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Systems Operation
320D, 321D, 323D, 324D, 325D, 326D, 328D, 329D, 330D, 336D, 336D2, 340D and 340D2
Excavators, 324D Forest Machine and 323D MHPU, 324D MHPU, 325D MHPU, 329D MHPU, 330D
MHPU and 336D MHPU Mobile Hydraulic Power Units Machine Electronic Control System
Media Number -RENR9848-30 Publication Date -01/04/2015 Date Updated -16/10/2017

i04591890

Diagnostic Operation
SMCS - 5050-EK

The ECM shows diagnostic information on the display in order to assist with troubleshooting. This control
system is used with the Electronic Technician Service Tool (ET). These tools can be used to perform several
diagnostic functions and programming functions.

The following list contains some of the diagnostic functions and programming functions that are performed
by the service tools:

The diagnostic codes of the ECM system are displayed.

The status of most of the inputs and the outputs are displayed.

The settings for the machine ECM are displayed.

Display the status of the input and output parameters in real time.

Display the value in hours of the internal diagnostic clock.

The number of occurrences and the clock hour of the first occurrence and the last occurrence is
displayed for each logged diagnostic code.

The definition for each logged diagnostic code and each event is displayed.

Load new FLASH software.

See the Troubleshooting, Diagnostic Code List section of this manual for the list of diagnostic codes for the
machine ECM.

Troubleshooting Procedures

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These procedures are only for the diagnostic codes that originate from the machine ECM. The diagnostic
codes can be viewed by using any of the following systems: Monitoring System and the Caterpillar Electronic
Technician (ET) See one of the following references:

Systems Operation, RENR8068, "Monitoring System"

Troubleshooting, "Using Caterpillar Electronic Technician to Determine Diagnostic Codes"

The following procedures may cause new diagnostic codes to be logged. Therefore, before any procedures are
performed, make a list of all the active diagnostic codes in order to determine the system problems. Clear the
diagnostic codes that were caused by the procedure, when each procedure is complete.

Note: Before you perform a procedure, always check all the circuit breakers. Repair the cause of any circuit
breaker that is tripped.

Module Identifier (MID)


System events from other electronic control modules are shown on the monitoring system. Other electronic
control modules transfer this diagnostic information on the Cat Data Link to the Monitoring System.

The module identifier (MID) identifies the electronic control module that detected the diagnostic code. Each
electronic control module on the machine has a unique MID. Use the following chart in order to match the
MID for each diagnostic code to a specific electronic control module. The chart for the Module Identifier
(MID) is located on the Electrical System Schematic for your machine. See the chart if the MID is not shown
on the display of your machine. After the operator determines the ECM that has detected the diagnostic code,
see the troubleshooting manual for the particular ECM.

If the MID is for the machine ECM, use this service manual module. The MID for the machine ECM is 039.
If the MID is different use the appropriate module.

Table 1
Description of the Module Identifier

MID Description

030 Monitor

036 Engine Electronic Control Module

039 Machine Electronic Control Module

122 ATT Product Link Module (Gateway)

Failure Mode Identifier


The codes for the Failure Mode Identifier are defined by the SAE standards. The following list contains a Cat
version of definitions.

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Table 2
Failure Mode Identifier

FMI Description of Failure

00 Data valid but above normal operating range

01 Data valid but below normal operating range

02 Data erratic, intermittent, or incorrect

03 Voltage above normal

04 Voltage below normal

05 Current below normal

06 Current above normal

07 Mechanical system not responding properly

08 Abnormal frequency, pulse width, or period

09 Abnormal update rate

10 Abnormal rate of change

11 Failure mode not identifiable

12 Bad device or component

13 Out of calibration

14 Not used

15 Not used

16 Parameter not available

17 Module not responding

18 Sensor supply fault

19 Condition not met

20 Not used

Detailed FMI Explanation

FMI 00 Data Valid But Above Normal Operating Range - Every electronic control system sets a high limit
for the expected operating range of the signal. The high limit includes over range signals. A sensor that is still
operating but sending a signal above the expected limit will cause an FMI 00 to be stored.

Some of the possible causes of an FMI 00 diagnostic code are listed:

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The signal is above normal.

The signal is shorted to the +battery.

The sensor is in need of calibration.

A PWM signal that is at a duty cycle of 80 percent is a valid signal. If the PWM signal has a duty cycle of 81
percent, the sensor is still working. But the sensor signal is above the expected signal limits.

FMI 01 Data Valid But Below Normal Operating Range - Every electronic control system sets a low limit
for the expected operating range of the signal. The limit includes signals that are under the lower limit. The
low signal could be the oil pressure signal. The sensor is still working but sending a signal below the expected
limit will cause an FMI 01 to be stored.

Some of the possible causes of an FMI 01 diagnostic code are listed:

The signal is below the normal range.

The timing is retarded.

This sensor is not expected to generate a PWM signal below a duty cycle of 5 percent with zero air pressure.
If the sensor generates a signal with a duty cycle of 4 percent when the engine is shut down, the sensor is still
working. Sending a signal below the expected limit will cause an FMI 01 to be stored.

FMI 02 Data Erratic, Intermittent, or Incorrect - The signal from a component is present. The control that
reads the diagnostic information cannot read the signal properly. The signal appears to be gone, unstable, or
invalid. The data can be correct or incorrect intermittently. Also, this condition relates to communication
between controls. This condition is an example of communication between controls. When the monitoring
system is looking for the engine speed from the engine ECM over the Cat Data Link.

There is a faulty connection.

The signal is intermittent or erratic.

The software has been changed.

The signal is noisy.

The signal is out of range.

FMI 03 Voltage Above Normal or Shorted High - The component or system voltage is higher than the
limit. FMI 03 most often relates to a signal circuit.

Some of the components that could cause an FMI 03 diagnostic code are listed:

The sensor or the switch is faulty.

The harness is damaged.

The electronic control has failed.

Some of the possible causes of an FMI03 diagnostic code are listed:

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A sensor that has failed and the voltage output is high.

Any wiring harness that has a sensor signal wire shorted to a high voltage. A high voltage is any voltage
that is greater than the sensor supply voltage.

A wiring harness that has an open circuit in the sensor signal wire will cause the control to pull up.
When this event occurs, the input circuit is pulled up to the supply voltage.

A faulty control will also cause an FMI 03.

FMI 04 Voltage Below Normal or Shorted Low - The component or system voltage is lower than the limit.
FMI 04 most often relates to a signal circuit.

Some of the components that could cause an FMI 03 diagnostic code are listed:

The sensor or the switch is faulty.

The harness is damaged.

The electronic control has failed.

Some of the possible causes of an FMI 04 diagnostic code are listed:

A sensor that has failed and the voltage output is low.

Any wiring harness that has a sensor signal wire shorted to ground.

A faulty control will also cause an FMI 04.

FMI 05 Current Below Normal or Open Circuit - The current through the component or the system is
lower than the limit. FMI 05 is most often related to a driver circuit.

Some of the possible causes of an FMI 05 diagnostic code are listed:

There is an open circuit or a poor harness connection.

There is an open relay.

There is a switch in the open position.

FMI 06 Current Above Normal or Grounded Circuit - The current through the component or the system is
higher than the limit. FMI 06 is most often related to a driver circuit. This fault is like an FMI 04 diagnostic
code.

Some of the possible causes of an FMI 06 diagnostic code are listed:

There is a short to ground in the harness connection.

There is a shorted relay.

A faulty control will also cause an FMI 06 diagnostic code.

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FMI 07 Mechanical System Not Responding Properly - The control detects a signal that is sent to a
mechanical system and the response is not correct.

Some of the possible causes of an FMI 07 diagnostic code are listed:

The component responds improperly.

The component is stuck in a position.

The component has failed.

The engine is shut down.

The machine is being used improperly.

FMI 08 Abnormal Frequency, Pulse Width, or Period - This event occurs when the signal is not in the
expected range. FMI 08 can also relate to a faulty sensor.

Some of the possible causes of an FMI 08 diagnostic code are listed:

The harness connections are intermittent or poor.

The engine misfired.

The signal is noisy due to nearby interference.

There are loose mechanical devices.

FMI 09 Abnormal Update - This event relates to communications on the Cat Data Link. FMI 09 occurs
when a control is not able to get information from another control.

Some of the possible causes of an FMI 09 diagnostic code are listed:

The control module is not communicating on the Cat Data Link correctly.

The rate of data transmission is abnormal.

The Cat Data Link has failed.

There is a mismatch of software.

FMI 10 Abnormal Rate of Change - This event relates to a signal that changes too fast. The rate of change
is outside of the expected limit.

FMI 11 Failure Mode Not Identifiable - The control identifies more than one FMI as being responsible for a
single failure.

Some of the possible causes of an FMI 11 diagnostic code are listed:

There is a mechanical failure.

There is damage to multiple circuits.

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FMI 12 Bad Device or Component - The electronic control sends a signal and the electronic control expects
a response. The control receives no response or the response is incorrect.

Some of the possible causes of an FMI 12 diagnostic code are listed:

There is a failure of the electronic control.

There is a failure on the Cat Data Link.

There are one or more controls with mismatched software.

FMI 13 Out of Calibration - The electrical signal is not within limits for a specific mechanical condition.

Some of the possible causes of an FMI 13 diagnostic code are listed:

Calibration is required.

The data is out of range.

FMI 14, 15, and 20 - These codes are not active.

FMI 16 Parameter Not Available - The control does not support the requested parameter.

FMI 17 Module Not Responding - The control does not respond to the request for data.

FMI 18 Sensor Supply Failure - The sensor power supply in the control has failed.

FMI 19 Condition Not Met - The conditions that are defined by the software were not met.

Event Codes

Table 3
EID Level
Event Description Recommended Response

Fuel Filter Restriction Examine fuel filter to determine if replacement is required.


5 2
Derate Engine output is decreasing because fuel filter is plugged.

In order to prevent engine coolant from overheating, engine


High Engine Coolant
15 2 output has been decreased. This code shows that the process of
Temperature Derate
decreasing the engine output has been instituted.

16 High Engine Coolant Immediate Safe Shutdown is Required.


3 Temperature Shutdown Allow the coolant time to return to an acceptable level before
resuming operation of the machine.

17 High Engine Coolant


The coolant for the engine has overheated. Change the operation
2 Temperature Warning
of the machine to allow the engine to cool.

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23 High Hydraulic Oil Engine power / output has been decreased to prevent the
Temperature Derate hydraulic oil from overheating.
2
Possible causes include - abusive machine operation, low
hydraulic oil level, and restricted hydraulic oil cooler.

25 High Inlet Air Engine output is decreased because engine inlet air temperature is
1 Temperature Derate too high. Refer to "Troubleshooting" in the maintenance manual
for the engine.

27 High Inlet Air


The air temperature for the engine inlet is too high. Refer to
1 Temperature Warning
"Troubleshooting" in the maintenance manual for the engine.

39 Low Engine Oil Engine output has decreased because engine oil pressure is low.
1 Pressure Derate Refer to "Troubleshooting" in the maintenance manual for the
engine.

The battery is not charging. Check for diagnostic codes relating to


Low System Voltage
43 2 system voltage or alternator output. To troubleshoot, check
Warning
associated diagnostic codes that will occur with this event code.

High System Voltage The system voltage is higher than normal. Check for diagnostic
50 2
Warning codes relating to system voltage or alternator output.

53 Low Fuel Pressure Check for any diagnostic codes related to the operation of the fuel
2
Warning pump. Check fuel lines for signs of leaks.

59 Low Engine Coolant Check the level of engine coolant. Check connections for coolant
2
Level Warning level switch.

95 Fuel Filter Restriction The number 2 fuel filter is plugged. Check or replace the number
2
Warning 2 fuel filter.

96 1 High Fuel Pressure Check the fuel filter or check the valve of the oil inlet cap.

100 Low Engine Oil The engine oil pressure has decreased . Check the oil level of the
3 Pressure Warning engine. The maximum engine speed is limited in order to protect
the engine.

119 Low Fuel Level Check the fuel level. Check any diagnostic codes related to the
2
function of the fuel sensor.

171 Low Engine Oil Level Check engine oil level and replace as needed. Check connections
2
for engine oil level switch.

172 High Air Filter


1 Replace air filter.
Restriction

179 Alternator Not Check tension on drive belt of alternator. Check electrical
2
Charging connections of alternator circuit.

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180 Auto Lube Distribution


Line Plugged

181 Limited Mobility This mode is engaged to allow the operator to relocate the
3
Mode machine to a safe location for service to be performed.

182
Suction Valve Off

190 Engine Overspeed Refer to "Troubleshooting" in the maintenance manual for the
1
Warning engine.

High Fuel/Water Water separator is full of water. Drain water from the water
232
2 Separator Water Level separator. If water is not present, check installation setting of the
water separator level switch.

Check the lube oil level on the liquid indicator on the side of the
234 Low Auto Lube Grease tank. Fill the tank if the indicator displays a low level. If the
2
Level gauge shows that the tank is full, check for damaged lubrication
lines.

Check the hydraulic oil level on the liquid indicator on the side of
235 Low Hydraulic Oil the tank. Fill the tank if the indicator displays a low level. If the
2
Level gauge shows that the tank is full, check for damaged hydraulic
lines.

Hydraulic oil return filter is plugged. Replace the hydraulic oil


236 Return Hydraulic Oil
2 and replace the return filter. If code continues, check connections
Filter Plugged
for the plugged switch of the hydraulic return filter

Immediately reduce the load on the machine by reducing the


237
3 Machine Overloaded amount of material being lifted. If machine is not overloaded,
check the installation setting of overload warning sensor.

An unauthorized key has been used to try to start the machine.


252 Loss of Key Table
02 Refer to the "Machine Security System" in the maintenance
Information
manual.

253 Hydraulic Oil Level Check hydraulic oil level and replace as needed. Check
2
Low connections for hydraulic oil level switch.

265 User Defined Shut The engine is shut down. Troubleshoot all diagnostic codes
1
down related to the key start switch.

The air inlet filter is plugged. Replace the air inlet filter for the
272 Inlet Air Restriction
2 engine. If code continues, check connections for the plugged
Warning
switch of the air filter.

273 Machine security system has detected that an unauthorized key


1 Unauthorized Key
has been used to attempt to start the machine.

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High Hydraulic Oil


600 The hydraulic oil has overheated. Change the operation of the
2 Temperature Warning
machine in order to allow the hydraulic system time to cool.

The attachment hydraulic oil filter is plugged. Replace the


862 Attachment Hydraulic
2 hydraulic oil filter. If code continues, check the installation setting
Oil Filter Plugged
of plugged switch for attachment hydraulic oil filter.

Abnormal Machine
863 The Autolube system is not operating properly. Check the
2 Auto Lube System
installation setting of the automatic lubrication system.
Operation

Data Status Codes

Table 4
Data Status Identification List

DSI Data Status Description

2 Erratic, Intermittent, or Incorrect Data

3 Voltage High

4 Voltage Low

5 Current Below Normal

6 Current Above Normal

8 Abnormal Frequency, Pulse Width, or Period

9 Abnormal Update

11 Other Failure Mode

12 Bad Component

13 Out of Calibration

16 Parameter Not Available

17 Module Not Responding

18 Sensor Power Supply Failure

19 Incomplete Data or Conditions Not Met

20 Disabled or Not Installed

Calibration Error ID List

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Table 5
Calibration Error ID List

ID Calibration Error Description

$0001 ECM Fault

$0002 Active Diagnostic Present

$0003 Another Calibration is Active

$0004 Calibration Active by Another ECM

$0005 Loss of Calibration Interlock

$0006 Calibration Aborted by Tool/Monitor

$0007 Requested Display Not Supported

$0008 Unavailable Display

$0009 Calibration Aborted by ECM

$000A Calibration Failure

$000B Calibration Not Supported

$0100 Out-of-Range Low - Incr/Decr Parameter

$0101 Out-of-Range High - Incr/Decr Parameter

$0102 Invalid Action/Key Stroke Command

$0103 Calibration Value Out-of-Range

$0104 Calibrated Range Too Small

$0105 Calibrated Range Too Large

$0106 Calibration Value Not Saved

$1000 See Service Manual

$1010 Engine Stopped (No Engine RPM)

$1011 Engine Running (Engine RPM Present)

$1012 Engine RPM Incorrect

$1013 Engine High Idle RPM Too Fast

$1014 Engine Low Idle RPM Too Slow

$1015 Abnormal Engine RPM Signal

$1016 Speed Sensor Circuit is Open

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$1017 Service Brake Pedal Pressed

$1018 Parking Brake Not Engaged

$1019 Parking Brake Engaged

$1074 Engine RPM Too Low

$101A Implement is Swinging/Traveling

$101B Machine Speed Not Zero

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