonation can occur if
a water/glycol solution leaks into a precombustion Recommended Repairs
chamber and the coolant is burned. If a water/glycol
solution is used, monitor the cylinder’s exhaust Check the Driven Equipment
port temperature. If the temperature is higher than
the average, inspect the cylinder for evidence of Determine whether the driven equipment has
coolant leaks in the precombustion chamber. generated a “Start Inhibit” or “Shutdown”
request. Determine the cause for the request.
Note: Significant leaking of any type of coolant will Service the driven equipment according to the
cause the cylinder to misfire. recommendations of the OEM of the equipment.
Check for Deposits in the Cylinders

Overfilling of engine oil can lead to deposits. Make
sure that the engine oil level is correct.
Note: Excessive deposits contribute to guttering of

the valves.
35
Check the Circuit for the Input i01635869
The circuit for the input is routed to the ECM via Electrohydraulic System Oil
one of the customer connectors in the terminal
box. Either the 70-pin connector (J3) or the 47-pin
Pressure (Low)
connector (J4) can be used. Refer to the engine’s SMCS Code: 1901-038
electrical Schematic. Check the wiring between the
driven equipment and the ECM for damage and/or
corrosion. Refer to Troubleshooting, “Inspecting Probable Causes
Electrical Connectors”. Repair the wiring, as
needed. • Incorrect setting of the pressure relief valve
Check the resistance of the circuit. The correct • Stuck pressure relief valve
resistance of the circuit is 5 ohms or less. If the
resistance is greater than 5 ohms, locate the source • Insufficient oil pressure
of the excessive resistance. Make repairs, as
needed. • Open electrical circuit for the hydraulic oil
pressure switch
i01324372
Recommended Repairs
ECM Will Not Accept Factory
Passwords Setting of the Pressure Relief Valve
Check the setting of the pressure relief valve. For
SMCS Code: 1901-038
instructions, refer to Systems Operation/Testing
and Adjusting, RENR5908, “Pressure Releif
Probable Causes Valve Setting”. Adjust the pressure relief valve, if
necessary.
One of the following items may not be recorded
correctly on the ET: Check the Pressure Relief Valve
• Passwords If the pressure relief valve is dirty, the valve can
become stuck. If the pressure relief valve is stuck
• Serial Numbers in the open position, the hydraulic oil pressure will
be too low.
• Total Tattletale
If you suspect that the pressure relief valve is stuck,
• Reason Code disassemble the valve and clean the parts. Replace
parts, if necessary.
Recommended Repairs
Low Hydraulic Oil Pressure
1. Verify that the correct passwords were entered.
Check every character in each password. Turn Check the hydraulic oil level. Observe the oil level
the engine control switch to the OFF/RESET in the sight gauge on the tank. If necessary, pour oil
position for 30 seconds and then retry. into the tank until the oil level is between the “ADD”
and “FULL” marks on the sight gauge.
2. Verify that ET is on the “Factory Password”
screen. The hydraulic oil pressure switch must remain
closed during engine operation. Use a gauge
3. Verify that the following information from ET has to check the oil pressure of the electrohydraulic
been recorded correctly: system at the outlet for the hydraulic pump while the
engine is cranking. Check the pressure while the
• Serial Number of the engine engine is at normal operating temperature, when
possible. Compare the pressure to the pressure
• Serial Number of the ECM that is described in Systems Operation/Testing
and Adjusting, RENR5908, “Pressure Releif Valve
• Serial Number of the ET Setting”.
• Total Tattletale If the pressure is too low, inspect the electrohydraulic

system for leaks. Inspect the hydraulic pump. Make
• Reason Code repairs, as needed.
36
Open Electrical Circuit i01661274
Open Circuit in the Hydraulic Oil Pressure Switch Electronic Service Tool Will
Check for proper operation of the hydraulic oil
Not Communicate with ECM or
pressure switch. Disconnect the engine harness ICSM
from the switch. Apply a known pressure to the
electrohydraulic system. While you apply the SMCS Code: 1901-038
pressure, use a ohmmeter between terminals “A”
and “B” on the switch. Observe the status of the Probable Causes
switch’s contact. If the switch does not function
properly, replace the switch. • Electrical power supply
Open Circuit in the Harness for the Hydraulic Oil • Electrical connectors or wiring harness
Pressure Switch
• Communication adapter and/or cables
Use the following procedure to check the harness.
Do not operate the engine during this procedure. • Personal computer
1. Turn the engine control switch to the STOP
position. Recommended Repairs
2. Disconnect the harness connector from the Electrical Power Supply
pressure switch. Use ET to observe the “Hydrax
Pressure Switch Status”. Check power to the ECM and/or the ICSM. Refer to
Troubleshooting, “Electrical Power Supply”.
The status of the switch should be “Open”.
Note: If the modules are not receiving battery
3. Attach a jumper wire between terminals “A” and voltage, the modules will not communicate.
“B” on the harness connector.
Electrical Connectors
4. Use ET to observe the “Hydrax Pressure Switch
Status”. Check the following components:
The status of the switch should be “Closed”. • Battery connections and ground to the ECM
and/or the ICSM
5. Continue to observe the “Hydrax Pressure Switch
Status”. Wiggle the harness from the harness • Wiring harnesses and the connectors for the ECM
connector to the ECM. and/or the ICSM
The status of the switch should still be “Closed”. • Wiring harnesses and the connectors in the
terminal box for the ECM or the ITSM
If the “Hydrax Pressure Switch Status”
momentarily changes to “Open”, the harness has • Connections for the personal computer and the
an intermittent circuit. communication adapter
If there is an intermittent circuit, locate the problem. Refer to Troubleshooting, “Inspecting Electrical
Make repairs to the harness, when possible. After Connectors”.
the harness is repaired, remove the jumper wire
from the 3-pin connector. Reconnect the connector.
Communication Adapter and/or Cables
If the harness cannot be repaired, replace the
1. Check the condition of the fuse for the
harness.
communication adapter.
2. Disconnect the communication adapter and the

cables from the service tool connector. Then
reconnect the communication adapter.
37
If you are using the 7X-1700 Communication Recommended Repairs

Adapter Gp, refer to Special Instruction,
SEHS9264, “Using the 7X1700 Communication Check for a Low Coolant Level and/or
Adapter Group”.
Coolant Leakage
If you are using the 171-4401 Communication
Note: Low coolant level can be the effect of
Adapter II, refer to Manual, NEHS0758,
“Communication Adapter II User’s Manual”. overheating rather than the cause.
Check the coolant level.

3. Verify that battery voltage is present between
terminal A and terminal B of the service tool
connector. If the communication adapter is not Run the engine to operating temperature. Inspect
the cooling system for leaks.
receiving power, the display will be blank.
Determine whether the leak occurs before the
Personal Computer engine overheats.
Use the personal computer and the communication Add coolant, if necessary. If leaking is found, make
adapter with a different known good ECM. If the the necessary repairs.
same problem occurs with a different engine, check
the personal computer and the related equipment
in order to determine the cause of the problem. Check for Aeration of the Coolant
Air can enter the cooling system if the pressure
i01635895 cap is not operating properly. Check the operation
of the pressure cap. Replace the pressure cap, if
Engine Coolant Temperature necessary.
(High) Install a ball check valve at the outlet of the water
SMCS Code: 1901-038 pump. Start the engine. Open the ball check valve
in order to check for aeration of the coolant. If air
bubbles are found in the coolant, determine the
Probable Causes source of the air.
• Low coolant level and/or coolant leakage If the coolant has been changed recently, make
sure that the air has been purged from the cooling
• Aeration of the coolant system. Make sure that the cooling system is
properly vented.
• Problem with the water pump
The supply pressure to the water pump must be
• High ambient temperature and/or high inlet air sufficient in order to prevent cavitation. Measure the
temperature supply pressure at the inlet to the water pump.
• Insufficient flow of air or coolant through the Water Pump

radiator or heat exchanger
The engine will overheat if the water pump is not
• Faulty water temperature regulators operating properly. Measure the coolant pressure at
the outlet of the water pump. Make sure that the
• Faulty coolant temperature sensor and/or circuit water pump is in good condition.
• Insufficient flow of coolant through the engine
Check for High Ambient Temperature
• Exhaust restriction and/or High Inlet Air Temperature
• Excessive load Determine if the ambient air temperature is within
the design specifications for the cooling system.
• Incorrect air/fuel ratio
Make sure that the engine’s exhaust does not heat
• Combustion gas in the coolant the radiator or the heat exchanger.
Check for high inlet air temperature. Refer to

Troubleshooting, “Inlet Air Temperature (High)”.
38
Determine the cause of the high air temperature. If a buildup of deposits restricts the coolant flow,
Make corrections, when possible. clean the cooling system.
Check for Insufficient Flow of Air and If the flow of coolant through the engine is not
sufficient, determine the cause of the obstruction.
Coolant Through the Radiator or Heat Make necessary repairs.
Exchanger
Check the Exhaust Restriction
Measure the coolant temperature at the inlet for the
coolant.
Check the back pressure of the exhaust system.
Refer to the engine’s Technical Marketing
Radiator
Information.
Check the fins of the radiator for obstructions.
If the back pressure exceeds the specifications for
Check the fan for proper operation.
the engine, determine the cause of the excessive
back pressure. Make the necessary repairs.
If the radiator fins are obstructed, clean the fins.
If the fan does not operate properly, make the
necessary repairs. Excessive Load
Heat Exchanger Make sure that the load is not excessive. Reduce
Check for sufficient flow and temperature of the equipment and test the engine.
cooling water through the heat exchanger. If the
flow of cooling water through the heat exchanger Air/Fuel Ratio
is insufficient, determine the location of the
obstruction. An air/fuel mixture that is too rich will cause
overheating. A change in the fuel energy content
Check the Water Temperature Regulators will change the air/fuel ratio. Obtain a fuel analysis.
Check the water temperature regulators for proper The fuel supply pressure must be adequate and
operation. Refer to Systems Operation/Testing and stable.
Adjusting, RENR5908, “Cooling System”.
Ensure that the electrohydraulic actuator for the fuel
Replace the water temperature regulators, if is operating correctly.
necessary.
Verify that the exhaust emissions are correct.
Check the Coolant Temperature Sensor
Check for Combustion Gas in the Coolant
and/or the Circuit
The following conditions can indicate that
Check the reading of the coolant temperature on
combustion gas is entering the cooling system:
ET. The temperature should rise steadily as the
engine is warmed. Ensure that the temperature is
reasonable. • Steam is escaping from the expansion tank.
If the reading on ET for the coolant temperature • A cylinder is misfiring.

is not reasonable, troubleshoot the circuit
and the coolant temperature sensor. Refer to • The cylinder temperature is too hot or too cold.
Troubleshooting, “Analog Sensor Signal”. If a leaking precombustion chamber is suspected,
operate the engine at a low load. Monitor the
Check the Flow of Coolant Through the exhaust port temperatures and the combustion burn
Engine times.
During normal operation, check the inlet pressure

of the engine coolant and the outlet pressure of the
engine coolant.
Measure temperatures and pressures at various

points in the cooling system in order to identify
possible locations of restrictions.
39
When a suspect cylinder is identified, shut down Check the operation of the water temperature
the engine. Inspect the spark plug for moisture and regulators according to Systems Operation/Testing
for evidence of deposits from coolant. Remove the and Adjusting, RENR5908, “Cooling System”.
combustion sensor and insert a borescope through Replace the water temperature regulators, if
the opening. Inspect the precombustion chamber necessary.
for evidence of coolant. If evidence of coolant is
found, replace the seals. Refer to the engine’s
i01636242
Disassembly and Assembly manual.
Engine Cranks but Will Not
i01636239 Start
Engine Coolant Temperature SMCS Code: 1000-038; 1901-038
(Low)
SMCS Code: 1901-038
Probable Causes
• Slow cranking
Probable Causes
• Cold engine
• Faulty jacket water heater
• Excessive load
• Faulty coolant temperature sensor and/or circuit
• Inlet air restriction
• Faulty water temperature regulators
• Problem with the air/fuel mixture
Recommended Repairs
• Problem with the gas shutoff valve
Check the Jacket Water Heater • Electrical connectors or power supply
Determine if the jacket water heaters are functioning • No signal from the engine speed/timing sensor
properly.
• Ignition system
If the jacket water heaters are not functioning
properly, determine the cause of the malfunction of
the heaters. Make the necessary repairs. Recommended Repairs
Check the Coolant Temperature Sensor Slow Cranking
and/or the Circuit The cranking speed must be sufficient for engine
start-up. Inspect the starting system. Make sure
Check the reading of the coolant temperature on
that the air supply has sufficient pressure. If the
ET. The temperature should rise steadily as the
starting motor is suspect, refer to Troubleshooting,
engine is warmed. Ensure that the temperature is
“Air Starting Motor”.
reasonable.
If the reading on ET for the coolant temperature Cold Engine

is not reasonable, troubleshoot the circuit
and the coolant temperature sensor. Refer to If the engine is too cold, the engine may not start.
Troubleshooting, “Analog Sensor Signal”. Refer to Application and Installation, LEKQ7249,
“Ambient Considerations”.
Check the Water Temperature Regulators
Excessive Load
The water temperature regulators should not
begin to open until jacket water reaches opening Make sure that the load is not excessive. Reduce
temperature for the regulators. Allow the engine the load. If necessary, disengage the driven
to cool and then start the engine. Check the hose equipment and test the engine.
at the outlet for the jacket water. If the hose is
warm and normal operating temperature is not Air/Fuel Mixture
achieved yet, a regulator may be stuck open. A
water temperature regulator that is stuck open can The following conditions can cause the engine to
result in piston seizure. malfunction:
40
• Low fuel pressure Inlet Air Restriction

• High fuel pressure For optimum operation, replace the air filter
elements when the inlet air restriction reaches
• Poor fuel quality 2.5 kPa (10 inches of H2O). The maximum allowable
inlet air restriction is 3.75 kPa (15 inches of H2O).
If the inlet air restriction is excessive, determine the
Make sure that fuel is supplied at a sufficient cause of the restriction and correct the condition.
pressure that is stable. Make sure that the size of
the fuel line is sufficient. Inspect the fuel system Electrical Connectors or Power Supply
for leaks. Inspect the fuel filter, the gas pressure
regulator, the gas shutoff valve, and the gas shutoff There may be an intermittent interruption of power.
valve’s solenoid. Check the wiring harnesses and the connectors.
Inspect the connectors in the terminal box. Inspect
When possible, interview the operator in order the battery connections and the ground.
to determine if fuel quality is in question. Try to
determine if the source of the fuel was changed. Inspect the wiring from the battery to the ECM.
Inspect the wires and the power relay. Check
Check the needle valves for the precombustion the power and ground connections. Refer to
chambers. If the needle valves are closed, no fuel Troubleshooting, “Electrical Power Supply”.
is supplied to the precombustion chamber. If the
needle valves are open too far, the air/fuel mixture Make sure that the run relay is activated. Refer to
will be too rich for combustion. Troubleshooting, “ECM Status Indicator Output”.
If the adjustment of the needle valves is suspect,
fully close all of the valves. Open the needle
Engine Speed/Timing Sensor
valves for four full turns. Adjust the needle valves
according to Testing and Adjusting, RENR5908, Make sure that the engine speed/timing sensor
and the timing wheel are installed correctly. If the
“BTU and Precombustion Chamber Adjustments”.
engine speed/timing sensor is suspect, refer to
Check the position of the air choke’s plate. The Troubleshooting, “Engine Speed/Timing Sensor”.
orientation of the plate is represented by the groove
on the end of the shaft for the choke plate. The Ignition System
air choke is fully open for start-up. If the air choke
is closed, the air/fuel mixture will be too rich for Under certain conditions, condensation forms on
combustion. the spark plugs after the engine is shut down.
The condensation can prevent the engine from
During cranking, the fuel actuator begins to open restarting.
at approximately 50 rpm. The actuator opens for
approximately 5 to 10 percent of the full travel. If the Maintain the spark plug according to Operation and
actuator opens for more than 30 percent, the fuel Maintenance Manual, SEBU7563, “Ignition System
pressure is probably too low. Spark Plugs - Check - Adjust”.
Make sure that the actuator and the linkage are Inspect the ignition transformers for loose
operating properly. For information on maintaining connections, moisture, short circuits, and open
the actuator, refer to the Operation and Maintenance circuits. Inspect the primary wiring and the
Manual, SEBU7563, “Electrohydraulic Actuator - secondary electrical connections. For information
Inspect”. For information on troubleshooting the on troubleshooting the ignition system, refer to
actuator, refer to Troubleshooting, “Fuel Actuator Troubleshooting, “Ignition Transformers Primary
Solenoid”. Circuit” and Troubleshooting, “Ignition Transformers
Secondary Circuit and Spark Plug”.
Gas Shutoff Valve
Make sure that the correct transformers and spark
plugs are installed. Inspect the extenders for signs
During cranking, measure the pressure in the fuel
or pin holes and arcing.
manifold. The gas pressure must be 1 to 10 kPa
(0.15 to 1.5 psi). If the pressure is zero, the gas
shutoff valve may not be operating properly. Refer to
the Operation and Maintenance Manual, SEBU7563,
“Gas Shutoff Valve - Inspect”.
41
i01638285 For detailed information on detection of misfire

and false misfire, refer to Testing and Adjusting,
Engine Misfires, Runs Rough RENR5908, “BTU and Precombustion Chamber
or Is Unstable Adjustments”.
SMCS Code: 1000-038; 1901-038 Spark Plug

Under certain conditions, condensation forms on
Probable Causes the spark plugs after the engine is shut down. The
condensation can cause misfire.
• Cold cylinder
A spark plug may require service. Maintain the
• Spark plug spark plug according to Operation and Maintenance
Manual, SEBU7563, “Ignition System Spark Plug -
• Check valve Check/Adjust”.
Check Valve
• Needle valve
Passages for the fuel to the precombustion
• Spark plug’s extension chamber’s check valve may be blocked by
contaminants in the air/fuel mixture. Make sure that
• Ignition transformer the passages are clean. Make sure that the air and
the fuel are properly filtered.
• Air/fuel pressure module
Combustion may have leaked past the check
• Gas admission valve valve’s gasket. During operation, check the
temperature of the supply tube for the needle valve.
• Precombustion chamber If the temperature of the supply tube is higher than
average, combustion is probably leaking into the
• Fuel supply lines for the precombustion chamber cylinder head. Remove the check valve and inspect
the check valve for evidence of combustion on the
• Valve lash outside of the check valve’s body.
• Cylinder head and related components The check valve may be stuck. The check valve
must move freely in order to allow fuel to enter the
• Incorrect electrical connection or power supply precombustion chamber. Clean the check valve with
a nonflammable solvent that will not leave residue.
• Air inlet restriction Replace the check valve, if necessary.
• Problem with the electrohydraulic system Air/Fuel Ratio

• Driven equipment Operate the engine with a different air/fuel mixture
in order to determine if the misfiring is affected by
Recommended Repairs the air/fuel ratio. To change the air/fuel ratio, operate
the engine in the prechamber calibration mode. Use
Note: If the symptom only occurs under certain ET to change the setting of the fuel’s BTU.
operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under If the rate of misfiring changes, use an emissions
the conditions. Troubleshooting the symptom under analyzer and tune the engine according to Testing
other conditions can give misleading results. and Adjusting, RENR5908, “BTU and Precombustion
Chamber Adjustments”.
Cold Cylinder
Before you can determine the cause of the cold
cylinder, use the display on the control panel in
order to locate the cold cylinder. You can view the
actual combustion burn times and the exhaust port
temperatures of the cylinders.
42
Needle Valve Remove the combustion sensor and use a

borescope to view the hole for the spark plug in the
Check the needle valves for the precombustion precombustion chamber. For a two-piece ignition
chambers. If the needle valves are closed, no fuel body / precombustion chamber, the locating pins
is supplied to the precombustion chamber. If the may be broken. This would allow the precombustion
needle valves are open too far, the air/fuel mixture chamber to move and the hole for the spark plug
will be too rich for combustion. If the adjustment could be misaligned. If this is the case, remove the
of the needle valves is suspect, fully close all of ignition body and the precombustion chamber in
the needle valves. Open the needle valves for order to make the necessary repairs.
four full turns. Adjust the needle valves according
to Testing and Adjusting, RENR5908, “BTU and Fuel Supply Lines for the Precombustion
Precombustion Chamber Adjustments”.
Chamber
Make sure that the fuel lines for the needle valves
Inspect the fuel supply lines and the passages
are not clogged.
between the needle valve and the check valve.
If adjustment of a needle valve does not affect Look for signs of debris and carbon buildup. Make
sure that the lines and passages are clean.
operation, the needle valve may be faulty. Replace
the needle valve.
Multiple problems with a check valve for a particular
cylinder can be caused by fuel supply lines and
Spark Plug Extension passages that are dirty.
Inspect the outside of the extension for oil and
moisture. Look for holes that are burned through Valve Lash
the extension’s insulator. Inspect the extension’s
Check the valve lash. Refer to Testing and Adjusting,
terminals for corrosion.
RENR5908, “Engine Timing Procedures”.
Ignition Transformer Cylinder Head and Related Components
Inspect the ignition transformers for loose
Measure the cylinder compression. Refer to
connections, moisture, short circuits, and open
circuits. Inspect the primary wiring and the
“Cylinder Pressure - Measure/Record”.
secondary electrical connections. For information
on troubleshooting the ignition system, refer to
Inspect the components of the valve train for good
Troubleshooting, “Ignition Transformers Primary
condition. Check for signs of damage and/or wear
Circuit” and Troubleshooting, “Ignition Transformers
to the valves, cylinder head gasket, etc. Inspect
Secondary Circuit and Spark Plug”.
the condition of the camshafts. If a camshaft is
replaced, new valve lifters must be installed.
Gas Admission Valve
Check the gas admission valve lash. Refer to
Electrical Connection or Power Supply
Testing and Adjusting, RENR5908, “Engine Timing
There may be an intermittent interruption of power.
Procedures”.
Check the wiring harnesses and the connectors.
Inspect the connectors in the terminal box. Inspect
Precombustion Chamber the battery connections and the ground.
Inspect the precombustion chamber. For instructions Inspect the wiring from the battery to the ECM.
on removal and installation, refer to Disassembly Inspect the wires and the power relay. Check
and Assembly, SENR5535, “Prechamber Check the power and ground connections. Refer to
Valve - Remove and Install”. Troubleshooting, “Electrical Power Supply”.
The precombustion chamber’s gasket and/or the
ignition body’s seals may have allowed coolant to
Air Inlet Restriction
enter the precombustion chamber. Inspect the spark
plug and the precombustion chamber for evidence The maximum allowable air inlet restriction is
3.75 kPa (15 inches of H2O). If the indication is
of coolant and residue of liquid crystalline material.
higher than the maximum permissible restriction,
If the gasket and/or the seals have leaked, clean
the sealing surfaces and install a new gasket and clean the filter element or install a new filter element.
Check the restriction again. If the restriction remains
seals. Also check for coolant leaks at the bottom of
too high, inspect the air inlet piping for obstructions.
the cylinder head.
43
Electrohydraulic System • Faulty engine oil pressure sensor

Make sure that the hydraulic oil is not contaminated.
Recommended Repairs
Make sure that the electrohydraulic actuators are
operating properly. During operation at a load that Engine Oil Filter Element
is less than 50 percent, observe the operation of the
air choke actuator. During operation at a load that is As the engine oil filter elements become plugged,
greater than 50 percent, observe the operation of the engine oil filter differential pressure rises.
the wastegate actuator. Replace the engine oil filters when the engine oil
filter differential pressure reaches 100 kPa (15 psi).
The governor gain may require adjustment. Refer
to Systems Operation/Testing and Adjusting, If an engine oil filter element is missing or the
RENR5908, “Governor Adjustment Procedure”. element is damaged, the unfiltered engine oil will
cause low engine oil filter differential pressure. Make
If a solenoid for an actuator is suspect, switch the sure that elements are installed in the engine oil filter
solenoid for another solenoid that is known to be housings. Inspect the engine oil filter elements for
good. Obtain a new solenoid, if necessary. good condition. Replace any suspect filter element.
Make sure that the linkage moves freely. If any rod Engine Oil Pressure Sensors
ends are worn, replace the rod ends.
Use the ET to compare the readings for the filtered
If an actuator is suspect, inspect the actuator engine oil pressure and the unfiltered engine oil
according to Operation and Maintenance Manual, pressure while the engine is OFF.
SEBU7563, “Electrohydraulic Actuator - Inspect”.
If the readings are not approximately zero for both
Driven Equipment of the sensors, there is a problem with a sensor.
Replace the sensor.
Make sure that the load is not excessive. Reduce
the load. If necessary, disengage the driven i01649374
equipment and test the engine.
Engine Oil Pressure (Low)
Variation of the load can cause instability. Make sure
that the signal for the engine speed is not corrupted. SMCS Code: 1901-038
i01638632 Probable Causes

Engine Oil Filter Differential • Low engine oil level
Pressure
• Incorrect viscosity
SMCS Code: 1308-035
• Contaminated engine oil
Probable Causes • Faulty oil pressure sensors
An indication of high engine oil filter differential • Improper circulation of the engine oil
pressure will be caused by either of the following
conditions: • Worn components
• Plugged engine oil filter element Recommended Repairs
• Faulty engine oil pressure sensor
Low Engine Oil Level
• Cold engine oil
Check the oil level. Add oil, as needed.
An indication of low engine oil filter differential
pressure will be caused by either of the following
conditions:
• An engine oil filter element is missing or an

element is damaged.
44
Contaminated Engine Oil • There is a problem with the engine oil pump.
Check the gears of the engine oil pump for
Engine oil that is contaminated with another liquid excessive wear. Engine oil pressure is reduced
will cause low engine oil pressure. High engine by gears that have too much wear.
oil level can be an indication of contamination.
Obtain an analysis of the engine oil. Determine the • The engine oil pump’s pressure regulating valve
reason for contamination of the engine oil and make or a bypass valve is stuck in the open position.
the necessary repairs. Change the engine oil and Clean the valve. Replace parts, if necessary.
the engine oil filter. For the correct engine oil to
use, refer to Operation and Maintenance Manual, • The priority valve is stuck in the open position.
“Engine Oil”. Clean the priority valve.
Incorrect Viscosity Worn Components

Make sure that the engine is supplied with the Excessive clearance at the crankshaft or camshaft
correct engine oil. For the correct engine oil to bearings will cause low engine oil pressure. Also,
use, refer to Operation and Maintenance Manual, inspect the clearance between the rocker arm
“Engine Oil”. shafts and the rocker arms. Check the engine
components for excessive clearance.
Faulty Engine Oil Pressure Sensors
Obtain an analysis of the engine oil. Check the
Use ET to compare the readings of the filtered analysis for the level of wear metals in the engine oil.
engine oil pressure and the unfiltered engine oil
pressure while the engine is OFF. Both readings i01640711
should be close to zero pressure.
Engine Oil Temperature (High)
If a reading is significantly different from zero,
replace the suspect engine oil pressure sensor. SMCS Code: 1901-038
Improper Circulation of the Engine Oil Probable Causes

Several factors could cause improper circulation of • Contaminated engine oil
the engine oil:
• Problem with the engine oil temperature regulators
• The engine oil filter is clogged. Replace the
engine oil filter. • Problem with the engine oil temperature sensor
• An engine oil line or a passage for engine oil is • Problem with the circuit for the aftercooler and
disconnected or broken. engine oil cooler
• The engine oil cooler is clogged. Thoroughly • Insufficient flow of coolant or engine oil through
clean the engine oil cooler. the engine oil cooler
• There is a problem with a piston cooling jet. • Mechanical friction

Breakage, a restriction, or incorrect installation
of a piston cooling jet will cause seizure of the
piston. Recommended Repairs
• The inlet screen of the suction tube for the engine Contaminated Engine Oil
oil pump can have a restriction. This restriction
will cause cavitation and a loss of engine oil Engine oil that is contaminated with another liquid
pressure. Check the inlet screen on the suction can cause low engine oil temperature. High engine
tube and remove any material that may be oil level can be an indication of contamination.
restricting engine oil flow. Obtain an analysis of the engine oil. Determine the
reason for contamination of the engine oil and make
• The suction tube is drawing in air. Check the joints the necessary repairs. Change the engine oil and
of the tube for cracks or a damaged O-ring seal. the engine oil filter. For the correct engine oil to
use, refer to Operation and Maintenance Manual,
“Engine Oil”.
45
Check the Engine Oil Temperature • The programmed crank cycle time is insufficient.
Regulators
• The gas supply to the engine is insufficient.
Make sure that the engine oil temperature regulators
open according to the correct values. Refer to • There is a problem with the relay for the starting
Specifications, RENR5907, “Engine Oil Temperature motor’s solenoid.
Regulators”.
• The ignition system is not functioning.
Check the Engine Oil Temperature
• The quality of the gas does not match the “Fuel
Sensor Quality” parameter.
Check the reading of the engine oil temperature
on ET. Compare the reading to a reading from Recommended Repairs
a separate device. The temperature should rise
steadily as the engine is warmed. Excessive Load
If the reading on ET for the engine oil temperature is Make sure that the load is not excessive. Reduce
not reasonable, replace the engine oil temperature the load. If necessary, disengage the driven
sensor. equipment and test the engine.
Check the Cooling System Crank Cycle

Make sure that the heat exchanger for the engine Note: A maximum of one crank cycle per overcrank
oil cooler and the aftercooler is operating properly. is recommended.
The heat exchanger must be properly sized for
the ambient conditions. Check the plumbing for Make sure that the engine can be cranked for a
obstructions. sufficient amount of time. Use ET to check the
“Cycle Crank Time” and the “Overcrank Time”
Check the Flow Through the Engine Oil parameters. Remember that the purge cycle is par
of the total crank cycle. Reprogram the parameters,
Cooler if necessary. For instructions, refer to Systems
Run the engine at normal operating temperature. “Electronic Control System Parameters”.
Determine the pressure differential for the coolant
and the engine oil between the inlet and the outlet of
the engine oil cooler. For comparative data, refer to Check the Gas Supply to the Engine
the Technical Marketing Information for the engine.
Check for low gas pressure. If the gas pressure is
If the pressure differential between the inlet and the low, refer to Troubleshooting, “Fuel Pressure”.
outlet of the engine oil cooler exceeds the data that
is published for the engine, there is an insufficient If the gas shutoff valve is closed, refer to Operation
flow of coolant or engine oil through the engine oil and Maintenance Manual, SEBU7563, “Gas Shutoff
cooler. Clean the engine oil cooler. Valve - Inspect”.
Mechanical Friction Check the Status of the Relay for the

Starting Motor’s Solenoid
Friction of gears and/or bearings will raise the
engine oil temperature. Measure the engine oil Attempt to start the engine while you observe the
temperature at various locations in order to locate status of the relay for the starting motor’s solenoid
the hot spot. Obtain an analysis of the engine oil. on the control panel’s display.
Make the necessary repairs.
If the status of the relay for the starting motor’s
solenoid indicates that the engine should crank but
i01643751 no cranking occurs, troubleshoot the starting circuit.
Refer to Troubleshooting, “ECM Output Circuit
Engine Overcrank (Starting Motor)”.
SMCS Code: 1901-038
If the engine should crank and cranking occurs,
check the engine rpm.
Probable Causes
• Excessive load
46
Check the Engine RPM Misfire

The ECM must detect a minimum of 50 rpm before A cold cylinder will cause the other cylinders to
the gas and the ignition are supplied to the engine. overload. Refer to Troubleshooting, “Engine Misfires,
Monitor the engine speed while you crank the Runs Rough or Is Unstable”.
engine.
Obtain a Fuel Analysis and Program the
The minimum recommended cranking speed is 80
rpm.
Fuel Energy Content
The maximum recommended cranking speed is Obtain an analysis of the gas in order to determine
the LHV. Program the correct LHV for the “Fuel
150 rpm.
Quality” configuration parameter.
Ignition System If the quality of the gas is not consistent, obtain
several analyses over a period of time. Program
Check for active diagnostic codes that relate to the “Fuel Quality” configuration parameter to the
the ignition system. If there is at least one active average value of the LHV.
diagnostic code that relates to the ignition system,
troubleshoot the diagnostic code.
i01643845
Check the Fuel Quality Engine Overspeed

Compare the Low Heat Value (LHV) of the gas SMCS Code: 1000-038; 1901-038
supply to the “Fuel Quality” parameter that is
programmed by the customer into the ECM. The
ECM uses the setting for start-up and for air/fuel Probable Causes
ratio control at low loads.
• Slow governor response
If the LHV of the fuel does not match the “Fuel
Quality” parameter that is programmed into the • Low trip point for engine overspeed
ECM, program the ECM with the correct setting for
the “Fuel Quality” parameter. • Binding of the electrohydraulic actuator for the
fuel
i01643832 • Energy of the driven equipment
Engine Overload
Recommended Repairs
SMCS Code: 1901-038
Check for Slow Governor Response
Probable Causes
If an engine overspeed occurs during start-up or
• Driven equipment when the load is reduced, the governor response
may be slow.
• Misfire
Observe the “Speed Governor Adjustment” screen
• The LHV of the gas or the specific gravity of the on ET. Look for the engine response to the worst
gas is significantly different from the value that is cases for step-loading and unloading.
programmed.
Use “Throttle Bump” feature of ET in order to disturb
steady state engine operation. If the undershoot or
Recommended Repairs the overshoot of the engine speed is excessive,
adjust the governor’s gain. Refer to Systems
Driven Equipment Operation/Testing and adjusting, “Electronic Control
System Parameters”.
the load.
47
Check the Trip Point Recommended Repairs

Note: Do not program the trip point for engine Check the Air Supply Pressure
overspeed higher than the maximum ratings of the
driven equipment. For a prelube pump that operates with pressurized
air, make sure that the air supply pressure is
The trip point or engine overspeed may be too low. adequate. Inspect the system for leaks.
Verify that the trip point for the engine overspeed
is properly programmed.
Check the Lubricator
This parameter requires a factory password in order
to change the trip point. Change the trip point to an For a prelube pump that operates with pressurized
air, make sure that the lubricator is adequately filled
acceptable speed.
with the correct lubricant.
Check for Binding of the Electrohydraulic
Check the Exhaust
Actuator
For a prelube pump that operates with pressurized
Slide the electrohydraulic actuator’s rod in and out air, make sure that the exhaust is not restricted.
while you feel the motion. If the motion is sticky
and/or rough, investigate the cause of the binding.
Make the necessary repairs. Refer to Operation and Check the Engine Oil Supply
Maintenance Manual, SEBU7563, “Electrohydraulic
Actuator - Recondition”. Check the engine oil level. Add oil until the oil level
is between the “ADD” and “FULL” marks on the oil
level gauge. Inspect the lubrication system for leaks.
Check the Driven Equipment
If the supply of engine oil is correct, look for leaks
Determine if the driven equipment has additional in the oil lines for the prelube pump. Make sure that
inputs of energy that could drive the engine beyond the supply of engine oil is not obstructed. Make
the rated rpm. Make corrections to the installation in repairs, as needed.
order to prevent the overspeed from recurring.
Check the Power Source for the Prelube
i01640899 Pump
Engine Pre-Lube Pressure Make sure that the output for the prelube pump is
(Low) activated. Refer to Troubleshooting, “ECM Output
Circuit (Prelubrication Oil Pump)”.
SMCS Code: 1901-038
Check the Prelube Pump’s Pressure
Probable Causes Switch
• Low air supply pressure The prelube pump’s pressure switch must close
before the starting motor relay will be energized.
• Low level of lubricant in the lubricator Make sure that the switch operates correctly. Refer
to Troubleshooting, “Prelubrication System”.
• Restriction of the prelube pump’s exhaust
Inspect the Prelube Pump
• Problem with the supply of engine oil
The prelube pump may have a mechanical problem.
• Electrical problem Inspect the prelube pump. For instructions on
removal and disassembly, refer to Disassembly and
• Problem with the prelube pump’s pressure switch Assembly, SENR5535.
• Problem with the pump

48
i01649439 i01691317
Engine Shutdown Engine Shutdown

SMCS Code: 1901-038
(Unexpected)
SMCS Code: 1901-038
Probable Causes
• The “Emergency Stop” button is pressed.
Probable Causes
• The circuit for the emergency stop or the normal • There is a problem with the Gas Shutoff Valve
stop switch is faulty. (GSOV).
• Either switch is activated by excessive vibration. • Incorrect input(s) to the Engine Control Switch
(ECS)
Recommended Repairs • There is a problem with the relay for the prelube.
Emergency Stop • There is a problem with the switch for the prelube.
Ask the operator if the stop was intentional. Make • There is a problem with the “Crank Terminate”
sure that the reason for the stop has been corrected. relay.
Reset the control system. Resume normal operation.
• There is a problem with the relay for the starting
If the stop was accidental, reset the control system. motor.
Resume normal operation.
• A shutdown has been requested by the driven
equipment.
Check the Circuit for the Stop Switches
Note: The circuit for the normal stop switch and the • There is a problem with the “Run” relay.
circuit for the emergency stop switch must remain
closed in order for the engine to run. • The “Crank Terminate Speed” is incorrectly
programmed.
Inspect the wiring between the switches and the
connector of the ECM. Look for damage and/or • The “Cycle Crank Time” is incorrectly
corrosion. Refer to Troubleshooting, “Inspecting programmed.
Electrical Connectors”.
• The “Engine Overcrank Time” is incorrectly
programmed.
Troubleshoot the engine control switch according to
• The delay time for the driven equipment is
excessive.
Inspect the Stop Switches
Inspect the stop switches for evidence of damage Recommended Repair
that has been caused by vibration. Disassemble the
switches. Inspect the components for looseness, Check the Circuit for the GSOV
cracks, and abrasion. Use an ohmmeter and toggle
the switches in order to check for proper electrical Troubleshoot for the following diagnostic codes:
operation.
• 17-05 Fuel Shutoff Valve open circuit
Replace any faulty components.
• 17-06 Fuel Shutoff Valve short to ground
• 17-12 Fuel Shutoff Valve malfunction
Refer to Troubleshooting, “ECM Output Circuit (Fuel
Control)”. Make repairs, as needed.
49
Check the Inputs to the ECS Refer to Troubleshooting, “ECM Status Indicator
Output”. Make repairs, as needed.
Troubleshoot for the diag336-02 Incorrect ECS
Switch inputs diagnostic code. Check the “Crank Terminate Speed”
Refer to Troubleshooting, “Electrical Power Supply”. The “Crank Terminate Speed” is a parameter
Make repairs, as needed. that can be configured. The ECM disengages
the starting motor when the engine exceeds
Check the Relay for the Prelube the programmed “Crank Terminate Speed”. The
default value of 250 rpm should be sufficient for
Troubleshoot for the following diagnostic codes: all applications.
• 338-05 Pre-Lube Relay open circuit If the “Crank Terminate Speed” is too slow, the
engine will shut down. Use ET to check the
• 338-06 Pre-Lube Relay short to ground programmed “Crank Terminate” speed. Use ET to
adjust the “Crank Terminate Speed”, if necessary.
(Prelubrication Oil Pump)”. Make repairs, as Check the “Cycle Crank Time”
needed.
The “Cycle Crank Time” is a parameter that can
Check the Pressure Switch for the be configured. This parameter determines the time
Prelube for engagement of the starting motor and the gas
shutoff valve during the crank cycle. If the engine
Troubleshoot for the diag339-05 Engine Pre-Lube does not start within the programmed “Cycle Crank
Pressure Switch open circuit diagnostic code. Time”, the attempt to start is suspended for an
equal “Rest” cycle.
Refer to Troubleshooting, “Prelubrication System”.
Make repairs, as needed. If the “Cycle Crank Time” is insufficient, the “Engine
Overcrank Time” can elapse before the engine is
able to start.
Check the “Crank Terminate” Relay
Use ET to check the “Cycle Crank Time”. Use ET
Troubleshoot for the diag443-03 “Crank Terminate
to increase the time, if necessary.
Relay short to +batt” diagnostic code.
Refer to Troubleshooting, “ECM Status Indicator Check the “Engine Overcrank Time”
Output”. Make repairs, as needed.
The “Engine Overcrank Time” is a parameter that
can be configured. This parameter determines the
Check the “Start” Relay length of time for the crank cycle. If the engine does
not start within the programmed “Engine Overcrank
Troubleshoot for the following diagnostic codes:
time”, the attempt to start is terminated. An
diagE225 (3) Engine Overcrank event is generated.
• 444-05 Start Relay open circuit
If the “Cycle Crank Time” is insufficient, the “Engine
• 444-06 Start Relay short to ground Overcrank Time” can elapse before the engine is
able to start.
(Starting Motor)”. Make repairs, as needed. Use ET to check the “Engine Overcrank Time”.
Use ET to increase the “Engine Overcrank Time”, if
Check for a Request for a Shutdown by necessary.
the Driven Equipment
Check the “Driven Equipment Delay
Determine whether a shutdown for the driven Time”
equipment has been requested. Refer to
Troubleshooting, “Driven Equipment”. Make
The “Driven Equipment Delay Time” is a parameter
corrections, as needed. that can be configured. The ECM provides a switch
input for the driven equipment in order to delay
Check the “Run” Relay engine start-up until the driven equipment is ready.
The ECM will not attempt to start the engine until
Troubleshoot for the diag445-03 “Run Relay short to the switch input for the driven equipment closes
+batt” diagnostic code. to ground and the prelubrication (if equipped) is
complete.
50
An event code is generated if the “Driven Equipment i01643939

Delay Time” elapses without closure of the switch
input. To disable this feature, program the delay Engine Starts but Stalls
time to zero. Immediately
If the programmed delay time is too long, the SMCS Code: 1000-038; 1901-038
engine may not start. Use ET to check the “Driven
Equipment Delay Time”. Use ET to program the
delay time to a reasonable amount of time. Probable Causes
• Fuel supply
i01643929
• Electrical connectors or power supply
Engine Shutdown without a
Diagnostic Code • Engine speed/timing sensor
SMCS Code: 1000-038; 1901-038 • Ignition system
Probable Causes • Excessive load
• The battery power to the ECM is lost. Recommended Repairs

• There is a problem with the fuel supply. Fuel Supply
Recommended Repairs Make sure that fuel is supplied at a sufficient

pressure that is stable. Make sure that the size of
the fuel line is sufficient. Inspect the fuel system
Battery Power to the ECM for leaks.
1. Refer to Troubleshooting, “Electrical Power The following conditions can cause the engine to
Supply”. malfunction:
2. Inspect the ground strap and the battery for
connections that are loose and/or corroded.
• Low fuel pressure
3. Inspect the ECM and the terminal box for proper

• High fuel pressure
installation of the connectors.
• Poor fuel quality
4. Check the circuit breaker for the ECM in the Make sure that the fuel pressure is correct.
terminal box. When possible, interview the operator in order
to determine if fuel quality is in question. Try to
Fuel Supply determine if the source of the fuel was changed.
• Check the fuel supply pressure. Inspect the fuel system components: fuel filter, gas
pressure regulator, gas shutoff valve, and actuator
• Inspect the fuel lines for foreign objects and for for the fuel. Verify that the system’s components are
obstructions that can block the fuel supply. operating correctly.
• Make sure that the fuel actuator is operating Replace the fuel filter, if necessary.
properly. Refer to Operation and Maintenance
Manual, SEBU7563, “Electrohydraulic Actuator Electrical Connectors or Power Supply
- Inspect”.
Check the wiring harnesses and the connectors.
• Inspect the gas shutoff valve according to Inspect the connectors in the terminal box. Inspect
Operation and Maintenance Manual, SEBU7563, the battery connections and the ground. Refer to
“Gas Shutoff Valve - Inspect”. Troubleshooting, “Inspecting Electrical Connectors”.
51
Inspect the wiring from the battery to the ECM. Recommended Repairs
Refer to the engine’s Electrical System Schematic.
Inspect the wires and the power relay. Check the Incorrect Engine Oil Level
power and ground connections to the ECM. Refer
to Troubleshooting, “Electrical Power Supply” for Overfilling the crankcase will increase the
more information. consumption of engine oil. Make sure that the
engine oil level is correct.
When the engine crankcase is full, engine oil will be
Make sure that the engine speed/timing sensor is initially consumed at a relatively rapid rate. The rate
installed correctly. Refer to Troubleshooting, “Engine of consumption is reduced as the engine oil level
Speed/Timing Sensor”. decreases. A crankcase that is always maintained at
the full level will have a faster rate of consumption.
Make sure that the timing wheel is correctly installed.
If the engine has a system for automatically filling
Ignition System the crankcase with engine oil, check the level for
the system. Adjust the system in order to provide
Inspect the ignition transformers for loose engine oil to a level that is less than the full level.
connections, moisture, short circuits, and open Make sure that the supply of engine oil is adequate.
circuits. Inspect the primary wiring and the
secondary electrical connections. Extended Operation with Low Loads
Make sure that the correct transformers and spark Extended operation at low idle or extended
plugs are installed. Inspect the extenders for signs operation at a reduced load will cause increased oil
or pin holes and arcing. consumption and carbon buildup in the cylinders.
This will occur if the engine is usually operated at a
Maintain the spark plug according to the engine’s torque that is significantly below the rated power.
Operation and Maintenance Manual.
The engine can be operated at a low load. However,
Excessive Load engine operation at a low load is limited. For
information on operation with a low load, refer to
Make sure that the load is not excessive. Reduce the engine’s Operation and Maintenance Manual,
the load. If necessary, disengage the driven “Engine Operation”.
External Leak
i01641523
Check for leakage at the seals at each end of
Excessive Engine Oil the crankshaft. Look for leakage at the gasket
for the engine oil pan and all lubrication system
Consumption connections. Look for any leaking from the
crankcase breather. This can be caused by
SMCS Code: 1300-038; 1901-038 combustion gas leakage around the pistons. A dirty
crankcase breather will cause high pressure in the
Probable Causes crankcase. A dirty crankcase breather will cause
the gaskets and the seals to leak.
• Incorrect engine oil level Measure the crankcase blowby according to the
engine’s Operation and Maintenance Manual,
• External leak “Crankcase Blowby - Measure/Record”.
• Internal leak
Internal Leak
• Worn components
There are several possible ways for engine oil to
• Extended operation at low loads leak into the combustion chambers:
• Excessive crankcase ventilation (bio-gas) • Leakage between worn valve guides and valve
stems
• Worn components or damaged components

(pistons, piston rings, or dirty passages for
engine oil)
52
• Incorrect installation of the compression ring • A check valve is stuck in the open position.
and/or the intermediate ring
• Incorrect adjustments of the needle valves
• Leakage past the seal rings in the turbocharger
• Deposits in the combustion chamber
• Overfilling of the crankcase
• Incorrect dipstick or guide tube
Recommended Repairs
Signs of internal leaks include high consumption of Misfire
engine oil, blue smoke, and excessive detonation.
Although the fuel does not ignite, fuel is still
If the pistons are suspected, check the cylinder supplied to a cold cylinder. The other cylinders
compression. Refer to the engine’s Operation must burn more fuel in order to maintain the
and Maintenance Manual, “Cylinder Pressure - load. This increases fuel consumption. Refer to
Measure/Record”. Troubleshooting, “Engine Misfires, Runs Rough or Is
Unstable”.
Worn Components
Air/Fuel Ratio
Excessively worn engine components and damaged
engine components can result from the following If the setting for the fuel’s LHV is too low, the air/fuel
conditions: ratio will be too rich. Obtain a gas analysis. Enter
the data into Caterpillar Software, LEKQ4196,
• Contaminated engine oil “Methane Number Program”. Use ET to program
the results for the ECM “Fuel Quality” and “Gas
• Incorrect fuel system settings Specific gravity” parameters. For more information,
refer to Systems operation/Testing and Adjusting,
• Contamination from the inlet air RENR5908, “Electronic Control System Parameters”.
Inspect the suspect system. Make the necessary If the quality of the gas is inconsistent, obtain
repairs. several analyses over a period of time. Program
the “Fuel Quality” parameter to the average value
of the LHV.
Check the Crankcase Ventilation
(Bio-Gas) Adjust the engine operation according to Systems
operation/Testing and Adjusting, RENR5908, “BTU
For engines that use bio-gas, the crankcase and Precombustion Chamber Adjustments”.
ventilation may be excessive. This will draw some
of the engine oil out of the atmosphere from the Fuel System Leaks
crankcase. Reduce the ventilation.
Always use a gas detector to determine the
i01641935 presence of gaseous fuel. If a leak is found,
contact your local provider of gas immediately for
Exhaust Emission Too assistance.
High/Fuel Consumption
Gas Admission Valve Lash
Too High
Adjust the gas admission valve lash according
SMCS Code: 1901-038 to Systems operation/Testing and Adjusting,
Probable Causes
Check Valve
• Misfire
The check valve may be stuck. The check valve
• Incorrect air/fuel ratio must move freely in order to prevent fuel from
continuously entering the precombustion chamber.
• Fuel system leaks Inspect the check valve. Clean the check valve with
a nonflammable solvent that will not leave residue.
• Improper gas admission valve lash Replace the check valve, if necessary.
53
Needle Valve Recommended Repairs

Check the needle valves for the precombustion Check for Suspect Thermocouples
chambers. If the needle valves are open too far, the
air/fuel mixture will be too rich. If the adjustment Observe the temperatures from the thermocouples
of the needle valves is suspect, fully close all of after the engine is shut off.
the needle valves. Open the needle valves for
four full turns. Adjust the needle valves according When the engine is operating properly, the
to Testing and Adjusting, RENR5908, “BTU and temperatures from similar locations are reduced at
Precombustion Chamber Adjustments”. a similar rate. Also, the temperatures from similar
locations are comparable.
If adjustment of a needle valve does not affect
operation, the needle valve may be faulty. Replace If any discrepancies are found, switch the suspect
the needle valve. thermocouple for another thermocouple. If the
temperature problem follows the thermocouple,
Deposits replace the thermocouple.
Deposits that are burned in the combustion If the temperature problem stays at the original
chamber will increase the exhaust emissions. An location of the suspect thermocouple, investigate
internal leak of engine oil or coolant can be burned the cause of the high temperature.
with the air and fuel.
Inspect the combustion chambers according to
Operation and Maintenance Manual, SEBU7563, Adjust the gas admission valve lash according
“Cylinders - Inspect”. Inspect the spark plug and to Systems operation/Testing and Adjusting,
the precombustion chamber for evidence of coolant RENR5908, “Engine Timing Procedures”.
and residue of liquid crystalline material. If the
gasket and/or the seals have leaked, clean the
sealing surfaces and install a new gasket and seals.
Air/Fuel Ratio
Also check for coolant leaks at the bottom of the
cylinder head. An air/fuel mixture that is too rich will increase the
exhaust temperature. A change in the fuel energy
Excessive consumption of engine oil may indicate content will change the air/fuel ratio.
an internal leak. Inspect the cylinder heads
If the setting for the fuel’s LHV is too low, the air/fuel
for evidence of leaking engine oil. Inspect
the turbocharger. Engine oil that leaks from a ratio will be too rich. Obtain a gas analysis. Enter
turbocharger can mix with the inlet air. the data into Caterpillar Software, LEKQ4196,
“Methane Number Program”. Use ET to program
the results for the ECM “Fuel Quality” and “Gas
i01641984 Specific gravity” parameters. For more information,
refer to Systems operation/Testing and Adjusting,
Exhaust Port Temperature RENR5908, “Electronic Control System Parameters”.
(High) If the quality of the gas is inconsistent, obtain
SMCS Code: 1901-038 several analyses over a period of time. Program
the “Fuel Quality” parameter to the average value
of the LHV.
Probable Causes
Adjust the engine operation according to Systems
• Problem with a thermocouple operation/Testing and Adjusting, RENR5908, “BTU
and Precombustion Chamber Adjustments”.
• Incorrect gas admission valve lash
Excessive Load
• Excessive load
• Exhaust restriction the load. If necessary, disengage the driven
• A buildup of deposits in the cylinder or internal
oil leaks
Measure the Exhaust Restriction
• Problem with exhaust valves
Measure the exhaust restriction during engine
• Missing retainer for a gas admission valve operation with a load. For data that is specific to the
engine, refer to the Technical Marketing Information.
54
Investigate the cause of the exhaust restriction. • Incorrect gas admission valve lash
Perform adjustments and/or make repairs, as
needed. • Low cylinder compression
Check for Deposits in the Cylinder and Recommended Repairs
Check for Internal Oil Leaks
Check for Misfire
Use a borescope to inspect the cylinders. Look for
the following conditions: Operation with a low load can result in low exhaust
temperatures. Operate the engine at low idle or
• Deposits on the valve seats near low idle in order to identify a misfire problem.
• Deposits on the valve faces Troubleshoot the cause of the misfire. Refer to
Troubleshooting, “Engine Misfires, Runs Rough or Is
• Deposits on the cylinder walls that are above the Unstable”.
upper limit of the piston stroke
Check for Suspect Thermocouples
• Signs of internal oil leaks
Observe the temperatures from the thermocouples
Other signs of internal oil leaks include high oil
after the engine is shut off.
consumption and blue smoke.
When the engine is operating properly, the
Note: Excessive deposits contribute to guttering of
temperatures from similar locations are reduced at
the valves.
a similar rate. Also, the temperatures from similar
locations are comparable.
If excessive deposits and/or signs of internal
oil leaks are found, investigate the cause of the
If any discrepancies are found, switch the suspect
condition. Make repairs, as needed. thermocouple for another thermocouple. If the
temperature problem follows the thermocouple,
Check the Exhaust Valves replace the thermocouple.
Measure the suspect cylinder pressure in order If the temperature problem stays at the original
to check for problems that are related to the location of the suspect thermocouple, investigate
exhaust valves. Refer to the Operation and the cause for the low temperature.
Maintenance Manual, SEBU7563, “Cylinder
Pressure - Measure/Record”.
Gas Admission Valve Adjust the gas admission valve lash according
to Systems operation/Testing and Adjusting,
If the retainer is missing from the gas admission RENR5908, “Engine Timing Procedures”.
valve’s support assembly, the air/fuel mixture will be
too rich. high exhaust temperatures will result. Make
sure that the retainer for the gas admission valve’s
Check the Cylinder Compression
support assembly is installed.
Measure the cylinder pressures of the suspect bank
in order to check for problems that are related to
i01642044 compression.
Exhaust Port Temperature If low compression is found, investigate the cause

of the low compression. Make repairs, as needed.
(Low)
SMCS Code: 1901-038
Probable Causes
• Misfire
• Problem with a thermocouple
55
i01642066 • Incorrect setting of the gas pressure regulator

Fuel Energy Content • Problem with a fuel system component
SMCS Code: 1901-038
Recommended Repairs
Probable Causes Air/Fuel Pressure Module
• The LHV of the gas or the specific gravity of the Use a separate device to measure the fuel pressure.
gas is significantly different from the value that is
Compare the measured fuel pressure to the fuel
programmed into the ECM.
pressure on the control panel’s display.
• Some type of condensation is forming in the gas. If the control panel’s display is questionable, switch
the air/fuel pressure module with a module that is
Recommended Repairs known to be good. Verify that the problem is solved.
Obtain a Gas Analysis and Program the Fuel Filter

“Fuel Quality” Parameter
Measure the fuel filter’s differential pressure
Obtain a gas analysis. Enter the data into Caterpillar according to Operation and Maintenance Manual,
Software, LEKQ4196, “Methane Number Program”. SEBU7563, “Fuel System Fuel Filter Differential
Use ET to program the results for the ECM “Fuel Pressure - Check”. Replace the filter element, if
Quality” and “Gas Specific gravity” parameters. For necessary.
more information, refer to Systems operation/Testing
and Adjusting, RENR5908, “Electronic Control Fuel System Leaks
System Parameters”.
Always use a gas detector to determine the
If the quality of the gas is inconsistent, obtain presence of gaseous fuel. If a leak is found,
several analyses over a period of time. Program contact your local provider of gas immediately for
the “Fuel Quality” parameter to the average value assistance.
of the LHV.
Adjust the Gas Pressure Regulator
Adjust the engine operation according to Systems
operation/Testing and Adjusting, RENR5908, “BTU Make sure that fuel is supplied at a sufficient
and Precombustion Chamber Adjustments”. pressure that is stable. For the correct pressures,
refer to Systems Operation, RENR5908, “Fuel
Check the Equipment that Treats the Gas System”.
Check the equipment that treats the gas before If the gas pressure regulator cannot be adjusted to
the gas is delivered to the engine. Any kind of the correct setting, repair the regulator or replace
condensation in the gas will change the fuel energy the regulator.
content. Make sure that the filter and the dryer
for the gas operate properly. Replace parts and Fuel System
repair the equipment, if necessary. Refer to the
service literature that is provided by the OEM of the Make sure that the size of the fuel supply line is
equipment. sufficient.
i01642146 Inspect the fuel system components: fuel supply

line, fuel filter, gas pressure regulator, gas shutoff
Fuel Pressure valve, and electrohydraulic actuator for the fuel.
SMCS Code: 1250-035 Observe the fuel pressure and strike the gas
pressure regulator with a soft hammer. If the fuel
pressure changes, inspect the internal parts of the
Probable Causes regulator for wear. Inspect the diaphragm for leaks.
Make sure that the valve moves freely. The valve
• Problem with the air/fuel pressure module must seat correctly.
• Plugged fuel filter Inspect the electrohydraulic actuator for the fuel
according to Operation and Maintenance Manual,
• Fuel system leaks SEBU7563, “Electrohydraulic Actuator - Inspect”.
56
i01642198 Recommended Repairs

Gas Temperature (High) High Ambient Air Temperature
SMCS Code: 1901-038
Determine if the ambient air temperature is within
the design specifications for the cooling system.
Probable Causes
Determine the cause of the high air temperature.
• Problem with the equipment that treats the gas Make corrections, when possible.
• Problem with the fuel temperature sensor Coolant Temperature

Recommended Repairs Refer to Troubleshooting, “Engine Coolant
Temperature (High)”.
Inspect the Equiment
Lean Operation
Check for proper operation of the equipment
that treats the gas prior to the engine. Repair If the air/fuel mixture is too lean, compression of the
the equipment, as needed. Refer to the service higher volume of air through the turbocharger will
information that is provided by the OEM of the increase the temperature. Correct the air/fuel ratio.
equipment.
Check for High Inlet Air Restriction
Check the Fuel Temperature Sensor and/or High Altitude
Allow the fuel temperature sensor to cool and When inlet air pressure is low, the turbocharger
remove the sensor. Check the reading for the sensor works harder in order to achieve the desired
on the control panel’s display. If the sensor is OK, inlet manifold pressure. This increases inlet air
the reading on the control panel’s display and the temperature.
ambient temperature will be approximately equal.
Measure the inlet air pressure while the engine is
If the reading is not correct, switch the suspect operating under load. For specific data, refer to the
sensor with a sensor that is known to be good. Technical Marketing Information for the engine.
Verify that the problem is solved.
Inlet Air Restriction
i01649761
Check for plugged air filters. Check for obstructions
Inlet Air Temperature (High) to the air inlet.
SMCS Code: 1901-038 Replace the air filters and/or remove the obstruction
from the air inlet.
Probable Causes High Altitude
• High ambient air temperature Make sure that the settings for the engine are
correct for the altitude.
• High temperature of the coolant for the separate
circuit
Check the Temperature Sensor and/or
• Lean operation the Circuit
• High inlet air restriction and/or high altitude Allow the sensor to cool and remove the sensor.
Check the reading for the inlet air temperature.
• Faulty inlet air temperature sensor and/or circuit If the sensor is OK, the reading and the ambient
temperature are approximately equal.
• Insufficient flow of cooling water through the
aftercooler If the reading is not correct, switch the sensor with
a sensor that is known to be good. Verify that the
problem is solved.
57
Check for Sufficient Flow of Cooling Electrical Connectors

Water Through the Aftercooler
1. Check the wiring harnesses and the connectors.
Check the inlet temperature of the coolant for the Inspect the connectors in the terminal box.
aftercooler. Compare the reading to the regulated Inspect the battery connections and the ground.
temperature. If the temperature is OK, check Refer to Troubleshooting, “Inspecting Electrical
the outlet temperature of the coolant. A high Connectors”.
temperature differential indicates an insufficient flow
rate. 2. Use the control panel’s display to check for
a diag168-02 System Voltage Intermittent
Make sure that the performance of the radiator or diagnostic code. If this diagnostic code is
the heat exchanger is correct. logged, proceed to Troubleshooting, “Electrical
Power Supply”.
If there is a high differential between the inlet
temperature and the outlet temperature of the 3. Inspect the wiring from the battery to the
coolant for the aftercooler, perform the following ECM. Refer to the engine’s electrical system
procedures: Schematic. Inspect the wires and the power
relay. Check the power and ground connections
• Check the water circuit of the aftercooler for to the ECM. Refer to Troubleshooting, “Electrical
obstructions. Power Supply”.
• Make sure that the water temperature regulators Circuit Breakers

are operating properly.
Check the circuit breaker in the terminal box. The
• Check the water pump for proper operation. circuit breaker may exceed the trip point due to
overheating. Reset the circuit breaker if the circuit
• Make repairs, if necessary. breaker is tripped.
i01642236
Fuel Supply
Intermittent Engine Shutdown Check the fuel lines for the following problems:
restrictions, obstructions, collapsed lines, and
SMCS Code: 1000-038; 1901-038 pinched lines. If problems are found with the fuel
lines, repair the lines and/or replace the lines.
Note: Use this procedure only if the engine shuts
down completely and the engine must be restarted. Check the fuel quality. Any type of condensation
in the fuel will affect the quality of the fuel. Obtain
a fuel analysis. Make sure that the equipment that
Probable Causes treats the fuel is operating correctly. Refer to the
service information that is provided by the OEM of
• Active engine shutdown the equipment.
• Electrical connectors Inspect the fuel filter. Replace the fuel filter, if
necessary.
• Circuit breaker
Check the fuel pressure. Refer to Systems
• Fuel supply Operation/Testing and Adjusting, RNEN5908, “Fuel
System” for the correct pressure values. If the
• Ignition transformer fuel pressure is still low, check the gas pressure
regulator.
Recommended Repairs
Make sure that the gas shutoff valve is operating
Active Engine Shutdown correctly. If the gas shutoff valve is suspect, refer to
Use the control panel’s display to check for any “Gas Shutoff Valve - Inspect”.
active engine shutdowns and/or logged engine
shutdowns. Determine the reason for the shutdown. Ignition Transformer
After correcting the problem, cycle the engine
control switch to the OFF/RESET position for at least Check the ignition transformer. Refer to
15 seconds before you try to restart the engine. Troubleshooting, “Ignition Transformers Primary
Circuit” and Troubleshooting, “Ignition Transformers
Secondary Circuit and Spark Plugs”.
58
i01649920 i01650080
Jacket Water Inlet Pressure Jacket Water Pressure (Low)

(High) SMCS Code: 1901-038
SMCS Code: 1901-038
Probable Causes
Probable Causes • Low coolant level
• There is a problem with the circuit for the pressure • Insufficient flow of coolant
switch at the jacket water pump’s inlet.
• The pressure at the jacket water pump’s inlet is Recommended Repairs

excessive.
Check the Coolant Level and Inspect the
Recommended Repairs Cooling System for Leaks
Check the Circuit of the Pressure Switch Check coolant level. If the coolant level is low,
inspect the cooling system for leaks.
for the Inlet of the Jacket Water Pump
If the coolant level is low, fill the cooling system. If
The contact for the switch’s terminals “A” and
leaks are found, make the necessary repairs.
“B” is normally open. The contact for the switch’s
terminals “B” and “C” is normally closed.
Check the Flow of Coolant
If the pressure at the inlet for the jacket water pump
rises to 462 ± 41 kPa (67 ± 6 psi), the contact for Use the ET to observe the pressure at the jacket
the switch’s terminals “A” and “B” is closed and water outlet with the engine OFF. Then observe the
the contact for terminals “B” and “C” is opened. An reading during engine operation.
diagE224 High Jacket Water Inlet Pressure event is
generated. If the reading is not reasonable or if the reading is
not within specifications, install a pressure gauge
If the contacts are abnormally shorted or opened, near the pressure sensor at the jacket water outlet.
the event code can be generated. Check the Compare the gauge reading with the reading from
connectors and the wiring for damage or corrosion. the ET.
Refer to Troubleshooting, “Inspecting Electrical
Connectors”. If the readings from the comparative gauge do not
agree approximately with the ET, troubleshoot the
If a problem with the connectors and/or the wiring is circuit for the pressure sensor at the jacket water
found, make repairs, as needed. Replace parts, if outlet. Refer to Troubleshooting, “PWM Sensor”.
necessary.
If the readings from the comparative gauge agree
approximately with the ET, check the following
Check the Inlet Pressure of the Jacket components:
Water Pump
• Check the water temperature regulators for
Use a gauge to check the pressure at the inlet for proper operation.
the jacket water pump.
• Check for plugging of the radiator or the heat
If the pressure is less than 462 ± 41 kPa (67 ± 6 psi) exchanger.
but the event code diagE224 High Jacket Water
Inlet Pressure is occurring, replace the pressure • Inspect the jacket water pump for damage to the
switch. impeller.
If a pressure of at least 462 ± 41 kPa (67 ± 6 psi) • Inspect the jacket water pump for cavitation.
is measured at the inlet for the jacket water, the
high pressure may be caused by excessive head Make the necessary repairs.
pressure. The high pressure could also be caused
by obstructions in the coolant passages after the
jacket water pump. Inspect the system. Make
repairs, as needed.
59
i01642777 i01642784
Jacket Water to Engine Oil Mechanical Noise (Knock) in

Differential Temperature (Low) Engine
SMCS Code: 1901-038 SMCS Code: 1000-038; 1901-038
Probable Causes Probable Causes

• High engine oil temperature or low engine coolant • Driven equipment
temperature
• Cylinder head and related components
• Faulty temperature sensor(s)
• Connecting rod bearing
• Faulty water temperature regulators
• Gear train
Recommended Repairs
• Crankshaft and related components
Check the Engine Oil Temperature and • Piston
the Engine Coolant Temperature
• Detonation
Observe the temperature of the engine oil and the
engine coolant on the control panel’s display.
Recommended Repairs
If the engine oil temperature is high, refer to
Troubleshooting, “Engine Oil Temperature (High)”. Driven Equipment
If the temperature of the engine coolant is low, refer Inspect the alignment and the balance of the driven
to Troubleshooting, “Engine Coolant Temperature equipment. Inspect the coupling. If necessary,
(Low)”. disconnect the driven equipment and test the
engine.
Check the Temperature Sensors
Cylinder Head and Related Components
Use a separate device to measure the temperatures
of the engine oil and the engine coolant. Compare Inspect the components of the valve train. Check for
the measured temperatures to the readings on the signs of damage and/or wear to the valves, valve
control panel’s display. bridges, valve lifters, cylinder head gasket, etc.
Inspect the condition of the camshafts. If a camshaft
If a reading is incorrect, switch the suspect sensor is replaced, new valve lifters must be installed.
with a sensor that is known to be good. Verify that
the problem is solved. Connecting Rod Bearing
Check the Water Temperature Regulators Inspect the connecting rod bearings and the
crankshaft’s bearing surfaces. Inspect the engine
The water temperature regulators should not oil filters for debris from the bearings. Install new
begin to open until jacket water reaches opening parts, if necessary.
temperature for the regulators. Allow the engine to
cool and then start the engine. Check the tube at Gear Train
the outlet for the jacket water. If the tube is warm
and normal operating temperature is not achieved Inspect the condition of the gear train.
yet, a regulator may be stuck open.
Inspect the engine oil filters for nonferrous material.
Check the water temperature regulators according Flaking of nonferrous material could indicate worn
to Systems Operation/Testing and Adjusting, gear train bearings.
RENR5908, “Cooling System”. Replace the water
temperature regulators, if necessary.
60
Crankshaft Insufficient Lubrication

Inspect the crankshaft and the related components. Inspect the valve train for sufficient lubrication. The
Inspect the main bearings and the bearing surfaces passages for the engine oil must be clean.
on the crankshaft. Make sure that the bearings are
in the correct position. Cylinder Head and Related Components
Look for worn thrust plates and wear on the Measure the cylinder compression. Refer to the
crankshaft. engine’s Operation and Maintenance Manual,
SEBU7563, “Cylinder Pressure - Measure/Record”.
Check the bolts of the counterweights. Refer to
Specifications, RENR5907, “Crankshaft”. Inspect the components of the valve train: valves,
valve springs, locks, and valve rotators.
Piston
Inspect the contact surfaces of the rocker arm and
Make sure that the piston pin is correctly installed. valve bridge.
The retaining rings must be secure.
Inspect the push rods.
Inspect the condition of the pistons according
to Guidelines for Reusable Parts and Salvage Check for free movement of the valves. If the valves
Operations. do not move freely, look for these conditions:
Detonation • A valve stem is bent.

Check the control panel’s display for the • The camshaft lifters are damaged or the lifters
occurrence of detonation. Refer to Troubleshooting, are worn.
“Detonation”.
• The camshaft is damaged or the camshaft is
worn.
i01642828
Noise Coming from Cylinder • A retaining bolt for a rocker shaft is loose or the
bolt is broken.
(Noisy Cylinder Head)
Replace components that are worn and/or
SMCS Code: 1000-038; 1290-038 damaged.
If a camshaft is replaced, new valve lifters must be

Probable Causes installed.
• Incorrect bridge and/or valve lash
Bolts for the Precombustion Chamber
• Insufficient lubrication Inspect the bolts for the precombustion chamber.
Make sure that the bolts are not loose or broken.
• Problem in the cylinder head and/or related Replace the bolts, if necessary.
components
• Problem with the bolts for the precombustion i01643577

chamber
Poor Coolant Flow
Recommended Repairs SMCS Code: 1000-038; 1901-038
Valve Bridge and Valve Lash
Probable Causes
Check the valve bridge and valve lash according
to Systems Operation/Testing and Adjusting, • Low coolant level
• Problem with the water pump
• Restriction through the aftercooler
61
• Insufficient flow of coolant Scale Buildup

• Buildup of scale in the cooling system Drain the cooling system. Clean the cooling system.
Fill the cooling system with new coolant. Maintain
the cooling system properly. For instructions, refer
Recommended Repairs to the engine’s Operation and Maintenance Manual,
SEBU7563, “Cooling System Coolant (DEAC) -
Check the Coolant Level and Inspect the Change”.
Cooling System for Leaks
i01368006
Check coolant level. If the coolant level is low,
inspect the cooling system for leaks. System Voltage
If the coolant level is low, fill the cooling system. If SMCS Code: 1901-038
leaks are found, make the necessary repairs.
Water Pump Probable Causes

Remove the water pump for inspection. Refer to There is a problem with the electrical system.
Disassembly and Assembly, SENR5535. Repair the
water pump, if necessary. Recommended Repairs
Aftercooler Troubleshoot the electrical system. Refer to
If the flow of coolant through the aftercooler is
restricted, clean the aftercooler core. i01643399
Check the Flow of Coolant Short Spark Plug Life

Use the ET to observe the pressure at the jacket SMCS Code: 1555-038
water outlet with the engine OFF. Then observe the
reading during engine operation. Probable Causes
If the reading is not reasonable or if the reading is • Faulty spark plug
not within specifications, install a pressure gauge
near the pressure sensor at the jacket water outlet. • Incorrect spark plug
Compare the gauge reading with the reading from
the ET. • Incorrect air/fuel ratio
If the readings from the comparative gauge do • Incorrect spark plug gap
not agree approximately with the ET, replace the
pressure sensor. • Excessive load
If the readings from the comparative gauge agree • Contamination of the air/fuel mixture
approximately with the ET, check the following
components:
Recommended Repairs
• Check the water temperature regulators for
proper operation. Faulty Spark Plug
• Check for plugging of the radiator or the heat Inspect the spark plug for wear. Look for evidence
exchanger. of combustion leaks above the gasket. Check the
insulator for cracks.
• Inspect the water pump for damage to the
impeller. If the spark plug is worn and/or damaged, install
a new spark plug.
Make the necessary repairs.
Incorrect Spark Plug
Install the spark plug that is listed in the engine’s
Parts Manual, “Ignition Gp - Gas Engine”.
62
Incorrect Air/Fuel Ratio Recommended Repairs

Adjust the engine according to Systems Static Load
Operation/Testing and Adjusting, RENR5908, “BTU
and Precombustion Chamber Adjustments”. Use a barring device in order to determine if the
crankshaft can be rotated. If necessary, disconnect
Incorrect Spark Plug Gap the driven equipment and test the engine.
Set the spark plug gap according to Specifications, Accessory Equipment

RENR5907, “Gas Engine Ignition”.
If the engine is driving accessory equipment such
Excessive Load as an air compressor, determine whether the
accessory equipment is preventing the crankshaft
Higher loads reduce the service life of spark plugs. from rotating.
Determine whether the engine has been operating
beyond the recommended rated load. Use a barring device in order to determine if the
crankshaft can be rotated. If necessary, disconnect
Contamination of the Air/Fuel Mixture the accessory equipment and test the engine.
Make sure that the equipment that treats the fuel Slow Starting Motor or Problem with the
prior to the engine is operating properly. Refer to Starting Motor
the service information that is provided by the OEM
of the equipment. Refer to Troubleshooting, “Air Starting Motor”.
Make sure that the air and the fuel are properly
filtered. There must be no leaks that allow
Internal Engine Problem
contamination to enter the systems.
Remove the spark plugs and inspect the cylinders
for fluid. If fluid is found in the cylinder, determine
If a turbocharger is leaking engine oil, the engine
oil can contaminate the inlet air. Inspect the the cause of the leak and make the necessary
turbocharger for leaks. repairs.
If the crankshaft will not rotate, the engine must be

i01643431 disassembled in order to check for these types of
internal problems:
Starting Motor Runs, Pinion
Engages But Does Not Turn • Contact of the valves and the pistons
the Flywheel • Piston seizure
SMCS Code: 1451-038; 1453-038 • Bearing seizure
Probable Causes • Damage to the crankshaft
• Static load i01643470
• Accessory equipment Too Much Vibration

• Slow starting motor SMCS Code: 1000-038; 1901-038
• Problem with the starting motor Probable Causes

• Internal engine problem • Misfire, rough operation, or instability
• Driven equipment
• Engine mounts or isolators
• Vibration damper
63
Recommended Repairs Excessive Load
Misfire or Rough Operation Make sure that the load is not excessive. Reduce
Refer to Troubleshooting, “Engine Misfires, Runs equipment and test the engine.
Rough or Is Unstable”.
Check for Event Codes for High Inlet
Driven Equipment Manifold Air Temperature
Inspect the mounting bolts for the driven equipment. Use the control panel’s display to check for the
Inspect the alignment and the balance of the driven following event codes:
equipment. Inspect the coupling. If necessary,
disconnect the driven equipment and test the • E026 (3) High Inlet Air Temperature (shutdown)
engine.
• E027 (1) High Inlet Air Temperature (warning)
Engine Mounts or Isolators
If one or more of the codes is active, refer to
Inspect the condition of the engine mounts. Look Troubleshooting, “Inlet Air Temperature (High)”.
for proper installation. Make sure that the bolts are
secure. Make sure that the isolators are in good Air/Fuel Ratio
condition.
An air/fuel mixture that is too rich will increase the
Vibration Damper exhaust temperature. A change in the fuel energy
content will change the air/fuel ratio. Obtain a fuel
Inspect the vibration damper for damage. Look for analysis.
evidence of overheating and leaks. Make sure that
the vibration damper is fastened securely. The fuel supply pressure must be adequate and
stable.
i01643487 Adjust the engine according to Systems

Operation/Testing and Adjusting, RENR5908, “BTU
Turbocharger Turbine and Precombustion Chamber Adjustments”.
Temperature (High)
Verify that the exhaust emissions are correct.
SMCS Code: 1052-038
Measure the Exhaust Restriction
Probable Causes Measure the exhaust restriction during engine
operation with a load. For data that is specific to the
• Low load engine, refer to the Technical Marketing Information.
• Excessive load Investigate the cause of the exhaust restriction.
Perform adjustments and/or make repairs, as
• High inlet manifold temperature needed.
Problem with a Valve
• Exhaust restriction
Make sure that the inlet valves, the exhaust valves,
• Problem with a valve and the gas admission valves are in good condition.
Check the cylinder compression. Refer to Operation
and Maintenance Manual, SEBU7563, “Cylinder
Recommended Repairs Pressure - Measure/Record”.
Low Load
At loads that are less than 50 percent, the inlet air
is controlled by the air choke actuator. If the air/fuel
mixture is too lean, compression of the higher
volume of air through the turbocharger will increase
the temperature. Correct the air/fuel ratio.
64
Troubleshooting with a Table 7

Failure Mode Identifiers
Diagnostic Code
FMI Description of Failure
00 “Data valid but above normal operating
i01313350
range”
Diagnostic Codes 01 “Data valid but below normal operating
range”
SMCS Code: 1901-038
02 “Data erratic, intermittent or incorrect”
Diagnostic codes alert the operator that a problem 03 “Voltage above normal or shorted high”
in the electronic system has been detected.
Diagnostic codes also indicate the nature of the 04 “Voltage below normal or shorted low”
problem to the service technician. Diagnostic codes 05 “Current below normal or open circuit”
may be viewed on a personal computer that has ET
software. Diagnostic codes consist of the module 06 “Current above normal or grounded
identifier (MID), the component identifier (CID), and circuit”
the failure mode identifier (FMI). 07 “Mechanical system not responding
properly”
Module Identifier (MID) – The MID is a code with
08 “Abnormal frequency, pulse, or period”
two or three digits that indicates the electronic
module which generated the diagnostic code. The 09 “Abnormal update”
MID for the ECM is 36. The MID for the Integrated
10 “Abnormal rate of change”
Temperature Sensing Module (ITSM) is 111. Some
electronic displays do not display the MID because 11 “Failure mode not identifiable”
the module which generates the code is obvious.
12 “Bad device or component”
Component Identifier (CID) – The CID is a number 13 “Out of calibration”
with three or four digits. The CID indicates the
component that generated the code. For example, 14 “Not used”
the CID number 0017 identifies the fuel shutoff 15 “Not used”
valve.
16 “Parameter not available”
Failure Mode Identifier (FMI) – The FMI is a two digit 17 “Module not responding”
code that indicates the type of failure. Table 7 is a
list of the failure mode identifiers that are adapted 18 “Sensor supply fault”
from the “SAE J1587” standard. 19 “Condition not met”
20 “Not used”
Note: Do not confuse diagnostic codes with

event codes. For information on event codes, see
Troubleshooting, “Troubleshooting with an Event
Code”.
Illustration 16 represents the operating range of an

oil temperature sensor. The diagram is a reference.
Do not use the diagram to troubleshoot the oil
temperature sensor.
65
This information is a valuable indicator for

troubleshooting intermittent problems. Any logged
diagnostic codes will automatically be deleted if no
additional occurrences are recorded in 100 hours.
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the
failure of the ECM. Diagnostic codes that are
logged repeatedly may indicate a problem that
needs special investigation.
Note: Always clear logged diagnostic codes after

investigating and correcting the problem which
generated the code.
i01684626
g00791619
MID 036 - CID 0017 - FMI 05
Illustration 16
Typical operating range of an oil temperature sensor
Fuel Shutoff Valve open circuit
(1) In these areas, the output voltage of the sensor is too high SMCS Code: 1901-038
or too low. The output is outside of the normal range. The
electronic problem will generate a diagnostic code.
(2) In this area, the oil temperature above 102 C (216 F) is higher Conditions Which Generate This Code:
than normal. The output voltage of the sensor will generate an
event code for a warning, a derating, or a shutdown for high oil • The ECM output to the fuel control relay is OFF.
temperature. The sensor does not have an electronic problem.
(3) This area represents the normal operating temperature for the
engine oil. The normal output voltage of the sensor is between • When no electrical load is provided, a resistor in
0.2 and 4.1 volts. the fuel shutoff valve rises to the +Battery side.
Note: This code cannot be detected by the ECM

Active Diagnostic Codes when the output for the fuel control relay is ON.
The output is normally ON when the engine control
An active diagnostic code represents a problem
switch is in the START position and the engine RPM
with the electronic control system. Correct the
is greater than zero.
problem as soon as possible.
System Response:
When an active diagnostic code is generated, the
“Active Alarm” indicator (“Engine Control Alarm
No fuel is provided to the engine. The alarm output
Status” on ET) is activated in order to alert the
is activated. The code is logged.
operator. If the condition that generated the code is
momentary, the message disappears from the list
Possible Performance Effect:
of active diagnostic codes. The diagnostic code
becomes logged.
The engine will not start due to the lack of fuel.
Logged Diagnostic Codes Troubleshooting:
When the ECM generates a diagnostic code the The most likely cause is one of the following
ECM logs the code in permanent memory. The conditions:
ECM has an internal diagnostic clock. The ECM will
record the following information when a code is • An open circuit in the harness or in the fuel
generated: control relay
• The hour of the first occurrence of the code • A short circuit to the +Battery in the harness or
in the fuel control relay
• The hour of the last occurrence of the code
Perform the following diagnostic procedure: “ECM
• The number of occurrences of the code Output Circuit (Fuel Control)”
66
Results: i01690934
• OK – STOP. MID 036 - CID 0017 - FMI 12

Fuel Shutoff Valve malfunction
i01684627
SMCS Code: 1901-038
MID 036 - CID 0017 - FMI 06
Conditions Which Generate This Code:
Fuel Shutoff Valve short to
ground The driver in the ECM for the gas shutoff valve is
OFF but the engine still runs.
SMCS Code: 1901-038
System Response:
The ECM will disable the ignition system and the
• The output for the fuel control relay is ON. gas shutoff valve in order to shut down the engine.
The shutdown output is activated. The code is
• The ECM detects excessive current on the output logged.
for the fuel control relay.
Note: This condition cannot be detected by the
ECM when the output for the fuel control relay is The engine is shut down.
OFF. The output is normally OFF when the engine
control switch is in the OFF/RESET position. Troubleshooting:
System Response: Perform the following diagnostic procedure: “ECM

Output Circuit (Fuel Control)”
The ECM will continue attempting to energize the
relay. The engine may shut down due to a lack of Results:
fuel. The alarm output is activated. The code is
logged. • OK – STOP.
Possible Performance Effect: i01631685
The engine will not start due to the lack of fuel. MID 036 - CID 0041 - FMI 03 8
Troubleshooting: Volt DC Supply short to +batt
The condition is probably caused by a short circuit SMCS Code: 1901-038
in the harness or by an internal short circuit in the
fuel control relay. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “ECM The voltage supply from the ECM to one of the
Output Circuit (Fuel Control)” following sensors has exceeded the normal range.
Results: • Detonation sensors
• OK – STOP. • Sensor for inlet manifold air pressure

• Sensor for engine coolant pressure
System Response:
Default values are assumed for the inputs to the

ECM from all of the 8 volt analog sensors. All of the
diagnostic codes for the 8 volt analog sensors to
the ECM are disabled while this code is active.
The fuel is shut off. The shutdown output is

activated. The code is logged.
67
Since the engine protection is disabled, the engine MID 036 - CID 0094 - FMI 03
is shut down. Fuel Pressure open/short to
Troubleshooting: +batt
Perform the following diagnostic procedure: “+8V SMCS Code: 1901-038
Sensor Voltage Supply”
Results:
The duty cycle is higher than the maximum limit and
• OK – STOP. the frequency is lower than the minimum limit for the
fuel side of the air/fuel pressure module.
i01631692 System Response:
MID 036 - CID 0041 - FMI 04 8 The shutdown output is activated. The code is
Volt DC Supply short to ground logged.
SMCS Code: 1901-038 Possible Performance Effect:
Conditions Which Generate This Code: Because the ECM is unable to calculate the fuel
flow, the engine is shut down.
The voltage supply from the ECM to one of the
following sensors is below the normal range. Troubleshooting:
• Detonation sensors Perform the following diagnostic procedure:

“Air/Fuel Pressure Module”
• Sensor for inlet manifold air pressure
Results:
• Sensor for engine coolant pressure
• OK – STOP.
System Response:
i01653957
Default values are assumed for the inputs to the
ECM from all of the 8 volt analog sensors. All of the
diagnostic codes for the 8 volt analog sensors to
MID 036 - CID 0094 - FMI 08
the ECM are disabled while this code is active. Fuel Pressure Noisy
The fuel is shut off. The shutdown output is SMCS Code: 1901-038
The duty cycle or the frequency for the fuel’s side
Since the engine protection is disabled,the engine of the air/fuel pressure module is higher than the
is shut down. maximum limit.
Troubleshooting: System Response:
Perform the following diagnostic procedure: “+8V The shutdown output is activated. The code is
Sensor Voltage Supply” logged.
Results: Possible Performance Effect:
• OK – STOP. Because the ECM is unable to calculate the fuel

flow, the engine is shut down.
Troubleshooting:
Perform the following diagnostic procedure:

68
Results: i01691095
• OK – STOP. MID 036 - CID 0100 - FMI 04

Engine Oil Pressure short to
i01631698 ground
MID 036 - CID 0100 - FMI SMCS Code: 1924-038
03 Engine Oil Pressure
open/short to +batt
The signal from the filtered oil pressure sensor to the
SMCS Code: 1924-038 ECM is less than 0.2 VDC for at least five seconds.
Conditions Which Generate This Code: Additionally, neither of the following diagnostic
codes are active:
The signal from the filtered oil pressure sensor to
the ECM is greater than 4.8 VDC for at least five
seconds.
• 262 - 03 5 Volt Sensor DC Power Supply short
to +batt
Additionally, neither of the following diagnostic
codes are active:
to ground
• 262 - 03 5 Volt Sensor DC Power Supply short System Response:
to +batt
The ECM assumes the last valid value for the engine
• 262 - 04 5 Volt Sensor DC Power Supply short oil pressure. The monitoring of the oil pressure is
to ground disabled. This disables the engine protection for
low oil pressure and excessive oil pressure.
System Response:
The ECM assumes the last valid value for the engine activated. The code is logged.
oil pressure. The monitoring of the oil pressure is
disabled. This disables the engine protection for Possible Performance Effect:
low oil pressure and excessive oil pressure.
Since the engine protection is disabled, the engine
The fuel is shut off. The shutdown output is is shut down.
Troubleshooting:
Perform the following diagnostic procedure: “Analog
Since the engine protection is disabled, the engine Sensor Signal”
is shut down.
Results:
Troubleshooting:
This condition indicates an open circuit or a short

• OK – STOP.
circuit to a positive voltage source.
i01630243
Sensor Signal” MID 036 - CID 0101 - FMI
Results:
03 Crankcase Pressure
open/short to +batt
• OK – STOP.
SMCS Code: 1916-038
The signal from the crankcase pressure sensor to

the ECM is greater than 4.5 VDC for at least five
seconds.
69
Additionally, neither of the following diagnostic System Response:

codes are active:
The ECM assumes the last valid value for the
• 262 - 03 5 Volt Sensor DC Power Supply short crankcase pressure. The monitoring of the
to +batt crankcase pressure is disabled. This disables the
engine protection for high crankcase pressure.
to ground The shutdown output is activated. The code is
logged.
System Response:
The ECM assumes the last valid value for the
crankcase pressure. The monitoring of the The engine is shut down.
crankcase pressure is disabled. This disables the
engine protection for high crankcase pressure. Troubleshooting:
The shutdown output is activated. The code is Perform the following diagnostic procedure: “Analog
logged. Sensor Signal”
Possible Performance Effect: Results:
The engine is shut down. • OK – STOP.

Troubleshooting:
i01626914
This condition indicates either an open circuit or a

short circuit to a positive voltage source.
MID 036 - CID 0106 - FMI 03 Air
Inlet Pressure Sensor short to
Sensor Signal”
+batt
SMCS Code: 1901-038
Results:
• OK – STOP.
The duty cycle for the inlet manifold air pressure is
i01630257 greater than the maximum possible value for more
than 2.67 ms during a 1.5 second interval.
MID 036 - CID 0101 - FMI 04
Crankcase Pressure short to Additionally, neither of the following diagnostic
codes are active:
ground
• 41 - 03 8 Volt DC Supply short to +batt
SMCS Code: 1916-038
• 41 - 04 8 Volt DC Supply short to ground
System Response:
The signal from the crankcase pressure sensor
to the ECM is less than 0.5 VDC for at least five The shutdown output is activated. The code is
seconds. logged.
Additionally, neither of the following diagnostic Possible Performance Effect:

codes are active:
The engine is shut down.
to +batt Troubleshooting:
• 262 - 04 5 Volt Sensor DC Power Supply short This condition indicates the possibility of an open
to ground circuit or a short circuit.

70
Results: System Response:
• OK – STOP. The alarm output is activated. The code is logged.

i01626920
MID 036 - CID 0106 - FMI 08 Air The engine performance is not affected.
Inlet Pressure Sensor noisy Troubleshooting:

signal The condition indicates a possible open circuit or
a short circuit.
SMCS Code: 1901-038
Perform the following diagnostic procedure: “PWM
Sensor”
The duty cycle or the frequency of the signal for the
Results:
inlet manifold air pressure is out of range.
System Response: • OK – STOP.
The shutdown output is activated. The code is i01691110

logged.
MID 036 - CID 0109 - FMI
08 Engine Coolant Outlet
The engine is shut down. Pressure Sensor noisy signal
Troubleshooting: SMCS Code: 1901-038
Perform the following diagnostic procedure: Conditions Which Generate This Code:
The duty cycle or the frequency of the signal from
Results: the pressure sensor for the outlet of the engine
coolant is out of range.
• OK – STOP.
codes are active:
i01631733
MID 036 - CID 0109 - FMI • 41 - 03 8 Volt DC Supply short to +batt

03 Coolant Outlet Pressure • 41 - 04 8 Volt DC Supply short to ground
open/short to +batt System Response:
SMCS Code: 1901-038
The alarm output is activated. The code is logged.
The duty cycle of the pressure sensor for the outlet
The engine performance is not affected.
of the engine coolant is greater than the maximum
limit.
Troubleshooting:
Perform the following diagnostic procedure: “PWM
codes are active:
Sensor”
• 41 - 03 8 Volt DC Supply short to +batt Results:
• OK – STOP.
71

MID 036 - CID 0110 - FMI 03 The ECM assumes the last valid value for the
Engine Coolant Temperature engine coolant temperature. The monitoring of the
coolant temperature is disabled. This disables the
open/short to +batt engine protection for low coolant temperature and
high coolant temperature.
SMCS Code: 1906-038
Conditions Which Generate This Code: activated. The code is logged.
The signal from the engine coolant temperature Possible Performance Effect:
sensor to the ECM is greater than 4.8 VDC for at
least five seconds. Since the engine protection is disabled, the engine
is shut down.
System Response:
Troubleshooting:
The ECM assumes the last valid value for engine
coolant temperature. The monitoring of the coolant Perform the following diagnostic procedure: “Analog
temperature is disabled. This disables the engine Sensor Signal”
protection for low coolant temperature and high
coolant temperature. Results:
The fuel is shut off. The shutdown output is • OK – STOP.
Since the engine protection is disabled, the engine

MID 036 - CID 0168 -
is shut down. FMI 02 System Voltage
Troubleshooting: intermittent/erratic
This condition indicates the possibility of an open SMCS Code: 1401-038
circuit or a short circuit.
Sensor Signal” The ECM has been powered for at least 5 seconds.
The engine is running. Either of the two following
Results: conditions occur:
• OK – STOP. • The battery voltage is less than 6 VDC for a

minimum of 0.060 seconds. The voltage returns
to the normal range within 0.015 seconds.
i01631755
• There are three voltage readings of less than 6
MID 036 - CID 0110 - FMI 04 VDC within 7 seconds.
Engine Coolant Temperature
System Response:
short to ground
SMCS Code: 1906-038
Note: If battery voltage is lost and the voltage does
Conditions Which Generate This Code: not return, the ECM will not log this diagnostic code.
The engine will shut down.
The signal from the engine coolant temperature
sensor to the ECM is less than 0.2 VDC for at least Possible Performance Effect:
five seconds.
The intermittent problem may not affect engine
operation. However, the engine may experience
speed burps, intermittent shutdowns, and/or
complete shutdowns.
72
Troubleshooting: i01631803
Perform the following diagnostic procedure: MID 036 - CID 0172 - FMI 04
“Electrial Power Supply” Intake Manifold Air Temp short
Results: to ground
• OK – STOP. SMCS Code: 1901-038

i01631799
The signal from the inlet manifold temperature
MID 036 - CID 0172 - FMI 03 sensor to the ECM is less than 0.2 VDC for at least
Intake Manifold Air Temp five seconds.
open/short to +batt Additionally, neither of the following diagnostic
codes are active:
SMCS Code: 1901-038

to +batt
The ECM has been powered for at least five
seconds. The signal from the inlet manifold
to ground
temperature sensor to the ECM is greater than 4.8
VDC for at least five seconds. Additionally, neither System Response:
of the following diagnostic codes are active:
The ECM assumes the last valid value for the inlet
• 262 - 03 5 Volt Sensor DC Power Supply short manifold air temperature. The monitoring of the
to +batt inlet manifold air temperature is disabled. This
disables the engine protection for high inlet manifold
• 262 -04 5 Volt Sensor DC Power Supply short to air temperature. The air/fuel ratio control cannot
ground compensate for the inlet air temperature.
System Response: The fuel is shut off. The shutdown output is
The ECM assumes the last valid value for the inlet
manifold air temperature. The monitoring of the Possible Performance Effect:
inlet manifold air temperature is disabled. This
disables the engine protection for high inlet manifold The engine is shut down.
air temperature. The air/fuel ratio control cannot
compensate for the inlet air temperature. Troubleshooting:
The fuel is shut off. The shutdown output is Perform the following diagnostic procedure: “Analog
activated. The code is logged. Sensor Signal”
• OK – STOP.
Troubleshooting:
The condition indicates a possible open circuit or a

short circuit to a positive voltage source.

Sensor Signal”
Results:
• OK – STOP.
73
i01630269 Additionally, neither of the following diagnostic

codes are active:
MID 036 - CID 0174 - FMI 03
Fuel Temperature open/short • 262 - 03 5 Volt Sensor DC Power Supply short
to +batt
to +batt
SMCS Code: 1901-038 to ground
Conditions Which Generate This Code: System Response:
The signal from the fuel temperature sensor to The ECM assumes the last valid value for the fuel
the ECM is greater than 4.5 VDC for at least five temperature. The monitoring of the inlet manifold air
seconds. temperature is disabled.
Additionally, neither of the following diagnostic The shutdown output is activated. The code is
codes are active: logged.
• 262 - 03 5 Volt Sensor DC Power Supply short Possible Performance Effect:

to +batt
to ground Troubleshooting:
System Response: Perform the following diagnostic procedure: “Analog
Sensor Signal”
The ECM assumes the last valid value for the fuel
temperature. The monitoring of the fuel temperature Results:
is disabled. This disables the engine protection for
high fuel temperature. • OK – STOP.
logged. i01685838

MID 036 - CID 0175 - FMI
03 Engine Oil Temperature
open/short to +batt
Troubleshooting:
SMCS Code: 1901-038
This condition indicates either an open circuit or a
short circuit to a positive voltage source. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Analog The signal from the engine oil temperature sensor
Sensor Signal” to the ECM is greater than 4.8 VDC for at least five
seconds.
Results:
codes are active:
• OK – STOP.
i01630437 to +batt
MID 036 - CID 0174 - FMI 04 • 262 - 04 5 Volt Sensor DC Power Supply short
Fuel Temperature short to to ground
ground
SMCS Code: 1901-038
The signal from the fuel temperature sensor to the

ECM is less than 0.5 VDC.
74
System Response: System Response:
The ECM assumes the last valid value for the The ECM assumes the last valid value for the
engine oil temperature. The monitoring of the engine engine oil temperature. The monitoring of the engine
oil temperature is disabled. Also, the monitoring oil temperature is disabled. Also, the monitoring
for high to engine oil to engine coolant differential for high engine oil to engine coolant differential
temperature is disabled. This disables the engine temperature is disabled. This disables the engine
protection for both parameters. protection for both parameters.
The shutdown output is activated. The code is The shutdown output is activated. The code is
logged. logged.
Possible Performance Effect: Possible Performance Effect:
Since engine protection is disabled, the engine is Since engine protection is disabled, the engine is
shut down. shut down.
Troubleshooting: Troubleshooting:
The condition indicates a possible open circuit or a Perform the following diagnostic procedure: “Analog
short circuit to a positive voltage source. Sensor Signal”
Perform the following diagnostic procedure: “Analog Results:

Sensor Signal”
• OK – STOP.
Results:
i01653982
• OK – STOP.
MID 036 - CID 0190 - FMI 02
i01685844 Loss of Engine Speed signal
MID 036 - CID 0175 - FMI 04 SMCS Code: 1912-038
Engine Oil Temperature short
to ground
The crankshaft is rotating faster than the cranking
SMCS Code: 1901-038
speed and the signal from the engine speed/timing
sensor is lost for at least one second.
System Response:
The signal from the engine oil temperature sensor
to the ECM is less than 0.2 VDC for at least five The shutdown output is activated. The code is
seconds.
logged.
Additionally, neither of the following diagnostic Possible Performance Effect:
codes are active:
If the engine is not running, the engine will not start.
• 262 - 03 5 Volt Sensor DC Power Supply short If the engine is running, the engine is shut down.
to +batt
Troubleshooting:
to ground
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor”
Results:
• OK – STOP.
75

MID 036 - CID 0190 - FMI 08 All of the inputs to the ECM for the 5 volt analog
Engine Speed signal abnormal sensors assume default values. All other diagnostic
codes for the 5 volt analog sensors are disabled
SMCS Code: 1912-038 while this diagnostic code is active. The “Status”
screen of ET indicates a “Sensor Supply Fault” for
Conditions Which Generate This Code: each sensor. This indicates that the sensors are not
operating due to an active diagnostic code.
The crankshaft is rotating faster than the cranking
speed. The signal from the engine speed/timing The shutdown indicator is activated. The code is
sensor is lost but the signal returns within one logged.
second.
System Response:
Since engine protection is disabled, the engine is
The shutdown output is activated. The code is shut down.
logged.
Troubleshooting:
Perform the following diagnostic procedure: “+5V
If the engine is not running, the engine will not start. Sensor Voltage Supply”
If the engine is running, the engine is shut down.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor” i01631863
Results: MID 036 - CID 0262 - FMI 04 5

• OK – STOP. Volt Sensor DC Power Supply
short to ground
i01631849
SMCS Code: 1408-038-NS
MID 036 - CID 0262 - FMI 03 5
Volt Sensor DC Power Supply
short to +batt The ECM supply voltage of the sensors for the
following parameters is less than the normal level:
SMCS Code: 1408-038-NS
• Inlet manifold air temperature
• Engine oil temperature
The ECM supply voltage of the sensors for the
following parameters is exceeding the normal level: • Filtered engine oil pressure
• Inlet manifold air temperature • Unfiltered engine oil pressure
• Engine oil temperature System Response:
• Filtered engine oil pressure All of the inputs to the ECM for the 5 volt analog
sensors assume default values. All other diagnostic
• Unfiltered engine oil pressure codes for the 5 volt analog sensors are disabled
while this diagnostic code is active. The “Status”
screen of ET indicates a “Sensor Supply Fault” for
each sensor. This indicates that the sensors are not
operating due to an active diagnostic code.

logged.
76
Since engine protection is disabled, the engine is MID 036 - CID 0301 - FMI
shut down. 06 Cylinder 1 - Transformer
Troubleshooting: Primary short
The condition indicates a possible short circuit to SMCS Code: 1901-038
ground or a short circuit between the sensor supply
and the return. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “+5V The path for the circuit driver of the transformer is
Sensor Voltage Supply” diagnosed with a short circuit.

i01685861
The cylinder will misfire.
MID 036 - CID 0301 - FMI
05 Cylinder 1 - Transformer Troubleshooting:
Primary open circuit One of the following conditions is the source of the
diagnostic code:
SMCS Code: 1901-038

• The wiring from the circuit driver for the
transformer to the coil has a short circuit.
The primary circuit of the transformer is diagnosed
with an open circuit.
• There is a short circuit within the transformer.
System Response:
• There is an internal failure of the ECM.
Perform the following diagnostic procedure: “Ignition
The alarm output is activated. The code is logged. Transformers Primary Circuit”
• OK – STOP.
Troubleshooting:
i01685867
One of the following conditions is the source of the
diagnostic code: MID 036 - CID 0302 - FMI
05 Cylinder 2 - Transformer
• A broken circuit driver’s wire for the transformer
Primary open circuit
• A broken return wire for the transformer
SMCS Code: 1901-038
• An open circuit within the primary winding of the
transformer Conditions Which Generate This Code:
• An internal failure of the ECM The primary circuit of the transformer is diagnosed
Transformers Primary Circuit” System Response:
Results: The alarm output is activated. The code is logged.
• OK – STOP.
77
The cylinder will misfire. • OK – STOP.

Troubleshooting:
i01685869

diagnostic code:
MID 036 - CID 0303 - FMI
• A broken circuit driver’s wire for the transformer Primary open circuit
• A broken return wire for the transformer SMCS Code: 1901-038
• An open circuit within the primary winding of the Conditions Which Generate This Code:
transformer
• An internal failure of the ECM with an open circuit.
Perform the following diagnostic procedure: “Ignition System Response:
Transformers Primary Circuit”
Results:
• OK – STOP.
i01631905
Troubleshooting:
MID 036 - CID 0302 - FMI
06 Cylinder 2 - Transformer diagnostic code:
Primary short
SMCS Code: 1901-038
The path for the circuit driver of the transformer is transformer
diagnosed with a short circuit.
• An internal failure of the ECM
System Response:
The alarm output is activated. The code is logged. Transformers Primary Circuit”
The cylinder will misfire. • OK – STOP.

Troubleshooting:
i01631910

diagnostic code:
MID 036 - CID 0303 - FMI
• The wiring from the circuit driver for the Primary short
SMCS Code: 1901-038
The path for the circuit driver of the transformer is
Perform the following diagnostic procedure: “Ignition diagnosed with a short circuit.
78
System Response: • An internal failure of the ECM

The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting:
i01631922
diagnostic code: MID 036 - CID 0304 - FMI
• The wiring from the circuit driver for the 06 Cylinder 4 - Transformer
Primary short
• There is a short circuit within the transformer. SMCS Code: 1901-038
• There is an internal failure of the ECM. Conditions Which Generate This Code:
Transformers Primary Circuit” diagnosed with a short circuit.
Results:
System Response:
i01685873 Possible Performance Effect:
MID 036 - CID 0304 - FMI The cylinder will misfire.

SMCS Code: 1901-038 diagnostic code:
Conditions Which Generate This Code: • The wiring from the circuit driver for the
with an open circuit. • There is a short circuit within the transformer.
System Response: • There is an internal failure of the ECM.
Results:
• OK – STOP.
Troubleshooting:

diagnostic code:

transformer
79

Results:
• OK – STOP.
Troubleshooting:
One of the following conditions is the source of the i01685878

diagnostic code:
MID 036 - CID 0306 - FMI
• A broken circuit driver’s wire for the transformer 05 Cyinder 6 - Transformer
• A broken return wire for the transformer Primary open circuit
SMCS Code: 1901-038
transformer
Perform the following diagnostic procedure: “Ignition with an open circuit.
System Response:
Results:
• OK – STOP. Possible Performance Effect:
i01631930 The cylinder will misfire.

MID 036 - CID 0305 - FMI Troubleshooting:
Primary short diagnostic code:
SMCS Code: 1901-038 • A broken circuit driver’s wire for the transformer
Conditions Which Generate This Code: • A broken return wire for the transformer
The path for the circuit driver of the transformer is • An open circuit within the primary winding of the
diagnosed with a short circuit. transformer
80

i01631936

Primary short One of the following conditions is the source of the
diagnostic code:
SMCS Code: 1901-038
Conditions Which Generate This Code: • A broken circuit driver’s wire for the transformer
The path for the circuit driver of the transformer is • A broken return wire for the transformer
System Response: transformer
The alarm output is activated. The code is logged. • An internal failure of the ECM
Results:
Troubleshooting:
• OK – STOP.
diagnostic code: i01631954
• The wiring from the circuit driver for the MID 036 - CID 0307 - FMI
transformer to the coil has a short circuit. 06 Cylinder 7 - Transformer
• There is a short circuit within the transformer. Primary short
• There is an internal failure of the ECM. SMCS Code: 1901-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Results: diagnosed with a short circuit.
• OK – STOP. System Response:

i01685883
MID 036 - CID 0307 - FMI Possible Performance Effect:
05 Cylinder 7 - Transformer The cylinder will misfire.

Primary open circuit Troubleshooting:
SMCS Code: 1901-038
diagnostic code:
The primary circuit of the transformer is diagnosed • The wiring from the circuit driver for the
81
• There is an internal failure of the ECM. i01631959
Perform the following diagnostic procedure: “Ignition MID 036 - CID 0308 - FMI
Transformers Primary Circuit” 06 Cylinder 8 - Transformer
Results: Primary short

i01685888
MID 036 - CID 0308 - FMI diagnosed with a short circuit.
System Response:
SMCS Code: 1901-038
with an open circuit. Troubleshooting:
System Response: One of the following conditions is the source of the
diagnostic code:

Troubleshooting:
One of the following conditions is the source of the Perform the following diagnostic procedure: “Ignition
diagnostic code: Transformers Primary Circuit”
• A broken circuit driver’s wire for the transformer Results:
• A broken return wire for the transformer • OK – STOP.
transformer i01685893
• An internal failure of the ECM MID 036 - CID 0309 - FMI

Transformers Primary Circuit” Primary open circuit
Results: SMCS Code: 1901-038
• OK – STOP. Conditions Which Generate This Code:

System Response:

82
Troubleshooting: Results:
One of the following conditions is the source of the • OK – STOP.

diagnostic code:
i01685896
MID 036 - CID 0310 - FMI 05
Cylinder 10 - Transformer
• An open circuit within the primary winding of the Primary open circuit
transformer
SMCS Code: 1901-038
Transformers Primary Circuit” The primary circuit of the transformer is diagnosed
Results:
System Response:
• OK – STOP.
i01631963
MID 036 - CID 0309 - FMI
Primary short Troubleshooting:
SMCS Code: 1901-038 One of the following conditions is the source of the
diagnostic code:
diagnosed with a short circuit. • A broken return wire for the transformer
System Response: • An open circuit within the primary winding of the
transformer
The cylinder will misfire. Transformers Primary Circuit”
One of the following conditions is the source of the • OK – STOP.

diagnostic code:
i01631967
transformer to the coil has a short circuit. MID 036 - CID 0310 - FMI 06
• There is a short circuit within the transformer. Cylinder 10 - Transformer
Primary short
SMCS Code: 1901-038
Transformers Primary Circuit” Conditions Which Generate This Code:

83

Results:
• OK – STOP.
Troubleshooting:
i01631973
diagnostic code: MID 036 - CID 0311 - FMI 06
• The wiring from the circuit driver for the Cylinder 11 - Transformer
Primary short
• There is a short circuit within the transformer. SMCS Code: 1901-038
• There is an internal failure of the ECM. Conditions Which Generate This Code:
Transformers Primary Circuit” diagnosed with a short circuit.
Results:
System Response:
MID 036 - CID 0311 - FMI 05 The cylinder will misfire.

Cylinder 11 - Transformer Troubleshooting:
Results:
• OK – STOP.
Troubleshooting:

diagnostic code:

transformer
84

Results:
• OK – STOP.
Troubleshooting:

diagnostic code:
MID 036 - CID 0313 - FMI 05
• A broken circuit driver’s wire for the transformer Cylinder 13 - Transformer
• A broken return wire for the transformer Primary open circuit
SMCS Code: 1901-038
transformer
Perform the following diagnostic procedure: “Ignition with an open circuit.
System Response:
Results:
i01631987 The cylinder will misfire.

MID 036 - CID 0312 - FMI 06 Troubleshooting:
Primary short diagnostic code:
SMCS Code: 1901-038 • A broken circuit driver’s wire for the transformer
Conditions Which Generate This Code: • A broken return wire for the transformer
The path for the circuit driver of the transformer is • An open circuit within the primary winding of the
diagnosed with a short circuit. transformer
System Response:

85
• An internal failure of the ECM i01685907
Perform the following diagnostic procedure: “Ignition MID 036 - CID 0314 - FMI 05
Transformers Primary Circuit” Cylinder 14 - Transformer
Results: Primary open circuit

i01631992
MID 036 - CID 0313 - FMI 06 with an open circuit.
System Response:
Primary short
SMCS Code: 1901-038
diagnosed with a short circuit. Troubleshooting:
System Response: One of the following conditions is the source of the
diagnostic code:


Troubleshooting:
transformer
diagnostic code:
• The wiring from the circuit driver for the Transformers Primary Circuit”
Results:
• OK – STOP.
Perform the following diagnostic procedure: “Ignition i01631998
MID 036 - CID 0314 - FMI 06
Results: Cylinder 14 - Transformer
• OK – STOP. Primary short
SMCS Code: 1901-038

System Response:

86
Possible Performance Effect: • An internal failure of the ECM

The cylinder will misfire. Perform the following diagnostic procedure: “Ignition
Troubleshooting:
Results:
diagnostic code: • OK – STOP.
• The wiring from the circuit driver for the i01632003
MID 036 - CID 0315 - FMI 06
• There is an internal failure of the ECM. Primary short
SMCS Code: 1901-038
Results:
• OK – STOP. diagnosed with a short circuit.
MID 036 - CID 0315 - FMI 05 The alarm output is activated. The code is logged.
Cylinder 15 - Transformer Possible Performance Effect:
SMCS Code: 1901-038
Troubleshooting:
The primary circuit of the transformer is diagnosed diagnostic code:
System Response: transformer to the coil has a short circuit.
The alarm output is activated. The code is logged. • There is a short circuit within the transformer.
Possible Performance Effect: • There is an internal failure of the ECM.
Troubleshooting:
Results:
diagnostic code: • OK – STOP.
transformer
87

Results:
• OK – STOP.
Troubleshooting:

diagnostic code:
MID 036 - CID 0323 - FMI 03
• A broken circuit driver’s wire for the transformer Shutdown Lamp short to +batt
• A broken return wire for the transformer SMCS Code: 1901-038
• An open circuit within the primary winding of the Conditions Which Generate This Code:
transformer
The ECM detects excessive current for the
• An internal failure of the ECM shutdown output.
Perform the following diagnostic procedure: “Ignition Note: This diagnostic condition cannot be detected
Transformers Primary Circuit” when the shutdown output is OFF.
• OK – STOP. The ECM limits the current for the shutdown output
to 0.3 amperes. The code is logged.
i01632016
MID 036 - CID 0316 - FMI 06 The engine operation is not affected.
Primary short Troubleshooting:
SMCS Code: 1901-038 Perform the following diagnostic procedure: “ECM

Status Indicator Output”
Results:
diagnosed with a short circuit. • OK – STOP.
System Response:

88
i01632139 Results:
MID 036 - CID 0324 - FMI 03 • OK – STOP.
Warning Lamp short to +batt
i01684629
SMCS Code: 1901-038
MID 036 - CID 0338 - FMI 05
Pre-Lube Relay open circuit
The ECM detects excessive current for the alarm
output. SMCS Code: 1319-038
Note: This diagnostic condition cannot be detected Conditions Which Generate This Code:
when the alarm output is OFF.
An open circuit or a short circuit to the +Battery
System Response: side is detected while the output from the ECM to
the prelube relay is OFF.
The ECM limits the current for the alarm output to
0.3 amperes. The code is logged. Note: This diagnostic condition can only be detected
by the ECM when the output for the prelube relay is
Possible Performance Effect: OFF. The output is normally OFF when the engine
control switch is in the STOP position and/or when
The engine operation is not affected. the prelube pressure switch is CLOSED.
Perform the following diagnostic procedure: “ECM An internal resistor rises to the +Battery side when
Status Indicator Output” no electrical load is present. This indicates an open
circuit in the harness or the solenoid. The alarm
Results: output is activated. The code is logged.

• OK – STOP.
The prelubrication will probably be disabled.
i01630459
Troubleshooting:
MID 036 - CID 0336 - FMI 02
Incorrect ECS Switch inputs Perform the following diagnostic procedure: “ECM
Output Circuit (Prelubrication Oil Pump)”
SMCS Code: 1901-038
Results:
• OK – STOP.
The ECM detects an invalid combination of these
inputs: switched +Battery, start, stop, and auto. This i01684630
indicates a problem with the engine control switch.
MID 036 - CID 0338 - FMI
System Response:
06 Pre-Lube Relay short to
The shutdown output is activated. The code is ground
logged.
SMCS Code: 1319-038
The ECM detects excessive current for the output
Troubleshooting: to the prelube relay. This indicates a possible short
circuit to the −Battery side.
“Electrical Power Supply”
89
Note: This diagnostic condition can only be detected Troubleshooting:

by the ECM when the output for the prelube relay
is ON. The output is normally ON when the engine Perform the following diagnostic procedure:
control switch is in the START position and the “Prelubrication System”
prelube pressure switch is still OPEN.
Results:
System Response:
• OK – STOP.
The ECM will continue to attempt to energize the
relay. The alarm output is activated. The code is
i01685945
logged.

MID 036 - CID 0401 - FMI
Secondary open circuit
Troubleshooting:
SMCS Code: 1901-038
Perform the following diagnostic procedure: “ECM Conditions Which Generate This Code:
Output Circuit (Prelubrication Oil Pump)”
The transformer’s secondary circuit is diagnosed
Results: with an open circuit.
i01632161 The status of the transformer’s secondary output is

set to 120 percent. The alarm output is activated
MID 036 - CID 0339 - FMI 05 and the code is logged.
Engine Pre-lube Pressure Possible Performance Effect:
Switch open circuit
SMCS Code: 1901-038
Troubleshooting:
The prelube pressure switch is OPEN. The oil problem:
pressure that is measured from the engine oil
pressure sensor is greater than 50 kPa (7.25 psi). • There is a problem with the transformer’s ground.
System Response: • The winding of the transformer’s secondary circuit
is open.
The ECM normally monitors the prelube pressure
switch. In this case, the engine oil pressure sensor • There is a problem with the connection to the
will be monitored. This determines if the prelube spark plug’s terminal post.
pump is supplying oil to the engine.
• The spark plug has internal damage or an open
If an “E233 (3) Low Engine Prelube Pressure” event circuit.
is active, the output to the starting motor will not be
energized and the engine will not start. • The spark plug gap is too wide.
The output to the prelube relay remains energized Transformers Secondary Circuit and Spark Plugs”
until the engine control switch is turned to the STOP
position. Results:
Possible Performance Effect: • OK – STOP.

90

MID 036 - CID 0401 - FMI The status of the transformer’s secondary output is
06 Cylinder 1 - Transformer set to 120 percent. The alarm output is activated
and the code is logged.
Secondary short to ground
SMCS Code: 1901-038
Troubleshooting:
with a short circuit. One of the following conditions is the source of the
problem:
System Response:
• There is a problem with the transformer’s ground.
The status of the transformer’s secondary output is
set to zero percent. The alarm output is activated • The winding of the transformer’s secondary circuit
and the code is logged. is open.
Possible Performance Effect: • There is a problem with the connection to the
spark plug’s terminal post.
Troubleshooting: circuit.
One of the following conditions is the source of the • The spark plug gap is too wide.
problem:
• The spark plug is fouled. Transformers Secondary Circuit and Spark Plugs”
• The spark plug gap is closed. Results:
• The winding of the transformer’s secondary circuit • OK – STOP.

is shorted.
Perform the following diagnostic procedure: “Ignition i01632192

Transformers Secondary Circuit and Spark Plugs”
MID 036 - CID 0402 - FMI
Results: 06 Cylinder 2 - Transformer
• OK – STOP. Secondary short to ground
SMCS Code: 1901-038
i01685951
MID 036 - CID 0402 - FMI
05 Cylinder 2 - Transformer The transformer’s secondary circuit is diagnosed
with a short circuit.
System Response:
SMCS Code: 1901-038
Conditions Which Generate This Code: set to zero percent. The alarm output is activated
with an open circuit. Possible Performance Effect:

91
Troubleshooting: • The spark plug gap is too wide.

problem: Transformers Secondary Circuit and Spark Plugs”
• The spark plug is fouled. Results:
• The spark plug gap is closed. • OK – STOP.

• The winding of the transformer’s secondary circuit i01632203
is shorted.

MID 036 - CID 0403 - FMI
Transformers Secondary Circuit and Spark Plugs” 06 Cylinder 3 - Transformer
Results:
SMCS Code: 1901-038
• OK – STOP.
i01685955
MID 036 - CID 0403 - FMI with a short circuit.
05 Cylinder 3 - Transformer System Response:
SMCS Code: 1901-038 set to zero percent. The alarm output is activated
with an open circuit. The cylinder will misfire.
System Response: Troubleshooting:
The status of the transformer’s secondary output is One of the following conditions is the source of the
set to 120 percent. The alarm output is activated problem:
• The spark plug is fouled.
• The spark plug gap is closed.
• The winding of the transformer’s secondary circuit
Troubleshooting: is shorted.
• There is a problem with the transformer’s ground. Results:

is open.
• There is a problem with the connection to the


circuit.
92
i01685958 i01632257
MID 036 - CID 0404 - FMI MID 036 - CID 0404 - FMI
05 Cylinder 4 - Transformer 06 Cylinder 4 - Transformer
Secondary open circuit Secondary short to ground
SMCS Code: 1901-038 SMCS Code: 1901-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The transformer’s secondary circuit is diagnosed The transformer’s secondary circuit is diagnosed
with an open circuit. with a short circuit.
The status of the transformer’s secondary output is The status of the transformer’s secondary output is
set to 120 percent. The alarm output is activated set to zero percent. The alarm output is activated
and the code is logged. and the code is logged.
The cylinder will misfire. The cylinder will misfire.
One of the following conditions is the source of the One of the following conditions is the source of the
problem: problem:
• There is a problem with the transformer’s ground. • The spark plug is fouled.
• The winding of the transformer’s secondary circuit • The spark plug gap is closed.
is open.
• There is a problem with the connection to the is shorted.
• The spark plug has internal damage or an open Transformers Secondary Circuit and Spark Plugs”
circuit.
Results:
• The spark plug gap is too wide.
• OK – STOP.
i01685960
Results: MID 036 - CID 0405 - FMI

• OK – STOP. 05 Cylinder 5 - Transformer
SMCS Code: 1901-038

93
Generation of the diagnostic code does not affect
engine performance. However, the engine will • The winding of the transformer’s secondary circuit
probably misfire. This will cause the engine to run is shorted.
rough. The engine may shut down.
Troubleshooting: Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the Results:

problem:
• OK – STOP.
i01685964
is open. MID 036 - CID 0406 - FMI
• There is a problem with the connection to the 05 Cylinder 6 - Transformer
spark plug’s terminal post. Secondary open circuit
• The spark plug has internal damage or an open SMCS Code: 1901-038
circuit.
System Response:
Results:
• OK – STOP. set to 120 percent. The alarm output is activated
i01632261
MID 036 - CID 0405 - FMI
06 Cylinder 5 - Transformer The cylinder will misfire.
Secondary short to ground Troubleshooting:
SMCS Code: 1901-038 One of the following conditions is the source of the
problem:
with a short circuit. • The winding of the transformer’s secondary circuit
is open.
System Response:
The status of the transformer’s secondary output is spark plug’s terminal post.
set to zero percent. The alarm output is activated
and the code is logged. • The spark plug has internal damage or an open
circuit.

94
• The spark plug gap is too wide. i01685988
Perform the following diagnostic procedure: “Ignition MID 036 - CID 0407 - FMI
Transformers Secondary Circuit and Spark Plugs” 05 Cylinder 7 - Transformer
Results: Secondary open circuit

i01632269
MID 036 - CID 0406 - FMI with an open circuit.
System Response:
SMCS Code: 1901-038 set to 120 percent. The alarm output is activated
with a short circuit. The cylinder will misfire.
set to zero percent. The alarm output is activated problem:


is open.
Troubleshooting:
problem:
circuit.
• The winding of the transformer’s secondary circuit Transformers Secondary Circuit and Spark Plugs”
is shorted.
Results:
• OK – STOP.
Results:
• OK – STOP.
95

SMCS Code: 1901-038 problem:
Conditions Which Generate This Code: • There is a problem with the transformer’s ground.
The transformer’s secondary circuit is diagnosed • The winding of the transformer’s secondary circuit
with a short circuit. is open.
System Response: • There is a problem with the connection to the
set to zero percent. The alarm output is activated • The spark plug has internal damage or an open
and the code is logged. circuit.
Possible Performance Effect: • The spark plug gap is too wide.
Troubleshooting:
Results:
problem: • OK – STOP.
i01632318
• The spark plug gap is closed. MID 036 - CID 0408 - FMI
• The winding of the transformer’s secondary circuit 06 Cylinder 8 - Transformer
is shorted.
Transformers Secondary Circuit and Spark Plugs” SMCS Code: 1901-038
Results: Conditions Which Generate This Code:

• OK – STOP. with a short circuit.

MID 036 - CID 0408 - FMI The status of the transformer’s secondary output is
05 Cylinder 8 - Transformer set to zero percent. The alarm output is activated
SMCS Code: 1901-038
Troubleshooting:
with an open circuit. One of the following conditions is the source of the
problem:
System Response:
set to 120 percent. The alarm output is activated • The spark plug gap is closed.
96

is shorted.
MID 036 - CID 0409 - FMI
Results:
SMCS Code: 1901-038
• OK – STOP.
i01686000 The transformer’s secondary circuit is diagnosed
MID 036 - CID 0409 - FMI
05 Cylinder 9 - Transformer System Response:
Secondary open circuit The status of the transformer’s secondary output is
SMCS Code: 1901-038 and the code is logged.
Conditions Which Generate This Code: Possible Performance Effect:
The transformer’s secondary circuit is diagnosed The cylinder will misfire.
Troubleshooting:
System Response:
The status of the transformer’s secondary output is problem:
is shorted.
Troubleshooting:
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
problem:
Results:
• OK – STOP.
is open.
i01686011
spark plug’s terminal post. MID 036 - CID 0410 - FMI 05
circuit. Secondary open circuit
• The spark plug gap is too wide. SMCS Code: 1901-038
• OK – STOP.
97

is open.
i01686017
• The spark plug has internal damage or an open Cylinder 11 - Transformer
Results:

SMCS Code: 1901-038
Troubleshooting:
The transformer’s secondary circuit is diagnosed problem:
System Response:
The status of the transformer’s secondary output is is open.
and the code is logged. • There is a problem with the connection to the
The cylinder will misfire. circuit.
98
Transformers Secondary Circuit and Spark Plugs” Cylinder 12 - Transformer
Results: Secondary open circuit

i01632349
MID 036 - CID 0411 - FMI 06 with an open circuit.
System Response:
SMCS Code: 1901-038 set to 120 percent. The alarm output is activated
with a short circuit. The cylinder will misfire.
set to zero percent. The alarm output is activated problem:


is open.
Troubleshooting:
problem:
circuit.
• The winding of the transformer’s secondary circuit Transformers Secondary Circuit and Spark Plugs”
is shorted.
Results:
• OK – STOP.
Results:
• OK – STOP.
99

SMCS Code: 1901-038 problem:
Conditions Which Generate This Code: • There is a problem with the transformer’s ground.
The transformer’s secondary circuit is diagnosed • The winding of the transformer’s secondary circuit
with a short circuit. is open.
System Response: • There is a problem with the connection to the
set to zero percent. The alarm output is activated • The spark plug has internal damage or an open
and the code is logged. circuit.
Possible Performance Effect: • The spark plug gap is too wide.
Troubleshooting:
Results:
problem: • OK – STOP.
i01632384
• The spark plug gap is closed. MID 036 - CID 0413 - FMI 06
• The winding of the transformer’s secondary circuit Cylinder 13 - Transformer
is shorted.
Transformers Secondary Circuit and Spark Plugs” SMCS Code: 1901-038

• OK – STOP. with a short circuit.

MID 036 - CID 0413 - FMI 05 The status of the transformer’s secondary output is
Cylinder 13 - Transformer set to zero percent. The alarm output is activated
SMCS Code: 1901-038
Troubleshooting:
with an open circuit. One of the following conditions is the source of the
problem:
System Response:
set to 120 percent. The alarm output is activated • The spark plug gap is closed.
100

is shorted.
MID 036 - CID 0414 - FMI 06
Results:
SMCS Code: 1901-038
• OK – STOP.
i01686036 The transformer’s secondary circuit is diagnosed
MID 036 - CID 0414 - FMI 05
Cylinder 14 - Transformer System Response:
Secondary open circuit The status of the transformer’s secondary output is
SMCS Code: 1901-038 and the code is logged.
Conditions Which Generate This Code: Possible Performance Effect:
The transformer’s secondary circuit is diagnosed The cylinder will misfire.
Troubleshooting:
System Response:
The status of the transformer’s secondary output is problem:
is shorted.
Troubleshooting:
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
problem:
Results:
• OK – STOP.
is open.
i01686039
• OK – STOP.
101

is open.
i01686042
• The spark plug has internal damage or an open Cylinder 16 - Transformer
Results:

SMCS Code: 1901-038
Troubleshooting:
The transformer’s secondary circuit is diagnosed problem:
System Response:
The status of the transformer’s secondary output is is open.
and the code is logged. • There is a problem with the connection to the
The cylinder will misfire. circuit.
102
Transformers Secondary Circuit and Spark Plugs” Crank Terminate Relay short
Results: to +batt

i01632407
The ECM detects excessive current for the crank
MID 036 - CID 0416 - FMI 06 terminate relay.
Note: This diagnostic condition cannot be detected
Secondary short to ground when the output for the crank terminate relay is
OFF. The output is normally OFF when the engine
SMCS Code: 1901-038 control switch is in the STOP position.
The transformer’s secondary circuit is diagnosed The ECM will limit the current for the crank terminate
with a short circuit. relay to 0.3 amperes. The alarm output is activated.
The code is logged.
System Response:
Troubleshooting:
set to zero percent. The alarm output is activated Perform the following diagnostic procedure: “ECM
and the code is logged. Status Indicator Output”
• OK – STOP.
Troubleshooting:
i01684631
problem: MID 036 - CID 0444 - FMI 05
Start Relay open circuit
SMCS Code: 1426-038
is shorted. The output from the ECM for the starting motor
relay is OFF. An open circuit or a short circuit to
Perform the following diagnostic procedure: “Ignition the +Battery is detected.
Note: This diagnostic condition can only be detected
Results: by the ECM when the output for the starting motor
relay is OFF. The output is normally OFF when the
• OK – STOP. engine control switch is in the STOP position or
when the crank terminate relay is energized.
System Response:
An internal resistor rises to the +Battery side when

no electrical load is present. The alarm output is
103
The engine will be unable to crank. MID 036 - CID 0445 - FMI 03
Troubleshooting:
Run Relay short to +batt
SMCS Code: 1901-038
The harness or the relay probably has an open
circuit. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “ECM The ECM detects excessive current for the run relay.
Output Circuit (Starting Motor)”
Note: This diagnostic condition cannot be detected
Results: when the output for the “Run” relay is OFF. The
output is normally OFF when the engine control
• OK – STOP. switch is in the STOP position.
i01684632
System Response:
MID 036 - CID 0444 - FMI 06 The ECM will limit the current to 0.3 amperes. The
“Status” screen of the ET will display “Relay Fault”.
Start Relay short to ground The code is logged.
SMCS Code: 1426-038 Troubleshooting:
Conditions Which Generate This Code: Perform the following diagnostic procedure: “ECM
Status Indicator Output”
The ECM detects excessive current for the output
of the starting motor relay. Results:
Note: This diagnostic condition can only be
detected by the ECM when the output for the
• OK – STOP.
starting motor relay is ON. The output is normally
ON when the engine control switch is turned from i01632442
the STOP position to the START position. The output
is ON until the crank terminate relay is energized. MID 036 - CID 0524 - FMI 03
System Response:
Desired Engine Speed Sensor
short to +batt
The ECM will continue to attempt to energize the
relay. The alarm output is activated. The code is SMCS Code: 1907-038
logged.
The ECM has been powered up for at least five
The engine will probably be unable to crank. seconds. The current to the ECM for the desired
speed input is greater than 22 mA for more than
Troubleshooting: five seconds.
This condition indicates an short circuit in the System Response:

harness or the relay.
When the “Idle/Rated” switch is in the “Rated”
Perform the following diagnostic procedure: “ECM position, the ECM assumes a default value for the
Output Circuit (Starting Motor)” desired engine speed.
Results: The alarm output is activated. The code is logged.
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 ET.
104
The diagnostic code is generated by one of the • OK – STOP.

following conditions:
i01630021
• A short circuit to the +Battery side
MID 036 - CID 0525 - FMI 05
• A short circuit to ground
Choke Actuator open circuit
“Desired Speed Input (4 - 20 mA)” SMCS Code: 1901-038
• OK – STOP. The circuit driver for the electrohydraulic actuator’s

solenoid is energized. The ECM detects no current
from the actuator or a current that is less than the
i01632502 normal level. This is caused by one of the following
MID 036 - CID 0524 - FMI 04 conditions:
Desired Engine Speed Sensor • There is an open circuit in either the high side or
the low side.
short to ground
SMCS Code: 1907-038 • The low side is shorted to ground.
System Response:
The ECM has been powered up for at least five
logged.
seconds. The current to the ECM for the desired
speed input is less than 2 mA for more than five Possible Performance Effect:
seconds.
System Response:
Troubleshooting:
When the “Idle/Rated” switch is in the “Rated”
position, the ECM assumes a default value for the Perform the following diagnostic procedure: “Choke
desired engine speed.
Actuator Solenoid”
The alarm output is activated. The code is logged. Results:
• OK – STOP.
The default value for the desired engine speed is
equal to the “Minimum Engine High Idle Speed” i01630025
that is programmed on the “Service/Configuration”
screen of ET. MID 036 - CID 0525 - FMI
Troubleshooting:
06 Choke Actuator short to
ground
The diagnostic code is generated by one of the
following conditions: SMCS Code: 1901-038
• An open circuit or a short circuit to ground Conditions Which Generate This Code:
• An open circuit or a short circuit to the +Battery The circuit driver for the electrohydraulic actuator’s
solenoid is energized. The ECM detects a current
Perform the following diagnostic procedure: from the actuator that is greater than the normal
“Desired Speed Input (4 - 20 mA)” level. This is caused by one of the following
conditions:
105
• There is a short circuit between the high side and i01630034

the low side.
MID 036 - CID 0526 - FMI 06
• The high side is shorted to ground. Wastegate Valve short
• The high side is shorted to the +Battery side. SMCS Code: 1057-038
System Response: Conditions Which Generate This Code:
The shutdown output is activated. The code is The circuit driver for the electrohydraulic actuator’s
logged. solenoid is energized. The ECM detects a current
from the actuator that is greater than the normal
Possible Performance Effect: level. This is caused by one of the following
conditions:
• There is a short circuit between the high side and
Troubleshooting: the low side.
Perform the following diagnostic procedure: “Choke • The high side is shorted to ground.
Actuator Solenoid”
• The high side is shorted to the +Battery side.
Results:
System Response:
• OK – STOP.
i01630031
logged.
MID 036 - CID 0526 - FMI 05 Possible Performance Effect:

Wastegate Valve open The engine is shut down.
Conditions Which Generate This Code: Perform the following diagnostic procedure:
“Wastegate Actuator Solenoid”
The circuit driver for the electrohydraulic actuator’s
solenoid is energized. The ECM detects no current Results:
from the actuator or a current that is less than the
normal level. This is caused by one of the following
conditions:
• OK – STOP.
• There is an open circuit in either the high side or i01632507

the low side.
MID 036 - CID 0542 - FMI 03
• The low side is shorted to ground. Unfiltered Engine Oil Pressure
System Response: open/short to +batt
The shutdown output is activated. The code is SMCS Code: 1924-038
logged.
The signal to the ECM from the sensor for unfiltered
The engine is shut down. engine oil pressure is greater than 4.8 VDC for at
least five seconds. Also, neither of the following
Troubleshooting: diagnostic codes are active:
Perform the following diagnostic procedure: • 262 - 03 5 Volt Sensor DC Power Supply short
“Wastegate Actuator Solenoid” to +batt
Results: • 262 - 04 5 Volt Sensor DC Power Supply short

to ground
• OK – STOP.
106
System Response: i01630082
The ECM assumes the last valid value for unfiltered MID 036 - CID 1040 - FMI 09
engine oil pressure. Monitoring for restriction of the
oil filters is disabled.
ICSM #1 not communicating
on link
SMCS Code: 1901-038
Engine operation is not affected.
Troubleshooting: seconds and the ECM did not receive ten
consecutive messages from the right side ICSM.
Sensor Signal” System Response:
Results: The shutdown output is activated. The code is

logged.
• OK – STOP.
i01632510 The engine is shut down.
MID 036 - CID 0542 - FMI 04 Troubleshooting:
Unfiltered Engine Oil Pressure
short to ground “Integrated Combustion Sensing Module (ICSM)”
SMCS Code: 1924-038 Results:
• OK – STOP.
The signal to the ECM from the sensor for unfiltered
engine oil pressure is less than 0.2 VDC for at i01630094
least five seconds. Also, neither of the following
diagnostic codes are active: MID 036 - CID 1041 - FMI 09
ICSM #2 not communicating
to +batt on link
• 262 - 04 5 Volt Sensor DC Power Supply short SMCS Code: 1901-038
to ground
System Response:
The ECM assumes the last valid value for unfiltered seconds and the ECM did not receive ten
engine oil pressure. Monitoring for restriction of the consecutive messages from the left side ICSM.
oil filters is disabled.
System Response:
Troubleshooting: logged.
Perform the following diagnostic procedure: “Analog Possible Performance Effect:

Sensor Signal”
Results:
Troubleshooting:
• OK – STOP.
“Integrated Combustion Sensing Module (ICSM)”
107
Results: • 0041 - 03 8 Volt DC Supply short to +batt

• OK – STOP. • 0041 - 04 8 Volt DC Supply short to ground
System Response:
i01686707
MID 036 - CID 1501 - FMI 03 The shutdown output is activated. The code is
logged.
Cylinder #1 Detonation Sensor
open/short to +batt
SMCS Code: 1901-038
Troubleshooting:
The run relay and the crank terminate relay are Perform the following diagnostic procedure:
“Detonation Sensors”
energized. The input of a signal from a detonation
sensor to the ECM is greater than 4.8 VDC for ten
seconds. Results:
Neither of the following diagnostic codes are active: • OK – STOP.
• 0041 - 03 8 Volt DC Supply short to +batt i01686767
• 0041 - 04 8 Volt DC Supply short to ground MID 036 - CID 1502 - FMI 03
System Response:
open/short to +batt
logged. SMCS Code: 1901-038
Possible Performance Effect: Conditions Which Generate This Code:
The engine is shut down. The run relay and the crank terminate relay are
energized. The input of a signal from a detonation
Troubleshooting: sensor to the ECM is greater than 4.8 VDC for ten
seconds.
“Detonation Sensors” Neither of the following diagnostic codes are active:
Results: • 0041 - 03 8 Volt DC Supply short to +batt

• OK – STOP. • 0041 - 04 8 Volt DC Supply short to ground
System Response:
i01686711
logged.
short to ground
SMCS Code: 1901-038
Conditions Which Generate This Code: Troubleshooting:

The run relay and the crank terminate relay
are energized. The input of the signal from the “Detonation Sensors”
detonation sensor to the ECM is less than 1.0 VDC
Results:
for ten seconds.

108

Cylinder #2 Detonation Sensor logged.
short to ground Possible Performance Effect:
SMCS Code: 1901-038 The engine is shut down.
The run relay and the crank terminate relay Perform the following diagnostic procedure:
for ten seconds. Results:
i01686825
System Response: Cylinder #5 Detonation Sensor
The shutdown output is activated. The code is short to ground
logged.
SMCS Code: 1901-038
Troubleshooting: are energized. The input of the signal from the
Perform the following diagnostic procedure: for ten seconds.
Neither of the following diagnostic codes are active:
Results:
• OK – STOP.
open/short to +batt Possible Performance Effect:
energized. The input of a signal from a detonation “Detonation Sensors”
seconds. Results:
109

open/short to +batt Possible Performance Effect:
seconds. Results:
i01687499
System Response: Cylinder #9 Detonation Sensor
The shutdown output is activated. The code is open/short to +batt
logged.
SMCS Code: 1901-038
The run relay and the crank terminate relay are
Troubleshooting: energized. The input of a signal from a detonation
Perform the following diagnostic procedure: seconds.
Results:
• OK – STOP.
110

i01687505
• 0041 - 04 8 Volt DC Supply short to ground MID 036 - CID 1510 - FMI
System Response: 04 Cylinder #10 Detonation
The shutdown output is activated. The code is Sensor short to ground
logged.
SMCS Code: 1901-038
Troubleshooting: are energized. The input of the signal from the
Perform the following diagnostic procedure: for ten seconds.
Results:
• OK – STOP.
MID 036 - CID 1510 - FMI The shutdown output is activated. The code is
03 Cylinder #10 Detonation logged.
Sensor open/short to +batt Possible Performance Effect:
seconds. Results:
111

Sensor open/short to +batt Possible Performance Effect:
seconds. Results:
i01687510
• 0041 - 04 8 Volt DC Supply short to ground MID 036 - CID 1514 - FMI
System Response: 03 Cylinder #14 Detonation
The shutdown output is activated. The code is Sensor open/short to +batt
logged.
SMCS Code: 1901-038
The run relay and the crank terminate relay are
Troubleshooting: energized. The input of a signal from a detonation
Perform the following diagnostic procedure: seconds.
Results:
• OK – STOP.
Sensor short to ground Possible Performance Effect:
112

Sensor short to ground Possible Performance Effect:
The run relay and the crank terminate relay Perform the following diagnostic procedure: “Fuel
are energized. The input of the signal from the Actuator Solenoid”
i01630000
System Response: Fuel Actuator short to ground
The shutdown output is activated. The code is SMCS Code: 1901-038
logged.
The circuit driver for the electrohydraulic actuator’s
The engine is shut down. solenoid is energized. The ECM detects a current
from the actuator that is greater than the normal
Troubleshooting: level. This is caused by one of the following
conditions:
“Detonation Sensors” • There is a short circuit between the high side and
the low side.
Results:
• The high side is shorted to ground.
• OK – STOP.
• The high side is shorted to the +Battery side.
i01629899
System Response:
Fuel Actuator open circuit logged.
SMCS Code: 1901-038 Possible Performance Effect:
Conditions Which Generate This Code: The engine is shut down.
The circuit driver for the electrohydraulic actuator’s Troubleshooting:
solenoid is energized. The ECM detects no current
from the actuator or a current that is less than the Perform the following diagnostic procedure: “Fuel
normal level. This is caused by one of the following Actuator Solenoid”
conditions:
Results:
• There is an open circuit in either the high side or
the low side. • OK – STOP.
• The low side is shorted to ground.
113
i01686115 i01630116
MID 109 - CID 0253 - FMI 02 MID 109 - CID 1040 - FMI 09
Personality Module mismatch ICSM #1 not communicating
SMCS Code: 1901-038
on link
SMCS Code: 1901-038
The right side ICSM’S software does not match the
left side ICSM’S software.
The ECM and the ICSM have been powered for at
least five seconds and the left side ICSM did not
System Response:
receive ten consecutive messages from the right
side ICSM.
logged.
System Response:
logged.
Troubleshooting:
Perform the following diagnostic procedure: The engine is shut down.

Troubleshooting:
Results:
• OK – STOP.
Results:
i01630107
• OK – STOP.
MID 109 - CID 0591 - FMI 12
EEPROM checksum fault or i01630467
ECM not programmed MID 109 - CID 1043 - FMI 02
SMCS Code: 1901-038 Cylinder #1 Firing Signal noisy
Conditions Which Generate This Code: SMCS Code: 1901-038
The right side ICSM detects a problem within the Conditions Which Generate This Code:
EPROM circuit.
One of the following conditions is detected by the
System Response: ICSM:
The code is logged. • Electrical noise has been generated on the

conductor that carries the firing signal.
• The frequency of the firing signal is not within the
The ICSM may not function. If the ICSM does not specified limits.
function, the engine is shut down.
System Response:
Troubleshooting:
Monitoring of the combustion burn time for the
Replace the ICSM. Follow the instructions in cylinder is lost. The alarm output is activated. The
Troubleshooting, “Replacing the ICSM”. code is logged.
• OK – STOP. The exhaust emissions are not controlled by the

engine control system.
114
Perform the following diagnostic procedure: MID 109 - CID 1043 - FMI 04
“Cylinder Firing Pulse” Cylinder #1 Firing Signal short
Results: to ground

i01631021
During normal operation, the ICSM continuously
MID 109 - CID 1043 - FMI sends a signal of 13 V. The ECM grounds the 13
03 Cylinder #1 Firing Signal V signal for the duration of ignition. The ICSM
interprets the grounding of the signal as the firing
open/short to +batt signal. When the 13 V signal returns to the high
side, the ICSM starts the timer for the combustion
SMCS Code: 1901-038 burn time.
Conditions Which Generate This Code: If the 13 V signal remains grounded, the ICSM
cannot interpret the firing signal and the ICSM
During normal operation, the ICSM continuously generates the diagnostic code.
sends a signal of 13 V. The ECM grounds the 13
V signal for the duration of ignition. The ICSM System Response:
signal. Monitoring of the combustion burn time is lost. The
alarm output is activated. The code is logged.
If the 13 V signal is not grounded, the ICSM does
not receive the firing signal and the ICSM generates Possible Performance Effect:
the diagnostic code.
The exhaust emissions are not controlled by the
System Response: engine control system.
Monitoring of the combustion burn time is lost. The Troubleshooting:
Possible Performance Effect: “Cylinder Firing Pulse”
The exhaust emissions are not controlled by the Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: i01631087

“Cylinder Firing Pulse”
MID 109 - CID 1043 - FMI
Results: 08 Cylinder #1 Firing Signal
• OK – STOP. abnormal signal
SMCS Code: 1901-038
The “Cylinder #1 Firing Signal” represents the

ignition of the first cylinder in the engine. The “All
Cylinders Firing Signal” represents the ignitions of
the remaining cylinders in the engine. The “Cylinder
#1 Firing Signal” is a reference for the “All Cylinders
Firing Signal”.
115
If the input for the “Cylinder #1 Firing Signal” is i01631058

switched with the input for the “All Cylinders Firing
Signal”, the “Cylinder #1 Firing Signal” is too MID 109 - CID 1044 - FMI 03
frequent. The ICSM generates the diagnostic code. All Cylinders Firing Signal
System Response: open/short to +batt
Monitoring of the combustion burn time is lost. The SMCS Code: 1901-038
The exhaust emissions are not controlled by the sends a signal of 13 V. The ECM grounds the 13
engine control system. V signal for the duration of ignition. The ICSM
Troubleshooting: signal.
Perform the following diagnostic procedure: If the 13 V signal is not grounded, the ICSM does
“Cylinder Firing Pulse” not receive the firing signal and the ICSM generates
Results:
System Response:
• OK – STOP.
Monitoring of the combustion burn time is lost. The
i01630987
MID 109 - CID 1044 - FMI 02 All
Cylinders Firing Signal noisy The exhaust emissions are not controlled by the
SMCS Code: 1901-038
Troubleshooting:
One of the following conditions is detected by the “Cylinder Firing Pulse”
ICSM:
Results:
• Electrical noise has been generated on the
conductor that carries the firing signal. • OK – STOP.
• The frequency of the firing signal is not within the i01631075
specified limits.
System Response:
MID 109 - CID 1044 - FMI 04 All
Cylinders Firing Signal short
to ground
SMCS Code: 1901-038
engine control system. During normal operation, the ICSM continuously
Troubleshooting: V signal for the duration of ignition. The ICSM
Perform the following diagnostic procedure: signal. When the 13 V signal returns to the high
“Cylinder Firing Pulse” side, the ICSM starts the timer for the combustion
burn time.
Results:
If the 13 V signal remains grounded, the ICSM
• OK – STOP. cannot interpret the firing signal and the ICSM
generates the diagnostic code.
116
System Response: • The wiring for the ignition is damaged.

Monitoring of the combustion burn time is lost. The • The combustion sensor is damaged.
• The extender is not properly contacting the
Possible Performance Effect: combustion sensor.
The exhaust emissions are not controlled by the Perform the following diagnostic procedure:
engine control system. “Combustion Sensor”
Perform the following diagnostic procedure: • OK – STOP.

i01631195
Results:
MID 109 - CID 1101 - FMI 04
• OK – STOP.
Cylinder #1 Combustion Probe
i01630640 short to ground
Cylinder #1 Combustion Probe Conditions Which Generate This Code:
noisy
The signal from the combustion sensor to the ICSM
SMCS Code: 1901-038 is less than the minimum acceptable value.
One of the following conditions is detected by the The combustion burn time for the cylinder is
ICSM: excluded from the average combustion burn time
and from the calculation for the fuel correction
• The signal from the combustion sensor is received factor. Diagnostics for the cylinder misfire are not
before combustion. available.
• The signal from the combustion sensor is received The code is logged.
within 1.8 milliseconds of the signal for ignition.
System Response:
The engine performance is not directly affected.
The combustion burn time for the cylinder is
excluded from the average combustion burn time Troubleshooting:
factor. Diagnostics for the cylinder misfire are not Perform the following diagnostic procedure:
available. “Combustion Sensor”
The code is logged. Results:

Troubleshooting:
One of the following conditions is probably the

cause of the diagnostic code:
• The wiring for the combustion sensor is damaged.

117
i01632915 i01632918
MID 109 - CID 1103 - FMI 02 MID 109 - CID 1103 - FMI 04
Cylinder #3 Combustion Probe Cylinder #3 Combustion Probe
noisy short to ground
One of the following conditions is detected by the The signal from the combustion sensor to the ICSM
ICSM: is less than the minimum acceptable value.
• The signal from the combustion sensor is received System Response:

before combustion.
• The signal from the combustion sensor is received excluded from the average combustion burn time
within 1.8 milliseconds of the signal for ignition. and from the calculation for the fuel correction
factor. Diagnostics for the cylinder misfire are not
System Response: available.
The combustion burn time for the cylinder is The code is logged.
excluded from the average combustion burn time
and from the calculation for the fuel correction Possible Performance Effect:
available. The engine performance is not directly affected.
The code is logged. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure:

“Combustion Sensor”
Results:
Troubleshooting:
• OK – STOP.
i01632926
• The wiring for the combustion sensor is damaged. MID 109 - CID 1105 - FMI 02
• The wiring for the ignition is damaged. Cylinder #5 Combustion Probe
• The combustion sensor is damaged.
noisy
SMCS Code: 1901-038
combustion sensor.
ICSM:
Results:
• The signal from the combustion sensor is received
before combustion.
• OK – STOP.
118
System Response: Possible Performance Effect:
The combustion burn time for the cylinder is The engine performance is not directly affected.
and from the calculation for the fuel correction Troubleshooting:
available. Perform the following diagnostic procedure:
The code is logged.
Results:
• OK – STOP.
i01632929
Troubleshooting:

MID 109 - CID 1107 - FMI 02
cause of the diagnostic code: Cylinder #7 Combustion Probe
noisy
SMCS Code: 1901-038
• The wiring for the ignition is damaged.
• The extender is not properly contacting the ICSM:
combustion sensor.
Perform the following diagnostic procedure: • The signal from the combustion sensor is received
before combustion.
Results: • The signal from the combustion sensor is received

i01632927 The combustion burn time for the cylinder is

MID 109 - CID 1105 - FMI 04 and from the calculation for the fuel correction
Cylinder #5 Combustion Probe factor. Diagnostics for the cylinder misfire are not
available.
short to ground
The code is logged.
SMCS Code: 1901-038
is less than the minimum acceptable value. Troubleshooting:
System Response: One of the following conditions is probably the

excluded from the average combustion burn time • The wiring for the combustion sensor is damaged.
factor. Diagnostics for the cylinder misfire are not • The wiring for the ignition is damaged.
available.
The code is logged.
119
• The extender is not properly contacting the • The signal from the combustion sensor is received
combustion sensor. before combustion.
“Combustion Sensor” within 1.8 milliseconds of the signal for ignition.
• OK – STOP. The combustion burn time for the cylinder is

i01632931
MID 109 - CID 1107 - FMI 04 available.
Cylinder #7 Combustion Probe The code is logged.

SMCS Code: 1901-038
Troubleshooting:
is less than the minimum acceptable value.
System Response:
excluded from the average combustion burn time • The wiring for the ignition is damaged.
factor. Diagnostics for the cylinder misfire are not • The combustion sensor is damaged.
available.
combustion sensor.
The code is logged.
Results:
Troubleshooting:
• OK – STOP.
“Combustion Sensor” i01632933
Results: MID 109 - CID 1109 - FMI 04

• OK – STOP.
short to ground
i01632932
SMCS Code: 1901-038
MID 109 - CID 1109 - FMI 02 Conditions Which Generate This Code:
noisy is less than the minimum acceptable value.
SMCS Code: 1901-038
System Response:
ICSM: and from the calculation for the fuel correction
available.
120
The code is logged. • The extender is not properly contacting the

combustion sensor.
The engine performance is not directly affected. “Combustion Sensor”

i01632938
Results:
MID 109 - CID 1111 - FMI 04
• OK – STOP.
Cylinder #11 Combustion
i01632937 Probe short to ground
Cylinder #11 Combustion Conditions Which Generate This Code:
Probe noisy
System Response:

i01632940
Troubleshooting: MID 109 - CID 1113 - FMI 02

One of the following conditions is probably the Cylinder #13 Combustion
Probe noisy
• The wiring for the combustion sensor is damaged. SMCS Code: 1901-038
• The wiring for the ignition is damaged. Conditions Which Generate This Code:
• The combustion sensor is damaged. One of the following conditions is detected by the
ICSM:
121
before combustion.
within 1.8 milliseconds of the signal for ignition. The engine performance is not directly affected.
The combustion burn time for the cylinder is Perform the following diagnostic procedure:
excluded from the average combustion burn time “Combustion Sensor”
factor. Diagnostics for the cylinder misfire are not Results:
available.
• OK – STOP.
The code is logged.
i01632947

MID 109 - CID 1115 - FMI 02
Troubleshooting:
Probe noisy
SMCS Code: 1901-038
• The wiring for the ignition is damaged. ICSM:
• The combustion sensor is damaged. • The signal from the combustion sensor is received
before combustion.
combustion sensor.
System Response:
Results:
• OK – STOP. and from the calculation for the fuel correction
i01632943 available.
MID 109 - CID 1113 - FMI 04 The code is logged.

Cylinder #13 Combustion Possible Performance Effect:
Probe short to ground
SMCS Code: 1901-038
Troubleshooting:
The signal from the combustion sensor to the ICSM cause of the diagnostic code:
System Response:
excluded from the average combustion burn time • The combustion sensor is damaged.
available.
122
• The extender is not properly contacting the i01631231

combustion sensor.
MID 109 - CID 1490 - FMI 03 Rt
Turbo Turbine Out Temp Sens
short to +batt
Results:
SMCS Code: 1901-038
• OK – STOP.
i01632951 The voltage of the signal from the thermocouple to
the ICSM is greater than the maximum acceptable
MID 109 - CID 1115 - FMI 04 value. This indicates a short circuit to the +Battery
Cylinder #15 Combustion side.
Probe short to ground System Response:
SMCS Code: 1901-038 Monitoring of the port’s temperature is lost. Also,
protection for the port is lost. The code is logged.
is less than the minimum acceptable value. Engine operation is not affected.
excluded from the average combustion burn time “Thermocouple Test”
available.
The code is logged.

• OK – STOP.
The engine performance is not directly affected. MID 109 - CID 1490 - FMI 04 Rt
Turbo Turbine Out Temp Sens
Troubleshooting:
short to ground
“Combustion Sensor” SMCS Code: 1901-038
• OK – STOP. The voltage of the signal from the thermocouple

to the ICSM is less than the minimum acceptable
value. This indicates one of the following conditions:
• A short circuit to the −Battery side

• A short circuit to the ground
System Response:
Monitoring of the port’s temperature is lost. Also,


123
Perform the following diagnostic procedure: Monitoring of the port’s exhaust temperature is lost.
“Thermocouple Test” Also, protection for the port is lost. The code is
logged.
Results:
• OK – STOP.
i01631295
Troubleshooting:
MID 109 - CID 1490 - FMI 05 Rt Perform the following diagnostic procedure:
Turbo Turbine Out Temp Sens “Thermocouple Test”
open circuit Results:
SMCS Code: 1901-038
• OK – STOP.
i01631538
The current of the signal from the thermocouple
to the ICSM is less than the minimum acceptable MID 109 - CID 1491 - FMI 04 Rt
value. This indicates an open circuit.
Turbo Turbine In Temp Sens
System Response: short to ground
Monitoring of the port’s temperature is lost. Also, SMCS Code: 1901-038
The voltage of the signal from the thermocouple
Engine operation is not affected. to the ICSM is less than the minimum acceptable
Troubleshooting:
“Thermocouple Test” • A short circuit to the ground
• OK – STOP. Monitoring of the port’s temperature is lost. Also,

i01631336
MID 109 - CID 1491 - FMI 03 Rt Engine operation is not affected.
short to +batt Troubleshooting:

SMCS Code: 1901-038
“Thermocouple Test”
Results:
The voltage of the signal from the thermocouple to
the ICSM is greater than the maximum acceptable • OK – STOP.
value. This indicates a short circuit to the +Battery
side.
124
i01632978 Troubleshooting:
MID 109 - CID 1491 - FMI 05 Rt Perform the following diagnostic procedure:
Turbo Turbine In Temp Sens “Thermocouple Test”
open circuit Results:
SMCS Code: 1901-038 • OK – STOP.
i01631554
to the ICSM is less than the minimum acceptable MID 109 - CID 1531 - FMI 04 Cyl
value. This indicates an open circuit. #1 Exhaust Port Temp Sensor
System Response: short to ground
Troubleshooting:
“Thermocouple Test” • A short circuit to the ground

• OK – STOP. protection for the port is lost. The code is logged.

MID 109 - CID 1531 - FMI 03 Cyl Engine operation is not affected.
#1 Exhaust Port Temp Sensor Troubleshooting:
short to +batt
SMCS Code: 1901-038 “Thermocouple Test”
Conditions Which Generate This Code: Results:
The voltage of the signal from the thermocouple to • OK – STOP.
side. i01632986
System Response:
MID 109 - CID 1531 - FMI 05 Cyl
#1 Exhaust Port Temp Sensor
protection for the port is lost. The code is logged. open circuit
Possible Performance Effect: SMCS Code: 1901-038
Engine operation is not affected. Conditions Which Generate This Code:

125
Monitoring of the port’s temperature is lost. Also, MID 109 - CID 1533 - FMI 04 Cyl
protection for the port is lost. The code is logged. #3 Exhaust Port Temp Sensor
Possible Performance Effect: short to ground
Engine operation is not affected. SMCS Code: 1901-038
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: The voltage of the signal from the thermocouple
“Thermocouple Test” to the ICSM is less than the minimum acceptable
Results:
• OK – STOP.
MID 109 - CID 1533 - FMI 03 Cyl Monitoring of the port’s temperature is lost. Also,
#3 Exhaust Port Temp Sensor protection for the port is lost. The code is logged.
short to +batt Possible Performance Effect:
SMCS Code: 1901-038 Engine operation is not affected.
The voltage of the signal from the thermocouple to Perform the following diagnostic procedure:
the ICSM is greater than the maximum acceptable “Thermocouple Test”
side. Results:
System Response:
• OK – STOP.
protection for the port is lost. The code is logged. i01633002
Possible Performance Effect: MID 109 - CID 1533 - FMI 05 Cyl

open circuit
Troubleshooting:
SMCS Code: 1901-038
“Thermocouple Test” Conditions Which Generate This Code:
Results: The current of the signal from the thermocouple

• OK – STOP. value. This indicates an open circuit.
System Response:


126
Troubleshooting: • A short circuit to the ground

Perform the following diagnostic procedure: System Response:
Results: protection for the port is lost. The code is logged.

i01631380
MID 109 - CID 1535 - FMI 03 Cyl Troubleshooting:
#5 Exhaust Port Temp Sensor Perform the following diagnostic procedure:

short to +batt
Results:
SMCS Code: 1901-038
Conditions Which Generate This Code: • OK – STOP.
The voltage of the signal from the thermocouple to i01633009

value. This indicates a short circuit to the +Battery MID 109 - CID 1535 - FMI 05 Cyl
side.
System Response: open circuit
Troubleshooting:
System Response:
“Thermocouple Test” Monitoring of the port’s temperature is lost. Also,
Results:
• OK – STOP.
i01631562
Troubleshooting:
MID 109 - CID 1535 - FMI 04 Cyl Perform the following diagnostic procedure:
#5 Exhaust Port Temp Sensor “Thermocouple Test”
short to ground Results:
SMCS Code: 1901-038
• OK – STOP.


127
short to +batt Results:
i01633016
the ICSM is greater than the maximum acceptable MID 109 - CID 1537 - FMI 05 Cyl
value. This indicates a short circuit to the +Battery #7 Exhaust Port Temp Sensor
side.
open circuit
System Response:
SMCS Code: 1901-038
protection for the port is lost. The code is logged. Conditions Which Generate This Code:
Possible Performance Effect: The current of the signal from the thermocouple
Engine operation is not affected. value. This indicates an open circuit.
Perform the following diagnostic procedure: Monitoring of the port’s temperature is lost. Also,
“Thermocouple Test” protection for the port is lost. The code is logged.

• OK – STOP.
Troubleshooting:
i01631564
MID 109 - CID 1537 - FMI 04 Cyl “Thermocouple Test”
Results:
short to ground
• OK – STOP.
SMCS Code: 1901-038
Conditions Which Generate This Code: i01631399

MID 109 - CID 1539 - FMI 03 Cyl
to the ICSM is less than the minimum acceptable #9 Exhaust Port Temp Sensor
short to +batt
• A short circuit to the −Battery side SMCS Code: 1901-038
• A short circuit to the ground Conditions Which Generate This Code:
System Response:
Monitoring of the port’s temperature is lost. Also, the ICSM is greater than the maximum acceptable
protection for the port is lost. The code is logged. value. This indicates a short circuit to the +Battery
side.
System Response:
128
Engine operation is not affected. MID 109 - CID 1539 - FMI 05 Cyl
Troubleshooting:
open circuit
“Thermocouple Test” SMCS Code: 1901-038
• OK – STOP. The current of the signal from the thermocouple

i01631568
System Response:
MID 109 - CID 1539 - FMI 04 Cyl
#9 Exhaust Port Temp Sensor Monitoring of the port’s temperature is lost. Also,
short to ground
SMCS Code: 1901-038
Troubleshooting:
to the ICSM is less than the minimum acceptable Perform the following diagnostic procedure:
value. This indicates one of the following conditions: “Thermocouple Test”
• A short circuit to the −Battery side Results:
• A short circuit to the ground • OK – STOP.
System Response:
i01631403
protection for the port is lost. The code is logged. MID 109 - CID 1541 - FMI 03 Cyl
short to +batt
SMCS Code: 1901-038
Troubleshooting:
“Thermocouple Test” The voltage of the signal from the thermocouple to
Results: value. This indicates a short circuit to the +Battery
side.
• OK – STOP.
System Response:


129
• OK – STOP. Engine operation is not affected.
Troubleshooting:
i01631571
Results:
short to ground
The voltage of the signal from the thermocouple MID 109 - CID 1543 - FMI 03 Cyl
short to +batt
SMCS Code: 1901-038
System Response:
side.
System Response:
Troubleshooting: protection for the port is lost. The code is logged.
Perform the following diagnostic procedure: Possible Performance Effect:

Results:
Troubleshooting:
• OK – STOP.
i01633024
MID 109 - CID 1541 - FMI 05 Cyl Results:
#11 Exhaust Port Temp Sensor • OK – STOP.

open circuit
SMCS Code: 1901-038

130
i01631409
value. This indicates one of the following conditions: #15 Exhaust Port Temp Sensor
• A short circuit to the −Battery side short to +batt
SMCS Code: 1901-038
Monitoring of the port’s temperature is lost. Also, The voltage of the signal from the thermocouple to
protection for the port is lost. The code is logged. the ICSM is greater than the maximum acceptable
Possible Performance Effect: side.
Engine operation is not affected. System Response:
Troubleshooting: Monitoring of the port’s temperature is lost. Also,

“Thermocouple Test” Possible Performance Effect:
Results: Engine operation is not affected.
Troubleshooting:
• OK – STOP.
i01633026 “Thermocouple Test”
• OK – STOP.
open circuit
SMCS Code: 1901-038 i01631576

MID 109 - CID 1545 - FMI 04 Cyl
to the ICSM is less than the minimum acceptable short to ground
SMCS Code: 1901-038
System Response:
protection for the port is lost. The code is logged. The voltage of the signal from the thermocouple
Possible Performance Effect: value. This indicates one of the following conditions:
Engine operation is not affected. • A short circuit to the −Battery side

131
• A short circuit to the ground i01686119
System Response: MID 110 - CID 0253 - FMI 02

Personality Module mismatch
protection for the port is lost. The code is logged. SMCS Code: 1901-038
Engine operation is not affected. The left side ICSM’S software does not match the
right side ICSM’S software.
Troubleshooting:
System Response:
“Thermocouple Test” The shutdown output is activated. The code is
logged.
Results:
• OK – STOP.
i01633031
Troubleshooting:
MID 109 - CID 1545 - FMI 05 Cyl
#15 Exhaust Port Temp Sensor “Integrated Combustion Sensing Module (ICSM)”
open circuit
Results:
SMCS Code: 1901-038
• OK – STOP.
i01630115
to the ICSM is less than the minimum acceptable MID 110 - CID 0591 - FMI 12
EEPROM checksum fault or
System Response: ECM not programmed
The left side ICSM detects a problem within the
Engine operation is not affected. EPROM circuit.
Perform the following diagnostic procedure: The shutdown output is activated. The code is
“Thermocouple Test” logged.
• OK – STOP. The ICSM may not function. If the ICSM does not
function, the engine is shut down.
Troubleshooting:
Replace the ICSM. Follow the instructions in

Troubleshooting, “Replacing the ICSM”.
Results:
• OK – STOP.
132

MID 110 - CID 1041 - FMI 09 The exhaust emissions are not controlled by the
ICSM #2 not communicating engine control system.
on link Troubleshooting:
SMCS Code: 1901-038 Perform the following diagnostic procedure:
Results:
The ECM and the ICSM have been powered for
at least five seconds and the right side ICSM did • OK – STOP.
not receive ten consecutive messages from the left
side ICSM.
i01633067
System Response:
MID 110 - CID 1044 - FMI 03
The shutdown output is activated. The code is All Cylinders Firing Signal
logged.
open/short to +batt
SMCS Code: 1901-038
Troubleshooting:
Perform the following diagnostic procedure: sends a signal of 13 V. The ECM grounds the 13
“Integrated Combustion Sensing Module (ICSM)” V signal for the duration of ignition. The ICSM
Results: signal.
If the 13 V signal is not grounded, the ICSM does

• OK – STOP. not receive the firing signal and the ICSM generates
i01633058
System Response:
MID 110 - CID 1044 - FMI 02 All
Cylinders Firing Signal noisy Monitoring of the combustion burn time is lost. The
SMCS Code: 1901-038
One of the following conditions is detected by the engine control system.
ICSM:
Troubleshooting:
• Electrical noise has been generated on the
conductor that carries the firing signal. Perform the following diagnostic procedure:
• The frequency of the firing signal is not within the
specified limits. Results:

133
i01633076 If the input for the “Cylinder #1 Firing Signal” is

switched with the input for the “All Cylinders Firing
MID 110 - CID 1044 - FMI 04 All Signal”, the ICSM detects the “Cylinder #1 Firing
Cylinders Firing Signal short Signal” more frequently than the “All Cylinders Firing
Signal”. The ICSM generates the diagnostic code.
to ground
System Response:
SMCS Code: 1901-038
Conditions Which Generate This Code: alarm output is activated. The code is logged.
During normal operation, the ICSM continuously Possible Performance Effect:
V signal for the duration of ignition. The ICSM The exhaust emissions are not controlled by the
interprets the grounding of the signal as the firing engine control system.
signal. When the 13 V signal returns to the high
side, the ICSM starts the timer for the combustion Troubleshooting:
burn time.
If the 13 V signal remains grounded, the ICSM “Cylinder Firing Pulse”
cannot interpret the firing signal and the ICSM
generates the diagnostic code. Results:
alarm output is activated. The code is logged. i01633090

MID 110 - CID 1102 - FMI 02
engine control system. noisy
Troubleshooting: SMCS Code: 1901-038
Perform the following diagnostic procedure: Conditions Which Generate This Code:
Results: ICSM:
• OK – STOP. • The signal from the combustion sensor is received

before combustion.
i01633080 • The signal from the combustion sensor is received

MID 110 - CID 1044 - FMI 08
All Cylinders Firing Signal System Response:
abnormal signal The combustion burn time for the cylinder is
SMCS Code: 1091-038 and from the calculation for the fuel correction
Conditions Which Generate This Code: available.
The “Cylinder #1 Firing Signal” represents the The code is logged.
ignition of the first cylinder. The “All Cylinders Firing
Signal” represents the ignitions of the remaining Possible Performance Effect:
cylinders. The “Cylinder #1 Firing Signal” is a
reference for the “All Cylinders Firing Signal”. The The engine performance is not directly affected.
“Cylinder #1 Firing Signal” is followed by the “All
Cylinders Firing Signal”.
134
One of the following conditions is probably the MID 110 - CID 1104 - FMI 02
cause of the diagnostic code: Cylinder #4 Combustion Probe
• The wiring for the combustion sensor is damaged. noisy
• The wiring for the ignition is damaged. SMCS Code: 1901-038
• The combustion sensor is damaged. Conditions Which Generate This Code:
• The extender is not properly contacting the One of the following conditions is detected by the
combustion sensor. ICSM:
“Combustion Sensor” before combustion.
Results: • The signal from the combustion sensor is received

• OK – STOP.
System Response:
i01633093 The combustion burn time for the cylinder is
MID 110 - CID 1102 - FMI 04 and from the calculation for the fuel correction
Cylinder #2 Combustion Probe factor. Diagnostics for the cylinder misfire are not
available.
short to ground
The code is logged.
SMCS Code: 1901-038
is less than the minimum acceptable value. Troubleshooting:
System Response: One of the following conditions is probably the
available.
The code is logged.


combustion sensor.
The engine performance is not directly affected. Perform the following diagnostic procedure:
Troubleshooting:
Results:
• OK – STOP.
Results:
• OK – STOP.
135

MID 110 - CID 1104 - FMI 04 The combustion burn time for the cylinder is
Cylinder #4 Combustion Probe excluded from the average combustion burn time
short to ground factor. Diagnostics for the cylinder misfire are not
available.
SMCS Code: 1901-038
The code is logged.
is less than the minimum acceptable value. The engine performance is not directly affected.
The combustion burn time for the cylinder is One of the following conditions is probably the
excluded from the average combustion burn time cause of the diagnostic code:
factor. Diagnostics for the cylinder misfire are not • The wiring for the combustion sensor is damaged.
available.
The code is logged.
The engine performance is not directly affected. combustion sensor.
Troubleshooting: Perform the following diagnostic procedure:
“Combustion Sensor” Results:
Results: • OK – STOP.
• OK – STOP.
i01633144
i01633097 MID 110 - CID 1106 - FMI 04

MID 110 - CID 1106 - FMI 02 Cylinder #6 Combustion Probe
Cylinder #6 Combustion Probe short to ground
noisy SMCS Code: 1901-038
SMCS Code: 1901-038 Conditions Which Generate This Code:
Conditions Which Generate This Code: The signal from the combustion sensor to the ICSM
ICSM: System Response:
• The signal from the combustion sensor is received The combustion burn time for the cylinder is
before combustion. excluded from the average combustion burn time
within 1.8 milliseconds of the signal for ignition. available.
The code is logged.

136

i01633151
Results:
MID 110 - CID 1108 - FMI 04
• OK – STOP.
i01633147 short to ground
Cylinder #8 Combustion Probe Conditions Which Generate This Code:
noisy
System Response:

i01633152
Troubleshooting: MID 110 - CID 1110 - FMI 02

One of the following conditions is probably the Cylinder #10 Combustion
Probe noisy
• The wiring for the combustion sensor is damaged. SMCS Code: 1901-038
• The wiring for the ignition is damaged. Conditions Which Generate This Code:
• The combustion sensor is damaged. One of the following conditions is detected by the
ICSM:
combustion sensor.
before combustion.
137
excluded from the average combustion burn time “Combustion Sensor”
available.
• OK – STOP.
The code is logged.
i01633155

MID 110 - CID 1112 - FMI 02
Troubleshooting:
Probe noisy
SMCS Code: 1901-038
• The wiring for the ignition is damaged. ICSM:
• The combustion sensor is damaged. • The signal from the combustion sensor is received
before combustion.
combustion sensor.
System Response:
Results:
• OK – STOP. and from the calculation for the fuel correction
i01633153 available.
MID 110 - CID 1110 - FMI 04 The code is logged.

Cylinder #10 Combustion Possible Performance Effect:
SMCS Code: 1901-038
Troubleshooting:
The signal from the combustion sensor to the ICSM cause of the diagnostic code:
System Response:
excluded from the average combustion burn time • The combustion sensor is damaged.
factor. Diagnostics for the cylinder misfire are not • The extender is not properly contacting the
available. combustion sensor.
The code is logged. Perform the following diagnostic procedure:


138
• OK – STOP. The combustion burn time for the cylinder is

i01633157
MID 110 - CID 1112 - FMI 04 available.
Cylinder #12 Combustion The code is logged.

Probe short to ground Possible Performance Effect:
SMCS Code: 1901-038
Troubleshooting:
System Response:
excluded from the average combustion burn time • The wiring for the ignition is damaged.
factor. Diagnostics for the cylinder misfire are not • The combustion sensor is damaged.
available.
combustion sensor.
The code is logged.
Results:
Troubleshooting:
• OK – STOP.
“Combustion Sensor” i01633164
Results: MID 110 - CID 1114 - FMI 04

• OK – STOP.
i01633160
SMCS Code: 1901-038
MID 110 - CID 1114 - FMI 02 Conditions Which Generate This Code:
Probe noisy is less than the minimum acceptable value.
SMCS Code: 1901-038
System Response:
ICSM: and from the calculation for the fuel correction
available.
before combustion.
The code is logged.
139
Possible Performance Effect: • The extender is not properly contacting the

combustion sensor.
Troubleshooting: “Combustion Sensor”
Perform the following diagnostic procedure: Results:

• OK – STOP.
Results:
i01633169
• OK – STOP.
MID 110 - CID 1116 - FMI 04
i01633166 Cylinder #16 Combustion
MID 110 - CID 1116 - FMI 02 Probe short to ground
Cylinder #16 Combustion SMCS Code: 1901-038
Probe noisy
SMCS Code: 1901-038
Conditions Which Generate This Code: is less than the minimum acceptable value.
One of the following conditions is detected by the System Response:

ICSM:
• The signal from the combustion sensor is received excluded from the average combustion burn time
before combustion. and from the calculation for the fuel correction
• The signal from the combustion sensor is received available.
The code is logged.
System Response:
excluded from the average combustion burn time The engine performance is not directly affected.
factor. Diagnostics for the cylinder misfire are not Troubleshooting:
available.
The code is logged. “Combustion Sensor”
The engine performance is not directly affected. • OK – STOP.

Troubleshooting:
i01631243

MID 110 - CID 1489 - FMI 03
Left Turbo Turbine Out Temp
• The wiring for the combustion sensor is damaged. Sens short to +batt
• The wiring for the ignition is damaged. SMCS Code: 1901-038
• The combustion sensor is damaged. Conditions Which Generate This Code:

side.
140
Monitoring of the port’s temperature is lost. Also, MID 110 - CID 1489 - FMI 05
protection for the port is lost. The code is logged. Left Turbo Turbine Out Temp
Possible Performance Effect: Sens open circuit
Engine operation is not affected. SMCS Code: 1901-038
Perform the following diagnostic procedure: The current of the signal from the thermocouple
“Thermocouple Test” to the ICSM is less than the minimum acceptable
Results:
System Response:
• OK – STOP.
i01631246
MID 110 - CID 1489 - FMI 04
Left Turbo Turbine Out Temp Engine operation is not affected.
Sens short to ground Troubleshooting:
SMCS Code: 1901-038 Perform the following diagnostic procedure:
Results:
• OK – STOP.
• A short circuit to the −Battery side i01631413
• A short circuit to the ground MID 110 - CID 1492 - FMI 03 Left
System Response:
short to +batt
protection for the port is lost. The code is logged. SMCS Code: 1901-038
Engine operation is not affected. The voltage of the signal from the thermocouple to
Troubleshooting: value. This indicates a short circuit to the +Battery
side.
“Thermocouple Test” System Response:
Results: Monitoring of the port’s temperature is lost. Also,

• OK – STOP.

141
Troubleshooting:
i01631630
MID 110 - CID 1492 - FMI 04 Left Perform the following diagnostic procedure:
Results:
short to ground
The voltage of the signal from the thermocouple MID 110 - CID 1532 - FMI 03 Cyl
short to +batt
SMCS Code: 1901-038
System Response:
side.
System Response:
Troubleshooting: protection for the port is lost. The code is logged.
Perform the following diagnostic procedure: Possible Performance Effect:

Results:
Troubleshooting:
• OK – STOP.
i01633179
MID 110 - CID 1492 - FMI 05 Left Results:
Turbo Turbine In Temp Sens • OK – STOP.

open circuit
SMCS Code: 1901-038

142
i01631419
value. This indicates one of the following conditions: #4 Exhaust Port Temp Sensor
• A short circuit to the −Battery side short to +batt
SMCS Code: 1901-038
Monitoring of the port’s temperature is lost. Also, The voltage of the signal from the thermocouple to
protection for the port is lost. The code is logged. the ICSM is greater than the maximum acceptable
Possible Performance Effect: side.
Engine operation is not affected. System Response:
Troubleshooting: Monitoring of the port’s temperature is lost. Also,

“Thermocouple Test” Possible Performance Effect:
Results: Engine operation is not affected.
Troubleshooting:
• OK – STOP.
i01633210 “Thermocouple Test”
• OK – STOP.
open circuit
SMCS Code: 1901-038 i01633224

MID 110 - CID 1534 - FMI 04 Cyl
to the ICSM is less than the minimum acceptable short to ground
SMCS Code: 1901-038
System Response:
protection for the port is lost. The code is logged. The voltage of the signal from the thermocouple
Possible Performance Effect: value. This indicates one of the following conditions:
Engine operation is not affected. • A short circuit to the −Battery side

143
• A short circuit to the ground i01631422
System Response: MID 110 - CID 1536 - FMI 03 Cyl

protection for the port is lost. The code is logged. short to +batt
Engine operation is not affected. Conditions Which Generate This Code:
Troubleshooting: The voltage of the signal from the thermocouple to

Perform the following diagnostic procedure: value. This indicates a short circuit to the +Battery
“Thermocouple Test” side.
• OK – STOP. Monitoring of the port’s temperature is lost. Also,

Troubleshooting:
open circuit
SMCS Code: 1901-038 “Thermocouple Test”
Conditions Which Generate This Code: Results:
• OK – STOP.
i01633259
System Response:
MID 110 - CID 1536 - FMI 04 Cyl
Monitoring of the port’s temperature is lost. Also, #6 Exhaust Port Temp Sensor
short to ground
SMCS Code: 1901-038
Troubleshooting:
Perform the following diagnostic procedure: to the ICSM is less than the minimum acceptable
“Thermocouple Test” value. This indicates one of the following conditions:
Results: • A short circuit to the −Battery side

• OK – STOP. • A short circuit to the ground
System Response:


144
Troubleshooting:
i01633261
Results:
open circuit
The current of the signal from the thermocouple MID 110 - CID 1538 - FMI 04 Cyl
short to ground
System Response:
SMCS Code: 1901-038
Possible Performance Effect: The voltage of the signal from the thermocouple
Engine operation is not affected. value. This indicates one of the following conditions:
Troubleshooting: • A short circuit to the −Battery side

Perform the following diagnostic procedure: • A short circuit to the ground
System Response:
Results:
• OK – STOP. protection for the port is lost. The code is logged.

i01631425
#8 Exhaust Port Temp Sensor Troubleshooting:

short to +batt Perform the following diagnostic procedure:
SMCS Code: 1901-038
Results:
The voltage of the signal from the thermocouple to • OK – STOP.

side.
145
i01633266 Results:
MID 110 - CID 1538 - FMI 05 Cyl • OK – STOP.
open circuit i01633269
SMCS Code: 1901-038

MID 110 - CID 1540 - FMI 04 Cyl
short to ground
to the ICSM is less than the minimum acceptable SMCS Code: 1901-038
System Response:
Monitoring of the port’s temperature is lost. Also, to the ICSM is less than the minimum acceptable
protection for the port is lost. The code is logged. value. This indicates one of the following conditions:
Possible Performance Effect: • A short circuit to the −Battery side
Engine operation is not affected. • A short circuit to the ground

• OK – STOP.
Troubleshooting:
i01631428
#10 Exhaust Port Temp Sensor Results:
short to +batt
• OK – STOP.
SMCS Code: 1901-038
The voltage of the signal from the thermocouple to MID 110 - CID 1540 - FMI 05 Cyl
the ICSM is greater than the maximum acceptable #10 Exhaust Port Temp Sensor
side. open circuit
System Response: SMCS Code: 1901-038
Monitoring of the port’s temperature is lost. Also, Conditions Which Generate This Code:
Possible Performance Effect: to the ICSM is less than the minimum acceptable
System Response:
Troubleshooting:
Perform the following diagnostic procedure: protection for the port is lost. The code is logged.
146
Engine operation is not affected. MID 110 - CID 1542 - FMI 04 Cyl
Troubleshooting:
short to ground
“Thermocouple Test” SMCS Code: 1901-038
• OK – STOP. The voltage of the signal from the thermocouple

i01631429
MID 110 - CID 1542 - FMI 03 Cyl • A short circuit to the −Battery side
#12 Exhaust Port Temp Sensor • A short circuit to the ground
short to +batt System Response:
SMCS Code: 1901-038 Monitoring of the port’s temperature is lost. Also,
the ICSM is greater than the maximum acceptable Engine operation is not affected.
side. Troubleshooting:
System Response: Perform the following diagnostic procedure:
protection for the port is lost. The code is logged. Results:
• OK – STOP.
i01633274
Troubleshooting:
MID 110 - CID 1542 - FMI 05 Cyl
Perform the following diagnostic procedure: #12 Exhaust Port Temp Sensor
open circuit
Results:
SMCS Code: 1901-038
• OK – STOP.

System Response:


147
Troubleshooting:
i01631434
Results:
short to +batt
The voltage of the signal from the thermocouple to MID 110 - CID 1544 - FMI 05 Cyl
side. open circuit
Monitoring of the port’s temperature is lost. Also, Conditions Which Generate This Code:
Possible Performance Effect: to the ICSM is less than the minimum acceptable
System Response:
Troubleshooting:
Perform the following diagnostic procedure: protection for the port is lost. The code is logged.
Results:
• OK – STOP.
Troubleshooting:
i01633277
#14 Exhaust Port Temp Sensor Results:

short to ground • OK – STOP.
SMCS Code: 1901-038


148
short to +batt Results:
i01633284
the ICSM is greater than the maximum acceptable MID 110 - CID 1546 - FMI 05 Cyl
value. This indicates a short circuit to the +Battery #16 Exhaust Port Temp Sensor
side.
open circuit
System Response:
SMCS Code: 1901-038
Possible Performance Effect: The current of the signal from the thermocouple
Engine operation is not affected. value. This indicates an open circuit.

• OK – STOP.
Troubleshooting:
i01633282
Results:
short to ground
• OK – STOP.
SMCS Code: 1901-038


System Response:


149
Troubleshooting with an The following format is used for event codes:
Event Code • “EXXX (X) Description of the code”

The “E” means that the code is an event code. The
i01324164 “XXX” represents a numeric identifier for the event
Event Codes code. The fourth “(X)” represents a numeric identifier
for the severity of the code. This is followed by a
description of the code. See the following example:
SMCS Code: 1901-038
Use this section for the troubleshooting of problems • “E004 (3) Engine Overspeed Shutdown”
that have generated event codes but do not have
active diagnostic codes. When the event code is The numbers that indicate the severity of the event
code are defined below:
generated, the event is active. Any generated code
becomes logged in the permanent memory of the
ECM. Warning (1) – This condition represents a serious
problem with engine operation. However, this
condition does not require a deration or a shutdown.
Event codes alert the operator that an abnormal
engine operating condition such as low oil pressure
Derate (2) – For this condition, the engine power is
or high coolant temperature has been detected.
reduced in order to help prevent possible engine
Events do not indicate problems with the electronic
system. Event codes also indicate the nature of the damage.
problem. Event codes may be viewed on a personal
Shutdown (3) – For this condition, the engine is
computer that has ET software.
shut down in order to help prevent possible engine
damage.
Illustration 17 represents the operating range of an
oil temperature sensor. The diagram is a reference.
Do not use the diagram to troubleshoot the oil These responses to certain events may be
programmed into the ECM. If the responses are
temperature sensor.
programmed, ET can display the event. If the
responses are not programmed, the display will not
appear. However, the occurrence of any event will
cause the event code to be logged in the ECM.
Note: Do not confuse event codes with diagnostic

codes. For information on diagnostic codes, see
Troubleshooting, “Troubleshooting with a Diagnostic
Code”.
Perform the following tasks before you troubleshoot

the event code:
• Gather enough information about the complaint in

order to describe the symptom(s) adequately.
• Verify that the complaint is not due to normal

engine operation.
• Repair all active diagnostic codes. See

Troubleshooting, “Troubleshooting With A
Diagnostic Code”.
g00791619
Illustration 17
Typical operating range of an oil temperature sensor Troubleshooting
(1) In these areas, the output voltage of the sensor is too high
or too low. The output is outside of the normal range. The For basic troubleshooting of the engine, perform
electronic problem will generate a diagnostic code.
(2) In this area, the oil temperature above 102 C (216 F) is higher the following steps first in order to diagnose a
than normal. The output voltage of the sensor will generate an malfunction.
event code for a warning, a derating, or a shutdown for high oil
temperature. The sensor does not have an electronic problem. 1. Gather information about the complaint from the
(3) This area represents the normal operating temperature for the
engine oil. The normal output voltage of the sensor is between
operator.
0.2 and 4.1 volts.
150
2. Verify that the complaint is not due to normal • The code was generated when the symptom
engine operation. Verify that the complaint is not occurred.
due to error of the operator.
• Codes that are repeatedly logged
3. Perform a visual inspection. Inspect the following
items: • The complaint is not due to normal engine
operation.
• Fuel supply
Other Symptoms
• Oil level
If other occurrences happened in addition to the
• Oil supply symptom, investigate the following conditions:
• Wiring • The other occurrences are related to the
symptom.
• Connectors
4. Check the diagnostic codes and event codes. • The symptoms have a probable cause that is
common.
Repair any active codes.
If these inspections do not reveal any problems, Active Event Codes

identify the probable causes with the procedures
in this manual that best describe the symptoms. An active event code represents a problem with
Check each probable cause according to the tests engine operation. Correct the problem as soon
that are recommended. as possible.
Be sure to check the connectors. This is specially When an event code is active, the “Active Alarm”
true for problems that are intermittent. See indicator (“Engine Control Alarm Status” on ET)
Troubleshooting, “Inspecting Electrical Connectors”. is activated in order to alert the operator. If the
condition that generated the code is momentary,
Narrow the probable cause. Consider the operator the message disappears. The event code will be
information, the conditions of operation, and the logged in the ECM memory.
history of the engine.
Active event codes are listed in ascending
numerical order. The code with the lowest number
Operator Information is listed first.
Obtain the following information from the operator:
Logged Event Codes
• The occurrence and the time of the occurrence
When the ECM generates an event code the ECM
• Determine the conditions for the occurrence. The logs the code in permanent memory. The ECM has
conditions will include the engine rpm and the an internal diagnostic clock. The ECM will record
load. the following information when a code is generated:
• Determine if there are any systems that were • The hour of the first occurrence of the code
installed by the dealer or the customer that could
cause the symptom. • The hour of the last occurrence of the code
• Determine whether any other occurrences • The number of occurrences of the code
happened in addition to the symptom.
This information can be helpful for troubleshooting
intermittent problems. Logged codes can also be
Diagnostic Codes and Event Codes used to review the performance of the engine. Any
logged event codes will automatically be deleted
Examine the following information regarding any
if no additional occurrences are recorded in 100
codes:
hours.
• The probable cause of the symptom is correlated Logged events are listed in chronological order. The
to the code.
most recent event code is listed first.
151
Note: Always clear logged event codes after Results:

investigating and correcting the problem which
generated the code. • OK – STOP.
i01633538 i01633543
E004 Engine Overspeed E016 High Engine Coolant

Shutdown Temperature Shutdown
The engine rpm has exceeded the trip point that is The crank terminate relay is set and the engine has
programmed into the ECM and the delay time has been running for at least 30 seconds. The engine
expired. The ECM has determined that the detected coolant temperature has exceeded the trip point
speed is accurate. and the delay time has expired. No other codes for
the engine coolant are active.
System Response:
System Response:
The gas shutoff valve and the ignition are shut
off. The shutdown output is activated. The code is The fuel is shut off. The shutdown output is
logged. activated. The code is logged.
The engine is shut down. The engine is shut down.
Refer to Troubleshooting, “Engine Overspeed”. Refer to Troubleshooting, “Engine Coolant

Results:
Results:
• OK – STOP.
• OK – STOP.
i01654071
i01633545
E013 High Crankcase Pressure
Shutdown E017 High Engine Coolant
Temperature Warning
SMCS Code: 1901-038
SMCS Code: 1901-038
The engine is running and the crankcase pressure
is greater than the setpoint. The crank terminate relay is set and the engine has
been running for at least 30 seconds. The engine
System Response: coolant temperature has exceeded the trip point
and the delay time has expired. No other codes for
The shutdown output is activated. The code is the engine coolant are active.
logged.
System Response:
Troubleshooting:
The engine operation is not immediately affected.
Refer to Troubleshooting, “Crankcase Pressure However, if the coolant temperature continues to
(High)”. rise, the engine will be shut down.
152
Refer to Troubleshooting, “Engine Coolant The alarm output is activated. The code is logged.
Results:
• OK – STOP. However, if the engine oil temperature continues to
rise, the engine can be shut down.
i01633603
Troubleshooting:
E019 High Engine Oil Refer to Troubleshooting, “Engine Oil Temperature
Temperature Shutdown (High)”.

The crank terminate relay is set and the engine has
been running for at least 30 seconds. The engine i01633755
oil temperature has exceeded the trip point and E026 High Inlet Air
the delay time has expired. No other codes for the
engine oil temperature are active. Temperature Shutdown
The fuel is shut off. The shutdown output is Conditions Which Generate This Code:
Possible Performance Effect: been running for at least 30 seconds. The inlet air
temperature has exceeded the trip point and the
The engine is shut off. delay time has expired. No other codes for the inlet
air temperature are active.
Troubleshooting:
System Response:
Refer to Troubleshooting, “Engine Oil Temperature
(High)”. The fuel is shut off. The shutdown output is
Results:
• OK – STOP.
i01633605
Troubleshooting:
E020 High Engine Oil Refer to Troubleshooting, “Inlet Air Temperature
Temperature Warning (High)”.

oil temperature has exceeded the trip point and
the delay time has expired. No other codes for the
engine oil temperature are active.
153
i01633756 Results:
E027 High Inlet Air • OK – STOP.
Temperature Warning
i01633762
SMCS Code: 1901-038
E040 Low Engine Oil Pressure
Shutdown
been running for at least 30 seconds. The inlet air SMCS Code: 1901-038
temperature has exceeded the trip point and the
delay time has expired. No other codes for the inlet Conditions Which Generate This Code:
air temperature are active.
System Response: been running for at least 10 seconds. The engine
oil pressure is less than the trip point and the
The alarm output is activated. The code is logged. delay time has expired. No codes for the engine oil
pressure sensor are active.
System Response:
However, if the inlet air temperature continues to The fuel is shut off. The shutdown output is
rise, the engine may be shut down. activated. The code is logged.
Troubleshooting: Possible Performance Effect:
Refer to Troubleshooting, “Inlet Air Temperature The engine is shut down.

(High)”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Engine Oil Pressure
(Low)”.
• OK – STOP.
Results:
i01633757
• OK – STOP.
E038 Low Engine Coolant
Temperature Warning i01633763
SMCS Code: 1901-038 E042 Low System Voltage

Conditions Which Generate This Code: Shutdown
The crank terminate relay is set and the engine SMCS Code: 1901-038
has been running for at least 30 seconds. The
temperature of the engine coolant is less than the Conditions Which Generate This Code:
trip point and the delay time has expired. No other
codes for the coolant temperature are active. The voltage is less than the trip point and the delay
time has expired. No other codes for the system
System Response: voltage are present.
The alarm output is activated. The code is logged. System Response:
Possible Performance Effect: The shutdown output is activated. The code is

logged.
Troubleshooting:
Refer to Troubleshooting, “Engine Coolant
Temperature (Low)”.
154
Refer to Troubleshooting, “System Voltage”. The engine operation is not immediately affected.
However, if the system voltage continues to increase
Results: the circuit breaker will switch OFF and the engine
will be shut down.
• OK – STOP.
Troubleshooting:
i01633765
Refer to Troubleshooting, “System Voltage”.
E043 Low System Voltage Results:
Warning
• OK – STOP.
SMCS Code: 1901-038
The voltage is less than the trip point and the delay
E096 High Fuel Pressure
time has expired. No other codes for the system
SMCS Code: 1901-038
voltage are present.
System Response:
The fuel pressure is higher than the trip point and
The alarm output is activated. The code is logged. the delay time has expired.
System Response:
However, if the system voltage continues to be
reduced, the engine will be shut down.
Troubleshooting:
For proper operation, the fuel pressure must be
Refer to Troubleshooting, “System Voltage”.
stable.
Results:
Troubleshooting:
• OK – STOP. Refer to Troubleshooting, “Fuel Pressure”.
i01633766 Results:
E050 High System Voltage • OK – STOP.

Warning
i01633787
SMCS Code: 1901-038
E100 Low Engine Oil Pressure
Warning
The voltage is greater than the trip point and the SMCS Code: 1901-038
delay time has expired. No other codes for the
system voltage are present.
System Response:
been running for at least ten seconds. The engine
The alarm output is activated. The code is logged. oil pressure is less than the trip point and the delay
time has expired. There are no active codes for the
engine oil pressure sensor.
155
The alarm output is activated. The code is logged. E127 Engine Oil Filter Diff
Pressure Low Warning
SMCS Code: 1901-038
However, if the oil pressure continues to be reduced, Conditions Which Generate This Code:
the engine may be shut down.
Troubleshooting: been running for at least 30 seconds. The engine oil
filter differential pressure is less than the trip point
Refer to Troubleshooting, “Engine Oil Pressure and the delay time has expired. There are no active
(Low)”. codes for the oil pressure sensors.
i01654094
E101 High Crankcase Pressure The engine operation is not immediately affected.
However, if the engine oil filter differential pressure
Warning continues to be reduced, the engine may be shut
down.
SMCS Code: 1901-038
Troubleshooting:
Refer to Troubleshooting, “Engine Oil Filter
The engine is running and the crankcase pressure Differential Pressure”.
is greater than the setpoint.
Results:
System Response:

• OK – STOP.
The engine operation is not immediately affected. E128 Engine Oil Filter Diff
However, if the crankcase pressure continues to
increase, the engine will be shut down.
Pressure Low Shutdown
SMCS Code: 1901-038
Troubleshooting:
Refer to Troubleshooting, “Crankcase Pressure
(High)”. The crank terminate relay is set and the engine has
been running for at least 30 seconds. The oil filter
Results: differential pressure is less than the trip point and
the delay time has expired. There are no active
• OK – STOP. codes for the oil pressure sensors.
System Response:


156
Refer to Troubleshooting, “Engine Oil Filter The fuel is shut off. The shutdown output is
Differential Pressure”. activated. The code is logged.
• OK – STOP. The engine is shut down.
Troubleshooting:
i01633828
E129 Engine Oil Filter Diff Refer to Troubleshooting, “Engine Oil Filter
Differential Pressure”.
Pressure High Warning
Results:
SMCS Code: 1901-038
• OK – STOP.
The crank terminate relay is set and the engine has i01633833
been running for at least 30 seconds. The oil filter
differential pressure is greater than the trip point
E135 Low Jacket Water
and the delay time has expired. There are no active Pressure Shutdown
codes for the oil pressure sensors.
SMCS Code: 1901-038
System Response:
Possible Performance Effect: been running for at least ten seconds. The pressure
of the jacket water is less than the trip point and the
The engine operation is not immediately affected. delay time has expired. There are no active codes
However, if the oil filter differential pressure for the pressure sensor at the outlet for the jacket
continues to increase, the engine may be shut water.
down.
System Response:
Troubleshooting:
Refer to Troubleshooting, “Engine Oil Filter activated. The code is logged.
Differential Pressure”.
Results:
The engine is shut off.
• OK – STOP.
Troubleshooting:
i01633832
Refer to Troubleshooting, “Jacket Water Pressure
E130 Engine Oil Filter Diff (Low)”.
Pressure High Shutdown Results:


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.
157
E200 Continuous Cylinder Refer to Troubleshooting, “Engine Misfires, Runs
Misfire Rough, or Is Unstable”.

The engine is operating in the combustion feedback i01633863
mode. At least 50 percent of the cylinders have
continuous misfire. The continuous misfire is E202 Cylinder #2 Intermittent
indicated by the following conditions:
Misfire
• The cylinder has an active “Exhaust Port Temp
Deviating Low” event. SMCS Code: 1901-038

• The ICSM has not received a signal from the
cylinder’s combustion sensor for 40 minutes.
The engine is operating in the combustion feedback
System Response: mode or the prechamber calibration mode. The
ICSM has not received 20 percent of the signals
The shutdown output is activated. The code is from the cylinder’s combustion sensor during a four
logged. minute period.
Possible Performance Effect: System Response:
The engine is shut down. The alarm output is activated. The code is logged.
Refer to Troubleshooting, “Engine Misfires, Runs The engine will run rough.
Troubleshooting:
Results:
Refer to Troubleshooting, “Engine Misfires, Runs
Rough, or Is Unstable”.
• OK – STOP.
Results:
i01633836
• OK – STOP.
E201 Cylinder #1 Intermittent
Misfire i01633873
SMCS Code: 1901-038 E203 Cylinder #3 Intermittent

Conditions Which Generate This Code: Misfire
The engine is operating in the combustion feedback SMCS Code: 1901-038
mode or the prechamber calibration mode. The
ICSM has not received 20 percent of the signals Conditions Which Generate This Code:
from the cylinder’s combustion sensor during a four
minute period. The engine is operating in the combustion feedback
System Response: ICSM has not received 20 percent of the signals
The alarm output is activated. The code is logged. minute period.
The engine will run rough. The alarm output is activated. The code is logged.
158
Troubleshooting:
Results:
• OK – STOP. Rough, or Is Unstable”.
Results:
i01633912
E204 Cylinder #4 Intermittent • OK – STOP.

Misfire i01633920
SMCS Code: 1901-038
Troubleshooting:
Results:
Results:
i01633917

Misfire
SMCS Code: 1901-038

minute period.
159
i01633924 Results:
Misfire
i01633931
SMCS Code: 1901-038
Misfire
mode or the prechamber calibration mode. The SMCS Code: 1901-038
from the cylinder’s combustion sensor during a four Conditions Which Generate This Code:
minute period.
The alarm output is activated. The code is logged. from the cylinder’s combustion sensor during a four
minute period.
System Response:
The engine will run rough.
Troubleshooting:
Rough, or Is Unstable”. The engine will run rough.
Results: Troubleshooting:

i01633926 Results:
Misfire
i01633932
SMCS Code: 1901-038
Misfire
mode or the prechamber calibration mode. The SMCS Code: 1901-038
from the cylinder’s combustion sensor during a four Conditions Which Generate This Code:
minute period.
The alarm output is activated. The code is logged. from the cylinder’s combustion sensor during a four
minute period.
System Response:
Troubleshooting:
Rough, or Is Unstable”. The engine will run rough.
160
Troubleshooting:
Results:
Results:
i01633936

Misfire i01633939
SMCS Code: 1901-038 E213 Cylinder #13 Intermittent

Troubleshooting:
Results:
Results:
i01633937

Misfire i01633941
SMCS Code: 1901-038
161
The alarm output is activated. The code is logged. E216 Cylinder #16 Intermittent
Misfire
SMCS Code: 1901-038
Troubleshooting:
Refer to Troubleshooting, “Engine Misfires, Runs mode or the prechamber calibration mode. The
Rough, or Is Unstable”. ICSM has not received 20 percent of the signals
Results: minute period.
i01633943
E215 Cylinder #15 Intermittent Possible Performance Effect:

Misfire The engine will run rough.
Conditions Which Generate This Code: Refer to Troubleshooting, “Engine Misfires, Runs
mode or the prechamber calibration mode. The Results:
minute period.
• OK – STOP.
The alarm output is activated. The code is logged. E223 High Gas Temperature
The engine will run rough. Conditions Which Generate This Code:
Troubleshooting: The crank terminate relay is set and the engine

has been running for at least 30 seconds. The
Refer to Troubleshooting, “Engine Misfires, Runs temperature of the gas has exceeded the trip point
Rough, or Is Unstable”. and the delay timer has expired. There are no active
codes for the fuel temperature sensor.
Results:
System Response:
• OK – STOP.

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)”.

162
Results: Results:
• OK – STOP. • OK – STOP.
i01633956 i01633968
E224 High Jacket Water Inlet E226 Driven Equipment Not

Pressure Ready
The crank terminate relay is set and the engine has The engine is ready to start. However, the ECM has
been running for at least 10 seconds. The trip point received a signal which indicates that the driven
for high pressure at the inlet for the jacket water has equipment is not ready for the engine to start.
been exceeded and the delay time has expired.
System Response:
System Response:
The shutdown output is activated. Engine cranking
The fuel is shut off. The shutdown output is is prevented. The code is logged.
The engine will not start.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Driven Equipment”.
Refer to Troubleshooting, “Jacket Water Inlet
Pressure (High)”. Results:
Results: • OK – STOP.
• OK – STOP. i01633972
i01633959 E229 Fuel Energy Content

E225 Engine Overcrank Setting Low

The crank terminate relay is set and the engine
The engine did not start within the programmed
has been running for at least 30 seconds. The fuel
parameters for starting.
correction factor is less than the trip point for 20
seconds.
System Response:
The fuel is shut off. Engine cranking is prevented. System Response:

The code is logged.
The engine performance may be erratic.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Engine Overcrank”.
Refer to Troubleshooting, “Fuel Energy Content”.
163
Results: Results:
i01633976 i01634004
E230 Fuel Energy Content E233 Low Engine Pre-Lube

Setting High Pressure
The crank terminate relay is set and the engine The prelube oil pressure is less than the trip point
has been running for at least 30 seconds. The fuel and the delay time has expired.
correction factor is greater than the trip point for
20 seconds. System Response:
System Response: The shutdown output is activated. Starting of the

engine is prevented. The signal driver for the
The alarm output is activated. The code is logged. prelube pump remains activated. The code is
logged.
The engine performance may be erratic.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Engine Pre-Lube Pressure
Results: (Low)”.
• OK – STOP. Results:
i01633997
• OK – STOP.
E231 Fuel Quality Out of Range i01635771
SMCS Code: 1901-038 E242 Engine Overload

The crank terminate relay is set and the engine has Conditions Which Generate This Code:
been running for at least 30 seconds. The LHV of
the fuel is less than the trip point OR the LHV of the The calculation by the ECM for the engine load is
fuel is greater than the trip point for 20 seconds. greater than 110 percent of the rated load.
The fuel is shut off. The shutdown output is The alarm output is activated. The code is logged.
The engine power is reduced.
The engine is shut off.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Engine Overload”.
Results:
• OK – STOP.
164

E243 High Left Turbo Turbine The following event codes are logged according to
Outlet Temperature the trip points for the temperature:
SMCS Code: 1052-038 • E244 (1) High Right Turbo Turbine Outlet
Temperature (warning)
• E244 (3) High Right Turbo Turbine Outlet
The temperature at the outlet for the left turbocharger Temperature (shutdown)
turbine has exceeded the trip point and the delay
time has expired. If a warning is generated, the alarm output is
activated.
System Response:
If a shutdown is generated, the shutdown output
The following event codes are logged according to is activated.
the trip points for the temperature:
• E243 (1) High Left Turbo Turbine Outlet
Temperature (warning) If a warning is generated, the engine performance
is not immediately affected.
• E243 (3) High Left Turbo Turbine Outlet
Temperature (shutdown) The engine will be shut down if the trip point for the
shutdown is exceeded.
If a warning is generated, the alarm output is
activated. Troubleshooting:
If a shutdown is generated, the shutdown output Refer to Troubleshooting, “Turbocharger Turbine

is activated. Temperature (High)”.
If a warning is generated, the engine performance • OK – STOP.

i01634041
The engine will be shut down if the trip point for the
shutdown is exceeded. E245 High Right Turbo Turbine
Troubleshooting: Inlet Temperature
Refer to Troubleshooting, “Turbocharger Turbine SMCS Code: 1052-038
Results:
The temperature at the inlet for the right
turbocharger turbine has exceeded the trip point
• OK – STOP. and the delay time has expired.

E244 High Right Turbo Turbine The following event codes are logged according to
Outlet Temperature the trip points for the temperature:
SMCS Code: 1052-038 • E245 (1) High Right Turbo Turbine Inlet
Temperature (warning)
• E245 (3) High Right Turbo Turbine Inlet
The temperature at the outlet for the right Temperature (shutdown)
turbocharger turbine has exceeded the trip point
and the delay time has expired. If a warning is generated, the alarm output is
activated.
165
If a shutdown is generated, the shutdown output Results:

is activated.
• OK – STOP.
i01634059
If a warning is generated, the engine performance
is not immediately affected. E264 Emergency Stop
The engine will be shut down if the trip point for the Activated
SMCS Code: 1901-038
Troubleshooting:
Refer to Troubleshooting, “Turbocharger Turbine
Temperature (High)”. The input for the emergency stop is activated.
• OK – STOP. The gas shutoff valve (GSOV) and the ignition are
shut off. The shutdown output is activated. The
code is logged.
i01634043
E246 High Left Turbo Turbine
Inlet Temperature The engine is shut off.
Conditions Which Generate This Code: Refer to Troubleshooting, “Engine Shutdown”.
The temperature at the inlet for the left turbocharger Results:

turbine has exceeded the trip point and the delay
time has expired. • OK – STOP.
System Response:
i01634061
The following event codes are logged according to

E266 Low Hydrax Oil Pressure
SMCS Code: 1901-038
• E246 (1) High Left Turbo Turbine Inlet Temperature
(warning) Conditions Which Generate This Code:
• E246 (3) High Left Turbo Turbine Inlet Temperature The crank terminate relay has been energized for
(shutdown) at least 30 seconds. The pressure switch for the
electrohydraulic actuator system opens for more
If a warning is generated, the alarm output is than one second. This indicates no oil pressure to
activated. the system.
If a shutdown is generated, the shutdown output System Response:
is activated.
Possible Performance Effect: activated. The code is logged.
If a warning is generated, the engine performance Possible Performance Effect:
shutdown is exceeded. Troubleshooting:
Troubleshooting: Refer to Troubleshooting, “Electrohydraulic System
Oil Pressure (Low)”.
Refer to Troubleshooting, “Turbocharger Turbine
166
• OK – STOP. Refer to Troubleshooting, “Engine Shutdown”.
Results:
i01634063
E268 Unexpected Engine • OK – STOP.

Shutdown i01634097
SMCS Code: 1901-038
E270 Driven Equipment
Conditions Which Generate This Code: Shutdown Requested
The crank terminate relay is set and the engine SMCS Code: 1901-038
is running. The engine rpm is less than the
programmed speed of the postlube cycle for 200 Conditions Which Generate This Code:
ms.
The crank terminate relay is set and the engine is
System Response: running. The input requests a shutdown for 200 ms.
The fuel is shut off. The shutdown output is System Response:

Possible Performance Effect: activated. The code is logged.
The engine is shut down. Possible Performance Effect:
Troubleshooting: The engine is shut down.
Refer to Troubleshooting, “Engine Shutdown Troubleshooting:

(Unexpected)”.
Refer to Troubleshooting, “Driven Equipment”.
Results:
Results:
• OK – STOP.
• OK – STOP.
i01634093
i01634098
E269 Customer Shutdown
Requested E337 High Engine Oil to Engine
Coolant Diff Temp
SMCS Code: 1901-038
SMCS Code: 1901-038
The engine is either cranking or running. The input
for the stop is set for 200 ms. Note: The cylinder liner and the piston assembly
can be damaged by this condition.
System Response:
The engine oil temperature is too high or the engine
The fuel is shut off. The shutdown output is coolant temperature is too low. The differential
activated. The code is logged. between the engine oil temperature and the engine
coolant temperature has exceeded the trip point
Possible Performance Effect: and the delay time has expired.
The engine is shut off. System Response:

167
• E337(1) High Engine Oil to Engine Coolant Diff i01637623

Temp (warning)
E402 Cylinder #2 Detonation
• E337 (3) High Engine Oil to Engine Coolant Diff
Temp (shutdown) SMCS Code: 1901-038
If a warning is generated, the alarm output is Conditions Which Generate This Code:
activated.
The level of detonation has exceeded the trip point.
If a shutdown is generated, the shutdown output There is no active diagnostic code for the cylinder’s
is activated. detonation sensor.
If a warning is generated, the engine performance The alarm output is activated. The code is logged.
shutdown is exceeded. The engine performance may be affected by
an adjustment of the timing in order to reduce
Troubleshooting: detonation.
Refer to Troubleshooting, “Jacket Water to Engine Troubleshooting:

Oil Differential Temperature (Low)”.
Refer to Troubleshooting, “Detonation”.
Results:
Results:
• OK – STOP.
• OK – STOP.
i01637607
i01637627
E401 Cylinder #1 Detonation E403 Cylinder #3 Detonation
SMCS Code: 1901-038
SMCS Code: 1901-038
There is no active diagnostic code for the cylinder’s The level of detonation has exceeded the trip point.
detonation sensor. There is no active diagnostic code for the cylinder’s
detonation sensor.
System Response:
System Response:
The engine performance may be affected by
an adjustment of the timing in order to reduce The engine performance may be affected by
detonation. an adjustment of the timing in order to reduce
detonation.
Troubleshooting:
Troubleshooting:
Results:
Results:
• OK – STOP.
• OK – STOP.
168
i01637634 i01637646

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
The engine performance may be affected by The engine performance may be affected by
an adjustment of the timing in order to reduce an adjustment of the timing in order to reduce
detonation. detonation.
Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.
Results: Results:
i01637642 i01637648

Results: Results:
169
i01637651 i01637657

Results: Results:
i01637653 i01637663

Results: Results:
170
i01637665 i01637699

Results: Results:
i01637696 i01637702

Results: Results:
171
i01637706 i01634746

SMCS Code: 1901-038
Shutdown

There is no active diagnostic code for the cylinder’s
detonation sensor.
Maximum retardation of the timing was unable
System Response: to control the detonation adequately during the
number of ignition sparks that are allowed. There
is no active diagnostic code for the cylinder’s
detonation sensor.
System Response:
The engine performance may be affected by
an adjustment of the timing in order to reduce
detonation.
Troubleshooting:
Troubleshooting:
Results:
• OK – STOP.
Results:
i01634664
• OK – STOP.
Shutdown i01634838
SMCS Code: 1901-038 E423 Cylinder #3 Detonation

Conditions Which Generate This Code: Shutdown
SMCS Code: 1901-038
to control the detonation adequately during the
is no active diagnostic code for the cylinder’s The level of detonation has exceeded the trip point.
detonation sensor.
System Response: number of ignition sparks that are allowed. There
detonation sensor.
System Response:

Troubleshooting:
Results:
• OK – STOP.
172
Troubleshooting:
i01635415
E424 Cylinder #4 Detonation Refer to Troubleshooting, “Detonation”.
Shutdown Results:

i01635417
to control the detonation adequately during the Shutdown
is no active diagnostic code for the cylinder’s SMCS Code: 1901-038
detonation sensor.
System Response:
The fuel is shut off. The shutdown output is Maximum retardation of the timing was unable
activated. The code is logged. to control the detonation adequately during the
Possible Performance Effect: is no active diagnostic code for the cylinder’s
detonation sensor.
System Response:
Troubleshooting:
Refer to Troubleshooting, “Detonation”. activated. The code is logged.
Troubleshooting:
i01635416
Shutdown Results:


detonation sensor.
System Response:

173
i01635420 Results:
E427 Cylinder #7 Detonation • OK – STOP.
Shutdown
i01635423
SMCS Code: 1901-038
Shutdown
Maximum retardation of the timing was unable SMCS Code: 1901-038
number of ignition sparks that are allowed. There Conditions Which Generate This Code:
detonation sensor. The level of detonation has exceeded the trip point.
The fuel is shut off. The shutdown output is is no active diagnostic code for the cylinder’s
activated. The code is logged. detonation sensor.
The engine is shut down. The fuel is shut off. The shutdown output is
Troubleshooting:
Results:
Troubleshooting:
• OK – STOP. Refer to Troubleshooting, “Detonation”.
i01635421 Results:
E428 Cylinder #8 Detonation • OK – STOP.
Shutdown
i01635424
SMCS Code: 1901-038
Shutdown
Maximum retardation of the timing was unable SMCS Code: 1901-038
number of ignition sparks that are allowed. There Conditions Which Generate This Code:
detonation sensor. The level of detonation has exceeded the trip point.
The fuel is shut off. The shutdown output is is no active diagnostic code for the cylinder’s
activated. The code is logged. detonation sensor.
The engine is shut down. The fuel is shut off. The shutdown output is
Troubleshooting:
174
Refer to Troubleshooting, “Detonation”. The fuel is shut off. The shutdown output is
Results:
• OK – STOP.
i01635428
Troubleshooting:
Shutdown
Results:
SMCS Code: 1901-038
• OK – STOP.
The level of detonation has exceeded the trip point. i01635431

number of ignition sparks that are allowed. There Shutdown
detonation sensor. SMCS Code: 1901-038
The fuel is shut off. The shutdown output is The level of detonation has exceeded the trip point.
activated. The code is logged. Maximum retardation of the timing was unable
Possible Performance Effect: number of ignition sparks that are allowed. There
The engine is shut down. detonation sensor.
Refer to Troubleshooting, “Detonation”. The fuel is shut off. The shutdown output is
Results:
• OK – STOP.
i01635429
Troubleshooting:
Shutdown
Results:
SMCS Code: 1901-038
• OK – STOP.

detonation sensor.
175
Shutdown Results:
SMCS Code: 1901-038
• OK – STOP.
S/N: BKE1-Up
i01635436

Maximum retardation of the timing was unable Shutdown
number of ignition sparks that are allowed. There SMCS Code: 1901-038
detonation sensor. Conditions Which Generate This Code:
System Response: The level of detonation has exceeded the trip point.
The fuel is shut off. The shutdown output is to control the detonation adequately during the
activated. The code is logged. number of ignition sparks that are allowed. There
Possible Performance Effect: detonation sensor.
The engine is shut down. System Response:
Troubleshooting: The fuel is shut off. The shutdown output is

Results:
• OK – STOP.
Troubleshooting:
i01635435 Refer to Troubleshooting, “Detonation”.
E435 Cylinder #15 Detonation Results:
Shutdown
• OK – STOP.
SMCS Code: 1901-038
i01635438

E601 Cylinder #1 Continuous
Maximum retardation of the timing was unable Misfire
number of ignition sparks that are allowed. There SMCS Code: 1901-038
detonation sensor. Conditions Which Generate This Code:
System Response: The engine is operating in the combustion feedback

mode. There is an active event for the low
The fuel is shut off. The shutdown output is temperature deviation of the cylinder’s exhaust
activated. The code is logged. port. The ICSM has not received a signal from the
System Response:
176
The engine runs rough. The alarm output is activated. The code is logged.
Refer to Troubleshooting, “Engine Misfires, Runs The engine runs rough.

Troubleshooting:
Results:
• OK – STOP. Rough or Is Unstable”.
Results:
i01635445
E602 Cylinder #2 Continuous • OK – STOP.

Misfire i01635455
SMCS Code: 1901-038
temperature deviation of the cylinder’s exhaust Conditions Which Generate This Code:
port. The ICSM has not received a signal from the
cylinder’s combustion sensor for 40 minutes. The engine is operating in the combustion feedback
System Response: temperature deviation of the cylinder’s exhaust
The alarm output is activated. The code is logged. cylinder’s combustion sensor for 40 minutes.

Troubleshooting:
Results:
Results:
i01635450

Misfire
SMCS Code: 1901-038

temperature deviation of the cylinder’s exhaust
177
i01635458 Results:
Misfire
i01635462
SMCS Code: 1901-038
Misfire
mode. There is an active event for the low SMCS Code: 1901-038
port. The ICSM has not received a signal from the Conditions Which Generate This Code:
System Response: mode. There is an active event for the low
The alarm output is activated. The code is logged. port. The ICSM has not received a signal from the
System Response:
The engine runs rough.
Troubleshooting:
Rough or Is Unstable”. The engine runs rough.

i01635459 Results:
Misfire
i01635464
SMCS Code: 1901-038
Misfire
mode. There is an active event for the low SMCS Code: 1901-038
port. The ICSM has not received a signal from the Conditions Which Generate This Code:
System Response: mode. There is an active event for the low
The alarm output is activated. The code is logged. port. The ICSM has not received a signal from the
System Response:
Troubleshooting:
Rough or Is Unstable”. The engine runs rough.
178

Troubleshooting:
Results:
Results:
i01635465

Misfire i01635471
SMCS Code: 1901-038 E611 Cylinder #11 Continuous


Troubleshooting:
Results:
Results:
i01635469

Misfire i01635473
SMCS Code: 1901-038
179
The alarm output is activated. The code is logged. E614 Cylinder #14 Continuous
Misfire
SMCS Code: 1901-038
Troubleshooting:
Refer to Troubleshooting, “Engine Misfires, Runs mode. There is an active event for the low
Rough or Is Unstable”. temperature deviation of the cylinder’s exhaust
Results: cylinder’s combustion sensor for 40 minutes.
i01635476
E613 Cylinder #13 Continuous Possible Performance Effect:

Misfire The engine runs rough.
Conditions Which Generate This Code: Refer to Troubleshooting, “Engine Misfires, Runs
mode. There is an active event for the low Results:
• OK – STOP.
The alarm output is activated. The code is logged. E615 Cylinder #15 Continuous
Misfire
SMCS Code: 1901-038
Troubleshooting:
Refer to Troubleshooting, “Engine Misfires, Runs mode. There is an active event for the low
Rough or Is Unstable”. temperature deviation of the cylinder’s exhaust
Results: cylinder’s combustion sensor for 40 minutes.
Troubleshooting:

180
Results: If a warning is generated, the alarm output is

activated.
• OK – STOP.
If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
i01635483
E616 Cylinder #16 Continuous Possible Performance Effect:
Misfire If a warning is generated, the engine performance

SMCS Code: 1901-038
Conditions Which Generate This Code: shutdown is exceeded.
The engine is operating in the combustion feedback Troubleshooting:

temperature deviation of the cylinder’s exhaust Refer to Troubleshooting, “Exhaust Port Temperature
port. The ICSM has not received a signal from the (High)”.
Results:
System Response:
• OK – STOP.

E802 Cylinder #2 High Exhaust
Port Temp
Troubleshooting:
SMCS Code: 1901-038
Rough or Is Unstable”. Conditions Which Generate This Code:
Results: The cylinder exhaust temperature has exceeded

the trip point and the delay time has expired.
• OK – STOP.
System Response:
i01635494
E801 Cylinder #1 High Exhaust the trip points for the temperature:
Port Temp • E802 (1) Cylinder #2 High Exhaust Port Temp

(warning)
SMCS Code: 1901-038
• E802 (3) Cylinder #2 High Exhaust Port Temp
Conditions Which Generate This Code: (shutdown)
The cylinder exhaust temperature has exceeded If a warning is generated, the alarm output is
the trip point and the delay time has expired. activated.
System Response: If a shutdown is generated, the shutdown output is

the trip points for the temperature: Possible Performance Effect:
• E801 (1) Cylinder #1 High Exhaust Port Temp If a warning is generated, the engine performance
(warning) is not immediately affected.
• E801 (3) Cylinder #1 High Exhaust Port Temp The engine will be shut down if the trip point for the
(shutdown) shutdown is exceeded.
181
Refer to Troubleshooting, “Exhaust Port Temperature E804 Cylinder #4 High Exhaust

(High)”. Port Temp
i01635503
The cylinder exhaust temperature has exceeded
System Response:
Port Temp
SMCS Code: 1901-038 the trip points for the temperature:
(warning)
(shutdown)
System Response:
The following event codes are logged according to activated.
• E803 (1) Cylinder #3 High Exhaust Port Temp activated and the fuel is shut off.
(warning)
(shutdown) If a warning is generated, the engine performance
activated. The engine will be shut down if the trip point for the
activated and the fuel is shut off. Troubleshooting:
Possible Performance Effect: Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
is not immediately affected. Results:
• OK – STOP.
Refer to Troubleshooting, “Exhaust Port Temperature E805 Cylinder #5 High Exhaust

(High)”. Port Temp

System Response:

182
• E805 (1) Cylinder #5 High Exhaust Port Temp Possible Performance Effect:
(warning)
• E805 (3) Cylinder #5 High Exhaust Port Temp is not immediately affected.
(shutdown)
If a warning is generated, the alarm output is shutdown is exceeded.
activated.
Troubleshooting:
activated and the fuel is shut off. Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
Results:
is not immediately affected. • OK – STOP.
i01635512
Troubleshooting:
Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature
(High)”. SMCS Code: 1901-038
• OK – STOP. The cylinder exhaust temperature has exceeded

E806 Cylinder #6 High Exhaust The following event codes are logged according to
Port Temp the trip points for the temperature:
SMCS Code: 1901-038 • E807 (1) Cylinder #7 High Exhaust Port Temp
(warning)
The cylinder exhaust temperature has exceeded (shutdown)
System Response: activated.
The following event codes are logged according to If a shutdown is generated, the shutdown output is
the trip points for the temperature: activated and the fuel is shut off.
• E806 (1) Cylinder #6 High Exhaust Port Temp Possible Performance Effect:
(warning)
• E806 (3) Cylinder #6 High Exhaust Port Temp is not immediately affected.
(shutdown)
If a warning is generated, the alarm output is shutdown is exceeded.
activated.
Troubleshooting:
activated and the fuel is shut off. Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
183
• OK – STOP. The following event codes are logged according to

i01635513
E808 Cylinder #8 High Exhaust (warning)

(shutdown)
SMCS Code: 1901-038
Conditions Which Generate This Code: activated.
The cylinder exhaust temperature has exceeded If a shutdown is generated, the shutdown output is
the trip point and the delay time has expired. activated and the fuel is shut off.
The following event codes are logged according to If a warning is generated, the engine performance
the trip points for the temperature: is not immediately affected.
(warning) shutdown is exceeded.
• E808 (3) Cylinder #8 High Exhaust Port Temp Troubleshooting:

(shutdown)
If a warning is generated, the alarm output is (High)”.
activated.
Results:
activated and the fuel is shut off. • OK – STOP.
i01635549
E810 Cylinder #10 High
Exhaust Port Temp
shutdown is exceeded. SMCS Code: 1901-038
Refer to Troubleshooting, “Exhaust Port Temperature The cylinder exhaust temperature has exceeded
(High)”. the trip point and the delay time has expired.
• OK – STOP. The following event codes are logged according to

i01635546
E809 Cylinder #9 High Exhaust (warning)
(shutdown)
SMCS Code: 1901-038
184

i01635568
shutdown is exceeded. E812 Cylinder #12 High
Troubleshooting: Exhaust Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1901-038
(High)”.
Results:
• OK – STOP. the trip point and the delay time has expired.
System Response:
i01635556
E811 Cylinder #11 High the trip points for the temperature:
Exhaust Port Temp
SMCS Code: 1901-038 (warning)
Conditions Which Generate This Code: • E812 (3) Cylinder #12 High Exhaust Port Temp
(shutdown)
the trip point and the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
The following event codes are logged according to activated and the fuel is shut off.
(warning) If a warning is generated, the engine performance
(shutdown) The engine will be shut down if the trip point for the
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (High)”.

Troubleshooting:

(High)”.
185
i01635570 • E814 (1) Cylinder #14 High Exhaust Port Temp

(warning)
Exhaust Port Temp • E814 (3) Cylinder #14 High Exhaust Port Temp
(shutdown)
SMCS Code: 1901-038
(warning) shutdown is exceeded.
• E813 (3) Cylinder #13 High Exhaust Port Temp Troubleshooting:

(shutdown)
If a warning is generated, the alarm output is (High)”.
activated.
Results:
activated and the fuel is shut off. • OK – STOP.
If a warning is generated, the engine performance E815 Cylinder #15 High

Exhaust Port Temp
shutdown is exceeded. SMCS Code: 1901-038
Refer to Troubleshooting, “Exhaust Port Temperature The cylinder exhaust temperature has exceeded
(High)”. the trip point and the delay time has expired.

• OK – STOP. the trip points for the temperature:
i01635577 • E815 (1) Cylinder #15 High Exhaust Port Temp

(warning)
Exhaust Port Temp • E815 (3) Cylinder #15 High Exhaust Port Temp
(shutdown)
SMCS Code: 1901-038
186
The engine will be shut down if the trip point for the i01635587
E821 Cyl #1 Exhaust Port Temp
Troubleshooting: Deviating High
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1901-038
(High)”.
Results:
The cylinder exhaust temperature is higher than the
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point
i01635584
and the delay time has expired.
E816 Cylinder #16 High System Response:

Exhaust Port Temp The following event codes are logged according to
SMCS Code: 1901-038

• E821 (1) Cyl #1 Exhaust Port Temp Deviating
High (warning)
High (shutdown)
System Response: If a warning is generated, the alarm output is
activated.
the trip points for the temperature: If a shutdown is generated, the shutdown output is
(warning) Possible Performance Effect:
• E816 (3) Cylinder #16 High Exhaust Port Temp If a warning is generated, the engine performance
(shutdown) is not immediately affected.
If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.
If a shutdown is generated, the shutdown output is Troubleshooting:
Possible Performance Effect: (High)”.
If a warning is generated, the engine performance Results:
• OK – STOP.
Troubleshooting:

(High)”.
Results:
• OK – STOP.
187

E822 Cyl #2 Exhaust Port Temp The following event codes are logged according to
Deviating High the trip points for the temperature:
SMCS Code: 1901-038 • E823 (1) Cyl #3 Exhaust Port Temp Deviating
High (warning)
The cylinder exhaust temperature is higher than the High (shutdown)
average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point If a warning is generated, the alarm output is
and the delay time has expired. activated.

• E822 (1) Cyl #2 Exhaust Port Temp Deviating If a warning is generated, the engine performance
High (warning) is not immediately affected.
• E822 (3) Cyl #2 Exhaust Port Temp Deviating The engine will be shut down if the trip point for the
High (shutdown) shutdown is exceeded.
If a warning is generated, the alarm output is Troubleshooting:

activated.
If a shutdown is generated, the shutdown output is (High)”.
Results:
• OK – STOP.
is not immediately affected. i01635604
The engine will be shut down if the trip point for the E824 Cyl #4 Exhaust Port Temp
Deviating High
Troubleshooting:
SMCS Code: 1901-038
(High)”. Conditions Which Generate This Code:
Results: The cylinder exhaust temperature is higher than the


High (warning)
188


• OK – STOP.
i01635612
Troubleshooting: E826 Cyl #6 Exhaust Port Temp

Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
i01635605 amount of deviation has exceeded the trip point
Deviating High System Response:
SMCS Code: 1901-038 The following event codes are logged according to
The cylinder exhaust temperature is higher than the High (warning)
amount of deviation has exceeded the trip point • E826 (3) Cyl #6 Exhaust Port Temp Deviating
and the delay time has expired. High (shutdown)

activated.
High (warning) Possible Performance Effect:
High (shutdown) is not immediately affected.


• OK – STOP.
189

High (warning)


activated.
Results:
• OK – STOP.
Deviating High
Troubleshooting:
SMCS Code: 1901-038


High (warning)
190


• OK – STOP.
i01635641
Troubleshooting: E831 Cyl #11 Exhaust Port

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating High
(High)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
E830 Cyl #10 Exhaust Port
Temp Deviating High System Response:

activated.


• OK – STOP.
191

E832 Cyl #12 Exhaust Port The following event codes are logged according to
Temp Deviating High the trip points for the temperature:
High (warning)


activated.
Results:
• OK – STOP.
The engine will be shut down if the trip point for the E834 Cyl #14 Exhaust Port
Temp Deviating High
Troubleshooting:
SMCS Code: 1901-038


Temp Deviating High the trip points for the temperature:
High (warning)
192


• OK – STOP.
i01635661

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating High
(High)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
Temp Deviating High System Response:

activated.


• OK – STOP.
193

Deviating Low the trip points for the temperature:
SMCS Code: 1901-038 • E842 (1) Cyl #2 Exhaust Port Temp Deviating Low
(warning)
• E841 (3) Cyl #2 Exhaust Port Temp Deviating Low
The cylinder exhaust temperature is less than the (shutdown)

• E841 (1) Cyl #1 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance
• E841 (3) Cyl #1 Exhaust Port Temp Deviating Low The engine will be shut down if the trip point for the

activated.
If a shutdown is generated, the shutdown output is (Low)”.
Results:
• OK – STOP.
Deviating Low
Troubleshooting:
SMCS Code: 1901-038
(Low)”. Conditions Which Generate This Code:
Results: The cylinder exhaust temperature is less than the


(warning)
194

Possible Performance Effect: (Low)”.

• OK – STOP.
i01635672
Troubleshooting: E845 Cyl #5 Exhaust Port Temp

Refer to Troubleshooting, “Exhaust Port Temperature Deviating Low
(Low)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
The cylinder exhaust temperature is less than the
Deviating Low System Response:
The cylinder exhaust temperature is less than the (warning)
amount of deviation has exceeded the trip point • E845 (3) Cyl #5 Exhaust Port Temp Deviating Low
and the delay time has expired. (shutdown)

activated.


• OK – STOP.
195

(warning)

• E846 (3) Cyl #6 Exhaust Port Temp Deviating Low The engine will be shut down if the trip point for the

activated.
Results:
• OK – STOP.
Deviating Low
Troubleshooting:
SMCS Code: 1901-038


(warning)
196


• OK – STOP.
i01635684

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating Low
(Low)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
Deviating Low System Response:
The cylinder exhaust temperature is less than the Low (warning)
and the delay time has expired. Low (shutdown)

activated.


• OK – STOP.
197

Temp Deviating Low the trip points for the temperature:
Low (warning)
The cylinder exhaust temperature is less than the Low (shutdown)

Low (warning) is not immediately affected.
Low (shutdown) shutdown is exceeded.

activated.
Results:
• OK – STOP.
The engine will be shut down if the trip point for the E853 Cyl #13 Exhaust Port
Temp Deviating Low
Troubleshooting:
SMCS Code: 1901-038


Temp Deviating Low the trip points for the temperature:
Low (warning)
The cylinder exhaust temperature is less than the Low (shutdown)
198


• OK – STOP.
i01635694

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating Low
(Low)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
Temp Deviating Low System Response:
The cylinder exhaust temperature is less than the Low (warning)
and the delay time has expired. Low (shutdown)

activated.
Low (warning) Possible Performance Effect:
Low (shutdown) is not immediately affected.


• OK – STOP.
199
i01635695

Temp Deviating Low
SMCS Code: 1901-038

System Response:


Low (warning)

Low (shutdown)

activated.


Troubleshooting:

(Low)”.
Results:
• OK – STOP.
200
Diagnostic Functional
Tests
i01626705
+5V Sensor Voltage Supply

SMCS Code: 1901-038
System Operation Description:
The ECM supplies 5.0 ± 0.5 VDC to the sensors for

these parameters:
• Inlet air temperature

• Unfiltered engine oil pressure
• Filtered engine oil pressure
• Fuel temperature
• Crankcase pressure
The ECM also provides 5 VDC to the “DESIRED
SPEED” potentiometer on the control panel (if
equipped). A “+5 Volt Sensor DC Power Supply
short to ground” diagnostic code will be activated
if both of these conditions occur:
• The desired speed signal wire is shorted to

ground.
• The “DESIRED SPEED” potentiometer is near

the maximum desired speed or at the maximum
desired speed.
A “+5 V sensor supply” diagnostic code is probably

caused by a short circuit or an open circuit in a
harness. The next likely cause is a sensor problem.
The least likely cause is a problem with the ECM.
Logged diagnostic codes provide an historical

record. Before you begin this procedure, use ET to
print the logged codes to a file.
This troubleshooting procedure may generate

additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.
201
g00845850
Illustration 18
Schematic for the analog sensors
202
Test Step 1. Inspect the Electrical

Connectors and Wiring
A. Turn the engine control switch to the OFF/RESET
position. Switch the 16 amp circuit breaker for
the ECM to the OFF position.
Note: For the following steps, refer to

Troubleshooting, “Inspecting Electrical Connectors”.
g00861762
Illustration 20
(6) Terminal strip in the control panel
g00842721
Illustration 19
(1) ECM Connectors J1/P1
(2) 16 amp circuit breaker
(3) Connectors J6/P6 for the harness from the sensors on the left
side of the engine
(4) Connectors J5/P5 for the harness from the sensors on the right
side of the engine
(5) Connectors J4/P4 for the harness from the control panel (if
equipped)
g00843053
Illustration 21
The inlet air temperature sensor is installed in the inlet air manifold
between the two center cylinder heads on the right side of the
engine.
(7) Inlet air temperature sensor
203
g00842958 g00843065
Illustration 22 Illustration 23
Front view Rear view
(8) Unfiltered engine oil pressure sensor (11) Fuel temperature sensor
(9) Engine oil temperature sensor
(10) Filtered engine oil pressure sensor
g00842996
Illustration 24
Right side view near the front of the engine
B. Thoroughly inspect each of the following

connectors:
• ECM J1/P1 connectors

• J4/P4, J5/P5, and J6/P6 connectors on the
terminal box
• Each connection for the sensors

• The terminal strip inside the control panel (if
equipped)
204
a. Check the torque of the Allen head screw for

the ECM connector and the P5 connector
and the P6 connector. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).
g00843268
Illustration 27
Harness side of the terminal box P6 connector
(P6-68) Return for the fuel temperature sensor
(P6-69) 5 VDC for the fuel temperature sensor
g00843183
Illustration 25
Harness side of the ECM P1 connector b. Perform a 45 N (10 lb) pull test on each of
(P1-2) +5 V supply
the wires that are associated with the circuit
(P1-3) Return for the sensors.
c. Check the harnesses and wiring for abrasion

and pinch points from the sensors to the ECM.
Expected Result:
All of the connectors, pins, and sockets are

connected properly. The connectors and the wiring
are free of corrosion, abrasion, and pinch points.
Results:
• OK – All of the connectors, pins, and sockets

are connected properly. The connectors and the
wiring are free of corrosion, abrasion, and pinch
g00843245 points. The components are in good condition
Illustration 26
Harness side of the terminal box P5 connector with proper connections. Proceed to Test Step 2.
(P5-15) Return for the engine oil temperature sensor
(P5-17) +5 VDC for the engine oil temperature sensor • Not OK – At least one of the connectors, pins,
(P5-25) Return for the unfiltered oil pressure sensor or sockets are not connected properly. At least
(P5-27) 5 VDC for the unfiltered oil pressure sensor one of the connectors or the wiring has corrosion,
(P5-33) Return for the filtered oil pressure sensor abrasion, and/or pinch points.
(P5-49) Return for the crankcase pressure sensor
(P5-51) 5 VDC for the crankcase pressure sensor
(P5-53) 5 VDC for the filtered oil pressure sensor Repair: Perform the necessary repairs and/or
(P5-59) Return for the inlet air temperature sensor replace parts, if necessary.
(P5-61) 5 VDC for the inlet air temperature sensor
STOP.
Test Step 2. Check for Diagnostic Codes

A. Connect ET to the service tool connector on the
terminal box.
205
Repair: There may be a problem with the wiring

and/or a connector. Refer to Troubleshooting,
“Inspecting Electrical Connectors”.
Verify that the wiring and/or connectors are OK.

Check for diagnostic codes again. Proceed to
Test Step 3, if necessary.
Test Step 3. Check the Analog Speed

Circuit
g00862185
Illustration 28
Control panel (if equipped)
(1) “DESIRED SPEED” potentiometer
B. Rotate the “DESIRED SPEED” potentiometer (if

equipped) counterclockwise to the minimum
speed position.
C. Switch the 16 amp circuit breaker for the ECM

ON. Turn the engine control switch to the STOP g00862185
position. Illustration 29
D. Observe the “Active Diagnostic” screen on ET. (1) “DESIRED SPEED” potentiometer
Wait at least thirty seconds so that any codes
may become activated. Look for these codes: A. Rotate the “DESIRED SPEED” potentiometer (if
equipped) clockwise to the maximum speed
• 262-03 5 Volt Sensor DC Power Supply short position.
to +batt
Expected Result:
• 262-04 5 Volt Sensor DC Power Supply short
to ground The 262-03 code or the 262-04 code is not active.
E. Observe the “Logged Diagnostic” screen on the Results:

ET. Look for the same codes.
• No codes – Rotating the “DESIRED SPEED”
Expected Result: potentiometer clockwise to the maximum speed
position did not cause an active code. The +5 V
The 262-03 code or the 262-04 code is not active sensor voltage supply is operating correctly at
or logged. this time. Resume normal operation. STOP.
Results: • Active code – Rotating the “DESIRED SPEED”

potentiometer clockwise to the maximum speed
• No codes – There are no active codes or logged position caused an active code. There is a
codes. Proceed to Test Step 3. problem with the analog speed circuit. Proceed
to Test Step 4.
• Active code – The 262-03 code or the 262-04
code is active. Proceed to Test Step 6.
• Logged code – The 262-03 code or the 262-04

code is not active. However, there is at least one
logged code for the +5 volt sensor supply.
206
Test Step 4. Disconnect the J4 Connector Expected Result:

and Check the Control Panel Wiring
The resistance is greater than 20,000 ohms.
A. Switch the 16 amp circuit breaker for the ECM
OFF. Turn the engine control switch to the Results:
OFF/RESET position.
• OK – The resistance is greater than 20,000 ohms.
The wiring to the control panel and inside the
control panel appears to be OK. Proceed to Test
Step 5.
• Not OK – The resistance is less than 20,000

ohms. There is a problem with the wiring to the
control panel or inside the control panel.
Repair: Perform the following procedure:
1. Carefully inspect the following items:
• Connector J4
• The harness from connector J4 to the control
panel
• The inside of the control panel

• The terminal strip inside the control panel
g00862213
Illustration 30
2. Verify that all connections and terminals are
J4 connector on the terminal box in good condition and free of moisture. Verify
that the harness from the J4 connector to the
B. Disconnect the J4 connector from the terminal control panel is in good condition.
box.
3. Perform any necessary repairs or replace
parts, if necessary.
4. Reconnect all of the connectors and perform

this procedure again. Verify that the original
problem is resolved.
STOP.
g00862266
Illustration 31
Harness connector J4
(J4-X) Signal wire for the “DESIRED SPEED” potentiometer
(J4-x) Ground
C. Measure the resistance from terminal X to x on

harness connector J4.
207
Test Step 5. Check the Wiring Inside the Repair: Reconnect all of the connectors. Resume
Terminal Box normal operation.
STOP.

ohms. There is a problem with a connector and/or
the wiring inside the terminal box.
Repair: Repair the connector and/or wiring, when

possible. Replace the wiring, if necessary.
STOP.
Test Step 6. Isolate the Wiring Harnesses

from the ECM
the ECM OFF.
g00862375
Illustration 32
(1) ECM connector P1
A. Disconnect ECM connector P1.
g00862450
Illustration 34
B. Use a 151-6320 Wire Removal Tool to remove

terminal 2 and terminal 18 from the P1 connector.

Illustration 33
g00862380 ON. Turn the engine control switch to the STOP
position.
ECM side of the P1 connector
(P1-16) Signal wire for the “DESIRED SPEED” potentiometer D. Use ET to look for active diagnostic codes.
(P1-69) Ground
Expected Result:
B. Measure the resistance between terminals 16
and 69 of connector P1.
No active codes
Expected Result:
Results:
• No codes – The 262-03 code or the 262-04 code
is not active. Disconnecting all of the +5 V wiring
Results:
from the ECM eliminated the active “5 Volt Sensor
Supply” diagnostic code. There is a problem
• OK – The resistance is greater than 20,000 ohms. with a connector and/or the wiring in a harness.
The wiring inside the terminal box appears to be
Proceed to Test Step 7.
OK. The problem appears to be resolved. The
initial diagnostic code was probably caused by a
poor electrical connection.
208

code is active. Disconnecting all of the +5 V
wiring from the ECM did not eliminate the +5 V
diagnostic code. There may be a problem with
the ECM.
Repair: It is unlikely that the ECM has failed.

Exit this procedure and perform this procedure
again. If the problem is not resolved, perform the
following steps:
Temporarily install a new ECM. Refer to

Troubleshooting, “Replacing the ECM”.
If the problem is resolved with the new ECM,

install the original ECM and verify that the
problem returns. If the new ECM operates
correctly and the original ECM does not operate
correctly, replace the original ECM. Refer to
STOP. Illustration 36 g00862185

Test Step 7. Connect the +5 V Wiring for
(1) “DESIRED SPEED” potentiometer
the Analog Speed Circuit to the ECM
A. Turn the engine control switch to the OFF/RESET C. Rotate the “DESIRED SPEED” potentiometer (if
position. Switch the 16 amp circuit breaker for equipped) clockwise to the maximum speed
the ECM OFF. position.
D. Switch the 16 amp circuit breaker for the ECM

ON. Turn the engine control switch to the STOP
position.
E. Use ET to look for diagnostic codes.
Expected Result:
No active codes
Results:
• No codes – The 262-03 code or the 262-04

code is not active. Connecting the wiring for the
g00862455 analog speed circuit to the ECM did not cause a
Illustration 35
ECM connector P1
diagnostic code. The wiring for the analog speed
circuit appears to be OK. Proceed to Test Step 8.
B. Insert terminal 18 into the P1 connector. Pull on
the wire in order to verify that the terminal is fully • Active code – The 262-03 code or the 262-04
inserted into the connector. code is active. Connecting the wiring for the
analog speed circuit to the ECM caused a
diagnostic code. Proceed to Test Step 4.
Test Step 8. Connect the +5 V Wiring for

the Sensors to the ECM
the ECM OFF.
209

• Fuel temperature
• Crankcase pressure
Note: An “Open Circuit” code will be generated for
each sensor that is disconnected. This is normal.
g00862457
Clear the codes after you complete this procedure.
Illustration 37
ECM connector P1 Expected Result:
B. Insert terminal 2 into the P1 connector. Pull on The original “5 Volt Sensor” diagnostic code
the wire in order to verify that the terminal is fully is deactivated when a particular sensor is
inserted into the connector. disconnected.
C. Switch the 16 amp circuit breaker for the ECM Results:

position. • Yes – The original “5 Volt Sensor” diagnostic
code is deactivated when a particular sensor is
D. Use ET to look for diagnostic codes. disconnected. The sensor and/or the wiring for
the sensor has a short circuit.
Expected Result:
No active codes
1. Reconnect the suspect sensor. Verify that the
Results: diagnostic code recurs.
• No codes – The 262-03 code or the 262-04 2. Disconnect the suspect sensor. Verify that the
code is not active. Connecting the 5 VDC for the diagnostic code is deactivated.
sensors did not cause a diagnostic code. The
problem appears to be resolved. If these conditions are true, replace the sensor.
Repair: The initial diagnostic code was probably 3. Clear all of the diagnostic codes. Verify that
caused by a poor electrical connection. Resume the problem is eliminated.
normal operation.
STOP.
STOP.
• No – The original “5 Volt Sensor” diagnostic code
• Active code – The 262-03 code or the 262-04 is still active after all of the +5 V sensors are
code is active. Connecting the 5 VDC for the disconnected. Do not reconnect the sensors.
sensors caused a diagnostic code. Proceed to Proceed to Test Step 10.
Test Step 9.
Test Step 10. Check the Engine
Test Step 9. Disconnect the +5 V Sensors Harnesses
and Look for Active Diagnostic Codes
A. Turn the engine control switch to the OFF
A. Observe the “Active Diagnostic” screen on ET. position. Switch the 16 amp circuit breaker for
Verify that the 262-03 code or the 262-04 code the ECM OFF.
is active.
B. Disconnect the P1 connector. Verify that all of
B. Disconnect the sensors for the following the sensors for the following parameters are
parameters one at a time. After you disconnect disconnected from the engine harness:
each sensor, wait for at least thirty seconds and
then observe the “Active Diagnostic” screen on • Inlet air temperature
ET.
210
• Unfiltered engine oil pressure Results:
• Filtered engine oil pressure • OK – Each check of the resistance is greater

than 20,000 ohms. The +5 V wires in the engine
• Fuel temperature harnesses do not have a problem. The problem
appears to be resolved. The initial diagnostic
• Crankcase pressure code was probably caused by a poor electrical
connection.
Repair: Reconnect all of the connectors. Resume

normal operation.
STOP.
• Not OK – At least one check of the resistance is

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

A. Disconnect the P6 connector. Verify that all of the
g00843355
Illustration 38 sensors are disconnected.
ECM side of the P1 ECM connector
C. Measure the resistance between terminal (2) of

the P1 connector and the points that are listed in
Table 8. During each measurement, wiggle the
harnesses in order to check for an intermittent
problem with the harness. Be sure to wiggle the
harnesses near each of the connectors for the
disconnected sensors. Also, wiggle the harness
at the terminal box’s connectors.
Table 8
Measure the Resistance for the Engine Harness.
Connector and Connector and Terminal
g00846024
Terminal Illustration 39
P1-2 P1-14 (inlet air temperature)

B. Measure the resistance between terminal (69) of
+5 V supply
P1-17 (engine oil temperature) the P6 connector and the points that are listed in
P1-26 (unfiltered engine oil pressure)
P1-24 (filtered engine oil pressure) problem with the harness. Be sure to wiggle the
harnesses near each of the connectors.
P1-15 (fuel temperature)
P1-25 (crankcase pressure)
P1-3 (analog return)
Ground strap for the engine
P1-69 (−battery terminal)
P1-57 (unswitched +battery terminal)
P1-70 (switched +battery terminal)
Expected Result:
Each check of the resistance is greater than 20,000

ohms.
211
Table 9 B. Measure the resistance between terminal 2 of

Measure the Resistance for the Left Engine Harness.
the P1 connector and the points that are listed
in Table 10. During each measurement, wiggle
Connector and Connector and Terminal the wires in the terminal box in order to check for
Terminal an intermittent problem. Be sure to wiggle the
P6-69 P6-55 (shield) harnesses near each of the connectors.
+5 V supply
P6-56 (fuel temperature) Table 10
P6-68 (analog return) Measure the Resistance for the Terminal

Box’s Harness.
P1-57 (unswitched +battery terminal) Terminal
P1-69 (−battery terminal) P1-2 P1-14 (inlet air temperature)
+5 V supply
P1-70 (switched +battery terminal) P1-17 (engine oil temperature)
P1-26 (unfiltered engine oil pressure)
Expected Result:
P1-24 (filtered engine oil pressure)
Each check of the resistance is greater than 20,000 P1-15 (fuel temperature)
ohms.
P1-25 (crankcase pressure)
Results: P1-3 (analog return)
• OK – Each check of the resistance is greater Ground strap for the engine
than 20,000 ohms. The +5 V wires in the left side P1-69 (unswitched +battery terminal)
harness do not have a problem. Proceed to Test
Step 12. P1-57 (−battery terminal)
connector and/or at least one of the +5 V wires Expected Result:
in the left side harness.
Repair: Repair the left side harness, when ohms.
possible. Replace the harness, if necessary.
Results:
STOP.
• OK – Each check of the resistance is greater
Test Step 12. Check the Terminal Box’s than 20,000 ohms. The +5 V wires in the terminal
Harness box do not have a short circuit. Proceed to Test
Step 13.
A. Disconnect the P5 connector. Verify that P6 and
P1 are also disconnected. This will isolate the • Not OK – At least one check of the resistance is
terminal box’s harness. less than 20,000 ohms. There is a problem with a
the terminal box.
Repair: Repair the terminal box’s harness, when

STOP.
Test Step 13. Check the Right Side

Harness
A. Reconnect connector P5. Verify that connectors
P1 and P6 are disconnected.
g00843355
Illustration 40
212
Repair: Reconnect all of the connectors and

resume normal operation.
STOP.
• Not OK – At least one check of the resistance

is less than 20,000 ohms. Connecting P5 to the
terminal box causes a resistance check to fail.
At least one of the +5 V wires in the right side
harness has a problem.
Repair: Repair the right side harness, when

g00843355
STOP.
Illustration 41
i01627823
B. Measure the resistance between terminal 2 of
the P1 connector and the points that are listed in
+8V Sensor Voltage Supply
SMCS Code: 1901-038
harnesses near each of the connectors for the
disconnected sensors. Also, wiggle the harness
The ECM supplies 8.0 ± 0.8 VDC to these sensors:
at the terminal box’s connectors.
Table 11 • Sensor for engine coolant pressure
Measure the Resistance for the Harnesses. • All of the detonation sensors
Terminal A “+8 V sensor supply” diagnostic code is probably
caused by a short circuit or an open circuit in a
P1-2 P1-14 (inlet air temperature) harness. The next likely cause is a sensor problem.
+5 V supply The least likely cause is a problem with the ECM.
P1-17 (engine oil temperature)
P1-26 (unfiltered engine oil pressure) Logged diagnostic codes provide an historical
P1-24 (filtered engine oil pressure) record. Before you begin this procedure, use ET to
P1-15 (fuel temperature)
P1-25 (crankcase pressure) This troubleshooting procedure may generate
P1-3 (analog return) correcting the cause of the original diagnostic code.
Ground strap for the engine Clear the diagnostic codes after the problem is
resolved.
P1-69 (unswitched +battery terminal)
P1-57 (−battery terminal)
Expected Result:

ohms.
Results:
• OK – Each check of the resistance is greater than

20,000 ohms. The problem seems to be resolved.
The initial diagnostic code was probably caused
by a poor electrical connection.
213
g00844644
Illustration 42
Schematic for the 8 V sensors
Test Step 1. Inspect the Electrical Note: For the following steps, refer to
Connectors and Wiring. Troubleshooting, “Inspecting Electrical Connectors”.

the ECM OFF.
214
g00844718 g00844902
(1) ECM connector J2/P2 Right side of the engine
(2) 16 amp circuit breaker (7) P675/J675 6-pin connectors
(3) J6/P6 connectors for the harness from the sensors on the left
(8) Connector for a detonation sensor
side of the engine
(4) J5/P5 connectors for the harness from the sensors on the right
side of the engine
g00844905
Illustration 46
Left side of the engine
g00871503
Illustration 44 (9) J676/P676 6-pin connectors
Right side and top view of the engine (10) Connector for a detonation sensor
(AA) Top view of the engine
(5) Sensor for engine coolant pressure B. Thoroughly inspect each of the following
(6) J215/P215 connector for the engine coolant pressure sensor connectors:
• Connectors (J2/P2) for the ECM

• (J215/P215) connectors for the engine coolant
pressure sensor
• Terminal box (J5/P5) and (J6/P6) connectors

215
• Ignition / detonation rail (J675/P675) and

(J676/P676) connectors
• All the connectors for the detonation sensors

6 ± 1 N·m (55 ± 9 lb in).
g00846299
Illustration 49
(P6-53) Shield for the left side detonation sensors
(P6-54) Return for the left side detonation sensors
(P6-67) +8 V supply for the left side detonation sensors
b. Perform a 45 N (10 lb) pull test on each of

the wires that are associated with the circuit
for the 8 V sensors.
g00846295
Illustration 47
Harness side of the ECM P2 connector
c. Check the harness and wiring for abrasion
and pinch points from the sensors to the ECM.
(P2-54) Return for the right side detonation sensors
(P2-55) Return for the left side detonation sensors
(P2-56) +8 V supply for the right side detonation sensors Expected Result:
(P2-57) +8 V supply for the left side detonation sensors
(P2-65) +8 V supply for the engine coolant pressure sensor All of the connectors, pins, and sockets are
(P2-66) Return for the engine coolant pressure sensor connected properly. The connectors and the wiring
Results:

points. The components are in good condition
with proper connections. Proceed to Test Step 2.
• Not OK – At least one of the connectors, pins,

and sockets are connected properly. At least
one of the connectors and/or the wiring have
corrosion, abrasion, and/or pinch points.
g00846296
Illustration 48
Repair: Perform the necessary repairs and/or
Harness side of the terminal box P5 connector replace parts, if necessary.
(P5-11) Shield for the engine coolant pressure sensor
(P5-13) Shield for the right side detonation sensors STOP.
(P5-21) Return for the engine coolant pressure sensor
(P5-23) Return for the right side detonation sensors
(P5-31) +8 V supply for the right side detonation sensors Test Step 2. Check for Diagnostic Codes
(P5-37) +8 V supply for the engine coolant pressure sensor
terminal box. Switch the 16 amp circuit breaker
for the ECM ON. Turn the engine control switch
to the STOP position.
B. Observe the “Active Diagnostic” screen on ET.

Wait at least thirty seconds so that any codes
may become activated. Look for these codes:
216
• 41-03 8 Volt DC Supply short to +batt 1. Reconnect the suspect sensor. Verify that the
diagnostic code recurs.
• 41-04 8 Volt DC Supply short to ground
2. Disconnect the suspect sensor. Verify that the
C. Observe the “Logged Diagnostic” screen on ET. diagnostic code is deactivated.
Look for the same codes.
If these conditions are true, repair the sensor
Expected Result: or the sensor’s harness. Replace parts, if
necessary.
The 41-03 code or the 41-04 code is not active.
3. Clear all of the diagnostic codes. Verify that
Results: the problem is eliminated.
• No codes – The 41-03 code or the 41-04 code is STOP.

not active. The +8 volt sensor supply is operating
correctly at this time. STOP. • No – The original “8 Volt DC Supply” diagnostic
code is still active after all of the +8 V sensors
• Active code – The 41-03 code or the 41-04 code are disconnected. Do not reconnect the sensors.
is active. Proceed to Test Step 3. Proceed to Test Step 4.
• Logged code – The 41-03 code or the 41-04 Test Step 4. Isolate the Wiring Harnesses
code is not active. However, there is at least one from the ECM
logged code for the 8 volt sensor supply.
Repair: There may be a problem with the wiring position. Switch the 16 amp circuit breaker for
and/or a connector. Refer to Troubleshooting, the ECM OFF.

Check for diagnostic codes again. Proceed to
Test Step 3, if necessary.
Test Step 3. Disconnect the 8 V Sensors

and Look for Active Diagnostic Codes.
A. Turn on the “Active Diagnostic” screen on ET.
Verify that the “41-03” or “41-04” code is active.
B. Disconnect each 8 V sensor one at a time.

After you disconnect each sensor, wait for at
least two seconds and then observe the “Active
Diagnostic” screen on ET.
Note: An “Open Circuit” code will be generated for

each sensor that is disconnected. This is normal.
Clear the codes after you complete this procedure.
Expected Result: Illustration 50

g00862672

The original “8 Volt DC Supply” diagnostic
disconnected.
the terminal 56, 57, and 65 from the P2 connector.
Results:
• Yes – The original “8 Volt DC Supply” diagnostic position.
disconnected. The sensor and/or the wiring for
D. Wait for thirty seconds and then observe the
the sensor has a short circuit.
“Active Diagnostics” screen on the ET. Determine
if a 41-03 code or a 41-04 code is active.
217
Expected Result: C. Disconnect the P2 connector. Verify that all of

the sensors for the following parameters are
No active codes disconnected from the engine harnesses:
Results: • Engine coolant pressure sensor

• No codes – The 41-03 code or the 41-04 code is • All of the detonation sensors
not active. Disconnecting all of the +8 V wiring
from the ECM eliminated the active “8 Volt DC
Supply” diagnostic code. There is a problem in a
connector and/or the wiring in a harness. Proceed
to Test Step 5.

code is not active. Disconnecting all of the +8
V wiring from the ECM eliminated the active “8
Volt DC Supply” diagnostic code. There may be a
problem with the ECM.

following steps:


STOP.
g00844823
Illustration 52
Test Step 5. Check the Engine Harnesses
Note: For the functions of the terminals, refer to
A. Turn the engine control switch to the OFF Table 12.
the ECM OFF. D. Measure the resistance between the terminals
that are listed in Table 12. During each
measurement, wiggle the harnesses in order
to check for an intermittent problem with the
harness. Be sure to wiggle the harnesses near
each of the connectors for the sensors and the
terminal box.
g00844743
Illustration 51
ECM connector P2
B. Insert terminals 56, 57, and 65 into the P2

connector. Pull on each wire in order to verify that
the terminals are fully inserted into the connector.
218
Table 12 • Not OK – At least one check of the resistance

Points for the Measurement of Resistance
is less than 20,000 ohms. There is a problem
with a connector and/or the wiring in a harness.
Connector and Terminal Connector and Terminal Proceed to Test Step 6.
P2-65 (+8 VDC) P2-68 (Engine coolant
pressure) Test Step 6. Check the Left Side Harness
and the Left Side Ignition / Detonation
P2-66 (Return) Rail Wiring
P2-56 (+8 VDC) P2-36 (Detonation sensor)
A. Disconnect the P6 connector. Thoroughly inspect
P2-37 (Detonation sensor) the P6/J6 connectors for corrosion and moisture.
P2-38 (Detonation sensor) Ensure that the connectors are in good condition.
Verify that all of the detonation sensors on the
P2-39 (Detonation sensor) left side of the engine are disconnected. This
P2-54 (Return) will isolate the left side harness and the ignition /
detonation rail wiring.
P2-57 (+8 VDC) P2-44 (Detonation sensor)
P2-45 (Detonation sensor)
P2-55 (Return)
P2-65 (+8 VDC) Engine ground
P2-56 (+8 VDC)
P2-57 (+8 VDC)
P2-65 (+8 VDC) P1-69 (−Battery terminal)
P2-56 (+8 VDC)
g00846626
P2-57 (+8 VDC) Illustration 53
Terminal box side of the P6 connector
P2-65 (+8 VDC) P1-57 (Unswitched
+Battery) For the functions of the terminals, refer to Table 13.
P2-56 (+8 VDC)
P2-57 (+8 VDC) B. Measure the resistance between terminal 67 of
the P6 connector and each of the points that are
P2-65 (+8 VDC) P1-70 (Switched +Battery) listed in the following table:
P2-56 (+8 VDC)
Table 13
P2-57 (+8 VDC) Points for the Measurement of Resistance
Connector and Terminal Connector and Terminal
Expected Result:
P6-67 (+8 V supply) P6-66 (Detonation sensor)
ohms.
Results:
• OK – Each check of the resistance is greater than P6-54 (Return)
20,000 ohms. The +8 V wires and connectors
P6-53 (Shield)
in all of the engine harnesses do not have a
problem. The problem appears to be resolved. Ground strap for the engine
Expected Result:
normal operation.
ohms.
STOP.
219
Results: Repair: Repair the left side harness, when

• OK – Each check of the resistance for the left
side harness and the ignition / detonation rail STOP.
wiring is greater than 20,000 ohms. The +8 volt
wires in the left side harness and the left side Test Step 8. Check the Wiring Inside the
ignition / detonation rail do not have a problem. Left Side Ignition / Detonation Rail
A. Verify that P676 and all of the left side detonation
• Not OK – At least one check of the resistance is sensors are disconnected. This will isolate the
less than 20,000 ohms. There is a problem with a wiring inside the left side ignition / detonation rail.
connector and/or the wiring in either the left side
harness or the wiring inside the left side ignition /
detonation rail. Proceed to Test Step 7.
Test Step 7. Check the Wiring in the Left

Side Harness
A. Verify that connector P6 is disconnected.
Disconnect the P676 connector from the ignition
/ detonation rail. This will isolate the left side
harness. Thoroughly inspect the J676/P676
connectors for corrosion and moisture. Ensure
that the connectors are in good condition.
B. Measure the resistance between terminal 67 of

g00846466
the P6 connector and each of points that are Illustration 54
listed in the following table: J676 is attached to the left side ignition / detonation rail.
For the functions of the terminals, refer to Table 15.
Table 14
Points for the Measurement of Resistance B. Measure the resistance between terminal A of
the J676 connector on the ignition / detonation
rail and each of the points that are listed in the
P6-67 (+8 V supply) P6-66 (Detonation sensor) following table:
P6-65 (Detonation sensor) Table 15
P6-64 (Detonation sensor) Points for the Measurement of Resistance
P6-63 (Detonation sensor) Connector and Terminal Connector and Terminal
P6-54 (Return) J676-A (+8 V supply) J676-B (Return)
P6-53 (Shield) J676-C (Detonation
Ground strap for the engine sensor)
J676-D (Detonation
sensor)
Expected Result:
J676-E (Detonation
Each check of the resistance is greater than 20,000 sensor)
ohms.
J676-F (Detonation
sensor)
Results:
• OK – Each check of the resistance is greater
than 20,000 ohms. The +8 V wires in the left side Expected Result:
engine harness do not have a problem when the
ignition / detonation rail is disconnected. There is Each check of the resistance is greater than 20,000
a problem in the +8 V wiring inside the left side ohms.
ignition / detonation rail. Proceed to Test Step 8.

connector and/or at least one of the +8 V wires
in the left side harness.
220
Results: B. Measure the resistance between terminal 31 of

the P5 connector and each of points that are
• OK – Each check of the resistance is greater listed in the following table:
than 20,000 ohms. The +8 V wires inside the
ignition / detonation rail do not have a problem. Table 16
The problem appears to be resolved. The initial Points for the Measurement of Resistance
diagnostic code was probably caused by a poor
electrical connection. Connector and Terminal Connector and Terminal
normal operation. P5-30 (Detonation sensor)
P5-29 (Engine coolant
STOP. pressure)
• Not OK – At least one check of the resistance is P5-23 (Return)

less than 20,000 ohms. There is a problem with a P5-22 (Detonation sensor)
inside the left side ignition / detonation rail. P5-21 (Return)
P5-13 (Shield)
Repair: The short circuit is probably caused by
a poor electrical connection and/or a wiring P5-12 (Detonation sensor)
problem inside the rail. Repair the electrical P5-11 (Shield)
connection and/or the wiring, when possible.
Replace the rail, if necessary. Ground strap for the engine
STOP. Expected Result:

Test Step 9. Check the Right Side Each check of the resistance is greater than 20,000
Harness and the Right Side Ignition / ohms.
Detonation Rail Wiring
Results:
A. Disconnect the P5 connector. Thoroughly inspect
the P5/J5 connectors for corrosion and moisture. • OK – Each check of the resistance for the right
Ensure that the connectors are in good condition. side harness and the ignition / detonation rail
Verify that all of the detonation sensors on the wiring is greater than 20,000 ohms. The +8 volt
right side of the engine are disconnected. Verify wires in the right side harness and the right side
that the J215/P215 connector for the engine ignition / detonation rail do not have a problem.
coolant pressure is disconnected. This will Proceed to Test Step 12.
isolate the right side harness and the ignition /
detonation rail wiring. • Not OK – At least one check of the resistance is
connector and/or the +8 V wires in either the right
side harness or the wiring inside the right side
ignition / detonation rail. Proceed to Test Step 10.
Test Step 10. Check the Wiring in the

Right Side Harness
A. Verify that J215 is disconnected. Verify that P5
is disconnected. Disconnect the P675 connector
from the ignition / detonation rail. This will isolate
the right side harness. Thoroughly inspect
the J675/P675 connectors for corrosion and
moisture. Ensure that the connectors are in good
g00846643 condition.
Illustration 55
Terminal box side of the P5 connector B. Measure the resistance between terminal 31 of
For the functions of the terminals, refer to Table 16. the J5 connector and each of points that are
listed in the following table:
221
Table 17
P5-29 (Engine coolant
pressure)
P5-23 (Return)
P5-21 (Return)
P5-21 (Shield) g00846597
Illustration 56
P5-12 (Detonation sensor) J675 is attached to the right side ignition / detonation rail.
For the functions of the terminals, refer to Table 18.
P5-11 (Shield)
Ground strap for the engine B. Measure the resistance between terminal A of
the J675 connector on the ignition / detonation
Expected Result: rail and each of the points that are listed in the
following table:
Each check of the resistance is greater than 20,000 Table 18
ohms.
Results: Connector and Terminal Connector and Terminal
• OK – Each check of the resistance is greater than J675-A (+8 V supply) J675-B (Return)
20,000 ohms. The +8 V wires in the right side J675-C (Detonation
engine harness do not have a problem when the sensor)
ignition / detonation rail is disconnected. There is
a problem in the +8 V wiring inside the right side J675-D (Detonation
ignition / detonation rail. Proceed to Test Step 11. sensor)
J675-E (Detonation
• Not OK – At least one check of the resistance is sensor)
connector and/or at least one of the +8 V wires in P675-F (Detonation
sensor)
the right side harness.
Repair: Repair the right side harness, when
Expected Result:
STOP.
ohms.
Test Step 11. Check the Wiring Inside the
Right Side Ignition / Detonation Rail Results:
A. Verify that P675 and all of the right side
detonation sensors are disconnected. This will • OK – Each check of the resistance is greater
than 20,000 ohms. The +8 V wires inside the
isolate the wiring inside the right side ignition /
right side ignition / detonation rail do not have a
detonation rail.
problem. The problem appears to be resolved.

normal operation.
STOP.
222
• Not OK – At least one check of the resistance is Table 19

less than 20,000 ohms. There is a problem with a Points for the Measurement of Resistance
inside the right side ignition / detonation rail. Connector and Terminal Connector and Terminal
P2-65 (+8 VDC) P2-68 (Engine coolant
Repair: The short circuit is probably caused by pressure)
a poor electrical connection and/or a wiring
problem inside the rail. Repair the electrical P2-66 (Return)
connection and/or the wiring, when possible. P2-56 (+8 VDC) P2-36 (Detonation sensor)
Replace the rail, if necessary.
STOP. P2-38 (Detonation sensor)
Test Step 12. Check the Terminal Box’s P2-39 (Detonation sensor)
Harness P2-54 (Return)
A. Verify that the P5 and P6 connectors are P2-57 (+8 VDC) P2-44 (Detonation sensor)
disconnected. Also verify that the P2 connector
is disconnected. This will isolate the terminal
box’s harness. P2-46 (Detonation sensor)
P2-55 (Return)
P2-65 (+8 VDC) Engine ground
P2-56 (+8 VDC)
P2-57 (+8 VDC)
P2-65 (+8 VDC) P1-69 (−Battery terminal)
P2-56 (+8 VDC)
P2-57 (+8 VDC)
P2-65 (+8 VDC) P1-57 (Unswitched
+Battery)
P2-56 (+8 VDC)
P2-57 (+8 VDC)
P2-65 (+8 VDC) P1-70 (Switched +Battery)
P2-56 (+8 VDC)
P2-57 (+8 VDC)
Expected Result:

ohms.
Illustration 57
g00844823 Results:
Note: For the functions of the terminals, see Table • OK – Each check of the resistance is greater
19. than 20,000 ohms. The +8 V wires in the terminal
box do not have a problem. The problem appears
B. Measure the resistance between the terminals to be resolved. The initial diagnostic code was
that are listed in Table 19. During each probably caused by a poor electrical connection.
measurement, wiggle the harnesses in order
to check for an intermittent problem with the Repair: Reconnect all of the connectors. Resume
harness. Be sure to wiggle the harnesses near normal operation.
each of the connectors.
STOP.
223

less than 20,000 ohms. There is a problem in a
the terminal box.
Repair: Repair the terminal box’s harness, when

possible. Replace the terminal box’s harness, if
necessary.
STOP.
i01626697
Air/Fuel Pressure Module

SMCS Code: 1901-038
Tubes that connect the air/fuel pressure module to

the inlet air manifold and the fuel manifold enable
the module to sense the absolute inlet manifold air
pressure and fuel pressure. The module calculates
the differential pressure between the fuel manifold
and the inlet air manifold. This fuel differential
pressure is the value of the fuel pressure minus the
value of the inlet manifold air pressure.
The module sends PWM signals that represent the

inlet manifold air pressure and the fuel differential
pressure to the ECM. The ECM uses the information
to help calculate the fuel flow.
The most likely causes of the diagnostic code are a

poor connection or a problem in a wiring harness.
The next likely cause is a problem with the module.
The least likely cause is a problem with the ECM.

The troubleshooting procedure may generate

resolved.
224
g00842539
Illustration 58
Schematic for the air/fuel pressure module

g00843984
Illustration 60
(4) Harness connector for the air/fuel pressure module
g00843978
Illustration 59
(1) ECM J1/P1 connectors B. Thoroughly inspect each of the following
(2) 16 amp circuit breaker for the ECM connectors:
(3) Terminal box J6/P6 connectors for the left engine harness
position. Switch the 16 amp circuit breaker for • Terminal box J6/P6 connectors
• Harness connectors for the air/fuel pressure
Note: For the following steps, refer to module
connectors P1 and P6. The proper torque is
6 ±1 N·m (55 ± 9 lb in).
225
g00844052 g00844069
Harness side of the ECM P1 connector Harness side of the terminal box P6 connector
(10) PWM signal for the inlet manifold air pressure (11) Keyswitch +Battery
(11) PWM signal for the fuel differential pressure (21) -Battery
(69) -Battery (22) PWM signal for the fuel differential pressure
(70) Keyswitch +Battery (30) PWM signal for the inlet manifold air pressure
b. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the circuit for
the air/fuel pressure module.
c. Check the harnesses and wiring for abrasion

and pinch points from the air/fuel pressure
module to the ECM.
Expected Result:

Results:

are properly connected. The connectors and the

or sockets are not connected properly. At least
one of the connectors or the wiring has corrosion,
abrasion, and/or pinch points.
226
Repair: Perform the necessary repairs and/or If any of the codes are logged and the engine is
replace parts, if necessary. not operating properly, troubleshoot the symptom.
Refer to Troubleshooting, “Troubleshooting without
STOP. a Diagnostic Code”.
Test Step 2. Check for Diagnostic Codes STOP.
A. Switch the 16 amp circuit breaker for the ECM to Test Step 3. Verify the Supply Voltage to
the ON position. Turn the engine control switch the Module
to the STOP position.
B. Observe the “Active Diagnostic” screen on ET. position. Switch the 16 amp circuit breaker for
Wait at least 30 seconds so that any codes may the ECM to the OFF position.
become activated. Look for these codes:
• 94-03 Fuel Pressure open/short to +batt

• 94-08 Fuel Pressure noisy
• 106-03 Air Inlet Pressure Sensor short to +batt
• 106-08 Air Inlet Pressure Sensor noisy signal
C. Determine whether any of the same codes are
logged.
Expected Result:
g00844095
None of the above diagnostic codes are active or Illustration 63
logged. Harness connector for the air/fuel pressure module
(A) Keyswitch +Battery
Results: (B) -Battery
(C) PWM signal for the differential pressure of the fuel manifold
• OK (No codes) – None of the above diagnostic and the inlet air manifold
(D) PWM signal for the inlet manifold air pressure
codes are active or logged. The problem seems
to be resolved. The air/fuel pressure module is
operating correctly at this time. B. Disconnect the harness connector from the
air/fuel pressure module.
Repair: The initial diagnostic code was probably
caused by a poor electrical connection. For C. Switch the 16 amp circuit breaker for the ECM to
intermittent problems, refer to Troubleshooting, the ON position. Turn the engine control switch
“Inspecting Electrical Connectors”. to the STOP position.
STOP. D. Measure the voltage between terminals “A” and

“B” on the harness connector for the air/fuel
pressure module. Wiggle the harness in order to
• Not OK (Active code) – There is an active check for an intermittent problem.
diagnostic code for the air/fuel pressure module.
Expected Result:
• No (Logged code) – There are no active The voltage between terminals “A” and “B” on the
diagnostic codes for the air/fuel pressure module.
However, there is a logged code for the air/fuel harness connector for the air/fuel pressure module
pressure module. is approximately 24 VDC.
Repair: There may be a problem with the wiring Results:

and/or a connector. Attempt to activate the code
by performing another pull test on the wires that • OK – The voltage between terminals “A” and “B”
are associated with the air/fuel pressure module. on the harness connector for the air/fuel pressure
Refer to Troubleshooting, “Inspecting Electrical module is approximately 24 VDC. Proceed to Test
Connectors”. Step 4.
227
• Not OK – The voltage between terminals “A”

and “B” on the harness connector for the air/fuel
pressure module is not approximately 24 VDC.
Repair: Use the following procedure to verify the

supply voltage at the terminal box.
g00843978
Illustration 64
(1) ECM J1/P1 connectors
(2) 16 amp circuit breaker for the ECM
(3) Terminal box J6/P6 connectors for the left engine harness
1. Turn the engine control switch to the

OFF/RESET position. Switch the 16 amp circuit
breaker for the ECM to the OFF position. g00844303
Illustration 65
Bottom of the terminal box
2. Disconnect connectors (J6/P6). Terminal box J6 connector
(J6-11) Keyswitch +Battery
3. Switch the 16 amp circuit breaker for the ECM
(J6-21) -Battery
to the ON position. Turn the engine control
switch to the STOP position.
4. Measure the voltage between terminals (J6-11)
and (J6-21). Wiggle the harness in the terminal
box in order to check for an intermittent
problem.
The correct voltage between terminals (J6-11)

and (J6-21) is approximately 24 VDC.
If the correct voltage is found on the J6

connector, there is a problem in the wiring
harness between the P6 connector and the
air/fuel pressure module. Repair the harness
or replace the harness.
If the correct voltage is not found on the J6

connector, there may be a problem in the
terminal box. Verify the voltage from the ECM.

OFF/RESET position. Switch the 16 amp
circuit breaker for the ECM to the OFF
position.
b. Disconnect the ECM J1/P1 connectors.
c. Switch the 16 amp circuit breaker for the

ECM to the ON position. Turn the engine
control switch to the STOP position.
228
g00844095
Illustration 67
Harness connector for the air/fuel pressure module
(A) Keyswitch +Battery
(B) -Battery
(C) PWM signal for the fuel differential pressure
(D) PWM signal for the inlet manifold air pressure
B. Connect a jumper wire with the appropriate

connectors on the ends between terminal “A” on
the harness connector for the air/fuel pressure
module and terminal “A” on the module’s
receptacle. Connect another jumper wire
between terminal “B” on the harness connector
Illustration 66 g00849901 for the air/fuel pressure module and terminal “B”
on the module’s receptacle.
ECM J1 connector
(J1-69) -Battery C. Use a multimeter to measure the duty cycle and
(J1-70) Keyswitch +Battery
the frequency of the suspect signal.
d. Measure the voltage between terminals
a. Switch the 16 amp circuit breaker for the ECM
(J1-69) and (J1-70).
switch to the STOP position.
The correct voltage between terminals
(J1-69) and (J1-70) is approximately 24
b. Measure the duty cycle and the frequency
VDC.
between terminals “B” and “C” on the
module’s receptacle.
If the correct voltage is found on the ECM
J1 connector, there is a problem with the
c. Measure the duty cycle and the frequency
terminal box’s wiring. Repair the wiring or
between terminals “B” and “D” on the
replace the wiring.
module’s receptacle.
If the correct voltage is not found on the
Expected Result:
ECM P1 connector, there may be a problem
with the electrical power supply. For further
The duty cycle between terminals “C”, “D” and
information on troubleshooting the electrical
terminal “B” is between 17 and 95 percent and the
power supply, refer to Troubleshooting,
frequency is between 450 and 600 Hz.
“Electrical Power Supply”.
Results:
STOP.
Test Step 4. Check for a Signal from the • Yes – The duty cycle and the frequency of the
suspect signal is correct. The module is operating
Module correctly. Proceed to Test Step 5.
position. Switch the 16 amp circuit breaker for • No – The duty cycle and/or the frequency of the
suspect signal is not correct. The module is not
operating correctly.
229
Repair: Turn the engine control switch to the a. Switch the 16 amp circuit breaker for the ECM
OFF/RESET position. Switch the 16 amp circuit to the ON position. Turn the engine control
breaker for the ECM to the OFF position. Remove switch to the STOP position.
the jumper wires from the connectors for the
air/fuel pressure module module. Replace the b. Insert a 7X-1710 Multimeter Probe into
air/fuel pressure module. terminal (P6-21). Measure the duty cycle and
the frequency between terminals (P6-21) and
STOP. (P6-22). Wiggle the harness in order to check
for an intermittent problem.
Test Step 5. Check for a Signal to the
Terminal Box c. Measure the duty cycle and the frequency
between terminals (P6-21) and (P6-30).
A. Turn the engine control switch to the OFF/RESET Wiggle the harness in order to check for an
position. Switch the 16 amp circuit breaker for intermittent problem.
Expected Result:
B. Remove the jumper wires from the connectors
for the air/fuel pressure module. Reconnect the The duty cycle between terminals (P6-22), (P6-30),
engine harness to the air/fuel pressure module. and (P6-21) is between 17 and 95 percent and the
Results:
• Yes – The duty cycle and the frequency of the

suspect signal is correct. The module is operating
correctly and the harness between the module
and the terminal box P6 connector is OK. There
may be a problem in the terminal box.
Repair: Remove the 7X-1710 Multimeter Probe.

Reinstall the disconnected terminals. Pull on the
wires in order to verify proper installation.
• No – The duty cycle and the frequency of the

suspect signal is not correct. The module is
operating correctly but there is a problem with
a connection and/or the wiring in the engine
harness.
Repair: Remove the 7X-1710 Multimeter Probe.

Reinstall the disconnected terminals. Pull on the
wires in order to verify proper installation. Repair
the harness, when possible. Replace the harness,
if necessary.
g00870486 STOP.
Illustration 68
(P6-22) PWM signal for the fuel differential pressure
Test Step 6. Check for a Signal at the ECM
(P6-30) PWM signal for the inlet manifold air pressure
(P6-21) -Battery A. Turn the engine control switch to the OFF/RESET
C. Use a 151-6320 Wire Removal Tool to remove the ECM to the OFF position.
terminals (P6-22) and (P6-30) from the harness
side of the terminal box P6 connector. Label the
wires.
D. Use a multimeter to check the signals from the

removed terminals.
230
Expected Result:
The duty cycle for terminals (P1-10), (P1-11), and

(P1-69) is between 17 and 95 percent and the
Results:
• Yes – The duty cycle and the frequency of the

suspect signal is correct. The ECM is receiving
a valid signal. However, a diagnostic code is
activated for the air/fuel pressure module. There
may be a problem with the ECM.
Repair: Turn the engine control switch to the

breaker for the ECM to the OFF position. Remove
the 7X-1710 Multimeter Probe. Reinstall the
terminals into the P1 connector. Pull on the wires
in order to verify proper installation.
It is unlikely that the ECM has failed. Exit this

procedure and perform this procedure again. If
the condition is not resolved, replace the ECM
according to Troubleshooting, “Replacing the
ECM”. Verify that the problem is resolved.
STOP.
g00870514
Illustration 69
Harness side of the ECM P1 connector • No – The duty cycle and the frequency of the
(P1-10) PWM signal for the inlet manifold air pressure suspect signal is not correct. The module is
(P1-11) PWM signal for the fuel differential pressure operating correctly and the engine harness is
(P1-69) -Battery OK. However, the ECM is not receiving a valid
signal. There is a problem with the wiring in the
B. Use a 151-6320 Wire Removal Tool to remove terminal box.
terminals (P1-10) and (P1-11) from the harness
side of the ECM P1 connector. Label the wires. Repair: Turn the engine control switch to the
C. Use a multimeter to check the signals from the breaker for the ECM to the OFF position. Remove
removed terminals. the 7X-1710 Multimeter Probe. Reinstall the
terminals into the P1 connector. Pull on the wires
a. Switch the 16 amp circuit breaker for the ECM in order to verify proper installation.
switch to the STOP position. Repair the connector(s) and/or the wiring, when
possible. Replace the connector(s) and/or the
b. Insert a 7X-1710 Multimeter Probe into wiring, if necessary.
terminal (P1-69). Measure the duty cycle and
the frequency between terminals (P1-69) and STOP.
(P1-10). Wiggle the harness in the terminal
box in order to check for an intermittent
problem. i01631818
c. Measure the duty cycle and the frequency

Analog Sensor Signal
between terminals (P1-69) and (P1-11).
SMCS Code: 1901-038
Wiggle the harness in the terminal box in
order to check for an intermittent problem.
Use this procedure to troubleshoot diagnostic codes

for open circuits or short circuits for the sensors of
these parameters:
231

• Engine coolant temperature
• Crankcase Pressure
• Fuel Temperature
The engine coolant temperature sensor does not
require +5 VDC from the ECM. The engine coolant
temperature sensor is an analog type of passive
sensor. The sensor operates without a voltage
supply from the ECM.
The ECM can be configured for one of these types

of speed control:
• Potentiometer
• 4-20 ma
The “DESIRED SPEED” potentiometer (if equipped)
must be supplied with +5 VDC from the ECM. If
the “DESIRED SPEED” potentiometer has a short
circuit or the potentiometer’s wiring has a short
circuit, a 262-03 or 262-04 diagnostic code may be
activated. There are no diagnostic codes for the
circuit of the “DESIRED SPEED” potentiometer.
The -03 code is probably caused by a problem in

an engine harness. There may be an open circuit
in a harness, or a short circuit to a positive voltage
source in a harness. The next likely cause is a
sensor problem. The least likely cause is a problem
with the ECM.
The -04 code is probably caused by a short circuit

to ground in an engine harness. The next likely
cause is a sensor problem. The least likely cause is
a problem with the ECM.


correcting the cause of the original diagnostic
code. Clear the diagnostic code after the problem
is resolved.
232
g00847059
Illustration 70
233
Schematic for the analog sensors

g00848213
Illustration 71
Terminal Box g00867318
Illustration 72
(1) ECM connector J2/P2 The inlet air temperature sensor is installed in the inlet manifold
(2) ECM connector J1/P1 between the two cylinder heads on the right side of the engine.
(4) J6/P6 connectors for the harness from the sensors on the left (6) Inlet air temperature sensor
side of the engine
(5) J5/P5 connectors for the harness from the sensors on the right
side of the engine
A. Thoroughly inspect each of the following

connectors:
• J2/P2and J1/P1 ECM connectors

• J5/P5 and J6/P6 connectors on the terminal
box

6 ± 1 N·m (55 ± 9 lb in).
g00847085
Illustration 73
Right side view and top side view of the engine
(7) Engine coolant temperature sensor
234
g00847095 g00847097
Front view Rear view
(8) Unfiltered engine oil pressure (12) Fuel temperature sensor
(9) Engine oil temperature
(10) Filtered engine oil pressure
b. Inspect each electrical connection for the
analog sensors. Check the harnesses and
wiring for abrasion and pinch points from
each of the analog sensors to the ECM.
Expected Result:

Results:

g00867324 wiring are free of corrosion, abrasion, and pinch
Illustration 75
Right side view near the front of the engine with proper connections. Proceed to Test Step 2.
and/or sockets are not connected properly. At
least one of the connectors and/or the wiring
have corrosion, abrasion, and/or pinch points.

replace parts, if necessary.
STOP.
235
Test Step 2. Check for Diagnostic Codes Table 20

Analog Sensor Diagnostic Codes
A. Connect ET to the service tool connector.
100-03 Engine Oil Pressure open/short to +batt
B. Switch the 16 amp circuit breaker for the ECM 100-04 Engine Oil Pressure short to ground
position. 101-03 Crankcase Pressure open/short to +batt
101-04 Crankcase Pressure short to ground
C. Clear any logged diagnostic codes.
110-03 Engine Coolant Temperature open/short to
D. Observe the “Active Diagnostic” screen on ET. +batt
Wait at least 30 seconds so that any codes may 110-04 Engine Coolant Temperature short to ground
become activated. Look for these codes:
172-03 Intake Manifold Air Temp open/short to +batt
• 262-03 5 Volt Sensor DC Power Supply short 172-04 Intake Manifold Air Temp short to ground
to +batt
174-03 Fuel Temperature open/short to +batt
• 262-04 5 Volt Sensor DC Power Supply short 174-04 Fuel Temperature short to ground
to +batt
175-03 Engine Oil Temperature open/short to +batt
Expected Result:
175-04 Engine Oil Temperature short to ground
The 262-03 code or the 262-04 code is not active. 542-03 Unfiltered Engine Oil Pressure open/short to
+batt
Results: 542-04 Unfiltered Engine Oil Pressure short to ground
• No codes – There are no active codes. The +5 V

sensor voltage supply is operating correctly at B. If one of the above codes is active, identify the
this time. Proceed to Test Step 3. type of diagnostic according to the condition: the
diagnostic code is either “open/short to +batt”
• Active code – There is an active “5 Volt Sensor DC (FMI 03) or “short to ground” (FMI 04).
Power Supply” diagnostic code. This procedure
will not work when this type of code is active. Expected Result:
Repair: Refer to Troubleshooting, “+5V Sensor None of the above codes are active.
Voltage Supply”.
Note: There are no diagnostic codes for the
STOP. “DESIRED SPEED” signal.
Test Step 3. Check for Active Analog Results:

Sensor Diagnostic Codes
• No active codes – None of the above codes are
A. Observe the “Active Diagnostic” screen on ET. active.
Wait at least 30 seconds so that any codes may
become activated. Look for the codes that are Repair: If any of the above codes are logged
listed in Table 20: and the engine is not running properly, refer
to Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
If the engine is running properly at this time,

there may be an intermittent problem in the
harness that is causing the codes to be logged.
Connectors”.
STOP.
• Active “open/short to +batt” (FMI 03) – There is

an active “open/short to +batt” diagnostic code.
If you are troubleshooting the sensor for engine
coolant temperature, proceed to Test Step 6.
Otherwise, proceed to Test Step 5.
236
• Active “short to ground” (FMI 04) – There is an

active “short to ground” diagnostic code. Proceed
to Test Step 4.
Test Step 4. Create an Open Circuit for

the Sensor
the ECM OFF.
B. Disconnect the sensor that has the “short to

ground” diagnostic code.
C. Turn the engine control switch to the STOP g00847511

Illustration 77
position.
Harness connectors for the various sensors
D. Observe the “Active Diagnostic” screen on ET. (A) +5 volt supply
Allow a minimum of thirty seconds for any codes (B) Return
to activate. Look for an active “open/short to (C) Signal
+batt” diagnostic code.
B. At the harness connector for the suspect sensor,
Expected Result: measure the voltage between terminal “A” and
terminal “B”.
There is an active “open/short to +batt” diagnostic
code for the disconnected sensor. Expected Result:
Results: The voltage between terminal “A” and terminal “B”

is 5.0 ± 0.5 VDC.
• Yes – Before the suspect sensor was Results:
disconnected, there was an active “short to
ground” diagnostic code. After the suspect
sensor was disconnected, there was an active • OK – The voltage between terminal “A” and
“open/short to +batt” diagnostic code. terminal “B” is 5.0 ± 0.5 VDC. +5 V is present at
the sensor connector. Proceed to Test Step 6.
Repair: Reconnect the sensor. If the active “short
to ground” diagnostic code recurs, replace the • Not OK – The voltage between terminal “A” and
original sensor. “B” is not 5.0 ± 0.5 VDC. +5 V is not present at
the sensor connector. The +5 V supply voltage
Verify that the code does not activate when must be present at the sensor in order to continue
the new sensor is installed. Clear the logged this procedure. The +5 V wiring problem may be
diagnostic code from the ECM. inside the terminal box, or in an engine harness.
STOP. Repair: Verify that the wiring and/or connectors

are OK. Repair any faulty wiring and/or
connectors, when possible. Replace any
• Not OK – Before the suspect sensor was
disconnected, there was an active “short to faulty wiring and/or connectors, if necessary.
ground” diagnostic code. After the suspect Refer to Troubleshooting, “Inspecting Electrical
sensor was disconnected, the active “short to Connectors”. Check for diagnostic codes again.
ground” diagnostic code remained. If you are
troubleshooting the sensor for engine coolant STOP.
temperature, proceed to Test Step 6. Otherwise,
proceed to Test Step 5. Test Step 6. Check the Pull-Up Voltage at
the Sensor
Test Step 5. Check the Supply Voltage at
the Sensor Connector A. Verify that the suspect sensor’s connector is
disconnected from the engine harness.
A. Verify that the suspect sensor is disconnected
from the engine harness.
237
Table 21
Sensor Signal Terminal
Inlet Air Temperature Sensor P5-60
Engine Coolant Temperature P5-42
Sensor
Engine Oil Temperature P5-16
Sensor
Unfiltered Engine Oil Pressure P5-26
Sensor
Filtered Engine Oil Pressure P5-34
Sensor
g00847511 Crankcase Pressure P5-50

Illustration 78
Harness connectors for the various sensors Fuel Temperature P6-56
(A) +5 volt supply
(B) Return
(C) Signal
B. At the harness connector for the suspect sensor,

measure the voltage between terminal “B” and
terminal “C”.
Expected Result:
The voltage between terminal “B” and terminal “C”

is 6.5 ± 0.5 VDC.
Results:
• OK – The voltage between terminal “B” and

terminal “C” is 6.5 ± 0.5 VDC. The pull-up voltage
that is created by the ECM is present at the
sensor connector. The signal wire and the return
wire for the suspect sensor appear to be OK.
g00867387
• Not OK – The voltage between terminal “B” and Illustration 79
terminal “C” is not 6.5 ± 0.5 VDC. Proceed to Test Bottom view of terminal box
Step 7. (P5-16) Engine Oil Temperature
(P5-26) Unfiltered Engine Oil Pressure
Test Step 7. Check the Pull-Up Voltage (P5-34) Filtered Engine Oil Pressure
(P5-42) Engine Coolant Temperature
at the Terminal Box (P5-50) Crankcase Pressure
(P5-59) Return
A. Turn the engine control switch to the OFF/RESET (P5-60) Inlet Air Temperature
position. Switch the 16 amp circuit breaker for (P6-56) Fuel Temperature
the ECM OFF.
C. Use a 151-6320 Wire Removal Tool to remove
B. Refer to Table 21. Determine the signal terminal the signal terminal that is appropriate for the
for the suspect sensor. suspect sensor.
D. Fabricate a jumper wire with Deutsch sockets

on the ends. Insert one end of the jumper wire
into the open terminal of the P5 or P6 connector.
Pull on the jumper wire in order to verify proper
installation of the terminal.
E. Connect a multimeter lead to the end of the

jumper wire that is not inserted into the connector.
238
F. Insert a 7X-1710 Multimeter Probe into terminal Reinstall the terminal that was removed from the
59 of the P5 connector. terminal box’s connector. Pull on the wire in order
to verify proper installation of the terminal.
G. Connect the other multimeter lead to the probe.
H. Switch the 16 amp circuit breaker for the ECM to
the ON position. Turn the engine control switch Test Step 8. Check the Pull-Up Voltage
to the STOP position. at the ECM
I. Measure the pull-up voltage. A. Verify that the Engine Control Switch is in the
OFF/RESET position. Verify that the 16 amp
Expected Result: circuit breaker for the ECM is OFF.
The pull-up voltage for the suspect sensor at the

terminal box is 6.5 ± 0.5 VDC.
Results:
• OK – The pull-up voltage for the suspect sensor

at the terminal box is 6.5 ± 0.5 VDC. The pull-up
voltage that is created by the ECM is present at
terminal box P5 connector. There is a problem
with the right side engine harness or a harness
connector.

g00847601
Turn the engine control switch to the OFF/RESET Illustration 80
position. Switch the 16 amp circuit breaker for Locations of the signal wires on the harness side of the P1
the ECM OFF. connector
(14) Inlet manifold air temperature
Disconnect the multimeter leads. (15) Fuel temperature
(16) Desired engine speed
(17) Oil temperature
Use a 151-6320 Wire Removal Tool to remove (18) +5 V supply
the jumper wire from the terminal box’s connector. (19) Unused ground for the ECM
(24) Filtered oil pressure
Reinstall the terminal that was removed from the (25) Crankcase pressure
(26) Unfiltered oil pressure
ECM connector. Pull on the wire in order to verify (27) Engine coolant temperature
proper installation of the terminal. (35) Analog return
Repair any faulty wiring and/or connectors, when B. Use a 151-6320 Wire Removal Tool to remove
possible. Replace the harness, if necessary. the signal wire for the suspect sensor from the
P1 connector.
STOP.
C. Use a jumper wire with Deutsch sockets on the
• Not OK. – The pull-up voltage for the suspect ends. Insert one end of the jumper wire into the
sensor at the terminal box is not 6.5 ± 0.5 VDC. open terminal of the P1 connector.
Repair: Perform the following procedure: D. Connect a multimeter lead to the end of the
Turn the engine control switch to the OFF/RESET
position. Switch the 16 amp circuit breaker for E. At the harness side of the P1 connector, insert a
the ECM OFF. 7X-1710 Multimeter Probe along terminal 3.
Disconnect the multimeter leads. F. Connect the other multimeter lead to the probe.
Use a 151-6320 Wire Removal Tool to remove G. Switch the 16 amp circuit breaker for the ECM
the jumper wire from the terminal box’s connector. ON. Turn the engine control switch to the STOP
position.
H. Measure the pull-up voltage at the ECM.

239
Expected Result: Repair: Perform the following procedure:
The pull-up voltage for the suspect sensor at the 1. Reconnect the suspect sensor. Verify that the
ECM is 6.5 ± 0.5 VDC. “open/short to +batt” diagnostic code recurs.
Results: 2. Disconnect the suspect sensor. Verify that

the “open/short to +batt” diagnostic code is
• OK – The pull-up voltage for the suspect sensor deactivated.
at the ECM is 6.5 ± 0.5 VDC. The ECM is
producing a pull-up voltage that is valid. There 3. Connect the new connector. Verify that no
is a problem with the signal wire between P1 diagnostic codes are activated.
and P5 inside the terminal box. There may be a
problem with a connector. If these conditions are true, replace the faulty
sensor with the new sensor. For the proper
Repair: Perform the following procedure: torque value for the new sensor, refer to
Specifications, RENR5907.
position. Switch the 16 amp circuit breaker for 4. Clear all of the diagnostic codes. Verify that
the ECM OFF. the problem has been resolved.
Disconnect the multimeter leads. STOP.
Use a 151-6320 Wire Removal Tool to remove • Not OK – The active “open/short to +batt” code
the jumper wire from the P1 connector. remains. Connecting a new sensor did not resolve
the problem. Proceed to Test Step 10.
Reinstall the terminal that was removed from the
P1 connector. Pull on the wire in order to verify Test Step 10. Check the Operation of the
proper installation of the terminal. ECM
Repair any faulty wiring and/or connectors, when
possible. Replace any wiring and/or connectors, if
necessary. Refer to Troubleshooting, “Inspecting
STOP.
• Not OK. – The pull-up voltage for the suspect

sensor at the ECM is not 6.5 ± 0.5 VDC. Proceed
to Test Step 10.
Test Step 9. Check the Sensor

g00847601
A. Temporarily connect a sensor that is known to be Illustration 81
good to the engine harness. Locations of the signal wires on the harness side of the P1
connector
B. Switch the 16 amp circuit breaker for the ECM (14) Inlet manifold air temperature
ON. Turn the engine control switch to the STOP (15) Fuel temperature
(16) Desired engine speed
position. (17) Oil temperature
(18) +5 V supply
C. Observe the “Active Diagnostic” screen on ET. (19) Unused ground for the ECM
Allow a minimum of 30 seconds for any codes (24) Filtered oil pressure
to activate. (25) Crankcase pressure
(26) Unfiltered oil pressure
(27) Engine coolant temperature
Expected Result: (35) Analog return
No diagnostic codes are activated. A. Verify that the signal wire for the suspect sensor
has been removed from the P1 connector.
Results:
B. Clear any existing diagnostic codes.
• OK – No diagnostic codes are activated when a
good sensor is temporarily installed. Connecting
a new sensor resolved the problem.
240
C. Observe the “Active Diagnostic” screen on ET. Results:

Allow a minimum of 30 seconds for any codes
to activate. • OK – Active “open/short to +batt” and “short
to ground” diagnostic codes are generated
An active “open/short to +batt” diagnostic code according to the above steps. The ECM is
is generated for the sensor. operating correctly. The initial diagnostic code
was probably caused by a poor electrical
D. Turn the engine control switch to the OFF/RESET connection.
the ECM to the OFF position. Repair: Perform the following procedure:

the ECM OFF.
Use a 151-6320 Wire Removal Tool to remove

the jumper wire from the P1 connector.
Reinstall the terminal that was removed from the

P1 connector. Pull on the wire in order to verify
proper installation of the terminal.
Resume normal operation.
STOP.
g00867468
Illustration 82
Harness side of the P1 connector • Not OK – No active “open/short to +batt” or “short
(19) Ground to ground” diagnostic codes were generated. The
ECM is not operating correctly.
E. Use a jumper wire that is the appropriate length
with Deutsch sockets on the ends. Install one Repair: It is unlikely that the ECM has failed.
end of the jumper wire into the terminal for Perform this entire procedure again. If the problem
the signal wire that was removed from the P1 is not resolved, perform the following steps:
connector. Install the other end of the jumper
wire into terminal (19) of the P1 connector. This Temporarily install a new ECM. Refer to
will replace the sensor circuit with a short circuit. Troubleshooting, “Replacing the ECM”.
F. Switch the 16 amp circuit breaker for the ECM If the problem is resolved with the new ECM,
ON. Turn the engine control switch to the STOP install the original ECM and verify that the problem
position. returns. If the new ECM operates correctly and
the original ECM does not operate correctly,
G. Observe the “Active Diagnostic” screen on ET. replace the ECM. Refer to Troubleshooting,
Allow a minimum of 30 seconds for any codes “Replacing the ECM”.
to activate.
STOP.
An active “short to ground” diagnostic code is
generated. i01644708
Expected Result: Choke Actuator Solenoid

Active “open/short to +batt” and “short to ground” SMCS Code: 1901-038
diagnostic codes are generated according to the
above steps. System Operation Description:
The ECM controls the air choke actuator by

adjusting current flow through the actuator’s
solenoid.
241
The 525-05 diagnostic code is probably caused by

a problem with an electrical connector or an open
circuit in a harness. Under certain circumstances,
the 525-05 diagnostic code can occur if the low
side wire is shorted to ground. The next likely cause
is an open circuit inside the actuator solenoid. The
least likely cause is a problem with the ECM.

a short circuit in a harness or a problem with an
electrical connector. The next likely cause is a short
circuit inside the actuator solenoid. The least likely
cause is a problem with the ECM.

print logged codes to a file.
g00850127
Illustration 83
Schematic of the circuit for the air choke actuator

Note: This step is important for troubleshooting a
problem with instability.

the ECM OFF.

g00850164
Illustration 84
(1) ECM connectors J2/P2
(2) J6/P6 connectors for the harness from the left side of the engine
242
g00850188
Illustration 87
Terminal box P6 connector
(P6-44) Low side wire for the air choke actuator
(P6-45) High side wire for the air choke actuator
b. Perform a 45 N (10 lb) pull test on the four

Illustration 85 g00866896 wires that are associated with the circuit for
the air choke actuator.
Left side view of the engine
(4) Air choke actuator c. Thoroughly inspect connectors (P527/J527)
(5) P527/J527 connectors for the air choke actuator
for the air choke actuator for moisture and
contamination. Check the harness and wiring
B. Thoroughly inspect each of the following for abrasion and pinch points from the air
connectors: choke actuator to the ECM.
• (J2/P2) ECM connectors Expected Result:
• (J6/P6) connectors on the terminal box All of the connectors and terminals are connected
properly. The connectors are free of moisture and
• (P527/J527) connectors for the air choke corrosion. The wiring is free of abrasion and pinch
actuator points.
a. Check the torque of the Allen head screw for Results:
the ECM connector and the P6 connector. The
proper torque is 6 ± 1 N·m (55 ± 9 lb in).
• OK – The components are in good condition with
proper connections. If you are troubleshooting a
525-05 diagnostic code, proceed to Test Step 2.
If you are troubleshooting a 525-06 diagnostic
code, proceed to Test Step 8.
• Not OK – The components are not in good

condition and/or at least one connection is
improper.

STOP.
Illustration 86
g00850186 Test Step 2. Check the Solenoid and
Harnesses for an Open Circuit
ECM P2 connector
(P2-63) High side wire for the air choke actuator A. Turn the engine control switch to the OFF/RESET
the ECM OFF.
243
B. Disconnect connector P2 from the ECM.
g00850190
Illustration 88
ECM side of connector P2
C. Measure the resistance between P2 terminal (63) Illustration 89 g00852300

and terminal (64). During this measurement,
wiggle the harnesses in order to check for
an intermittent problem with the harness. Be (1) Ground strap for the ECM
sure to wiggle the harnesses near each of the
connectors.
B. Measure the resistance between the ground
strap for the ECM and P2 terminal (64). During
Expected Result:
this measurement, wiggle the harnesses in order
The resistance is between 5.0 and 20.6 ohms.
harness. Be sure to wiggle the harnesses near
Results:
Expected Result:
• OK – The resistance is between 5.0 and 20.6
ohms. The solenoid and wiring appear to be OK.
The low side wire may have a short to ground, or
the ECM may have a problem. Proceed to Test
Results:
Step 3.
• Not OK – The resistance is higher than 20.6 • OK – The resistance measurement is greater
than 20,000 ohms. The low side wire for the air
choke actuator appears to be OK. Proceed to
the wiring for the solenoid, or the solenoid may
Test Step 12.
have a problem. Proceed to Test Step 6.
Test Step 3. Check All of the Low Side • Not OK – The resistance measurement is less
than 20,000 ohms. There is a problem with the
Wiring for a Short to Ground low side wire for the air choke actuator. Proceed
to Test Step 4.
A. Verify that harness connector P2 is disconnected
from the ECM.
Test Step 4. Check the Low Side Wiring
Inside the Engine Harness for a Short to
Ground
A. Disconnect connector P6 from the terminal box.
244
Test Step 5. Check the Solenoid for an

Internal Short Circuit
A. Disconnect connector P527 from the air choke
actuator.
g00852362
Illustration 90
The side of connector P6 that faces toward the terminal box
(1) Ground Strap for the ECM

strap for the ECM and harness connector P6
terminal (44). During this measurement, wiggle
the harnesses in order to check for an intermittent
g00850485
Illustration 91
Expected Result:
(1) Solenoid for the air choke actuator
(J527-B) Low side
The resistance is greater than 20,000 ohms. (Shell) Shell for the connector
Results: B. Measure the resistance between terminal (B) and

the connector’s shell.
• OK – The resistance measurement is greater
than 20,000 ohms. The low side wire inside the Expected Result:
engine harness appears to be OK. The low side
wire inside the terminal box may have a problem. The resistance is greater than 20,000 ohms.
There may be a problem with a connector.
Results:
Repair: Repair the harness and/or the connector,
when possible. Replace the harness, if necessary. • OK – The resistance is greater than 20,000
ohms. The solenoid does not have an internal
STOP. short circuit. The low side wire inside the engine
harness has a short to ground.
• Not OK – The resistance measurement is less
than 20,000 ohms. The low side wire inside the Repair: Repair the engine harness or connectors,
engine harness may have a problem, or there when possible. Replace the harness, if necessary.
may be a problem with the solenoid. Proceed to
Test Step 5. STOP.

ohms. The solenoid has an internal short circuit.
245
Repair: Replace the solenoid. Refer to Operation Test Step 7. Check the Solenoid for an
and Maintenance Manual, “Electrohydraulic Open Circuit
Actuator - Recondition”.
. actuator.
STOP.
Test Step 6. Check the Engine Harness

and the Solenoid for an Open Circuit
g00852315
Illustration 92
Harness connector P6
B. Measure the resistance between P6 terminal (44)

g00850456
and terminal (45). During this measurement, Illustration 93
wiggle the harnesses in order to check for (1) Solenoid on the air choke actuator
an intermittent problem with the harness. Be (J527-B) Low side
sure to wiggle the harnesses near each of the (J527-A) High side
connectors.
B. Measure the resistance between terminals (B)
Expected Result: and (A) on the connector for the air choke
actuator (J527).
Expected Result:
Results:
ohms. The engine harness and the solenoid Results:
appear to be OK. The wiring inside the terminal
box or the terminal box’s connectors may have • OK – The resistance of the solenoid is between
a problem. 5.0 and 10.3 ohms. The solenoid does not have
an open circuit. There is an open circuit in the
Repair: Repair the wiring and/or connectors, engine harness. There may be a problem with a
when possible. Replace the wiring, if necessary. connector.
STOP. Repair: Repair the engine harness or connectors,

when possible. Replace the harness, if necessary.
• Not OK – The resistance is greater than 20.6
ohms. There is a problem with the engine harness STOP.
or the solenoid. Proceed to Test Step 7.
• Not OK – The resistance of the solenoid is higher
than 10.3 ohms. The resistance of the solenoid is
incorrect. The solenoid has an open circuit.
246
Repair: Replace the solenoid. Refer to Operation

and Maintenance Manual, “Electrohydraulic
STOP.
Test Step 8. Check all of the Wiring and

the Solenoid for a Short Circuit
A. Disconnect connector P2 from the ECM.
g00852315
Illustration 95
The side of connector P6 that faces the terminal box
B. Measure the resistance between harness

connector P6 terminal (44) and terminal (45).
During this measurement, wiggle the harnesses
in order to check for an intermittent problem with
the harness. Be sure to wiggle the harnesses
g00850190
Illustration 94 near each of the connectors.
ECM side of the ECM P2 connector
(P2-63) High side wire for the air choke actuator Expected Result:
and terminal (64). During this measurement, Results:
an intermittent problem with the harness. Be • OK – The resistance is between 5.0 and 20.6
sure to wiggle the harnesses near each of the ohms. The engine harness and the solenoid
connectors. appear to be OK. The wiring inside the terminal
box has a problem. There may be a problem with
Expected Result: a connector.
The resistance is between 5.0 and 20.6 ohms. Repair: Repair the wiring and/or the connector,
Results:
STOP.
ohms. The solenoid and wiring do not have a • Not OK – The resistance is lower than 5.0 ohms.
short circuit. Proceed to Test Step 11. There is a problem with the engine harness or the
solenoid. Proceed to Test Step 10.
• Not OK – The resistance is less than 5.0 ohms.
There is a problem with a connector and/or the Test Step 10. Check the Solenoid for a
wiring, or the solenoid has a problem. Proceed Short Circuit
to Test Step 9.
Test Step 9. Check the Engine Harness actuator.
and the Solenoid for a Short Circuit
247
Test Step 11. Create an Open Circuit and

Check the Operation of the ECM
A. Prevent fuel from entering the engine. Verify
that the gas supply to the engine is OFF.
B. Verify that the engine control switch is in the

circuit breaker for the ECM is OFF.
g00850186
Illustration 97
(P2-63) High side of the air choke actuator
(P2-64) Low side of the air choke actuator
g00850456
Illustration 96
(1) Solenoid on the air choke actuator C. Use a 151-6320 Wire Removal Tool to remove
(J527-B) Low side terminal (63) and terminal (64) from harness
(J527-A) High side connector P2. This will replace the wiring for the
air choke actuator with an open circuit.
and (A) on the connector for the air choke D. Switch the 16 amp circuit breaker for the ECM
actuator (J527). ON.
Expected Result: E. If a 525-05 diagnostic code and/or a 525-06
diagnostic code is logged, clear the code.
F. Turn the engine control switch to the START
Results: position and crank the engine. Allow a minimum
of 30 seconds for the generation of any codes.
• OK – The resistance of the solenoid is between Then turn the engine control switch to the STOP
5.0 and 10.3 ohms. The solenoid does not have position.
a problem. The engine harness appears to have
a short circuit. G. Observe the “Active Diagnostic” screen on ET.
Look for a 525-05 diagnostic code.
Repair: Repair the engine harness or connectors,
when possible. Replace the harness, if necessary. Expected Result:
STOP. A 525-05 diagnostic code is displayed on the ET.
• Not OK – The resistance of the solenoid is lower Results:
incorrect. • OK – When an open circuit was created, a
525-05 diagnostic code was generated. The ECM
Repair: Replace the solenoid. Refer to Operation is operating correctly. The problem appears to
and Maintenance Manual, “Electrohydraulic be resolved. The initial diagnostic code was
Actuator - Recondition”. probably caused by a poor electrical connection.
STOP. Repair: Perform the following procedure:
248
Turn the engine control switch to the OFF position.

Switch the 16 amp circuit breaker for the ECM
OFF.
Reinstall the terminals that were removed from

connector P2. Pull on the wires in order to verify
proper installation of the terminals.
Reconnect all of the connectors. Verify that the

STOP.
• Not OK – When an open circuit was created, a

525-05 diagnostic code was not generated. The g00850186
ECM may have a problem. Illustration 98
Repair: It is unlikely that the ECM has failed. (P2-63) High side of the air choke actuator
Exit this procedure and perform this procedure (P2-64) Low side of the air choke actuator
following procedure: C. Use a 151-6320 Wire Removal Tool to remove
terminal (63) and terminal (64) from harness
Temporarily install a new ECM. Refer to connector P2.
D. Use a jumper wire that is 125 ± 25 mm
If the problem is resolved with a new ECM, install (5.0 ± 1.0 inch) long with Deutsch sockets on
the original ECM and verify that the problem the ends. Insert one end of the jumper wire into
returns. If the new ECM operates correctly and the open terminal (63) of the P2 connector. Verify
the original ECM does not operate correctly, that the socket is making contact with pin 63 in
replace the original ECM. Follow the instructions the J2 connector.
in Troubleshooting, “Replacing the ECM”.
E. Insert the other end of the jumper wire into the
STOP. open terminal (64) of the P2 connector. Verify
that the socket is making contact with pin 64 in
Test Step 12. Create a Short Circuit and the J2 connector. This will replace the wiring for
Check the Operation of the ECM the air choke actuator with a short circuit.
A. Prevent fuel from entering the engine. Verify F. Switch the 16 amp circuit breaker for the ECM
that the gas supply to the engine is OFF. ON.
B. Verify that the engine control switch is in the G. If a 525-05 diagnostic code and/or a 525-06
OFF/RESET position. Verify that the 16 amp diagnostic code is logged, clear the code.
H. Turn the engine control switch to the START
position and crank the engine. Allow a minimum
Then turn the engine control switch to the STOP
position.
I. Observe the “Active Diagnostic” screen on ET.

Expected Result:
A 525-06 diagnostic code is displayed on the ET.

249
Results: When the flame front reaches the sensor, the

sensor briefly outputs a low voltage signal that
• OK – When the wiring for the air choke actuator is approximately −80 millivolts. The sensor’s low
was replaced with a short circuit, a 525-06 voltage signal is detected by the ICSM. The ICSM
diagnostic code was generated by the ECM. The measures the length of time from the all cylinders
ECM is operating correctly. The problem appears firing signal to the combustion sensor’s signal. The
to be resolved. The initial diagnostic code was ICSM determines the combustion burn time for the
probably caused by a poor electrical connection. cylinder.
Repair: Perform the following procedure: Each combustion sensor has a single terminal that
is connected to a signal wire. The signal wire from
Turn the engine control switch to the OFF position. each sensor is shielded.
OFF. Use this procedure to troubleshoot the system
only when there is an active noisy diagnostic code
Remove the jumper wire from the P2 connector. or an active short circuit diagnostic code that is
associated with a combustion sensor.
connector P2. Pull on the wires in order to verify A noisy diagnostic code indicates that the signal
proper installation of the terminals. from the sensor is noisy or connected to the wrong
cylinder.
problem is resolved. The short to ground diagnostic code indicates that
the sensor’s signal has a short circuit or the signal
STOP. is below the acceptable range.
• Not OK – When the wiring for the air choke Logged diagnostic codes provide an historical
actuator was replaced with a short circuit, a record. Before you begin this procedure, use ET to
525-06 diagnostic code was not generated by the print the logged codes to a file.
ECM. The ECM may have a problem.
Repair: It is unlikely that the ECM has failed. additional diagnostic codes. Keep your mind on
Exit this procedure and perform this procedure correcting the cause of the original diagnostic code.
again. If the problem is not resolved, perform the Clear the diagnostic codes after the problem is
following procedure: resolved.

If the problem is resolved with a new ECM, install

the original ECM and verify that the problem
returns. If the new ECM operates correctly and
replace the original ECM. Follow the instructions
STOP.
i01662520
Combustion Sensor
SMCS Code: 1901-038
Each cylinder has a combustion sensor that is

positioned on the edge of the cylinder. When the
engine control switch is in the STOP, START, or
AUTO position, the ICSM provides +80 VDC to the
combustion sensors.
250
g00865595
Illustration 99
Schematic for the circuit of the combustion sensors for the 12 cylinder engine
251
g00858406
Illustration 100
Schematic for the circuit of the combustion sensors for the 16 cylinder engine
Test Step 1. Inspect the Electrical Note: For the following steps, refer to
Connectors and Wiring Troubleshooting, “Inspecting Electrical Connectors”.
A. Turn the engine control switch to the OFF/RESET Note: Illustration 101 shows one side of the engine.
position. Switch the 16 amp circuit breaker for The other side of the engine is similar.
the ECM OFF.
252
B. Thoroughly inspect the suspect connector (2) at

the ICSM for corrosion or moisture.
C. Thoroughly inspect the suspect connector (3) for

corrosion or moisture.
D. Thoroughly check the suspect harness for

abrasion and pinch points from the sensor to
the ICSM.
E. Verify that the suspect harness has the proper

length in order to reach from the sensor to the
ICSM.
F. Verify that the suspect harness is connected to

the correct connector on the ICSM.
For a 12 cylinder engine, refer to Table 22 for

the proper connections:
Table 22
g00858362
Illustration 101 Cylinder Connectors on Connectors on
Left side of the engine the Left Side the Right Side
ICSM ICSM
(1) ICSM
(2) Connectors for the combustion sensors 1 R3
2 L3
3 R2
4 L2
5 R1
6 L1
7 L1
8 R1
9 L2
10 R2
11 L3
12 R3
For a 16 cylinder engine, refer to Table 23 for

the proper connections:
g00858414
Illustration 102
Section view of a cylinder head with a combustion sensor
(3) Harness connector
(4) Extension
(5) Sensor
253
Table 23 Test Step 2. Replace the Harness

Cylinder Connectors on Connectors on
the Left Side the Right Side
ICSM ICSM
1 R4
2 L4
3 R3
4 L3
5 R2
6 L2
7 R1
8 L1
9 L1
10 R1
11 L2
12 R2
13 L3
14 R3
15 L4
16 R4
g00858679
Illustration 103
Expected Result: (1) Harness connector
(2) Seal
All of the connectors are connected properly. The (3) Connector
connectors and the wiring are free of corrosion,
abrasion, and pinch points. The sensors are A. Temporarily exchange the suspect harness with
connected to the correct connector on the ICSM. a harness that is known to be good. The new
harness must be long enough to reach from
Results: the sensor to the ICSM. Verify that seal (2) is
installed in connector (1) on the new harness.
• OK – The components are in good condition with Ensure that connectors (1) and (3) are clean,
proper connections. If you are troubleshooting a dry, and properly connected. Do not install the
noisy diagnostic code, proceed to Test Step 2. If new harness onto the engine.
you are troubleshooting a diagnostic code for a
short circuit, proceed to Test Step 4. B. Start the engine. Use ET to place the engine in
the prechamber calibration mode.
condition and/or at least one of the connections C. Observe the “Active Diagnostics” screen on
are improper. ET. The engine must be in the prechamber
calibration mode for at least 30 seconds in order
Repair: Perform the necessary repairs and/or for the -02 diagnostic code to become activated.
replace parts, if necessary. Look for an active -02 diagnostic code.
STOP. Expected Result:
The -02 code is not active.
Results:
• No -02 code – Before the suspect harness was

replaced, there was a -02 diagnostic code. After
the suspect harness was replaced, there was
no -02 diagnostic code. The suspect harness is
faulty.
254
Repair: Completely install the new harness onto If the problem is resolved with a new ICSM,
the engine. Resume normal operation. install the original ICSM and verify that the
problem returns. If the new ICSM operates
STOP. correctly and the original ICSM does not operate
correctly, replace the original ICSM. Refer to
• Active -02 code – Before the harness was Troubleshooting, “Replacing the ICSM”.
replaced, there was a -02 diagnostic code. After
the harness was replaced, the -02 diagnostic STOP.
code remained.
Test Step 4. Disconnect the Combustion
Repair: Turn the engine control switch to the Sensor
breaker for the ECM OFF. Remove the new A. Verify that the engine control switch is in the
harness and install the original harness. OFF/RESET position. Verify that the 16 amp
Test Step 3. Inspect the Extension and

the Combustion Sensor
A. Inspect the combustion sensor and clean the
sensor, if necessary. Refer to Operation and
Maintenance Manual, SEBU7563, “Combustion
Sensor - Clean/Inspect/Replace”.
B. Start the engine. Use ET to place the engine in

the prechamber calibration mode.
C. Observe the “Active Diagnostics” screen on

ET. The engine must be in the prechamber
calibration mode for at least 30 seconds in order
for the -02 diagnostic code to become activated.
Look for an active -02 diagnostic code.
Expected Result:
The -02 diagnostic code is not active.
Results:
• No -02 code – Before the sensor and extension

were serviced, there was a -02 diagnostic code.
After the sensor and extension were serviced,
g00858679
there was no -02 diagnostic code. Resume Illustration 104
normal operation. STOP. Section view of a cylinder head with a combustion sensor
(1) Harness connector
• Active -02 code – Before the sensor and extension (2) Seal
were serviced, there was a -02 diagnostic code. (3) Connector
After the sensor and extension were serviced, the
noisy diagnostic code remained. The ICSM may B. Disconnect harness connector (1) for the suspect
have a problem. sensor.
Repair: It is unlikely that the ICSM has failed. C. Switch the 16 amp circuit breaker for the ECM
Exit this procedure and perform this procedure ON. Turn the engine control switch to the STOP
again. If the problem is not resolved, perform the position.
following steps:
D. Observe the “Active Diagnostics” screen on ET.
Temporarily install a new ICSM. Refer to Wait at least 30 seconds so that any codes may
Troubleshooting, “Replacing the ICSM”. become activated. Look for an active -04 short
circuit diagnostic code.
255
Expected Result:
The -04 diagnostic code is not active.
Results:
• No -04 code – Before the harness connector was

disconnected, there was a -04 diagnostic code.
After the harness connector was disconnected,
there was no -04 diagnostic code. There is a
problem with the extension or the sensor.
Repair: Perform the following steps:
1. Thoroughly inspect harness connector (1) g00858905

and connector (3) for moisture. Inspect Illustration 105
O-ring seal (2) in the harness connector. ICSM
Refer to Operation and Maintenance (1) ICSM
Manual, SEBU7563, “Combustion Sensor - (2) Connector
Clean/Inspect/Replace”.
B. Disconnect the suspect connector (2) from the
2. Reconnect harness connector (1). ICSM.
3. Switch the 16 amp circuit breaker for the ECM The connectors for the 12 cylinder engine are
ON. Turn the engine control switch to the STOP identified in Table 24:
position. Observe the “Active Diagnostics”
screen on ET. Wait at least 30 seconds so that Table 24
any codes may become activated. Verify that Diagnostic Cylinder Connectors Connectors
the problem is resolved. Code on the Left on the Right
Side ICSM Side ICSM
STOP. 1101-04 1 R3
• Active -04 code – Before the harness was 1102-04 2 L3

disconnected at the sensor there was a
1103-04 3 R2
-04 diagnostic code. After the harness was
disconnected the -04 diagnostic code remained. 1104-04 4 L2
There is a problem with the harness or the ICSM.
1105-04 5 R1
1106-04 6 L1
Test Step 5. Disconnect the Harness at 1107-04 7 L1
the ICSM
1108-04 8 R1
1109-04 9 L2
the ECM OFF. 1110-04 10 R2
1111-04 11 L3
1112-04 12 R3
The connectors for the 16 cylinder engine are

identified in Table 25:
256
Table 25 Repair: It is unlikely that the ICSM has failed.

Diagnostic Cylinder Connectors Connectors
Code on the Left on the Right again. If the problem is not resolved, perform the
Side ICSM Side ICSM following steps:
1101-04 1 R4 Temporarily install a new ICSM. Refer to
1102-04 2 L4 Troubleshooting, “Replacing the ICSM”.
1103-04 3 R3 If the problem is resolved with a new ICSM,
1104-04 4 L3 install the original ICSM and verify that the
1105-04 5 R2 correctly and the original ICSM does not operate
1106-04 6 L2 correctly, replace the original ICSM. Refer to
1107-04 7 R1
1108-04 8 L1 STOP.
1109-04 9 L1
i01657871
1110-04 10 R1
1111-04 11 L2
Cylinder Firing Pulse
1112-04 12 R2 SMCS Code: 1901-038
1113-04 13 L3
1114-04 14 R3
Use this procedure to troubleshoot cylinder firing
1115-04 15 L4 signals that have diagnostic codes which are active
1116-04 16 R4 or easily repeated.
There are two different types of cylinder firing

C. Switch the 16 amp circuit breaker for the ECM signals. The number one cylinder firing signal
ON. Turn the engine control switch to the STOP indicates that the ECM is commanding the spark
position. plug in the number one cylinder to fire. The all
cylinders firing signal indicates that the ECM is
D. Observe the “Active Diagnostics” screen on ET. commanding the spark plug in each cylinder to fire.
Wait at least 30 seconds so that any codes may Each signal is developed on a wire that connects
become activated. Look for an active -04 code. the ECM to the left and right integrated combustion
sensing modules.
Expected Result:
The number one cylinder firing signal is created
The -04 diagnostic code is not active. by the integrated combustion sensing modules
and the ECM. The modules maintain the signal
Results: wire at +13 volts. The ECM pulls the signal wire
to ground potential whenever the number one
• No -04 code – Before the harness was cylinder is commanded to fire. The ECM maintains
disconnected from the ICSM, there was a -04 the wire at ground potential for approximately 200
diagnostic code. Disconnecting the harness from microseconds.
the ICSM cleared the -04 diagnostic code. The
harness is faulty. The all cylinders firing signal is also created by
the integrated combustion sensing modules and
Repair: Replace the harness. Verify that the the ECM. The modules maintain the signal wire at
original condition is resolved. +13 volts. The ECM pulls the signal wire to ground
potential whenever a spark plug is commanded to
STOP. fire. The ECM maintains the wire at ground potential
for approximately 300 microseconds.
• Active -04 code – Before the harness was
disconnected from the ICSM, there was a The 1043-08 diagnostic code is caused if the
-04 diagnostic code. After the harness was number one cylinder firing signal and the all
disconnected from the ICSM ,the -04 code cylinders firing signal are connected to the opposite
remained. The ICSM may have a problem. terminals somewhere in the circuit.
257
A -02, -03, and -04 diagnostic code is probably

caused by a problem with a harness connector or
wiring. The next likely cause is a faulty electronic
component.

record. Before you begin this procedure, print the
logged codes to a file.

resolved.
g00855960
Illustration 106
Schematic of the circuit for the cylinder firing signals

the ECM OFF.

258
• J1/P1
• J5/P5
• J6/P6
• J73/P73
• J83/P83
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the circuit for the
cylinder firing signals.
D. Check the harnesses and wiring for abrasion

and pinch points from the connector for each
module to the terminal box.
E. Check the wiring inside the terminal box for

moisture, abrasion and pinch points.
Illustration 107 g00856128 Expected Result:

Terminal Box
All of the connectors and terminals are connected
(1) Ground strap
properly. The connectors and wiring are free of
(3) J6/P6 connector for the harness from the left side of the engine moisture, corrosion, abrasion and pinch points.
(4) J5/P5 connector for the harness from the right side of the
engine Results:
(5) Circuit breaker for the ECM
Note: Illustration 108 shows one side of the engine. proper connections. Proceed to Test Step 2.
The other side of the engine is similar.
improper.

STOP.
Test Step 2. Verify that the Diagnostic

Codes are Still Active
A. To prevent the engine from starting, shut the
main gas supply OFF.
B. Connect ET to the service tool connector.

ON.
D. Crank the engine for ten seconds. Look for the

g00856142 codes that are listed in Table 26:
Illustration 108
(6) ICSM
(7) P73/J73 connectors for the ICSM
B. Thoroughly inspect the following connectors and

terminals:
259
Table 26
Diagnostic Codes for the Cylinder Firing Signal
1043-02 Cylinder #1 Firing Signal noisy
1043-03 Cylinder #1 Firing Signal open/short to +batt
1043-04 Cylinder #1 Firing Signal short to ground
1043-08 Cylinder #1 Firing Signal abnormal signal
1044-02 All Cylinder Firing Signal noisy
1044-03 All Cylinder Firing Signal open/short to +batt
1044-04 All Cylinder Firing Signal short to ground
Expected Result:
There are no active codes or logged codes.
Results:
• OK - No codes – The problem seems to be g00863809

resolved. There are no active codes or logged Illustration 109
codes. The cylinder firing signals are operating (1) P6 connector for the harness from the left side of the engine
correctly at this time. (2) P5 connector for the harness from the right side of the engine
caused by a poor electrical connection in one B. Disconnect connectors P1, P5, and P6. This will
of the harness connectors or terminals. Resume isolate the wiring inside the terminal box.
normal operation.
STOP.
• Not OK - Active -02 Noisy – There is an active

diagnostic code for a noisy cylinder firing signal.
• Not OK - Active -03 Open – There is an active

code for a cylinder firing signal that has an open
circuit, or a short circuit to a positive voltage
source. Proceed to Test Step 3.
• Not OK - Active -04 Short – There is an active

code for a cylinder firing signal that has a short
to ground. Proceed to Test Step 7.
• Not OK - Active -08 Abnormal – A cylinder firing

signal is abnormal. Proceed to Test Step 3.
Test Step 3. Check the Terminal Box’s

Wiring for an Open Circuit or a Short
Circuit to a Positive Voltage Source
the ECM OFF.
260
The correct resistance measurements for Table

27 are less than 5 ohms. If the resistance
measurements are incorrect, there is an open
circuit.
g00863864
Illustration 111
(P1-49) All cylinder firing signal
(P1-53) +BATT
(P1-58) Number one cylinder firing signal
D. Measure the resistance between the terminals

measurement, wiggle the harness in order
harness. Be sure to wiggle the harness near
Table 28
g00863859
Illustration 110 Connector and Terminal Connector and Terminal
P1-53 P1-58
(P1-49) All cylinders firing signal
(J6-9) All cylinders firing signal P1-49
(J6-19) Number one cylinder firing signal
(J5-9) All cylinders firing signal
(J5-19) Number one cylinder firing signal The correct resistance measurements for
Table 28 are greater than 20,000 ohms. If the
C. Measure the resistance between the terminals resistance measurements are incorrect, there is
that are listed in Table 27. During each a short circuit to a positive voltage source.
measurement, wiggle the harness in order to
check for an intermittent problem. Be sure to Expected Result:
wiggle the harness near each of the connectors.
All of the resistance checks are within the
Table 27 specifications.
Results:
P1-58 J6-19 • OK – All of the resistance checks are within the
specifications. The wires for the cylinder firing
J5-19 signals inside the terminal box do not have an
P1-49 J6-9 open circuit or a short circuit to a positive voltage
source. Proceed to Test Step 4.
J5-9
261
• Not OK – At least one of the resistance checks

is not within the specifications. There is an open
circuit in the wiring inside the terminal box or
there is a short circuit to a positive voltage source.
Repair: Repair the harness or the connector, when

possible. Replace the harness or the connector, if
necessary.
STOP.
Test Step 4. Check the Left Side Harness

for an Open Circuit or a Short Circuit to
a Positive Voltage Source
A. Connect the P6 connector. This will add the left
side harness to the circuit.
B. Disconnect connector P73 from the left ICSM.
g00863893
Illustration 113
(P73-E) Number one cylinder firing signal
(P73-H) All cylinder firing signal
D. Measure the resistance between terminals P73-E

and P73-H. During the measurement, wiggle the
harness in order to check for an intermittent
g00857104
Illustration 112 problem with the harness. Be sure to wiggle the
Harness connector P1 harness near the P73 connector. The correct
resistance measurement is less than 5 ohms.
C. Fabricate a jumper wire that is the appropriate

length with Deutsch terminals on the ends.
Connect the jumper wire between terminals
P1-49 and P1-58.
g00864199
Illustration 114
(P1-69) -BATT
E. At the P1 connector, connect the jumper wire

between terminals P1-49 and P1-69.
262
I. Measure the resistance between the terminals

measurement, wiggle the harness in order
Table 29
P1-53 P1-58
P1-49

29 are greater than 20,000 ohms.
Expected Result:
The resistance checks are within the specifications.
Results:
• OK – All of the resistance checks are within the

specifications. The wires for the cylinder firing
signals inside the left harness do not have an
g00864207 open circuit or a short circuit to a positive voltage
Illustration 115
source. The wires for the cylinder firing signals
(P73-B) -BATT are not switched. Proceed to Test Step 5.
(P73-H) All cylinder firing signal
F. Measure the resistance between terminals P73-B

and P73-H. The correct resistance measurement circuit in the wiring inside the left harness or there
is less than 5 ohms. is a short circuit to a positive voltage source.
G. Remove the jumper wire from the P1 connector.
H. possible. Replace the harness or the connector, if
necessary.
STOP.
Test Step 5. Check the Right Side

Harness for an Open Circuit or a Short to
a Positive Voltage Source
A. Connect the P5 connector. This will add the right
side harness to the circuit.
B. Disconnect connector P83 from the right ICSM.
g00863864
Illustration 116
(P1-53) +BATT
263
g00857104 g00864199
Harness connector P1 Harness connector P1
(P1-49) All cylinder firing signal (P1-49) All cylinder firing signal
(P1-58) Number one cylinder firing signal (P1-69) -BATT
C. Connect a jumper wire between terminals P1-58 E. At the P1 connector, connect the jumper wire
and P1-49. between terminals P1-49 and P1-69.
g00863912 g00864222
(P83-E) Number one cylinder firing signal (P83-B) -BATT
(P83-H) All cylinder firing signal (P83-H) All cylinder firing signal
D. Measure the resistance between terminals P83-E F. Measure the resistance between terminals P83-B
and P83-H. During the measurement, wiggle the and P83-H. The correct resistance measurement
harness in order to check for an intermittent is less than 5 ohms.
harness near the P83 connector. The correct G. Remove the jumper wire from the P1 connector.
264

necessary.
STOP.

Code is still Active
B. Reconnect connectors P1, P73, and P83.
g00863864 C. Switch the 16 amp circuit breaker for the ECM

Illustration 121
ON.
(P1-49) All cylinder firing signal D. Crank the engine for ten seconds. Look for the
(P1-53) +BATT codes that are listed in Table 31:
Table 31
H. Measure the resistance between the terminals
that are listed in Table 30. During each Diagnostic Codes for the Cylinder Firing Signal
measurement, wiggle the harness in order 1043-03 Cylinder #1 Firing Signal open/short to +batt
harness. Be sure to wiggle the harness near 1044-03 All Cylinder Firing Signal open/short to +batt
each of the connectors. 1043-08 Cylinder Firing Signal Abnormal
Table 30
Expected Result:
Connector and Terminal Connector and Terminal The codes that are listed in Table 31 are not active
or logged.
P1-53 P1-58
P1-49 Results:

• No codes – The problem seems to be resolved.
The cylinder firing signals are operating correctly
30 are greater than 20,000 ohms. at this time.
Expected Result: Repair: The initial diagnostic code was probably
caused by a poor electrical connection in one
The resistance checks are within the specifications. of the harness connectors or terminals. Resume
normal operation.
Results:
STOP.
specifications. The wiring inside the right harness
does not have an open circuit. The wiring inside
• Active code – At least one of the diagnostic
codes is active. Proceed to Test Step 13.
the right harness does not have a short circuit
to a positive voltage source. The wires for the
cylinder firing signals are not switched. Connect
all of the connectors. Proceed to Test Step 6.

circuit in the wiring inside the left harness or there
is a short circuit to a positive voltage source.
265
Test Step 7. Check for +13 V at the ECM Test Step 8. Crank the Engine and Check
for Diagnostic Codes
B. Crank the engine for ten seconds. Look for the

codes that are listed in Table
Table 32
Diagnostic Codes for the Cylinder Firing Signal
1043-02 Cylinder #1 Firing Signal noisy
1043-04 Cylinder #1 Firing Signal short to ground
1043-08 Cylinder #1 Firing Signal abnormal signal
1044-02 All Cylinder Firing Signal noisy
1044-04 All Cylinder Firing Signal short to ground
Expected Result:
Illustration 122
g00863734 None of the codes are active or logged.
Results:
(P1-69) -BATT • No codes – None of the codes are active or
logged. The problem seems to be resolved. The
A. At the harness side of the P1 connector, insert cylinder firing signals appear to be operating
two 7X-1710 Multimeter Probes. Insert the first correctly at this time.
probe into terminal 69. If you are troubleshooting
a problem with the signal for the number one Repair: The initial diagnostic code was probably
cylinder firing signal, insert the second probe caused by a poor electrical connection. Resume
into terminal 58. If you are troubleshooting a normal operation.
problem with the all cylinders firing signal, insert
the second probe into terminal 49. STOP.
B. Connect a voltmeter to the probes and measure • Code – At least one of the diagnostic codes is
the voltage. active or logged. Proceed to Test Step 14.
Expected Result: Test Step 9. Disconnect the ECM from the

Circuit and Check for Voltage
The voltage at the P1 connector is 13 ± 3 VDC.
Results: position. Switch the 16 amp circuit breaker for
the ECM OFF.
• OK – The voltage at the P1 connector is 13 ±
3 VDC. The voltage that is developed by the
modules appears to be OK. The ECM does not
have an internal short circuit. Remove the probes
from the P1 connector. Proceed to Test Step 8.
• Not OK – The voltage at the P1 connector is not

13 ± 3 VDC. The voltage that is developed by
the modules is not within the specification. An
ICSM may have a problem, or the ECM may be
faulty. Do not remove the probe in terminal 69.
Remove the probe from terminal 49 or terminal
58. Proceed to Test Step 9.
266

breaker for the ECM OFF.
2. Remove the probe from terminal 69. Insert

terminal 49 or 58 into the P1 connector. Pull on
the wire in order to verify that the terminal is
fully inserted into the connector.

again. If the problem is not resolved, temporarily
install a new ECM. Refer to Troubleshooting,
“Replacing the ECM”.

Illustration 123 g00863734 STOP.

(P1-49) All cylinders firing signal
• Not OK – The voltage on the wire that was
removed from the ECM is not 13 ± 3 VDC. There
(P1-69) -BATT may be a problem with an ICSM. Proceed to Test
Step 10.
terminal 58 or 49 from ECM connector P1. If you Test Step 10. Check the Left Side ICSM
are troubleshooting a problem with the number for a Short Circuit.
one cylinder firing signal, remove terminal 58. If
you are troubleshooting a problem with the all A. Switch the 16 amp circuit breaker for the ECM
cylinders firing signal, remove terminal 49. OFF. Turn the engine control switch to the
OFF/RESET position.
C. Connect one voltmeter lead to the probe that
is inserted into terminal 69. Connect the other
voltmeter lead to the terminal that has been
removed from P1.

position.
E. Measure the voltage on the wire that was

removed from the P1 connector.
Expected Result:
The voltage is 13 ± 3 VDC.
Results:
• OK – The voltage on the wire that was removed

from the ECM is 13 ± 3 VDC. The voltage that is
developed by the ICSM appears to be OK. When
the ECM is connected to the circuit, the voltage is Illustration 124 g00863754
not OK. There may be a problem with the ECM. (1) Left side ICSM
(2) P73 connector
Perform the following steps: B. Disconnect connector P73 from the left ICSM.
267
• Not OK – The resistance check is less than

20,000 ohms. There may be a problem with the
ICSM.
Repair: It is unlikely that the ICSM has failed.

following steps:
Install a known good ICSM according to

If the problem is resolved with the new ICSM,

install the original ICSM and verify that the
problem returns.
If the new ICSM operates correctly and the

original ICSM does not operate correctly, replace
the original ICSM. Refer to Troubleshooting,
“Replacing the ICSM”.
STOP.
Test Step 11. Check the Right Side ICSM

for a Short Circuit.
g00857182
Illustration 125
J73 connector on the left side ICSM
C. Measure the resistance between the terminals

that are listed in Table 33 according to the
corresponding diagnostic code:
Table 33
Diagnostic Code Connector and Terminals
1043-02 J73-E and J73-B g00863943
Illustration 126
1043-04
(1) Right side ICSM
1044-02 J73-H and J73-B (2) P83 connector
1044-04
A. Disconnect connector P83 from the right side
Expected Result: ICSM.
The resistance check is greater than 20,000 ohms.
Results:
• OK – The resistance check is greater than 20,000

ohms. The left ICSM does not have a short circuit.
268
• Not OK – The resistance check is less than

20,000 ohms. There may be a problem with the
right side ICSM.

following steps:
Install a known good ICSM according to


problem returns.

original ICSM does not operate correctly, replace
STOP.
Test Step 12. Check the Wiring for the

ICSM
A. Reconnect connector J73 to the left side ICSM.
B. Verify that connectors P5 and P6 are connected.
C. Verify that connector P1 is disconnected.
D. Measure the resistance between the terminals

that are listed in Table 35:
g00863765
Illustration 127
Table 35
J83 connector on the right side ICSM
P83 Points for the Measurement of Resistance
B. Measure the resistance between the terminals Terminal Connector and Terminals
that are listed in Table 34 according to the
corresponding diagnostic code: P83-E P83-A
P83-B
Table 34 P83-D
P83-H
Points for the Measurement of Resistance P83-J
P83-K
Diagnostic Code Connector and Terminals
P83-M
1043-02 J83-E and J83-B P83-N
1043-04
P83-H P83-A
1044-02 J83-H and J83-B P83-B
1044-04 P83-D
P83-E
P83-J
Expected Result: P83-K
P83-M
The resistance check is greater than 20,000 ohms. P83-N
Results: Expected Result:

• OK – The resistance check is greater than 20,000 All of the resistance checks are greater than 20,000
ohms. The right ICSM does not have a short ohms.
circuit. Proceed to Test Step 12.
269
Results:
• OK – All of the resistance checks are greater

than 20,000 ohms. The wiring for the modules
appears to be OK. Proceed to Test Step 14.
• Not OK – At least one of the resistance checks is

connector and/or the wiring for the modules.
Repair: Repair the connector and/or wiring, when

possible. Replace the connector and/or wiring, if
necessary.
STOP.
Test Step 13. Check the Modules for the

Correct Configuration.
A. Use ET in order to verify that the engine
configuration is correct for each of the modules.
“G3612 Vee” is an example of a configuration. Illustration 128 g00863334
The configuration for both of the modules must Harness connector P1
be identical and the configurations must match
(P1-5) Ground
the type of engine. (P1-49) All cylinder firing signal
Expected Result:
a. At the harness side of the P1 connector, insert
Each module has the correct configuration. The three 7X-1710 Multimeter Probes. Insert the
module configurations match the type of engine. first probe into terminal 49. Insert the second
probe into terminal 58. Insert the third probe
Results: into terminal 5.
• OK – The engine configuration is correct for each b. Connect one trace of the oscilloscope to the
module. Proceed to Test Step 14. probe on terminal 49. Connect the other trace
of the oscilloscope to the probe on terminal
• Not OK – The engine configuration is not correct 58.
for a module.
c. Use the probe that is connected to terminal 5
Repair: Change the configuration parameters as a ground connection.
to the correct values. Verify that the diagnostic
codes are no longer active. B. Adjust the settings of the oscilloscope to
two volts for each vertical division, and ten
If the original diagnostic codes are still active, milliseconds for each horizontal division.
proceed to Test Step 14.
C. Start the engine and run the engine.
Test Step 14. Use an Oscilloscope to
View the Cylinder Firing Signals
Note: This step is recommended.
A. Connect a dual trace oscilloscope by performing

the following steps:
270
g00863306
Illustration 129
Display for the oscilloscope
(1) All cylinder firing signal (2) Number one cylinder firing signal
D. Compare the display on the oscilloscope with

Illustration 129.
E. Adjust the oscilloscope for one millisecond for

each horizontal division.
271
g00863309
Illustration 130
Display for the oscilloscope
(A) 300 microseconds ±100 microseconds (B) 200 microseconds ±100 microseconds
F. Compare the display on the oscilloscope with i01654502

Illustration 130.
Desired Speed Input (4 - 20
Expected Result: mA)
The signals are within the specification. SMCS Code: 1901-038
Results: System Operation Description:
• OK – The signals are within the specification. Note: For this troubleshooting procedure,
If a diagnostic code is still active, consult the “Desired Speed Input” configuration
with Caterpillar customer service for large gas parameter must be set to “4-20 mA Input” in the
engines. STOP. “Service/Configuration” screen of ET. The selection
of this setting requires a 4 to 20 mA signal for
• Not OK – The signals are not within the regulation of the desired engine speed. If the
specification. Consult with Caterpillar customer “Desired Speed Input” is set to “0-5 VDC Input”, do
service for large gas engines. STOP. not use this procedure to troubleshoot the circuit.
272
When the desired speed input is correspondingly

configured, the ECM controls the engine speed
according to the 4 to 20 mA current.
The value of the current corresponds to a range

of desired engine speeds between minimum high
idle and maximum high idle. The “Minimum Engine
High Idle Speed” and the “Maximum Engine High
Idle Speed” are set with the “Service/Configuration”
screen of ET. For more information, refer to Systems
“Electronic Control System Parameters”.
When the “Idle/Rated” switch is in the Rated

position, a current value of 4.0 mA corresponds
to the programmed “Minimum Engine High Idle
Speed”. A current value of 20.0 mA corresponds
to “Maximum Engine High Idle Speed”. Current
values within this range will vary the desired engine
speed in a linear fashion between “Minimum Engine
High Idle Speed” and “Maximum Engine High Idle
Speed”. Illustration 131 g00854357
Schematic of the 4 to 20 mA desired speed input

The ECM will generate a diagnostic code in
response to current outside of the range of 4 to 20 Test Step 1. Inspect the Electrical
mA.
Current values that are greater than 22.0 mA will
activate the “524-03 Desired Engine Speed Sensor
short to +batt” diagnostic code. Current values
that are less than 2.0 mA will activate the “524-04
Desired Engine Speed Sensor short to ground”
diagnostic code.
The most likely causes of the diagnostic code

are a poor connection or a problem in a wiring
harness. The next likely cause is a problem with
a component. The least likely cause is a problem
with the ECM.

record. Before you begin this procedure, use ET to Illustration 132 g00854386
The troubleshooting procedure may generate (3) 70-pin customer connector J3
additional diagnostic codes. Keep your mind on (4) Terminal box’s 47-pin connector for the control panel (if
correcting the cause of the original diagnostic code. equipped)
resolved. A. Turn the engine control switch to the OFF/RESET
the ECM OFF.

273
g00862834
Illustration 133
Inside of the control panel
(5) Terminal strip
B. Thoroughly inspect the following components:

• 70-pin customer connectors J3/P3 (if
equipped)
• Terminal box’s 47-pin connectors J4/P4 for the

control panel (if equipped) g00856110
Illustration 134
• Terminal strip in the control panel (if equipped) Harness side of the ECM P1 connector
(36) + Signal
• Wiring and the connections between the (37) − Signal
terminal box and the device that supplies the
4 to 20 mA signal b. Perform a 45 N (10 lb) pull test on each of
the wires that are associated with the 4 to 20
a. Check the torque of the Allen head screw mA circuit.
for the ECM J1/P1 connector and the 70-pin
J3/P3 customer connector. The proper torque c. Inspect the terminal strip in the control panel
is 6 ± 1 N·m (55 ± 9 lb in). (if equipped) for loose wires, frayed wires,
foreign objects, and corrosion.
d. Check the harness and wiring for abrasion

and pinch points between the device that
supplies the 4 to 20 mA signal and the ECM.
Expected Result:

Results:

“524-03 Desired Engine Speed Sensor short to
+batt” diagnostic code, proceed to Test Step 2. If
you are troubleshooting a “524-04 Desired Engine
Speed Sensor short to ground” diagnostic code,
274

improper.

STOP.
Test Step 2. Check for a Short Circuit to

the +Battery Side at the ECM P1 Terminal
36
A. Verify that the engine control switch is in the
OFF/RESET position and the 16 amp circuit g00862700
Illustration 136
ECM J1 connector
B. Make sure that there is no electrical power to the (J1-70) Keyswitch +Battery
device that provides the 4 to 20 mA signal.
E. Use an ohmmeter to measure the resistance
C. Remove the two wires (“+” and “-”) for the 4 to between terminals (P1-36) and (J1-70).
20 mA signal from the device that supplies the
4 to 20 mA signal. Tape the leads in order to Expected Result:
ensure that the leads do not contact any object.
D. Disconnect the ECM P1 connector.
Results:
• Yes – The resistance is greater than 20,000

ohms. The wiring from terminal P1-36 is not
shorted to the +Battery side. Do not reconnect
any connectors. Proceed to Test Step 3.
• No – The resistance is less than 20,000 ohms.

There is a problem with a connection and/or the
wiring from terminal P1-36.
Repair: The problem may be between the ECM

P1 connector and the J3 or J4 connector.
Alternatively, the problem may be between the
g00870622
P3 or P4 connector and the device that provides
Illustration 135 the 4 to 20 mA signal.
(P1-36) + Signal Repair the connection and/or the wire, when
possible. Replace parts, if necessary. Verify that
the problem is resolved.
STOP.
Test Step 3. Check for a Short to Ground

at the ECM P1 Terminal 37
OFF/RESET position and the 16 amp circuit
B. Make sure that the leads of the wires for the 4 to

20 mA signal do not contact any object.
275

P1 connector and the J3 or J4 connector.
J3 or J4 connector and the device that provides
the 4 to 20 mA signal.
Locate the wire with the short circuit and replace

the wire. Verify that the problem is resolved.
STOP.
Test Step 4. Check for a Short Circuit to

the +Battery Side at the ECM P1 Terminal
37
g00856589
Illustration 137
(1) ECM P1 connector OFF/RESET position and the 16 amp circuit
(2) Ground strap
B. Make sure that there is no electrical power to the

device that provides the 4 to 20 mA signal.
C. Remove the two wires (“+” and “-”) for the 4 to

20 mA signal from the device that supplies the
4 to 20 mA signal. Tape the leads in order to
ensure that the leads do not contact any object.
D. Disconnect the ECM P1 connector.
g00856119
Illustration 138
(P1-37) − Signal
C. Use an ohmmeter to measure the resistance

between terminal (P1-37) and the ECM ground
strap.
Expected Result:
g00856119
The resistance is greater than 20,000 ohms. Illustration 139
Results: (P1-37) − Signal
• Yes – The resistance is greater than 20,000 ohms.

The wiring from terminal P1-37 appears to be ok.
Repair: Reconnect the ECM P1 connector.

Reconnect the two wires (“+” and “-”) for the 4 to
20 mA signal to the device that supplies the 4 to
20 mA signal.
• No – The resistance for at least one of the

measurements is less than 20,000 ohms. There
is a problem with a connection and/or the wiring
that is connected to P1-37.
276
g00862700 g00856589
ECM J1 connector (1) ECM P1 connector
(J1-70) Keyswitch +Battery (2) Ground strap
E. Use an ohmmeter to measure the resistance

between terminals (P1-37) and (J1-70).
Expected Result:
Results:
• Yes – The resistance is greater than 20,000

ohms. The wiring from terminal P1-37 is not
shorted to the +Battery side. Do not reconnect
any connectors. Proceed to Test Step 5.
g00856119
Illustration 142
There is a problem with a connection and/or the ECM side of the P1 connector
wiring from terminal P1-37. (P1-36) + Signal
Repair: The problem may be between the ECM C. Use an ohmmeter to measure the resistance
P1 connector and the J3 or J4 connector. between terminal (P1-36) and the ECM ground
Alternatively, the problem may be between the strap.
the 4 to 20 mA signal. Expected Result:
Repair the connection and/or the wire, when The resistance is greater than 20,000 ohms.
possible. Replace parts, if necessary. Verify that
the problem is resolved. Results:
STOP. • Yes – The resistance is greater than 20,000

ohms. The wiring from terminal P1-36 appears
Test Step 5. Check for a Short Circuit to to be OK. Do not reconnect any connectors.
Ground at the ECM P1 Terminal 36 Proceed to Test Step 6.
A. Verify that the engine control switch is in the • No – The resistance is less than 20,000 ohms.
OFF/RESET position and the 16 amp circuit There is a problem with a connection and/or the
breaker for the ECM OFF. wiring from terminal P1-36.
B. Make sure that the ends of the wires for the 4 to Repair: The problem may be between the ECM
20 mA signal do not contact any object. P1 connector and the J3 or J4 connector.
the 4 to 20 mA signal.
277
Repair the connection and/or the wire, when Repair the connection and/or the wire, when
possible. Replace parts, if necessary. Verify that possible. Replace parts, if necessary. Verify that
the problem is resolved. the problem is resolved.
STOP. STOP.
Test Step 6. Check for an Open Circuit Test Step 7. Check the Device that
Provides the 4 to 20 mA Signal
A. Install a jumper wire between the two wires (“+”
and “-”) that were removed from the device that Measure the 4 to 20 mA signal according to the
supplies the 4 to 20 mA signal. literature that is provided by the OEM of the device
that provides the 4 to 20 mA signal. Verify that the
correct signal is provided to the ECM.
g00870629
Illustration 143
(P1-36) + Signal
(P1-37) − Signal
B. Use an ohmmeter to measure the resistance

between terminals (P1-36) and (P1-37) on the
ECM side of the P1 connector.
Expected Result:
The resistance is less than 5 ohms.
Results:
g00856110
• OK – The resistance is less than 5 ohms. The Illustration 144
circuit is not open. Harness side of the P1 connector
(P1-36) + Signal
Repair: Remove the jumper wire. Reconnect the (P1-37) − Signal
two wires (“+” and “-”) for the 4 to 20 mA signal
to the device that supplies the 4 to 20 mA signal. Verify the correct 4 to 20 mA signal at the ECM P1
Reconnect the ECM P1 connector. terminals (36) and (37).
Proceed to Test Step 7. Expected Result:
• Not OK – The resistance is greater than 5 ohms. The correct 4 to 20 mA signal is provided to the
There is a problem with a connector and/or the ECM.
wiring from the P1 connector.
Results:
P1 connector and the J3 or J4 connector. • Yes – The correct 4 to 20 mA signal is provided
Alternatively, the problem may be between the to the ECM. However, the ECM is not responding
P3 or P4 connector and the device that provides correctly to the signal. There may be a problem
the 4 to 20 mA signal. with the ECM.
278
Repair: It is unlikely that the ECM is faulty. Exit The ECM will diagnose the detonation sensors for
this procedure and perform this procedure again. a signal that is shorted to the −Battery side, the
If the problem is not resolved, replace the ECM +Battery side, or an open circuit. To avoid detecting
according to Troubleshooting, “Replacing the vibrations that are not related to detonation, the
ECM”. Verify that the problem is resolved. ECM only monitors a detonation sensor when one
of the sensor’s cylinders is between top center and
STOP. 40 degrees after top center. Therefore, the “Block
Tap” method of testing the detonation sensors does
• No – The ECM is not receiving the correct 4 to not work for the G3600 Engine.
20 mA signal. There is probably a problem with
the device that provides the 4 to 20 mA. An input from a detonation sensor that is diagnosed
by the ECM as “short to ground” may actually
Repair: Service the device that provides the 4 to indicate an open circuit.
20 mA according to the literature that is provided
by the OEM of the device. Verify that the problem The ECM also supports event codes when the levels
is resolved. of detonation warrant a reaction from the ECM. If the
timing has been retarded by the maximum amount
STOP. and the level of detonation remains high, the ECM
will shut down the engine.
i01654922
Detonation Sensors record. Before you begin this procedure, use ET to
SMCS Code: 1559-038
System Operation Description: poor connection or a problem in a wiring harness.
The next likely cause is a problem with a sensor.
Detonation sensors are located on the upper The least likely cause is a problem with the ECM.
cylinder block between every two cylinders.
Each sensor monitors two adjacent cylinders. For The troubleshooting procedure may generate
example, one sensor monitors cylinders 1 and 3. additional diagnostic codes. Keep your mind on
The ECM supplies 8 VDC in order to power the Clear the diagnostic codes after the problem is
sensors. The detonation sensors provide electrical resolved.
signals to the ECM that indicate mechanical
engine vibrations. Each sensor outputs an electrical
signal that is filtered and the signal is amplified.
The frequency of the signal corresponds to the
mechanical frequency of the vibrations. The
amplitude of the signal is proportional to the
intensity of the vibrations.
The ECM monitors the signals in order to determine

the presence and the severity of the detonation. The
ECM retards the timing in order to limit detonation
levels. The timing may be retarded for a single
cylinder or for all of the cylinders, if necessary. If
retardation of the timing does not sufficiently limit
the detonation, the engine is shut down.
The ECM can retard timing by as few as three

degrees for light detonation levels. The timing can
be retarded up to six degrees for severe detonation.
For most applications, the minimum allowable actual
timing is ten degrees BTC. A proportional strategy
is used for advancing the timing after the timing
has been retarded. The rate of advance is based
upon the level of detonation. The rate is faster for
lighter detonation. The fastest rate of advance is
one degree per minute.
279
g00854585
Illustration 145
Schematic for the detonation sensors
The wiring for the detonation sensors is routed through rails on each side of the engine. Each detonation sensor has a 3-pin connector that is
connected to a receptacle on the rail.
Each rail has a 6-pin connector for a wiring harness that connects the detonation sensors to the terminal box.
280

g00855048
Illustration 148
g00854917
Illustration 146 (9) Rail on the left side of the engine
(1) ECM J2/P2 connectors (10) 6-pin J676/P676 connectors for the detonation sensors
(2) 16 amp circuit breaker (11) Connectors on the rail for the detonation sensor
(3) Terminal box’s J6/P6 connectors for the left side detonation (12) Detonation sensor
sensors
(4) Terminal box’s J5/P5 connectors for the right side detonation B. Thoroughly inspect the following connectors:
sensors
position. Switch the 16 amp circuit breaker for • The suspect detonation sensor’s connectors
the ECM OFF.
• For a diagnostic code on the right side
Note: For the following steps, refer to of the engine, inspect terminal box’s
Troubleshooting, “Inspecting Electrical Connectors”. J5/P5 connectors and the 6-pin J675/P675
connectors on the right side rail.
• For a diagnostic code on the left side of

the engine, inspect terminal box’s J6/P6
connectors and the 6-pin J676/P676
connectors on the left side rail.
a. Check the torque of the Allen head screws

for the ECM connector (P2) and the terminal
box’s connector (P5) or (P6). The proper
torque is 6 ± 1 N·m (55 ± 9 lb in).

g00855045
the detonation sensor. Refer to the schematic.
Illustration 147
Right side of the engine c. Check the harnesses and wiring for abrasion
(5) Rail on the right side of the engine and pinch points from the suspect detonation
(6) 6-pin J675/P675 connectors for the detonation sensors sensor to the ECM.
(7) Connectors on the rail for the detonation sensor
d. Make sure that the detonation sensors are
properly installed according to the torque
in Specifications, RENR5907, “Detonation
Sensors”.
Expected Result:

281
Results: Test Step 3. Check for Active Diagnostic

Codes for the Detonation Sensors
proper connections. Proceed to Test Step 2. Note: The run relay and the crank terminate relay
must be energized before a diagnostic code for a
• Not OK – The components are not in good detonation sensor can be generated. Therefore, the
condition and/or at least one connection is engine must be running. The engine will shut down
improper. soon after the diagnostic code is activated.
Repair: Perform the necessary repairs and/or A. Start the engine and run the engine.
B. Allow a minimum of 30 seconds for any
STOP. diagnostic codes to become active. Observe the
“Active Diagnostic” screen of ET and look for the
Test Step 2. Check for Diagnostic Codes diagnostic codes that are listed in Table 36:
for the +8 V Sensor Supply
Table 36
A. Switch the 16 amp circuit breaker for the ECM Code Description Cylinders
position. 1501-03 Cylinder #1 Detonation
Sensor short to +batt
1 and 3
B. Observe the “Active Diagnostic” screen of ET. 1501-04 Cylinder #1 Detonation
Wait at least 30 seconds so that any codes may Sensor short to ground
become activated. Look for these diagnostic
1502-03 Cylinder #2 Detonation
codes:
2 and 4
• “41-03 8 Volt DC Supply short to +batt” 1502-04 Cylinder #2 Detonation
Sensor short to ground
• “41-04 8 Volt DC Supply short to ground” 1505-03 Cylinder #5 Detonation
Expected Result: 5 and 7
Neither of the “8 Volt DC Supply” diagnostic codes Sensor short to ground
are active. 1506-03 Cylinder #6 Detonation
Results: 6 and 8
• OK – Neither of the “8 Volt DC Supply” diagnostic
codes are active. Proceed to Test Step 3. 1509-03 Cylinder #9 Detonation
• Not OK – At least one of the “8 Volt DC Supply” 9 and 11
diagnostic codes is active.
Repair: The “8 Volt DC Supply” diagnostic code 1510-03 Cylinder #10 Detonation
must be resolved before you can proceed with Sensor short to +batt
this functional test. 10 and 12
Exit this procedure and refer to Troubleshooting,
“+8V Sensor Voltage Supply”. 1513-03 Cylinder #13 Detonation
13 and 15
If necessary, return to this functional test in order 1513-04 Cylinder #13 Detonation
to troubleshoot the detonation sensor after the Sensor short to ground
“8 Volt DC Supply” diagnostic code has been
resolved. 1514-03 Cylinder #14 Detonation
14 and 16
STOP. 1514-04 Cylinder #14 Detonation
Note: A “short to ground” diagnostic code can

indicate either an actual short to ground or an open
circuit.
282
Expected Result: B. Disconnect the suspect sensor’s 3-pin connector

from the rail.
None of the above diagnostic codes are active.
Results: ON. Turn the engine control switch to the STOP
position.
• OK (No active codes) – None of the above codes
are active at this time. The problem seems to D. Measure the voltage between terminals (A)
be resolved. The original diagnostic code was and (B) on the rail’s receptacle for the sensor’s
probably caused by a poor electrical connection connector.
in one of the harness connectors.
Expected Result:
Repair: If any of the above codes are logged
and the engine is not running properly, refer The voltage is between 7.6 VDC and 8.4 VDC.
Diagnostic Code”. Results:
If any of the above codes are logged and the • OK – The voltage is between 7.6 VDC and 8.4
engine is running properly, there may be an VDC. The correct voltage is available to the
intermittent problem in a connector or a wiring sensor. Do not reconnect the sensor. Proceed to
harness. Refer to Troubleshooting, “Inspecting Test Step 5.
• Not OK – The voltage is not between 7.6 VDC
STOP. and 8.4 VDC. The correct voltage is not available
to the sensor. There is probably an open circuit in
• Not OK (Active Code) – A “short to +batt” or the +8 volt supply or in the return for the sensor.
“short to ground” diagnostic code was activated.
Repair: The open circuit may be caused by a poor
Repair: Note the diagnostic code and note the electrical connection or a wiring problem between
location of the suspect detonation sensor. the ECM and the connector for the sensor.
Proceed to Test Step 4. If only one detonation sensor has an “04 short to
ground” diagnostic code, the open circuit for the
Test Step 4. Verify the Presence of the +8 volt supply is in the rail. Repair the electrical
Supply Voltage to the Sensor connection and/or the wiring, when possible.
Replace the rail, if necessary.
position. Switch the 16 amp circuit breaker for If more than one detonation sensor has an
the ECM OFF. “04 short to ground” diagnostic code, use the
following procedure to locate the open circuit for
the +8 volt supply:

g00857709
Illustration 149
(AA) View of the rail’s receptacle for the sensor’s connector
(A) +8 V supply
(B) Return
(C) Signal
283
4. Use a voltmeter to measure the voltage

between terminals “A” and “B” on the engine
harness’ 6-pin connector.
If the voltage is between 7.6 VDC and 8.4

VDC, the open circuit is in the rail. Repair the
electrical connection and/or the wiring, when
possible. Replace the rail, if necessary.
If the voltage is not between 7.6 VDC and 8.4

VDC, the open circuit may be in the engine
harness. Proceed to the next Step.

g00857795
Illustration 150 breaker for the ECM OFF.
(1) 6-pin J675/P675 connectors on the rail for the right side
detonation sensors 6. Disconnect the appropriate harness from the
terminal box.
If you are troubleshooting the sensors on

the right side of the engine, disconnect the
harness from connector (J5).
If you are troubleshooting the sensors on the

left side of the engine, disconnect the harness
from connector (J6).

ON. Turn the engine control switch to the
STOP position.
g00857796
Illustration 151
(2) 6-pin J676/P676 connectors on the rail for the left side
detonation sensors
2. Disconnect the 6-pin connector from the rail

on the suspect sensors’ side of the engine.

STOP position.
g00857845
Illustration 153
Bottom view of the terminal box
(J6) Terminal box’s connector for the harness on the left side of
the engine
(J6-54) Return
g00858454 (J6-57) +8 V supply
Illustration 152
(J5) Terminal box’s connector for the harness on the right side
6-pin connector on the engine harness
of the engine
(J5-31) +8 V supply
(J5-23) Return
284
8. Measure the voltage between the terminals for Results:

the detonation sensors’ supply and the return.
• Yes – The voltage is between 0.4 VDC and 0.6
If you are troubleshooting the sensors on the VDC.
left side of the engine, measure the voltage
between terminals (J6-54) and (J6-57). Repair: Reconnect the suspect sensor. Start the
engine again and check for the diagnostic code.
If you are troubleshooting the sensors on the
right side of the engine, measure the voltage If the diagnostic code recurs, replace the
between terminals (J5-23) and (J5-31). detonation sensor with a known good detonation
sensor. Tighten the detonation sensor according
If the voltage is between 7.6 VDC and 8.4 VDC, to Specifications, RENR5907, “Detonation
the open circuit is in the engine harness. Repair Sensor”. Verify that the problem is resolved.
the electrical connection and/or the wiring, when
possible. Replace the harness, if necessary. STOP.
If the voltage is not between 7.6 VDC and 8.4 • No – The voltage is not between 0.4 VDC and 0.6
VDC, the open circuit is in the terminal box VDC. If the voltage is less than 0.4 VDC, there
between the ECM J2 connector and the engine is probably a short to ground or an open circuit
harness connector on the terminal box. between the rail’s connector for the detonation
sensor and the ECM. If the voltage is greater than
Repair the electrical connection and/or the wiring, 4.8 VDC, there is probably a short circuit to a
when possible. Replace the components, if +Battery source between the rail’s connector for
necessary. the detonation sensor and the ECM.
STOP. Repair:
Test Step 5. Measure the Voltage of the Proceed to Test Step 6.

Signal Wire at the Rail
Test Step 6. Measure the Voltage of the
A. Ensure that the 16 amp circuit breaker for the Suspect Signal Terminal at the ECM
ECM is ON and that the engine control is in the
STOP position. A. Turn the engine control switch to the OFF/RESET
the ECM OFF.
g00857709
Illustration 154
(AA) View of the rail’s receptacle for the sensor’s connector
(A) +8 V supply
(B) Return
(C) Signal
B. Measure the voltage between terminals (B) and

(C) on the rail’s receptacle for the sensor’s
connector.
Expected Result:
The voltage is between 0.4 VDC and 0.6 VDC.

285
Expected Result:
The voltage is between 0.4 VDC and 0.6 VDC.
Results:
• Yes – The voltage is between 0.4 VDC and 0.6

VDC. The ECM is OK. There is a problem with a
connection and/or the wiring between the ECM
and the rail’s connector for the detonation sensor.
If you suspect that there is a short circuit to a
+Battery source, proceed to test Step 7. If you
suspect that there is an open circuit, proceed to
Test Step 8. If you suspect that there is a short to
ground, proceed to Test Step 9.
• No – The voltage is not between 0.4 VDC and 0.6

VDC. There is a problem with the ECM.


the jumper wire from ECM P2 connector. Reinstall
the original signal wire into the P2 connector. Pull
on the wire in order to verify that the terminal is
secure.
g00857753
Illustration 155
Harness side of the ECM P2 connector Replace the ECM according to Troubleshooting,
(P2-36) Signal for cylinders 1 and 3 “Replacing the ECM”.
(P2-37) Signal for cylinders 5 and 7
(P2-38) Signal for cylinders 9 and 11 STOP.
(P2-54) Return (right side)
(P2-44) Signal for cylinders 14 and 16 Test Step 7. Monitor the Voltage and
(P2-45) Signal for cylinders 10 and 12 Isolate the Short Circuit
(P2-47) Signal for cylinders 2 and 4 A. Turn the engine control switch to the OFF/RESET
(P2-55) Return (left side)
the ECM OFF.
the suspect signal wire from ECM P2 connector.
the jumper wire from the ECM P2 connector.
C. Install one end of jumper wire with the
Reinstall the removed suspect signal wire into
appropriate connectors on the ends into the
the terminal. Pull on the wire in order to verify
terminal for the suspect signal wire. Leave the
proper installation.
other end of the jumper wire unconnected. Pull
on the jumper wire in order to verify that the
jumper wire is properly connected.
D. Insert a lead of a 7X-1710 Multimeter Probe into

the terminal for the corresponding return wire.
E. Connect the leads of a voltmeter to the 7X-1710

Multimeter Probe and to the loose end of the
jumper wire.
F. Switch the 16 amp circuit breaker for the ECM

position.
G. Use the voltmeter to measure the voltage.

286
g00857795
Illustration 157
(1) 6-pin J675/P675 connectors on the rail for the right side
detonation sensors
g00857753
Illustration 156
(P2-38) Signal for cylinders 9 and 11 g00857796
(P2-39) Signal for cylinders 13 and 15 Illustration 158
(P2-54) Return (right side) (2) 6-pin J676/P676 connectors on the rail for the left side
(P2-44) Signal for cylinders 14 and 16 detonation sensors
(P2-47) Signal for cylinders 2 and 4 G. Disconnect the 6-pin connector from the rail on
(P2-55) Return (left side) the suspect sensor’s side of the engine.
C. Insert the lead of a 7X-1710 Multimeter Probe H. Switch the 16 amp circuit breaker for the ECM
into the terminal for the suspect sensor’s signal ON. Turn the engine control switch to the STOP
wire in the harness side of the ECM P2 connector. position.
D. Verify that the voltmeter is properly connected I. Use the voltmeter to measure the voltage again.
to the leads of the 7X-1710 Multimeter Probes. Compare the voltage to the previously noted
Switch the 16 amp circuit breaker for the ECM voltage.
position. If the voltage is between 0.4 VDC and 0.6 VDC,
there is a short circuit in the rail on the suspect
E. Measure the voltage. sensor’s side of the engine. Repair the electrical
connection and/or the wiring, when possible.
Because a short circuit to a +Battery source is Replace the rail, if necessary.
suspected, the expected voltage is greater than
4.8 VDC. If the voltage is still greater than 4.8 VDC, the rail
is probably OK. Continue with this procedure.
F. Turn the engine control switch to the OFF/RESET
the ECM OFF.
287

position. Switch the 16 amp circuit breaker for the
ECM OFF. Repair the harness, when possible.
Replace the harness, if necessary.
STOP.
• No – Before the harness was disconnected,

the voltage was greater than 4.8 VDC. After the
harness was disconnected, the voltage was still
greater than 4.8 VDC. There is a problem in the
terminal box.

g00854917
Illustration 159 breaker for the ECM OFF. Repair the connector
(1) ECM J2/P2 connectors and/or wiring, when possible. Replace the
(2) 16 amp circuit breaker connector and/or wiring, if necessary.
(3) Terminal box’s J6/P6 connectors for the left side engine harness
(4) Terminal box’s J5/P5 connectors for the right side engine
harness STOP.
J. Turn the engine control switch to the OFF/RESET Test Step 8. Check the Engine Harness
position. Switch the 16 amp circuit breaker for for a Short Circuit to Ground
the ECM OFF.
K. Disconnect the appropriate harness from the

terminal box.
If you are troubleshooting a sensor on the right

side of the engine, disconnect the harness from
the J5 connector.
If you are troubleshooting a sensor on the left

side of the engine, disconnect the harness from
the J6 connector.
L. Switch the 16 amp circuit breaker for the ECM

position. Illustration 160
M. Use the voltmeter to measure the voltage again. (2) 16 amp circuit breaker
Compare the voltage to the previously noted (4) Terminal box’s J5/P5 connectors for the right side engine
voltage. harness
Expected Result: A. Turn the engine control switch to the OFF/RESET

Before the harness was disconnected, the voltage the ECM OFF.
was greater than 4.8 VDC. After the harness was
disconnected, the voltage was between 0.4 VDC B. Use a 151-6320 Wire Removal Tool to remove
and 0.6 VDC. the jumper wire from ECM connector (P2).
Reinstall the suspect signal wire into connector
Results: (P2). Pull on the wire in order to verify that the
terminal is secure.
• Yes – Before the harness was disconnected,
the voltage was greater than 4.8 VDC. After the
harness was disconnected, the voltage was
between 0.4 VDC and 0.6 VDC. There is a
problem in the engine harness.
Repair: The problem is probably caused by

a poor electrical connection and/or a wiring
problem in the harness.
288
g00855045 g00858454
Right side of the engine 6-pin connector on the engine harness
(5) Rail on the right side of the engine
(6) 6-pin J675/P675 connectors for the detonation sensors
g00858460
Illustration 164
Ground strap for the ICSM
g00855048 D. Measure the resistance between the ground

Illustration 162
strap for the ICSM and the terminal for the
suspect signal wire on the engine harness’ 6-pin
(9) Rail on the left side of the engine connector.
(10) 6-pin J676/P676 connector for the detonation sensors
(12) Detonation sensor The terminals on the 6-pin connectors for the
detonation sensors’ signal wires are identified
C. Disconnect the appropriate engine harness’ in Table 37.
6-pin connector from the rail.
Table 37
If you are troubleshooting a problem on the right Terminals on the 6-Pin Connectors for the
side of the engine, disconnect the connector. Detonation Sensors’ Signal Wires
Terminal Right Side Harness Left Side Harness
If you are troubleshooting a problem on the P675 P676
left side of the engine, disconnect the P676
connector. C Cylinders 1 and 3 Cylinders 14 and 16
D Cylinders 5 and 7 Cylinders 10 and 12
E Cylinders 9 and 11 Cylinders 6 and 8
F Cylinders 13 and 15 Cylinders 2 and 4
If the resistance is greater than 20,000 ohms,

the signal wire from the engine harness to the
ECM is OK. The signal wire is probably shorted
to ground in the rail.
289
Verify that the short circuit is in the rail.

Reconnect the engine harness’ 6-pin connector
to the rail’s receptacle. Measure the resistance
between the ground strap for the ICSM and the
terminal for the suspect signal wire on the rail’s
3-pin connector for the detonation sensor. If the
resistance is less than 5 ohms, the short circuit is
in the rail. The short circuit is caused by a poor
electrical connection and/or a wiring problem in
the rail. Repair the connector and/or the wiring,
when possible. Replace the rail, if necessary.
If the resistance is less than 5 ohms, the short

circuit is probably in the engine harness or the
terminal box. Continue with this procedure.
E. Ensure that the engine control switch is in the

OFF/RESET position. Ensure that the 16 amp
g00858514
Illustration 166
Connectors J6 and J5 on the bottom of the terminal box
(J6-63) Signal for cylinders 2 and 4
G. Measure the resistance between the ground

strap for the ECM and the terminal for the
Illustration 165
g00858507 suspect signal wire on connector J6 or J5.
(13) Ground strap for the ECM
(3) J6/P6 connectors for the left side engine harness
Expected Result:
(4) J5/P5 connectors for the right side engine harness
F. Disconnect the suspect engine harness from the
terminal box. Results:
If you are troubleshooting a problem on the right • Yes – The resistance is greater than 20,000 ohms.
side of the engine, disconnect the P5 connector. The signal wire from the terminal box’s connector
to the ECM is OK. The signal wire is probably
If you are troubleshooting a problem on the left shorted to ground in the engine harness.
side of the engine, disconnect the P6 connector.
Repair: Verify that the short circuit is in the engine
harness. Reconnect the engine harness to the
terminal box. Measure the resistance between the
ground strap for the ICSM and the terminal for
the suspect signal wire on the engine harness’
6-pin connector for the detonation sensors. If the
resistance is less than 5 ohms, the short circuit is
in the engine harness.
The short circuit is caused by a poor electrical

connection or a wiring problem in the harness.
Repair the connector and/or the wiring, when
STOP.
290
• No – The resistance is less than 5 ohms. The

short circuit is in the terminal box.
Repair: The short circuit is caused by a poor

electrical connection or a wiring problem in the
terminal box. Repair the connector and/or the
wiring, when possible. Replace the wiring, if
necessary.
STOP.
Test Step 9. Isolate the Open Circuit
g00855045
Illustration 168
Right side of the engine
(5) Rail on the right side of the engine
(6) 6-pin J675/P675 connectors for the detonation sensors
(7) 3-pin connectors on the rail for the detonation sensor
g00854917
Illustration 167
(4) Terminal box’s J5/P5 connectors for the right side engine
harness

g00855048
the ECM OFF. Illustration 169
B. Use a 151-6320 Wire Removal Tool to remove (9) Rail on the left side of the engine
the jumper wire from the ECM P2 connector. (10) 6-pin J676/P676 connectors for the detonation sensors
Reinstall the suspect signal wire into the P2 (11) 3-pin connectors on the rail for the detonation sensor
connector. Pull on the wire in order to verify that (12) Detonation sensor
the terminal is secure.
C. Disconnect the appropriate engine harness’
6-pin connector from the rail.
If you are troubleshooting a problem on the right

side of the engine, disconnect the J675/P675
connectors.
If you are troubleshooting a problem on the left

side of the engine, disconnect the J675/P675
connectors.
D. Use a jumper wire with the appropriate terminals

on the ends. Install the jumper wire onto the
terminals for the suspect signal wire and the
voltage supply wire on the rail’s 3-pin connector
for the detonation sensor.
291
g00858654 g00854917
6-pin connector on the rail (1) ECM J2/P2 connectors
E. Measure the resistance between the terminals for (4) Terminal box’s J5/P5 connectors for the right side engine
the suspect signal wire and the voltage supply harness
on the rail’s 6-pin connector.
F. Make sure that the engine control switch is in the
The terminals on the rail’s 6-pin connectors for OFF/RESET position and that the 16 amp circuit
the detonation sensors’ signal wires and voltage breaker for the ECM is OFF.
supply wires are identified in Table 38.
G. Disconnect the appropriate engine harness
Table 38
connector from the terminal box.
Terminals for the Voltage Supply Wires and Signal
Wires on the Rails’ 6-Pin Connectors If you are troubleshooting a problem on the right
Terminal Right Side Harness Left Side Harness
side of the engine, disconnect the P5 connector.
J675 J676
If you are troubleshooting a problem on the left
A +8 VDC +8 VDC side of the engine, disconnect the P6connector.
C Signal for cylinders Signal for cylinders
1 and 3 14 and 16
D Signal for cylinders Signal for cylinders
5 and 7 10 and 12
E Signal for cylinders Signal for cylinders
9 and 11 6 and 8
F Signal for cylinders Signal for cylinders
13 and 15 2 and 4
If the resistance is greater than 20,000 ohms,

there is an open circuit in the rail. The open
circuit is probably caused by a poor electrical
connection and/or a broken wire. Repair the
electrical connection and/or the wiring, when
possible. Replace the rail, if necessary.
If the resistance is less than 5 ohms, the rail is

OK. There is probably an open circuit between
the ECM and the rail. Proceed to the next Step.
g00858710
Illustration 172
Engine harness connectors
(AA) 6-pin connector for the detonation sensors
(BB) Connector for the terminal box
292
H. Install a jumper wire into the terminals for the Repair: The open circuit is probably caused by a
suspect signal wire and the voltage supply on poor electrical connection and/or broken wire in
the engine harness’ 6-pin connector for the the engine harness. Repair the connector and/or
detonation sensors. the wiring, when possible. Replace the engine
harness, if necessary.
The terminals for the 6-pin connectors are
identified in Table 39. STOP.
I. Measure the resistance between the

i01687516
corresponding terminals for the suspect signal
wire and the voltage supply on the engine
harness connector for the terminal box.
ECM Output Circuit (Fuel
Control)
The corresponding terminal box’s connectors are
identified in Table 39. SMCS Code: 1901-038
Table 39 System Operation Description:

Terminals on the Engine Harness Connectors
for the Detonation Sensors The ECM contains the logic and the outputs for
control of prelubrication, starting, and shutdown
Harness’ Corresponding Corresponding of the engine. The logic for starting and stopping
6-Pin Terminals Terminals is customer programmable. The logic responds
Connector Right Side Left Side Harness to inputs from the following components: engine
Terminals Harness P5 P6 Connector
Connector
control switch, emergency stop switch, remote start
switch, data link, and other inputs.
A + 8 VDC + 8 VDC
P5-31 P6-67 The Gas Shutoff Valve (GSOV) is energize-to-run.
C Signal for cylinders Signal for cylinders To enable fuel flow to the engine, the solenoid for
1 and 3 14 and 16 the GSOV must be energized. The ECM provides
P5-38 P6-66 +Battery voltage to the solenoid for the GSOV when
the logic determines that fuel is required for engine
D Signal for cylinders Signal for cylinders operation. For engine shutdown, the ECM removes
5 and 7 10 and 12
the voltage from the GSOV. This stops the fuel flow.
P5-30 P6-65
E Signal for cylinders Signal for cylinders Logged diagnostics provide an historical record.
9 and 11 6 and 8 Before you begin this procedure, use ET to print the
P5-22 P6-64 logged codes to a file.
F Signal for cylinders Signal for cylinders
13 and 15 2 and 4 The most likely causes of the diagnostic code are a
P5-12 P6-63 poor electrical connection or a problem in a wiring
the GSOV. The least likely cause is a problem with
Expected Result: the ECM.
The resistance is less than 5 ohms. The troubleshooting procedure may generate
Results: correcting the cause of the original diagnostic code.
• Yes – The resistance is less than 5 ohms. The resolved.
engine harness is OK. There is a problem with a
connector for the signal wire or the wire in the
terminal box is broken.
Repair: Repair the connector and/or the wire,

when possible. Replace the connector and/or the
wire, if necessary.
STOP.
• No – The resistance is greater than 5 ohms.

There is an open circuit in the engine harness.
293
g00869570 g00869720
Schematic of the solenoid for the GSOV Harness side of the ECM P2 connector
(P2-11) Circuit driver for the gas shutoff valve’s solenoid
Test Step 1. Inspect the Electrical (P2-21) Return
g00869702
Illustration 174
(1) ECM P2 connectors
(3) Terminal box’s J6 connector for the left engine harness
(4) 70-pin customer connector J3
(5) Control panel’s 47-pin connector J4

ECM OFF. Switch the 6 amp circuit breaker OFF.

294
g00869726 g00869896
Harness side of the terminal box P6 connector 70-pin customer connector J3
(P6-70) Circuit driver for the gas shutoff valve’s solenoid (J3-60) Circuit driver for the gas shutoff valve’s solenoid
(P6-57) Return
g00869878
Illustration 178
Control panel’s 47-pin connector J4
(J4-m) Circuit driver for the gas shutoff valve’s solenoid
295
d. Inspect the terminal strip in the control panel

(if equipped) for loose wires, frayed wires,
foreign material, and corrosion.
Expected Result:

Results:

proper connections. Proceed to Test Step 2.
g00869732
Illustration 179
Terminal strip in the control panel condition and/or at least one connection is
improper.
Repair: Perform the necessary repairs, when

possible. Replace parts, if necessary.
STOP.

ON. Switch the 6 amp circuit breaker ON. Turn
the engine control switch to the STOP position.
Note: The “17-05 Fuel Shutoff Valve open circuit”

g00869737
diagnostic code can only be detected when the
Illustration 180 output for the gas shutoff valve’s solenoid is OFF.
Gas shutoff valve’s solenoid The output is OFF when the engine control switch is
in the STOP position and the engine is not running.
B. Thoroughly inspect the following connectors and
the wiring harnesses for the connectors: B. Wait for 30 seconds and use ET to check for an
active “17-05 Fuel Shutoff Valve open circuit”
• ECM J2/P2 connectors diagnostic code.
• Terminal box’s connectors (J6/P6) If there is an active “17-05 Fuel Shutoff Valve
open circuit” diagnostic code, proceed to the
• 70-pin customer connector J3 “Results” for this Test Step. Otherwise, continue
this procedure.
• Control panel’s 47-pin connector J4
C. Use ET to check the logged diagnostic codes.
• Terminal strip in the control panel (if equipped) If there is a “17-06 Fuel Shutoff Valve short
to ground” or a “17-12 Fuel Shutoff Valve
• Connector for the gas shutoff valve’s solenoid malfunction” diagnostic code, clear the code.
a. Check the torque of the Allen head screw for D. To prevent the engine from starting, shut the gas
the 70-pin connectors. The proper torque is supply OFF.
6 ± 1 N·m (55 ± 9 lb in).
Note: To provide the output for the gas shutoff
b. Perform a 45 N (10 lb) pull test on each of the valve’s solenoid, the sequence for engine start-up
wires that are associated with the gas shutoff must be initiated. Otherwise, a “17-06 Fuel Shutoff
valve’s solenoid. Valve short to ground” or a “17-12 Fuel Shutoff Valve
malfunction” diagnostic code cannot be generated.
and pinch points from the ECM to the gas Note: The ECM will not provide output for the gas
shutoff valve’s solenoid. shutoff valve’s solenoid unless the prelube pressure
switch is closed. Make sure that the prelube
pressure switch is operating properly.
296
E. Turn the engine control switch to the START Test Step 3. Check for a Short Circuit to
position for at least 30 seconds. Then turn the the +Battery Side
engine control switch to the STOP position.
F. Use 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. Gaseous fuel is present. Personal Injury or Death
can result from an open flame or spark igniting the
Expected Result: gaseous fuel causing an explosion and/or fire. Al-
ways use a gas detector to determine the presence
When the engine control switch was in the STOP of gaseous fuel when maintaining and servicing.
position, there was no active “17-05 Fuel Shutoff Contact you local gas provider immediately for as-
Valve open circuit” diagnostic code. sistance in the event of a leak.
After the engine was cranked, there was no logged Note: Open sparks can be generated during this
“17-06 Fuel Shutoff Valve short to ground” or “17-12 test.
Fuel Shutoff Valve malfunction” diagnostic code.
A. Make sure that no combustible gas is present in
Results: the surrounding atmosphere.
• OK – No diagnostic codes were generated. B. Ensure that the engine control switch is in the
The output for the gas shutoff valve’s solenoid STOP position.
seems to be OK at this time. The initial diagnostic
code was probably caused by a poor electrical
connection.
Repair: If there is an intermittent problem

that is causing the codes to be logged, refer
to Troubleshooting, “Inspecting Electrical
Connectors”.
STOP.
• Not OK (“17-05 Fuel Shutoff Valve open circuit”

diagnostic code) – A “17-05 Fuel Shutoff Valve
open circuit” diagnostic code was activated. This
can be caused by an actual open circuit or by a
short circuit to the +Battery side. Proceed to Test g00859796
Illustration 181
Step 3. Typical connector for a solenoid
• Not OK (“17-06 Fuel Shutoff Valve short to ground” C. Disconnect the connector from the gas shutoff
diagnostic code) – After the engine was cranked, valve’s solenoid. Then reconnect the connector.
a “17-06 Fuel Shutoff Valve short to ground” Listen for an audible click from the solenoid.
diagnostic code was generated. Proceed to Test
Step 8. If the ambient noise is too loud, touch the
solenoid when the solenoid is reconnected in
• Not OK (“17-12 Fuel Shutoff Valve malfunction” order to feel the vibration. The solenoid will
diagnostic code) – After the engine was cranked, vibrate when the solenoid is de-energized and
a “17-12 Fuel Shutoff Valve malfunction” energized.
diagnostic code was generated. The ECM
disabled the ignition. Expected Result:
Repair: Turn the engine control switch to the There is no audible click and/or vibration when the
OFF/RESET position. Switch the 16 amp circuit solenoid is disconnected and reconnected. The
breaker for the ECM OFF. solenoid is not energized when the engine control
switch is in the STOP position.
Replace the gas shutoff valve’s solenoid.
STOP.
297
Results:
• OK – There is no audible click and/or vibration

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

vibration when the solenoid is disconnected and
connected. The solenoid is receiving power when
the engine control switch is in the STOP position.
There is probably a short circuit to the +Battery
side in a connector or a wiring harness. Proceed
to Test Step 4.
Test Step 4. Determine the Cause of the

Energized Solenoid
Gaseous fuel is present. Personal Injury or Death

gaseous fuel causing an explosion and/or fire. Al-
of gaseous fuel when maintaining and servicing.
Contact you local gas provider immediately for as-
sistance in the event of a leak. g00869915
Illustration 182
Note: Open sparks can be generated during this (P6-70) Circuit driver for the gas shutoff valve’s solenoid
test.
A. Turn the engine control switch to the OFF/RESET terminal (P6-70) from the harness side of the
position. Switch the 16 amp circuit breaker for terminal box P6 connector.
the ECM OFF.
position.
g00859796
Illustration 183
Typical connector for a solenoid
D. Disconnect the connector from the gas shutoff

valve’s solenoid. Then reconnect the connector.
Listen for an audible click from the solenoid.
298
If the ambient noise is too loud, touch the

order to feel the vibration. The solenoid will
vibrate when the solenoid is de-energized and
energized.
Expected Result:
There is no audible click and/or vibration when the

solenoid is disconnected and reconnected. The
solenoid is not energized when the circuit driver for
the solenoid is disconnected from the J6 connector.
Results:

reconnected. The solenoid is not energized when
the circuit driver for the solenoid is disconnected
from the J6 connector.
Repair: Use the following procedure to determine

whether the circuit driver for the solenoid is faulty:

can result from an open flame or spark igniting the Illustration 184 g00869921
gaseous fuel causing an explosion and/or fire. Al- Harness side of the ECM P2 connector
sistance in the event of a leak. 3. Use a 151-6320 Wire Removal Tool to remove
terminal (P2-11).
Note: Open sparks can be generated during this 4. Switch the 16 amp circuit breaker for the ECM
test. ON. Turn the engine control switch to the
STOP position.
OFF/RESET position. Switch the 16 amp circuit 5. Disconnect the connector from the gas
breaker for the ECM OFF. shutoff valve’s solenoid. Then reconnect the
connector. Listen for an audible click from the
2. Reinstall the removed wire into terminal solenoid.
(P6-70). Pull on the wire in order to verify that
the terminal is properly installed. If the ambient noise is too loud, touch the
energized.
If the solenoid is energized, there is a problem

with a connector and/or wiring in the terminal
box. Repair the wiring and/or the connector,
when possible. Replace parts, if necessary.
If the solenoid is not energized, there may be

a problem with the ECM. Continue with this
procedure.
299

7. Reinstall the terminal that was removed from

terminal (P2-11). Pull on the wire in order to
verify proper installation of the terminal.

STOP position.
9. Disconnect the connector from the gas

shutoff valve’s solenoid. Then reconnect the
connector. Listen for an audible click from the g00859796
solenoid. Illustration 185
solenoid when the solenoid is reconnected in C. Install a jumper wire with the appropriate
order to feel the vibration. The solenoid will connectors on the ends into terminals “A” and
vibrate when the solenoid is de-energized and “B” of the solenoid’s connector.
energized.
If the solenoid is not energized, there is ON. Turn the engine control switch to the STOP
an intermittent problem with a connector position.
and/or the wiring. Refer to Troubleshooting,
“Inspecting Electrical Connectors”. Note: The “17-05 Fuel Shutoff Valve open circuit”
If the solenoid is energized, there is a problem output for the gas shutoff valve’s solenoid is OFF.
with the ECM. Replace the ECM according to The output is OFF when the engine control switch is
Troubleshooting, “Replacing the ECM”. in the STOP position and the engine is not running.
STOP. E. Wait for 30 seconds and use the “Active

Diagnostic” screen of ET to look for a “17-05 Fuel
• Not OK – There is an audible click and/or Shutoff Valve open circuit” diagnostic code.
reconnected. The solenoid is energized when the Expected Result:
circuit driver for the solenoid is disconnected from
the terminal box J6 connector. There is a short A “17-05 Fuel Shutoff Valve open circuit” diagnostic
circuit to the +Battery side in the engine harness. code was not generated when the jumper wire was
installed.
Repair: Repair the connector and/or wiring in
the engine harness, when possible. Replace the Results:
engine harness, if necessary.
• OK – A “17-05 Fuel Shutoff Valve open circuit”
STOP. diagnostic code was not generated when the
jumper wire was installed. The harness and
Test Step 5. Create a Short Circuit in the ECM are OK. There is a problem with the
order to Check for an Open Circuit solenoid.
A. Turn the engine control switch to the OFF/RESET Repair: Perform the following procedure:
the ECM OFF. 1. Turn the engine control switch to the
B. Disconnect the gas shutoff valve’s solenoid. breaker for the ECM OFF.
2. Remove the jumper wire from the solenoid’s

connector.
3. Inspect the solenoid’s connectors for damage,

moisture, and corrosion.
4. Make repairs, as needed.

300
If the problem is not resolved, replace the D. Install a jumper wire with the appropriate Deutsch
solenoid. connectors on the ends into terminals (P6-70)
and (P6-57). Pull on the jumper wire in order to
STOP. verify proper installation.
• Not OK – A “17-05 Fuel Shutoff Valve open E. Switch the 16 amp circuit breaker for the ECM
circuit” diagnostic code was generated when the ON. Turn the engine control switch to the STOP
jumper wire was installed. There may be an open position.
circuit in the engine harness. Proceed to Test
Step 6. Note: The “17-05 Fuel Shutoff Valve open circuit”
Test Step 6. Check the Engine Harness output for the gas shutoff valve’s solenoid is OFF.
The output is OFF when the engine control switch is
A. Ensure that the engine control switch is in the in the STOP position and the engine is not running.
OFF/RESET position and that the 16 amp circuit
breaker for the ECM is OFF. F. Wait for 30 seconds and use ET to check for an
active “17-05 Fuel Shutoff Valve open circuit”
B. Disconnect the P6 connector from the terminal diagnostic code.
box. Inspect the P6 and J6 connectors for
damage, moisture, and corrosion. Make repairs, Expected Result:
if necessary.
There is no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code.
Results:
• OK – When the jumper wire was installed, there

was no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code. There is a problem in
the engine harness.
Repair: Repair the engine harness, when possible.

Replace the engine harness, if necessary.
STOP.
• Not OK – When the jumper wire was installed, a

“17-05 Fuel Shutoff Valve open circuit” diagnostic
code was activated. The ECM did not detect
the jumper wire in the P6 connector. There is
a problem in the terminal box. Proceed to test
Step 7.
Test Step 7. Check the ECM

the ECM OFF.
g00869726 B. Use a 151-6320 Wire Removal Tool to remove
Illustration 186
Harness side of the terminal box P6 connector the jumper wire from the P6 connector.
(P2-57) Return C. Reinstall the terminals into P6-70 and P6-57.
Make sure that the terminals are installed into
C. Reconnect the P6 connector to the terminal the correct locations. Pull on the wires in order to
box. Use a 151-6320 Wire Removal Tool to verify proper installation of the terminals.
remove terminals (P6-70) and (P6-57). Label the
terminals. D. Disconnect the ECM J2/P2 connectors. Inspect
the connectors for damage, moisture, and
corrosion.
301
Make repairs, if necessary. Results:

was no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code. The ECM detects the
jumper wire at the P2 connector. However, the
ECM did not detect the jumper wire at the P6
connector. There is a problem between the ECM
P2 connector and the terminal box P6 connector.

2. Use a 151-6320 Wire Removal Tool to remove

3. Reinstall the terminals into P2-11 and P2-21.

the correct locations. Pull on the wires in order
to verify proper installation of the terminals.
4. Disconnect the ECM J2/P2 connectors. Inspect

corrosion.
5. Thoroughly inspect the terminal box J6

g00869720 connector for the engine harness.
Illustration 187
6. Use an ohmmeter to measure the resistance
(P2-21) Return between the P2-11 terminal and the J6-70
terminal. Also, measure the resistance between
E. Use the 151-6320 Wire Removal Tool to the P2-21 terminal and the J6-57 terminal.
terminals. If the resistance is less than 5 ohms, the circuit
has good continuity. Otherwise, there is an
F. Reconnect the ECM J2/P2 connectors. open circuit.
G. Install the jumper wire into terminals (P2-11) and Make repairs, if necessary.
(P2-21). Pull on the jumper wire in order to verify
proper installation. STOP.
H. Switch the 16 amp circuit breaker for the ECM • No – When the jumper wire was installed, a
ON. Turn the engine control switch to the STOP “17-05 Fuel Shutoff Valve open circuit” diagnostic
position. code was activated. The ECM did not detect the
jumper wire. There is a problem with the ECM.
Note: The “17-05 Fuel Shutoff Valve open circuit”
diagnostic code can only be detected when the Repair: Perform the following procedure:
output for the gas shutoff valve’s solenoid is OFF.
The output is OFF when the engine control switch is 1. Turn the engine control switch to the
in the STOP position and the engine is not running. OFF/RESET position. Switch the 16 amp circuit
I. Wait for 30 seconds and use the “Active
Diagnostic” screen of ET to look for an active 2. Use a 151-6320 Wire Removal Tool to remove
“17-05 Fuel Shutoff Valve open circuit” diagnostic the jumper wire from the P2 connector.
code.
Expected Result: Make sure that the terminals are installed into
the correct locations. Pull on the wires in order
There is no active “17-05 Fuel Shutoff Valve open to verify proper installation of the terminals.
302
4. Replace the ECM according to Troubleshooting, 2. Inspect the connections of the solenoid for
“Replacing the ECM”. Verify that the problem damage and/or corrosion.
is resolved.
STOP.
If the problem is not resolved, replace the
Test Step 8. Create an Open Circuit in solenoid.
order to Check for a Short Circuit to
Ground STOP.
A. Turn the engine control switch to the OFF/RESET • Not OK – A “short to ground” diagnostic
position. code was generated when the solenoid was
disconnected. Proceed to Test Step 9.
B. Disconnect the gas shutoff valve’s solenoid.
Test Step 9. Create an Open Circuit at the
C. Turn the engine control switch to the STOP Terminal Box
position.
D. Use ET to clear the logged “17-06 Fuel Shutoff position. Switch the 16 amp circuit breaker for
Valve short to ground” diagnostic code. the ECM OFF.
E. To prevent the engine from starting, shut OFF the

main gas supply.
Note: To provide the output for the gas shutoff

valve’s solenoid, the sequence for engine start-up
must be initiated. Otherwise, a “17-06 Fuel Shutoff
Valve short to ground” diagnostic code cannot be
generated.
Note: The ECM will not provide output for the gas
shutoff valve’s solenoid unless the prelube pressure

position for at least 30 seconds. Then turn the
G. Use ET to look for a logged “17-06 Fuel Shutoff

Valve short to ground” diagnostic code again.
Expected Result:
A “17-06 Fuel Shutoff Valve short to ground” was

not generated.
Results:
g00869915
Illustration 188
• OK – When the solenoid was connected, a “short Harness side of the terminal box P6 connector
to ground” diagnostic code was generated. When (P6-70) Circuit driver for the gas shutoff valve’s solenoid
the solenoid was disconnected, no “short to
ground” diagnostic code was generated. There B. Use a 151-6320 Wire Removal Tool to remove
is a problem with the solenoid. terminal (P6-70).
Repair: Perform the following procedure: C. Switch the 16 amp circuit breaker for the ECM
1. Turn the engine control switch to the position.
breaker for the ECM OFF. D. Use ET to clear the logged “17-06 Fuel Shutoff
Valve short to ground” diagnostic code.
303
E. To prevent the engine from starting, shut OFF the Test Step 10. Check the ECM
main gas supply.
Note: To provide the output for the gas shutoff position. Switch the 16 amp circuit breaker for
valve’s solenoid, the sequence for engine start-up the ECM OFF.
must be initiated. Otherwise, a “17-06 Fuel Shutoff
Valve short to ground” diagnostic code cannot be
generated.
Note: The ECM will not provide output for the gas
shutoff valve’s solenoid unless the prelube pressure


Valve short to ground” diagnostic code again.
Expected Result:
A “17-06 Fuel Shutoff Valve short to ground” was

not generated.
Results:
• OK – A “17-06 Fuel Shutoff Valve short to ground”

diagnostic code was not generated when the
output to the solenoid was disconnected from the
g00869921
Illustration 189
Repair: Perform the following procedure: Harness side of the ECM P2 connector
OFF/RESET position. Switch the 16 amp circuit B. Use the 151-6320 Wire Removal Tool to remove
breaker for the ECM OFF. terminal (P2-11).
2. Reinstall the terminal that was removed from C. Switch the 16 amp circuit breaker for the ECM
P6-70. Pull on the wire in order to verify proper ON. Turn the engine control switch to the STOP
installation of the terminal. position.
3. Repair the harness, when possible. Replace D. Use ET to clear the logged “17-06 Fuel Shutoff
the harness, if necessary. Valve short to ground” diagnostic code.
STOP. E. To prevent the engine from starting, shut OFF the
main gas supply.
• Not OK – A “17-06 Fuel Shutoff Valve short to
ground” diagnostic code was generated when Note: To provide the output for the gas shutoff
the output to the solenoid was disconnected from valve’s solenoid, the sequence for engine start-up
the terminal box P6 connector. There is probably must be initiated. Otherwise, a “17-06 Fuel Shutoff
a short circuit to ground in the terminal box. Valve short to ground” diagnostic code cannot be
generated.
Repair: Reinstall the terminal that was removed
from P6-57. Pull on the wire in order to verify Note: The ECM will not provide output for the gas
proper installation of the terminal. shutoff valve’s solenoid unless the prelube pressure
Proceed to Test Step 10. pressure switch is operating properly.
304
F. Turn the engine control switch to the START i01689108

engine control switch to the STOP position. ECM Output Circuit
(Prelubrication Oil Pump)
Valve short to ground” diagnostic code again. SMCS Code: 1901-038
Expected Result: System Operation Description:
The “17-06 Fuel Shutoff Valve short to ground” The ECM contains the logic and the outputs for
diagnostic code was not generated. control of prelubrication, starting, and shutdown
of the engine. The logic for starting and stopping
Results: is customer programmable. The logic responds
to inputs from the following components: engine
• OK – When the output to the solenoid was control switch, emergency stop switch, remote start
disconnected from the ECM P2 connector, switch, data link, and other inputs.
the “17-06 Fuel Shutoff Valve short to ground”
diagnostic code was not generated. However, a The prelube pump will not operate if the emergency
“short to ground” diagnostic code was generated stop button is activated or if the engine speed is
when the output to the solenoid was disconnected greater than 0 rpm.
from the terminal box P6 connector. There is a
problem in the terminal box between the ECM When the conditions permit operation and the logic
connector and the terminal box P6 connector. determines that lubrication is required, the ECM
provides +Battery voltage to the prelube pump’s
Repair: Perform the following procedure: solenoid. After activation, the prelube pump will
operate until one of the following occurrences:
OFF/RESET position. Switch the 16 amp circuit • The prelube pressure switch closes.
• The programmable “Engine Pre-lube Time Out
2. Reinstall the terminal that was removed from Period” expires.
P2-11. Pull on the wire in order to verify proper
installation of the terminal. • The emergency stop button is pressed.
3. Repair the harness, when possible. Replace The prelube pump can also be operated with
the harness, if necessary. a manual switch. When the switch is closed, a
+Battery signal is sent to the ECM. The ECM
STOP. provides +Battery voltage to the prelube pump’s
solenoid until the switch is released or until the
• Not OK – A “17-06 Fuel Shutoff Valve short to prelube pressure switch closes.
ground” diagnostic code was generated when
the output to the solenoid was disconnected from The prelubrication system also operates after
the ECM P2 connector. There seems to be a shutdown. This ensures that the turbocharger has
problem with the ECM. adequate lubrication during coastdown. When the
engine reaches 0 rpm, the output for the prelube
Repair: Perform the following procedure: pump will operate for three minutes.
1. Turn the engine control switch to the When +Battery voltage is supplied to the prelube
OFF/RESET position. Switch the 16 amp circuit pump’s solenoid, the ECM also provides +Battery
breaker for the ECM OFF. voltage to the “Prelube Active” indicator in the
control panel (if equipped).
P2-11. Pull on the wire in order to verify proper Before you troubleshoot the prelubrication system,
installation of the terminal. make sure that the ECM is programmed properly.
The “Engine Pre-Lube Time Out Period” must
3. Replace the ECM according to Troubleshooting, be programmed to a value between 30 and 300
“Replacing the ECM”. Verify that the problem seconds. Make sure that the hardware is installed:
is resolved. prelube pump, solenoid for the pump, prelube
pressure switch, and manual prelube switch. Make
STOP. sure that the wiring is installed. Refer to the engine’s
electrical Schematic.
305
If Caterpillar did not supply the prelubrication

system, the prelubrication function and the E233 (3)
event code are disabled. The 338-05, 338-06, and
339-05 diagnostic codes are disabled.
Logged diagnostics provide an historical record.

Before you begin this procedure, use ET to print the
logged codes to a file.

poor electrical connection or a problem in a wiring
harness. The next likely cause is a problem with the
prelube pump’s solenoid. The least likely cause is a

resolved.
g00870079
Illustration 190
Schematic for the prelube pump’s solenoid
306

g00870200
Illustration 191
(5) 70-pin customer connector J3
(6) Control panel’s 47-pin connector J4
(7) Terminal box’s J6 connector for the left engine harness

ECM OFF. Switch the 6 amp circuit breaker OFF. g00870205
Illustration 192
Note: For the following steps, refer to Harness side of the ECM P2 connector
Troubleshooting, “Inspecting Electrical Connectors”. (P2-12) Return
(P2-22) Circuit driver for the prelube pump’s solenoid
307
g00870225
Illustration 195
Control panel’s 47-pin connector J4
(J4-T) Input signal for the manual prelube
(J4-c) Circuit driver for the prelube pump’s solenoid
g00870206
Illustration 193
(P6-28) Return
g00870220
Illustration 194
g00870215
Inside of the control panel (if equipped) Illustration 196
(8) “Manual Prelube” switch and “Prelube Active” indicator 70-pin customer connector J3
(9) Terminal strip
(J3-58) Input signal for the manual prelube
(J3-59) Circuit driver for the prelube pump’s solenoid
308

and pinch points from the ECM to the prelube
pump’s solenoid.
d. Inspect the terminal strip in the control panel

foreign material, and corrosion.
Expected Result:

Results:


improper.

STOP.
g00870226
Illustration 197 Test Step 2. Check for Diagnostic Codes
ECM connector P1
(P1-56) Input signal for the manual prelube A. Switch the 16 amp circuit breaker for the ECM
ON. Switch the 6 amp circuit breaker ON. Turn
B. Thoroughly inspect the following connectors and the engine control switch to the STOP position.
the wiring harnesses for the connectors:
Note: The “338-05 Prelube Relay open circuit”
• ECM J1/P1 connectors diagnostic code can only be detected when the
ECM output for the prelube pump’s solenoid is OFF.
• ECM J2/P2 connectors The output is normally OFF when the engine control
switch is in the STOP position and when the prelube
• Terminal box’s J6/P6 connectors pressure switch is closed.
• 70-pin customer connector J3 B. Wait for 30 seconds and use ET to check for
an active “338-05 Prelube Relay open circuit”
• Control panel’s 47-pin connector J4 diagnostic code.
• Terminal strip in the control panel (if equipped) If there is an active “338-05 Prelube Relay
• “Manual Prelube” switch and “Prelube Active” “Results” for this Test Step. Otherwise, continue
indicator in the control panel (if equipped) this procedure.
• Connector for the prelube pump’s solenoid C. Use ET to check the logged diagnostic codes. If
there is a “338-06 Prelube Relay short to ground”
a. Check the torque of the Allen head screw for diagnostic code, clear the code.
the 70-pin connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in). Note: The “338-06 Prelube Relay short to ground”
b. Perform a 45 N (10 lb) pull test on each of ECM output for the prelube pump’s solenoid is ON.
the wires that are associated with the prelube The output is normally ON when the engine control
pump’s solenoid. switch is in the START position and the prelube
pressure switch is open.
309
D. Activate the manual prelube switch for at least B. Ensure that the engine control switch is in the
30 seconds. Then release the switch. STOP position.
E. Use ET to look for a logged “338-06 Prelube

Relay short to ground” diagnostic code again.
Expected Result:
When the engine control switch was in the STOP

position, there was no active “338-05 Prelube Relay
open circuit” diagnostic code.
After the manual prelube switch was operated,

there was no logged “338-06 Prelube Relay short to
Results:
g00859796
Illustration 198
• OK – No diagnostic codes were generated. The Typical connector for a solenoid
output for the prelube pump’s solenoid seems to
be OK at this time. The initial diagnostic code was C. Disconnect the connector from the prelube
probably caused by a poor electrical connection. pump’s solenoid. Then reconnect the connector.
that is causing the codes to be logged, refer If the ambient noise is too loud, touch the
to Troubleshooting, “Inspecting Electrical solenoid when the solenoid is reconnected in
Connectors”. order to feel the vibration. The solenoid will
STOP. energized.
• Not OK (“338-05 Prelube Relay open circuit” Expected Result:

diagnostic code) – A “338-05 Prelube Relay open
circuit” diagnostic code was activated. This can There is no audible click and/or vibration when the
be caused by an actual open circuit or by a short solenoid is disconnected and reconnected. The
circuit to the +Battery side. Proceed to Test Step solenoid is not energized when the engine control
3. switch is in the STOP position.
• Not OK (“338-06 Prelube Relay short to ground” Results:

diagnostic code) – After the manual prelube
switch was operated, a “338-06 Prelube Relay • OK – There is no audible click and/or vibration
short to ground” diagnostic code was generated. when the solenoid is disconnected and
Proceed to Test Step 8. connected. There is no short circuit to the
+Battery side. There is an open circuit. Proceed
Test Step 3. Check for a Short Circuit to to Test Step 5.
the +Battery Side
the engine control switch is in the STOP position.
Gaseous fuel is present. Personal Injury or Death There is probably a short circuit to the +Battery
can result from an open flame or spark igniting the side in a connector or a wiring harness. Proceed
gaseous fuel causing an explosion and/or fire. Al- to Test Step 4.
sistance in the event of a leak.
Note: Open sparks can be generated during this

test.
A. Make sure that no combustible gas is present in

the surrounding atmosphere.
310

Energized Solenoid

Note: Open sparks can be generated during this Illustration 200 g00859796
test.
position. Switch the 16 amp circuit breaker for D. Disconnect the connector from the prelube
the ECM OFF. pump’s solenoid. Then reconnect the connector.

energized.
Expected Result:

Results:


g00870241
Illustration 199 Gaseous fuel is present. Personal Injury or Death
Harness side of the terminal box P6 connector can result from an open flame or spark igniting the
(P6-36) Circuit driver for the prelube pump’s solenoid gaseous fuel causing an explosion and/or fire. Al-
B. Use a 151-6320 Wire Removal Tool to remove of gaseous fuel when maintaining and servicing.
terminal (P6-36) from the harness side of the Contact you local gas provider immediately for as-
terminal box P6 connector. sistance in the event of a leak.

test.
position.
311
1. Turn the engine control switch to the If the solenoid is not energized, there may be
OFF/RESET position. Switch the 16 amp circuit a problem with the ECM. Continue with this
breaker for the ECM OFF. procedure.
2. Reinstall the removed wire into terminal 6. Turn the engine control switch to the
(P6-36). Pull on the wire in order to verify that OFF/RESET position. Switch the 16 amp circuit
the terminal is properly installed. breaker for the ECM OFF.

terminal (P2-12). Pull on the wire in order to
verify proper installation of the terminal.

STOP position.
9. Disconnect the connector from the prelube

pump’s solenoid. Then reconnect the
solenoid.

energized.
If the solenoid is not energized, there is

an intermittent problem with a connector

with the ECM. Replace the ECM according to
g00870243
Illustration 201
Harness side of the ECM P2 connector STOP.
3. Use a 151-6320 Wire Removal Tool to remove vibration when the solenoid is disconnected and
terminal (P2-12). reconnected. The solenoid is energized when the
circuit driver for the solenoid is disconnected from
4. Switch the 16 amp circuit breaker for the ECM the terminal box P6 connector. There is a short
ON. Turn the engine control switch to the circuit to the +Battery side in the engine harness.
STOP position.
Repair: Repair the connector and/or wiring in
5. Disconnect the connector from the prelube the engine harness, when possible. Replace the
pump’s solenoid. Then reconnect the engine harness, if necessary.
solenoid. STOP.
If the ambient noise is too loud, touch the Test Step 5. Create a Short Circuit in
solenoid when the solenoid is reconnected in order to Check for an Open Circuit
vibrate when the solenoid is de-energized and A. Turn the engine control switch to the OFF/RESET
energized. position. Switch the 16 amp circuit breaker for
the ECM OFF.
with a connector and/or wiring in the terminal B. Disconnect the prelube pump’s solenoid.
312
3. Inspect the solenoid’s connectors for damage,

moisture, and corrosion.

solenoid.
STOP.
• Not OK – A “338-05 Prelube Relay open circuit”

diagnostic code was generated when the jumper
wire was installed. There may be an open circuit
in the engine harness. Proceed to Test Step 6.
g00859796
Illustration 202 Test Step 6. Check the Engine Harness
A. Ensure that the engine control switch is in the
C. Install a jumper wire with the appropriate OFF/RESET position and that the 16 amp circuit
connectors on the ends into terminals “A” and breaker for the ECM is OFF.
“B” of the solenoid’s connector.
B. Disconnect the P6 connector from the terminal
D. Switch the 16 amp circuit breaker for the ECM box. Inspect the P6 and J6 connectors for
ON. Turn the engine control switch to the STOP damage, moisture, and corrosion. Make repairs,
position. if necessary.

The output is normally OFF when the engine control
pressure switch is closed.
E. Wait for 30 seconds and use the “Active

Diagnostic” screen of ET to look for a “338-05
Prelube Relay open circuit” diagnostic code.
Expected Result:
A “338-05 Prelube Relay open circuit” diagnostic

code was not generated when the jumper wire was
installed.
Results:
• OK – A “338-05 Prelube Relay open circuit”

the ECM are OK. There is a problem with the
solenoid.
1. Turn the engine control switch to the Illustration 203 g00870206

OFF/RESET position. Switch the 16 amp circuit Harness side of the terminal box P6 connector
(P6-28) Return
connector.
313
C. Reconnect the P6 connector to the terminal D. Disconnect the ECM J2/P2 connectors. Inspect
box. Use a 151-6320 Wire Removal Tool to the connectors for damage, moisture, and
remove terminals (P6-28) and (P6-36). Label the corrosion.
terminals.
Make repairs, if necessary.
D. Install a jumper wire with the appropriate Deutsch
connectors on the ends into terminals (P6-28)
verify proper installation.
E. Switch the 16 amp circuit breaker for the ECM

position.

The output is normally OFF when the engine control
F. Wait for 30 seconds and use ET to check for

an active “338-05 Prelube Relay open circuit”
diagnostic code.
Expected Result:
There is no active “338-05 Prelube Relay open

Results:

g00870205
was no active “338-05 Prelube Relay open circuit” Illustration 204
diagnostic code. There is a problem in the engine Harness side of the ECM P2 connector
harness. (P2-12) Return
Replace the engine harness, if necessary. E. Use the 151-6320 Wire Removal Tool to
STOP. terminals.
• Not OK – When the jumper wire was installed, a F. Reconnect the ECM J2/P2 connectors.
“338-05 Prelube Relay open circuit” diagnostic
code was activated. The ECM did not detect G. Install the jumper wire into terminals (P2-12) and
the jumper wire in the P6 connector. There is (P2-22). Pull on the jumper wire in order to verify
a problem in the terminal box. Proceed to test proper installation.
Step 7.
H. Switch the 16 amp circuit breaker for the ECM
Test Step 7. Check the ECM ON. Turn the engine control switch to the STOP
position.
position. Switch the 16 amp circuit breaker for Note: The “338-05 Prelube Relay open circuit”
the ECM OFF. diagnostic code can only be detected when the
B. Use a 151-6320 Wire Removal Tool to remove The output is normally OFF when the engine control
the jumper wire from the P6 connector. switch is in the STOP position and when the prelube
C. Reinstall the terminals into P6-28 and P6-36.
Make sure that the terminals are installed into I. Wait for 30 seconds and use the “Active
the correct locations. Pull on the wires in order to Diagnostic” screen of ET to look for an active
verify proper installation of the terminals. “338-05 Prelube Relay open circuit” diagnostic
code.
314
Expected Result: 2. Use a 151-6320 Wire Removal Tool to remove

There is no active “338-05 Prelube Relay open
circuit” diagnostic code. 3. Reinstall the terminals into P2-12 and P2-22.
Results: the correct locations. Pull on the wires in order
was no active “338-05 Prelube Relay open 4. Replace the ECM according to Troubleshooting,
circuit” diagnostic code. The ECM detects the “Replacing the ECM”. Verify that the problem
jumper wire at the P2 connector. However, the is resolved.
ECM did not detect the jumper wire at the P6
connector. There is a problem between the ECM STOP.
Test Step 8. Create an Open Circuit in
Repair: Perform the following procedure: order to Check for a Short Circuit to
Ground
OFF/RESET position. Switch the 16 amp circuit A. Turn the engine control switch to the OFF/RESET
breaker for the ECM OFF. position.
2. Use a 151-6320 Wire Removal Tool to remove B. Disconnect the prelube pump’s solenoid.
C. Turn the engine control switch to the STOP
3. Reinstall the terminals into P2-12 and P2-22. position.
the correct locations. Pull on the wires in order D. Use ET to clear the logged “338-06 Prelube
to verify proper installation of the terminals. Relay short to ground” diagnostic code.
4. Disconnect the ECM J2/P2 connectors. Inspect Note: The “338-06 Prelube Relay short to ground”
the connectors for damage, moisture, and diagnostic code can only be detected when the
corrosion. ECM output for the prelube pump’s solenoid is ON.
The output is normally ON when the engine control
5. Thoroughly inspect the terminal box J6 switch is in the START position and the prelube
connector for the engine harness. pressure switch is open.
6. Use an ohmmeter to measure the resistance E. Activate the manual prelube switch for at least
between the P2-12 terminal and the J6-36 30 seconds. Then release the switch.
terminal. Also, measure the resistance between
the P2-22 terminal and the J6-28 terminal. F. Use ET to look for a logged “338-06 Prelube
If the resistance is less than 5 ohms, the circuit
has good continuity. Otherwise, there is an Expected Result:
open circuit.
After the manual prelube switch was operated,
Make repairs, if necessary. there was no logged “338-06 Prelube Relay short to
STOP.
Results:
• No – When the jumper wire was installed, a
“338-05 Prelube Relay open circuit” diagnostic • OK – When the solenoid was connected, a “short
code was activated. The ECM did not detect the to ground” diagnostic code was generated. When
jumper wire. There is a problem with the ECM. the solenoid was disconnected, no “short to
ground” diagnostic code was generated. There
Repair: Perform the following procedure: is a problem with the solenoid.
1. Turn the engine control switch to the Repair: Perform the following procedure:
breaker for the ECM OFF. 1. Turn the engine control switch to the
315
2. Inspect the connections of the solenoid for Note: The “338-06 Prelube Relay short to ground”
damage and/or corrosion. diagnostic code can only be detected when the
ECM output for the prelube pump’s solenoid is ON.
3. Make repairs, as needed. The output is normally ON when the engine control
switch is in the START position and the prelube
If the problem is not resolved, replace the pressure switch is open.
solenoid.
E. Activate the manual prelube switch for at least
STOP. 30 seconds. Then release the switch.
• Not OK – After the manual prelube switch was F. Use ET to look for a logged “338-06 Prelube
operated, a “338-06 Prelube Relay short to Relay short to ground” diagnostic code again.
ground” diagnostic code was logged. Proceed
to Test Step 9. Expected Result:
Test Step 9. Create an Open Circuit at the A “338-06 Prelube Relay short to ground” was not
Terminal Box generated.
A. Turn the engine control switch to the OFF/RESET Results:

the ECM OFF. • OK – A “338-06 Prelube Relay short to ground”


3. Repair the harness, when possible. Replace

the harness, if necessary.
STOP.
• Not OK – A “338-06 Prelube Relay short to

the output to the solenoid was disconnected from
the terminal box P6 connector. There is probably
a short circuit to ground in the terminal box.
Repair: Reinstall the terminal that was removed

from P6-36. Pull on the wire in order to verify
g00870241
Illustration 205 proper installation of the terminal.
(P6-36) Circuit driver for the prelube pump’s solenoid Proceed to Test Step 10.
B. Use a 151-6320 Wire Removal Tool to remove Test Step 10. Check the ECM
terminal (P6-36).
C. Switch the 16 amp circuit breaker for the ECM position. Switch the 16 amp circuit breaker for
ON. Turn the engine control switch to the STOP the ECM OFF.
position.
D. Use ET to clear the logged “338-06 Prelube

Relay short to ground” diagnostic code.
316
Results:
• OK – When the output to the solenoid was

disconnected from the ECM P2 connector, the
“338-06 Prelube Relay short to ground” diagnostic
code was not generated. However, a “short to
the terminal box P6 connector. There is a problem
in the terminal box between the ECM connector
and the terminal box P6 connector.



STOP.
g00870243
• Not OK – A “338-06 Prelube Relay short to
Illustration 206 ground” diagnostic code was generated when
Harness side of the ECM P2 connector the output to the solenoid was disconnected from
(P2-12) Circuit driver for the prelube pump’s solenoid the ECM P2 connector. There seems to be a
B. Use the 151-6320 Wire Removal Tool to remove
terminal (P2-12). Repair: Perform the following procedure:
C. Switch the 16 amp circuit breaker for the ECM 1. Turn the engine control switch to the
ON. Turn the engine control switch to the STOP OFF/RESET position. Switch the 16 amp circuit
position. breaker for the ECM OFF.
D. Use ET to clear the logged “338-06 Prelube 2. Reinstall the terminal that was removed from
Relay short to ground” diagnostic code. P2-12. Pull on the wire in order to verify proper
Note: The “338-06 Prelube Relay short to ground”
diagnostic code can only be detected when the 3. Replace the ECM according to Troubleshooting,
ECM output for the prelube pump’s solenoid is ON. “Replacing the ECM”. Verify that the problem
The output is normally ON when the engine control is resolved.
switch is in the START position and the prelube
pressure switch is open. STOP.
E. Activate the manual prelube switch for at least

30 seconds. Then release the switch.
F. Use ET to look for a logged “338-06 Prelube

Expected Result:
The “338-06 Prelube Relay short to ground”

diagnostic code was not generated.
317
i01657629 Test Step 1. Inspect the Electrical

ECM Output Circuit (Starting
Motor)
SMCS Code: 1901-038
The ECM contains the logic and the outputs for

control of prelubrication, starting, and shutdown
of the engine. The logic for starting and stopping
is customer programmable. The logic responds
to inputs from the following components: engine
control switch, emergency stop switch, remote start
switch, data link, and other inputs.
g00868419
The ECM supplies +Battery voltage to the starting Illustration 208
motor’s solenoid when the logic determines that it (1) ECM J2/P2 connectors
is necessary. The ECM removes the voltage when (2) 16 amp circuit breaker
(3) Terminal box J6 connector for the left engine harness
the crank terminate relay is energized. The voltage
is also removed if the customer programmable
“Overcrank Time” has expired. A. Turn the engine control switch to the OFF/RESET
the ECM OFF.

g00855708
Illustration 207
Schematic for the starting motor’s solenoid
g00859811
Illustration 209
(P2-10) Circuit driver for the starting motor’s solenoid
(P2-20) Return
318
Results:


improper.

STOP.

position.
B. Wait for 30 seconds and use ET to check for an

active “444-05 Start Relay open circuit”diagnostic
code.
If there is an active “444-05 Start Relay open

circuit” diagnostic code, proceed to the “Results”
for this Test Step. Otherwise, continue this
procedure.
g00859966
Illustration 210
Harness side of the terminal box P6 connector C. Use ET to check the logged diagnostic codes. If
(P6-29) Return there is a “444-06 Start Relay short to ground”
(P6-37) Circuit driver for the starting motor’s solenoid code, clear the code.
B. Thoroughly inspect the following connectors and D. To prevent the engine from starting, shut the gas
the wiring harnesses for the connectors: supply OFF.
• ECM J2/P2 connectors Note: To provide the output for the starting motor’s
solenoid, the sequence for engine start-up must be
• Terminal box J6/P6 connectors initiated. Otherwise, a “444-06 Start Relay short to
ground” diagnostic code cannot be generated.
• Connector to the starting motor’s solenoid
E. Turn the engine control switch to the START
a. Check the torque of the Allen head screw for position for at least 30 seconds. Then turn the
the 70-pin connectors. The proper torque is engine control switch to the STOP position.
6 ± 1 N·m (55 ± 9 lb in).
F. Use ET to look for a logged “444-06 Start Relay
b. Perform a 45 N (10 lb) pull test on each of short to ground” diagnostic code again.
the wires that are associated with the starting
motor’s solenoid. Expected Result:
c. Check the harness and wiring for abrasion When the engine control switch was in the STOP
and pinch points from the ECM to the starting position, there was no active “444-05 Start Relay
motor’s solenoid. open circuit” diagnostic code.
Expected Result: After the engine was cranked, there was no logged
“444-06 Start Relay short to ground” diagnostic
All of the connectors, pins, and sockets are code.
319
Results:
• OK – No diagnostic codes were generated. The

output for the starting motor’s solenoid seems to
be OK at this time. The initial diagnostic code was
probably caused by a poor electrical connection.

that is causing the codes to be logged, refer
Connectors”.
STOP.
• Not OK (“444-05 Start Relay open circuit” g00859796

diagnostic code) – A “444-05 Start Relay open Illustration 211
circuit” diagnostic code was activated. This can Typical connector for a solenoid
be caused by an actual open circuit or by a short
circuit to the +Battery side. Proceed to Test Step C. Disconnect the connector from the starting
3. motor’s solenoid. Then reconnect the connector.
• Not OK (“444-06 Start Relay short to ground”
diagnostic code) – After the engine was cranked, If the ambient noise is too loud, touch the
a “444-06 Start Relay short to ground” diagnostic solenoid when the solenoid is reconnected in
code was generated. Proceed to Test Step 8. order to feel the vibration. The solenoid will
Test Step 3. Check for a Short Circuit to energized.
the +Battery Side
Expected Result:

Gaseous fuel is present. Personal Injury or Death solenoid is not energized when the engine control
can result from an open flame or spark igniting the switch is in the STOP position.
ways use a gas detector to determine the presence Results:
Contact you local gas provider immediately for as- • OK – There is no audible click and/or vibration
sistance in the event of a leak. when the solenoid is disconnected and
connected. There is no short circuit to the
Note: Open sparks can be generated during this +Battery side. There is an open circuit. Proceed
test. to Test Step 5.
A. Make sure that no combustible gas is present in • Not OK – There is an audible click and/or
the surrounding atmosphere. vibration when the solenoid is disconnected and
B. Ensure that the engine control switch is in the the engine control switch is in the STOP position.
STOP position. There is probably a short circuit to the +Battery
side in a connector or a wiring harness. Proceed
to Test Step 4.
320

Energized Solenoid

Note: Open sparks can be generated during this Illustration 213 g00859796
test.
position. Switch the 16 amp circuit breaker for D. Disconnect the connector from the starting
the ECM OFF. motor’s solenoid. Then reconnect the connector.

energized.
Expected Result:

Results:


g00868932
Illustration 212 Gaseous fuel is present. Personal Injury or Death
Harness side of the terminal box P6 connector can result from an open flame or spark igniting the
(P6-37) Circuit driver for the starting motor’s solenoid gaseous fuel causing an explosion and/or fire. Al-
B. Use a 151-6320 Wire Removal Tool to remove of gaseous fuel when maintaining and servicing.
terminal (P6-37) from the harness side of the Contact you local gas provider immediately for as-
terminal box P6 connector. sistance in the event of a leak.

test.
position.
321
1. Turn the engine control switch to the If the solenoid is not energized, there may be
OFF/RESET position. Switch the 16 amp circuit a problem with the ECM. Continue with this
breaker for the ECM OFF. procedure.
2. Reinstall the removed wire into terminal (37) of 6. Turn the engine control switch to the
the terminal box J6 connector. Pull on the wire OFF/RESET position. Switch the 16 amp circuit
in order to verify that the terminal is properly breaker for the ECM OFF.
installed.

STOP position.
9. Disconnect the connector from the starting

motor’s solenoid. Then reconnect the
solenoid.

energized.
If the solenoid is not energized, there is

an intermittent problem with a connector

with the ECM. Replace the ECM according to
g00868867
Illustration 214 STOP.
(P2-10) Circuit driver for the starting motor’s solenoid • Not OK – There is an audible click and/or
3. Use a 151-6320 Wire Removal Tool to remove reconnected. The solenoid is energized when the
terminal (P2-10). circuit driver for the solenoid is disconnected from
the terminal box J6 connector. There is a short
4. Switch the 16 amp circuit breaker for the ECM circuit to the +Battery side in the engine harness.
STOP position. Repair: Repair the connector and/or wiring in
the engine harness, when possible. Replace the
5. Disconnect the connector from the starting engine harness, if necessary.
motor’s solenoid. Then reconnect the
connector. Listen for an audible click from the STOP.
solenoid.
Test Step 5. Create a Short Circuit in
If the ambient noise is too loud, touch the order to Check for an Open Circuit
order to feel the vibration. The solenoid will A. Turn the engine control switch to the OFF/RESET
vibrate when the solenoid is de-energized and position. Switch the 16 amp circuit breaker for
energized. the ECM OFF.
If the solenoid is energized, there is a problem B. Disconnect the starting motor’s solenoid.
with a connector and/or wiring in the terminal
322

solenoid.
STOP.
• Not OK – A “444-05 Start Relay open circuit”

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

A. Ensure that the engine control switch is in the
g00859796
breaker for the ECM is OFF.
Illustration 215
Typical connector for a solenoid B. Disconnect the P6 connector from the terminal
box. Inspect the P6 and J6 connectors for
C. Install a jumper wire with the appropriate damage, moisture, and corrosion. Make repairs,
connectors on the ends into terminals “A” and if necessary.
“B” of the solenoid’s connector.

position.
E. Wait for 30 seconds and use the “Active

Diagnostic” screen of ET to look for a “444-05
Start Relay open circuit” diagnostic code.
Expected Result:
A “444-05 Start Relay open circuit” diagnostic

code was not generated when the jumper wire was
installed.
Results:
• OK – A “444-05 Start Relay open circuit”

the ECM are OK. There is a problem with the
solenoid.

breaker for the ECM OFF. Illustration 216 g00859966

(P6-29) Return
connector. (P6-37) Circuit driver for the starting motor’s solenoid
3. Inspect the solenoid’s connectors for damage, C. Reconnect the P6 connector to the terminal
moisture, and corrosion. box. Use a 151-6320 Wire Removal Tool to
4. Make repairs, as needed. terminals.
323
D. Install a jumper wire with the appropriate Deutsch

connectors on the ends into terminals (P6-29)
verify proper installation.

position.
F. Wait for 30 seconds and use ET to check for

an active “444-05 Start Relay open circuit”
diagnostic code.
Expected Result:
There is no active “444-05 Start Relay open circuit”

diagnostic code.
Results:

was no active “444-05 Start Relay open circuit”
diagnostic code. There is a problem in the engine
harness.

Replace the engine harness, if necessary.
g00859811
STOP. Illustration 217
• Not OK – When the jumper wire was installed, a (P2-10) Circuit driver for the starting motor’s solenoid
“444-05 Start Relay open circuit” diagnostic code (P2-20) Return
was activated. The ECM did not detect the jumper
wire in the P6 connector. There is a problem in E. Use the 151-6320 Wire Removal Tool to
the terminal box. Proceed to test Step 7. remove terminals (P2-10) and (P2-20). Label the
terminals.
Test Step 7. Check the ECM
F. Reconnect the ECM J2/P2 connectors.
position. Switch the 16 amp circuit breaker for G. Install the jumper wire into terminals (P2-10) and
the ECM OFF. (P2-20). Pull on the jumper wire in order to verify
proper installation.
the jumper wire from the P6 connector. H. Switch the 16 amp circuit breaker for the ECM
C. Reinstall the terminals into P6-29 and P6-37. position.
the correct locations. Pull on the wires in order to I. Wait for 30 seconds and use the “Active
verify proper installation of the terminals. Diagnostic” screen of ET to look for an active
“444-05 Start Relay open circuit” diagnostic
D. Disconnect the ECM J2/P2 connectors. Inspect code.
corrosion. Expected Result:
Make repairs, if necessary. There is no active “444-05” diagnostic code.

324
Results: 3. Reinstall the terminals into P2-10 and P2-20.

• OK – When the jumper wire was installed, the correct locations. Pull on the wires in order
there was no active “444-05 Start Relay open to verify proper installation of the terminals.
circuit” diagnostic code. The ECM detects the
jumper wire at the P2 connector. However, the 4. Replace the ECM according to Troubleshooting,
ECM did not detect the jumper wire at the P6 “Replacing the ECM”. Verify that the problem
connector. There is a problem between the ECM is resolved.
STOP.
Test Step 8. Create an Open Circuit in
1. Turn the engine control switch to the order to Check for a Short Circuit to
OFF/RESET position. Switch the 16 amp circuit Ground
2. Use a 151-6320 Wire Removal Tool to remove position.
B. Disconnect the starting motor’s solenoid.
Make sure that the terminals are installed into C. Turn the engine control switch to the STOP
the correct locations. Pull on the wires in order position.
D. Use ET to clear the logged “444-06 Start Relay
4. Disconnect the ECM J2/P2 connectors. Inspect short to ground” diagnostic code.
corrosion. E. To prevent the engine from starting, shut OFF the
main gas supply.
5. Thoroughly inspect the terminal box J6
connector for the engine harness. Note: To provide the output for the starting motor’s
6. Use an ohmmeter to measure the resistance initiated. Otherwise, a “444-06 Start Relay short to
between the P2-10 terminal and the J6-37 ground” diagnostic code cannot be generated.
terminal. Also, measure the continuity between
the P2-20 terminal and the J6-29 terminal. F. Turn the engine control switch to the START
If the resistance is less than 5 ohms, the circuit engine control switch to the STOP position.
has good continuity. Otherwise, there is an
open circuit. G. Use ET to look for a logged “444-06 Start Relay
short to ground” diagnostic code again.
Make repairs, if necessary.
Expected Result:
STOP.
A “444-06 Start Relay short to ground” was not
• Not OK – When the jumper wire was installed, generated.
a “444-05 Start Relay open circuit” diagnostic
code was activated. The ECM did not detect the Results:
jumper wire. There is a problem with the ECM.
• OK – When the solenoid was connected, a “short
Repair: Perform the following procedure: to ground” diagnostic code was generated. When
the solenoid was disconnected, no “short to
1. Turn the engine control switch to the ground” diagnostic code was generated. There
OFF/RESET position. Switch the 16 amp circuit is a problem with the solenoid.
2. Use a 151-6320 Wire Removal Tool to remove
the jumper wire from the P2 connector. 1. Turn the engine control switch to the
325
2. Inspect the connections of the solenoid for E. To prevent the engine from starting, shut OFF the
damage and/or corrosion. main gas supply.
3. Make repairs, as needed. Note: To provide the output for the starting motor’s
If the problem is not resolved, replace the initiated. Otherwise, a “444-06 Start Relay short to
solenoid. ground” diagnostic code cannot be generated.
STOP. F. Turn the engine control switch to the START

• Not OK – A “short to ground” diagnostic engine control switch to the STOP position.
code was generated when the solenoid was
disconnected. Proceed to Test Step 9. G. Use ET to look for a logged “444-06 Start Relay
Test Step 9. Create an Open Circuit at the
Terminal Box Expected Result:
A. Turn the engine control switch to the OFF/RESET A “444-06 Start Relay short to ground” was not
position. Switch the 16 amp circuit breaker for generated.
the ECM OFF.
Results:
• OK – A “444-06 Start Relay short to ground”


2. Reinstall the terminal that was removed into


STOP.
• Not OK – A “short to ground” diagnostic code

was generated when the output to the solenoid
was disconnected from the terminal box P6
connector. There is probably a short circuit to
ground in the terminal box.
g00868932
Illustration 218
Harness side of the terminal box P6 connector Repair: Reinstall the terminal that was removed
(P6-37) Circuit driver for the starting motor’s solenoid into P6-37. Pull on the wire in order to verify
terminal (P6-37). Proceed to Test Step 10.
C. Switch the 16 amp circuit breaker for the ECM Test Step 10. Check the ECM
position. A. Turn the engine control switch to the OFF/RESET
D. Use ET to clear the logged “444-06 Start Relay the ECM OFF.
short to ground” diagnostic code.
326
Results:
• OK – When the output to the solenoid was

disconnected from the ECM P2 connector, the
“444-06 Start Relay short to ground” diagnostic
code was not generated. However, a “short to
the terminal box P6 connector. There is a problem
in the terminal box between the ECM connector
and the terminal box P6 connector.

2. Reinstall the terminal that was removed into


STOP.
g00868867
• Not OK – A “444-06 Start Relay short to ground”
Illustration 219 diagnostic code was generated when the output
Harness side of the ECM P2 connector to the solenoid was disconnected from the ECM
(P2-10) Circuit driver for the starting motor’s solenoid P2 connector. There seems to be a problem with
the ECM.
B. Use the 151-6320 Wire Removal Tool to remove
terminal (P2-10). Repair: Perform the following procedure:
C. Switch the 16 amp circuit breaker for the ECM 1. Turn the engine control switch to the
ON. Turn the engine control switch to the STOP OFF/RESET position. Switch the 16 amp circuit
position. breaker for the ECM OFF.
D. Use ET to clear the logged “444-06 Start Relay 2. Reinstall the terminal that was removed into
short to ground” diagnostic code. P2-10. Pull on the wire in order to verify proper
E. To prevent the engine from starting, shut OFF the
main gas supply. 3. Replace the ECM according to Troubleshooting,
“Replacing the ECM”. Verify that the problem
Note: To provide the output for the starting motor’s is resolved.
initiated. Otherwise, a “444-06 Start Relay short to STOP.
ground” diagnostic code cannot be generated.

G. Use ET to look for a logged “444-06 Start Relay

Expected Result:
The “444-06 Start Relay short to ground” diagnostic

code was not generated.
327
i01659692 The most likely causes of a diagnostic code for a

status indicator is a poor electrical connection or a
ECM Status Indicator Output problem in a wiring harness. The next likely cause
is a problem with an indicator. The least likely cause
SMCS Code: 1901-038 is a problem with the ECM.
System Operation Description: Logged diagnostic codes provide an historical
The ECM has four outputs in order to indicate the print the logged codes to a file.
status of engine operation: “Run Relay”, “Crank
Terminate”, “Active Alarm”, and “Engine Failure”. The troubleshooting procedure may generate
These outputs can be used to energize indicator additional diagnostic codes. Keep your mind on
lamps or the outputs can be used to interface with correcting the cause of the original diagnostic code.
other controls. Clear the diagnostic codes after the problem is
resolved.
When the output is OFF, the circuit is open. The
output provides a maximum current of 0.3 amperes
to the ECM. The ECM grounds the current to the
-Battery side in order to activate the appropriate
output.
If any of the outputs have a short circuit to the

+Battery side or excessive current, a diagnostic
code is generated.
“Run Relay” – This output indicates that the engine

is in the “Run” status. The engine will start soon or
the engine is running.
“Crank Terminate” – This output indicates that the

engine rpm is greater than the programmed engine
speed that is required for disengagement of the
starting motor.
“Active Alarm” – This is the alarm output. This output

indicates that the ECM has detected an electrical
problem or an abnormal operating condition.
“Engine Failure” – This is the shutdown output.

This output indicates that a potentially damaging
operating condition was detected by the ECM. The
ECM has shut down the engine.
A “323-03 Shutdown Lamp short to +batt” or

“324-03 Warning Lamp short to +batt” diagnostic
code can only be generated if a shutdown condition
or an alarm condition is active. Failure to correct
these serious conditions can result in engine
damage.
Use ET to determine the event code or the

diagnostic code that corresponds to the 323-03
or 324-03 diagnostic code. Troubleshoot that
event code or that diagnostic code before you
troubleshoot the 323-03 or 324-03 diagnostic
code. Refer to Troubleshooting, “Troubleshooting
with an Event Code” or Troubleshooting,
“Troubleshooting with a Diagnostic Code”.
328

g00856552
Illustration 221
(4) Customer connector J3
(5) Connector J4 for the optional control panel

position. Switch circuit breakers (1) and (2) OFF.
Note: Some indicators may obtain the status of the

engine via a data link. If all of the status indicators
are not directly controlled by the ECM, do not
proceed with this test.
g00856682
Illustration 222
Inside of the control panel
g00856505
Illustration 220 (6) “Engine Failure” indicator
Schematic for the status indicators (7) “Active Alarm” indicator
(8) “Engine On” indicator
(9) Terminal strip
B. Check the wiring of the equipment in order to

determine if the indicators for the engine status
are present. Determine whether the circuit for
the status indicators is directly controlled by the
ECM.

329
g00857399 g00857008
Location of the output wires for the status indicators on the harness Customer connector J3
side of the P2 connector (J3-7) Crank terminate
(10) Ground strap (J3-8) Active alarm
(P2-28) “Run Relay” (J3-9) Engine failure
(P2-29) “Crank Terminate” (J3-19) Run relay
(P2-30) “Engine Failure”
(P2-31) “Active Alarm”
C. Thoroughly inspect the ECM J2/P2 connectors.
Inspect the customer connectors (J3) and (P3)
(if equipped). Inspect connectors (J4) and (P4)
for the control panel (if equipped). Inspect the
wiring and the connections for the circuit of the
status indicators.

the ECM connector (P2) and the customer
connector (P3) (if equipped). The proper
torque is 6 N·m (55 lb in).

the status indicators.
Note: These outputs do not provide enough current

for illumination of standard incandescent lights. If a
lamp is burned out, replace the lamp with the lamp
that is specified in the engine’s Parts Manual.
c. Inspect the wiring and the receptacles for the

g00863317 status indicators.
Illustration 224
Terminal box’s side of the 47-pin connector (P4)
(P4-C) “Crank Terminate”
d. Check the harness and wiring for abrasion
(P4-H) “Active Alarm” and pinch points from the status indicators
(P4-P) “Engine Failure” to the ECM.
(P4-Z) “Run Relay”
330
e. Inspect the terminal strip in the control panel Results:

foreign objects, and corrosion. • Yes (Original 443-03 or 445-03 Diagnostic Code) –
The original diagnostic code was “443-03 Crank
Expected Result: Terminate Relay short to +batt” or “445-03 Run
Relay short to +batt”. When the engine was
All of the connectors, pins, and sockets are started, the “Engine On” indicator and the “Crank
connected properly. The connectors and the wiring Terminate” indicator (if equipped) illuminated
are free of corrosion, abrasion, and pinch points. normally. The “Active Alarm” indicator and the
“Engine Failure” indicator did not illuminate. There
Results: are no active diagnostic codes.
• OK – The components are in good condition with Repair: The outputs for the status indicators seem
proper connections. Proceed to Test Step 2. to be operating correctly at this time. The original
diagnostic code was probably caused by a poor
• Not OK – The components are not in good electrical connection.
improper. If there is an intermittent problem that is causing
the codes to be logged, refer to Troubleshooting,
Repair: Perform the necessary repairs and/or “Inspecting Electrical Connectors”.
STOP.
STOP.
• Yes (Original 323-03 or 324-03 Diagnostic Code) –
Test Step 2. Check for Diagnostic Codes The original diagnostic code was “323-03
Shutdown Lamp short to +batt” or “324-03
A. Switch the 16 amp circuit breaker for the ECM Warning Lamp short to +batt”. When the engine
ON. was started, the “Engine On” indicator and
the “Crank Terminate” indicator (if equipped)
B. Attempt to start the engine and observe the illuminated normally. The “Active Alarm” indicator
status indicators. Allow a minimum of 30 seconds and the “Engine Failure” indicator did not
for any diagnostic codes to activate. Use the illuminate. There are no active diagnostic codes.
“Active Diagnostic” screen on ET to look for the
codes that are listed in Table 40: Repair: The 323-03 and 324-03 diagnostic codes
can only be activated when the corresponding
Table 40 indicator is activated. There may still be a
Diagnostic Codes and Descriptions with problem with the output for the alarm indicator
Corresponding ECM Outputs or the shutdown indicator. The alarm and/or the
shutdown must be activated.
Code Description ECM Output
323-03 Shutdown Lamp short to “Engine Failure” Allow the engine operation to continue. Proceed
+batt to Test Step 3.
324-03 Warning Lamp short to “Active Alarm”
+batt
• Not OK (Active 323-03 or 324-03 Diagnostic
Code) – There is an active “323-03 Shutdown
443-03 Crank Terminate Relay “Crank Lamp short to +batt” or “324-03 Warning Lamp
short to +batt Terminate” short to +batt”. There must be a shutdown
condition before a 323-03 diagnostic code
445-03 Run Relay short to +batt “Run Relay”
can be generated. There must be an alarm
condition before a 324-03 diagnostic code can be
Expected Result: generated. Both of these conditions are serious.
There are no active diagnostic codes. The “Engine Repair: Use ET to determine the event code or the
On” indicator and the “Crank Terminate” indicator (if diagnostic code that corresponds to the 323-03
equipped) illuminated normally. The “Active Alarm” or 324-03 diagnostic code. Troubleshoot that
indicator and the “Engine Failure” indicator did not event code or that diagnostic code before you
illuminate. troubleshoot the 323-03 or 324-03 diagnostic
code. Refer to Troubleshooting, “Troubleshooting
with an Event Code” or Troubleshooting,
“Troubleshooting with a Diagnostic Code”.
331
Exit this procedure. After you have resolved the Note: When the filtered engine oil pressure sensor
condition, return to this procedure in order to is disconnected, the engine will shut down.
troubleshoot the 323-03 and/or 324-03 diagnostic
code, if necessary. B. Disconnect connector (2) for the filtered engine
oil pressure sensor. Observe the “Engine Failure”
STOP. indicator on the control panel (if equipped).
• Not OK (Active 443-03 or 445-03 Diagnostic C. Use the “Diagnostics” screen on ET to look for
Code) – When the engine was started, the active diagnostic codes.
“Engine On” indicator and/or the “Crank
Terminate” indicator (if equipped) did not Expected Result:
illuminate normally. The “Active Alarm” indicator
and the “Engine Failure” indicator did not The “Active Alarm” indicator illuminated and a
illuminate. A 443-03 or 445-03 diagnostic code “542-03 Unfiltered Engine Oil Pressure open/short
was activated. There is a problem with the output to +batt” diagnostic code was activated when
for the “Engine On” indicator and/or the “Crank the unfiltered engine oil pressure sensor is
Terminate” indicator (if equipped). Proceed to disconnected.
Test Step 4.
The “Engine Failure” indicator illuminated and a
Test Step 3. Check for Proper Operation “100-03 Engine Oil Pressure open/short to +batt”
of the Status Indicators for the Alarm and diagnostic code was activated when the filtered
Shutdown engine oil pressure sensor is disconnected. The
engine was shut down.
Allow the engine operation to continue for this
procedure. Results:
• OK – The indicators, diagnostic codes, and

shutdown were activated according to the
“Expected Result”. The outputs for the status
indicators seem to be operating correctly at this
time. The original problem seems to be resolved.
Repair: The original diagnostic code was probably

caused by a poor electrical connection.
If there is an intermittent problem that is causing

the codes to be logged, refer to Troubleshooting,
STOP.
• Not OK – The “Active Alarm” indicator and/or

the “Engine Faiure” indicator did not illuminate
normally when the sensors were disconnected. A
“323-03 Shutdown Lamp short to +batt” and/or a
“324-03 Warning Lamp short to +batt” diagnostic
code was generated. There is a problem with the
output for the status indicators. The “542-03” and
the “100-03” diagnostic codes were generated.
The engine was shut down. Proceed to Test Step
4.
g00856957
Illustration 226
A. During engine operation, disconnect connector

(1) for the unfiltered oil pressure sensor. Observe
the “Active Alarm” indicator on the control panel
(if equipped).
If you are only troubleshooting a “324-03 Warning

Lamp short to +batt”, proceed to the “Expected
Result”.
332
Test Step 4. Measure the Voltage of

the Suspect Indicator at the ECM P2
Connector
g00863378
Illustration 228
Terminal strip in the control panel
(14) “Engine On”
(15) “Crank Terminate”
(16) “Active Alarm”
(17) “Engine Failure”
G. Disconnect the suspect control wire from the

terminal strip in the control panel (if equipped).
Disconnect the wire from the indicator’s side of
the terminal strip.
If the customer has equipment for the status

indicators, disconnect the output wire of the
suspect indicator.
g00871059 Tape the end of the disconnected wire in order

Illustration 227
to ensure that the wire is isolated.
Location of the output wires for the status indicators on the harness
side of the P2 connector
H. Switch circuit breakers (1) and (2) ON. Turn the
(1) 16 amp circuit breaker engine control switch to the STOP position.
(3) Ground strap
(P2-28) “Run Relay” I. Note the voltage that is displayed on the
(P2-29) “Crank Terminate” voltmeter.
(P2-30) “Engine Failure”
Expected Result:
A. Turn the engine control switch to the OFF/RESET Before the suspect indicator was disconnected,
position. Switch circuit breakers (1) and (2) OFF. voltage was displayed on the voltmeter. After the
suspect indicator was disconnected, the voltmeter
B. Insert a 7X-1710 Multimeter Probe into the displayed approximately zero volts.
suspect control terminal in the ECM P2 connector.
Results:
C. Connect the other lead of the 7X-1710
Multimeter Probe to the positive lead of a
voltmeter. Connect the voltmeter’s negative lead
• Yes – Before the suspect indicator was
disconnected from the terminal strip, voltage was
to ground strap (3). displayed on the voltmeter. After the suspect
indicator was disconnected, the voltmeter
D. Switch circuit breakers (1) and (2) ON. Turn the displayed approximately zero volts. There is a
engine control switch to the STOP position. problem in the control panel (if equipped) or in
the customer’s panel.
E. Note the voltage that is displayed on the
voltmeter. Repair: The problem could be caused by a poor
electrical connection, a wire, or a component in
F. Turn the engine control switch to the OFF/RESET the panel.
position. Switch circuit breakers (1) and (2) OFF.
333
Turn the engine control switch to the OFF/RESET The voltage is approximately zero. – After
position. Switch circuit breakers (1) and (2) OFF. customer connector (P3) was disconnected,
the reading on the voltmeter was approximately
Thoroughly inspect all of the wiring and the zero. There is a problem with a connection
connectors in the panel. Refer to Troubleshooting, and/or the wiring between customer connector
“Inspecting Electrical Connectors”. (P3) and the indicator in the customer’s
panel. Turn the engine control switch to the
If you suspect that the indicator has an internal OFF/RESET position. Switch circuit breakers
short circuit, switch a known good indicator for (2) and (3) OFF. Repair the connection and/or
the suspect indicator. Test the indicator. Verify that the wiring, when possible. Replace parts, if
the problem is resolved. necessary. Stop
Make the necessary repairs, when possible. The voltage remained. – After customer
Replace parts, if necessary. connector (P3) was disconnected, voltage was
still displayed on the voltmeter. Proceed to the
STOP. next Step.
• No – Before the suspect indicator was 3. Turn the engine control switch to the
disconnected from the terminal strip, voltage was OFF/RESET position. Switch circuit breakers
displayed on the voltmeter. After the suspect (2) and (3) OFF. Disconnect connector (P4) (if
indicator was disconnected, the voltage was equipped) from terminal box’s connector (J4).
still displayed on the voltmeter. The problem is
between the indicator’s terminal strip and the 4. Switch circuit breakers (2) and (3) ON. Turn
ECM. the engine control switch to the STOP position.
Observe the reading on the voltmeter.
Repair: Do not disconnect the voltmeter. Perform
the following procedure: Results
The voltage is approximately zero. – After

connector (P4) was disconnected, the reading
on the voltmeter was approximately zero.
There is a problem with a connection and/or
the wiring between connector (P4) and the
terminal strip in the control panel. Turn the
engine control switch to the OFF/RESET
position. Switch circuit breakers (2) and (3)
OFF. Repair the connection and/or the wiring,
Stop
The voltage remained. – After customer

connector (P4) was disconnected, voltage was
g00856552
Illustration 229 still displayed on the voltmeter. Continue with
(1) ECM J2/P2 connectors this procedure.
(3) 6 amp circuit breaker 5. Turn the engine control switch to the
(4) Customer connector J3
(5) Connector J4 for the optional control panel
OFF/RESET position. Switch circuit breakers
(2) and (3) OFF. Remove the 7X-1710
1. Turn the engine control switch to the Multimeter Probe from the suspect control
OFF/RESET position. Switch circuit breakers terminal in the ECM P2 connector.
(2) and (3) OFF. Disconnect customer
connector (P3) (if equipped) from terminal
box’s connector (J3).
2. Switch circuit breakers (2) and (3) ON. Turn

the engine control switch to the STOP position.
Observe the reading on the voltmeter.
Results
334
The voltage is approximately zero. – After the

suspect terminal was removed from connector
(P2), the reading on the voltmeter was
approximately zero. There is a problem with a
connection and/or the wiring in the terminal
box. Turn the engine control switch to the
OFF/RESET position. Switch circuit breakers
(2) and (3) OFF. Repair the connection and/or
the wiring, when possible. Replace parts, if
necessary. Stop
The voltage remained. – After the suspect

terminal was removed from connector (P2),
voltage was still displayed on the voltmeter.
There is a problem with the ECM. Replace the
ECM according to Troubleshooting, “Replacing
the ECM”. Verify that the problem is resolved.
STOP.
i01664144
Electrical Power Supply

SMCS Code: 1401-038

g00863371
Illustration 230
This procedure tests whether proper voltage is
Location of the output wires for the status indicators on the harness
supplied to the ECM, the Integrated Combustion
side of the P2 connector
Sensing Modules, and the Air/Fuel Pressure Module.
(2) 16 amp circuit breaker In addition to troubleshooting diagnostic codes,
(6) Ground strap use this procedure if you suspect that the ECM,
(P2-28) “Run Relay” an Integrated Combustion Sensing Module, or the
(P2-29) “Crank Terminate” Air/Fuel Pressure Module are not receiving the
(P2-30) “Engine Failure” proper supply voltage. The cause of an intermittent
power supply can occur on either the positive side
or the negative side of the power supply.
6. Use a 151-6320 Wire Removal Tool to
remove the suspect terminal from the ECM P2 The 24 VDC power supply for the engine can be
connector. Tape the terminal in order to isolate
provided by a battery or an electrical power supply.
the terminal.
The minimum requirement for the power supply is
22 VDC at 16 amperes. The 24 VDC power supply
7. Insert the 7X-1710 Multimeter Probe into
can be connected to the terminal box or to the
the suspect control terminal in the ECM P2
control panel. The power supply should be routed
connector. Use the voltmeter to measure the through a dedicated fuse or through a dedicated
voltage between the suspect terminal in the
circuit breaker.
ECM and ground strap (6). Switch circuit
breakers (2) and (3) ON. Turn the engine The ECM input at terminal 70 of the P1 connector
control switch to the STOP position. Observe
(“Switched +Battery”) receives battery voltage from
the reading on the voltmeter. the engine control switch when the switch is in the
START, STOP, or AUTO position. When the ECM
Results
detects battery voltage at this input, the ECM will
power up. When battery voltage is removed from
this input, the ECM will power down after the engine
has shut down.
335
The “168-02” diagnostic code indicates that the

voltage of the power supply is intermittent or low
while the engine is running. If the supply voltage
drops to zero and stays at zero, the ECM will not
log this code. The engine will shut down.
The “336-02” diagnostic code indicates that the

ECM has detected a problem with the circuit for
the engine control switch.

This procedure may generate additional diagnostic

codes. Keep your mind on correcting the cause of
the original diagnostic code. Clear the diagnostic
codes after the problem is resolved.
336
g00867850
Illustration 231
Schematic for the electrical power source
The 24 VDC power supply is connected to the terminal box.
337
g00867852
Illustration 232
Schematic for the electrical power source
The 24 VDC power supply is connected to the control panel.
338

the ECM OFF.

g00868008
Illustration 234
ECM connector P1

wires that are associated with the electrical
power supply:
• Unswitched +Battery terminals 52, 53, 55,

and 57
• −Battery terminals 63, 65, 67, and 69

• Switched +Battery terminal 70
g00868000 and pinch points from the power supply to
Illustration 233 the ECM and from the engine control switch
(1) J1/P1 connectors for the ECM to the ECM.
Expected Result:
B. Disconnect the J1/P1 connectors. Inspect the J1
connector and the P1 connector for damage, All of the connectors, pins, and sockets are
corrosion, and moisture. Reconnect the J1/P1 connected properly. The connectors and the wiring
connectors. are free of corrosion, abrasion, and pinch points.
C. Thoroughly inspect the following connections: Results:
• Connectors for the circuit breaker • OK – The components are in good condition with
• Connectors for the 24 VDC power supply
• Connectors for the engine control switch condition and/or at least one connection is
improper.
a. Check the torque of the Allen head screw
for the ECM connector. The proper torque is Repair: Perform the necessary repairs and/or
6 ± 1 N·m (55 ± 9 lb in). replace parts, if necessary. Ensure that all of the
seals are properly installed. Make sure that the
connectors are properly fastened. Verify that the
repair has eliminated the problem.
STOP.
339
Test Step 2. Check the Voltage at the Expected Result:

Power Supply and at the ECM
The voltage that is measured at the terminals for the
A. Make sure that the engine will not crank during power supply is at least 22 VDC. The voltage that
this procedure. For an engine with an electric is measured at the P1 connector is within 2 VDC of
starting motor, make sure that the battery cables the voltage that was measured at the terminals for
are disconnected from the motor. For an engine the power supply. The voltage measurements are
with an air starting motor, make sure that the constant.
pressurized air supply is OFF. Make sure that the
air is purged from the system. Results:
Note: If a power supply is used instead of batteries, • OK – The ECM is receiving the correct voltage at
the minimum voltage for the power supply is 22 the P1 connector.
VDC at 16 amperes.
B. Measure the voltage at the terminals for the
power supply. Record the voltage. Switch the 16 amp circuit breaker for the ECM
OFF.
Remove the probes from connector P1.
• Not OK – The ECM is not receiving the correct

voltage at the P1 connector.

OFF.
2. Remove the probes from connector P1.
3. Use a voltmeter to check the wiring. Refer to

the appropriate schematic for the electrical
system. Locate the source of the voltage drop.
STOP.
Test Step 3. Check the Engine Control

Switch
A. Make sure that the engine will not crank during
g00867982 this procedure. For an engine with an electric
Illustration 235
Harness side of ECM connector P1 starting motor, make sure that the battery cables
are disconnected from the motor. For an engine
C. Insert two 7X-1710 Multimeter Probes into the with an air starting motor, make sure that the
harness side of the P1 connector. Insert the first pressurized air supply is OFF. Make sure that the
probe into terminal 52. Insert the second probe air is purged from the system.
into terminal 63. Connect a multimeter to the
probes. B. Connect ET to the service tool connector.
D. Switch the 16 amp circuit breaker for the ECM C. Switch the 16 amp circuit breaker for the ECM
ON. ON.
E. Measure the power supply voltage at the P1 Note: An “E225 Engine Overcrank” and/or an “E233
connector. During the measurement, wiggle the Low Engine Prelube Pressure” event code may
harness in order to check for an intermittent be generated during this step. After you have
problem. Be sure to wiggle the harness near completed this step, clear the events from the
each of the connections. “Logged Events” screen of ET.
340
D. Observe the “Active Diagnostic” screen on ET

and turn the engine control switch to the STOP
position, the START position, and the AUTO
position. Look for an active “336-02 Incorrect
ECS Switch inputs” diagnostic code. Repeat this
step several times.
Expected Result:
A “336-02 Incorrect ECS Switch inputs” diagnostic

code was not activated when the engine control
switch was turned to the STOP position, the START
position, and the AUTO position.
Results:
• OK – A “336-02 Incorrect ECS Switch inputs”

diagnostic code was not activated. The inputs
to the engine control switch are correct. The
problem seems to be resolved.
Repair: The problem may be intermittent.

Connectors”.
STOP.
• Not OK – A “336-02 Incorrect ECS Switch inputs” g00868154

diagnostic code was activated. The ECM has Illustration 236
detected an invalid pattern for the input to the Harness side of ECM connector P1
engine control switch. Proceed to Test Step 4.
C. Insert two 7X-1710 Multimeter Probes into the
Test Step 4. Check the Circuit of the harness side of the P1 connector. Insert the first
Engine Control Switch probe into terminal 31. Insert the second probe
into terminal 61. Connect a multimeter to the
A. Make sure that the engine will not crank during probes.
this procedure. For an engine with an electric
starting motor, make sure that the battery cables D. Switch the 16 amp circuit breaker for the ECM
are disconnected from the motor. For an engine ON.
with an air starting motor, make sure that the
pressurized air supply is OFF. Make sure that the Note: An “E225 Engine Overcrank” and/or an “E233
air is purged from the system. Low Engine Prelube Pressure” event code may be
generated during the test. After you have completed
B. Turn the engine control switch to the OFF/RESET the test, clear the events from the “Logged Events”
position. Switch the 16 amp circuit breaker for screen of ET.
the ECM OFF.
Note: During these measurements, wiggle the
harness in order to check for an intermittent
problem. Be sure to wiggle the harness near each
of the connections.
E. Turn the engine control switch to the STOP

position and measure the voltage between
terminal 31 and terminal 61 of the P1 connector.
The correct voltage measurement is less than
one volt.
F. Remove the probe from terminal 61 and insert

the probe into terminal 62.
341
G. Turn the engine control switch to the START • Not OK – The P1 connector does not have the
position and measure the voltage between correct voltage.
The correct voltage measurement is less than Repair: Perform the following steps:
one volt.
H. Remove the probe from terminal 62 and insert OFF/RESET position. Switch the 16 amp circuit
the probe into terminal 64. breaker for the ECM OFF.
I. Turn the engine control switch to the AUTO 2. Disconnect the wires for the STOP, START, and
position and measure the voltage between AUTO positions from the engine control switch.
The correct voltage measurement is less than 3. Use an ohmmeter to check the contacts for
one volt. the switch. Turn the switch to each position in
order to check the contacts.
J. Remove the probe from terminal 31 and insert the
probe into terminal 69. Remove the probe from 4. If the engine control switch is faulty, replace
terminal 64 and insert the probe into terminal 70. the switch. If the problem is not resolved,
repair the harness, when possible. Replace
K. Turn the engine control switch to the STOP the harness, if necessary.
terminal 69 and terminal 70 of the P1 connector. STOP.
The correct voltage measurement is at least 20
VDC.
i01644510
L. Turn the engine control switch to the START

terminal 69 and terminal 70 of the P1 connector. SMCS Code: 1912-038
The correct voltage measurement is at least +20
VDC. System Operation Description:
M. Turn the engine control switch to the AUTO
The correct voltage measurement is at least +20
VDC.
Expected Result:
The voltage checks are within the specifications.
Results:
• OK – The voltage checks are within the

specifications. Remove the probes from the P1
connector. Start the engine and run the engine.
If the original problem is not resolved, the ECM
may have a problem.

Perform the following procedure:
g00850136
Temporarily install a new ECM. Refer to Illustration 237
Troubleshooting, “Replacing the ECM”. Position of the speed-timing wheel with the number one cylinder at
the top center position on the compression stroke
If the problem is resolved with the new ECM, (1) Speed-timing wheel
install the original ECM and verify that the problem (2) Engine speed/timing sensor
returns. If the new ECM operates correctly and (3) Extra tooth
replace the ECM. Refer to Troubleshooting,
STOP.
342
The engine speed/timing sensor provides The troubleshooting procedure may generate
information about engine speed and the position additional diagnostic codes. Keep your mind on
of the crankshaft to the ECM. The sensor monitors correcting the cause of the original diagnostic code.
the rotation of a speed-timing wheel. The passive Clear the diagnostic codes after the problem is
sensor has a coil around a permanent magnet resolved.
which generates voltage as the teeth of the
speed-timing wheel pass through the magnetic
field. The speed-timing wheel is installed on the
rear of the right camshaft.
The engine speed/timing sensor generates a signal

that matches the pattern of the speed-timing
wheel’s teeth. The ECM monitors the speed of the
signal pulses in order to determine the engine rpm.
The speed-timing wheel has a special tooth

pattern that indicates the position of the camshaft.
The speed-timing wheel has 36 teeth that are
evenly spaced and one extra tooth. The number
one cylinder is at the top center position on the
compression stroke when the centerline of the first
tooth after the extra tooth aligns with the centerline
of the sensor. All 37 teeth pass the sensor during
one revolution of the camshaft or two revolutions of
the crankshaft.
With the information from the engine speed/timing

sensor, the ECM is able to calculate the positions of
the pistons in the cylinders. The ECM determines
the desired ignition timing according to the engine
speed and load. If detonation is detected in any
of the cylinders, the ECM retards the timing of the
affected cylinders. The ECM sends voltage pulses
to the ignition transformers for firing the spark plugs
according to the desired timing.
If the ECM detects a problem with the engine

speed/timing sensor’s signal, the ECM will shut
down the engine. If there is a problem with the
engine speed/timing sensor’s signal during start-up,
the ECM will not initiate the ignition. The engine will
not start. The corresponding diagnostic code is
generated.
If the engine speed/timing sensor is replaced,

the sensor does not require calibration and the
speed-timing wheel does not require adjustment.

engine speed/timing sensor. The least likely cause
is a problem with the ECM.

343
g00850348
Illustration 238
Schematic for the circuit of the engine speed/timing sensor
The ECM is connected to the engine speed/timing sensor via the J6/P6 connectors on the terminal box.

g00850522
Illustration 240
Connectors for the engine speed/timing sensor
g00843978
Illustration 239
(1) ECM J1/P1 connectors B. Thoroughly inspect the ECM J1/P1 connectors,
(2) 16 amp circuit breaker for the ECM the terminal box J6/P6 connectors, and the
(3) J6/P6 connectors for the left engine harness connectors for the engine speed/timing sensor.


g00850527
Illustration 241
(P6-13) Shield
(P6-23) − Signal
(P6-31) + Signal
344
Test Step 2. Check the Sensor
g00850524
Illustration 242
Harness side of the ECM P1 connector g00850545
Illustration 243
(P1-32) + Signal Engine speed/timing sensor
(P1-33) − Signal
(1) Terminal for the - signal
(P1-51) Shield
(2) Terminal for the + signal
(3) Bracket
a. Perform a 45 N (10 lb) pull test on each of the (4) Integral connector on the sensor
wires that are associated with the circuit for (5) O-ring seal
the engine speed/timing sensor. (6) Sensor
b. Check the torque of the Allen head screw for

the ECM P1 connector and the terminal box’s
P6 connector. The proper torque is 6 ± 1 N·m
(55 ± 9 lb in).

and pinch points from the engine speed/timing
sensor to the ECM.
Expected Result:

are free of corrosion, abrasion, and pinch points. g00862402
Illustration 244
Results: Engine speed/timing sensor
(4) Integral connector on the sensor
• OK – The components are in good condition with (7) Cover
A. Disconnect the engine harness from connector
• Not OK – The components are not in good (4). Remove the bolt from bracket (3) and remove
condition and/or at least one connection is sensor (6) and the bracket as a unit.
improper.
B. Inspect the sensor for damage. Inspect O-ring
Repair: Perform the necessary repairs and/or seal (5). If the O-ring seal is damaged, obtain a
replace parts, if necessary. new O-ring seal for assembly.
STOP. C. Clean the tip of the sensor, the sensor’s mounting

flange and the counterbore for the sensor in the
rear housing.
D. Use an ohmmeter to measure the resistance

between terminals (1) and (2) in connector (4).
345
c. Make sure that the connector on the engine

harness is in good condition. Connect the
engine harness to the sensor’s connector.
Make sure that the mating of the connection
is secure.
2. Verify that the condition is resolved.
STOP.
• Not OK – The sensor and/or the speed-timing

wheel’s teeth are damaged.
Repair: Obtain a new sensor and/or a new

g00862412
speed-timing wheel. Perform the following
Illustration 245 procedure:
(8) Speed-timing wheel
1. Install the sensor:
E. Remove cover (7) and inspect speed-timing
wheel (8) for damage. a. Lubricate the sensor’s O-ring seal with
clean engine oil.
Expected Result:
b. Install the sensor into the counterbore in the
The sensor appears to be in good condition. rear housing. Make sure that the sensor is
properly seated and that the bracket is flush
The resistance between terminals (1) and (2) is with the mounting surface. Use the bolt to
between 75 and 230 ohms. secure the bracket to the rear housing.
Note: At a temperature of 25 C (77 F), the c. Make sure that the connector on the engine
resistance is between 110 and 200 ohms. harness is in good condition. Connect the
The speed-timing wheel is in good condition. Make sure that the mating of the connection
is secure.
Results:
2. Install the speed-timing wheel.
• OK – The sensor appears to be in good condition.
The resistance is within the specifications. The a. Install the timing pin into the camshaft
speed-timing wheel is in good condition. There according to the instructions in Systems
may be a problem with a connector and/or the Operation/Testing and Adjusting,
wiring in the engine harness. Install the cover. RENR5908, “Engine Timing Procedures”.
Reconnect the sensor to the engine harness. Do
not install the sensor yet. Proceed to Test Step 3. b. Orient one of the camshaft drive gear’s
1/2-13 threaded holes to the 12 o’clock
• Not OK – The sensor is damaged and/or the position. The four 1/2-13 threaded holes
sensor’s resistance is not within the specifications. form a diamond pattern.
Repair: Obtain a new sensor. Perform the

following procedure:
1. Install the sensor:
a. Lubricate the sensor’s O-ring seal with

clean engine oil.

rear housing. Make sure that the sensor is
with the mounting surface. Use the bolt to
secure the bracket to the rear housing.
346
g00862461 g00850816
Rear view and section view Terminal box’s side of the P6 connector
(1) Spacer (P6-13) Shield
(2) Speed-timing wheel (P6-23) - Signal
(3) Direction of the camshaft’s rotation (P6-31) + Signal
(4) Extra tooth
(5) Bolt B. Measure the resistance between terminals
(P6-23) and (P6-31) on the terminal box’s side
c. Install spacer (1) and speed-timing wheel of the connector.
(2). Orient extra tooth (4) near the sensor.
Loosely install four bolts (5) in order to C. Wiggle the engine harness as you measure the
enable speed-timing wheel to be moved. resistance in order to check for an intermittent
d. Rotate the speed-timing wheel in the harness near the sensor’s connector.
direction of the camshaft’s rotation (3) until
the first tooth after the extra tooth is aligned Expected Result:
with the centerline of the sensor.
The resistance is between 75 and 230 ohms.
e. Tighten the four bolts.
Note: At a temperature of 25 C (77 F), the
f. Install the cover for the speed-timing wheel. resistance is between 110 and 200 ohms.
3. Verify that the condition is resolved. Results:
STOP.
• OK – The resistance is within the specifications.
The circuit between the P6 connector and the
Test Step 3. Measure the Sensor’s sensor seems to be OK. There may be a problem
Resistance from the Terminal Box P6 with a connection and/or the wiring in the terminal
Connector box. Reconnect the P6 connector to the J6
connector on the terminal box. Proceed to Test
A. Disconnect the terminal box P6 connector. Step 4.
• Not OK – The resistance is not within the

specifications. There is a problem with a
connection and/or the wiring in the engine
harness between the P6 connector and the
connector for the engine speed/timing sensor.
Repair: Repair the connector(s) and/or the wiring,

when possible. Replace the engine harness, if
necessary.
STOP.
347
Test Step 4. Measure the Sensor’s Test Step 5. Verify the Engine Operation
Resistance from the ECM P1 Connector
A. Install the sensor:
A. Disconnect the ECM P1 connector.
a. Lubricate the sensor’s O-ring seal with clean
engine oil.

rear housing. Make sure that the sensor is
with the mounting surface. Use the bolt to
secure the bracket to the rear housing.

harness is in good condition. Connect the
is secure.
g00850802
Illustration 248 Note: It is possible that a diagnostic code is
ECM side of the P1 connector generated for the engine speed/timing sensor
(P1-32) + Signal only when the engine runs at normal operating
(P1-33) - Signal temperature.
(P1-51) Shield
B. Start the engine. Run the engine at normal
B. Measure the resistance between terminals operating temperature.
(P1-32) and (P1-33) on the ECM side of the
connector. Expected Result:
C. Wiggle the wiring harness as you measure the The engine operates normally.
resistance in order to check for an intermittent
problem with the harness. Results:
Expected Result: • OK – The engine operates normally. The initial
diagnostic code was probably caused by a
The resistance is between 75 and 230 ohms. poor electrical connection in one of the harness
connectors. Resume normal operation. STOP.
Note: At a temperature of 25 C (77 F), the
resistance is between 110 and 200 ohms. • Not OK (No Start-Up) – The engine did not
operate normally. The engine did not start. A
Results: 190-02 or 190-08 diagnostic code was activated.
• OK – The resistance is within the specifications.
The sensor, the engine harness, and the wiring • Not OK (Shutdown After Warm-Up) – The engine
in the terminal box seem to be OK. However, it was shut down after normal operating temperature
is possible that there is still a problem with the was achieved. A 190-02 or 190-08 diagnostic
sensor. Reconnect the ECM P1 connector to the code was activated. Proceed to Test Step 6.
ECM J1 connector. Proceed to Test Step 5.
Test Step 6. Switch the Sensor
• Not OK – The resistance is not within the
specifications. The resistance through the engine A. Make sure that the engine control switch is in the
harness and through the sensor was OK. When OFF/RESET position and that the 16 amp circuit
the resistance through the wiring harness in breaker for the ECM is OFF.
the terminal box was added, the result was not
correct. There is a problem with a connector or B. Remove the original engine speed/timing sensor.
the wiring between the P1 connector and the J6 Install an engine speed/timing sensor that is
connector. known to be good. Use the following procedure:
Repair: Repair the connector(s) and/or the wiring, a. Lubricate the sensor’s O-ring seal with clean
when possible. Replace the connector(s) and/or engine oil.
the wiring, if necessary.
STOP.
348
b. Install the sensor into the counterbore in the Repair: It is unlikely that the ECM has failed.
rear housing. Make sure that the sensor is Exit this procedure and perform this procedure
properly seated and that the bracket is flush again. If the condition is not resolved, install a
with the mounting surface. Use the bolt to known good ECM according to Troubleshooting,
secure the bracket to the rear housing. “Replacing the ECM”. Verify that the problem is
resolved.
harness is in good condition. Connect the STOP.
i01641123
is secure.

Fuel Actuator Solenoid
to the ON position. SMCS Code: 1901-038
D. Prepare to use the “Status - Gas Engine Group 1” System Operation Description:
screen of ET for observation of the engine speed.
The ECM controls the fuel actuator by adjusting
E. Shut OFF the main fuel supply to the engine. current flow through the actuator’s solenoid.
F. Observe the status of the engine speed and turn The 23-05 diagnostic code is probably caused by
the engine control switch to the START position. a problem with an electrical connector or an open
G. After the engine speed stabilizes at the normal the 23-05 diagnostic code can occur if the low side
cranking speed, turn the engine control switch wire is shorted to ground. The next likely cause is
to the STOP position. an open circuit inside the actuator solenoid. The
H. Use the “Diagnostics” screen of ET to check for
active diagnostic codes. The 23-06 diagnostic code is probably caused by
a short circuit in a harness or a problem with an
Expected Result: electrical connector. The next likely cause is a short
When the engine control switch was turned to the cause is a problem with the ECM.
START position, the engine speed accelerated from
“0” rpm to an approximate speed of “60” rpm. The
engine speed gradually increased to the normal
cranking speed. When the engine control switch
was turned to the STOP position, the engine speed
returned to “0” rpm when the crankshaft stopped
rotating.
No 190-02 or 190-08 diagnostic code was activated.
Results:
• OK – The correct engine speed was displayed.

The ECM is receiving a good signal from the
engine speed/timing sensor. No 190-02 or 190-08
diagnostic code was activated. Switching the
sensor resolved the problem. Resume normal
operation. STOP.
• Not OK – The correct engine speed was not

displayed. A 190-02 or 190-08 diagnostic code
was activated. The wiring and the sensor are
apparently OK. There may be a problem with the
ECM.
349
g00848732
Illustration 249
Schematic of the circuit for the fuel actuator
The ECM is connected to the fuel actuator via the J5/P5 connectors on the terminal box.



g00849064
Illustration 251
Right side view of the engine above the terminal box
(4) Fuel actuator
(5) P525/J525 connectors for the fuel actuator
g00849037 B. Thoroughly inspect each of the following

Illustration 250
connectors:
(2) J5/P5 connectors for the harness from the right side of the
engine • (J2/P2) ECM connectors
• (J5/P5) connectors on the terminal box
• (P525/J525) connectors for the fuel actuator
350

proper torque is 6 N·m (53 lb in).
g00849316
Illustration 252
ECM P2 connector
(P2-6) High side wire for the fuel actuator
(P2-7) Low side wire for the fuel actuator
g00849064
Illustration 254
Right side view of the engine above the terminal box
(4) Fuel actuator
(5) P525/J525 connector for the fuel actuator
c. Thoroughly inspect the connectors

(P525/J525) for the fuel actuator for moisture
and contamination. Check the harness and
wiring for abrasion and pinch points from the
g00849319
Illustration 253 fuel actuator to the ECM.
(P5-57) Low side wire for the fuel actuator Expected Result:
All of the connectors and terminals are connected
b. Perform a 45 N (10 lb) pull test on the four properly. The connectors are free of moisture and
wires that are associated with the circuit for corrosion. The connectors and the wiring are free of
the fuel actuator. corrosion, abrasion, and pinch points.
Results:

23-05 diagnostic code, proceed to Test Step 2. If
you are troubleshooting a 23-06 diagnostic code,

improper.
351

STOP.
Test Step 2. Check the Solenoid and

Harnesses for an Open Circuit
the ECM OFF.
g00868352
Illustration 256
(1) Ground strap for the ECM

Illustration 255
g00849558 strap for the ECM and P2 terminal (64). During
this measurement, wiggle the harnesses in order
(P2-6) High side wire for the fuel actuator harness. Be sure to wiggle the harnesses near
C. Measure the resistance between P2 terminal
Expected Result:
(6) and terminal (7). During this measurement,
an intermittent problem with the harness. Be
Results:
connectors.
Expected Result: • OK – The resistance measurement is greater

than 20,000 ohms. The low side wire for the fuel
actuator appears to be OK. Proceed to Test Step
12.
Results:
than 20,000 ohms. There is a problem with the
• OK – The resistance is between 5.0 and 20.6 low side wire for the fuel actuator. Proceed to Test
Step 4.
Test Step 4. Check the Low Side Wiring
Step 3.
inside the Engine Harness for a Short to
Ground
• Not OK – The resistance is higher than 20.6
the wiring for the solenoid, or the solenoid may A. Disconnect connector P5 from the terminal box.
Test Step 3. Check All of the Low Side

Wiring for a Short to Ground
from the ECM.
352
Test Step 5. Check the Solenoid for an

Internal Short Circuit
A. Disconnect connector P525 from the fuel
actuator.
g00868364
Illustration 257

strap for the ECM and harness connector P5
terminal (57). During this measurement, wiggle
the harnesses in order to check for an intermittent
g00868369
Illustration 258
Expected Result:
(1) Solenoid for the fuel actuator
(2) Solenoid connector
The resistance is greater than 20,000 ohms. (J525-B) Low side
(Shell) Shell for the connector
Results:
B. Measure the resistance between terminal (B) and
• OK – The resistance measurement is greater the connector’s shell.
than 20,000 ohms. The low side wire inside the
engine harness appears to be OK. The low side Expected Result:
wire inside the terminal box may have a problem.
There may be a problem with a connector. The resistance is greater than 20,000 ohms.
Repair: Repair the harness and/or the connector, Results:

• OK – The resistance is greater than 20,000
STOP. ohms. The solenoid does not have an internal
short circuit. The low side wire inside the engine
• Not OK – The resistance measurement is less harness has a short to ground.
than 20,000 ohms. The low side wire inside the
engine harness may have a problem, or there Repair: Repair the engine harness or connectors,
may be a problem with the solenoid. Proceed to when possible. Replace the harness, if necessary.
Test Step 5.
STOP.

353

STOP.

g00852133
Illustration 259
(P5-57) Low side wire for the fuel actuator g00849459
(P5-70) High side wire for the fuel actuator Illustration 260
(1) Solenoid on the fuel actuator
B. Measure the resistance between P5 terminal (57) (J525-B) Low side
and terminal (70). During this measurement, (J525-A) High side
an intermittent problem with the harness. Be B. Measure the resistance between terminals (B)
sure to wiggle the harnesses near each of the and (A) on the connector for the fuel actuator
connectors. (J525).
Expected Result: Expected Result:
The resistance is between 5.0 and 20.6 ohms. The resistance is between 5.0 and 10.3 ohms.
Results: Results:
• OK – The resistance is between 5.0 and 20.6 • OK – The resistance of the solenoid is between
ohms. The engine harness and the solenoid 5.0 and 10.3 ohms. The solenoid does not have
appear to be OK. The wiring inside the terminal an open circuit. There is an open circuit in the
box or the terminal box’s connectors may have engine harness. There may be a problem with a
a problem. connector.
Repair: Repair the wiring and/or connectors, Repair: Repair the engine harness or connectors,
when possible. Replace the wiring, if necessary. when possible. Replace the harness, if necessary.
STOP. STOP.
• Not OK – The resistance is greater than 20.6 • Not OK – The resistance of the solenoid is higher
ohms. There is a problem with the engine harness than 10.3 ohms. The resistance of the solenoid is
or the solenoid. Proceed to Test Step 7. incorrect. The solenoid has an open circuit.
Test Step 7. Check the Solenoid for an Repair: Replace the solenoid. Refer to Operation
Open Circuit and Maintenance Manual, “Electrohydraulic
actuator. STOP.
354

g00852133
Illustration 262
g00849558
Illustration 261
ECM side of the ECM P2 connector B. Measure the resistance between harness
(P2-6) High side wire for the fuel actuator connector P5 terminal (57) and terminal (70).
(P2-7) Low side wire for the fuel actuator During this measurement, wiggle the harnesses
B. Measure the resistance between P2 terminal the harness. Be sure to wiggle the harnesses
(6) and terminal (7). During this measurement, near each of the connectors.
an intermittent problem with the harness. Be Expected Result:
connectors. The resistance is between 5.0 and 20.6 ohms.
Expected Result: Results:
The resistance is between 5.0 and 20.6 ohms. • OK – The resistance is between 5.0 and 20.6
ohms. The engine harness and the solenoid
Results: appear to be OK. The wiring inside the terminal
box has a problem. There may be a problem with
• OK – The resistance is between 5.0 and 20.6 a connector.
ohms. The solenoid and wiring do not have a
short circuit. Proceed to Test Step 11. Repair: Repair the wiring and/or the connector,
There is a problem with a connector and/or the STOP.
wiring, or the solenoid has a problem. Proceed
to Test Step 9. • Not OK – The resistance is lower than 5.0 ohms.
There is a problem with the engine harness or the
Test Step 9. Check the Engine Harness solenoid. Proceed to Test Step 10.
Test Step 10. Check the Solenoid for a
A. Disconnect connector P5 from the terminal box. Short Circuit
actuator.
355
Test Step 11. Create an Open Circuit and

that the gas supply to the engine is OFF.
B. Verify that the engine control switch is in the

g00849316
Illustration 264
(P2-6) High side of the fuel actuator
(P2-7) Low side of the fuel actuator
g00849459
Illustration 263
(1) Solenoid on the fuel actuator C. Use a 151-6320 Wire Removal Tool to remove
(2) J525 connector on the solenoid terminal (6) and terminal (7) from harness
(J525-B) Low side connector P2. This will replace the wiring for the
(J525-A) High side
fuel actuator with an open circuit.
and (A) on the connector for the fuel actuator
ON.
(J525).
E. If a 23-05 diagnostic code and/or a 23-06
Expected Result:
Results:
• OK – The resistance of the solenoid is between position.
5.0 and 10.3 ohms. The solenoid does not have
a problem. The engine harness appears to have
G. Observe the “Active Diagnostic” screen on ET.
a short circuit.
Expected Result:
STOP.
Results:
• Not OK – The resistance of the solenoid is lower
incorrect. • OK – When an open circuit was created, a 23-05
diagnostic code was generated. The ECM is
operating correctly. The problem appears to be
resolved. The initial diagnostic code was probably
caused by a poor electrical connection.
STOP.
356

OFF.

connector P2. Pull on the wires in order to verify

STOP.

525-05 diagnostic code was not generated. The g00849316
ECM may have a problem. Illustration 265
Repair: It is unlikely that the ECM has failed. (P2-6) High side of the fuel actuator
Exit this procedure and perform this procedure (P2-7) Low side of the fuel actuator
following procedure: C. Use a 151-6320 Wire Removal Tool to remove
terminal (6) and terminal (7) from harness
Temporarily install a new ECM. Refer to connector P2.
D. Use a jumper wire that is 125 ± 25 mm
If the problem is resolved with a new ECM, install (5.0 ± 1.0 inch) long with Deutsch sockets on
the original ECM and verify that the problem the ends. Insert one end of the jumper wire into
returns. If the new ECM operates correctly and the open terminal (6) of the P2 connector. Verify
the original ECM does not operate correctly, that the socket is making contact with pin 6 in
replace the original ECM. Follow the instructions the J2 connector.
E. Insert the other end of the jumper wire into the
STOP. open terminal (7) of the P2 connector. Verify that
the socket is making contact with pin 7 in the J2
Test Step 12. Create a Short Circuit and connector. This will replace the wiring for the fuel
Check the Operation of the ECM actuator with a short circuit.
A. Prevent fuel from entering the engine. Verify F. Switch the 16 amp circuit breaker for the ECM
that the gas supply to the engine is OFF. ON.
B. Verify that the engine control switch is in the G. If a 525-05 diagnostic code and/or a 525-06
OFF/RESET position. Verify that the 16 amp diagnostic code is logged, clear the code.
H. Turn the engine control switch to the START
position.

Expected Result:

357
Results: i01667965
• OK – When the wiring for the fuel actuator was Ignition Transformers Primary
replaced with a short circuit, a 525-06 diagnostic
code was generated by the ECM. The ECM is
Circuit
operating correctly. The problem appears to be SMCS Code: 1561-038
resolved. The initial diagnostic code was probably
caused by a poor electrical connection. System Operation Description:
Repair: Perform the following procedure: The ECM has internal circuit drivers for the
transformers. The circuit drivers send a signal of
Turn the engine control switch to the OFF position. +108 volts through terminals that are in pairs. The
Switch the 16 amp circuit breaker for the ECM signal goes to the high side of the primary circuits
OFF. of the ignition transformers. The transformers deliver
high voltage (8000 to 37,000 volts) to the spark
Remove the jumper wire from the P2 connector. plugs.
Reinstall the terminals that were removed from The pairs of cylinders that are opposite by 360
connector P2. Pull on the wires in order to verify degrees in the firing order reach Top Center
proper installation of the terminals. simultaneously. These pairs of cylinders share the
same high side circuit driver inside the ECM. This
Reconnect all of the connectors. Verify that the means that a short circuit to the high side on any
problem is resolved. cylinder will also affect the cylinder that is opposite
by 360 degrees. If any cylinder’s high side has an
STOP. open circuit, only that cylinder is affected.
• Not OK – When the wiring for the fuel actuator is For the 12 cylinder engine, each following pair of
replaced with a short circuit, a 23-06 diagnostic cylinders are supplied by one of the six high side
code is not generated by the ECM. The ECM circuit drivers: 1-11, 2-12, 3-9, 4-10, 5-7, and 6-8.
may have a problem.
For the 16 cylinder engine, each following pair of
Repair: It is unlikely that the ECM has failed. cylinders are supplied by one of the eight high side
Exit this procedure and perform this procedure circuit drivers: 1-15, 2-16, 3-13, 4-14, 5-11, 6-12,
again. If the problem is not resolved, perform the 7-9, and 8-10.
The ECM has internal returns for the transformers.
Temporarily install a new ECM. Refer to These returns consist of groups of terminals for
Troubleshooting, “Replacing the ECM”. each primary circuit. The current for the return
to ground is limited to a single transformer. This
If the problem is resolved with a new ECM, install means that a return short circuit to the −Battery side
the original ECM and verify that the problem will affect only one cylinder. The groups of return
returns. If the new ECM operates correctly and terminals for the transformers are connected by
the original ECM does not operate correctly, diodes inside the ECM. This means that a return
replace the original ECM. Follow the instructions short circuit to the +Battery side can simultaneously
in Troubleshooting, “Replacing the ECM”. affect all of the cylinders that are grouped.
STOP. For the 12 cylinder engine, each following group of
cylinders are coupled by an internal diode to one
low side circuit driver: 1-5-9, 2-6-10, 3-7-11, and
4-8-12.
For the 16 cylinder engine, each following group of

cylinders are coupled by an internal diode to one
low side circuit driver: 1-3-5-9, 2-4-6-10, 7-11-13-15,
and 8-12-14-16.
Because the circuits are in pairs or groups,

multiple diagnostic codes can be activated for a
single problem. If multiple diagnostic codes are
active for the primary ignition, troubleshooting the
circuits one at a time is an effective way to find the
root cause.
358
Illustration 266 is a schematic of the internal circuitry

for a 12 cylinder engine’s ECM.
g00863814
Illustration 266
Illustration 267 is a schematic of the internal circuitry

for a 16 cylinder engine’s ECM.
359


an ignition transformer. The least likely cause is a
The ignition wiring is continuous from the ECM P2

connector to the connectors for the transformers.
The ignition wiring for each bank of cylinders is
routed through a rail on each side of the engine.
Illustration 268 is a schematic of the ignition system

for the 12 cylinder engine.
g00862203
Illustration 267
360
g00861571
Illustration 268
Illustration 269 is a schematic of the ignition system

for the 16 cylinder engine.
361
g00861484
Illustration 269
362

g00861911
Illustration 271
Terminals for the ignition wiring on the harness side of the ECM
Illustration 270
g00861708 P2 connector (G3612 Engine)
(1) ECM P2 connector (P2-1) Number 1 transformer’s circuit driver

(2) 16 amp circuit breaker (P2-2) Number 1 transformer’s return
(P2-42) Number 2 transformer’s circuit driver
(P2-43) Number 2 transformer’s return
A. Turn the engine control switch to the OFF/RESET (P2-48) Number 3 transformer’s circuit driver
position. Switch the 16 amp circuit breaker for (P2-49) Number 3 transformer’s return
the ECM OFF. (P2-16) Number 4 transformer’s circuit driver
Note: For the following steps, refer to (P2-25) Number 5 transformer’s return
Troubleshooting, “Inspecting Electrical Connectors”. (P2-60) Number 6 transformer’s circuit driver
B. Thoroughly inspect the ECM J2/P2 connectors. (P2-58) Number 7 transformer’s circuit driver
a. Check the torque of the Allen head screw for (P2-27) Number 8 transformer’s return
the ECM P2 connector. The proper torque is (P2-14) Number 9 transformer’s circuit driver
6 ± 1 N·m (55 ± 9 lb in). (P2-15) Number 9 transformer’s return
b. Perform a 45 N (10 lb) pull test on each of (P2-40) Number 11 transformer’s circuit driver
the wires that are associated with the circuit (P2-41) Number 11 transformer’s return
of the ignition system. (P2-3) Number 12 transformer’s circuit driver
The terminals for G3612 Engines are identified
in Illustration 271.

363
c. Check the ignition harness and wiring

for abrasion and pinch points from the
transformer’s connector to the rail and check
from the rail to the ECM.
Expected Result:

Results:

g00720097
Illustration 272
Terminals for the ignition wiring on the harness side of the ECM • Not OK – The components are not in good
P2 connector (G3616 Engine) condition and/or at least one connection is
(P2-1) Number 1 transformer’s circuit driver improper.
(P2-4) Number 2 transformer’s return Repair: Perform the necessary repairs and/or
(P2-24) Number 3 transformer’s circuit driver replace parts, if necessary. Ensure that all of the
(P2-25) Number 3 transformer’s return seals are properly installed. Make sure that the
(P2-26) Number 4 transformer’s circuit driver connections are properly fastened. Verify that the
repair has eliminated the problem.
(P2-16) Number 6 transformer’s circuit driver If the condition is not resolved, proceed to Test
(P2-17) Number 6 transformer’s return Step 2.
(P2-52) Number 8 transformer’s circuit driver Test Step 2. Check for Diagnostic Codes
(P2-62) Number 8 transformer’s return for the Primary Circuit
(P2-33) Number 9 transformer’s return A. Connect ET to the service tool connector on the
(P2-35) Number 10 transformer’s return terminal box. Switch the 16 amp circuit breaker
(P2-48) Number 11 transformer’s circuit driver for the ECM ON.
(P2-50) Number 12 transformer’s circuit driver B. Attempt to start the engine and use ET. Determine
if the following codes are active or logged:
(P2-60) Number 14 transformer’s circuit driver • 301-05 Ignition Transformer Primary #1 open
(P2-61) Number 14 transformer’s return circuit through 316-05 Ignition Transformer
(P2-40) Number 15 transformer’s circuit driver Primary #16 open circuit
(P2-43) Number 16 transformer’s return • 301-06 Ignition Transformer Primary #1 short
through 316-06 Ignition Transformer Primary
#16 short
Note: If a diagnostic code for the primary circuit is

logged but not currently active, attempt to repeat
the condition that generated the code. Run the
engine to full operating temperature.
Note: If a transformer’s driver circuit is shorted to

the +Battery side, the cylinder that is opposite by
360 degrees will also be affected. If a return circuit
is shorted to the −Battery side, only one cylinder is
affected. If a return circuit is shorted to the +Battery
side, 3 cylinders will be simultaneously affected
in a 12 cylinder engine and 4 cylinders will be
g00861683 simultaneously affected in a 16 cylinder engine.
Illustration 273
(3) Typical connectors for ignition transformers
(4) Rail
364
Expected Result:
None of the above diagnostic codes are active.
Results:
• No (Active “open circuit”) – There is an open

primary circuit. Proceed to Test Step 3.
• No (Active “short”) – There is a short primary

circuit. Proceed to Test Step 3.
• Yes (Logged only) – None of the above diagnostic

codes are active. The original diagnostic code
was probably caused by a poor electrical g00861770
connection. There may be an intermittent problem Illustration 274
with the ignition wiring. Section view of an ignition transformer and front view of the
transformer’s connector
Repair: Make sure that the connectors and (1) Mounting flange
the wiring are in good condition. Inspect (2) Terminal for the spark plug’s extension
(A) Transformer’s circuit driver
the connectors for damage and/or corrosion. (B) Transformer’s return
Make sure that the connections are secure. (C) Unused
Connectors”. D. Use a multimeter to check the transformer.
STOP. Note: The transformer’s resistance will vary with

the temperature. Illustration 275 demonstrates the
Test Step 3. Check the Transformer relationship between the transformer’s resistance
and the temperature. A reading that is within ±
1000 ohms is acceptable. For example, if the
transformer’s temperature is 60 C (140 F), the
correct resistance is 22,000 ± 1000 ohms.
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.

the ECM OFF.
B. Disconnect the transformer. Visually inspect the

connectors for dirt, moisture, and corrosion.
Make sure that the pins and sockets are not
loose. g00863850
Illustration 275
C. Remove the transformer. Resistance versus temperature
(Y) Resistance in ohms
(X) Temperature in degrees celsius (Degree Fahrenheit)
a. Set the multimeter to the 40,000 ohm scale.

Measure the resistance between mounting
flange (1) and terminal (2) for the spark plug’s
extension.
365
Test Step 4. Check the Ignition Harness

for an Open Circuit
g00754013
Illustration 276 position. Switch the 16 amp circuit breaker for
Symbol for a diode the ECM OFF.
b. Set the multimeter to the diode scale. Measure

the voltage between terminals (A) and (B).
c. Reverse the polarity of the probe and measure

the voltage between terminals (A) and (B)
again.
Expected Result:
The resistance between the mounting flange and

the terminal for the spark plug’s extension is within
the acceptable tolerance.
For the diode of the primary circuit, the voltage g00861936

Illustration 277
between terminals (A) and (B) is approximately
0.450 VDC. When the polarity is reversed, the Typical harness connectors for the transformers
reading is infinite.
B. Disconnect the suspect ignition harness from
Results: the transformer. Inspect the connectors of the
harness and the transformer for damage and/or
• Not OK – At least one of the measurements is corrosion.
incorrect. There is a problem with the transformer.
Repair: Replace the transformer.
STOP.
• OK – Both of the measurements are correct.

1. Switch the suspect transformer with a

transformer from a different cylinder that is
known to be good. Install the transformers.
2. Reset the control system. Clear any logged g00861968

Illustration 278
codes.
Ignition harness’ connector for the transformer
3. Restart the engine. Operate the engine. Check (A) Transformer’s circuit driver
for a recurrence of the problem. (B) Transformer’s return
(C) Unused
If the problem stays with the suspect transformer,

replace the transformer. C. Install a jumper wire with the appropriate
connectors onto terminals (A) and (B) of the
suspect ignition harness’ connector for the
If the problem stays with the suspect cylinder,
continue to troubleshoot the problem according transformer.
to the type of original diagnostic code.
D. Use a 151-6320 Wire Removal Tool to remove
If the original diagnostic code is a “05 open the suspect circuit driver and return terminals
from the ECM P2 connector. Label the wires.
circuit”, proceed to Test Step 4. If the original
diagnostic code is a “06 short”, proceed to Test
Step 5. The terminals for G3612 Engines are identified

366
g00861911 g00720097
Terminals for the ignition wiring on the harness side of the ECM Terminals for the ignition wiring on the harness side of the ECM
P2 connector (G3612 Engine) P2 connector (G3616 Engine)
(P2-1) Number 1 transformer’s circuit driver (P2-1) Number 1 transformer’s circuit driver
(P2-2) Number 1 transformer’s return (P2-2) Number 1 transformer’s return
E. Use an ohmmeter to measure the resistance of

the suspect terminals that were removed from
the ECM P2 connector.
Expected Result:
Results:
• Yes – The resistance is less than 5 ohms. The

ignition harness is OK. There may be a problem
with the ECM.
367
Repair: It is unlikely that the ECM has failed. Exit

this procedure and perform this procedure again.
If the problem is not resolved, replace the ECM
STOP.
• No – The resistance is greater than 5 ohms.

There is a problem in the ignition harness.
Repair: The problem is caused by a poor

electrical connection and/or a broken wire in the
ignition harness. Repair the connection and/or
the wiring, when possible. Replace the ignition g00861911
harness, if necessary. Illustration 282
STOP. P2 connector (G3612 Engine)
Test Step 5. Check the Ignition Harness (P2-2) Number 1 transformer’s return
for a Short Circuit (P2-43) Number 2 transformer’s return
A. Turn the engine control switch to the OFF/RESET (P2-49) Number 3 transformer’s return
position. Switch the 16 amp circuit breaker for (P2-16) Number 4 transformer’s circuit driver
the ECM OFF. (P2-24) Number 5 transformer’s circuit driver
g00861936
Illustration 281
Typical harness connectors for the transformers
B. Disconnect the suspect ignition harness from

the transformer. Inspect the connectors of the
harness and the transformer for damage and/or
corrosion.

the suspect circuit driver and return terminals
from the ECM P2 connector. Label the wires.


368
Repair: It is unlikely that the ECM has failed. Exit

this procedure and perform this procedure again.
If the problem is not resolved, replace the ECM
STOP.

There is a problem in the ignition harness.
Repair: There is a poor electrical connection

and/or a wiring problem in the ignition harness.
Repair the connection and/or the wiring, when
g00720097
possible. Replace the ignition harness, if
Illustration 283 necessary.
P2 connector (G3616 Engine) STOP.
(P2-3) Number 2 transformer’s circuit driver i01671782
Ignition Transformers
Secondary Circuit and Spark
(P2-14) Number 5 transformer’s circuit driver Plugs
SMCS Code: 1561-038
(P2-18) Number 7 transformer’s return System Operation Description:
(P2-62) Number 8 transformer’s return The transformers are located on the covers for the
(P2-33) Number 9 transformer’s return valve lifters. Each transformer is grounded to a
(P2-34) Number 10 transformer’s circuit driver cover via the transformer’s mounting flange. The
(P2-35) Number 10 transformer’s return transformers initiate combustion by providing high
(P2-48) Number 11 transformer’s circuit driver voltage to the spark plugs. The positive output from
the transformer’s secondary circuit is delivered to
(P2-51) Number 12 transformer’s return the connection for the spark plug.
D. Use an ohmmeter to measure the resistance of

the suspect terminals that were removed from
the ECM P2 connector.
Expected Result:

g00863996
Illustration 284
Results: Ignition transformer and spark plug
(1) Primary connection
• Yes – The resistance is greater than 20,000 (2) Mounting flange (ground)
ohms. The ignition harness is OK. There may be (3) Ignition transformer
a problem with the ECM. (4) Extension
(5) Secondary connection
(6) Spark plug
369
The secondary circuit of the transformer provides Test Step 1. Check the Status Screen
an initial 8,000 to 37,000 V to the spark plug via of the ET for the Outputs of the
the extension. This voltage ionizes the spark plug Transformers’ Secondary Circuits
gap. This voltage is then reduced to about 1000
V. The total duration of the spark is approximately A. Turn the engine control switch to the OFF/RESET
400 µ seconds. position. Switch the 16 amp circuit breaker for
the ECM OFF.
The ECM can diagnose the primary circuit of the
ignition transformers for open circuits and/or for B. Connect ET to the service tool connector on the
short circuits. Secondary open circuits and short terminal box.
circuits will not directly shut down the engine.
However, these conditions may lead to misfire which C. Switch the 16 amp circuit breaker for the ECM
can cause lugging of the engine. Lugging of the ON. Turn the engine control switch to the STOP
engine can cause a shutdown. position.
D. Use ET to view the status screens that are listed

in Table 41:
Table 41
Status Screens on the ET
Screen 1 Screen 2
Group 8 Group 9
“Cylinder #1 Transformer “Cylinder #2 Transformer
Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage”
Illustration 285 g00864025 Percentage” Percentage”
Schematic for the transformer and spark plug “Cylinder #9 Transformer “Cylinder #10 Transformer
Caterpillar spark plugs are high voltage devices Percentage” Percentage”
with internal resistors. The spark plugs operate at a “Cylinder #11 Transformer “Cylinder #12 Transformer
voltage that is greater than 5,000 volts. Secondary Output Voltage Secondary Output Voltage
Most ignition systems are not affected by resistance
in the secondary circuit. If a measurement of the “Cylinder #13 Transformer “Cylinder #14 Transformer
resistance is desired, a megohmmeter must be
used. A low voltage multimeter will not provide a
reliable reading of the resistance because oxidation “Cylinder #15 Transformer “Cylinder #16 Transformer
of the spark plug’s internal components will affect Secondary Output Voltage Secondary Output Voltage
the readings of those meters. Percentage” Percentage”
Logged diagnostic codes provide an historical E. Start the engine. Apply the normal load at rated
record. Before you begin this procedure, use ET to speed. Allow the engine to warm up to normal
print the logged codes to a file. operating temperature.
The most likely cause of the diagnostic code is a F. Observe the value of the output for the secondary
problem with the spark plug. The next likely cause circuit of each transformer.
is a poor electrical connection or a problem with the
extension. The least likely cause is a problem with Expected Result:
an ignition transformer.
The displayed value of the output for the secondary
circuit of each transformer is between 1 and 90
percent.
370
Results: C. Remove the four bolts in order to remove the

transformer (2) and extension (3) as a unit.
• OK – The displayed value of the output for
the secondary circuit of each transformer is D. Inspect the transformer’s body and the mounting
between 1 and 90 percent. The ignition system flange for corrosion and/or damage.
components are operating properly.
E. Unscrew the extension from the transformer.
Repair: Investigate other possible root causes of Inspect the internal threads of the transformer
the problem. Troubleshoot the symptom. Refer and the external threads of the extension for
to Troubleshooting, “Troubleshooting Without A corrosion and/or damage.
Diagnostic Code”.
F. Inspect the extension’s spark plug connector for
STOP. corrosion and/or damage. Inspect O-ring seal (4)
inside the extension for damage.
• Not OK – At least one of the outputs displayed
a value of 0 percent or a value that is greater G. Use an extra spark plug to check for a secure
than 90 percent. The ignition system components connection between the extension and the spark
require maintenance. Proceed to Test Step 2. plug.
Test Step 2. Inspect the Transformer and Note: Punch through is caused by misfire in the
the Extension engine that does not generate a diagnostic code.
H. Check the extension near the spacer for signs of

punch through (pin holes) and/or arcing.
There is a strong electrical shock hazard when the
crankshaft is rotating. NOTICE
The extension can be scratched and damaged with a
Do not touch the wires that are associated with wire brush. Do not use a wire brush on the extension.
the ignition system when the engine is cranking
or when the engine is running. I. Clean any deposits from the inside of the
extension. Use a 6V-7093 Brush with isopropyl
A. Turn the engine control switch to the OFF/RESET alcohol. Clean the internal threads of the
position. Switch the 16 amp circuit breaker for transformer and the external threads of the
the ECM OFF. extension.
NOTICE Expected Result:

Pulling on the wiring harness may break the wires. Do
not pull on the wiring harness. The transformer and the extension are in good
condition.
Results:
• OK – The transformer and the extension appear

to be in good condition. Proceed to Test Step 3.
• Not OK – An inspection found a problem with the

transformer and/or the extension.
g00864072
Illustration 286
(1) Ignition harness Repair: Repair the components, when possible.
(2) Transformer Replace the components, if necessary.
(3) Extension
(4) O-ring seal Resume normal operation.
B. Disconnect ignition harness (1) from the STOP.
transformer’s connector. Visually inspect the
connectors for dirt, moisture, and corrosion. Test Step 3. Check the Spark Plug
Make sure that the pins and sockets are not
loose. A. Make sure that the engine control switch is in the
371
B. Perform the following procedures according to Test Step 4. Check the Transformer
the instructions in Operation and Maintenance
Manual, SEBU7563, “Ignition System Spark
Plugs - Check/Adjust”.
a. Remove the spark plug.
b. Inspect the spark plug.
c. Clean the spark plug.
C. Measure the spark plug’s resistance after the

spark plug has been cleaned.
Note: A standard ohmmeter cannot be used for

measuring the resistance of a used spark plug.
g00861770
Illustration 287
a. Use the 142-5055 Insulation Testing Gp Section view of an ignition transformer and front view of the
(Electrical) to measure the resistance of transformer’s connector
the spark plug. Follow the warnings and (1) Mounting flange
instructions that are provided with the tool. (2) Terminal for the spark plug’s extension
(A) Transformer’s circuit driver
(B) Transformer’s return
b. Connect the red lead of the tester to the (C) Unused
terminal post. Because the ground strap
is close to the center electrode, you will A. Use a multimeter to check the transformer.
need to connect a smaller lead to the center
electrode. Then connect the black lead of the Note: The transformer’s resistance will vary with
tester to the smaller lead. the temperature. Illustration 288 demonstrates the
c. Use the tester’s “20 K
” scale.
relationship between the transformer’s resistance
and the temperature. A reading that is within ±
1000 ohms is acceptable. For example, if the
Expected Result: transformer’s temperature is 60 C (140 F), the
correct resistance is 22,000 ± 1000 ohms.
The spark plug is in good condition.
The resistance is less than 10,000 ohms.
Results:
• OK – The spark plug is in good condition. The

resistance is less than 10,000 ohms.
Repair: Install the spark plug according to

“Ignition System Spark Plugs - Check/Adjust”.
• Not OK – The spark plug is not in good Illustration 288

g00863850
condition and/or the resistance is not within the
Resistance versus temperature
specification.
(Y) Resistance in ohms
(X) Temperature in degrees celsius (Degree Fahrenheit)
Repair: Discard the spark plug. Install a new
spark plug according to the instructions in
a. Set the multimeter to the 40,000 ohm scale.
Operation and Maintenance Manual, SEBU7563, Measure the resistance between mounting
“Ignition System Spark Plugs - Check/Adjust”.
flange (1) and terminal (2) for the spark plug’s
extension.
Reset the control system. Restart the engine.
Clear the logged codes.
STOP.
372
i01692912
Inspecting Electrical
Illustration 289 g00754013
Connectors
Symbol for a diode SMCS Code: 1901-038
b. Set the multimeter to the diode scale. Measure System Operation Description:
the voltage between terminals (A) and (B).
Many of the troubleshooting procedures direct you
c. Reverse the polarity of the probe and measure to a specific electrical connector. Use the following
the voltage between terminals (A) and (B) test steps to help determine whether the connector
again. is the cause of the problem. If a problem is found
in a connector, repair the connector and verify that
Expected Result: the problem is corrected.
The resistance between the mounting flange and Intermittent electrical problems are often caused
the terminal for the spark plug’s extension is within by poor connections. Always check for an active
the acceptable tolerance. diagnostic code before you open any connection.
Immediately after you reconnect the connector,
For the diode of the primary circuit, the voltage check for codes again. Sometimes, simply
between terminals (A) and (B) is approximately disconnecting a connector and then reconnecting
0.450 VDC. When the polarity is reversed, the the connector can solve a problem. If this occurs,
reading is infinite. the following conditions are likely causes:
Results: • Loose terminals

• Not OK – At least one of the measurements is • Bent terminals
incorrect. There is a problem with the transformer.
• Improperly crimped terminals
Repair: Replace the transformer.
• Improperly mated connectors
STOP.
• Moisture
• OK – Both of the measurements are correct.
• Corrosion
Repair: Perform the following Steps in order to
determine whether the transformer or the spark
plug has a problem:
1. Switch the suspect transformer with a

transformer from a different cylinder that is
known to be good. Install the transformers.
2. Reset the control system. Clear any logged

codes.
3. Restart the engine. Operate the engine. Check

for a recurrence of the problem.
If the problem stays with the suspect transformer,

g00700045
replace the transformer. Illustration 290
If the problem stays with the suspect cylinder, The MS Connectors have a metal housing. The pins
replace the spark plug according to Operation and the sockets are soldered to the electrical wires.
and Maintenance Manual, SEBU7563, “Ignition The solder connections are usually protected by
System Spark Plugs - Check/Adjust”. a chemical potting which prevents access to the
solder point.
STOP.
373
g00700064
Illustration 291
Deutsch connectors have a plastic housing. The

pins and the sockets are crimped onto the electrical
wires. The connector has a locking mechanism
in order to hold the pins and the sockets. These
connectors are repairable without cutting the wires.
g00700442
Illustration 292
Use the following test steps in order to thoroughly

inspect the connectors and determine if the
connectors are the cause of the problem.
374
Test Step 1. Check the Connectors. • Not OK

A. Always turn the engine control switch to the Repair: Repair the connector or replace the
OFF/RESET position before you inspect electrical connector, as required.
conductors. Switch the circuit breaker for the
ECM OFF. Verify that the repair eliminates the problem.
B. For the MS connectors, make sure that the STOP.

receptacle is turned fully in the clockwise
direction. Check that the threading is properly Test Step 3. Perform a Pull Test on Each
aligned and securely mated. Wire Connection.
C. For the Deutsch HD connectors, make sure A. Each terminal and each connector should easily
that the plug and the receptacle are aligned withstand 45 N (10 lb) of pull and each wire
properly with the index markings. Make sure that should remain in the connector body. This test
the receptacle is turned fully in the clockwise checks whether the wire was properly crimped
direction. Verify that the receptacle is clicked in the terminal and whether the terminal was
into the locked position. Make sure that the two properly inserted into the connector.
halves cannot be pulled apart.
B. The DT connectors use an orange wedge to lock
D. For the Deutsch DT style, make sure that the the terminals in place. Ensure that the orange
orange wedge is used in order to lock the pins. wedge is not missing and that the orange wedge
Check that the receptacle has clicked into the is installed properly on the DT connectors.
locked position. Make sure that the two halves
cannot be pulled apart. Note: Terminals should ALWAYS be crimped onto
the wires by using a Crimp Tool. Do not solder
Expected Result: terminals. Use the 1U-5804 Crimp Tool.
All connectors are properly mated and free of Expected Result:

damage.
Each terminal and each connector easily withstands
Results: 45 N (10 lb) of pull and each wire remains in the
connector body.
• OK – Proceed to test step 2.
Results:
• Not OK
• OK – Proceed to Test Step 4.
Repair: Repair the connectors and/or replace the
connectors. Reconnect all of the connectors. • Not OK
STOP. Repair: Repair the circuit.
Test Step 2. Check the Allen Head Screw Verify that the repair eliminates the problem.
on the ECM Connector.
STOP.
A. Ensure that the allen head screw is properly
tightened. Be careful not to overtighten the screw Test Step 4. Monitor the Electronic
and break the screw. Service Tool While the Wiring and the
Connectors Are Being Pulled.
B. When you connect the 70-pin “AMP” connector to
the ECM, do not exceed 6 ± 1 N·m (55 ± 9 lb in)
of torque on the screw.
Expected Result: There is a strong electrical shock hazard when

the crankshaft is rotating. Do not touch wires that
The ECM connector is secure and the allen head are associated with the ignition transformer circuit
screw is properly torqued. when the engine is cranking or running.
Results: A. If there is an active diagnostic code that pertains

to the circuit, perform the following steps:
375
a. Turn the engine control switch to the Repair: Turn the engine control switch to the
OFF/RESET position. Switch the circuit OFF/RESET position. Switch the circuit breaker for
breaker for the ECM OFF. the ECM OFF. Repair the circuit.
b. Connect ET to the service tool connector on Verify that the repair eliminates the problem.
the terminal box.
STOP.
c. Switch the circuit breaker for the ECM ON.
Turn the engine control switch to the “STOP” Test Step 5. Check Wires for Nicks or
position. Then start the engine. Run the Abrasion in the Insulation.
engine under normal operating conditions.
A. Turn the engine control switch to the “STOP”
d. Monitor the “Active Diagnostic Code” screen position. Allow the engine to coast to a stop.
on ET while you pull on all harnesses and
connectors for the circuit with the active code. B. Turn the engine control switch to the
“OFF/RESET” position. Switch the circuit breaker
If the harness is being pulled and the active for the ECM OFF.
diagnostic code disappears, there is a
problem in the wiring or the connector. C. Carefully inspect each wire for signs of abrasion,
nicks, or cuts.
B. If there are no active diagnostic codes that
pertain to the circuit, perform the following test: The following areas are likely locations:
a. Run the engine under normal operating • Places with exposed insulation
conditions.
• Points with wiring that rubs against the engine
b. Monitor the “Display Status” screen on
ET while you pull on all harnesses and • Places with wiring that rubs against a sharp
connectors for the circuit. point
If the harness is being pulled and the reading D. Check all of the hold down clamps for the
changes erratically, there is a problem in the harness in order to verify that the harness is
wiring or the connector. properly clamped. Also, check all of the hold
down clamps in order to verify that the harness
C. If there are no active diagnostic codes and there is not compressed by the clamps. Pull back the
are complaints about intermittent changes in harness sleeves in order to check for flattening
speed or power cutouts, perform the following of the wires by the clamps.
test:
Expected Result:
a. Run the engine under normal operating
conditions. The wires are free of abrasion, nicks, or cuts and
the harness is properly clamped.
b. Listen for speed burps or power cutouts while
the wiring and/or the connectors are pulled. Results:
If the harness is being pulled and the engine • OK – Proceed to Test Step 6.
has a speed burp or a power cutout, there
could be a problem in the wiring or the • Not OK
connector.
Repair: Repair the wires or replace the wires, as
Expected Result: required.
The problem appears to be external to the Verify that the repair eliminates the problem.
harnesses and connectors. Pulling on the harness
and the connectors has no effect on the active STOP.
diagnostic code, component status, or engine
performance.
Results:

• Not OK
376
Test Step 6. Check the Connectors for Note: It is normal to see some minor seal abrasion
Moisture or Corrosion. on the ECM connector seals. Minor seal abrasion
will not allow the entry of moisture.
If moisture or corrosion is evident in the connector,

the source of the moisture entry must be found
and the source of the moisture entry must be
repaired. If the repair is not made, the problem will
recur. Simply drying the connector will not fix the
problem. The following list includes likely paths for
the entrance of moisture:
• Missing seals or plugs

• Improperly installed seals or plugs
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also wick from one connector through
the inside of a wire to the ECM connector. If
moisture is found in the ECM connector, thoroughly
Illustration 293
g00690571 check all connectors and wires on the harness that
connects to the ECM. The ECM is not the source of
A. Ensure that the connector seals and the white the moisture. Do not replace an ECM if moisture is
sealing plugs are in place. If any of the seals or found in either ECM connector.
plugs are missing, replace the seal or plug. If
necessary, replace the connector. Note: If corrosion is evident on the pins, sockets or
the connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush
to remove the corrosion. Do not use any cleaners
that contain 1,1,1 trichloro-ethylene because 1,1,1
trichloro-ethylene may damage the connector.
Expected Result:
All of the connectors are completely coupled and

all of the seals are completely inserted. The harness
and the wiring is free of corrosion, abrasion, and
pinch points.
Results:

• Not OK
Repair: Repair the circuit. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled.
g00690568
Illustration 294
B. Check all of the wiring harnesses in order to

verify that the harness does not make a sharp
bend out of a connector. This will deform the
connector seal and this will create a path for the
entrance of moisture.
Thoroughly inspect ECM J1/P1 and J2/P2

connectors for evidence of moisture entry.
377
Verify that the repair eliminates the problem Note: This is especially important for intermittent
by running the engine for several minutes and problems.
by checking again for moisture. If moisture
reappears, the moisture is wicking into the A. One at a time, insert a new pin into each socket.
connector. Even if the moisture entry path is Make sure that the pin is properly gripped by
repaired, it may be necessary to replace the the socket.
wires that have moisture. These wires may have
moisture that is trapped inside the insulation. B. One at a time, insert a new socket onto each pin.
Verify that the repair eliminates the problem. Make sure that the pin is properly gripped by the
socket. Verify that the socket holds the pin when
STOP. the connector hangs freely.
Test Step 7. Inspect the Connector Expected Result:

Terminals.
Each socket firmly grips each pin.
Verify that the terminals are not damaged. Verify that
the terminals are properly aligned in the connector Results:
and verify that the terminals are properly located in
the connector. • OK – The pins and sockets mate properly. STOP.
Expected Result: • Not OK – The pins and sockets do not mate
properly.
The terminals are properly aligned and the terminals
appear undamaged. Repair: Repair any bad pins and sockets.
Replace the connectors, if necessary. Replace
Results: the wiring, if necessary.
• OK – Proceed to Test Step 7. Verify that the repair eliminates the problem.
• Not OK STOP.
Repair: Repair the terminals and/or replace the

i01655570
terminals, as required.
Verify that the repair eliminates the problem.

Integrated Combustion
Sensing Module (ICSM)
STOP.
SMCS Code: 1901-038
Test Step 8. Check the Individual
Retention of the Pins and Sockets. System Operation Description:
The left side ICSM and the right side ICSM monitor
the combustion sensors and the thermocouples
for each bank. Each ICSM performs calculations
in order to optimize the engine’s operation. Each
ICSM broadcasts the following information:
• Fuel correction factor

• Actual combustion burn time for each cylinder
• Average combustion burn time for each bank of
cylinders
• Actual exhaust port temperature of each cylinder

• Average exhaust port temperature for each bank
of cylinders
• The temperature of the exhaust at the inlet and at

the outlet of each turbocharger
g00690572
Illustration 295
378
Information from an ICSM travels across the CAT

data link. The ICSM must be programmed in order
to communicate across the CAT data link. The
CAT data link must be in good condition so that
the ICSM can transmit the information. An ICSM
may be able to communicate with ET even though
communication with the ECM is not possible.
An ICSM can generate these diagnostic codes:
• A 253-02 diagnostic code indicates that the

programs of the Integrated Combustion Sensing
Modules do not match.
• A 591-12 diagnostic code is caused by an ICSM

that requires programming. The ICSM may have
an internal failure.
• A -09 diagnostic code is probably caused by a

problem with the CAT data link. This diagnostic
code can also be caused by a problem with the
power supply for the ICSM, or a faulty ICSM.
g00855193
Illustration 296
Schematic for the CAT data link for the ICSM
379
Test Step 1. Inspect the Electrical • Connectors J1/P1 for the ECM
• Connector J7 for ET
position. Switch the 16 amp circuit breaker for • Terminal box J5/P5 and (J6/P6) connectors
the ECM OFF.
• Connector J73/P73 for the left side ICSM
Troubleshooting, “Inspecting Electrical Connectors”. • Connector J83/P83 for the right side ICSM
C. Check the torque of the Allen head screw for
the ECM P1connector and harness connectors
P5 and P6. The proper torque is 6 ± 1 N·m
(55 ± 9 lb in).
D. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the CAT data link
for the ICSM.
E. Check the harness and wiring for abrasion and

pinch points from each ICSM to the terminal box.
Expected Result:
g00857755
Illustration 297 All of the connectors, terminals, and sockets are
Terminal box connected properly. The connectors and the wiring
(1) ECM J1/P1 connector are free of corrosion, abrasion and pinch points.
(2) Ground strap
(3) 16 amp circuit breaker Results:
(4) Service tool connector J7
(5) Connector J5 for the right engine harness
(6) Connector J6 for the left engine harness • OK – All of the connectors, terminals, and sockets
Note: Illustration 298 shows one side of the engine. wiring are free of corrosion, abrasion, and pinch
The other side is similar. points. The components are in good condition
• Not OK – At least one of the connectors,

terminals, or sockets is not connected properly.
At least one of the connectors and/or the wiring
has corrosion, abrasion, and/or pinch points.

STOP.

Code is Active
position.
B. The ECM must operate for at least five seconds

in order for these codes to become activated.
g00857762 Look for the codes that are listed in Table 42:
Illustration 298
(7) ICSM
(8) Connectors J73/P73 for the ICSM

connectors:
380
Table 42
Diagnostic Codes for the ICSM
253-02 Incorrect ECM Software
591-12 EEPROM Checksum Fault
1040-09 ICSM #1 (Right Side) Not Communicating
on Link
1041-09 ICSM #2 (Left Side) Not Communicating
on Link
Expected Result:
There are no active codes.

g00857875
Illustration 299
Results: Service tool connector J7
• No codes – The problem seems to be resolved. B. Disconnect ET from service tool connector J7.
There are no active codes. The modules appear
to be operating correctly at this time.

of the harness connectors or terminals. Resume
normal operation.
STOP.
• 253-02 – The programming of both of the

Integrated Combustion Sensing Modules do not
match.
Repair: The programming of both of the Integrated

g00857873
Combustion Sensing Modules must match. Use Illustration 300
ET to flash the software from the ICSM that is ECM P1 connector
known to be good to the suspect ICSM. Refer to
Troubleshooting, “Replacing the ICSM”. Verify that
STOP.
• 591-12 – An ICSM has a problem. The problem

may be resolved by programming the ICSM.
• 1040-09 – The right side ICSM is not

communicating with the ECM. Proceed to Test
Step 3.
• 1041-09 – The left side ICSM is not

communicating with the ECM. Proceed to Test
Step 4.
Test Step 3. Check the Right Side CAT

Data Link for Continuity
A. Turn the engine control to the OFF/RESET Illustration 301
g00857920
Right side of the engine
the ECM OFF.
(1) ICSM
(2) Connector P83 for the CAT data link
381
C. Disconnect connector P1 and P83. F. Remove the jumper wire from connector P1.
g00857942 g00865258
ECM side of connector P1 Harness connector P1
(P1-8) CAT data link + (P1-8) CAT data link +
(P1-9) CAT data link − (P1-9) CAT data link −
(P1-63) -Battery
D. Fabricate a jumper wire that is the appropriate
length with Deutsch terminals on each end. G. Measure the resistance between the terminals
Connect the jumper wire between terminals P1-8 that are listed in Table 43. During each
and P1-9. measurement, wiggle the harness in order
Table 43
Connection Connector and Terminal
P1-63 P1-8
P1-9

Expected Result:
Results:

specifications. The wiring for the CAT data link
does not have an open circuit or a short circuit
to ground.

g00857947
Illustration 303 1. Verify that the suspect ICSM is receiving
Connector P83 the proper supply voltage. Refer to
E. Measure the resistance between terminal P83-J
and terminal P83-N. During the measurement,
wiggle the harness in order to check for an
intermittent problem. Be sure to wiggle the
harness near each of the connectors. The correct
382
2. If the suspect ICSM is receiving the correct

supply voltage and the original diagnostic
code is still active, there may be a problem
with the ICSM. It is unlikely that the ICSM
has failed. Exit this procedure and perform
this procedure again. If the problem is not
resolved, perform the following procedure:
Temporarily install a known good ICSM according

to Troubleshooting, “Replacing the ICSM”.

problem returns.
g00857873
If the new ICSM operates correctly and the Illustration 306
original ICSM does not operate correctly, replace ECM P1 connector
STOP.

is not within the specifications. The wiring for
the CAT data link has an open circuit or a short
circuit to ground. There may be a problem with a
connector.

necessary.
STOP.
Test Step 4. Check the Left Side CAT Data

Link for Continuity
A. Turn the engine control to the OFF/RESET
position. Switch the 16 amp circuit breaker for g00865266
Illustration 307
the ECM OFF. Left side of the engine
(1) ICSM
(2) Connector P73 for the CAT data link
C. Disconnect connectors P1 and P73.
g00857875
Illustration 305
Service tool connector J7
B. Disconnect the ET from connector J7.

383
g00857942 g00865258
ECM side of connector P1 Harness connector P1
(P1-8) CAT data link + (P1-8) CAT data link +
(P1-9) CAT data link − (P1-9) CAT data link −
(P1-63) -Battery
D. Fabricate a jumper wire that is the appropriate
length with Deutsch terminals on each end. G. Measure the resistance between the terminals
Connect the jumper wire between terminals P1-8 that are listed in Table 43. During each
and P1-9. measurement, wiggle the harness in order
Table 44
Connection Connector and Terminal
P1-63 P1-8
P1-9

Expected Result:
Results:

specifications. The wiring for the CAT data link
does not have an open circuit or a short circuit
to ground.

g00865288
Illustration 309 1. Verify that the suspect ICSM is receiving
Connector P73 the proper supply voltage. Refer to
E. Measure the resistance between terminal P73-J
and terminal P73-N. During the measurement, 2. If the suspect ICSM is receiving the correct
wiggle the harness in order to check for an supply voltage and the original diagnostic
intermittent problem. Be sure to wiggle the code is still active, there may be a problem
harness near each of the connectors. The correct with the ICSM. It is unlikely that the ICSM
resistance measurement is less than 5 ohms. has failed. Exit this procedure and perform
this procedure again. If the problem is not
F. Remove the jumper wire from connector P1. resolved, perform the following procedure:
384
Temporarily install a known good ICSM according i01653504

to Troubleshooting, “Replacing the ICSM”.
Prelubrication System
install the original ICSM. Verify that the problem SMCS Code: 1319-038
returns.
original ICSM does not operate correctly, replace The prelube pump will not operate if the emergency
the original ICSM. Refer to Troubleshooting, stop button is activated or if the engine speed is
“Replacing the ICSM”. greater than 0 rpm.
STOP. When the conditions permit operation and the logic

determines that lubrication is required, the ECM
• Not OK – At least one of the resistance checks provides +Battery voltage to the prelube pump’s
is not within the specifications. The wiring for solenoid. After activation, the prelube pump will
the CAT data link has an open circuit or a short operate until one of the following occurrences:
circuit to ground. There may be a problem with a
connector. • The prelube pressure switch closes.
Repair: Repair the harness or the connector, when • The programmable “Engine Pre-lube Time Out
possible. Replace the harness or the connector, if Period” expires.
necessary.
• The emergency stop button is pressed.
STOP.
The ECM monitors the prelube pressure switch
Test Step 5. Program the ICSM in order to verify lubrication of the engine prior to
start-up. The pressure switch is normally open.
The software in both of the Integrated Combustion
Sensing Modules must match. Use ET to flash the Before start-up, the pressure switch closes when
software from the ICSM that is known to be good the prelube pump raises the engine oil pressure
to the suspect ICSM. Refer to Troubleshooting, to 9 ± 3 kPa (1.3 ± 0.4 psi). After the pressure
“Replacing the ICSM”. Verify that the problem is switch closes, the prelube pump operates for the
resolved. programmable “Engine Pre-Lube Time Out Period”.
The engine starting sequence continues.
Expected Result:
If the ECM does not detect closure of the pressure
The 591-12 diagnostic code is not active. switch within the programmed period of time,
the ECM monitors the engine oil pressure sensor
Results: in order to determine whether lubrication has
occurred. If the prelubrication does not occur, an
• No code – Before the ICSM was programmed, “E233 Low Engine Prelube Pressure” event code is
there was a 591-12 diagnostic code. After the generated. The starting sequence is terminated.
ICSM was programmed, there was no 591-12
diagnostic code. Resume normal operation. At shutdown, the pressure switch opens when
STOP. the engine oil pressure is reduced to 9 ± 3 kPa
(1.3 ± 0.4 psi).
• Active 591-12 diagnostic code. – Before the
ICSM was programmed, there was an active Note: To troubleshoot the circuit for the prelube
591-12 diagnostic code. After the ICSM was pump’s solenoid, refer to Troubleshooting, “ECM
programmed, there was an active 591-12 Output Circuit (Prelubrication Oil Pump)”.
diagnostic code. The ICSM has failed.
The prelube pump can also be operated with
Repair: Replace the ICSM. Refer to a manual switch. When the switch is closed, a
Troubleshooting, “Replacing the ICSM”. +Battery signal is sent to the ECM. The ECM
provides +Battery voltage to the prelube pump’s
STOP. solenoid until the switch is released or until the
prelube pressure switch closes.
385
The prelubrication system also operates after

shutdown. This ensures that the turbocharger has
adequate lubrication during coastdown. When the
engine reaches 0 rpm, the output for the prelube
pump will operate for three minutes.
Before you troubleshoot the prelubrication system,

make sure that the ECM is programmed properly.
The “Engine Pre-Lube Time Out Period” must
be programmed to a value between 30 and 300
seconds. Make sure that the hardware is installed:
prelube pump, solenoid for the pump, prelube
pressure switch, and manual prelube switch. Make
sure that the wiring is installed. Refer to the engine’s
electrical Schematic.
If Caterpillar did not supply the prelubrication

system, the prelubrication function and the E233 (3)
event code are disabled. The 338-05, 338-06, and
339-05 diagnostic codes are disabled.


pressure switch. The least likely cause is a problem
with the ECM.

Clear the diagnostic codes after the problem is Illustration 311 g00853659
resolved.
g00853863
Illustration 312
(3) Terminal box’s J5/P5 connectors

the ECM OFF.
386

position.
B. Observe the “Diagnostics” screen on ET.

Determine whether the following diagnostic
codes are logged:
If there is an active “338-05 Prelube Relay

“Results” for this Test Step. Otherwise, continue
this procedure.
g00853871
Illustration 313
• 338-05 Pre-Lube Relay open circuit
Location of the prelube pressure switch
• 338-06 Prelube Relay short to ground
Troubleshooting, “Inspecting Electrical Connectors”. • 339-05 Engine Prelube Pressure Switch open
circuit
B. . Thoroughly inspect the following connectors:
Expected Result:
• ECM J1/P1
Neither of the diagnostic codes are logged.
• Terminal box J5/P5
Results:
• Connectors for the prelube pressure switch
• OK (No Codes) – None of the codes are logged.
connectors (P1) and (P5). The proper torque Repair: The problem seems to be resolved.
is 6 ± 1 N·m (55 ± 9 lb in). If there is an intermittent problem, refer
b. Perform a 45 N (10 lb) pull test on each of the Connectors”.
the prelube system. STOP.
c. Check the harness and wiring for abrasion • Not OK (Logged 339-05) – There is a logged
and pinch points from the prelube pressure 339-05 diagnostic code. Proceed to Test Step 3.
switch to the ECM.
• Not OK (Logged 338-05 or 338-06) – There is a
Expected Result: logged 338-05 or 338-06 diagnostic code.
All of the connectors, pins, and sockets are Repair: Refer to Troubleshooting, “ECM Output
connected properly. The connectors and the wiring Circuit (Prelubrication Oil Pump)”.
STOP.
Results:
Test Step 3. Check the Prelube Pressure
• OK – The components are in good condition with Switch
• Not OK – The components are not in good position. Switch the 16 amp circuit breaker for
condition and/or at least one connection is the ECM OFF.
improper.

STOP.
387
Expected Result:
When the prelube pump was OFF, the resistance

was greater than 20,000 ohms. When the prelube
pump was ON and the engine oil pressure rose to
9 ± 3 kPa (1.3 ± 0.4 psi), the resistance was less
than 5 ohms.
Results:
• Yes – When the prelube pump was OFF, the

resistance was greater than 20,000 ohms. When
the prelube pump was ON and the engine oil
pressure rose to 9 ± 3 kPa (1.3 ± 0.4 psi), the
g00854095
resistance was less than 5 ohms. The pressure
Illustration 314 switch is operating properly. There may be a
Prelube pressure switch problem in the engine harness.
(AA) Connector for the prelube pressure switch
(A) Switch input Repair: Turn the engine control switch to the
(B) Return OFF/RESET position. Switch the circuit breaker
(C) Unused
for the ECM OFF.
B. Disconnect the prelube pressure switch from the
Remove the pressure switch and the pressure
engine harness. Remove the prelube pressure
gauge from the tee. Remove the tee from the
switch from the cylinder block.
cylinder block’s port. Install the pressure switch
into the cylinder block’s port. Tighten the pressure
C. Install a tee that has 1/4-18 NPTF threads into
switch according to Specifications, RENR5907,
the cylinder block’s port for the pressure switch.
“Prelube Pressure Switch”.
If a tee cannot be installed into the port, install a
flexible hose that has the appropriate fitting into
the port and attach the tee to the hose.
• No – At least one of the resistance measurements
is not correct. The contacts of the prelube
Install the pressure switch into one side of the
pressure switch are stuck in the closed position
tee. Attach a pressure gauge to the other side
or the open position.
of the tee.
D. Connect an ohmmeter between terminals (A) and
OFF/RESET position. Switch the circuit breaker
(B) on the pressure switch’s connector. Measure
for the ECM OFF.
the resistance between terminals (A) and (B)
on the pressure switch’s connector. Wiggle the
Remove the pressure switch and the pressure
switch’s harness as you measure the resistance
gauge from the tee. Remove the tee from the
cylinder block’s port.
the harness.
Install a new prelube pressure switch. Tighten
the pressure switch according to Specifications,
RENR5907, “Prelube Pressure Switch”. Connect
position. Manually operate the prelube pump.
the engine harness to the switch.
Press the “Manual Prelube” switch on the control
panel (if equipped). Make sure that the prelube
STOP.
pump operates.
F. Observe the pressure gauge. Look for a rise • No – The engine oil pressure did not rise to
9 ± 3 kPa (1.3 ± 0.4 psi) when the prelube pump
in the engine oil pressure. When the engine
was ON. The engine oil is blocked from the
oil pressure rises to 9 ± 3 kPa (1.3 ± 0.4 psi),
passages to the port for the pressure switch.
measure the resistance between terminals (A)
and (B) on the pressure switch’s connector.
Wiggle the switch’s harness as you measure the
OFF/RESET position. Switch the circuit breaker
resistance in order to check for an intermittent
for the ECM OFF.
problem with the harness.
G. Turn OFF the prelube pump.

388
Determine the cause of the obstruction in the Results:

passages for the engine oil. Make the necessary
repairs. • OK – The resistance is less than 5 ohms. The
engine harness seems to be OK. There may be
STOP. a problem in the terminal box. Proceed to Test
Step 5.
• Not OK – The resistance is greater than 5 ohms.
A. Make sure that the engine control switch is in the There is a problem with a connection or the
OFF/RESET position and that the 16 amp circuit wiring in the engine harness between the P5
breaker for the ECM is OFF. connector and the connector for the prelube
pressure switch.
Repair: Repair the connector(s) and/or the wiring,

STOP.
Test Step 5. Check the Terminal Box

A. Make sure that the engine control switch is in the
g00854167
Illustration 315
(AA) Engine harness connector for the prelube pressure switch
(A) Switch input
(B) Return
(C) Unused
(BB) Terminal box’s side of the engine harness P5 connector
(P5-56) Return
(P5-69) Switch input
B. Disconnect the terminal box P5 connector.
C. Install a jumper wire with the appropriate

terminals into terminals “A” and “B” of the engine
harness connector for the pressure switch.
D. Use an ohmmeter to measure the resistance

between terminals (P5-56) and (P5-69) on the
terminal box’s side of the connector. Wiggle the
engine harness as you measure the resistance
in order to check for an intermittent problem. Be
sure to wiggle the harness near the connectors.
Expected Result:

389
Expected Result:
The continuity for both of the measurements is less

than 5 ohms.
Results:
• Yes – The continuity for both of the measurements

is less than 5 ohms. The prelube pressure switch,
the engine harness, and the wiring in the terminal
box seem to be OK. There may be a problem
with the ECM.

Reconnect the P1 connector to the ECM.
Reconnect the engine harness P5 connector to
the terminal box. Reconnect the prelube pressure
switch to the engine harness.

again. If the condition is not resolved, replace the
ECM according to Troubleshooting, “Replacing
the ECM”. Verify that the problem is resolved.
STOP.
• Not OK – The continuity for one or both of the

measurements is greater than 5 ohms. There is a
problem with a connector or the wiring between
the P1 connector and the J6 connector.
Repair: Turn the engine control switch to the OFF

the ECM OFF. Repair the connector(s) and/or the
wiring, when possible. Replace the connector(s)
and/or the wiring, if necessary.
STOP.
i01631130
g00854193
Illustration 316
PWM Sensor
ECM side of the P1 connector and terminal box’s J5 connector for
the right engine harness
SMCS Code: 1901-038
(P1-30) Switch input
(P1-31) Return
(J5-56) Return
(J5-69) Switch input
The engine coolant pressure sensor is a PWM
B. Disconnect the ECM P1 connector. sensor. A Pulse Width Modulated sensor (PWM)
produces a digital signal. In a digital signal, the
C. Use an ohmmeter to measure the continuity duty cycle varies as the input condition changes.
between the terminals (P1-30) and (J5-69). The frequency remains constant. Refer to illustration
Wiggle the harness as you measure the continuity 317.
in order to check for an intermittent problem.
D. Use an ohmmeter to measure the continuity

between terminals (P1-31) and (J5-56). Wiggle
the harness as you measure the continuity in
order to check for an intermittent problem.
390
g00852792
Illustration 317
Sample duty cycles that are low, medium, and high.
Note: Excessive pressure can generate false “noisy

signal” 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, the code will be generated.
If a “109-08” diagnostic code is generated, measure

the absolute pressure with a pressure gauge before
you troubleshoot the sensor. If the pressure is
actually too high, reduce the pressure in order
to avoid the false diagnostic codes from being
activated.
The “109-03” diagnostic code is probably caused

by a problem with an electrical connector or a
a sensor. The least likely cause is a problem with
the ECM.

391
g00844963
Illustration 318
Schematic of the circuit for the PWM sensor
The PWM sensor is connected to the ECM via the J5/P5 connector on the terminal box.


g00871201
Illustration 320
Right side and top view of the engine
(3) PWM sensor
(4) J215/P215 connector for the PWM sensor

connectors:
Illustration 319
g00844981 • J2/P2 connectors for the ECM
(2) J5/P5 connectors for the harness on the right side of the engine • J5/P5 connectors on the terminal box
• (J215/P215) connectors for the sensor
a. Check the torque of the Allen head screw
for J2/P2 and J5/P5. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).
392

improper.

STOP.
Test Step 2. Check for Active “8 Volt DC

Supply” Diagnostic Codes
terminal box. Switch the circuit breaker for the
g00844989 ECM ON. Turn the engine control switch to the
Illustration 321
STOP position.
(P2-65) +8 Volt supply B. Observe the “Active Diagnostic” screen on ET.
(P2-66) Return Allow a minimum of thirty seconds for any codes
(P2-68) Signal for the engine coolant pressure to activate. Look for these codes:
• 41-03 8 Volt DC Supply short to +batt

Expected Result:
There are no active “8 Volt DC Supply” diagnostic

codes.
Results:
• No codes – There are no active “8 Volt DC

Supply” diagnostic codes. Proceed to Test Step 3.
• Active code – There is an active “8 Volt DC

g00844994 Supply” diagnostic code. This procedure will not
Illustration 322
work when this type of code is active.
(P5-11) Shield Repair: Refer to Troubleshooting, “+8 V Sensor
(P5-21) Return Voltage Supply”.
(P5-29) Signal for the engine coolant pressure
(P5-37) +8 Volt supply
STOP.
b. Perform a 45 N (10 lb) pull test on each of
the wires that are associated with the circuit Test Step 3. Check for Active Diagnostic
for the PWM sensor. Codes for the PWM Sensors
c. Thoroughly check the harness and wiring for A. Turn on the “Active Diagnostic” screen on ET.
abrasion and pinch points from the sensor Determine if any of these diagnostic codes are
to the ECM. active:
Expected Result: • 109-03 Coolant Outlet Pressure open/short to

+batt
connected properly. The connectors and the wiring • 109-08 Engine Coolant Outlet Pressure noisy
are free of corrosion, abrasion, and pinch points. signal
Results: Expected Result:
• OK – The components are in good condition with One of the above codes is active.
393
Results:
• Yes – At least one of the above diagnostic codes

is active. Proceed to Test Step 4.
• No – None of the above codes are active.

Repair: If any of the above codes are logged
and the engine is not running properly, refer
Diagnostic Code”.
If the engine is running properly at this time,

there may be an intermittent problem in the
harness that is causing the codes to be logged. g00852837
Refer to Troubleshooting, “Inspecting Electrical Illustration 324
Connectors”. Harness connector J215
(J215-A) +8 Volt supply
STOP. (J215-B) Return
(J215-C) Signal
Test Step 4. Check the Supply Voltage at
the Sensor D. Measure the voltage between J215 terminals (A)
and (B).
position. Switch the 16 amp circuit breaker for Expected Result:
the ECM OFF.
The voltage is 8.0 ± 0.8 VDC.
Results:
• OK – The voltage is within the specification. The

correct voltage is available to the sensor. Proceed
to Test Step 5.
• Not OK – The voltage is not within the

specification. The correct supply voltage is not
available to the sensor. There is probably an open
circuit or a short circuit in a harness between the
ECM and the J215 connector. Proceed to Test
Step 9.
Test Step 5. Check the Pull-Up Voltage at

the Sensor
g00845338
Illustration 323
Right side and top view of the engine
(1) PWM sensor
(2) J215/P215 connectors for the sensor
B. Disconnect connector (J215) from the engine

coolant pressure sensor.

Illustration 325
position. Harness connector J215
(J215-A) +8 Volt supply
(J215-B) Return
(J215-C) Signal
394
A. Measure the voltage between J215 terminals (B) Repair: Perform the following procedure:
and (C).
Expected Result: OFF/RESET position. Switch the 16 amp circuit
2. Remove the adapter cable.
Results:
3. Reconnect the sensor to the harness.
pull-up voltage that is created by the ECM is Proceed to Test Step 7.
present at the sensor connector. The signal wire
appears to be OK. Proceed to Test Step 6. • Not OK – The sensor signal is not within the
specifications. The sensor is receiving the correct
• Not OK - Low voltage – The voltage is less than supply voltage but the sensor is not producing
6.0 VDC. The signal wire has an open circuit or a a valid signal.
short to ground. The ECM may have a problem.
Proceed to Test Step 10. Repair: Perform the following procedure:
• Not OK - High voltage – The voltage is above 10.0 1. Thoroughly inspect the connectors J215
VDC. The signal wire may have a short circuit to and P215 for moisture and corrosion. Refer
a positive voltage source. The ECM may have a to Troubleshooting, “Inspecting Electrical
problem. Proceed to Test Step 14. Connectors”.
Test Step 6. Check the Sensor Signal at 2. Check the frequency and the duty cycle of the
the Sensor sensor signal again.
A. Turn the engine control switch to the OFF/RESET 3. If the frequency and the duty cycle of the
position. Switch the 16 amp circuit breaker for sensor signal are incorrect, disconnect the
the ECM OFF. sensor. Connect a sensor that is known to be
good. Do not install the new sensor into the
B. Install an 8T-8726 Adapter Cable (3 Pin engine yet.
Breakout) between the J215 and P215
connectors. 4. Switch the 16 amp circuit breaker for the ECM
C. Use a multimeter that is capable of measuring STOP position.
both the duty cycle and the frequency. Connect
the multimeter to terminal C (signal) and terminal 5. Check for an active diagnostic code for the
B (return) of the breakout t. PWM sensor. If the code is not active for the
new sensor, install the sensor into the engine.
D. Turn the engine control switch to the STOP Clear any logged diagnostic codes. Verify that
position. Switch the 16 amp circuit breaker for the problem is resolved.
the ECM ON.
STOP.
E. Measure the duty cycle and the frequency of the
sensor.
Expected Result:
The frequency is between 400 and 600 Hz.
The duty cycle is between 5 and 95 percent.
Record the values of the frequency and the duty

cycle.
Results:
• OK – The frequency and the duty cycle are within

the specifications. The sensor is creating a valid
signal.
395
Test Step 7. Check the Sensor’s Signal • Not OK – The frequency or the duty cycle of the
at the Terminal Box signal are not within the specifications. The signal
that is developed by the sensor is not present at
the ECM. The signal wire in the engine harness
has a problem. There may be a problem with a
connector.

STOP.
Test Step 8. Check the Sensor’s Signal

at the ECM
the ECM OFF.
g00866149
Illustration 326
Harness side of connector P5
A. Insert two 7X-1710 Multimeter Probes into the

harness side of the P5 connector. Insert the first
probe into terminal 29. Insert the second probe
into terminal 21.
B. Connect a multimeter to the probes.

position.
D. Measure the frequency and the duty cycle of

the signal.
Expected Result:
The duty cycle is between 5 and 95 percent.

g00866171
Illustration 327
The frequency and the duty cycle should be
Harness side of ECM connector P2
approximately equal to the values that were
recorded.
B. Insert two 7X-1710 Multimeter Probes into the
Results: harness side of the P2 connector. Insert the first
into terminal 66.
• OK – The frequency and the duty cycle of the
signal are within the specifications. The signal
that is developed by the sensor is present at the C. Connect the multimeter leads to the probes.
terminal box. The engine harness appears to be
OK. There may be a problem with a connector or D. Switch the 16 amp circuit breaker for the ECM
the harness inside the terminal box. There may be ON. Turn the engine control switch to the STOP
a problem with the ECM. Proceed to Test Step 8. position.
E. Measure the frequency and the duty cycle of

the signal.
396
Expected Result: Test Step 9. Check the Sensor Supply

Voltage at the Terminal Box
The duty cycle is between 5 and 95 percent. position. Switch the 16 amp circuit breaker for
the ECM OFF.
The frequency and the duty cycle should be
approximately equal to the values that were
recorded.
Results:
• OK – The frequency and the duty cycle of the

signal are within the specifications. The signal
that is developed by the sensor is present at the
ECM. The connectors and the harness inside the
terminal box appear to be OK. There may be a

Perform the following procedure:

2. Remove the probes from connector P2.

g00866184
Illustration 328
again. If the problem is not resolved, temporarily
install a new ECM. Refer to Troubleshooting,
B. Insert two 7X-1710 Multimeter Probes into the
harness side of the P5 connector. Insert the first
into terminal 21.
C. Connect the multimeter leads to the probes.
position.
Clear any logged diagnostic codes. Verify that
E. Measure the voltage on the terminals.
STOP.
Expected Result:
• Not OK – The frequency or the duty cycle of the The voltage is 8.0 ± 0.8 VDC.
signal are not within the specifications. The signal
that is developed by the sensor is not present at
Results:
the ECM. There is a problem with the harness
inside the terminal box. There may be a problem
with a connector. • OK – The sensor voltage supply is present at
the terminal box. The engine harness appears to
have a problem. There may be a problem with a
connector.
Repair: Repair the engine harness or the
STOP.
connector, when possible. Replace the harness, if
necessary.
STOP.
397
• Not OK – The sensor voltage supply is not

present at the terminal box. The harness inside
the terminal box appears to have a problem.

STOP.
Test Step 10. Check the Pull-Up Voltage

at the Terminal Box
the ECM OFF.
g00866221
Illustration 330
C. Fabricate a jumper wire with Deutsch sockets on

the ends. Insert one end of the jumper wire into
the open terminal of the P5 connector. Pull on the
jumper wire in order to verify proper installation
of the terminal.
D. Connect a multimeter lead to the end of the

E. Insert a 7X-1710 Multimeter Probe into terminal

21 of the P5 connector.
F. Connect the other multimeter lead to the probe.

g00866219
Illustration 329
Harness side of connector P5 G. Switch the 16 amp circuit breaker for the ECM
B. Use a 151-6320 Wire Removal Tool to remove position.
terminal 29 from the P5 connector.
H. Measure the voltage.
Expected Result:
Results:

pull-up voltage is present at the P5 connector.
The signal wire inside the engine harness has an
open circuit or a short to ground.

the ECM OFF.
Remove both of the multimeter probes from the

P5 connector.
398
Reinstall the terminal that was removed from A. Use a 151-6320 Wire Removal Tool to remove
connector P5. Pull on the wire in order to verify terminal 68 from the P2 connector.

specification. The pull-up voltage is not present at
the P5 connector. There may be a problem with a
connector or the harness inside the terminal box.
There may be a problem with the ECM.

the ECM OFF.
Disconnect the multimeter leads.

the jumper wire from the terminal box’s connector.
Reinstall the terminal that was removed from

connector P5. Pull on the wire in order to verify
Test Step 11. Measure the Pull-Up Voltage g00866263

at the ECM Illustration 332
B. Fabricate a jumper wire with Deutsch sockets on

the ends. Insert one end of the jumper wire into
the open terminal of the P2 connector. Pull on the
jumper wire in order to verify proper installation
of the terminal.
C. Connect a multimeter lead to the end of the

D. Insert a 7X-1710 Multimeter Probe into terminal

E. Connect the other multimeter lead to the probe.

position.
G. Measure the pull-up voltage.
Expected Result:
g00866257
Illustration 331
399
Results: Test Step 12. Measure the Resistance of

the Signal Wire Inside the Terminal Box
pull-up voltage is present at the P2 connector. A. Disconnect the P2 connector.
The ECM appears to be OK. The signal wire
inside the terminal box has an open circuit or a
short to ground.

the ECM OFF.

the jumper wire from the ECM connector.


specification. The pull-up voltage is not present
at the P2 connector. The ECM appears to have
a problem.

g00866283
Turn the engine control switch to the OFF/RESET Illustration 333
position. Switch the 16 amp circuit breaker for Terminal box and harness connector P2
the ECM OFF. (1) ECM ground strap
(2) Harness side of the P2 connector
B. Measure the resistance from the ECM ground
Use a 151-6320 Wire Removal Tool to remove strap to terminal 68 of harness connector P2.
the jumper wire from the ECM connector.
Expected Result:
connector P2. Pull on the wire in order to verify The resistance is greater than 20,000 ohms.
Results:
procedure and perform this procedure again. If • OK – The resistance is greater than 20,000 ohms.
the problem is not resolved, temporarily install a The signal wire inside the terminal box does not
new ECM. Refer to Troubleshooting, “Replacing have a short to ground. The signal wire inside the
the ECM”. terminal box has an open circuit. There may be a
problem with a connector.
install the original ECM and verify that the Repair: Repair the harness or the connector, when
problem returns. If the new ECM operates possible. Replace the harness, if necessary.
correctly, replace the original ECM. Refer to STOP.
STOP. ohms. The signal wire inside the terminal box
has a short to ground. There could be a problem
with a connector.
400
Repair: Repair the harness or the connector, when Repair: Repair the harness or the connector, when
possible. Replace the harness, if necessary. possible. Replace the harness, if necessary.
STOP. STOP.
Test Step 13. Measure the Resistance • Not OK – The resistance is less than 20,000
of the Signal Wire Inside the Engine ohms. The signal wire inside the terminal box
Harness has a short to ground. There could be a problem
with a connector.
A. Verify that the P2 connector has been
reconnected. Disconnect the P5 connector. Repair: Repair the harness or the connector, when
STOP.
Test Step 14. Check the Pull-Up Voltage

at the Terminal Box
the ECM OFF.
g00866324
Illustration 334
Terminal box and harness connector P5
(1) ECM ground strap
(2) Terminal box’s side of the P5 connector g00866219
Illustration 335
B. Measure the resistance from the ECM ground
strap to terminal 29 of harness connector P5. B. Use a 151-6320 Wire Removal Tool to remove
terminal 29 from the P5 connector.
Expected Result:
Results:
• OK – The resistance is greater than 20,000 ohms.

The signal wire inside the engine harness does
not have a short to ground. The signal wire inside
the engine harness has an open circuit. There
could be a problem with a connector.
401

the jumper wire from the terminal box’s connector.

Repair the harness or the connector, when

STOP.

specification. The pull-up voltage is not present at
the P5 connector. There may be a problem with a
connector or the harness inside the terminal box.
The ECM may have a problem.

Illustration 336 g00866221 position. Switch the 16 amp circuit breaker for
the ECM OFF.
C. Insert one end of a jumper wire into the open Disconnect the multimeter leads.
terminal of the P5 connector. Pull on the jumper
wire in order to verify proper installation of the Use a 151-6320 Wire Removal Tool to remove
terminal. the jumper wire from the terminal box’s connector.
D. Connect a multimeter lead to the end of the Reinstall the terminal that was removed from
jumper wire that is not inserted into the connector. connector P5. Pull on the wire in order to verify
E. Insert a 7X-1710 Multimeter Probe into terminal
21 of the P5 connector. Proceed to Test Step 15.
F. Connect the other multimeter lead to the probe.
G. Switch the 16 amp circuit breaker for the ECM

position.
H. Measure the voltage.
Expected Result:
Results:

pull-up voltage is present at the P5 connector.
The signal wire inside the engine harness has a
short circuit to a positive voltage source. There
could be a problem with a connector.

the ECM OFF.

402
Test Step 15. Measure the Pull-Up Voltage

at the ECM
g00866263
Illustration 338
g00866257
Illustration 337
Harness side of connector P2 B. Insert one end of a jumper wire into the open
terminal of the P2 connector. Pull on the jumper
A. Use a 151-6320 Wire Removal Tool to remove wire in order to verify proper installation of the
terminal 68 from the P2 connector. terminal.
C. Connect a multimeter lead to the end of the

D. Insert a 7X-1710 Multimeter Probe into terminal

E. Connect the other multimeter lead to the probe.

position.
G. Measure the voltage.
Expected Result:

403
Results: If the problem is resolved with the new ECM,

• OK – The voltage is within the specification. The problem returns. If the new ECM operates
pull-up voltage is present at the P2 connector. correctly and the original ECM does not operate
The ECM appears to be OK. The signal wire correctly, replace the original ECM. Refer to
inside the terminal box has a short circuit to a Troubleshooting, “Replacing the ECM”.
positive voltage source. There may be a problem
with a connector. STOP.

i01653028

Thermocouple Test
the ECM OFF. SMCS Code: 7498-038
Disconnect the multimeter leads. System Operation Description:
Use a 151-6320 Wire Removal Tool to remove Use this procedure to troubleshoot thermocouples
the jumper wire from the P2 connector. that have diagnostic codes which are active or
easily repeated.
connector P2. Pull on the wire in order to verify A thermocouple is installed into the exhaust port of
proper installation of the terminal. each engine cylinder, the inlet for each turbocharger
turbine, and the outlet for each turbocharger turbine.
Repair the terminal box’s harness or the
connector, when possible. Replace the terminal The thermocouples do not require a supply voltage
box’s harness, if necessary. from the ICSM. Each thermocouple has two wires.
Each thermocouple develops a low voltage signal
STOP. that is detected by the ICSM.
• Not OK – The voltage is not within the A -03 diagnostic code may be caused by a
specification. The incorrect pull-up voltage is thermocouple wire that has a short circuit to a high
present at the P2 connector. The ECM appears voltage. A -03 diagnostic code may also occur if
to have a problem. the thermocouple’s voltage is above an acceptable
range.
A -04 diagnostic code may be caused by a
Disconnect the multimeter leads. thermocouple wire that has a short circuit to a low
voltage. A -04 diagnostic code may also occur if
Use a 151-6320 Wire Removal Tool to remove the thermocouple has a short to ground.
A -05 diagnostic code may be caused by a
Reinstall the terminal that was removed from thermocouple’s circuit that has a low current flow.
connector P2. Pull on the wire in order to verify A -05 diagnostic code may also occur if there is
proper installation of the terminal. an open circuit.
Turn the engine control switch to the OFF/RESET A diagnostic code is probably caused by a problem
position. Switch the 16 amp circuit breaker for with a harness connector or a wiring problem. The
the ECM OFF. next likely cause is a faulty thermocouple. The least
likely cause is a problem with the ICSM.
procedure and perform this procedure again. If Logged diagnostic codes provide an historical
the problem is not resolved, temporarily install a record. Before you begin this procedure, use ET to
new ECM. Refer to Troubleshooting, “Replacing print the logged codes to a file.
the ECM”.
resolved.
404
g00866013
Illustration 339
Schematic for the circuit of the thermocouples for the 12 cylinder engine
405
g00853564
Illustration 340
Schematic for the circuit of the thermocouples for the 16 cylinder engine

the ECM OFF.

Note: Illustrations 341 and 342 show one side of the

engine. The other side of the engine is similar.
406
g00853835
Illustration 341
(1) ICSM
(2) 20-pin connector P72 for the thermocouples
g00853840
Illustration 342
Right side view of the engine
(3) Thermocouple for the outlet of the turbocharger turbine
(4) Thermocouple for the inlet of the turbocharger turbine
(5) Thermocouple for the exhaust port of a cylinder
(6) Connector for the thermocouple for the turbocharger inlet
(7) Connector for the thermocouple for the turbocharger outlet
(8) Connector for the thermocouple for the exhaust port
(9) Thermocouple harness to the ICSM
B. Thoroughly inspect the following connectors for

moisture, corrosion, and contamination:
• 20-pin connectors on the Integrated

Combustion Sensing Modules
• Connectors for the thermocouple

C. Verify that all of the connectors are completely
connected. Verify that terminals in the suspect
thermocouple’s connector are completely
inserted into the connector.
D. Check the harness and wiring for abrasion and

pinch points from the suspect thermocouple to
the ICSM.
407
Expected Result: Table 45

Diagnostic Code Description
All of the connectors are free of moisture, corrosion
and contamination. All of the connectors are 1489-03 “Left Turbo Turbine Out Temp Sens
completely connected. The terminals in the suspect short to +batt”
thermocouple’s connector are completely inserted 1489-04 “Left Turbo Turbine Out Temp Sens
into the connector. The harness and wiring are free short to Ground”
of corrosion, abrasion and pinch points.
1489-05 “Left Turbo Turbine Out Temp Sens
Results: open circuit”
1490-03 “Right Turbo Turbine Out Temp
• OK – The components are in good condition with Sens short to +batt”
Sens short to ground”
condition and/or at least one connection is 1490-05 “Right Turbo Turbine Out Temp
improper. Sens open circuit”
Repair: Perform the necessary repairs and/or Sens short to +batt”
replace parts, if necessary. Verify that the repair
eliminates the problem. 1491-04 “Right Turbo Turbine Out Temp
Sens short to ground”
STOP. 1491-05 “Right Turbo Turbine Out Temp
Sens open circuit”
A. Switch the 16 amp circuit breaker for the ECM short to +batt”
ON. Turn the engine control switch to the STOP 1492-04 “Left Turbo Turbine Out Temp Sens
position. short to ground”
B. Observe the “Active Diagnostic” screen on ET.
open circuit”
become activated. Look for the codes that are 1531-03 through “Cylinder #1 Exhaust Port Temp
listed in Table 45: 1546-03 Sensor sort to +batt” through
“Cylinder #16 Exhaust Port Temp
Sensor sort to +batt”
1531-04 through “Cylinder #1 Exhaust Port Temp
1546-04 Sensor short to ground” through
Sensor short to ground”
1531-05 through “Cylinder #1 Exhaust Port Temp
1546-05 Sensor open circuit” through
Sensor open circuit”
Expected Result:
None of the above codes are active.
Results:
• No active codes – The problem seems to be

resolved. There are no active codes. The
thermocouples are operating correctly at this time.

of the harness connectors. Resume normal
operation.
STOP.
408
• Active 03 “short to +batt” – There is an active 5. Observe the “Active Diagnostic” screen on
“short to +batt” diagnostic code. Proceed to Test ET. Wait at least 30 seconds so that any
Step 3. codes may become activated. If the active
“short circuit” diagnostic code recurs, the
• Active 04 “short to ground” – There is an active thermocouple is the source of the problem.
“short to ground” diagnostic code. Proceed to
Test Step 3. 6. Turn the engine control switch to the
• Active 05 “open circuit” – There is an active “open breaker for the ECM OFF.
circuit” diagnostic code. Proceed to Test Step 4.
7. Temporarily connect a new thermocouple to
Test Step 3. Disconnect the Sensor in the harness. Do not install the thermocouple
Order to Create an Open Circuit onto the engine.
A. Turn the engine control switch to the OFF/RESET 8. Switch the 16 amp circuit breaker for the ECM
position. Switch the 16 amp circuit breaker for ON. Turn the engine control switch to the
the ECM OFF. STOP position.
B. Disconnect the thermocouple that has the short 9. Observe the “Active Diagnostic” screen on
circuit diagnostic code. ET. Wait at least 30 seconds so that any
codes may become activated. If the active
C. Switch the 16 amp circuit breaker for the ECM “short circuit” diagnostic code does not recur,
ON. Turn the engine control switch to the STOP replace the thermocouple. The correct torque
position. for a thermocouple is 12 ± 3 N·m (9 ± 2 lb ft).
Clear all of the logged diagnostic codes. Verify
D. Observe the “Active Diagnostic” screen on ET. that the problem is resolved.
become activated. STOP.
Expected Result: • Not OK – Before the suspect thermocouple was

disconnected, there was an active “short circuit”
An open circuit diagnostic code was generated for diagnostic code. After the thermocouple was
the suspect thermocouple. disconnected, the active “short circuit” diagnostic
code remained. If the problem is on the left
Results: side of the engine, proceed to Test Step 5. If
the problem is on the right side of the engine,
• OK – Before the suspect thermocouple was proceed to Test Step 6.
disconnected, there was an active “short circuit”
diagnostic code. After the thermocouple was Test Step 4. Create a Short Circuit at the
disconnected, there was an active “open circuit” Connector for the Thermocouple
diagnostic code.
Repair: Perform the following procedure: ON. Turn the engine control switch to the STOP
position.
OFF/RESET position. Switch the 16 amp circuit B. Fabricate a jumper wire with the appropriate
breaker for the ECM OFF. terminals on each end.
2. Thoroughly inspect the thermocouple’s Note: Observe the “Active Diagnostic” screen on ET
connectors for moisture. Inspect the seals for before installing the jumper wire and after installing
the connectors. the jumper wire.
3. Reconnect the thermocouple to the harness.

STOP position.
409
• Not OK – A “short circuit” diagnostic code is not

active when the jumper wire is connected. The
“open circuit” diagnostic code remains active
at all times. The engine harness or the ICSM
appears to have a problem. If the problem is on
the left side of the engine, proceed to Test Step 5.
If the problem is on the right side of the engine,
Test Step 5. Check the Operation of the

Left Side ICSM
g00853960 the ECM OFF.
Illustration 343
Harness connectors for the thermocouples
(2) Negative wire for the turbocharger’s thermocouple
(1) Positive wire for the turbocharger’s thermocouple
(A) Negative wire for the exhaust port’s thermocouple
(B) Positive wire for the exhaust port’s thermocouple
(C) This terminal is not used.
C. Create a short circuit by inserting the jumper

wire into the harness connector for the suspect
thermocouple. If the connector has two terminals,
insert one end of the jumper wire into each
terminal. If the connector has three terminals,
insert one end of the jumper wire into terminal
(A) and insert the other end of the jumper wire
into terminal (B). The jumper wire must remain
connected in this manner for at least 30 seconds.
D. Remove the jumper wire from the engine

harness. The jumper wire must be removed for
at least 30 seconds.
g00853835
Expected Result: Illustration 344
View of the center of the left side of the engine
A “short circuit” diagnostic code becomes active (1) ICSM
when the jumper wire is connected to the engine (2) 20-pin connector P72 for the thermocouples on the left side
harness for 30 seconds. An “open circuit” diagnostic of the engine
code becomes active when the jumper wire is
removed from the engine harness for 30 seconds. B. Disconnect connector (P72) from the ICSM.
Thoroughly inspect connectors P72 and J72 for
Results: moisture, corrosion, and contamination.
• OK – A “short circuit” diagnostic code becomes Note: When P72 is disconnected from the
active when the jumper wire is connected. An ICSM, numerous “open circuit” codes for the
“open circuit” diagnostic code becomes active thermocouples will become active. Keep your
when the jumper wire is removed. The engine mind on the diagnostic code for the suspect
harness and the ICSM appear to be functioning thermocouple.
properly.
Repair: To verify that the thermocouple is faulty, ON. Turn the engine control switch to the STOP
reconnect the suspect thermocouple for at least position.
30 seconds. If the “open circuit” diagnostic code
returns, replace the thermocouple. Tighten the Wait at least 30 seconds so that any codes may
new thermocouple to 12 ± 3 N·m (9 ± 2 lb ft). become activated. “Open circuit” diagnostic
Verify that the new thermocouple does not create codes for the thermocouples on the left side of
a diagnostic code. the engine should activate. An “open circuit”
diagnostic code for the suspect thermocouple
STOP. should also be activated.
410
D. Turn the engine control switch to the OFF/RESET

the ECM OFF.
E. Refer to Table 46 for the terminal locations for the

12 cylinder engine and the 16 cylinder engine.
Determine the positive terminal and the negative
terminal for the suspect thermocouple.
Table 46
20-Pin Cylinder Number or Turbocharger
Connector
Terminal 12 Cylinder 16 Cylinder
J72 Left Bank Left Bank
B + 2 2
C -
M + 4 4
N -
P + 6 6
D -
F + 8 8
E -
H + 10 10
G -
R + 12 12
Q -
V + N/A 14
- g00854298
U Illustration 345
+ 20-pin connector J72 for the ICSM

A N/A 16
L - F. Connect one end of a jumper wire to the
+ appropriate positive terminal on connector J72.
K Inlet for the Inlet for the
Turbocharger Turbocharger Connect the other end of the jumper wire to the
T - appropriate negative terminal on connector J72.
Turbine Turbine
J + Outlet for the Outlet for the G. Switch the 16 amp circuit breaker for the ECM
Turbocharger Turbocharger ON. Turn the engine control switch to the STOP
S -
Turbine Turbine position. Wait at least 30 seconds so that any
codes may become activated. A “short circuit”
diagnostic code for the suspect sensor should
be activated.
Expected Result:
An “open circuit” diagnostic code for the suspect

thermocouple is activated when P72 is disconnected
from the ICSM. A “short circuit” diagnostic code
becomes active when the jumper wire is connected
for at least 30 seconds.
411
Results:
• OK – Active diagnostic codes are created

according to the above steps. The ICSM appears
to be working properly. There appears to be
a problem with the left side harness for the
thermocouples.
Repair: Repair any faulty wiring and/or connectors,

when possible. Replace any faulty wiring and/or
connectors, if necessary. Clear any diagnostic
codes. Verify that the condition is resolved.
STOP.
• Not OK – Active diagnostic codes are not created

according to the above steps. The ICSM does
not respond properly when connector P72 is
removed and when the jumper wire is connected.
The ICSM may have a problem.
Repair: It is unlikely that the ICSM has failed. Illustration 346 g00854335
Exit this procedure and perform this procedure View of the center of the right side of the engine
(1) ICSM
following procedure: (2) 20-pin connector P82 for the thermocouples on the right side
of the engine
Temporarily install a new ICSM. Refer to
Troubleshooting, “Replacing the ICSM”. B. Disconnect connector P82 from the ICSM.
Thoroughly inspect connectors P82 and J82 for
If the problem is resolved with a new ICSM, install moisture, corrosion, and contamination.
the original ICSM and verify that the problem
returns. If the new ICSM operates correctly and Note: When P82 is disconnected from the
the original ICSM does not work correctly, replace ICSM, numerous “open circuit” codes for the
the original ICSM. Refer to Troubleshooting, thermocouples will become active. Keep your
“Replacing the ICSM”. mind on the diagnostic code for the suspect
thermocouple.
STOP.
Test Step 6. Check the Operation of the ON. Turn the engine control switch to the STOP
Right Side ICSM position. Wait at least 30 seconds so that any
codes may become activated. “Open circuit”
A. Turn the engine control switch to the OFF/RESET diagnostic codes for the thermocouples on the
position. Switch the 16 amp circuit breaker for right side of the engine should activate. An
the ECM OFF. “open circuit” diagnostic code for the suspect
thermocouple should also be activated.
D. Turn the engine control switch to the OFF/RESET

the ECM OFF.
E. Refer to Table 47 for the terminal locations for the

12 cylinder engine and the 16 cylinder engine.
Determine the positive terminal and the negative
terminal for the suspect thermocouple.
412
Table 47
20-Pin Cylinder Number or Turbocharger
Connector
J82 12 Cylinder 16 Cylinder
Terminal Right Bank Right Bank
B + 1 1
C -
M + 3 3
N -
P + 5 5
D -
F + 7 7
E -
H + 9 9
G -
R + 11 11
Q -
V + N/A 13
U -
A + N/A 15
L -
K + Inlet for the Inlet for the

Turbocharger Turbocharger
T -
Turbine Turbine
J + Outlet for the Outlet for the
g00854356
Turbocharger Turbocharger Illustration 347
S -
Turbine Turbine 20-pin connector J82 on the ICSM
F. Connect one end of a jumper wire to the

appropriate positive terminal on connector J82.
Connect the other end of the jumper wire to the
appropriate negative terminal on connector J82.
G. Switch the 16 amp circuit breaker for the ECM

position. Wait at least 30 seconds so that any
codes may become activated. An active “short
circuit” diagnostic code for the suspect sensor
should be activated.
Expected Result:
An “open circuit” diagnostic code for the suspect

thermocouple is activated when P82 is disconnected
from the ICSM. A “short circuit” diagnostic code
becomes active when the jumper wire is connected
for at least 30 seconds.
413
Results: Logged diagnostic codes provide an historical

• OK – Active diagnostic codes are created print logged codes to a file.
according to the above steps. The ICSM appears
to be working properly. There appears to be
a problem with the left side harness for the
thermocouples.
Repair: Repair any faulty wiring and/or

connectors, when possible. Replace the harness,
if necessary. Clear any diagnostic codes. Verify
that the condition is resolved.
STOP.
• Not OK – Active diagnostic codes are not created

according to the above steps. The ICSM does
not respond properly when connector P82 is
removed and when the jumper wire is connected.
The ICSM may have a problem.

Temporarily install a new ICSM. Refer to

If the problem is resolved with a new ICSM,

correctly and the original ICSM does not operate
correctly, replace the original ICSM. Refer to
STOP.
i01645648
Wastegate Solenoid
SMCS Code: 1057-038
The ECM controls the wastegate actuator by

adjusting the current flow through the actuator’s
solenoid.

a problem with an electrical connector or an open
the 526-05 diagnostic code can occur if the low
side wire is shorted to ground. The next likely cause
is an open circuit inside the actuator solenoid. The

a problem with an electrical connector or a short
circuit in a harness. The next likely cause is a short
cause is a problem with the ECM.
414
g00850571
Illustration 348
Schematic of the circuit for the wastegate actuator
The ECM is connected to the wastegate actuator via the J5/P5 connectors on the terminal box.


the ECM OFF.

g00850659
Illustration 350
Left side view of the engine
(4) Wastegate actuator
(5) P526/J526 connectors for the wastegate actuator
g00849037 B. Thoroughly inspect each of the following

Illustration 349
connectors:
(2) J5/P5 connectors for the harness from the left side of the engine
(3) 16 amp circuit breaker • (J2/P2) ECM connectors
• (J5/P5) connectors on the terminal box
• (P526/J526) connectors for the wastegate
actuator
415
a. Check the torque of the Allen head screw for Results:

proper torque is 6 ± 1 N·m (55 ± 9 lb in). • OK – The components are in good condition with
526-05 diagnostic code, proceed to Test Step 2.
If you are troubleshooting a 526-06 diagnostic
code, proceed to Test Step 8.

improper.

STOP.
Test Step 2. Check the Solenoid and

g00850664
Illustration 351 Harnesses for an Open Circuit
ECM P2 connector
(P2-8) High side wire for the wastegate actuator A. Turn the engine control switch to the OFF/RESET
(P2-9) Low side wire for the wastegate actuator position. Switch the 16 amp circuit breaker for
the ECM OFF.
g00850666
Illustration 352
(P5-39) Low side wire for the wastegate actuator g00850667
Illustration 353
(P5-47) High side wire for the wastegate actuator
b. Perform a 45 N (10 lb) pull test on the four (P2-8) High side wire for the wastegate actuator
wires that are associated with the circuit for (P2-9) Low side wire for the wastegate actuator
the wastegate actuator.
C. Measure the resistance between P2 terminal
c. Thoroughly inspect connectors (P526/J526) (8) and terminal (9). During this measurement,
for the wastegate actuator for moisture wiggle the harnesses in order to check for
and contamination. Check the harness and an intermittent problem with the harness. Be
wiring for abrasion and pinch points from the sure to wiggle the harnesses near each of the
wastegate actuator to the ECM. connectors.
Expected Result: Expected Result:
All of the connectors and terminals are connected The resistance is between 5.0 and 20.6 ohms.
properly. The connectors are free of moisture and
corrosion. The wiring is free of abrasion and pinch Results:
points.
Step 3.
416
• Not OK – The resistance is higher than 20.6 Test Step 4. Check the Low Side Wiring
ohms. There is a problem with a connector and/or Inside the Engine Harness for a Short to
the wiring for the solenoid, or the solenoid may Ground
Test Step 3. Check All of the Low Side
Wiring for a Short to Ground
from the ECM.
g00868476
Illustration 355
(P5-39) Low side wire for the wastegate actuator
g00851601
Illustration 354 B. Measure the resistance between the ground
ECM side of connector P2 strap for the ECM and harness connector P5
(1) Ground strap for the ECM terminal (39). During this measurement, wiggle
(P2-9) Low side wire for the wastegate actuator the harnesses in order to check for an intermittent
B. Measure the resistance between the ground harnesses near each of the connectors.
strap for the ECM and P2 terminal (9). During
this measurement, wiggle the harnesses in order Expected Result:
harness. Be sure to wiggle the harnesses near The resistance is greater than 20,000 ohms.
Results:
Expected Result:
• OK – The resistance measurement is greater
The resistance is greater than 20,000 ohms. than 20,000 ohms. The low side wire inside the
engine harness appears to be OK. The low side
Results: wire inside the terminal box may have a problem.
• OK – The resistance measurement is greater than
20,000 ohms. The low side wire for the wastegate Repair: Repair the harness and/or the connector,
actuator appears to be OK. Proceed to Test Step when possible. Replace the harness, if necessary.
12.
STOP.
than 20,000 ohms. There is a problem with the • Not OK – The resistance measurement is less
low side wire for the wastegate actuator. Proceed than 20,000 ohms. The low side wire inside the
to Test Step 4. engine harness may have a problem, or there
may be a problem with the solenoid. Proceed to
Test Step 5.
417
Test Step 5. Check the Solenoid for an Repair: Replace the solenoid. Refer to Operation
Internal Short Circuit and Maintenance Manual, “Electrohydraulic
A. Disconnect connector P526 from the wastegate
actuator. .
STOP.

g00851590
Illustration 357

g00868482
Illustration 356 and terminal (47). During this measurement,
(1) Solenoid for the wastegate actuator wiggle the harnesses in order to check for
(2) Solenoid connector an intermittent problem with the harness. Be
(J526-B) Low side sure to wiggle the harnesses near each of the
(Shell) Shell for the connector
connectors.
B. Measure the resistance between terminal (B) and Expected Result:
the connector’s shell.
Expected Result:
Results:
Results:
appear to be OK. The wiring inside the terminal
• OK – The resistance is greater than 20,000 box or the terminal box’s connectors may have
ohms. The solenoid does not have an internal a problem.
short circuit. The low side wire inside the engine
harness has a short to ground. Repair: Repair the wiring and/or connectors,
when possible. Replace the wiring, if necessary.
when possible. Replace the harness, if necessary. STOP.
STOP.
• Not OK – The resistance is greater than 20.6
ohms. There is a problem with the engine harness
• Not OK – The resistance is less than 20,000 or the solenoid. Proceed to Test Step 7.
418
Test Step 7. Check the Solenoid for an • Not OK – The resistance of the solenoid is higher
Open Circuit than 10.3 ohms. The resistance of the solenoid is
incorrect. The solenoid has an open circuit.
actuator. Repair: Replace the solenoid. Refer to Operation
STOP.

g00850667
Illustration 359
ECM side of the ECM P2 connector
g00850682
Illustration 358
(1) Solenoid on the wastegate actuator B. Measure the resistance between P2 terminal
(2) Solenoid connector (8) and terminal (9). During this measurement,
(J526-B) Low side wiggle the harnesses in order to check for
(J526-A) High side
an intermittent problem with the harness. Be
B. Measure the resistance between terminals (B) connectors.
and (A) on the connector for the wastegate
actuator (J526). Expected Result:
Expected Result: The resistance is between 5.0 and 20.6 ohms.
The resistance is between 5.0 and 10.3 ohms. Results:
Results:
ohms. The solenoid and wiring do not have a
• OK – The resistance of the solenoid is between short circuit. Proceed to Test Step 11.
5.0 and 10.3 ohms. The solenoid does not have
an open circuit. There is an open circuit in the
engine harness. There may be a problem with a
There is a problem with a connector and/or the
connector. wiring, or the solenoid has a problem. Proceed
to Test Step 9.
when possible. Replace the harness, if necessary. Test Step 9. Check the Engine Harness
STOP.
419
g00851590
Illustration 360
B. Measure the resistance between harness

connector P5 terminal (39) and terminal (47).
During this measurement, wiggle the harnesses
the harness. Be sure to wiggle the harnesses
near each of the connectors.
Expected Result:
g00850682
Illustration 361
The resistance is between 5.0 and 20.6 ohms. (1) Solenoid on the wastegate actuator
(2) Connector on the solenoid
Results: (J526-B) Low side
(J526-A) High side
• OK – The resistance is between 5.0 and 20.6 B. Measure the resistance between terminals (B)
appear to be OK. The wiring inside the terminal and (A) on the connector for the wastegate
box has a problem. There may be a problem with actuator (J526).
a connector.
Expected Result:
Repair: Repair the wiring and/or the connector,
when possible. Replace the harness, if necessary. The resistance is between 5.0 and 10.3 ohms.
STOP. Results:
• Not OK – The resistance is lower than 5.0 ohms. • OK – The resistance of the solenoid is between
There is a problem with the engine harness or the 5.0 and 10.3 ohms. The solenoid does not have
solenoid. Proceed to Test Step 10. a problem. The engine harness appears to have
a short circuit.
Test Step 10. Check the Solenoid for a
Short Circuit Repair: Repair the engine harness or connectors,
actuator. STOP.
• Not OK – The resistance of the solenoid is lower

incorrect.

STOP.
420
Test Step 11. Create an Open Circuit and Repair: Perform the following procedure:
A. Prevent fuel from entering the engine. Verify Switch the 16 amp circuit breaker for the ECM
that the gas supply to the engine is OFF. OFF.
B. Verify that the engine control switch is in the Reinstall the terminals that were removed from
OFF/RESET position. Verify that the 16 amp connector P2. Pull on the wires in order to verify
circuit breaker for the ECM is OFF. proper installation of the terminals.

STOP.

526-05 diagnostic code was not generated. The
ECM may have a problem.

g00850664
Illustration 362 Temporarily install a new ECM. Refer to
Harness connector P2 Troubleshooting, “Replacing the ECM”.
(P2-8) High side of the wastegate actuator
(P2-9) Low side of the wastegate actuator If the problem is resolved with a new ECM, install
the original ECM and verify that the problem
C. Use a 151-6320 Wire Removal Tool to remove returns. If the new ECM operates correctly and
terminal (8) and terminal (9) from harness the original ECM does not operate correctly,
connector P2. This will replace the wiring for the replace the original ECM. Follow the instructions
wastegate actuator with an open circuit. in Troubleshooting, “Replacing the ECM”.
D. Switch the 16 amp circuit breaker for the ECM STOP.

ON.
Test Step 12. Create a Short Circuit and
E. If a 526-05 diagnostic code and/or a 526-06 Check the Operation of the ECM
F. Turn the engine control switch to the START that the gas supply to the engine is OFF.
of 30 seconds for the generation of any codes. B. Verify that the engine control switch is in the
Then turn the engine control switch to the STOP OFF/RESET position. Verify that the 16 amp
position. circuit breaker for the ECM is OFF.
G. Observe the “Active Diagnostic” screen on ET.

Expected Result:
Results:
• OK – When an open circuit was created, a

526-05 diagnostic code was generated. The ECM
is operating correctly. The problem appears to
be resolved. The initial diagnostic code was
421
Results:
• OK – When the wiring for the wastegate actuator

was replaced with a short circuit, a 526-06
diagnostic code was generated by the ECM. The
ECM is operating correctly. The problem appears
to be resolved. The initial diagnostic code was

OFF.
g00850664
Illustration 363 Remove the jumper wire from the P2 connector.
(8) High side of the wastegate actuator Reinstall the terminals that were removed from
(9) Low side of the wastegate actuator connector P2. Pull on the wires in order to verify
terminal (8) and terminal (9) from harness Reconnect all of the connectors. Verify that the
connector P2. problem is resolved.
D. Use a jumper wire that is 125 ± 25 mm STOP.

(5.0 ± 1.0 inch) long with Deutsch sockets on
the ends. Insert one end of the jumper wire into • Not OK – When the wiring for the wastegate
the open terminal (8) of the P2 connector. Verify actuator was replaced with a short circuit, a
that the socket is making contact with pin 8 in 526-06 diagnostic code was not generated by the
the J2 connector. ECM. The ECM may have a problem.
E. Insert the other end of the jumper wire into the Repair: It is unlikely that the ECM has failed.
open terminal (9) of the P2 connector. Verify that Exit this procedure and perform this procedure
the socket is making contact with pin 9 in the again. If the problem is not resolved, perform the
J2 connector. This will replace the wiring for the following procedure:
wastegate actuator with a short circuit.
F. Switch the 16 amp circuit breaker for the ECM Troubleshooting, “Replacing the ECM”.
ON.
If the problem is resolved with a new ECM, install
G. If a 526-05 diagnostic code and/or a 526-06 the original ECM and verify that the problem
diagnostic code is logged, clear the code. returns. If the new ECM operates correctly and
H. Turn the engine control switch to the START replace the original ECM. Follow the instructions
position and crank the engine. Allow a minimum in Troubleshooting, “Replacing the ECM”.
Then turn the engine control switch to the STOP STOP.
position.

Expected Result:

422
Index Section
Index
Numerics E043 Low System Voltage Warning .................... 154
E050 High System Voltage Warning ................... 154
+5V Sensor Voltage Supply................................. 200 E096 High Fuel Pressure .................................... 154
+8V Sensor Voltage Supply................................. 212 E100 Low Engine Oil Pressure Warning ............. 154
E101 High Crankcase Pressure Warning ............ 155
E127 Engine Oil Filter Diff Pressure Low
A Warning ............................................................. 155
E128 Engine Oil Filter Diff Pressure Low
Air Starting Motor .................................................. 31 Shutdown........................................................... 155
Probable Causes ............................................... 31 E129 Engine Oil Filter Diff Pressure High
Recommended Repairs ..................................... 32 Warning ............................................................. 156
Air/Fuel Pressure Module .................................... 223 E130 Engine Oil Filter Diff Pressure High
Analog Sensor Signal .......................................... 230 Shutdown........................................................... 156
E135 Low Jacket Water Pressure Shutdown....... 156
E200 Continuous Cylinder Misfire ....................... 157
C E201 Cylinder #1 Intermittent Misfire .................. 157
E202 Cylinder #2 Intermittent Misfire .................. 157
Choke Actuator Solenoid..................................... 240 E203 Cylinder #3 Intermittent Misfire .................. 157
Combustion Sensor ............................................. 249 E204 Cylinder #4 Intermittent Misfire .................. 158
Crankcase Pressure (High) ................................... 32 E205 Cylinder #5 Intermittent Misfire .................. 158
Probable Causes ............................................... 32 E206 Cylinder #6 Intermittent Misfire .................. 158
Recommended Repairs ..................................... 33 E207 Cylinder #7 Intermittent Misfire .................. 159
Customer Passwords............................................. 22 E208 Cylinder #8 Intermittent Misfire .................. 159
Cylinder Firing Pulse ........................................... 256 E209 Cylinder #9 Intermittent Misfire .................. 159
E210 Cylinder #10 Intermittent Misfire ................ 159
D E212 Cylinder #12 Intermittent Misfire ................ 160
Desired Speed Input (4 - 20 mA)......................... 271 E214 Cylinder #14 Intermittent Misfire ................ 160
Detonation ............................................................. 33 E215 Cylinder #15 Intermittent Misfire ................ 161
Probable Causes ............................................... 33 E216 Cylinder #16 Intermittent Misfire ................ 161
Recommended Repairs ..................................... 33 E223 High Gas Temperature ............................... 161
Detonation Sensors ............................................. 278 E224 High Jacket Water Inlet Pressure............... 162
Diagnostic Codes .................................................. 64 E225 Engine Overcrank ...................................... 162
Active Diagnostic Codes .................................... 65 E226 Driven Equipment Not Ready..................... 162
Logged Diagnostic Codes.................................. 65 E229 Fuel Energy Content Setting Low .............. 162
Diagnostic Functional Tests................................. 200 E230 Fuel Energy Content Setting High.............. 163
Driven Equipment .................................................. 34 E231 Fuel Quality Out of Range.......................... 163
Probable Causes ............................................... 34 E233 Low Engine Pre-Lube Pressure ................. 163
Recommended Repairs ..................................... 34 E242 Engine Overload ........................................ 163
E243 High Left Turbo Turbine Outlet
Temperature....................................................... 164
E E244 High Right Turbo Turbine Outlet
Temperature....................................................... 164
E004 Engine Overspeed Shutdown .................... 151 E245 High Right Turbo Turbine Inlet
E013 High Crankcase Pressure Shutdown ......... 151 Temperature....................................................... 164
E016 High Engine Coolant Temperature E246 High Left Turbo Turbine Inlet Temperature.. 165
Shutdown........................................................... 151 E264 Emergency Stop Activated ......................... 165
E017 High Engine Coolant Temperature E266 Low Hydrax Oil Pressure ........................... 165
Warning ............................................................. 151 E268 Unexpected Engine Shutdown ................... 166
E019 High Engine Oil Temperature Shutdown .... 152 E269 Customer Shutdown Requested ................ 166
E020 High Engine Oil Temperature Warning....... 152 E270 Driven Equipment Shutdown Requested ... 166
E026 High Inlet Air Temperature Shutdown ........ 152 E337 High Engine Oil to Engine Coolant Diff
E027 High Inlet Air Temperature Warning ........... 153 Temp .................................................................. 166
E038 Low Engine Coolant Temperature E401 Cylinder #1 Detonation............................... 167
Warning ............................................................. 153 E402 Cylinder #2 Detonation............................... 167
E040 Low Engine Oil Pressure Shutdown........... 153 E403 Cylinder #3 Detonation............................... 167
E042 Low System Voltage Shutdown.................. 153 E404 Cylinder #4 Detonation............................... 168
423
Index Section
E405 Cylinder #5 Detonation............................... 168 E824 Cyl #4 Exhaust Port Temp Deviating High.. 187
E410 Cylinder #10 Detonation............................. 169 E829 Cyl #9 Exhaust Port Temp Deviating High.. 189
E411 Cylinder #11 Detonation............................. 169 E830 Cyl #10 Exhaust Port Temp Deviating
E412 Cylinder #12 Detonation............................. 170 High ................................................................... 190
E421 Cylinder #1 Detonation Shutdown.............. 171 E833 Cyl #13 Exhaust Port Temp Deviating
E422 Cylinder #2 Detonation Shutdown.............. 171 High ................................................................... 191
E429 Cylinder #9 Detonation Shutdown.............. 173 E841 Cyl #1 Exhaust Port Temp Deviating Low .. 193
E430 Cylinder #10 Detonation Shutdown............ 173 E842 Cyl #2 Exhaust Port Temp Deviating Low .. 193
E601 Cylinder #1 Continuous Misfire .................. 175 E849 Cyl #9 Exhaust Port Temp Deviating Low .. 196
E602 Cylinder #2 Continuous Misfire .................. 176 E850 Cyl #10 Exhaust Port Temp Deviating Low.. 196
E609 Cylinder #9 Continuous Misfire .................. 178 ECM Output Circuit (Fuel Control)....................... 292
E610 Cylinder #10 Continuous Misfire ................ 178 ECM Output Circuit (Prelubrication Oil Pump) .... 304
E611 Cylinder #11 Continuous Misfire ................ 178 ECM Output Circuit (Starting Motor) ................... 317
E612 Cylinder #12 Continuous Misfire ................ 178 ECM Status Indicator Output............................... 327
E613 Cylinder #13 Continuous Misfire ................ 179 ECM Will Not Accept Factory Passwords.............. 35
E614 Cylinder #14 Continuous Misfire ................ 179 Probable Causes ............................................... 35
E615 Cylinder #15 Continuous Misfire ................ 179 Recommended Repairs ..................................... 35
E616 Cylinder #16 Continuous Misfire ................ 180 Electrical Connectors and Functions..................... 12
E801 Cylinder #1 High Exhaust Port Temp ......... 180 Harness Wire Identification ................................ 12
E802 Cylinder #2 High Exhaust Port Temp ......... 180 Sensors.............................................................. 14
E803 Cylinder #3 High Exhaust Port Temp ......... 181 Terminal Box ...................................................... 13
E804 Cylinder #4 High Exhaust Port Temp ......... 181 Electrical Power Supply....................................... 334
E805 Cylinder #5 High Exhaust Port Temp ......... 181 Electrohydraulic System Oil Pressure (Low) ......... 35
E806 Cylinder #6 High Exhaust Port Temp ......... 182 Probable Causes ............................................... 35
E807 Cylinder #7 High Exhaust Port Temp ......... 182 Recommended Repairs ..................................... 35
E808 Cylinder #8 High Exhaust Port Temp ......... 183 Electronic Service Tool Will Not Communicate with
E809 Cylinder #9 High Exhaust Port Temp ......... 183 ECM or ICSM....................................................... 36
E810 Cylinder #10 High Exhaust Port Temp ....... 183 Probable Causes ............................................... 36
E811 Cylinder #11 High Exhaust Port Temp ....... 184 Recommended Repairs ..................................... 36
E812 Cylinder #12 High Exhaust Port Temp ....... 184 Electronic Service Tools ........................................ 18
E813 Cylinder #13 High Exhaust Port Temp ....... 185 Electronic Technician (ET) ................................. 20
E814 Cylinder #14 High Exhaust Port Temp ....... 185 Electronic Troubleshooting .................................... 10
E815 Cylinder #15 High Exhaust Port Temp ....... 185 Engine Coolant Temperature (High) ...................... 37
E816 Cylinder #16 High Exhaust Port Temp ....... 186 Probable Causes ............................................... 37
E821 Cyl #1 Exhaust Port Temp Deviating High.. 186 Recommended Repairs ..................................... 37
E822 Cyl #2 Exhaust Port Temp Deviating High.. 187
E823 Cyl #3 Exhaust Port Temp Deviating High.. 187
424
Index Section
Engine Coolant Temperature (Low) ....................... 39 Exhaust Port Temperature (Low)........................... 54

Probable Causes ............................................... 39 Probable Causes ............................................... 54
Recommended Repairs ..................................... 39 Recommended Repairs ..................................... 54
Engine Cranks but Will Not Start ........................... 39
Probable Causes ............................................... 39
Recommended Repairs ..................................... 39 F
Engine Misfires, Runs Rough or Is Unstable ......... 41
Probable Causes ............................................... 41 Factory Passwords ................................................ 22
Recommended Repairs ..................................... 41 Factory Passwords Worksheet .............................. 25
Engine Monitoring System .................................... 21 Flash Programming ............................................... 23
Engine Oil Filter Differential Pressure ................... 43 Flash Programming............................................ 23
Probable Causes ............................................... 43 Fuel Actuator Solenoid ........................................ 348
Recommended Repairs ..................................... 43 Fuel Energy Content.............................................. 55
Engine Oil Pressure (Low)..................................... 43 Probable Causes ............................................... 55
Probable Causes ............................................... 43 Recommended Repairs ..................................... 55
Recommended Repairs ..................................... 43 Fuel Pressure ........................................................ 55
Engine Oil Temperature (High) .............................. 44 Probable Causes ............................................... 55
Recommended Repairs ..................................... 44
Engine Overcrank.................................................. 45
Probable Causes ............................................... 45 G
Engine Overload.................................................... 46 Gas Temperature (High) ........................................ 56
Probable Causes ............................................... 46 Probable Causes ............................................... 56
Recommended Repairs ..................................... 46 Recommended Repairs ..................................... 56
Engine Overspeed................................................. 46
Probable Causes ............................................... 46
Recommended Repairs ..................................... 46 I
Engine Pre-Lube Pressure (Low) .......................... 47
Probable Causes ............................................... 47 Ignition Transformers Primary Circuit .................. 357
Recommended Repairs ..................................... 47 Ignition Transformers Secondary Circuit and Spark
Engine Shutdown .................................................. 48 Plugs.................................................................. 368
Probable Causes ............................................... 48 Important Safety Information ................................... 2
Recommended Repairs ..................................... 48 Inlet Air Temperature (High) .................................. 56
Engine Shutdown (Unexpected)............................ 48 Probable Causes ............................................... 56
Recommended Repair ....................................... 48 Inspecting Electrical Connectors ......................... 372
Engine Shutdown without a Diagnostic Code........ 50 Integrated Combustion Sensing Module (ICSM).. 377
Probable Causes ............................................... 50 Intermittent Engine Shutdown ............................... 57
Recommended Repairs ..................................... 50 Probable Causes ............................................... 57
Engine Speed/Timing Sensor.............................. 341 Recommended Repairs ..................................... 57
Engine Starts but Stalls Immediately..................... 50
Probable Causes ............................................... 50
Recommended Repairs ..................................... 50 J
Event Codes ........................................................ 149
Active Event Codes.......................................... 150 Jacket Water Inlet Pressure (High)........................ 58
Diagnostic Codes and Event Codes ................ 150 Probable Causes ............................................... 58
Logged Event Codes ....................................... 150 Recommended Repairs ..................................... 58
Operator Information........................................ 150 Jacket Water Pressure (Low)................................. 58
Other Symptoms .............................................. 150 Probable Causes ............................................... 58
Troubleshooting................................................ 149 Recommended Repairs ..................................... 58
Excessive Engine Oil Consumption....................... 51 Jacket Water to Engine Oil Differential Temperature
Probable Causes ............................................... 51 (Low).................................................................... 59
Recommended Repairs ..................................... 51 Probable Causes ............................................... 59
Exhaust Emission Too High/Fuel Consumption Too Recommended Repairs ..................................... 59
High ..................................................................... 52
Probable Causes ............................................... 52
Exhaust Port Temperature (High) .......................... 53
Probable Causes ............................................... 53
425
Index Section
M MID 036 - CID 0301 - FMI 06 Cylinder 1 - Transformer

Primary short ....................................................... 76
Mechanical Noise (Knock) in Engine..................... 59 MID 036 - CID 0302 - FMI 05 Cylinder 2 - Transformer
Probable Causes ............................................... 59 Primary open circuit............................................. 76
Recommended Repairs ..................................... 59 MID 036 - CID 0302 - FMI 06 Cylinder 2 - Transformer
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open Primary short ....................................................... 77
circuit ................................................................... 65 MID 036 - CID 0303 - FMI 05 Cylinder 3 - Transformer
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short Primary open circuit............................................. 77
to ground.............................................................. 66 MID 036 - CID 0303 - FMI 06 Cylinder 3 - Transformer
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve Primary short ....................................................... 77
malfunction .......................................................... 66 MID 036 - CID 0304 - FMI 05 Cylinder 4 - Transformer
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short Primary open circuit............................................. 78
to +batt................................................................. 66 MID 036 - CID 0304 - FMI 06 Cylinder 4 - Transformer
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short Primary short ....................................................... 78
to ground.............................................................. 67 MID 036 - CID 0305 - FMI 05 Cylinder 5 - Transformer
MID 036 - CID 0094 - FMI 03 Fuel Pressure Primary open circuit............................................. 79
open/short to +batt .............................................. 67 MID 036 - CID 0305 - FMI 06 Cylinder 5 - Transformer
MID 036 - CID 0094 - FMI 08 Fuel Pressure Primary short ....................................................... 79
Noisy.................................................................... 67 MID 036 - CID 0306 - FMI 05 Cyinder 6 - Transformer
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure Primary open circuit............................................. 79
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure Primary short ....................................................... 80
short to ground .................................................... 68 MID 036 - CID 0307 - FMI 05 Cylinder 7 - Transformer
MID 036 - CID 0101 - FMI 03 Crankcase Pressure Primary open circuit............................................. 80
MID 036 - CID 0101 - FMI 04 Crankcase Pressure Primary short ....................................................... 80
short to ground .................................................... 69 MID 036 - CID 0308 - FMI 05 Cylinder 8 - Transformer
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Primary open circuit............................................. 81
Sensor short to +batt ........................................... 69 MID 036 - CID 0308 - FMI 06 Cylinder 8 - Transformer
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Primary short ....................................................... 81
Sensor noisy signal.............................................. 70 MID 036 - CID 0309 - FMI 05 Cylinder 9 - Transformer
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure Primary open circuit............................................. 81
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Primary short ....................................................... 82
Pressure Sensor noisy signal .............................. 70 MID 036 - CID 0310 - FMI 05 Cylinder 10 -
MID 036 - CID 0110 - FMI 03 Engine Coolant Transformer Primary open circuit......................... 82
Temperature open/short to +batt ......................... 71 MID 036 - CID 0310 - FMI 06 Cylinder 10 -
MID 036 - CID 0110 - FMI 04 Engine Coolant Transformer Primary short ................................... 82
Temperature short to ground ............................... 71 MID 036 - CID 0311 - FMI 05 Cylinder 11 -
MID 036 - CID 0168 - FMI 02 System Voltage Transformer Primary open circuit......................... 83
intermittent/erratic................................................ 71 MID 036 - CID 0311 - FMI 06 Cylinder 11 -
MID 036 - CID 0172 - FMI 03 Intake Manifold Air Transformer Primary short ................................... 83
Temp open/short to +batt..................................... 72 MID 036 - CID 0312 - FMI 05 Cylinder 12 -
MID 036 - CID 0172 - FMI 04 Intake Manifold Air Transformer Primary open circuit......................... 84
Temp short to ground........................................... 72 MID 036 - CID 0312 - FMI 06 Cylinder 12 -
MID 036 - CID 0174 - FMI 03 Fuel Temperature Transformer Primary short ................................... 84
open/short to +batt .............................................. 73 MID 036 - CID 0313 - FMI 05 Cylinder 13 -
MID 036 - CID 0174 - FMI 04 Fuel Temperature short Transformer Primary open circuit......................... 84
to ground.............................................................. 73 MID 036 - CID 0313 - FMI 06 Cylinder 13 -
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature Transformer Primary short ................................... 85
open/short to +batt .............................................. 73 MID 036 - CID 0314 - FMI 05 Cylinder 14 -
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature Transformer Primary open circuit......................... 85
short to ground .................................................... 74 MID 036 - CID 0314 - FMI 06 Cylinder 14 -
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed Transformer Primary short ................................... 85
signal ................................................................... 74 MID 036 - CID 0315 - FMI 05 Cylinder 15 -
MID 036 - CID 0190 - FMI 08 Engine Speed signal Transformer Primary open circuit......................... 86
abnormal.............................................................. 75 MID 036 - CID 0315 - FMI 06 Cylinder 15 -
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Transformer Primary short ................................... 86
Supply short to +batt ........................................... 75 MID 036 - CID 0316 - FMI 05 Cylinder 16 -
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Transformer Primary open circuit......................... 87
Supply short to ground ........................................ 75 MID 036 - CID 0316 - FMI 06 Cylinder 16 -
MID 036 - CID 0301 - FMI 05 Cylinder 1 - Transformer Transformer Primary short ................................... 87
Primary open circuit............................................. 76
426
Index Section
MID 036 - CID 0323 - FMI 03 Shutdown Lamp short MID 036 - CID 0413 - FMI 05 Cylinder 13 -
to +batt................................................................. 87 Transformer Secondary open circuit .................... 99
MID 036 - CID 0324 - FMI 03 Warning Lamp short to MID 036 - CID 0413 - FMI 06 Cylinder 13 -
+batt..................................................................... 88 Transformer Secondary short to ground .............. 99
MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch MID 036 - CID 0414 - FMI 05 Cylinder 14 -
inputs ................................................................... 88 Transformer Secondary open circuit .................. 100
MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open MID 036 - CID 0414 - FMI 06 Cylinder 14 -
circuit ................................................................... 88 Transformer Secondary short to ground ............ 100
MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short MID 036 - CID 0415 - FMI 05 Cylinder 15 -
to ground.............................................................. 88 Transformer Secondary open circuit .................. 100
MID 036 - CID 0339 - FMI 05 Engine Pre-lube MID 036 - CID 0415 - FMI 06 Cylinder 15 -
Pressure Switch open circuit ............................... 89 Transformer Secondary short to ground ............ 101
Secondary open circuit ........................................ 89 Transformer Secondary open circuit .................. 101
Secondary short to ground .................................. 90 Transformer Secondary short to ground ............ 102
MID 036 - CID 0402 - FMI 05 Cylinder 2 - Transformer MID 036 - CID 0443 - FMI 03 Crank Terminate Relay
Secondary open circuit ........................................ 90 short to +batt ..................................................... 102
MID 036 - CID 0402 - FMI 06 Cylinder 2 - Transformer MID 036 - CID 0444 - FMI 05 Start Relay open
Secondary short to ground .................................. 90 circuit ................................................................. 102
MID 036 - CID 0403 - FMI 05 Cylinder 3 - Transformer MID 036 - CID 0444 - FMI 06 Start Relay short to
Secondary open circuit ........................................ 91 ground................................................................ 103
MID 036 - CID 0403 - FMI 06 Cylinder 3 - Transformer MID 036 - CID 0445 - FMI 03 Run Relay short to
Secondary short to ground .................................. 91 +batt................................................................... 103
MID 036 - CID 0404 - FMI 05 Cylinder 4 - Transformer MID 036 - CID 0524 - FMI 03 Desired Engine Speed
Secondary open circuit ........................................ 92 Sensor short to +batt ......................................... 103
MID 036 - CID 0404 - FMI 06 Cylinder 4 - Transformer MID 036 - CID 0524 - FMI 04 Desired Engine Speed
Secondary short to ground .................................. 92 Sensor short to ground ...................................... 104
MID 036 - CID 0405 - FMI 05 Cylinder 5 - Transformer MID 036 - CID 0525 - FMI 05 Choke Actuator open
Secondary open circuit ........................................ 92 circuit ................................................................. 104
MID 036 - CID 0405 - FMI 06 Cylinder 5 - Transformer MID 036 - CID 0525 - FMI 06 Choke Actuator short
Secondary short to ground .................................. 93 to ground............................................................ 104
MID 036 - CID 0406 - FMI 05 Cylinder 6 - Transformer MID 036 - CID 0526 - FMI 05 Wastegate Valve
Secondary open circuit ........................................ 93 open................................................................... 105
MID 036 - CID 0406 - FMI 06 Cylinder 6 - Transformer MID 036 - CID 0526 - FMI 06 Wastegate Valve
Secondary short to ground .................................. 94 short................................................................... 105
MID 036 - CID 0407 - FMI 05 Cylinder 7 - Transformer MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
Secondary open circuit ........................................ 94 Pressure open/short to +batt ............................. 105
MID 036 - CID 0407 - FMI 06 Cylinder 7 - Transformer MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
Secondary short to ground .................................. 95 Pressure short to ground ................................... 106
MID 036 - CID 0408 - FMI 05 Cylinder 8 - Transformer MID 036 - CID 1040 - FMI 09 ICSM #1 not
Secondary open circuit ........................................ 95 communicating on link ....................................... 106
MID 036 - CID 0408 - FMI 06 Cylinder 8 - Transformer MID 036 - CID 1041 - FMI 09 ICSM #2 not
Secondary short to ground .................................. 95 communicating on link ....................................... 106
MID 036 - CID 0409 - FMI 05 Cylinder 9 - Transformer MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation
Secondary open circuit ........................................ 96 Sensor open/short to +batt ................................ 107
MID 036 - CID 0409 - FMI 06 Cylinder 9 - Transformer MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation
Secondary short to ground .................................. 96 Sensor short to ground ...................................... 107
Transformer Secondary open circuit .................... 96 Sensor open/short to +batt ................................ 107
Transformer Secondary short to ground .............. 97 Sensor short to ground ...................................... 108
427
Index Section
MID 036 - CID 1509 - FMI 03 Cylinder #9 Detonation MID 109 - CID 1111 - FMI 04 Cylinder #11
Sensor open/short to +batt ................................ 109 Combustion Probe short to ground.................... 120
Sensor short to ground ...................................... 110 Combustion Probe noisy.................................... 120
Sensor short to ground ...................................... 110 Combustion Probe noisy.................................... 121
MID 036 - CID 1513 - FMI 04 Cylinder #13 Detonation MID 109 - CID 1490 - FMI 03 Rt Turbo Turbine Out
Sensor short to ground ...................................... 111 Temp Sens short to +batt................................... 122
Sensor open/short to +batt ................................ 111 Temp Sens short to ground ............................... 122
Sensor short to ground ...................................... 112 Temp Sens open circuit ..................................... 123
MID 036 - CID 1844 - FMI 05 Fuel Actuator open MID 109 - CID 1491 - FMI 03 Rt Turbo Turbine In
circuit ................................................................. 112 Temp Sens short to +batt................................... 123
MID 036 - CID 1844 - FMI 06 Fuel Actuator short to MID 109 - CID 1491 - FMI 04 Rt Turbo Turbine In
ground................................................................ 112 Temp Sens short to ground ............................... 123
MID 109 - CID 0253 - FMI 02 Personality Module MID 109 - CID 1491 - FMI 05 Rt Turbo Turbine In
mismatch ........................................................... 113 Temp Sens open circuit ..................................... 124
MID 109 - CID 0591 - FMI 12 EEPROM checksum MID 109 - CID 1531 - FMI 03 Cyl #1 Exhaust Port
fault or ECM not programmed............................ 113 Temp Sensor short to +batt ............................... 124
MID 109 - CID 1040 - FMI 09 ICSM #1 not MID 109 - CID 1531 - FMI 04 Cyl #1 Exhaust Port
communicating on link ....................................... 113 Temp Sensor short to ground ............................ 124
MID 109 - CID 1043 - FMI 02 Cylinder #1 Firing MID 109 - CID 1531 - FMI 05 Cyl #1 Exhaust Port
Signal noisy ....................................................... 113 Temp Sensor open circuit .................................. 124
Signal open/short to +batt ................................. 114 Temp Sensor short to +batt ............................... 125
Signal short to ground ....................................... 114 Temp Sensor short to ground ............................ 125
Signal abnormal signal ...................................... 114 Temp Sensor open circuit .................................. 125
MID 109 - CID 1044 - FMI 02 All Cylinders Firing MID 109 - CID 1535 - FMI 03 Cyl #5 Exhaust Port
Signal noisy ....................................................... 115 Temp Sensor short to +batt ............................... 126
Signal open/short to +batt ................................. 115 Temp Sensor short to ground ............................ 126
Signal short to ground ....................................... 115 Temp Sensor open circuit .................................. 126
Probe noisy........................................................ 116 Temp Sensor short to +batt ............................... 127
Probe short to ground........................................ 116 Temp Sensor short to ground ............................ 127
Probe noisy........................................................ 117 Temp Sensor open circuit .................................. 127
Probe short to ground........................................ 117 Temp Sensor short to +batt ............................... 127
Probe noisy........................................................ 117 Temp Sensor short to ground ............................ 128
Probe short to ground........................................ 118 Temp Sensor open circuit .................................. 128
Combustion Probe noisy.................................... 120 Temp Sensor short to ground ............................ 130
428
Index Section
MID 109 - CID 1543 - FMI 05 Cyl #13 Exhaust Port MID 110 - CID 1492 - FMI 03 Left Turbo Turbine In
Temp Sensor open circuit .................................. 130 Temp Sens short to +batt................................... 140
Temp Sensor short to +batt ............................... 130 Temp Sens short to ground ............................... 141
Temp Sensor short to ground ............................ 130 Temp Sens open circuit ..................................... 141
MID 109 - CID 1545 - FMI 05 Cyl #15 Exhaust Port MID 110 - CID 1532 - FMI 03 Cyl #2 Exhaust Port
Temp Sensor open circuit .................................. 131 Temp Sensor short to +batt ............................... 141
MID 110 - CID 0253 - FMI 02 Personality Module MID 110 - CID 1532 - FMI 04 Cyl #2 Exhaust Port
mismatch ........................................................... 131 Temp Sensor short to ground ............................ 142
MID 110 - CID 0591 - FMI 12 EEPROM checksum MID 110 - CID 1532 - FMI 05 Cyl #2 Exhaust Port
fault or ECM not programmed............................ 131 Temp Sensor open circuit .................................. 142
MID 110 - CID 1041 - FMI 09 ICSM #2 not MID 110 - CID 1534 - FMI 03 Cyl #4 Exhaust Port
communicating on link ....................................... 132 Temp Sensor short to +batt ............................... 142
Signal noisy ....................................................... 132 Temp Sensor short to ground ............................ 142
Signal open/short to +batt ................................. 132 Temp Sensor open circuit .................................. 143
Signal short to ground ....................................... 133 Temp Sensor short to +batt ............................... 143
Signal abnormal signal ...................................... 133 Temp Sensor short to ground ............................ 143
Probe noisy........................................................ 134 Temp Sensor short to ground ............................ 144
Probe short to ground........................................ 135 Temp Sensor open circuit .................................. 145
Combustion Probe short to ground.................... 137 Temp Sensor open circuit .................................. 146
Combustion Probe noisy.................................... 137 Temp Sensor short to +batt ............................... 147
Combustion Probe short to ground.................... 138 Temp Sensor short to ground ............................ 147
Combustion Probe noisy.................................... 138 Temp Sensor open circuit .................................. 147
Combustion Probe short to ground.................... 138 Temp Sensor short to +batt ............................... 148
Combustion Probe short to ground.................... 139 Temp Sensor open circuit .................................. 148
MID 110 - CID 1489 - FMI 03 Left Turbo Turbine Out
Temp Sens short to +batt................................... 139
Temp Sens short to ground ............................... 140
Temp Sens open circuit ..................................... 140
429
Index Section
N W
Noise Coming from Cylinder (Noisy Cylinder Wastegate Solenoid ............................................ 413
Head) ................................................................... 60
Probable Causes ............................................... 60
Poor Coolant Flow ................................................. 60

Probable Causes ............................................... 60
Prelubrication System ......................................... 384
Programming Parameters...................................... 22
PWM Sensor ....................................................... 389
Replacing the ECM................................................ 25

Replacing the ICSM............................................... 26
Short Spark Plug Life ............................................ 61

Probable Causes ............................................... 61
Starting Motor Runs, Pinion Engages But Does Not
Turn the Flywheel ................................................ 62
Probable Causes ............................................... 62
Symptoms.............................................................. 31
Diagnostic Codes and Event Codes .................. 31
Operator Information.......................................... 31
Other Symptoms ................................................ 31
System Configuration Parameters......................... 24
System Overview................................................... 10
Control System .................................................. 10
System Voltage...................................................... 61
Probable Causes ............................................... 61
Table of Contents..................................................... 3
Thermocouple Test .............................................. 403
Too Much Vibration................................................ 62
Probable Causes ............................................... 62
Troubleshooting Data Sheet .................................. 28
Report the Service Information.......................... 29
Troubleshooting Section ........................................ 10
Troubleshooting with a Diagnostic Code ............... 64
Troubleshooting with an Event Code ................... 149
Troubleshooting without a Diagnostic Code .......... 31
Turbocharger Turbine Temperature (High)............. 63
Probable Causes ............................................... 63
430
Index Section
431
Index Section
©2002 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR5910

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Noise Coming from Cylinder (Noisy Cylinder

+5V Sensor Voltage Supply ................................ 200

Troubleshooting Section Governing the Engine

For example, a high pressure pump provides Table 1

For more information on monitoring of the engine, RD Red

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

Note: There is one detonation sensor between each

The engine has an Integrated Combustion Sensing

Exhaust temperatures are monitored for each

At loads that are less than 40 percent, the air/fuel

When the load reaches approximately 40 percent,

Electronic Service Tools

Caterpillar Electronic Service Tools are designed to

Note: Either the 171-4401 Communication Adapter

Electronic Technician (ET)

6. Connect cable (5) to the service tool connector

7. Turn the engine control switch to the ON position.

Connecting ET with the 7X-1701

1. Turn the engine control switch to the OFF i01653858

The ECM monitors the operating parameters of

The status of the parameters can be viewed on

To accommodate unique applications and sites,

• Select the available responses.

Programming Parameters Note: Be sure to record the customer passwords.

i01409654 Customer Passwords

Customer Passwords Customer Password #1

Certain monitoring system parameters and system i01298784

• Current ECM 2. Turn the engine control switch to the STOP

Flash Programming When the flash is completed, this message will

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

If a communication error occurs, select a slower

1. Connect the ET to the service tool connector.

“WinFlash” Error Messages (Table 4, contd)

The status of the parameters can be viewed on the “Wastegate Stability”

If the ECM is replaced, the appropriate parameters Start/Stop Control

Table 4 is a list of the parameters that can be “Engine Cooldown Duration”

Verify that the suspect ECM is the cause of the

Telephone Number a. Connect the ET with the communications

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

4. Program the configuration parameters and

a. Switch circuit breaker (1) to the ON position.

b. Turn the engine control switch to the “STOP”

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

d. Select the replacement ECM and click “OK”.

e. Select “Service/Copy Configuration/ECM

Install a test ICSM in place of the suspect ICSM.

If the test ICSM resolves the problem, reconnect

Use the following procedure to replace the ICSM:

You may also select the “Print” function in order

Note: Before you replace an ICSM, record all of the

a. Connect ET with the communications adapter.

ET will load the configuration parameters and

a. Turn the engine control switch to the

e. Select “Service/Copy Configuration/ECM

f. Select “Program ECM” from the lower left

g. After the loading is complete, a window with

Note: When you program a new ICSM, factory

a. Use the mounting hardware to install the new