Renr9346 06 00 All

RENR9346-06
December 2009
Troubleshooting
C27 and C32 Engines for 773F and
777F Off-Highway Truck/Tractors and
for the 775F Quarry Truck
EED1-Up (Machine)
EXD1-Up (Machine)
EYG1-Up (Machine)
JRP1-Up (Machine)
JXP1-Up (Machine)
DLS1-Up (Machine)
LJW1-Up (Engine)
EHX1-Up (Engine)
LJX1-Up (Engine)
SAFETY.CAT.COM
i03684547
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.
A non-exhaustive list of 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. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. 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 become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
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.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR9346-06 3
Table of Contents
Table of Contents CID 0002 FMI 05 Cylinder #2 Injector open

circuit ................................................................... 50
CID 0002 FMI 06 Cylinder #2 Injector short ......... 51
CID 0003 FMI 05 Cylinder #3 Injector open
Troubleshooting Section circuit ................................................................... 51
Electronic Troubleshooting
System Overview .................................................... 6
circuit ................................................................... 52
Electronic Service Tools .......................................... 7
Replacing the ECM ................................................ 11
Self-Diagnostics .................................................... 12
circuit ................................................................... 52
Sensors and Electrical Connectors ....................... 13
Programming Parameters
circuit ................................................................... 53
Programming Parameters ..................................... 19
Test ECM Mode .................................................... 19
Factory Passwords ............................................... 20
circuit ................................................................... 53
Flash Programming .............................................. 20
Injector Trim File ................................................... 21
circuit ................................................................... 54
System Configuration Parameters
System Configuration Parameters ........................ 22
circuit ................................................................... 54
Troubleshooting without a Diagnostic Code
Alternator (Noisy Operation) ................................. 26
Can Not Reach Top Engine RPM ......................... 26
circuit ................................................................... 55
Coolant in Engine Oil ............................................ 27
CID 0010 FMI 06 Cylinder #10 Injector short ....... 55
Coolant Temperature Is Too High ......................... 28
ECM Will Not Accept Factory Passwords ............. 29
circuit ................................................................... 56
ECM Will Not Communicate with Other Systems or
CID 0011 FMI 06 Cylinder #11 Injector short ........ 56
Display Modules .................................................. 30
Electronic Service Tool Will Not Communicate with
circuit ................................................................... 56
ECM .................................................................... 30
CID 0012 FMI 06 Cylinder #12 Injector short ....... 56
Engine Cranks but Will Not Start .......................... 31
CID 0041 FMI 03 8 Volt DC Supply short to +batt .. 57
Engine Has Early Wear ........................................ 33
CID 0041 FMI 04 8 Volt DC Supply short to
Engine Misfires, Runs Rough or Is Unstable ........ 33
ground ................................................................. 57
Engine Oil in Cooling System ............................... 34
CID 0091 FMI 08 Throttle Position signal
Engine Oil Temperature Is Too High ..................... 35
abnormal ............................................................. 57
Engine Stalls at Low RPM .................................... 35
CID 0094 FMI 03 Fuel Pressure open/short to
Engine Vibration ................................................... 36
+batt .................................................................... 58
Engine Will Not Crank ........................................... 36
CID 0094 FMI 04 Fuel Pressure short to ground .. 58
Excessive Black Smoke ........................................ 37
CID 0100 FMI 03 Engine Oil Pressure open/short to
Excessive Engine Oil Consumption ...................... 38
+batt .................................................................... 58
Excessive Fuel Consumption ............................... 39
CID 0100 FMI 04 Engine Oil Pressure short to
Excessive Valve Lash ........................................... 40
ground ................................................................. 58
Excessive White Smoke ....................................... 40
CID 0100 FMI 10 Engine Oil Pressure Sensor
Exhaust Temperature Is Too High ......................... 41
abnormal rate of change ..................................... 59
Fuel in Cooling System ......................................... 41
CID 0110 FMI 03 Engine Coolant Temperature
Fuel Dilution of Engine Oil .................................... 42
open/short to +batt .............................................. 59
Intermittent Engine Shutdown ............................... 42
CID 0110 FMI 04 Engine Coolant Temperature short
Low Engine Oil Pressure ...................................... 43
to ground ............................................................. 59
Low Power/Poor or No Response to Throttle ....... 44
CID 0168 FMI 00 System Voltage High ................ 60
Mechanical Noise (Knock) in Engine .................... 46
CID 0168 FMI 01 System Voltage Low ................. 60
Noise Coming from Cylinder ................................. 46
CID 0168 FMI 02 System Voltage intermittent/
Poor Acceleration or Response ............................ 46
erratic .................................................................. 60
Valve Rotator or Spring Lock Is Free .................... 48
CID 0172 FMI 03 Intake Manifold Air Temp open/short
to +batt ................................................................ 61
Troubleshooting with a Diagnostic Code
CID 0172 FMI 04 Intake Manifold Air Temp short to
Diagnostic Codes .................................................. 49
ground ................................................................. 61
CID 0174 FMI 03 Fuel Temperature open/short to
circuit ................................................................... 50
+batt .................................................................... 61
CID 0174 FMI 04 Fuel Temperature short to
ground ................................................................. 62
4 RENR9346-06
Table of Contents
CID 0190 FMI 08 Engine Speed signal abnormal .. 62 CID 1795 FMI 04 Turbo #2 Outlet Pressure Sensor
CID 0253 FMI 02 Personality Module mismatch .. 62 voltage below normal .......................................... 73
CID 0261 FMI 11 Engine Timing Offset fault ........ 63 CID 1795 FMI 10 Turbo #2 Outlet Pressure Sensor
CID 0261 FMI 13 Engine Timing Calibration abnormal rate of change ..................................... 74
required ............................................................... 64 CID 1796 FMI 03 Intake Manifold #2 Air Temperature
CID 0262 FMI 03 5 Volt Sensor DC Power Supply Sensor voltage above normal ............................. 74
short to +batt ....................................................... 64 CID 1796 FMI 04 Intake Manifold #2 Air Temperature
CID 0262 FMI 04 5 Volt Sensor DC Power Supply Sensor voltage below normal .............................. 74
short to ground .................................................... 64 CID 2271 FMI 05 Engine Oil Renewal System
CID 0267 FMI 02 Incorrect Engine Shutdown Switch Actuation Solenoid current below normal ........... 75
inputs .................................................................. 65 CID 2271 FMI 06 Engine Oil Renewal System
CID 0268 FMI 02 Check Programmable Actuation Solenoid current above normal ........... 75
Parameters ......................................................... 65 CID 2350 FMI 03 Left Exhaust #2 Temperature
CID 0274 FMI 03 Atmospheric Pressure open/short voltage above normal .......................................... 75
to +batt ................................................................ 65 CID 2350 FMI 04 Left Exhaust #2 Temperature
CID 0274 FMI 04 Atmospheric Pressure short to voltage below normal .......................................... 76
ground ................................................................. 66 CID 2350 FMI 08 Left Exhaust #2 Temperature
CID 0291 FMI 05 Engine Cooling Fan Solenoid open abnormal frequency, pulse width, or period ........ 76
circuit ................................................................... 66 CID 2351 FMI 03 Right Exhaust #2 Temperature
CID 0291 FMI 06 Engine Cooling Fan Solenoid short voltage above normal .......................................... 76
to ground ............................................................. 66 CID 2351 FMI 04 Right Exhaust #2 Temperature
CID 0342 FMI 08 Secondary Engine Speed signal voltage below normal .......................................... 77
abnormal ............................................................. 66 CID 2351 FMI 08 Right Exhaust #2 Temperature
CID 0533 FMI 09 Brake Control abnormal update abnormal frequency, pulse width, or period ........ 77
rate ...................................................................... 67 CID 2417 FMI 05 Ether Injection Control Solenoid
CID 0533 FMI 14 Brake Control special current low .......................................................... 77
instruction ............................................................ 67 CID 2417 FMI 06 Ether Injection Control Solenoid
CID 0544 FMI 02 Engine Cooling Fan Speed Sensor current high ......................................................... 78
loss of signal ....................................................... 67 CID 2533 FMI 05 Compression Brake Low/High
CID 0544 FMI 08 Engine Cooling Fan Speed signal Solenoid #1 current below normal ...................... 78
abnormal ............................................................. 68 CID 2533 FMI 06 Compression Brake Low/High
CID 0569 FMI 05 Oil Injection Solenoid current below Solenoid #1 current above normal ...................... 78
normal ................................................................. 68 CID 2534 FMI 05 Compression Brake Low/High
CID 0569 FMI 06 Oil Renewal Solenoid short to Solenoid #2 current below normal ...................... 78
ground ................................................................. 68 CID 2534 FMI 06 Compression Brake Low/High
CID 0827 FMI 03 Left Exhaust Temperature Solenoid #2 current above normal ...................... 79
open/short to +batt .............................................. 69 CID 2535 FMI 05 Compression Brake Medium/High
CID 0827 FMI 04 Left Exhaust Temperature short to Solenoid #1 current below normal ...................... 79
ground ................................................................. 69 CID 2535 FMI 06 Compression Brake Medium/High
CID 0827 FMI 08 Left Exhaust Temperature signal Solenoid #1 current above normal ...................... 79
abnormal ............................................................. 69 CID 2536 FMI 05 Compression Brake Medium/High
CID 0828 FMI 03 Right Exhaust Temperature Solenoid #2 current below normal ...................... 79
open/short to +batt .............................................. 70 CID 2536 FMI 06 Compression Brake Medium/High
CID 0828 FMI 04 Right Exhaust Temperature short Solenoid #2 current above normal ...................... 80
to ground ............................................................. 70
CID 0828 FMI 08 Right Exhaust Temperature signal Troubleshooting with an Event Code
abnormal ............................................................. 70 Event Codes ........................................................ 81
CID 1273 FMI 09 Unable to Communicate with E096 High Fuel Pressure ...................................... 84
Chassis Control Module ...................................... 71 E171 Low Engine Oil Level ................................... 84
CID 1273 FMI 14 Chassis Control Module special E172 High Air Filter Restriction ............................. 85
instruction ............................................................ 71 E194 High Exhaust Temperature .......................... 85
CID 1589 FMI 03 Turbo Inlet Air Pressure Sensor E321 High Right Exhaust Temperature ............... 87
open/shrt to +bat ................................................. 71 E322 High Left Exhaust Temperature .................. 88
CID 1589 FMI 04 Turbo Inlet Air Pressure Sensor E360 Low Engine Oil Pressure ............................. 90
short to ground .................................................... 72 E361 High Engine Coolant Temperature .............. 90
CID 1785 FMI 03 Intake Manifold Pressure Sensor E362 Engine Overspeed ....................................... 92
voltage high ......................................................... 72 E363 High Fuel Supply Temperature .................... 92
CID 1785 FMI 04 Intake Manifold Pressure Sensor E390 Fuel Filter Restriction .................................. 93
voltage low .......................................................... 72 E539 High Intake Manifold Air Temperature ......... 93
CID 1785 FMI 10 Intake Manifold Pressure Signal E540 Low Engine Oil Refill Tank Level ................. 94
abnormal rate of change ..................................... 72 E775 High Left Exhaust #2 Temperature .............. 95
CID 1795 FMI 03 Turbo #2 Outlet Pressure Sensor E776 High Right Exhaust #2 Temperature ........... 96
voltage above normal .......................................... 73 E1000 High Left Intake Manifold Air Temperature .. 98
RENR9346-06 5
Table of Contents
Diagnostic Functional Tests

5 Volt Engine Pressure Sensor Supply Circuit -
Test ................................................................... 100
Cat Data Link Circuit - Test ................................. 105
Compression Brake Solenoid Circuit - Test ........ 108
Digital Sensor Supply Circuit - Test ..................... 117
Electrical Connectors - Inspect ........................... 121
Electrical Power Supply Circuit - Test ................. 126
Engine Fan Control Solenoid Circuit - Test ......... 129
Engine Fan Speed Sensor Circuit - Test ............. 133
Engine Oil Level Switch Circuit - Test ................. 137
Engine Oil Renewal Solenoid Circuit - Test ........ 141
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 145
Engine Shutdown Switch Circuit - Test ............... 152
Engine Speed/Timing Sensor Circuit - Test ........ 156
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 161
Ether Injection System - Test .............................. 167
Fuel Filter Differential Pressure Switch Circuit -
Test ................................................................... 170
Injector Solenoid Circuit - Test ............................ 173
Sensor Signal (PWM) - Test ............................... 181
Throttle Position Sensor Circuit - Test ................ 187
Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 192
Index Section
Index ................................................................... 194
6 RENR9346-06
Troubleshooting Section
Troubleshooting Section Cold Mode

The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
Electronic Troubleshooting during cold mode operation. Cold mode operation
provides the following benefits:
i02397878 • Increased cold weather starting capability

System Overview • Reduced warm-up time
SMCS Code: 1900
• Reduced white smoke
System Operation Cold mode is activated whenever the engine
temperature falls below a predetermined value. Cold
This engine is electronically controlled. Each cylinder mode remains active until the engine temperature
has an electronic unit injector. The Electronic Control rises above a predetermined value or until a time
Module (ECM) sends a signal to each injector limit is exceeded.
solenoid in order to control the operation of the fuel
injection system. Fuel Injection
Electronic Controls The ECM controls the amount of fuel that is injected
by varying the signals to the injectors. The injector will
The electronic system consists of the following pump fuel only if the injector solenoid is energized.
components: the ECM, the Mechanically Actuated The ECM sends a high voltage signal to the solenoid.
Electronically Controlled Unit Injectors (MEUI), the This high voltage signal energizes the solenoid. By
wiring harness, the switches, and the sensors. The controlling the timing and the duration of the high
ECM is the computer. The flash file is the software voltage signal, the ECM can control injection timing
for the computer. The flash file contains the operating and the engine RPM.
maps. The operating maps define the following
characteristics of the engine: The flash file inside the ECM sets certain limits on
the amount of fuel that can be injected. The “FRC
• Horsepower Fuel Limit” is used to control the air/fuel ratio for
control of emissions. The “FRC Fuel Limit” is a limit
• Torque curves that is based on the turbocharger outlet pressure.
A higher turbocharger outlet pressure indicates that
The ECM determines the timing and the amount of there is more air in the cylinder. When the ECM
fuel that is delivered to the cylinders. These decisions senses a higher turbocharger outlet pressure, the
are based on the actual conditions and/or on the ECM increases the “FRC Fuel Limit”. When the ECM
desired conditions at any given time. increases the “FRC Fuel Limit”, the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
The ECM compares the desired engine speed to programmed into the ECM at the factory. The “FRC
the actual engine speed. The actual engine speed Fuel Limit” cannot be changed.
is determined through a signal from the engine
speed/timing sensor. The desired engine speed is The “Rated Fuel Limit” is a limit that is based on the
determined with the following factors: power rating of the engine and on engine rpm. The
“Rated Fuel Limit” is similar to the rack stops and to
• Throttle signal the torque spring on a mechanically governed engine.
The “Rated Fuel Limit” provides the power curves
• Other input signals from sensors and the torque curves for a specific engine family and
for a specific engine rating. The “Rated Fuel Limit” is
• Certain diagnostic codes programmed into the ECM at the factory. The “Rated
Fuel Limit” cannot be changed.
If the desired engine speed is greater than the actual
engine speed, the ECM injects more fuel in order to
increase the actual engine speed.
RENR9346-06 7
Once the ECM determines the amount of fuel that Table 1

is required, the ECM must determine the timing Service Tools
of the fuel injection. The ECM calculates the top
center position of each cylinder from the engine Pt. No. Description
speed/timing sensor's signal. The ECM decides when N/A 4 mm Allen Wrench
fuel injection should occur relative to the top center
position and the ECM provides the signal to the 151-6320 Wire Removal Tool (14-GA TO 18-GA,
injector at the desired time. The ECM adjusts timing RED)
for optimum engine performance, for optimum fuel 1U-5804 Crimp Tool (12−AWG TO 18−AWG)
economy, and for optimum control of white smoke.
6V-2197 Transducer
Programmable Parameters 7X-1171 Transducer Adapter
7X-1695 Cable As
Certain parameters that affect the engine operation
may be changed with Caterpillar Electronic 146-4080 Digital Multimeter Gp (RS232)
Technician (ET). The parameters are stored in 7X-1710 Multimeter Probes
the ECM, and some parameters are protected
from unauthorized changes by passwords. These 326-4904 Adapter Cable As (3-PIN BREAKOUT)
passwords are called factory passwords. 7X-1715 Adapter Cable As (40-PIN BREAKOUT)
134-5195 Harness (40-PIN)
Passwords For ADEM 2 ECM (two 40-pin
connectors)
Several system configuration parameters and most 208-0059 Adapter Cable As (70-PIN BREAKOUT)
logged events are protected by factory passwords. For ADEM 3 ECM (two 70-pin
Factory passwords are available only to Caterpillar connectors) and for ADEM 4 ECM
dealers. Refer to Troubleshooting, “Factory (one 70-pin connector and one 120-pin
Passwords” for additional information. connector)
257-8718 Adapter Cable As (120-PIN BREAKOUT)
i03786171
For ADEM 4 ECM (one 70-pin connector
and one 120-pin connector)
Electronic Service Tools Repair Kits for Connectors
SMCS Code: 0785 270-5051 Connector Repair Kit (AMPSEAL)

175-3700 Connector Repair Kit (DEUTSCH DT)
Service Tools Bypass Harnesses for the ECM
Most of the tools that are listed in Table 1 are required 129-2018 Power Cable
in order to enable a service technician to perform the Stand-alone cable for ADEM 2 ECM
test procedures that are found in this manual. Some 217-0113 Wiring Harness (ECM BYPASS)
of the devices are specific to the type of Electronic The bypass harness connects to the
Control Module (ECM) that is being used. battery. The bypass harness is used
with the following harnesses for different
types of electronic control modules.
328-2292 Harness (ENGINE ECM BYPASS)
For ADEM 3 ECM and ADEM 4 ECM
277-4734 Harness (ENGINE ECM BYPASS)
For A4:E2 ECM (Two 64-pin connectors)
Two short jumper wires are needed to check the

continuity of some wiring harness circuits by shorting
two adjacent terminals together in a connector. A
long extension wire may also be needed to check the
continuity of some wiring harness circuits.
Optional Service Tools

Table 2 lists the optional service tools that may be
needed during testing or repair.
8 RENR9346-06
Table 2 Note: For more information regarding the use of

Optional Service Tools
Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
Pt. No. Description software.
198-4240 Digital Pressure Indicator
or or Connecting Cat ET
1U-5470 Engine Pressure Group
4C-4075
Connecting the Communication Adapter
Crimp Tool (4−AWG TO 10−AWG)
4C-4911(1) Battery Load Tester Table 4 lists the standard hardware that is required in
5P-7277
order to connect Cat ET.
Voltage Tester
6V-9130(2) Temperature Adapter (MULTIMETER) Note: The 275-5120 Communication Adapter
8T-5319
Gp was cancelled and replaced by the 317-7484
Connector Tool Group
Communication Adapter Gp. However, the 275-5120
349-4199 AC/DC Current Probe Communication Adapter Gp can still be used.
348-5430 Multi-Tool Gp Table 4
(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911
Standard Hardware for the Use of Cat ET
Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteries”
and Special Instructions, SEHS7633, “Battery Test Procedure”. Part Number Description
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
Temperature Adapter Group”. N/A Personal Computer (PC)
Caterpillar Electronic Technician 317-7484

Communication Adapter
Gp
Cat ET can be used by the technician to help perform Components of the 317-7484 Communication
the following procedures: Adapter Gp
Communication Adapter
• Diagnostic tests 317-7485
(3)
• Calibrations 353-5083 Cable As (USB)

327-8981 Cable As (DATA LINK)
• Flash programming
Tool Operating Manual & Software CD ROM,
• Configuration of the Electronic Control Module NETG5057, “Communication Adapter 3”
(ECM)
Follow the instructions for the communication
Cat ET can display the following information: adapter. Use the following procedure in order to
connect Cat ET and the communication adapter to
• Parameters a PC.
• Event codes 1. Remove the electrical power from the ECM.
• Diagnostic codes
• Engine configuration
Always use the latest revision of Cat ET. The media
is available on CD and the media can also be
downloaded from various Caterpillar web sites.
Table 3
Software, JEBD3003, “CATERPILLAR
ELECTRONIC TECHNICIAN”
Once you have downloaded Cat ET onto your

PC, you will need a license from your Caterpillar
dealer in order to use the software. Various licenses
are available for different users with different
requirements. Consult your Caterpillar dealer.
RENR9346-06 9
Dual Data Links
When the connection of the communication adapter

is complete,observe the communication adapter
and Cat ET. If the “J1939 / DeviceNet” and the “Cat
Data Link” indicators are flashing and Cat ET does
not display a message that indicates “Service tool
support is limited”, Cat ET is communicating with the
ECM on both data links.
Refer to Troubleshooting, “Electronic Service Tool

Does Not Communicate” if the “J1939 / DeviceNet”
indicator and the “Cat Data Link” indicator are not
flashing. Both indicators must be flashing.
Communicating with the Wireless Communication

Adapter
Table 5 lists the optional hardware that is needed

in order to connect Cat ET by using a wireless
connection.
g02051513
Illustration 1
(1) PC
Note: Some applications cannot use a wireless
(2) 353-5083 Cable As (USB) connection. Also, a dual data link cannot be used
(3) 317-7485 Communication Adapter (3) with a wireless connection.
(4) 327-8981 Cable As (DATA LINK)
Table 5
2. Connect cables (2) and (4) to communication Optional Hardware for the Use of Cat ET
adapter (3).
Part Number Description
3. Connect cable (2) to the USB port of the PC.
N/A Personal Computer (PC)
4. Connect cable (4) to a service tool connector. Wireless Communication
261-3363(1)
Adapter Gp
5. Restore electrical power to the ECM. Verify that
the “POWER” indicator on the communication
(1) Refer to Tool Operating Manual, “Using the 261-3363
Wireless Communication Adapter Gp” for information that is
adapter is illuminated. Make sure that the PC is related to the installation and the configuration.
powered up.
6. Establish communication between Cat ET and the

ECM. If Cat ET indicates that there is more than
one ECM, select the engine ECM.
7. If Cat ET and the communication adapter

do not communicate with the ECM, refer to
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.
Refer to Troubleshooting, “Electronic Service Tool

Does Not Communicate” if any of the following
conditions exist:
• Cat ET displays a message that refers to a

communication problem.
• Cat ET displays “Error #142 The interface

hardware is not responding”.
• Cat ET displays a message that indicates that g01297379

the firmware in the communications adapter is Illustration 2
old. (1) Personal computer (PC)
(7) 261-4867 Card (PCMCIA)
(8) 239-9955 Communication Radio Gp
(9) 259-3183 Data Link Cable As
10 RENR9346-06
Note: Items (7), (8), and (9) are part of the 261-3363
Wireless Communication Adapter Gp.
Use the following procedure in order to connect the

wireless communication adapter for use with Cat ET.
1. Remove the electrical power from the ECM.
2. Ensure that the computer has been correctly

configured for the 261-4867 Card. Verify that
the PC card is installed in the computer's PCI
expansion slot.
3. Connect cable (9) between communication radio

(8) and the service tool connector.
4. Restore the electrical power to the ECM. If Cat ET

and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate with ECM”.
PL1000E Communication ECM
g01163897
Illustration 3
The “PL1000E” is an ECM that provides the

customer with the ability to integrate Caterpillar
engines into specific applications. The “PL1000E”
enables communication from a “J1939” data link
to a “Modbus”. A PC with Cat ET installed can be
connected to the “PL1000E” through the RS232
serial port of the PC. The “PL1000E” contains an
embedded communications adapter that will allow
Cat ET to communicate with the engine over the
“J1939” data link.
RENR9346-06 11
i02881454 1. Print the parameters from the “Configuration”

screen on Caterpillar Electronic Technician
Replacing the ECM (ET). If a printer is unavailable, record all of the
parameters. Record any logged diagnostic codes
SMCS Code: 1901-510 and logged event codes for your records. Record
the injector serial numbers from the “Calibrations”
NOTICE screen under the “Service” menu on Cat ET.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Note: The injector serial numbers are necessary for
ing, adjusting and repair of the product. Be prepared to obtaining the correct injector trim files. The ECM
collect the fluid with suitable containers before open- uses the injector trim files in order to compensate for
ing any compartment or disassembling any compo- manufacturing variations between individual injectors.
nent containing fluids. If you replace any of the unit injectors, you must
reprogram the injector trim files for the new injectors.
Refer to Special Publication, NENG2500, “Caterpillar Also, if you replace the ECM, the injector trim files
Dealer Service Tool Catalog” for tools and supplies must be installed into the new ECM. A successful
suitable to collect and contain fluids on Caterpillar “Copy Configuration” process will accomplish this
products. task. For more instruction, refer to programming
parameters Troubleshooting, “Injector Trim File”.
Dispose of all fluids according to local regulations and
mandates. 2. Use the “Copy Configuration/ECM Replacement”
feature that is found under the “Service” menu on
Cat ET. Select “Load from ECM” in order to copy
NOTICE the configuration from the suspect ECM.
Keep all parts clean from contaminants.
Note: If the “Copy Configuration” process fails and
Contaminants may cause rapid wear and shortened the parameters were not obtained in Step 1, the
component life. parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
The Electronic Control Module (ECM) contains no plate, but most parameters must be obtained from
moving parts. Replacement of the ECM can be the factory.
costly. Replacement can also be a time consuming
task. Use these procedures to ensure that the ECM 3. Remove the ECM from the engine.
is the cause of the problem.
a. Remove the electrical power from the ECM.
Note: Ensure that the ECM is receiving power and
that the ECM is properly wired to the negative battery b. Disconnect the J1/P1 and J2/P2 ECM
circuit before you attempt to replace the ECM. Refer connectors.
to the diagnostic functional test Troubleshooting,
“Electrical Power Supply Circuit - Test”. NOTICE
Use a suitable container to catch any fuel that might
Some application software supports the use of a new spill. Clean up any spilled fuel immediately.
ECM as a test ECM. A new ECM can be temporarily
placed into a “Test ECM Mode”. This ECM can
then be used to replace a suspect ECM in order NOTICE
to determine if the suspect ECM is faulty. Refer to Do not allow dirt to enter the fuel system. Thoroughly
programming parameters Troubleshooting, “Test clean the area around a fuel system component that
ECM Mode”. will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
If the flash file and engine application are not matched, c. Remove the fuel lines (if equipped) from the
engine damage may result. ECM.
Perform the following procedure in order to replace d. Remove the mounting bolts from the ECM.
the ECM:
e. Disconnect the ECM ground strap from the
engine.
4. Install the replacement ECM.

12 RENR9346-06
a. If the old mounting hardware is in good repair, d. If necessary, program the engine monitoring
you can use the old mounting hardware to system.
install the replacement ECM.
8. Program the injector trim files. Refer to
b. Reconnect the fuel lines (if equipped). programming parameters Troubleshooting,
“Injector Trim File”.
c. Ensure that the ECM mounting hardware is
installed correctly. The fuel lines must not put 9. Check for an active diagnostic code for timing
tension on the ECM. The rubber grommets calibration.
are used to protect the ECM from excessive
vibration. The ECM must be able to drift in If the diagnostic code is active, calibrate the
the rubber grommets. If the ECM cannot be injection timing. Refer to calibration procedures
moved slightly in the grommets, check that the Troubleshooting, “Engine Speed/Timing Sensor -
fuel lines (if equipped) are not pulling the ECM Calibrate”.
against one side of the grommets.
10. Check for diagnostic codes and for event codes.
d. Connect the ECM ground strap.
i02378227
e. Connect the J1/P1 and J2/P2 ECM connectors.
Tighten the allen head screw on each of the
ECM connectors to the proper torque. Refer to
Self-Diagnostics
the diagnostic functional test Troubleshooting, SMCS Code: 1901
“Electrical Connectors - Inspect” for the correct
torque value. The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
5. Program the flash file into the ECM. Refer to with engine operation. When a problem is detected, a
programming parameters Troubleshooting, “Flash code is generated. An alarm may also be generated.
Programming”. There are two types of codes:
6. If the replacement ECM was used previously for
a different application, use Cat ET to match the
• Diagnostic
engine application and the flash file.
• Event
7. Configure the ECM. Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
a. If the “Load from ECM” process from Step diagnostic code. This indicates the specific problem
2 was successful, return to the “Copy with the circuitry.
Configuration/ECM Replacement” screen on
Cat ET and select “Program ECM”. Diagnostic codes can have two different states:
After using the “Program ECM” feature, be sure
to cycle the power to the ECM. Wait at least
• Active
15 seconds after turning the keyswitch to the
OFF position.
• Logged
Active Code
Note: Some control modules have a power off delay.
The 15 seconds will be sufficient to cover this delay. An active diagnostic code indicates that an active
problem has been detected. Active codes require
b. If the “Program ECM” process was successful, immediate attention. Always service active codes
proceed to Step 9. prior to servicing logged codes.
c. If the “Program ECM” process was Logged Code
unsuccessful, manually program the ECM
parameters into the replacement ECM. The Every generated code is stored in the permanent
parameters must match the parameters from memory of the ECM. The codes are logged.
Step 1.
Note: If the “Copy Configuration” process fails and

the parameters were not obtained in Step 1, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.
RENR9346-06 13
Logged codes may not indicate that a repair is

needed. The problem may have been temporary. The
problem may have been resolved since the logging
of the code. If the system is powered, it is possible
to generate an active diagnostic code whenever a
component is disconnected. When the component is
reconnected, the code is no longer active. Logged
codes may be useful to help troubleshoot intermittent
problems. Logged codes can also be used to review
the performance of the engine and of the electronic
system.
Event Code
An event code is generated by the detection of an

abnormal engine operating condition. For example,
an event code will be generated if the oil pressure is
too low. In this case, the event code indicates the
symptom of a problem.
i02819587
Sensors and Electrical

Connectors
SMCS Code: 1439; 7553-WW
14 RENR9346-06
g01406305
Illustration 4
Components for the engine's control system
RENR9346-06 15
C27 and C32 Engines
g01270303
Illustration 5
(1) Engine coolant temperature sensor (5) Turbocharger #2 outlet pressure (C32 (7) Primary engine speed/timing sensor
(2) Atmospheric pressure sensor only) (8) Engine oil level switch
(3) Intake manifold pressure sensor (6) Intake manifold #2 air temperature (9) Engine oil pressure sensor
(4) Intake manifold air temperature sensor sensor (C32 only)
16 RENR9346-06
g01269662
Illustration 6
(6) Intake manifold #2 air temperature (12) J2/P2 ECM connectors (16) Fuel pressure sensor
sensor (C32 only) (13) J1/P1 ECM connectors (17) Fuel temperature sensor
(10) Connector for the left bank valve cover (14) Secondary engine speed/timing sensor
(11) Connector for the right bank valve cover (15) Fuel filter differential pressure switch
RENR9346-06 17
g01406392
Illustration 7
(18) “FRONT LEFT EXHAUST TC” (20) Engine oil level switch (C32 only)
(19) Engine oil renewal soleniod (C32 only) (21) “REAR LEFT EXHAUST TC”
18 RENR9346-06
g01406395
Illustration 8
Cooling fan drive assembly
(22) Cooling fan drive assembly
(23) Connector for the engine fan speed sensor
(24) Engine fan control solenoid
g01406396
Illustration 9
Air cleaner assembly
(25) Turbocharger inlet pressure sensor
RENR9346-06 19
Programming Parameters 2. Use the “Copy Configuration/ECM Replacement”

feature on Cat ET to copy the configuration
parameters from the suspect ECM to your personal
i03312021 computer (PC). If the “Copy Configuration/ECM
Replacement” feature cannot be used, record
Programming Parameters the programmed values into the “Parameters
Worksheet” in system configuration parameters
SMCS Code: 1901 Troubleshooting, “System Configuration
Parameters”. Record the injector serial numbers
The electronic service tool can be used to view from the “Calibrations” screen under the “Service”
certain parameters that can affect the operation of the menu on Cat ET.
engine. The electronic service tool can also be used
to change certain parameters. The parameters are Note: Some applications use injectors that have trim
stored in the Electronic Control Module (ECM). Some codes or injector trim files that are associated with
of the parameters are protected from unauthorized the injectors. If injector trim codes are necessary,
changes by passwords. Parameters that can be the injector trim codes are printed on the injector. If
changed have a tattletale number. The tattletale injector trim files are necessary, the injector serial
number shows if a parameter has been changed. numbers are necessary for obtaining the correct
injector trim files from Cat ET. The injector trim file is a
i02419708
number that is specific to each unit injector. The ECM
uses this number to compensate for manufacturing
Test ECM Mode variations between individual injectors. If you replace
any of the unit injectors, you must program the
SMCS Code: 1901 injector trim files for the new injectors. Also, if you
replace the ECM, you must program all of the injector
“Test ECM Mode” is a feature on Caterpillar Electronic trim files into the new ECM.
Technician (ET) that is used to troubleshoot an
engine that may have a problem with the Electronic 3. Disconnect the suspect ECM. Temporarily connect
Control Module (ECM). If an application supports this the new ECM to the engine. Do not mount the
feature, Cat ET will allow a new ECM to be used new ECM on the engine.
temporarily as a test ECM.
Note: The “Test ECM Mode” must be activated
When the “Test ECM Mode” is activated, an internal before the engine serial number is programmed
timer sets a 24 hour clock. This clock will count into the new ECM. “Test ECM Mode” can only be
down only while the ECM is powered. If the new activated if the engine serial number has not already
ECM fixes the problem, the engine can be released been programmed during normal operation of the
while the “Test ECM Mode” is still active. After the ECM. If the engine serial number is programmed and
ECM has counted down the 24 hour period, the ECM the new ECM is not in “Test ECM Mode”, the new
will exit the “Test ECM Mode”. The parameters, the ECM can never be used as a test ECM.
accumulated hours, and the engine serial number
will be permanently programmed into the new ECM. 4. Start the “Test ECM Mode” on Cat ET. Access the
The new ECM can no longer be used for another feature through the “Service” menu. Cat ET will
engine or for a test ECM. display the status of the “Test ECM Mode” and the
hours that are remaining for the “Test ECM Mode”.
Note: When the“Test ECM Mode” is activated, the
“Personality Module Code” is 0. After the ECM has 5. Program the correct flash file into the new ECM.
counted down the 24 hour period, the “Personality
Module Code” will be dependent on the application. Note: If the “Copy Configuration/ECM Replacement”
feature cannot be used, program the values from the
If the problem is not solved with the new ECM and “Parameters Worksheet”.
the 24 hour period has not expired, the ECM can be
removed from the engine and reused as a new ECM 6. Use the “Copy Configuration/ECM Replacement”
on another engine. Anytime prior to the 24 hour limit feature on Cat ET to program the correct
of the “Test ECM Mode”, a new engine serial number parameters into the new ECM.
and new parameters can be reprogrammed.
7. Program the engine serial number into the new
1. Search for the latest flash file for the engine. ECM.
Note: If a newer software version is available for the If the problem is resolved with the new ECM,
engine, install the newest software on the suspect remove the original ECM and permanently install
ECM. If the new software does not fix the problem the new ECM.
continue with this procedure.
20 RENR9346-06
If the new ECM does not fix the problem, the i02419726
original ECM is not the problem. Remove the new
ECM before the 24 hour timer expires. Reconnect Flash Programming
the original ECM.
SMCS Code: 1901-591
i02433393 Flash Programming – This is a method of

programming or updating the flash file in an engine's
Factory Passwords Electronic Control Module (ECM).
SMCS Code: 0785 Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engine's ECM.
NOTICE
Operating the engine with a flash file not designed for If you do not have the flash file, use the “Flash File
that engine will damage the engine. Be sure the flash Search” tool on the Service Technician Workbench
file is correct for your engine. (STW) to obtain the flash file for your engine.
Alternatively, use the “Service Software Files” feature
on SIS Web to obtain the flash file for your engine.
Note: Factory passwords are provided only to
You must have the engine serial number in order to
Caterpillar dealers.
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write
Factory passwords are required to perform each of
down the name of the flash file for future reference.
the following functions:
• Program a new Electronic Control Module (ECM). Programming a Flash File

When an ECM is replaced, the system configuration 1. Establish communication between Cat ET and the
parameters must be programmed into the new engine's ECM.
ECM. A new ECM will allow these parameters to
be programmed once without factory passwords. 2. Select “WinFlash” from the “Utilities” menu on Cat
After the initial programming, some parameters are ET.
protected by factory passwords.
Note: If “WinFlash” will not communicate with the
• Clear event codes. ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, “Electronic Service Tool Will
Most event codes require the use of factory Not Communicate with ECM”.
passwords to clear the code once the code has
been logged. Clear these codes only when you are 3. Program the flash file into the ECM.
certain that the problem has been corrected.
a. Select the engine ECM under the “Detected
• Unlock parameters. ECMs”.
Factory passwords are required in order to b. Press the “Browse” button in order to select the
unlock certain system configuration parameters. name of the flash file that will be programmed
Refer to Troubleshooting, “System Configuration into the ECM.
Parameters”.
c. When the correct flash file is selected, press
Since factory passwords contain alphabetic the “Open” button.
characters, the Caterpillar Electronic Technician (ET)
must be used to perform these functions. In order to d. Verify that the “File Values” match the
obtain factory passwords, proceed as if you already application. If the “File Values” do not match
have the password. If factory passwords are needed, the application, obtain the correct flash file.
Cat ET will request the factory passwords and Cat ET
will display the information that is required to obtain e. When the correct flash file is selected, press
the passwords. For the worksheet that is used for the “Begin Flash” button.
acquiring factory passwords, refer to programming
parameters Troubleshooting, “Factory Passwords f. Cat ET will indicate when flash programming
Worksheet”. has been successfully completed.
4. Start the engine and check for proper operation.

Repair any active diagnostic or event codes.
RENR9346-06 21
“WinFlash” Error Messages 5. Connect Cat ET to the service tool connector. Refer
to electronic troubleshooting Troubleshooting,
If you receive any error messages during flash “Electronic Service Tools”.
programming, click on the “Cancel” button in order
to stop the process. Access the information about 6. Select the following menu options on Cat ET:
the “ECM Summary” under the “Information” menu.
Make sure that you are flashing the correct file for • Service
your engine.
• Calibrations
i02490769
• Injector Trim Calibration
Injector Trim File 7. Select the appropriate cylinder.
SMCS Code: 1290
8. Click on the “Change” button.
The Caterpillar Electronic Technician (ET) is used to
load the injector trim files into the Electronic Control 9. Select the appropriate injector trim file from the
Module (ECM). PC.
The injector trim files must be loaded into the ECM if 10. Click on the “Open” button.
any of the following conditions occur:
11. If you are prompted by Cat ET enter the injector
confirmation code into the field.
• An injector is replaced.
12. Click on the “OK” button.
• The ECM is replaced.
The injector trim file is loaded into the ECM.
• “Injector Trim” is displayed below a 268-02
diagnostic code on Cat ET.
13. Repeat the procedure for each cylinder, as
required.
• Injectors are exchanged between cylinders.
Exchanging Injectors
Exchanging injectors can help determine if a

combustion problem is in the injector or in the
cylinder. If two injectors that are currently installed
in the engine are exchanged between cylinders,
the injector trim files can also be exchanged. Press
the “Exchange” button at the bottom of the “Injector
Trim Calibration” screen on Cat ET. Select the two
injectors that will be exchanged and press the “OK”
button. The tattletale for the injectors that were
exchanged will increase by one.
Note: The injector serial number and the injector

confirmation code are located on the injector. Cat ET
may require the entry of injector confirmation code
during this process. Cat ET will prompt you for the
code, if necessary.
1. Record the injector serial number and the injector

confirmation code for each injector.
2. Click on “Service Software Files” in SIS Web.
3. Enter the serial number for the injector in the

search field.
4. Download the injector trim file to the PC. Repeat

this procedure for each injector, as required.
22 RENR9346-06
System Configuration Software Group Release Date

Parameters This parameter identifies the release date of the flash
file that is currently installed in the ECM.
i02529692
Software Group Description
System Configuration
This parameter identifies the description of the
Parameters application for the flash file that is currently installed
in the ECM.
SMCS Code: 1901
System configuration parameters are parameters

Full Load Setting (FLS)
that are configured to specify the engine's emissions
FLS is a parameter that represents the adjustment
levels, the power rating, and the specific application.
to the fuel system that was made at the factory
Default values for the parameters are programmed
in order to fine tune the fuel system. The correct
at the factory. Some parameters may be changed in
value for this parameter is stamped on the engine
order to equip the engine for a specific application.
information plate. Only change this value if the engine
The system configuration parameters must be
is rerated or if a new ECM has been installed. Factory
reprogrammed if the Electronic Control Module
passwords are required to change this parameter.
(ECM) is replaced. It is not necessary to reprogram
the system configuration parameters if you update
the ECM flash file. Certain configuration parameters Full Torque Setting (FTS)
are stamped into the engine information plate.
FTS is similar to FLS. Only change this value if the
Note: If the parameters that are protected with engine is rerated or if a new ECM has been installed.
the factory passwords are changed, the Caterpillar Factory passwords are required to change this
warranty may be voided. parameter.
Parameter Descriptions Rated Power

This parameter specifies the rated power of the
Equipment ID engine.
The “Equipment ID” parameter allows the customer
to enter a description into the ECM in order to identify Rated Peak Torque
the engine's application. A maximum of 17 characters
can be entered in the field. This parameter specifies the rated peak torque of
the engine.
Engine Serial Number
Top Engine Speed Range
Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine This parameter specifies the maximum speed setting
information plate. The engine serial number is not for the engine.
preprogrammed on a replacement ECM.
Test Spec
ECM Part Number
This is the engine's “Test Specifiction Number”. Use
This parameter identifies the part number for the this number to retrieve data that is related to the
ECM. engine's specifications from the Technical Marketing
Information System (TMI). The following information
can be retrieved from TMI:
ECM Serial Number
This parameter identifies the serial number for the
• “As shipped consists”
ECM.
• “Engine test specifications”
Software Group Part Number • “Systems data”
This parameter identifies the part number of the flash • “Physical data”
file that is currently installed in the ECM.
• “Gasket kit data”
RENR9346-06 23
• “Reman parts”
• “Performance data”
A link to TMI Web can be found on the web site for
the Service Information System (SIS).
Total Tattletale
The total tattletale counts the number of changes to
system parameters.
Ether Solenoid Configuration

This parameter is enabled in order to define the
installation status of an ether starting aid for the
engine.
Engine Retarder Enable Command

(Option)
This parameter is enabled in order to define the
installation status of compression brakes for the
engine.
24 RENR9346-06
Parameter Table
Table 6
System Configuration Parameters

Parameter Available Range or Options Default Required Password
Configuration Group 1
Equipment ID 17 alphanumeric characters Blank None
ECM Identification Parameters
Engine Serial Number 0XX00000 or XXX00000 Blank Factory
ECM Serial Number Hardware Dependent Blank Read Only(1)
ECM Part Number Hardware Dependent Blank Read Only(1)
Software Group Part Number Software Dependent Read Only(1)
Software Group Release Date Software Dependent Read Only(1)
Software Group Description Software Dependent Read Only(1)
System Parameters
FLS Programmed at the Factory Factory
FTS Programmed at the Factory Factory
Rated Power Software Dependent Read Only(1)
Rated Peak Torque Software Dependent Read Only(1)
Top Engine Speed Range Software Dependent Read Only(1)
Test Spec Software Dependent Read Only(1)
Total Tattletale 0 to 65535 0 Read Only(1)
Engine Configuration Parameters
Not Installed Continuous Flow
Ether Solenoid Configuration None
Continuous Flow Solenoid Solenoid
On
Engine Fan Control Off None
Off
Engine Retarder Enable Command Enabled
Disabled None
(Option) Disabled
(1) This parameter can be viewed only. No changes are allowed.
Parameter Worksheet
Record the following information before you change
any programmable parameter.
RENR9346-06 25
Table 7
Engine Parameters
Equipment ID
ECM Serial Number
ECM Part Number
Software Group Part

Number
Software Group Release
Date
Total Tattletale
FLS
FTS
Ether Solenoid
Configuration
Engine Fan Control
Engine Retarder Enable

Command
Table 8
Information From Engine Information Plate
FLS
FTS
Note: Compare the FLS and the FTS from the

ECM with the values that are listed on the engine
information plate. Use of incorrect parameters could
cause damage to the engine. Use of the incorrect
parameters may also void the Caterpillar warranty or
the emission certification for the engine.
26 RENR9346-06
Troubleshooting without a Probable Causes

Diagnostic Code • Diagnostic codes and event codes
• Cold mode operation
i02398533
Alternator • Throttle signal

(Noisy Operation) • Intake manifold pressure sensor and atmospheric
pressure sensor
SMCS Code: 1405-035
• Fuel supply
Probable Causes • Air inlet and exhaust system
• Alternator drive belts • Accessory equipment
• Alternator drive pulley
Recommended Actions
• Alternator bearings
Diagnostic Codes and Event Codes
Recommended Actions
Use Caterpillar Electronic Technician (ET) to check
for logged derates. The engine speed or the engine
Alternator Drive Belts power may be limited due to one of the following
conditions: high altitude, high intake manifold air
1. Inspect the condition of the alternator drive belts. If temperature, low oil pressure, air filter restriction,
the belts are worn or damaged, replace the belts. and other factors. Refer to Troubleshooting,
“Troubleshooting with an Event Code” for the specific
2. Check the tension on the belts. Adjust the tension, events that are applicable to this application.
if necessary.
3. Ensure that the belts are in proper alignment. Cold Mode Operation
Inspect the alternator mounting bracket for cracks
and wear. Repair the mounting bracket or replace Use Cat ET to verify that the engine has exited
the mounting bracket in order to ensure that the cold mode. Cold mode operation may cause a slow
belts and the alternator drive pulley are aligned. throttle response. Engine speed may also be limited
during cold mode operation.
Alternator Drive Pulley
Throttle Signal
Check the condition of the alternator drive pulley.
Look for deep grooves that have been worn into the Use Cat ET in order to monitor the throttle position
pulley by the belt. If there is excessive wear, replace while you operate the throttle pedal. Ensure that the
the pulley. Check that the nut for the pulley has not throttle position sensor is operating correctly. Refer
become loose. If necessary, tighten the nut. to Troubleshooting, “Throttle Position Sensor Circuit -
Test”.
Alternator Bearings
Intake Manifold Pressure Sensor and
Check the alternator bearings for signs of wear. Atmospheric Pressure Sensor
Repair the alternator or replace the alternator, as
needed. 1. Monitor the status of “Fuel Position”, of “Rated
Fuel Limit”, and of “FRC Fuel Limit” on Cat ET
while the engine is operating under full load. These
i02433834 parameters must reflect the information below.
Can Not Reach Top Engine Table 9
RPM “Fuel Position” = “Rated Fuel Limit”
and
SMCS Code: 1915-035 “Fuel Position” < “FRC Fuel Limit”
Note: If this problem occurs only under load, refer to

Troubleshooting, “Low Power/Poor or No Response
to Throttle”.
RENR9346-06 27
If “Fuel Position” equals “Rated Fuel Limit” and Air Inlet and Exhaust System
“Fuel Position” is less than “FRC Fuel Limit”, the
electronics are operating correctly. Otherwise, 1. Check for an air filter restriction indicator. Clean
proceed with the next Step. plugged air filters or replace plugged air filters.
Refer to the Operation and Maintenance Manual.
2. Use Cat ET in order to monitor the status of the
“Boost Pressure”. With the engine stopped, the 2. Check the air inlet and exhaust system for
correct “Boost Pressure” is 0 kPa (0 psi). restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
3. Start the engine and monitor the status of “Boost Exhaust System”.
Pressure” while you vary the engine speed.
Ensure that the pressure reading is fluctuating Accessory Equipment
with the engine speed.
Check all accessory equipment for problems that
4. Use Cat ET in order to check the status of the may create excessive load on the engine. Make the
“Atmospheric Pressure”. Verify that the pressure necessary repairs to damaged components. Replace
reading is reasonable for the current conditions. parts, if necessary.
Fuel Supply
i02381103
1. Check the fuel lines for the following problems:

restrictions, collapsed lines, and pinched lines. If
Coolant in Engine Oil
problems are found with the fuel lines, repair the SMCS Code: 1348-035; 1395-035
lines and/or replace the lines.
2. Check the fuel tank for foreign objects or debris Probable Causes
which may block the fuel supply.
• Engine oil cooler core
3. Prime the fuel system if any of the following items
have been serviced recently: • Cylinder head gasket
• Fuel filters • Cylinder head
• Low pressure fuel supply circuit • Cylinder liner
• Unit injectors • Cylinder block

Note: A sight glass in the low pressure supply line Recommended Actions
is helpful in diagnosing air in the fuel. Refer to
Testing and Adjusting, “Air in Fuel - Test” for more
information. Engine Oil Cooler Core
1. Check for leaks in the oil cooler core. If a leak is
NOTICE found, install a new oil cooler core. Refer to the
Do not crank the engine continuously for more than Disassembly and Assembly manual.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. 2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters.
4. Cold weather adversely affects the characteristics Refer to the Operation and Maintenance Manual.
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving Cylinder Head Gasket
the characteristics of the fuel during cold weather
operation. 1. Remove the cylinder head. Refer to the
Disassembly and Assembly manual.
5. Check the fuel pressure during engine cranking.
Refer to Systems Operation/Testing and Adjusting, 2. Check the cylinder liner projection. Refer to the
“Fuel System” for the correct procedure. If the fuel Systems Operation/Testing and Adjusting manual.
pressure is below specifications, replace the fuel
filters. If this does not correct the problem, check 3. Install a new cylinder head gasket and new water
for the proper operation of the following items: fuel seals in the spacer plate. Refer to the Disassembly
transfer pump, fuel pressure relief valve, and fuel and Assembly manual.
pressure regulator valve.
28 RENR9346-06
Cylinder Head Recommended Repairs

Check for cracks in the cylinder head. If a crack Low Coolant Level
is found, repair the cylinder head and/or replace
the cylinder head. Refer to the Disassembly and
Assembly manual.
Pressurized System: Hot coolant can cause seri-
Cylinder Liner ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
Check for cracked cylinder liners. Replace any components are cool. Loosen the cooling system
cracked cylinder liners. Refer to the Disassembly and pressure cap slowly in order to relieve the pres-
Assembly manual. sure.
Cylinder Block
Note: Low coolant level can be the result of
Inspect the cylinder block for cracks. If a crack is overheating rather than the cause.
found, repair the cylinder block or replace the cylinder
block. Check the coolant level.
Run the engine to operating temperature.

i02422808
Inspect the cooling system for leaks. Check for the
Coolant Temperature Is Too presence of coolant in the engine oil. This would
High indicate an internal coolant leak.
SMCS Code: 1395-035 Determine whether the leak occurs before the engine
overheats.
Probable Causes Add coolant, if necessary. If leaking is found, make
the necessary repairs.
• Low coolant level
• Air in coolant Air in Coolant
Air can enter the cooling system if the pressure cap
• Water pump is not operating properly. Check the operation of the
pressure cap. Replace the pressure cap, if necessary.
• Environmental conditions
If the coolant has been changed recently, ensure that
• Shunt line restriction the air has been purged from the cooling system.
Refer to Systems Operation/Testing and Adjusting.
• Radiator or heat exchanger
The supply pressure to the water pump must be
• Water temperature regulator sufficient in order to prevent cavitation. Measure the
supply pressure at the inlet to the water pump.
• Coolant temperature sensor
• Engine coolant flow Water Pump
• Exhaust restriction The engine will overheat if the water pump is not
operating properly. Measure the coolant pressure
• Excessive load at the outlet of the water pump. Make sure that the
water pump is in good condition.
• Combustion gas in the coolant
Environmental Conditions
Determine if the ambient air temperature is within the
design specifications for the cooling system.
Ensure that the engine's exhaust does not heat the

radiator or the heat exchanger.
Check for high inlet air temperature.

RENR9346-06 29
Determine the cause of the high air temperature. Engine Coolant Flow
Make corrections, when possible.
Insufficient coolant through the engine can be
Refer to Systems Operation/Testing and Adjusting. identified by checking the coolant temperature at
various points in the cooling system.
Shunt Line Restriction
During normal operation, measure temperatures at
If the cooling system is equipped with a shunt line, several different points in the cooling system. This
check for a restriction in the line. A restricted shunt will help to identify possible locations of restrictions.
line can cause cavitation in the water pump. Remove
the restriction or replace the shunt line. If a buildup of deposit in the cooling system is
suspected, clean the cooling system.
Radiator or Heat Exchanger If the flow of coolant through the engine is not
sufficient, determine the cause of the obstruction.
Measure the coolant temperature at the inlet to the
Make necessary repairs.
engine.
Radiator Exhaust Restriction
If the engine is equipped with a radiator, check the Check the back pressure of the exhaust system.
fins of the radiator for obstructions. Check the fan Refer to the engine's Technical Marketing Information.
for proper operation.
If the back pressure exceeds the specifications for
If the radiator fins are obstructed, clean the fins. If the the engine, determine the cause of the excessive
fan does not operate properly, make the necessary back pressure. Make the necessary repairs.
repairs.
Excessive Load
Heat Exchanger
Make sure that the load is not excessive. Reduce the
If the engine is equipped with a heat exchanger, load. If necessary, disengage the driven equipment
check for sufficient flow and temperature of the and test the engine for high coolant temperature.
cooling water through the heat exchanger. If the
flow of cooling water through the heat exchanger is Combustion Gas in the Coolant
insufficient, determine the location of the obstruction.
Check the cooling system for combustion gas. This
Water Temperature Regulator can be identified by small air bubbles in the coolant
during engine operation. Identify the source of the
Check the water temperature regulators for proper combustion gas. Make the necessary repairs.
operation. Refer to Systems Operation/Testing and
Adjusting.
i02826488
Replace the water temperature regulators, if

necessary.
ECM Will Not Accept Factory
Passwords
Coolant Temperature Sensor
SMCS Code: 1901-035
Compare the reading for the coolant temperature
from the Caterpillar Electronic Technician (ET) to Probable Causes
the reading for the coolant temperature from a
mechanical gauge. The temperature should rise One of the following items may not be recorded
steadily as the engine is warmed. Ensure that correctly on the Caterpillar Electronic Technician
the temperature is reasonable. Refer to Systems (ET):
Operation/Testing and Adjusting.
• Passwords
If the reading on Cat ET for the coolant temperature
is not reasonable, troubleshoot the circuit and the • Serial numbers
coolant temperature sensor. Refer to the diagnostic
functional test Troubleshooting, “Engine Temperature • Total tattletale
Sensor Open or Short Circuit - Test”.
• Reason code
30 RENR9346-06
Recommended Actions • Wiring to other control modules

1. Verify that the correct passwords were entered. 3. Troubleshoot the Cat Data Link for possible
Check every character in each password. Remove problems. Refer to the diagnostic functional test
the electrical power from the engine for 30 Troubleshooting, “Cat Data Link Circuit - Test”.
seconds and then retry.
i02429900
2. Verify that Cat ET is displaying the “Enter Factory
Passwords” dialog box. Electronic Service Tool Will
3. Use Cat ET to verify that the following information Not Communicate with ECM
has been entered correctly:
SMCS Code: 0785-035; 1901-035
• Engine serial number
Probable Causes
• Serial number for the electronic control module
• Configuration for the communications adapter
• Serial number for Cat ET
• Electrical connectors
• Total tattletale
• Communication adapter and/or cables
• Reason code
For additional information, refer to Troubleshooting,
• Electrical power supply to the service tool
connector
“Factory Passwords”.
• Caterpillar Electronic Technician (ET) and related
i02471377 hardware
ECM Will Not Communicate • Electrical power supply to the Electronic Control
Module (ECM)
with Other Systems or Display
Modules • Flash file
SMCS Code: 1901-035 • Cat Data Link
Probable Causes Recommended Actions

• Electronic Control Module (ECM) Start the engine. If the engine starts, but the ECM
will not communicate with Cat ET, continue with
• Electrical connectors this procedure. If the engine will not start, refer
to the troubleshooting without a diagnostic code
• Cat Data Link procedure Troubleshooting, “Engine Cranks but Will
Not Start”. If the engine will not crank, refer to the
troubleshooting without a diagnostic code procedure
Recommended Actions Troubleshooting, “Engine Will Not Crank”.
1. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. If the ECM does not Configuration for the Communications
communicate with Cat ET, refer to troubleshooting Adapter
without a diagnostic code Troubleshooting,
“Electronic Service Tool Will Not Communicate 1. Access “Preferences” under the “Utilities” menu
with ECM”. on Cat ET.
2. Ensure that the following items are correctly 2. Verify that the correct “Communications Interface
installed and undamaged. Refer to the diagnostic Device” is selected.
functional test Troubleshooting, “Electrical
Connectors - Inspect”. 3. Verify that the correct port is selected for use by
the communication adapter.
• ECM connector J1/P1
Note: The most commonly used port is “COM 1”.
• Machine connector
• Wiring to display modules
RENR9346-06 31
4. Check for any hardware that is utilizing the Note: A new ECM is not programmed to any specific
same port as the communications adapter. If any engine until a flash file has been installed. The engine
devices are configured to use the same port, exit will not start and the engine will not communicate
or close the software programs for that device. with Cat ET until the flash file has been downloaded.
Refer to programming parameters Troubleshooting,
Electrical Connectors “Flash Programming”.
Check for correct installation of the J1/P1 and Cat Data Link
J2/P2 ECM connectors and of the service tool
connector. Refer to the diagnostic functional test Troubleshoot the Cat Data Link for possible
Troubleshooting, “Electrical Connectors - Inspect”. problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”.
Communication Adapter and/or Cables
i02881458
1. If you are using a “Communication Adapter II”,
ensure that the firmware and driver files for the Engine Cranks but Will Not
communication adapter are the most current files
that are available. If the firmware and driver files Start
do not match, the communication adapter will not
communicate with Cat ET. SMCS Code: 1000-035
2. Disconnect the communication adapter and the Probable Causes

cables from the service tool connector. Reconnect
the communication adapter to the service tool • Diagnostic codes
connector.
• Event codes
3. Verify that the correct cable is being used between
the communication adapter and the service tool • Electrical power supply to the Electronic Control
connector. Refer to electronic troubleshooting Module (ECM)
Troubleshooting, “Electronic Service Tools”.
• Starting aids (if applicable)
Electrical Power Supply to the Service
Tool Connector • Engine shutdown switches
Verify that battery voltage is present between • Engine speed/timing

terminals A and B of the service tool connector. If the
communication adapter is not receiving power, the • Unit injectors
display on the communication adapter will be blank.
• Fuel supply
Cat ET and Related Hardware • Combustion
In order to eliminate Cat ET and the related hardware
as the problem, connect Cat ET to a different engine. Recommended Actions
If the same problem occurs on a different engine,
check Cat ET and the related hardware in order to Diagnostic Codes, Event Codes, and
determine the cause of the problem. Electrical Power Supply to the ECM
Electrical Power Supply to the Electronic Certain diagnostic codes and/or event codes may
Control Module (ECM) prevent the engine from starting. Connect the
Caterpillar Electronic Technician (ET) and check for
Check power to the ECM. Refer to the diagnostic active codes and/or for logged codes. Troubleshoot
functional test Troubleshooting, “Electrical Power any codes that are present before continuing with
Supply Circuit - Test”. this procedure.
Note: If the ECM is not receiving battery voltage, the Note: If Cat ET will not communicate with the
ECM will not communicate. ECM, the problem is most likely with the electrical
power supply to the ECM. Refer to Troubleshooting,
“Electrical Power Supply Circuit - Test”.
Flash File
Ensure that the correct flash file is properly installed
in the ECM.
32 RENR9346-06
Starting Aids 2. Check the fuel lines for the following problems:
1. If cold ambient conditions exist, check operation problems are found with the fuel lines, repair the
of starting aids. Verify that the ether system is lines and/or replace the lines.
operating correctly. Refer to Troubleshooting,
“Ether Injection System - Test”. 3. Check the fuel tank for foreign objects which may
block the fuel supply.
2. Ensure the proper operation of the jacket water
heater. Repair the jacket water heater and/or 4. Check for air in the low pressure fuel supply
replace the jacket water heater, if necessary. system if any of the following procedures have
been performed:
Engine Shutdown Switches (If Equipped)
• Replacement of the fuel filters
The engine shutdown switches should be in the
OFF position. Use Cat ET to verify the status of the • Service on the low pressure fuel supply circuit
shutdown switches. When a shutdown occurs, the
keyswitch must be turned to the OFF position for at • Replacement of unit injectors
least 15 seconds before restarting the engine.
Note: A sight glass in the low pressure supply line
Note: If Cat ET will not communicate with the is helpful in diagnosing air in the fuel. Refer to the
ECM, the problem is most likely with the electrical Systems Operation/Testing and Adjusting manual for
power supply to the ECM. Refer to Troubleshooting, more information.
“Electrical Power Supply Circuit - Test”.
NOTICE
Engine Speed/Timing Do not crank the engine continuously for more than
1. Crank the engine and observe the engine speed minutes before cranking the engine again.
on the Cat ET status screen. If Cat ET indicates
zero rpm, refer to Troubleshooting, “Engine 5. Purge air from the low pressure fuel supply circuit.
Speed/Timing Sensor Circuit - Test”. Refer to Operation and Maintenance Manual,
“Fuel System - Prime” for the correct procedure.
Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is 6. Cold weather adversely affects the characteristics
abnormal. This message will be replaced with an of the fuel. Check for presence of solidified fuel
engine speed once the ECM is able to calculate a (wax). Refer to the Operation and Maintenance
speed from the signal. Manual for information on improving the
characteristics of the fuel during cold weather
2. Ensure that the timing reference gear is installed operation.
correctly. The engine will not start if the gear was
installed backward. Check for proper orientation 7. Check the fuel pressure during engine cranking.
between the crankshaft and camshaft drive gears. Check the fuel pressure after the fuel filter. Refer
Correct the orientation and/or replace the drive to Systems Operation/Testing and Adjusting, “Fuel
gear, if necessary. Refer to the Disassembly and System” for the correct pressure values. If the fuel
Assembly manual for information that is related to pressure is low, replace the fuel filters. If the fuel
timing the engine's front gear train. pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
Unit Injectors fuel pressure regulating valve.
Perform the “Injector Solenoid Test” on Cat ET in Combustion

order to determine if all of the injector solenoids
are being energized by the ECM. Refer to Check for combustion problems. Check for signs of
Troubleshooting, “Injector Solenoid Circuit - Test” for poor sealing around the cylinder head or for leakage
additional information. around the injector.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel
gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary
to purge the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.
RENR9346-06 33
i03506600 Leaks in Air Intake System

Engine Has Early Wear A leak in the air intake system may allow unfiltered
air into the engine. Inspect the air intake system for
SMCS Code: 1000-035 streaks which may indicate a leakage of unfiltered air.
Inspect all of the gaskets and the connections. Repair
Probable Causes any leaks. Refer to Systems Operation, Testing and
Adjusting for more information.
Engine Oil
Inspect the air filter. Replace the air filter, if necessary.
• Incorrect maintenance intervals
Inspect the Fuel Filters for Contamination
• Contaminated engine oil
1. Remove the fuel filters. Inspect the fuel filters for
• Low oil pressure contamination. Install new fuel filters. Refer to the
Operation and Maintenance Manual. Determine
Contaminated Air the cause of the contamination.
2. Contaminants in the fuel such as hydrogen sulfide

• Leaks in air intake system and sulfur can lead to the formation of acids in the
crankcase. Obtain a fuel analysis.
Contaminated Fuel
• Inspect the fuel filters for contamination. i02513923
Engine Misfires, Runs Rough

Recommended Actions
or Is Unstable
Incorrect Maintenance Intervals SMCS Code: 1000-035
Use engine oil that is recommended and change the
Note: If the symptom is intermittent and the symptom
engine oil at the interval that is recommended by the
cannot be repeated, refer to troubleshooting without
engine's Operation and Maintenance Manual.
a diagnostic code Troubleshooting, “Intermittent Low
Power or Power Cutout”. If the symptom is consistent
Contaminated Engine Oil and the symptom can be repeated, continue with this
procedure.
Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters. Refer to
the engine's Operation and Maintenance Manual. Probable Causes
If the oil filter bypass valve is open, the oil will not be • Diagnostic codes
filtered. Check the oil filter bypass valve for a weak
spring or for a broken spring. If the spring is broken, • Electrical connectors
replace the spring. Refer to the engine's Disassembly
and Assembly manual. Make sure that the oil bypass • Cold mode
valve is operating correctly.
• Throttle signal
Low Oil Pressure • Unit injectors
When some components of the engine show bearing
wear in a short time, the cause can be a restriction in
• Fuel supply
a passage for engine oil.
• Air inlet and exhaust system
An indicator for the engine oil pressure may indicate
sufficient pressure, but a component is worn due Recommended Actions
to a lack of lubrication. In such a case, look at the
passage for the engine oil supply to the component. Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under
those conditions. Troubleshooting the symptom
under other conditions can give misleading results.
34 RENR9346-06
Diagnostic Codes 4. Cold weather adversely affects the characteristics

Check for active diagnostic codes on the Caterpillar Maintenance Manual for information on improving
Electronic Technician (ET). Troubleshoot any active the characteristics of the fuel during cold weather
codes before continuing with this procedure. operation.
Electrical Connectors 5. Check the fuel pressure during engine cranking.

Check the fuel pressure after the fuel filter. Refer
Check for correct installation of the J1/P1 and to Systems Operation/Testing and Adjusting, “Fuel
J2/P2 Electronic Control Module (ECM) connectors System” for the correct pressure values. If the fuel
and the unit injector connectors. Refer to the pressure is low, replace the fuel filters. If the fuel
diagnostic functional test Troubleshooting, “Electrical pressure is still low, check the following items: fuel
Connectors - Inspect”. transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve.
Cold Mode
Air Inlet and Exhaust System
Use Cat ET to verify that the engine has exited cold
mode. Cold mode operation may cause the engine to 1. Check for an air filter restriction. Clean plugged air
run rough and the engine power may be limited. filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual.
Throttle Signal 2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Monitor throttle signal on Cat ET. Verify that the Operation/Testing and Adjusting, “Air Inlet and
throttle signal is stable from the low idle position to
Exhaust System”.
the high idle position.
Unit Injectors i02549498
1. Use Cat ET to determine if there are any active Engine Oil in Cooling System
diagnostic codes for the unit injectors.
SMCS Code: 1348-035; 1350-035
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids Probable Causes
are being energized by the ECM.
• Engine oil cooler core
3. Perform the “Cylinder Cutout Test” on Cat ET in
order to identify any misfiring cylinder(s). Refer • Cylinder head gasket
“Injector Solenoid Circuit - Test”. • Water pump
Fuel Supply Recommended Actions
Engine Oil Cooler Core
problems are found with the fuel lines, repair the
1. Inspect the engine oil cooler core for leaks. If a
leak is found, replace the oil cooler core. Refer to
Disassembly and Assembly.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters.
3. Prime the fuel system if any of the following
Refer to Operation and Maintenance Manual.
procedures have been performed:
• Replacement of the fuel filters Cylinder Head Gasket
• Service on the low pressure fuel supply circuit 1. Remove the cylinder head. Refer to Disassembly
and Assembly.
• Replacement of unit injectors
2. Check the cylinder liner projection. Refer to
Systems Operation/Testing and Adjusting.
RENR9346-06 35
3. Install a new cylinder head gasket and new water i02455784

seals in the spacer plate. Refer to Disassembly
and Assembly. Engine Stalls at Low RPM
SMCS Code: 1915-035
Water Pump
Check the weep hole in the water pump for blockage. Probable Causes
Check the water pump seals.
• Unit injectors
i02421677
• Fuel supply
Engine Oil Temperature Is Too • Air supply
High
• Engine idle
SMCS Code: 1348-035-TA
• Accessory equipment
Probable Causes
Recommended Actions
• Engine oil level
Unit Injectors
• Engine oil cooler bypass valve
1. Check for correct installation of the J1/P1 and
• Engine oil cooler core J2/P2 connectors for the Electronic Control
Module (ECM). Check for correct installation of the
• Engine coolant temperature J300/P300 connectors for the unit injectors. Refer
Recommended Actions “Electrical Connectors - Inspect”.
2. Perform the “Injector Solenoid Test” with the

Engine Oil Level Caterpillar Electronic Technician (ET) in order to
determine if all of the injector solenoids are being
Use the engine oil dipstick to check for the correct oil
energized by the ECM.
level. If necessary, add engine oil to the crankcase.
3. Perform the “Cylinder Cutout Test” with Cat ET
Engine Oil Cooler Bypass Valve in order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test
Inspect the components of the engine oil cooler Troubleshooting, “Injector Solenoid Circuit - Test”.
bypass valve for damage. Clean the engine oil
cooler bypass valve and clean the bore for the
valve. Ensure that the bypass valve is not stuck
Fuel Supply
in the open position. Replace the components of
1. Check the fuel pressure. Refer to Systems
the bypass valve, if necessary. Refer to Systems
Operation/Testing and Adjusting for information that
is related to troubleshooting an increased engine oil
temperature.
Engine Oil Cooler Core lines and/or replace the lines.
Check the engine oil cooler core for damage and for 3. Check the fuel tank for foreign objects which may
plugging. Clean the engine oil cooler core or replace block the fuel supply.
the engine oil cooler core, if necessary.
NOTICE
Engine Coolant Temperature Do not crank the engine continuously for more than
If a high coolant temperature condition is also minutes before cranking the engine again.
occurring, refer to troubleshooting without a
diagnostic code Troubleshooting, “Coolant
Temperature Is Too High”. 4. Prime the fuel system if any of the following

36 RENR9346-06
• Service on the low pressure fuel supply circuit Recommended Actions

• Replacement of unit injectors Vibration Damper
Note: A sight glass in the low pressure supply line is Check the vibration damper for damage. Install a
helpful in diagnosing air in the fuel. Refer to Systems new vibration damper, if necessary. Inspect the
Operation/Testing and Adjusting. mounting bolts for damage and/or for wear. Replace
any damaged bolts. Refer to the Disassembly and
5. Cold weather adversely affects the characteristics Assembly manual.
Maintenance Manual.
Engine Supports
6. Check the fuel pressure after the fuel filter
while the engine is being cranked. For the Inspect the mounts and the brackets while you run
correct pressure values, refer to the Systems the engine through the speed range. Look for mounts
Operation/Testing and Adjusting manual. If the and brackets that are loose and/or broken. Tighten
fuel pressure is low, replace the fuel filters. If the all of the mounting bolts. Install new components, if
fuel pressure is still low, check the following items: necessary.
fuel transfer pump, fuel transfer pump coupling,
and fuel pressure regulating valve. Driven Equipment
Air Supply Check the alignment and the balance of the driven
equipment.
Check for restrictions in the air inlet system. Refer to
Systems Operation/Testing and Adjusting. Engine Misfiring or Running Rough
Engine Idle Refer to troubleshooting without a diagnostic code

Troubleshooting, “Engine Misfires, Runs Rough or
Check the parameter for the low engine idle (if Is Unstable”.
applicable). Refer to Troubleshooting, “System
Configuration Parameters”. i02445247
Accessory Equipment Engine Will Not Crank

Check all accessory equipment for problems that SMCS Code: 1000-035
may create excessive load on the engine. Repair
any damaged components or replace any damaged Probable Causes
components.
• Engine shutdown switches (if applicable)
i02419766
• Circuit breakers
Engine Vibration
• Battery cables
SMCS Code: 1000-035
• Batteries
Probable Causes • Starting circuit
• Vibration damper • Flywheel ring gear
• Engine supports • Driven equipment
• Driven equipment • Engine accessories
• Engine misfiring or running rough • Hydraulic cylinder lock
• Internal engine problem
RENR9346-06 37
Recommended Actions 3. Remove any engine accessories that may lock

up the engine. Inspect the condition of the
Engine Shutdown Switches (If accessories.
Applicable) The following list illustrates examples of engine
accessories that may lock up the engine:
The engine shutdown switches should be in the OFF
position. Use Caterpillar Electronic Technician (ET)
to verify the status of the shutdown switches. When a • Fuel transfer pump
shutdown occurs, the engine control must be in the
OFF/RESET mode for at least 15 seconds before • Air compressor
restarting the engine.
• Engine oil pump
Note: If Cat ET will not communicate with the
Electronic Control Module (ECM), the problem Hydraulic Cylinder Lock
is most likely with the electrical power supply to
the ECM. Refer to the diagnostic functional test Check for fluid in the cylinders (hydraulic cylinder
Troubleshooting, “Electrical Power Supply Circuit - lock) by removing the individual unit injectors.
Test”.
Note: Be sure to drain the fuel from the cylinder head
prior to removing the injectors. Fuel will flow from the
Circuit Breakers cylinder head into the cylinders when the unit injector
is removed.
Check the state of each of the circuit breakers. Reset
the circuit breakers if the circuit breakers are tripped.
Prior to returning the engine to service, determine Internal Engine Problem
the condition that caused the circuit breaker to trip.
Make the necessary repairs. 1. Inspect the internal components for the following
conditions:
Battery Cables and/or Batteries
• Seizure
1. Inspect the battery disconnect switch, bus bars,
battery posts, and battery cables for loose • Broken components
connections and corrosion. If the battery cables
are corroded, remove the battery cables and clean • Bent components
the battery cables. Tighten any loose connections.
i02432467
2. Inspect the batteries.
Excessive Black Smoke
a. Charge the batteries. Refer to Special
Instruction, SEHS7633, “Battery Test SMCS Code: 1088-035
Procedure”.
Probable Causes
b. Load test the batteries. Refer to Special
Instruction, SEHS9249, “Use of 4C-4911 • Air inlet or exhaust system
Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”. • Engine speed/timing sensor
Starting Circuit • Atmospheric pressure sensor
Test the operation of the starting motor and • Boost pressure sensor
associated circuit components. Refer to the Systems
Operation/Testing and Adjusting manual. • “Fuel Position” and/or “FRC Fuel Limit”
Driven Equipment and/or Engine • Flash file

Accessories
• Fuel quality
1. Ensure free movement of the driveline.
• Valve adjustment
2. Ensure that the timing pin was not left in the
flywheel housing.
38 RENR9346-06
Recommended Actions 3. Monitor the status of “Boost Pressure” and

“Atmospheric Pressure” on Cat ET. When the
Air Inlet or Exhaust System engine is not running, “Boost Pressure” should be
0 kPa (0 psi).
1. Check the air inlet system for restrictions and/or
for leaks. Note: A problem with the “FRC Fuel Limit” will only
cause black smoke during acceleration. A problem
a. Check for an air filter restriction. with the “FRC Fuel Limit” will not cause black smoke
during steady state operation.
b. Perform a visual inspection of the system for
restrictions and/or for leaks in the air inlet Flash File
piping .
Verify that the correct flash file is installed. Refer
2. Ensure that the turbocharger is in good repair. to Troubleshooting, “Flash Programming” for
information.
3. Check the exhaust system for restrictions.
Fuel Quality
4. Repair any leaks that were found. Remove
any restrictions that were found. Replace any Cold weather adversely affects the characteristics of
damaged components that were found. the fuel. Refer to Operation and Maintenance Manual
for information on improving the characteristics of the
Engine Speed/Timing fuel during cold weather operation.
1. Check the calibration of the engine speed/timing Valve Adjustment

sensor. Refer to Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”. Check the valve adjustment. Refer to Systems
Operation/Testing and Adjusting for information on
2. Verify that the crankshaft and the camshaft drive valve adjustments.
gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
i02410997
Atmospheric Pressure Sensor Excessive Engine Oil

1. Remove the sensor. Consumption
2. Remove debris, moisture, or ice from the sensor. SMCS Code: 1348-035
3. Install the sensor. Probable Causes

4. Check the Caterpillar Electronic Technician (ET)
for active diagnostic codes on the sensor. If no
• Oil leaks
active diagnostic code exists, the sensor may be
used. The correct reading for the atmospheric
• Oil level
pressure is between 50 kPa (7.25 psi) and
100 kPa (14.5 psi).
• Turbocharger seal
• Internal engine wear
Boost Pressure Sensor, “Fuel Position”,
and/or “FRC Fuel Limit” Recommended Actions
1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full Oil Leaks
load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit”, Check the engine compartment for oil leaks. Repair
the Electronic Control Module (ECM) is providing any oil leaks that are identified.
the correct control. Otherwise, proceed to the next
Step. Oil Level
2. Verify that there are no active diagnostic codes for Check the engine oil level. Too much oil in the engine
the boost pressure sensor. crankcase can cause the engine to consume oil.
Remove excessive engine oil from the crankcase.
RENR9346-06 39
Ensure that the dipstick is properly calibrated Fuel Leaks

and/or that the dipstick is correct for the application.
Calibrate the dipstick and/or replace the dipstick. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
Turbocharger to Systems Operation/Testing and Adjusting for the
correct pressure values. If the fuel pressure is low,
Check for turbocharger shaft seal leakage. Remove replace the fuel filters. If the fuel pressure is still low,
the air inlet piping and the exhaust outlet piping from check the following items: fuel transfer pump, fuel
the turbocharger. Check the compressor wheel and transfer pump coupling, and fuel pressure regulating
the turbine for evidence of an oil leak. If necessary, valve.
repair the turbocharger or replace the turbocharger.
Refer to Systems Operation/Testing and Adjusting. Fuel Quality
Internal Engine Wear Cold weather adversely affects the characteristics

of the fuel. Refer to the Operation and Maintenance
Internal engine wear can cause excessive oil leakage Manual for information on improving the
into the combustion area of the cylinders. Excessive characteristics of the fuel during cold weather
wear on the following components may cause oil operation.
consumption:
Engine Speed/Timing
• Piston rings
Perform a speed/timing sensor calibration. Refer to
• Valve guides the calibration procedure Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
Check for excessive crankcase blowby at the
engine crankcase breather. Refer to Systems Unit Injectors
1. Check for correct installation of the J1/P1
i02430014
and J2/P2 Electronic Control Module (ECM)
connectors and the unit injector connectors. Refer
Excessive Fuel Consumption to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
SMCS Code: 1250-035
order to determine if all of the injector solenoids
Probable Causes are being energized by the ECM.
• Engine operation 3. Perform the “Cylinder Cutout Test” on Cat ET
in order to identify any injectors that might be
• Fuel leaks misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
• Fuel quality
• Engine speed/timing Air Inlet and Exhaust System
• Unit injectors 1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter
• Air inlet and exhaust system or replace the air filter.
• Accessory equipment 2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Recommended Actions
Accessory Equipment
Engine Operation
Check all accessory equipment for problems that
Use the Caterpillar Electronic Technician (ET) to may create excessive load on the engine. Repair
check the “Current Totals” for excessive idle time any damaged components or replace any damaged
and/or for a high load factor which would be indicative components.
of poor operating habits.
Note: Engine operation may also be affected by

environmental conditions such as wind and snow.
40 RENR9346-06
i02285926 i02711029
Excessive Valve Lash Excessive White Smoke

SMCS Code: 1105-035 SMCS Code: 1088-035
Note: Some white smoke may be present during

Probable Causes cold start-up conditions when the engine is operating
normally. If the white smoke persists, there may be
• Lubrication a problem.
• Valve lash
Probable Causes
• Valve train components
• Starting aids (if applicable)
Recommended Actions
• Coolant temperature sensor
Lubrication • Engine speed/timing
1. Remove the valve mechanism covers. Refer to • Unit injectors
the engine's Disassembly and Assembly manual
for the correct procedure. • Flash file
2. Check the lubrication in the valve compartment. • Fuel supply
Ensure that there is adequate engine oil flow in
the valve compartment. The passages for the • Component wear
engine oil must be clean.
• Cooling system
Valve Lash
Adjust the engine valve lash. Refer to the engine's
Recommended Actions
Systems Operation/Testing and Adjusting manual for
the correct procedure. Starting Aids
1. Check for proper operation of the jacket water
Valve Train Components heater. Repair the jacket water heater or replace
the jacket water heater.
1. Inspect the following components of the valve
train:
2. Ensure that the ether canister is not empty or low.
Replace the ether canister if the ether canister is
• Rocker arms empty or low. Refer to Troubleshooting, “Ether
Injection System - Test”.
• Roller followers (rocker arm)
• Camshaft Coolant Temperature Sensor
• Valve stems 1. Use the Caterpillar Electronic Technician (ET) to

verify that the engine has exited cold mode.
• Valve guides
2. Compare the coolant temperature from Cat ET to
• Rocker shafts the coolant temperature that is obtained from the
6V-9130 Temperature Adapter (MULTIMETER).
2. Check the components for the following conditions: Ensure that the temperature readings are
abnormal wear, excessive wear, straightness, and reasonable for the conditions that are present.
cleanliness. Replace parts, if necessary.
Engine Speed/Timing
Note: If you replace the camshaft, you must also
replace the roller followers (rocker arm). 1. Check the calibration of the engine speed/timing
sensor. Refer to Troubleshooting, “Engine
3. Adjust the engine valve lash. Refer to the engine's Speed/Timing Sensor - Calibrate”.
Systems Operation/Testing and Adjusting manual
for the correct procedure.
RENR9346-06 41
2. Verify that the timing of the crankshaft and i02514091

camshaft drive gears are set with the proper
orientation. Refer to Disassembly and Assembly Exhaust Temperature Is Too
for information that is related to the correct gear High
installation.
Unit Injectors
1. Perform the “Cylinder Cutout Test” on Cat ET in
Probable Causes
order to try to isolate any cylinders that may be
misfiring. A misfiring cylinder could be related to • Diagnostic codes
an injector that is worn or in poor repair. Refer to
Troubleshooting, “Injector Solenoid Circuit - Test”. • Electrical connectors
2. Cut out each individual cylinder for 30 to 60 • Air inlet and exhaust system
seconds. Verify that the smoke decreases.
Recommended Actions
Flash File
Diagnostic Codes
Verify that the correct flash file is installed. Refer to
Troubleshooting, “Flash Programing”. Connect the Caterpillar Electronic Technician (ET)
and check for active diagnostic codes. Troubleshoot
Fuel Supply any active diagnostic codes before continuing with
this procedure.
1. Inspect the fuel system components.
Electrical Connectors
2. Check the fuel pressure during engine cranking.
Check the filtered fuel pressure. Refer to Systems Check for correct installation of the J2/P2 Electronic
Operation/Testing and Adjusting for the correct Control Module (ECM) connector and of the
pressure values. If the fuel pressure is low, J300/P300 connector that is for the injectors. Refer
replace the fuel filters. If the fuel pressure is still to the diagnostic functional test Troubleshooting,
low, check the following items: fuel transfer pump, “Electrical Connectors - Inspect”.
fuel transfer pump coupling, and fuel pressure
regulating valve. Air Inlet and Exhaust System
3. Check the fuel quality. Low cetane fuel can create 1. Check the air inlet manifold pressure. Check for
white smoke. If necessary, replace the fuel with a air inlet restrictions and/or leaks. Refer to Systems
higher cetane fuel. Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and 2. Check for leaks between the exhaust manifold and
Maintenance Manual for information on improving the turbocharger. Check for exhaust restrictions.
the characteristics of the fuel during cold weather Refer to Systems Operation/Testing and Adjusting,
operation. “Air Inlet and Exhaust System”.
Component Wear
i02281012
Check the engine for the following problems:

Excessive valve wear, piston wear, ring wear, liner
Fuel in Cooling System
wear, and reduced compression pressure. SMCS Code: 1350-035
Cooling System The probable root cause is a damaged O-ring seal

for a fuel injector.
Check for an internal coolant leak into the
cylinder and/or the exhaust. Refer to Systems Perform the following procedure:
Operation/Testing and Adjusting for information on
inspecting the cooling system.
42 RENR9346-06
Remove the valve cover. Remove the fuel supply. Inspect the cooling system for contamination of fuel.
Disconnect the fuel return line from the cylinder head. Inspect the crankcase for dilution of the engine oil.
Cap the fuel return connector and apply 700 kPa This may be a sign of a cracked cylinder head or of a
(102 psi) maximum air pressure to the fuel supply leaking cylinder head gasket.
connector. Check for fuel leakage around each fuel
injector. If leakage is present, remove the leaking fuel Leakage of the Drive Shaft Seal on the
injector. Install a new O-ring seal onto the injector.
Install the injector. Connect the fuel return line. Install
Fuel Transfer Pump
the valve cover. Verify that the problem is resolved.
Ensure that the weep hole for the fuel transfer pump
is not plugged. Inspect the front of the pump for signs
i02360438 of leakage. If necessary, repair the fuel transfer pump
or replace the fuel transfer pump.
Fuel Dilution of Engine Oil
SMCS Code: 1348-035 i02881460
Intermittent Engine Shutdown

Probable Causes
SMCS Code: 1000-035
• Leaking seals on the body or the sleeve of the unit
injector Note: Use this procedure only if the engine shuts
down completely during operation.
• Excessive leakage from the unit injector tip or a
broken unit injector tip
Probable Causes
• Cracked cylinder head or leaking cylinder head • Diagnostic codes
gasket
• Leakage of the drive shaft seal on the fuel transfer • Event codes
pump
• Electrical connectors
Recommended Actions • Air inlet and exhaust restrictions
Leaking Seals on the Body or the Sleeve • Circuit breakers
of the Unit Injector
• Fuel supply
Check the torque for the unit injector clamp retaining
bolts. Ensure that the unit injectors are properly Recommended Actions
installed into the cylinder head.
Diagnostic Codes and/or Event Codes
If damage to the unit injector sleeves or to the O-ring
seals is suspected, remove the unit injectors and/or Certain diagnostic codes and/or event codes may
the unit injector sleeves. Inspect the O-ring seals and cause an engine shutdown. Connect the Caterpillar
the unit injector sleeves for damage. Replace any Electronic Technician (ET) and check for active codes
seals or sleeves that show evidence of leakage. and for logged codes. Troubleshoot any codes that
are present prior to continuing with this procedure.
Excessive Leakage from the Unit Injector
Tip or a Broken Unit Injector Tip Electrical Connectors
Look for signs of damage to the unit injectors. 1. Check for correct installation of the J1/P1 and
If necessary, replace the unit injectors that have J2/P2 connectors for the Electronic Control Module
damaged tips. (ECM). Also, thoroughly inspect the connectors
for the engine speed/timing sensors. Refer to
Cracked Cylinder Head or Leaking the diagnostic functional test Troubleshooting,
Cylinder Head Gasket
Check for symptoms of a damaged cylinder head or
cylinder head gasket.
RENR9346-06 43
2. Inspect the battery wires from the ECM to the 5. Check fuel quality. Cold weather adversely
battery compartment. Refer to the Schematic for affects the characteristics of the fuel. Refer to the
specific wiring information. Check the unit injector Operation and Maintenance Manual.
connectors and associated wiring for damage, or
for intermittent problems. Inspect the wires and 6. Check the filtered fuel pressure while the
connectors to all circuit protection for the engine. engine is being cranked. Refer to Systems
Check the power and ground connections to Operation/Testing and Adjusting.
the ECM. Check any engine shutdown switches
and associated wiring. Refer to the diagnostic If the fuel pressure is low, replace the fuel filters.
functional test Troubleshooting, “Electrical Power Clean the primary filter/water separator of debris.
Supply Circuit - Test”. Refer to the Operation and Maintenance Manual.
Air Inlet and Exhaust Restrictions If the fuel pressure is still low, check the operation
of the fuel pressure regulating valve. Also, check
Check the air inlet system for the following problems: for the proper operation of the fuel transfer pump.
restrictions, collapse, and pinched line. Repair the Refer to Systems Operation/Testing and Adjusting.
i02430113
Check for an air filter restriction. Replace plugged air
filters and/or clean filters. Repair any leaks. Low Engine Oil Pressure
Circuit Breakers SMCS Code: 1348-035-LP
Check the state of each of the circuit breakers. Reset NOTICE

the circuit breakers if the circuit breakers are tripped. Do not operate engine with low oil pressure. Engine
Prior to returning the engine to service, determine damage will result. If measured engine oil pressure is
the condition that caused the circuit breaker to trip. low, discontinue engine operation until the problem is
Make the necessary repairs. corrected.
Fuel Supply
Probable Causes
1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel • Engine oil level
to the fuel tank. If the engine has been run out of
fuel, it will be necessary to prime the fuel system. • Engine oil filters and oil filter bypass valve
Refer to the Operation and Maintenance Manual.
• Engine oil pump
restrictions, collapsed lines, and pinched lines. If • Engine oil cooler
lines and/or replace the lines. • Fuel dilution
3. Check the fuel tank for debris or foreign objects • Engine wear
Recommended Actions
NOTICE
Do not crank the engine continuously for more than Engine Oil Level
minutes before cranking the engine again. Inspect the engine oil level. If engine oil is low add
engine oil. Refer to the Operation and Maintenance
Manual.
4. Prime the fuel system if any of the following
Engine Oil Filters and Oil Filter Bypass
• Replacement of the fuel filters Valve
• Service on the low pressure fuel supply circuit Check the service records of the engine for
information that is related to the last oil change. If
• Replacement of unit injectors necessary, perform an oil change on the engine and
replace the engine oil filters.
Note: Check the fuel system for air. Refer to the
Systems Operation/Testing and Adjusting manual.
44 RENR9346-06
Check the operation of oil filter bypass valve. Clean • Fuel supply
the bypass valve and the housing. If necessary,
install new parts.
Recommended Actions
Engine Oil Pump Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Check for blockage of the inlet screen for the engine Examples of certain conditions are high engine
oil pump. Check the components of the engine oil speed, full load, and engine operating temperature.
pump for excessive wear. If necessary, repair the oil Troubleshooting the symptoms under other
pump or replace the oil pump. conditions can give misleading results.
Oil Cooler Engine Derate or Active Codes

Check the engine's oil cooler for plugging or Some engine monitoring parameters that are capable
blockage. Clean the engine oil cooler core(s) and/or of triggering an engine derate do not produce an
install new engine oil cooler core(s). event code. Connect Caterpillar Electronic Technician
(ET) in order to check for a derate of the engine.
Fuel Dilution
Certain diagnostic codes and/or event codes may
Check for presence of fuel in lubricating oil. Refer cause poor performance. Use Cat ET to check for
to the troubleshooting without a diagnostic code active codes and for logged codes. Troubleshoot any
procedure Troubleshooting, “Fuel Dilution of Engine codes that are present before continuing with this
Oil”. procedure.
Engine Wear Note: Although a sensor's signal may be in the

operational range of the sensor, the signal may
Inspect the camshaft and/or camshaft bearings not represent the actual reading. Use Cat ET to
for excessive wear. Inspect the crankshaft and/or check that the pressures and the temperatures are
crankshaft bearings. Excessive wear to discrete fluctuating. Also check that the values are reasonable
components may be an indication of a blocked oil for the conditions that are present.
passage. Use an oil pressure gauge to check the
oil pressure at the main oil gallery. This will help Cold Mode
determine if the excessive wear is from low system
pressure or from passages that are blocked. 1. Use Cat ET to verify that the engine has exited
cold mode. Cold mode operation may cause the
engine to run rough and engine power may be
i02437042 limited.
Low Power/Poor or No 2. Observe the coolant temperature on the Cat ET
Response to Throttle status screen. Verify that the reading is valid.
SMCS Code: 1000-035 Throttle Signal
Probable Causes Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
• Engine derate or active codes and that the engine is able to reach high idle speed.
Refer to Troubleshooting, “Throttle Position Sensor
• Cold mode Circuit - Test” for the correct procedure.
• Throttle signal Electrical Connectors

• Electrical connectors Check for correct installation of the J1/P1 and J2/P2
Electronic Control Module (ECM) connectors and the
• Unit injectors J300/P300 connectors for the unit injectors. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
• Intake manifold pressure sensor
Unit Injectors
• Parameters order to determine if all of the injector solenoids
RENR9346-06 45
2. Perform the “Cylinder Cutout Test” on Cat ET in Fuel Supply

order to identify any misfiring cylinder(s). Refer to
Troubleshooting, “Injector Solenoids Circuit - Test” 1. Visually check the fuel level in the fuel tank. Do
for more information. not rely on the fuel gauge only. If necessary, add
fuel to the fuel tank. If the engine has been run
Intake Manifold Pressure Sensor out of fuel, it will be necessary to purge the air
from the fuel system. Refer to Operation and
1. Monitor the status of “Fuel Position”, “Rated Fuel Maintenance Manual, “Fuel System - Prime” for
Limit”, and “FRC Fuel Limit” on Cat ET while the correct procedure.
the engine is operating under full load. These
parameters should reflect the information below. 2. Check the fuel lines for the following problems:
Table 10 problems are found with the fuel lines, repair the
“Fuel Position” = “Rated Fuel Limit”
and 3. Check the fuel tank for debris or foreign objects
“Fuel Position” < “FRC Fuel Limit”
NOTICE
If “Fuel Position” equals “Rated Fuel Limit” and
Do not crank the engine continuously for more than
electronics are operating correctly. Otherwise, minutes before cranking the engine again.
proceed with the next Step.
2. Monitor the status of “Boost Pressure” and 4. Prime the fuel system if any of the following
“Atmospheric Pressure” for normal operation procedures have been performed:
on Cat ET. When the engine is not running, the
correct value for “Boost Pressure” is 0 kPa (0 psi) • Replacement of the fuel filters
while the engine is off.
• Service on the low pressure fuel supply circuit
1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the Note: Check the fuel system for air. Refer to Systems
Operation and Maintenance Manual for additional Operation/Testing and Adjusting, “Air in Fuel - Test”
information. for information that is related to checking the fuel
system for air.
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems 5. Check fuel quality. Cold weather adversely
Operation/Testing and Adjusting, “Air Inlet and affects the characteristics of the fuel. Refer to the
Exhaust System”. engine's Operation and Maintenance Manual for
information on improving the characteristics of the
fuel during cold weather operation.
Parameters
6. Check the filtered fuel pressure while the
If the ECM has been replaced, compare the values
engine is being cranked. Refer to Systems
that are on the engine information plate to following
Operation/Testing and Adjusting for the test
parameters from Cat ET:
procedure and for the correct pressure values.
• FRC offset If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris.
• Full Load Setting (FLS) Refer to the Operation and Maintenance Manual
for details.
• Full Torque Setting (FTS)
If the fuel pressure is still low, check the operation
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
for test information.
46 RENR9346-06
i02286073 Recommended Actions

Mechanical Noise (Knock) in Diagnostic Codes
Engine
Check for active diagnostic codes on the Caterpillar
SMCS Code: 1000-035 Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure.
The probable root causes are listed below:
Fuel Quality
• Faulty accessory
Refer to Operation and Maintenance Manual for
• Damage to valve train components information on the characteristics of the fuel.
• Failure of connecting rod bearing Unit Injectors

• Crankshaft bearings 1. Check the connectors at the Electronic Control
Perform the following checks: Module (ECM). Check for correct installation
of the J1/P1 and J2/P2 ECM connectors. Also,
1. Isolate the source of the noise. Remove thoroughly inspect the unit injector wiring harness
the suspect engine accessories. Inspect from the ECM to the J300/P300 valve cover entry
the suspect engine accessories. Repair the connector. Refer to the diagnostic functional test
engine accessories and/or replace the engine Troubleshooting, “Electrical Connectors - Inspect”.
accessories.
2. Remove the valve cover from the suspect order to determine if all of the injector solenoids
cylinder(s). Check the following items for damage: are being energized by the ECM.
camshaft, valve rotocoil, valve springs, roller
followers (rocker arm), rocker shaft, bridges, and 3. Perform the “Cylinder Cutout Test” on Cat ET
injectors. Check for valves that do not move freely. in order to identify any injectors that may be
Remove the cylinder head and inspect the valves. misfiring. Refer to the diagnostic functional test
Replace any damaged parts. If damage has Troubleshooting, “Injector Solenoid Circuit - Test”.
occurred, ensure that the following components
are free of contamination: cylinder liner, piston, Valve Lash
and exhaust system. Replace any damaged parts.
Check the engine valve lash settings. Inspect the
3. Inspect the connecting rod bearings and the valve train for sufficient lubrication. Check damage to
bearing surfaces (journals) on the crankshaft. valve train components which may cause excessive
Check the piston pin for excessive wear. Replace valve lash. Repair any problems that are found.
any damaged parts. Refer to troubleshooting without a diagnostic code
Troubleshooting, “Excessive Valve Lash”.
4. Check main journals of the crankshaft and the
main journal bearings for excessive wear. Replace Cylinder Head and Related Components
any damaged parts.
Check for signs of damage and/or wear to the valves,
cylinder head gasket, etc. Inspect the condition of
i02477338
the camshafts.
Noise Coming from Cylinder
i02422401
SMCS Code: 1000-035
Poor Acceleration or Response
Probable Causes SMCS Code: 1000-035
• Diagnostic codes
Probable Causes
• Fuel quality
• Engine derate or active codes
• Unit injectors
• Cold mode
• Valve lash
• Flash file
• Cylinder head and related components
RENR9346-06 47
• Throttle signal Electrical Connectors

• Electrical connectors Check for correct installation of the J1/P1 and J2/P2
Electronic Control Module (ECM) connectors and the
• Unit injectors J300/P300 connectors for the unit injectors. Refer to
• Intake manifold pressure
Unit Injectors
• Fuel supply order to determine if all of the injector solenoids
Recommended Actions
2. Perform the “Cylinder Cutout Test” on Cat ET
Note: If the problem only occurs under certain in order to determine the performance of each
conditions, test the engine under those conditions. cylinder. Refer to Troubleshooting, “Injector
Examples of certain conditions are high engine Solenoid Circuit - Test” for the proper procedure.
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other Intake Manifold Pressure
conditions can give misleading results.
1. Monitor the status of “Fuel Position”, “Rated Fuel
Engine Derate or Active Codes Limit”, and “FRC Fuel Limit” on Cat ET while
the engine is operating under full load. These
Some engine monitoring parameters that are capable parameters should reflect the information below.
of triggering an engine derate do not produce an
Table 11
event code. Connect Caterpillar Electronic Technician
(ET) in order to check for a derate of the engine. “Fuel Position” = “Rated Fuel Limit”
and
Certain diagnostic codes and/or event codes may
cause poor performance. Use Cat ET to check for “Fuel Position” < “FRC Fuel Limit”
active codes and for logged codes. Troubleshoot any
codes that are present before continuing with this
If “Fuel Position” equals “Rated Fuel Limit” and
procedure.
electronics are operating correctly. Otherwise,
Note: Although a sensor's signal may be in the
proceed with the next Step.
operational range of the sensor, the signal may
not represent the actual reading. Use Cat ET to
2. Monitor the status of the “Boost Pressure”
check that the pressures and the temperatures are
parameter and the “Atmospheric Pressure”
fluctuating. Also check that the values are reasonable
parameter on Cat ET. When the engine is not
for the conditions that are present.
running, the correct value for the intake manifold
pressure sensor is 0 kPa (0 psi).
Cold Mode
Use Cat ET to verify that the engine has exited
cold mode. Cold mode operation may slow throttle
1. Observe the check engine lamp. Check for an
response.
air filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the
Flash File Operation and Maintenance Manual.
Verify that the latest flash file is installed in the 2. Check the air inlet and exhaust system for
Electronic Control Module (ECM). restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Throttle Signal Exhaust System”.
Monitor the status for “Throttle Position” on Cat ET.

Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed.
Refer to Troubleshooting, “Speed Control - Test” for
information that is related to testing the system.
48 RENR9346-06
Fuel Supply i02643299
1. Visually check the fuel level in the fuel tank. Do Valve Rotator or Spring Lock
not rely on the fuel gauge only. If necessary, add Is Free
fuel to the fuel tank. If the engine has been run
out of fuel, it will be necessary to purge the air SMCS Code: 1109-035
from the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for Use this procedure in order to troubleshoot a problem
the correct procedure. with the valve rotators or spring locks.
restrictions, collapsed lines, and pinched lines. If Probable Cause
lines and/or replace the lines. • Valve Components
3. Check the fuel tank for debris or foreign objects Recommended Actions
Valve components
NOTICE
Do not crank the engine continuously for more than 1. A valve rotator that is cracked or a valve rotator
30 seconds. Allow the starting motor to cool for two that is broken is an indication of an engine
minutes before cranking the engine again. overspeed. Determine the cause of the engine
overspeed. Repair the condition.
4. Prime the fuel system if any of the following 2. Inspect the following components for damage:
• Valve rotators
• Spring locks
• Service on the low pressure fuel supply circuit
• Valve springs
Note: Check the fuel system for air. Refer to Systems
• Valves
Operation/Testing and Adjusting, “Air in Fuel - Test” Note: Ensure that the valve has not contacted the
for information that is related to checking the fuel piston. If the valve has contacted the piston, check
system for air. the exhaust system for debris.
5. Check fuel quality. Cold weather adversely 3. Replace any damaged components.
affects the characteristics of the fuel. Refer to the
engine's Operation and Maintenance Manual for
information on improving the characteristics of the
fuel during cold weather operation.
6. Check the filtered fuel pressure while the

engine is being cranked. Refer to Systems
Operation/Testing and Adjusting for the test
procedure and for the correct pressure values.
If the fuel pressure is low, replace the fuel filters.

Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual
for details.
If the fuel pressure is still low, check the operation

for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
for test information.
RENR9346-06 49
Troubleshooting with a
Diagnostic Code
i02281051
Diagnostic Codes
SMCS Code: 1900
Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to
the service technician. The Caterpillar Electronic
Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic
codes may be viewed on a personal computer that
has Cat ET software. Diagnostic codes consist of
the component identifier (CID) and the failure mode
identifier (FMI).
Component Identifier (CID) – The CID is a number

with three or four digits. The CID indicates the
component that generated the code. For example,
the CID number 0001 identifies the fuel injector for
the number one cylinder.
Failure Mode Identifier (FMI) – The FMI is a two

digit code that indicates the type of failure.
Do not confuse diagnostic codes with event codes.

Event codes alert the operator that an abnormal Illustration 10
g01117578
operating condition such as low oil pressure or high
Output voltage from a typical analog temperature sensor
coolant temperature has been detected. Refer to
Troubleshooting, “Troubleshooting with an Event
Illustration 10 indicates the signal range for a typical
Code” for additional information on event codes.
analog sensor. Diagnostic codes will be generated if
the sensor's output signal is below 0.2 VDC or above
4.8 VDC.
Active Diagnostic Codes

An active diagnostic code represents a problem with
the electronic control system. Correct the problem
as soon as possible.
When the Electronic Control Module (ECM)

generates an active diagnostic code, the “Active
Alarm” indicator (“Engine Control Alarm Status” on
Cat ET) is activated in order to alert the operator. If
the condition that generated the code is momentary,
the message disappears from the list of active
diagnostic codes. The diagnostic code becomes
logged.
50 RENR9346-06
Logged Diagnostic Codes Possible Performance Effect:
When the ECM generates a diagnostic code, the • Engine misfires

ECM logs the code in permanent memory. The
ECM has an internal diagnostic clock. Each ECM • Low power
will record the following information when a code is
generated: Troubleshooting:
• The hour of the first occurrence of the code Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
• The hour of the last occurrence of the code
Results:
• The number of occurrences of the code
• OK – STOP.
This information is a valuable indicator for
troubleshooting intermittent problems.
i02504233
A code is cleared from memory when one of the

following conditions occur:
CID 0001 FMI 06 Cylinder #1
Injector short
• The service technician manually clears the code.
SMCS Code: 1290-038
• The code does not recur for 100 hours.
Conditions Which Generate This Code:
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is The Electronic Control Module (ECM) is attempting to
cleared. operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that System Response:
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection The ECM will log the diagnostic code. The ECM will
or damaged wiring. The next likely cause is a continue to attempt to operate the injector after the
component failure. The least likely cause is the failure code has been logged.
of an electronic module. Diagnostic codes that are
logged repeatedly may indicate a problem that needs Possible Performance Effect:
special investigation.
• Engine misfires
Note: Always clear logged diagnostic codes after
investigating and correcting the problem which • Low power
generated the code.
Troubleshooting:
i02504219 Perform the following diagnostic procedure: “Injector
CID 0001 FMI 05 Cylinder #1 Solenoid Circuit - Test”
Injector open circuit Results:
SMCS Code: 1290-038 • OK – STOP.

i02504240
The Electronic Control Module (ECM) is attempting

to operate the injector. The ECM detects an open
circuit in the circuit for the injector. Injector open circuit
System Response: SMCS Code: 1290-038
The ECM will log the diagnostic code. The ECM will Conditions Which Generate This Code:
continue to attempt to operate the injector after the
code has been logged. The Electronic Control Module (ECM) is attempting
circuit in the circuit for the injector.
RENR9346-06 51
System Response: i02504251
The ECM will log the diagnostic code. The ECM will CID 0003 FMI 05 Cylinder #3
continue to attempt to operate the injector after the Injector open circuit
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
• Engine misfires
• Low power to operate the injector. The ECM detects an open
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
Results: code has been logged.
• OK – STOP. Possible Performance Effect:
i02504248 • Engine misfires

CID 0002 FMI 06 Cylinder #2 • Low power
Injector short Troubleshooting:
SMCS Code: 1290-038 Perform the following diagnostic procedure: “Injector
Results:
The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects a short circuit
• OK – STOP.
continue to attempt to operate the injector after the Injector short
SMCS Code: 1290-038
• Engine misfires
• Low power operate the injector. The ECM detects a short circuit
Troubleshooting:
System Response:
• Engine misfires
• Low power
52 RENR9346-06
Troubleshooting: Possible Performance Effect:
Perform the following diagnostic procedure: “Injector • Engine misfires

• Low power
Results:
Troubleshooting:
• OK – STOP.
i02504275
CID 0004 FMI 05 Cylinder #4 Results:
Injector open circuit • OK – STOP.

SMCS Code: 1290-038
i02504291

The Electronic Control Module (ECM) is attempting Injector open circuit
circuit in the circuit for the injector. SMCS Code: 1290-038
System Response: Conditions Which Generate This Code:
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting
continue to attempt to operate the injector after the to operate the injector. The ECM detects an open
code has been logged. circuit in the circuit for the injector.
Possible Performance Effect: System Response:
• Engine misfires The ECM will log the diagnostic code. The ECM will
• Low power code has been logged.

• Low power
Results:
Troubleshooting:
• OK – STOP.
i02504282
Injector short • OK – STOP.

SMCS Code: 1290-038
i02504292

The Electronic Control Module (ECM) is attempting to Injector short
in the circuit for the injector. SMCS Code: 1290-038
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting to
continue to attempt to operate the injector after the operate the injector. The ECM detects a short circuit
code has been logged. in the circuit for the injector.
RENR9346-06 53
SMCS Code: 1290-038
• Engine misfires
Troubleshooting:
System Response:

Injector open circuit Troubleshooting:
Results:
• OK – STOP.
SMCS Code: 1290-038
• Engine misfires
Troubleshooting:
System Response:
• Engine misfires
• Low power
54 RENR9346-06

• Low power
Results:
Troubleshooting:
• OK – STOP.
i02420867

SMCS Code: 1290-038
i02420872


• Low power
Results:
Troubleshooting:
• OK – STOP.
i02420728

SMCS Code: 1290-038
i02420746

RENR9346-06 55
SMCS Code: 1290-038
• Engine misfires
Troubleshooting:
System Response:

Injector short Troubleshooting:
Results:
• OK – STOP.
SMCS Code: 1290-038
• Engine misfires
Troubleshooting:
System Response:
• Engine misfires
• Low power
56 RENR9346-06

• Low power
Results:
Troubleshooting:
• OK – STOP.
i02420757

SMCS Code: 1290-038
i02420764


• Low power
Results:
Troubleshooting:
• OK – STOP.
i02420922

SMCS Code: 1290-038
i02420927

RENR9346-06 57
The ECM will log the diagnostic code. The ECM will CID 0041 FMI 04 8 Volt DC
continue to attempt to operate the injector after the Supply short to ground
SMCS Code: 1439-038
• Engine misfires
The voltage level of the 8 volt supply is below normal.
• Low power
System Response:
Troubleshooting:
The Electronic Control Module (ECM) logs the
Perform the following diagnostic procedure: “Injector diagnostic code. The ECM flags all digital sensors
Solenoid Circuit - Test” as invalid data and all digital sensors are set to the
respective default values.
Results:
• OK – STOP.
• The engine may experience low power.
i02419277
Troubleshooting:
CID 0041 FMI 03 8 Volt DC
Perform the following diagnostic procedure: “Digital
Supply short to +batt Sensor Supply Circuit - Test”
SMCS Code: 1439-038 Results:
• OK – STOP.
The voltage level of the 8 volt supply is above normal.
i02440965
System Response:
CID 0091 FMI 08 Throttle
The Electronic Control Module (ECM) will log the Position signal abnormal
diagnostic code. The ECM flags all digital sensors
as invalid data and all digital sensors are set to the SMCS Code: 1439-038; 1913-038
respective default values.
The Electronic Control Module (ECM) detects an
• The engine may experience low power. incorrect frequency on the throttle signal or the
throttle position sensor is out of the acceptable range.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Digital
Sensor Supply Circuit - Test” The code is logged. The ECM flags the throttle
position as invalid data and a default value of zero
Results: percent is used.
• The engine speed is limited to low idle.

Troubleshooting:
Perform the following diagnostic procedure: “Throttle

Position Sensor Circuit - Test”
Results:
• OK – STOP.
58 RENR9346-06
i02424760 i02424766
CID 0094 FMI 03 Fuel Pressure CID 0100 FMI 03 Engine Oil
open/short to +batt Pressure open/short to +batt
SMCS Code: 1439-038; 1718-038 SMCS Code: 1439-038-OC; 1924-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) detects signal
voltage that is above normal. voltage that is above normal.
System Response: System Response:
The ECM will log the diagnostic code. The ECM flags The ECM will log the diagnostic code. The ECM flags
fuel pressure as invalid data and a default value is oil pressure as invalid data.
used.
• There are no performance effects.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”
Pressure Sensor Open or Short Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02424648
CID 0100 FMI 04 Engine Oil

i02424763
CID 0094 FMI 04 Fuel Pressure Pressure short to ground

short to ground
SMCS Code: 1439-038-OC; 1924-038
SMCS Code: 1439-038; 1718-038
The Electronic Control Module (ECM) detects a
The Electronic Control Module (ECM) reads signal signal voltage that is below normal.
voltage that is below normal.
System Response:
System Response:
The code is logged. The ECM flags oil pressure as
The ECM will log the diagnostic code. The ECM flags invalid data and a default value is used.
fuel pressure as invalid data and a default value is
used. Possible Performance Effect:
Possible Performance Effect: • There are no performance effects.

• There are no performance effects. Troubleshooting:
Troubleshooting: Perform the following diagnostic procedure: “Engine

Pressure Sensor Open or Short Circuit - Test” Results:
Results: • OK – STOP.
• OK – STOP.
RENR9346-06 59
i02581776 i02427669
CID 0100 FMI 10 Engine Oil CID 0110 FMI 03 Engine

Pressure Sensor abnormal Coolant Temperature
rate of change open/short to +batt
SMCS Code: 1439-038-OC; 1924-038 SMCS Code: 1439-038-CLT; 1906-038
This code indicates that the 5 volt supply is missing The signal voltage from the engine coolant
from the sensor connector. temperature sensor is above normal.
During normal engine operation, the oil pressure System Response:

fluctuates slightly. When the 5 volt supply is missing
from the oil pressure sensor, the signal from the The Electronic Control Module (ECM) will log the
oil pressure sensor goes to a midrange value. The diagnostic code. The ECM flags coolant temperature
signal does not fluctuate. If the signal from the oil as invalid data and a default value is used. The
pressure sensor remains abnormally steady for more engine will not go into cold mode.
than 30 seconds, the Engine Control Module (ECM)
activates this code. Possible Performance Effect:
System Response: • The engine may misfire.

A snapshot is triggered. The ECM uses a default • The engine may experience reduced speed (rpm)
value for the oil pressure. and/or low power.
Possible Performance Effect: Troubleshooting:
• There are no performance effects. Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
Troubleshooting:
Results:
Repair the Open Circuit
• OK – STOP.
A. Repair the supply wire or replace the supply wire
between the ECM and the sensor.
i02427678
Expected Result: CID 0110 FMI 04 Engine

The problem is resolved. Coolant Temperature short to
Results:
ground
SMCS Code: 1439-038-CLT; 1906-038
• OK – The problem is resolved. STOP.
• Not OK – The problem is not resolved.
The signal voltage from the engine coolant
Repair: Refer to the diagnostic functional test
temperature sensor is below normal.
Troubleshooting, “5 Volt Engine Pressure Sensor
Supply Circuit - Test”.
System Response:
STOP. The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags coolant temperature
as invalid data and a default value is used. The
engine will not go into cold mode.
• The engine may misfire.

60 RENR9346-06
• The engine may experience reduced speed (rpm) i02480880

and/or low power.
CID 0168 FMI 01 System
Troubleshooting: Voltage Low
Perform the following diagnostic procedure: “Engine SMCS Code: 1401-038
Results:
The Electronic Control Module (ECM) has been
• OK – STOP. powered for at least three seconds. The ECM detects
the following condition:
i02424772
• For 12 volt systems, the ECM reads battery voltage
CID 0168 FMI 00 System that is below 9 VDC.
Voltage High • For 24 volt systems, the ECM reads battery voltage
that is below 18 VDC.
SMCS Code: 1401-038
System Response:
The ECM will log the diagnostic code.
The Electronic Control Module (ECM) detects the
following condition: Possible Performance Effect:
• For 12 volt systems, the ECM reads battery voltage • The engine may shut down.
that is above 16 VDC.
• The engine may have hard starting and/or misfire.
• For 24 Volt systems, the ECM reads battery
voltage that is above 32 VDC.
• The contacts for the starting motor solenoid may
be chatter during cranking. This can damage the
Note: Excessive voltage to the ECM may damage contacts.
the ECM.
Troubleshooting:
System Response:
Perform the following diagnostic procedure:
The ECM will log the diagnostic code. “Electrical Power Supply Circuit - Test”
Possible Performance Effect: Results:
• There are no performance effects. • OK – STOP.
Troubleshooting:
i02508878
“Electrical Power Supply Circuit - Test” CID 0168 FMI 02 System
Voltage intermittent/erratic
Results:
SMCS Code: 1401-038
• OK – STOP.
While the engine is running the Electronic Control

Module (ECM) detects battery voltage that drops
below 6 VDC and returns above 9 VDC.
System Response:
The ECM will log the diagnostic code.
• An engine misfire may occur.

RENR9346-06 61
• An engine shutdown condition may occur. System Response:
Troubleshooting: The Electronic Control Module (ECM) will log the

diagnostic code. The ECM will flag the intake
Perform the following diagnostic procedure: manifold air temperature as invalid data and a default
“Electrical Power Supply Circuit - Test” value is used.
Results: Possible Performance Effect:
• OK – STOP. • There are no performance effects.

Troubleshooting:
i02440612
CID 0172 FMI 03 Intake Perform the following diagnostic procedure: “Engine
Manifold Air Temp open/short
to +batt Results:
SMCS Code: 1439-038-AI; 1921-038 • OK – STOP.
Conditions Which Generate This Code: i02424795
The Electronic Control Module (ECM) detects a CID 0174 FMI 03 Fuel
signal voltage that is above normal or the intake
manifold air temperature is below −35 °C (−31 °F) .
Temperature open/short to
+batt
System Response:
SMCS Code: 1439-038; 1922-038
The code is logged. The ECM will flag the intake
manifold air temperature as invalid data and the Conditions Which Generate This Code:
intake manifold air temperature is set to a default
value. The Electronic Control Module (ECM) detects a
signal voltage from the sensor that is above normal.
System Response:
The ECM will log the diagnostic code. The ECM flags
Troubleshooting: fuel temperature as invalid data and fuel temperature
is set to a default value.
Temperature Sensor Open or Short Circuit - Test” Possible Performance Effect:
Results: • There are no performance effects.

• OK – STOP. Troubleshooting:

i02430464
CID 0172 FMI 04 Intake Results:
Manifold Air Temp short to
ground • OK – STOP.
SMCS Code: 1439-038-AI; 1921-038
The signal voltage from the intake manifold air

temperature sensor is below normal or the intake
manifold air temperature is above 140 °C (284 °F).
62 RENR9346-06
i02424798 Results:
CID 0174 FMI 04 Fuel • OK – STOP.
Temperature short to ground
i02428636
SMCS Code: 1439-038; 1922-038
CID 0253 FMI 02 Personality
Module mismatch
The Electronic Control Module (ECM) detects signal
voltage that is below normal. SMCS Code: 1902-038
The ECM will log the diagnostic code. The ECM flags The flash file that is used for replacement is for
fuel temperature as invalid data and a default value a different engine family or for a different engine
is used. application.
Caterpillar Electronic Technician (ET) will not be able

• There are no performance effects. to clear the code.
Troubleshooting:
Temperature Sensor Open or Short Circuit - Test” • The fuel injection system is disabled and the
engine will not start.
Results:
Troubleshooting:
• OK – STOP. Check the Part Number of the Flash File
i02424806 A. Restore the electrical power to the Electronic
Control Module (ECM).
CID 0190 FMI 08 Engine Speed
signal abnormal B. Verify that the part number for the flash file agrees
with the latest update that is available on Service
SMCS Code: 1439-038-VF; 1907-038 Technician Workbench (STW), or on SIS Web.
Conditions Which Generate This Code: Expected Result:
The Electronic Control Module (ECM) receives erratic The correct flash file is installed in the ECM.
data from the engine speed/timing sensor.
Results:
System Response:
• OK – The correct flash file is installed in the ECM.
The ECM will log the diagnostic code. The check
engine lamp will illuminate after a delay. The ECM Repair: The engine will not start until the 253-02
will default to the signal from the secondary engine diagnostic code is cleared. Clearing this code
speed/timing sensor. requires factory passwords.
Possible Performance Effect: Acquire factory passwords. Clear the 253-02

diagnostic code. Return the engine to service.
STOP.
Note: If the signals from both engine speed/timing
sensors are lost, then the engine will shut down. • Not OK – The correct flash file is not installed in
the ECM.
Troubleshooting:

Speed/Timing Sensor Circuit - Test”
RENR9346-06 63
Repair: Flash program the ECM with the correct B. Check for the correct installation of the sensor's
flash file. Refer to programming parameters connectors. Ensure that the electrical connector
Troubleshooting, “Flash Programming”. Verify that is securely latched. Check for the correct polarity
the problem is resolved. in the wiring at each sensor connector and at the
ECM connector.
STOP.
C. Ensure that the harness is properly secured, and
ensure that each tie-wrap is placed in the correct
i02437198
location.
CID 0261 FMI 11 Engine Timing Expected Result:
Offset fault
The sensors, the connectors, and the wiring are
SMCS Code: 1439-038; 1912-038 correctly installed.
Conditions Which Generate This Code: Results:
The signals from the engine speed/timing sensors • OK – The sensors and the harness are OK. The
indicate that the expected position of the camshaft is problem is not with the sensor or the harness.
incorrect with respect to the crankshaft, or the polarity There may be a mechanical problem with the
of the wiring to one of the speed/timing sensors is engine's front gear train. Proceed to Test Step 2.
reversed.
• Not OK – A problem has been identified with the
System Response: installation of the sensors and/or the harness.
The Electronic Control Module (ECM) will log the Repair: Correct the problem that has been
diagnostic code. identified. Replace parts, if necessary. Ensure that
the diagnostic code is no longer active.
The ECM sets engine timing calibration to zero
degrees. A timing calibration is necessary after this
diagnostic code has become active. Refer to the
Possible Performance Effect: diagnostic functional test Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
• The engine may misfire.
STOP.
• The engine may experience low power and/or
reduced speed. Test Step 2. Check the Condition of the
Engine's Front Gear Train
• The engine may experience increased exhaust
emissions and/or white exhaust smoke. The problem may be due to the incorrect orientation
of the camshaft gear with respect to the orientation of
Troubleshooting: the crankshaft gear during engine operation. Check
the front gear train for damage and excessive wear:
Test Step 1. Check the Installation of the
Speed/Timing Sensors Refer to Disassembly and Assembly.
A. Visually inspect the sensors for correct installation: A. Remove the cover from the front gear housing.
a. Ensure that the sensor's mounting flanges are B. Check for correct timing between the crankshaft
fully seated onto the surface of the engine. gear and the camshaft gear.
b. Ensure that the locating notch on the flange of C. Check the gear train for gear tooth failure.
each sensor is oriented correctly.
D. Check the gear train for excessive gear tooth
c. Ensure that the sensor's brackets are not wear and gear tooth failure. Perform a timing gear
bent or broken. Ensure that the brackets are backlash check.
securely holding the sensor in place.
E. Check each idler gear assembly for excessive
d. Ensure that the sensors are tight in the housing wear to the bearing and/or the idler stub shaft.
bore. If a sensor is loose in the bore, check the Check for correct bearing clearance.
condition of the sensor's O-ring seals. Ensure
that the seals are not missing. Also, inspect the
seals for damage.
64 RENR9346-06
Expected Result: Troubleshooting:
The mechanical condition of the gear train is within Perform the following diagnostic procedure: “Engine
specifications. Speed/Timing Sensor - Calibrate”
Results: Results:
• OK – The condition of the gear train is OK. • OK – STOP.

Repair: The problem is not in the gear train. Clear
i02445665
the diagnostic code. There may be a problem with
the circuit for the speed/timing sensors. Refer to
the diagnostic functional test Troubleshooting,
CID 0262 FMI 03 5 Volt Sensor
“Engine Speed/Timing Sensor Circuit - Test”. DC Power Supply short to
STOP.
+batt
SMCS Code: 1439-038
• Not OK – The mechanical condition of the gear
train is not within specifications.
Repair: A problem with the gear train has been
The voltage level of the 5 volt supply is above normal.
identified. Make the necessary repairs to the
gear train. Clear the diagnostic code. A timing System Response:
calibration is necessary after this diagnostic
code has become active. Refer to the calibration
The Electronic Control Module (ECM) will log the
procedure Troubleshooting, “Engine Speed/Timing diagnostic code. The ECM flags all 5 volt sensors
Sensor - Calibrate”.
as invalid data and the respective default values are
used.
Verify that the original problem has been resolved.
STOP.
• The engine may experience low power.
i02445663
Troubleshooting:
CID 0261 FMI 13 Engine Timing
Calibration required Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test”
SMCS Code: 1439-038; 1912-038
Results:
• OK – STOP.
incorrect engine timing. i02445677
Note: A timing calibration is required for a new CID 0262 FMI 04 5 Volt Sensor
engine, replacing an ECM that fails to communicate
or following work on the front gear train, the camshaft,
DC Power Supply short to
or the crankshaft. ground
System Response: SMCS Code: 1439-038
The check engine lamp will illuminate while this Conditions Which Generate This Code:
diagnostic code is active. The ECM uses default
timing. Timing may be off as much as three degrees. The 5 volt sensor supply voltage drops below normal.
• The engine may run rough and/or the engine may The Electronic Control Module (ECM) logs the
emit white smoke in the exhaust. diagnostic code. The ECM flags all 5 volt sensors
as invalid data and the respective default values are
used.
RENR9346-06 65
• The engine may experience low power. The diagnostic code will only be active. The check
engine lamp will illuminate while this diagnostic code
Troubleshooting: is active. Any unprogrammed parameters are set to
the default value.
Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test” Possible Performance Effect:
Results: • The unprogrammed parameters determine the

action that is taken by the ECM.
• OK – STOP.
Troubleshooting:
i02281090
Program the missing parameter.
CID 0267 FMI 02 Incorrect If a system configuration parameter has not been
Engine Shutdown Switch programmed, refer to Troubleshooting, “System
inputs Configuration Parameters”.
If an injector trim file has not been programmed,

SMCS Code: 7332-038
refer to programming parameters Troubleshooting,
Conditions Which Generate This Code: “Injector Trim File”.
Results:
The engine is running. Both inputs from the engine
shutdown control (ground level) are connected to
ground or both inputs are an open circuit. • OK – STOP.
The Electronic Control Module (ECM) will log the CID 0274 FMI 03 Atmospheric
diagnostic code. The engine shutdown control
(ground level) will not operate. Therefore, the
Pressure open/short to +batt
keyswitch or the engine shutdown control on the SMCS Code: 1439-038-AI; 1923-038
engine control panel must be used to shut down the
engine.
Troubleshooting:
signal voltage that is above normal.
Shutdown Switch Circuit - Test”
System Response:
Results: The code is logged. The ECM will use the default
value for atmospheric pressure.
• OK – STOP.
i02445689
• The engine power is derated.
CID 0268 FMI 02 Check
Programmable Parameters Troubleshooting:

SMCS Code: 1901-038
Results:
The Electronic Control Module (ECM) detects one of
the following conditions: • OK – STOP.
• At least one system configuration parameter is not

programmed.
• At least one injector trim file is not programmed.

66 RENR9346-06
i02416783 Results:
CID 0274 FMI 04 Atmospheric • OK – STOP.
Pressure short to ground
i02455005
SMCS Code: 1439-038-AI; 1923-038
CID 0291 FMI 06 Engine
Cooling Fan Solenoid short to
The Electronic Control Module (ECM) detects a ground
signal that is below normal.
SMCS Code: 5479-038
System Response:
The code is logged. The ECM will use the default
value for atmospheric pressure. The Electronic Control Module (ECM) detects a
short to ground condition in the circuit for the engine
Possible Performance Effect: cooling fan solenoid.
• The engine power is derated. System Response:
Troubleshooting: The ECM logs the diagnostic code. While the

condition is present, the ECM will default to maximum
Perform the following diagnostic procedure: “Engine fan speed.
Results:
• The engine may experience overcooling.
• OK – STOP.
Troubleshooting:
i02455004
CID 0291 FMI 05 Engine Fan Control Solenoid Circuit - Test”
Cooling Fan Solenoid open Results:
circuit
• OK – STOP.
SMCS Code: 5479-038
i02424825
CID 0342 FMI 08 Secondary
open circuit or a short to +Battery condition in the Engine Speed signal abnormal
circuit for the engine cooling fan solenoid.
SMCS Code: 1439-038-VF; 1907-038
System Response:
The ECM logs the diagnostic code. While the
condition is present, the ECM will default to maximum The Electronic Control Module (ECM) detects the
fan speed. signal from the secondary engine speed/timing
sensor has been lost.
System Response:
• The engine may experience overcooling. The ECM will log the diagnostic code. The ECM will
Troubleshooting: default to the primary engine speed/timing sensor.
Perform the following diagnostic procedure: “Engine Possible Performance Effect:

Fan Control Solenoid Circuit - Test”
• The engine performance is not affected.
Note: If the signals from both engine speed/timing
sensors are lost, the engine will shut down.
RENR9346-06 67
Perform the following diagnostic procedure: “Engine • All features that depend on the missing data will
Speed/Timing Sensor Circuit - Test” be affected.
Results: Troubleshooting:
• OK – STOP. There is at least one parameter that is requested by

the engine ECM that is not being received.
i02522321
Ensure that the Flash Files for the
CID 0533 FMI 09 Brake Control Machine's Control Modules are Current
abnormal update rate A. Ensure that each control module that is on the
machine has been updated with the most current
SMCS Code: 7610-038-BRK flash file.
Conditions Which Generate This Code: Expected Result:
The engine Electronic Control Module (ECM) loses All of the flash files for the machine are the latest part
communication with the brake ECM. number.
System Response: Results:
The engine ECM will log the diagnostic code. • OK – The flash files are the latest part number.
Possible Performance Effect: Repair: Contact the Dealer Solution Network (DSN)
for information that is related to troubleshooting
• All features that depend on input from the brake the problem further.
ECM will be affected.
STOP.
Troubleshooting:
Perform the following diagnostic procedure: “Cat i02454362
Data Link Circuit - Test”

Results: Cooling Fan Speed Sensor
• OK – STOP.
loss of signal
SMCS Code: 1439-038-FM
i02522324
CID 0533 FMI 14 Brake Control
special instruction While the engine is running the Electronic Control
Module (ECM) detects the loss of a signal from the
SMCS Code: 7610-038-BRK engine cooling fan speed sensor.
Conditions Which Generate This Code: System Response:
After successful communication has been The ECM will log the diagnostic code. The ECM will
established, the engine Electronic Control Module default to maximum fan speed.
(ECM) has not received all the information that was
requested over the Cat Data Link from the brake Possible Performance Effect:
(ECM).
• The engine may experience overcooling.
System Response:
Troubleshooting:
The engine ECM will log the diagnostic code.
Fan Speed Sensor Circuit - Test”
68 RENR9346-06
• OK – STOP. Perform the following diagnostic procedure: “Engine

Oil Renewal Solenoid Circuit - Test”
i02455016
Results:
• OK – STOP.
Cooling Fan Speed signal
abnormal i02521220
SMCS Code: 1439-038-FM CID 0569 FMI 06 Oil Renewal

Solenoid short to ground
SMCS Code: 1349-038-OD; 5479-038-OC
The Electronic Control Module (ECM) detects fan
speed that is out of the acceptable range. S/N: EXD1-Up
System Response: S/N: EYG1-Up
The ECM will log the diagnostic code. The ECM will S/N: JXP1-Up
default to maximum fan speed. S/N: JRP1-Up; LJW1-Up
Possible Performance Effect: Conditions Which Generate This Code:
• The engine may experience overcooling. The Electronic Control Module (ECM) detects
excessive current in the circuit.
Troubleshooting:
System Response:
Fan Speed Sensor Circuit - Test” The code is logged.
Results: Possible Performance Effect:
• OK – STOP. • The oil renewal system is disabled.
i02521218 Troubleshooting:
CID 0569 FMI 05 Oil Injection Perform the following diagnostic procedure: “Engine
Solenoid current below normal
Results:
SMCS Code: 1349-038-OD; 5479-038-OC
S/N: EXD1-Up • OK – STOP.
S/N: EYG1-Up
S/N: JXP1-Up
S/N: JRP1-Up; LJW1-Up
The Electronic Control Module (ECM) detects low

current in the circuit.
System Response:
The code is logged.
• The oil renewal system is disabled.

RENR9346-06 69
i02817711 Possible Performance Effect:

CID 0827 FMI 03 Left Exhaust • There are no performance effects.
Troubleshooting:
+batt
Perform the following diagnostic procedure: “Sensor
SMCS Code: 1439-038-TA; 1919-038 Signal (PWM) - Test”
S/N: EXD1-Up
Results:
S/N: EYG1-Up
• OK – STOP.
S/N: JXP1-Up
S/N: JRP1-Up; LJW1-Up i02817824
Conditions Which Generate This Code: CID 0827 FMI 08 Left Exhaust
Temperature signal abnormal
signal voltage that is above normal. SMCS Code: 1439-038-TA; 1919-038
System Response: S/N: EXD1-Up
The code is logged. The ECM will flag the exhaust S/N: EYG1-Up
temperature as invalid data. S/N: JXP1-Up
Possible Performance Effect: S/N: JRP1-Up; LJW1-Up
• There are no performance effects. Conditions Which Generate This Code:
Troubleshooting: The Electronic Control Module (ECM) detects an

incorrect frequency for the exhaust temperature
Perform the following diagnostic procedure: “Sensor sensor or the exhaust temperature sensor is out of
Signal (PWM) - Test” the acceptable range.
Results: System Response:
• OK – STOP. The code is logged. The ECM will flag the exhaust
temperature as invalid data.
i02817787
CID 0827 FMI 04 Left Exhaust
Troubleshooting:
SMCS Code: 1439-038-TA; 1919-038
S/N: EXD1-Up
Signal (PWM) - Test”
S/N: EYG1-Up
Results:
S/N: JXP1-Up
• OK – STOP.

signal voltage that is below normal.
System Response:
The code is logged. The ECM will flag the exhaust

70 RENR9346-06
i02817756 Possible Performance Effect:

CID 0828 FMI 03 Right Exhaust • There are no performance effects.
Troubleshooting:
+batt
SMCS Code: 1439-038-TA; 1919-038 Signal (PWM) - Test”
S/N: EXD1-Up
Results:
S/N: EYG1-Up
• OK – STOP.
S/N: JXP1-Up
S/N: JRP1-Up; LJW1-Up i02817830
Conditions Which Generate This Code: CID 0828 FMI 08 Right Exhaust
Temperature signal abnormal
signal voltage that is above normal. SMCS Code: 1439-038-TA; 1919-038
System Response: S/N: EXD1-Up
The code is logged. The ECM will flag the exhaust S/N: EYG1-Up
temperature as invalid data. S/N: JXP1-Up
Possible Performance Effect: S/N: JRP1-Up; LJW1-Up
• There are no performance effects. Conditions Which Generate This Code:
Troubleshooting: The Electronic Control Module (ECM) detects an

incorrect frequency for the exhaust temperature
Perform the following diagnostic procedure: “Sensor sensor or the exhaust temperature sensor is out of
Signal (PWM) - Test” the acceptable range.
Results: System Response:
• OK – STOP. The code is logged. The ECM will flag the exhaust
i02817799
CID 0828 FMI 04 Right Exhaust
Troubleshooting:
SMCS Code: 1439-038-TA; 1919-038
S/N: EXD1-Up
S/N: EYG1-Up
Results:
S/N: JXP1-Up
• OK – STOP.

System Response:

RENR9346-06 71
i02524260 Ensure that the Flash Files for the

Machine's Control Modules are Current
CID 1273 FMI 09 Unable to
Communicate with Chassis A. Ensure that each control module that is on the
machine has been updated with the most current
Control Module flash file.
SMCS Code: 7610-038-CS Expected Result:

Conditions Which Generate This Code: All of the flash files for the machine are the latest part
number.
The engine Electronic Control Module (ECM) loses
communication with the chassis ECM. Results:
System Response: • OK – The flash files are the latest part number.
The engine ECM will log the diagnostic code. Repair: Contact the Dealer Solution Network (DSN)
for information that is related to troubleshooting
Possible Performance Effect: the problem further.
• All features that depend on input from the chassis STOP.

ECM will be affected.
Troubleshooting: i02443808
Perform the following diagnostic procedure: “Cat

CID 1589 FMI 03 Turbo Inlet Air
Data Link Circuit - Test” Pressure Sensor open/shrt to
Results: +bat
SMCS Code: 1439-038-PX; 1917-038
• OK – STOP.
i02524160
The Electronic Control Module (ECM) detects signal
CID 1273 FMI 14 Chassis voltage that is above normal.
Control Module special
System Response:
instruction
The ECM will log the diagnostic code. The ECM flags
SMCS Code: 7610-038-CS turbocharger inlet pressure as invalid data and a
default value is used.
After successful communication has been
established, the engine Electronic Control Module • There are no performance effects.
(ECM) has not received all the information that was
requested over the Cat Data Link from the chassis Troubleshooting:
(ECM).
System Response: Pressure Sensor Open or Short Circuit - Test”
The engine ECM will log the diagnostic code. Results:

Possible Performance Effect: • OK – STOP.
• All features that depend on the missing data will
be affected.
Troubleshooting:
There is at least one parameter that is requested by

the engine ECM that is not being received.
72 RENR9346-06
i02445694 Results:
CID 1589 FMI 04 Turbo Inlet • OK – STOP.
Air Pressure Sensor short to
ground i02407894
SMCS Code: 1439-038-PX; 1917-038

CID 1785 FMI 04 Intake
Manifold Pressure Sensor
voltage low
signal voltage that is below normal. SMCS Code: 1439-038-IL
The ECM will log the diagnostic code. The ECM flags The Electronic Control Module (ECM) detects a
turbocharger inlet pressure as invalid data and a signal voltage below the normal.
default value is used.
System Response:
The code is logged. The ECM flags intake manifold
pressure as invalid data and a default value is used.
• The engine may have low power.
Perform the following diagnostic procedure: “Engine • The engine power will be derated.
Troubleshooting:
Results:
• OK – STOP.
Results:
i02407892
• OK – STOP.
CID 1785 FMI 03 Intake
Manifold Pressure Sensor i02487751
voltage high CID 1785 FMI 10 Intake
SMCS Code: 1439-038-IL Manifold Pressure Signal
Conditions Which Generate This Code: abnormal rate of change
The Electronic Control Module (ECM) detects a SMCS Code: 1439-038-IL
signal voltage above normal.
System Response:
This code indicates that the 5 volt supply is missing
The code is logged. The ECM flags intake manifold from the sensor connector.
During normal engine operation, the intake manifold
Possible Performance Effect: pressure fluctuates slightly. When the 5 volt supply is
missing from the intake manifold pressure sensor, the
signal from the pressure sensor floats to a midrange
• The engine power will be derated. value. The signal does not fluctuate. If the signal
Troubleshooting: from the intake manifold pressure sensor remains
abnormally steady for more than 30 seconds, the
Perform the following diagnostic procedure: “Engine Engine Control Module (ECM) activates this code.
RENR9346-06 73
System Response: Troubleshooting:
The ECM uses a default value for the intake manifold Perform the following diagnostic procedure: “Engine
pressure. Pressure Sensor Open or Short Circuit - Test”
Possible Performance Effect: Results:
• Low power • OK – STOP.

Troubleshooting:
i02509453
Repair the Sensor Supply Circuit CID 1795 FMI 04 Turbo #2

A. Repair the circuit for the supply wire between the Outlet Pressure Sensor
ECM and the sensor.
voltage below normal
Expected Result: SMCS Code: 1439-038-PX; 1917-038
The problem is resolved. S/N: EXD1-Up
Results: S/N: EYG1-Up

S/N: JXP1-Up
• Not OK – The problem is not resolved.
Repair: Replace the sensor.
STOP. signal voltage below the normal.
i02509423 System Response:
CID 1795 FMI 03 Turbo #2 The code is logged. The ECM flags intake manifold
Outlet Pressure Sensor
voltage above normal Possible Performance Effect:
SMCS Code: 1439-038-PX; 1917-038 • The engine power will be derated.

S/N: EXD1-Up Troubleshooting:
S/N: EYG1-Up
S/N: JXP1-Up Pressure Sensor Open or Short Circuit - Test”
S/N: JRP1-Up; LJW1-Up Results:
Conditions Which Generate This Code: • OK – STOP.

signal voltage above normal.
System Response:
The code is logged. The ECM flags intake manifold

• The engine power will be derated.

74 RENR9346-06
i02509473 i02509512
CID 1795 FMI 10 Turbo #2 CID 1796 FMI 03 Intake

Outlet Pressure Sensor Manifold #2 Air Temperature
abnormal rate of change Sensor voltage above normal
SMCS Code: 1439-038-PX; 1917-038 SMCS Code: 1439-038-AI; 1921-038
S/N: EXD1-Up S/N: EXD1-Up
S/N: EYG1-Up S/N: EYG1-Up
S/N: JXP1-Up S/N: JXP1-Up
S/N: JRP1-Up; LJW1-Up S/N: JRP1-Up; LJW1-Up
This code indicates that the 5 volt supply is missing The Electronic Control Module (ECM) detects a
from the sensor connector. signal voltage that is above normal or the intake
manifold air temperature is below −35 °C (−31 °F) .
During normal engine operation, the intake manifold
pressure fluctuates slightly. When the 5 volt supply is System Response:
missing from the intake manifold pressure sensor, the
signal from the pressure sensor floats to a midrange The code is logged. The ECM will flag the intake
value. The signal does not fluctuate. If the signal manifold air temperature as invalid data and the
from the intake manifold pressure sensor remains intake manifold air temperature is set to a default
abnormally steady for more than 30 seconds, the value.
Engine Control Module (ECM) activates this code.
System Response:
The ECM uses a default value for the intake manifold
pressure. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure: “Engine

• Low power
Results:
Troubleshooting:
• OK – STOP.
Repair the Sensor Supply Circuit
i02509521
A. Repair the circuit for the supply wire between the
ECM and the sensor. CID 1796 FMI 04 Intake
Expected Result: Manifold #2 Air Temperature
The problem is resolved.
Sensor voltage below normal
SMCS Code: 1439-038-AI; 1921-038
Results:
S/N: EXD1-Up
S/N: EYG1-Up
• Not OK – The problem is not resolved. S/N: JXP1-Up
Repair: Replace the sensor. S/N: JRP1-Up; LJW1-Up
STOP. Conditions Which Generate This Code:
The signal voltage from the intake manifold air

temperature sensor is below normal or the intake
manifold air temperature is above 140 °C (284 °F).
RENR9346-06 75
The Electronic Control Module (ECM) will log the CID 2271 FMI 06 Engine Oil
diagnostic code. The ECM will flag the intake Renewal System Actuation
manifold air temperature as invalid data and a default
value is used. Solenoid current above normal
Possible Performance Effect: SMCS Code: 5479-038-OC
S/N: EXD1-Up
S/N: EYG1-Up
Troubleshooting:
S/N: JXP1-Up
Temperature Sensor Open or Short Circuit - Test” S/N: JRP1-Up; LJW1-Up
Results: Conditions Which Generate This Code:
• OK – STOP. The Electronic Control Module (ECM) detects high

i02527831 System Response:

CID 2271 FMI 05 Engine Oil The code is logged.
Renewal System Actuation
Solenoid current below normal
• The engine oil renewal solenoid may not activate.
SMCS Code: 5479-038-OC
Troubleshooting:
S/N: EXD1-Up
S/N: EYG1-Up Perform the following diagnostic procedure: “Engine
S/N: JXP1-Up
Results:

• OK – STOP.
The Electronic Control Module (ECM) detects low i02817760

CID 2350 FMI 03 Left Exhaust
System Response: #2 Temperature voltage above
The code is logged. normal
Possible Performance Effect: SMCS Code: 1919-038-LT
S/N: EXD1-Up
• The engine oil renewal solenoid may not activate.
S/N: EYG1-Up
Troubleshooting:
S/N: JXP1-Up
Oil Renewal Solenoid Circuit - Test” S/N: JRP1-Up; LJW1-Up
• OK – STOP. The Electronic Control Module (ECM) detects a

System Response:

76 RENR9346-06
Possible Performance Effect: i02817831
• There are no performance effects. CID 2350 FMI 08 Left Exhaust

#2 Temperature abnormal
Troubleshooting:
frequency, pulse width, or
period
SMCS Code: 1919-038-LT
Results:
S/N: EXD1-Up
• OK – STOP.
S/N: EYG1-Up
i02817802 S/N: JXP1-Up

CID 2350 FMI 04 Left Exhaust S/N: JRP1-Up; LJW1-Up
#2 Temperature voltage below Conditions Which Generate This Code:
normal
SMCS Code: 1919-038-LT incorrect frequency for the exhaust temperature
sensor or the exhaust temperature sensor is out of
S/N: EXD1-Up the acceptable range.
S/N: EYG1-Up System Response:
S/N: JXP1-Up
S/N: JRP1-Up; LJW1-Up temperature as invalid data.
Conditions Which Generate This Code: Possible Performance Effect:
The Electronic Control Module (ECM) detects a • There are no performance effects.
Troubleshooting:
System Response:
The code is logged. The ECM will flag the exhaust Signal (PWM) - Test”
Results:
• OK – STOP.
i02817762
Troubleshooting:
CID 2351 FMI 03 Right Exhaust
Signal (PWM) - Test” #2 Temperature voltage above
Results:
normal
SMCS Code: 1919-038-RI
• OK – STOP.
S/N: EXD1-Up
S/N: EYG1-Up
S/N: JXP1-Up

RENR9346-06 77
The code is logged. The ECM will flag the exhaust CID 2351 FMI 08 Right Exhaust
temperature as invalid data. #2 Temperature abnormal
Possible Performance Effect: frequency, pulse width, or
period
Troubleshooting:
S/N: EXD1-Up
Signal (PWM) - Test” S/N: EYG1-Up
Results: S/N: JXP1-Up

• OK – STOP.
i02817804
CID 2351 FMI 04 Right Exhaust incorrect frequency for the exhaust temperature
sensor or the exhaust temperature sensor is out of
#2 Temperature voltage below the acceptable range.
normal
System Response:
S/N: EXD1-Up temperature as invalid data.
S/N: EYG1-Up Possible Performance Effect:
S/N: JXP1-Up
Troubleshooting:
The Electronic Control Module (ECM) detects a Signal (PWM) - Test”
Results:
System Response:
• OK – STOP.
i02418270
Possible Performance Effect: CID 2417 FMI 05 Ether Injection

• There are no performance effects. Control Solenoid current low
Troubleshooting: SMCS Code: 5479-038
Perform the following diagnostic procedure: “Sensor Conditions Which Generate This Code:
Results: current in the circuit.
• OK – STOP. System Response:
The code is logged.
• The engine may be difficult to start.

78 RENR9346-06
Troubleshooting: Troubleshooting:
Perform the following diagnostic procedure: “Ether Perform the following diagnostic procedure:
Injection System - Test” “Compression Brake Solenoid Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02418652 i02510965
CID 2417 FMI 06 Ether Injection CID 2533 FMI 06 Compression

Control Solenoid current high Brake Low/High Solenoid #1
SMCS Code: 5479-038
current above normal
SMCS Code: 1129-038-OD; 5479-038-BRK
The Electronic Control Module (ECM) detects Conditions Which Generate This Code:
excessive current flow in the circuit.
The Electronic Control Module (ECM) detects
System Response: excessive current in the circuit.
System Response:
The code is logged.
The code is logged.
• The engine may be difficult to start.
Troubleshooting: • The engine compression brake may not activate.
Troubleshooting:
Perform the following diagnostic procedure: “Ether
Injection System - Test”
“Compression Brake Solenoid Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02511159
CID 2533 FMI 05 Compression i02511335
Brake Low/High Solenoid #1 CID 2534 FMI 05 Compression

current below normal Brake Low/High Solenoid #2
SMCS Code: 1129-038-OD; 5479-038-BRK
current below normal
Conditions Which Generate This Code: SMCS Code: 1129-038-OD; 5479-038-BRK

System Response:
System Response:
The code is logged.
Possible Performance Effect: The code is logged.

• The engine compression brake may not activate.
RENR9346-06 79
Perform the following diagnostic procedure: Perform the following diagnostic procedure:
“Compression Brake Solenoid Circuit - Test” “Compression Brake Solenoid Circuit - Test”
Results: Results:
i02511529 i02511535
CID 2534 FMI 06 Compression CID 2535 FMI 06 Compression

Brake Low/High Solenoid #2 Brake Medium/High Solenoid
current above normal #1 current above normal
SMCS Code: 1129-038-OD; 5479-038-BRK SMCS Code: 1129-038-OD; 5479-038-BRK
The Electronic Control Module (ECM) detects The Electronic Control Module (ECM) detects
excessive current in the circuit. excessive current in the circuit.
The code is logged. The code is logged.
Possible Performance Effect: Possible Performance Effect:
• The engine compression brake may not activate. • The engine compression brake may not activate.
Perform the following diagnostic procedure: Perform the following diagnostic procedure:
“Compression Brake Solenoid Circuit - Test” “Compression Brake Solenoid Circuit - Test”
Results: Results:
i02511361 i02511372
CID 2535 FMI 05 Compression CID 2536 FMI 05 Compression

Brake Medium/High Solenoid Brake Medium/High Solenoid
#1 current below normal #2 current below normal
SMCS Code: 1129-038-OD; 5479-038-BRK SMCS Code: 1129-038-OD; 5479-038-BRK
The Electronic Control Module (ECM) detects low The Electronic Control Module (ECM) detects low
current in the circuit. current in the circuit.
The code is logged. The code is logged.
Possible Performance Effect: Possible Performance Effect:
• The engine compression brake may not activate. • The engine compression brake may not activate.
80 RENR9346-06
Troubleshooting:

Results:
• OK – STOP.
i02511545
CID 2536 FMI 06 Compression

Brake Medium/High Solenoid
#2 current above normal
SMCS Code: 1129-038-OD; 5479-038-BRK

excessive current in the circuit.
System Response:
The code is logged.

Troubleshooting:

Results:
• OK – STOP.
RENR9346-06 81
Troubleshooting with an Derate (2) – For this condition, the engine's power
is reduced in order to help prevent possible engine
Event Code damage. However, this condition does not require
a shutdown.
i02815105 Shutdown (3) – For this condition, the operator is
Event Codes alerted of the event. The operator must shut down the
engine in order to prevent possible engine damage.
SMCS Code: 1901
Event codes alert the operator that an abnormal

engine operating condition such as low oil pressure
or high coolant temperature has been detected.
When the event code is generated, this indicates that
an event has taken place.
Active Event Codes

An event code represents a problem with the
operating condition of the engine. Correct the
problem as soon as possible.
Each event has a trip point. The trip point is a value

that is out of the normal operating range for a system
such as the engine cooling system or the lubrication
system. Once the trip point has been exceeded,
the Electronic Control Module (ECM) will count
down the trip delay for the code. Once the trip delay
expires, the code will be logged. The trip delay is
the amount of time before the ECM will act on the
code. This delay helps to ensure that the condition
is valid. There is also a start delay that prevents the
ECM from mistakenly generating event codes during
engine start-up. The start delay is the amount of
time after the engine starts before an event code
can be generated. Once the system falls below the
reset level and the reset delay expires, the event will
become inactive.
In the format for an event code, the “E” is used to

identify the code as an event code. The first three
numbers “XXX” represent a numeric identifier for the g01100964
event code. The fourth “(X)” identifies the event as a Illustration 11
warning, a derate, or a shutdown. This is followed Output voltage from a typical temperature sensor
by a description of the code. Refer to the following
example: Illustration 11 shows the typical output voltage
from an analog sensor. If the output signal voltage
• E360(1) Low Oil Pressure Warning is between 4.2 VDC and 4.8 VDC, the ECM will
generate an event code.
• E360(2) Low Oil Pressure Derate
These responses to certain events may be
• E360(3) Low Oil Pressure Shutdown programmed into the ECM. If the responses are
programmed, Caterpillar Electronic Technician (ET)
The definition for a warning, a derate, and a shutdown can display the event. If the responses are not
are defined below: programmed, the display will not appear. However,
the occurrence of any event will cause the event
Warning (1) – This condition represents a serious code to be logged in the ECM.
problem with engine operation. However, this
condition does not require a derate or a shutdown. Note: Do not confuse event codes with diagnostic
codes. For information on diagnostic codes, refer to
Troubleshooting, “Troubleshooting with a Diagnostic
Code”.
82 RENR9346-06
Logged Event Codes 2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
When the ECM generates an event code the code is due to error of the operator.
logged into permanent memory. The ECM has an
internal diagnostic clock that is used to time stamp 3. Narrow the probable cause. Consider the operator
the activation of the event. The ECM will record information, the conditions of operation, and the
the following information when an event code is history of the engine.
generated:
4. Perform a visual inspection. Inspect the following
• The hour of the first occurrence of the code items:
• The hour of the last occurrence of the code • Condition of the fuel and fuel system
components
• The number of occurrences of the code
• Oil level and condition of the oil
Logged events are listed in chronological order. The
most recent event code is listed first. • Engine wiring and condition of the connectors
This information can be helpful for troubleshooting Be sure to check the connectors. This is very
intermittent problems. Logged codes can also be important for problems that may be logged several
used to review any performance problems with the times over a long period of time. This may indicate
engine. that an intermittent problem exists. If an intermittent
condition is suspected, refer to Troubleshooting,
Clearing Event Codes
If these steps do not resolve the problem, identify
A code is cleared from memory when one of the
the procedures in this manual that best describe the
following conditions occur:
event. Check each probable cause according to the
tests that are recommended.
• The code does not recur for 100 hours.
• A new code is logged and there are already ten Trip Points for the Monitoring
codes in memory. In this case, the oldest code is System
cleared.
The monitoring system determines the level of action
• The service technician manually clears the code. that is taken by the ECM in response to a condition
that can damage the engine. When any of these
Always clear logged event codes after investigating conditions occur, the appropriate event code will trip.
and correcting the problem which generated the
code. Table 12 contains the conditions that are monitored
and the default trip points for each condition. Each
Troubleshooting condition has an associated parameter. The settings
for each parameter can be viewed with Cat ET.
For basic troubleshooting of the engine, perform the The trip points for some of the parameters may be
following steps in order to diagnose a malfunction: adjustable.
1. Obtain the following information about the

complaint:
• The event and the time of the event

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

installed by the dealer or by the customer that
could cause the event.
• Determine whether any additional events

occurred.
RENR9346-06 83
Table 12
Trip Points for the Monitoring System
Time Delay in
Event Default Set Points
Parameter Action Seconds
Code Value
Range Default Range Default
Always 758 kPa
High Fuel Pressure E096 Warning None 8 None
On (110 psi)
Switch Switch Open
Low Engine Oil Level E171 Warning None N/A N/A
Closed on Low Level
7.5 kPa
Warning
(1.1 psi)
High Air Filter Restriction E172 On None 30 None
9.0 kPa
Derate
(1.3 psi)
High Exhaust Temperature E194 Refer to Troubleshooting, “E194 High Exhaust Temperature” for information.
760 °C
Warning
High Right Exhaust Always (1400 °F)
E321 None 15 None
Temperature On 805 °C
Derate
(1481 °F)
760 °C
Warning
High Left Exhaust Always (1400 °F)
E322 None 15 None
Derate
(1481 °F)
760 °C
Warning
High Left Exhaust #2 Always (1400 °F)
E775 None 15 None
Derate
(1481 °F)
760 °C
Warning
High Right Exhaust #2 Always (1400 °F)
E776 None 15 None
Derate
(1481 °F)
Warning Always 8 Maps are not programmable. (1)
Low Engine Oil Pressure E360 None
Shutdown On 4 Maps are not programmable. (2)
Warning Always None 110 °C (230 °F)

High Engine Coolant On
E361 Derate 1 to 120 10 None 111 °C (232°F)
Temperature
Shutdown On 116 °C (241 °F)
Warning Always 2600
Engine Overspeed E362 None 0.6 None
Derate On 2800
Always
Warning None 30 90 °C (194 °F)
High Fuel Temperature E363 On None
Derate On 1 to 120 10 91 °C (196 °F)
Warning Switch 3600 138 ± 14 kPa
Fuel Filter Restriction(3) E390 None None
Derate Closed 14400 (20 ± 2 psi)(4)
High Intake Manifold Air Warning Always 82 °C (179 °F)

E539 None 8 None
Temperature Derate On 86 °C (187 °F)
Low Engine Oil Refill Switch Switch Open
E540 Warning None N/A N/A
Tank Level Closed on Low Level
(continued)
84 RENR9346-06
(Table 12, contd)

Trip Points for the Monitoring System
Time Delay in
Event Default Set Points
Parameter Action Seconds
Code Value
Range Default Range Default
760 °C
Warning
High Left Exhaust #2 Always (1400 °F)
E775 None 15 None
Derate
(1481 °F)
760 °C
Warning
High Right Exhaust #2 Always (1400 °F)
E776 None 15 None
Derate
(1481 °F)
High Left Intake Manifold Warning Always 82 °C (179 °F)

E1000 None 8 None
Air Temperature Derate On 86 °C (187 °F)
(1) Refer to Table 13 for trigger points.
(2) Refer to Table 14 for trigger points.
(3) This event is disabled for fuel temperatures that are below 60 °C (140 °F).
(4) Pressures for the 258-0883 Pressure Switch Gp
Table 13 Possible Performance Effect:

Trip Points for Low Oil Pressure Warning
(Gauge Pressures) E096(1)
0 rpm 0 kPa (0 psi) • There are no performance effects.

500 rpm 0 kPa (0 psi)
Check the Fuel System
1600 rpm 154 kPa (22 psi)
2400 rpm 154 kPa (22 psi) A. Verify that the check valve in the fuel manifold is
operating correctly. Check for damage or for dirt
in the check valve.
Table 14
Trip Points for Low Oil Pressure Shutdown B. Check the return line from the check valve to the
(Gauge Pressures) fuel tank for damage or collapse.
0 rpm 0 kPa (0 psi)
Results:
500 rpm 0 kPa (0 psi)
1600 rpm 104 kPa (15 psi) • OK – A problem was found in either the check
valve or in the return line to the fuel tank.
2400 rpm 104 kPa (15 psi)
Repair: Replace all suspect parts.
i02490670 STOP.
E096 High Fuel Pressure
i02512722
SMCS Code: 1250-038-HQ
E171 Low Engine Oil Level
SMCS Code: 1348-038-LO
problem with the engine's fuel pressure. Information Conditions Which Generate This Code:
on default settings and ranges for this event code
can be found in Troubleshooting, “Event Codes”. The Electronic Control Module (ECM) detects a low
oil condition. Information on default settings and
System Response: ranges for this event can be found in Troubleshooting,
“Event Codes”.
The event code will be logged.
RENR9346-06 85
System Response: Possible Performance Effect:
The event code will be logged. 172(1)
Possible Performance Effect: • There are no performance effects.

E171(1) 172(2)
There are no performance effects. • The engine power will be derated.

The following conditions can cause the event code. Check for Restrictions in the Air Inlet
System
• Low oil level
A. Inspect the air filter for restrictions and/or clogging.
• Faulty low oil level switch Clean the air filter or replace the air filter.
Check the Engine Oil Level B. Check the air inlet piping for restrictions and for
damage. Refer to Systems Operation/Testing and
A. Check the engine oil level. Adjusting.
Expected Result: Expected Result:
The engine oil level is low. The air filter was cleaned or the air filter was
replaced. No restrictions have been found in the air
Results: inlet system.
• OK – The engine oil level is low. Results:
Repair: Add oil to the engine. Check for leaks that • OK – The air filter and the air inlet system are OK.
might cause the low oil level.
Repair: If an electrical problem with the sensor is
STOP. suspected, refer to the diagnostic functional test
Troubleshooting, “Engine Pressure Sensor Open
• Not OK – The engine had the proper amount of oil. or Short Circuit - Test”.
Repair: Check for proper operation of the oil level STOP.

switch. Refer to Troubleshooting, “Engine Oil Level
Switch Circuit - Test”. • Not OK – There is a problem with the air filter
and/or the air inlet system.
STOP.
Repair: Clean the air filter or replace the air filter,
if necessary. Repair any damage that has been
i02515471
found with the air inlet system.
E172 High Air Filter Restriction STOP.
SMCS Code: 1054-038
i03251205
E194 High Exhaust
an abnormal difference in pressure between the
Temperature
atmospheric pressure and the turbocharger inlet
pressure. Information on default settings and ranges SMCS Code: 1088-038-TA
for this event can be found in Troubleshooting, “Event
Codes”.
The Electronic Control Module (ECM) monitors the
System Response:
following parameters in order to calculate the exhaust
The ECM logs the event code. temperature:
• Intake manifold air temperature

86 RENR9346-06
• Barometric pressure • Not OK – The fins of the ATAAC are clear of

obstructions. Proceed to Test Step 3.
• Engine speed
Test Step 3. Check the 5 Volt Supply to
High intake manifold air temperature, high altitude the Atmospheric Pressure Sensor
operation, and high engine loads can cause the
exhaust temperature to increase to a level that may If the atmospheric pressure sensor is not being
damage the components of the exhaust system. powered by the 5 volt supply, the output of the sensor
When this occurs, the ECM derates the engine may float to a value that is interpreted by the ECM
in order to reduce the exhaust temperature. This as a high altitude condition. The ECM receives the
protects the components of the exhaust system from erroneous value of altitude and the ECM derates
damage. the engine.
System Response: A. Verify that the keyswitch is in the ON position.
The code is logged. Passwords are not required in B. Measure the value of the 5 volt supply at the
order to clear the logged code. harness connector for the atmospheric pressure
sensor.
Expected Result:
Engine power is reduced.
The voltage is approximately five volts.
Test Step 1. Determine the Operating
Conditions Results:
Interview the operator, when possible. Determine if • OK – The supply voltage at the atmospheric
the engine was under heavy load or the engine is pressure sensor is approximately five volts. There
operating at a high altitude. are no further troubleshooting procedures for this
event. Clear the event and return the engine to
Expected Result: service. STOP.
The event occurred because of normal engine • Not OK – The supply voltage at the atmospheric
operation. pressure sensor is not approximately five volts.
There is a problem with the wiring for the 5 volt
Results: supply between the atmospheric pressure sensor
and the ECM.
• OK – The event occurred because of normal
engine operation. Clear the logged event and Repair: Identify the wiring problem and make the
return the engine to service. STOP. necessary repairs.
• Not OK – The event should not have occurred. When the 5 volt supply is present at the
Proceed to Test Step 2. atmospheric pressure sensor, clear the event and
return the engine to service.
Test Step 2. Check the Air-to-Air
Aftercooler (ATAAC) STOP.
The intake manifold air temperature can increase

if the ATAAC is obstructed. Check the fins of the
ATAAC for obstructions.
Expected Result:
The fins of the ATAAC are obstructed.
Results:
• OK – The fins of the ATAAC are obstructed.

Repair: Clean the fins of the ATAAC. Clear the
event. Return the engine to service.
STOP.
RENR9346-06 87
i02817265 Results:
E321 High Right Exhaust • OK – There are no active diagnostic codes.
Temperature Proceed to Test Step 2.
SMCS Code: 1088-038-TA • Not OK – There are active diagnostic codes.

Resolve any active diagnostic codes before
S/N: EXD1-Up proceeding to Test Step 2.
S/N: EYG1-Up Test Step 2. Inspect the Air Inlet and
S/N: JXP1-Up Exhaust System
S/N: JRP1-Up; LJW1-Up Check for air inlet restrictions and/or leaks. A one
degree increase in the inlet manifold temperature will
Conditions Which Generate This Code: increase the exhaust temperature by approximately
three degrees. Check for leaks between the exhaust
The Electronic Control Module (ECM) detects an manifold and the turbocharger. Check for exhaust
excessive exhaust temperature for the engine at restrictions. Refer to the Systems Operation/Testing
the “FRONT RIGHT EXHAUST TC”. This sensor and Adjusting manual for more information on
is located in the exhaust manifold below the inspecting the air inlet and exhaust system.
turbocharger. This sensor measures the exhaust gas
temperature for cylinders 2, 4, and 6. Information Results:
on default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”. • OK – There are no problems with the air inlet and
exhaust system. Proceed to Test Step 3.
System Response:
The event code will be logged. air inlet or the exhaust system.
Possible Performance Effect: Repair: Resolve the problem and verify if the E321
code has been eliminated.
E321(1)
STOP.
Test Step 3. Check for Faults with the
E321(2) Fuel Injectors
• The engine power will be derated. Faulty injectors that deliver too much fuel will
increase exhaust temperatures. Connect Cat ET in
Troubleshooting: order to determine if any diagnostic codes for the
injector solenoids are present. Perform the “Injector
High exhaust temperature can be caused by Solenoid Test”. Observe that the injector solenoids
problems with the following. are being energized on Cat ET. Perform the “Cylinder
Cutout Test”. Locate the misfiring cylinder. Refer to
• Diagnostic codes Troubleshooting, “Injector Solenoid - Test”.
• Air inlet and exhaust system Results:
• Fuel injectors • OK – There are no problems with the fuel injectors.

Proceed to Test Step 4.
• Aftercooler (if applicable)
• Exhaust temperature sensor fuel injectors.
Test Step 1. Check for Diagnostic Codes Repair: Resolve the problem and verify if the E321
Connect Cat ET and check for active and/or logged
diagnostic codes. Troubleshoot any active diagnostic STOP.
88 RENR9346-06
Test Step 4. Inspect the Aftercooler (if i02817685

applicable)
E322 High Left Exhaust
Normal intake manifold pressure with high exhaust Temperature
temperature can be caused by blockage in the
aftercooler. SMCS Code: 1088-038-TA
If the application has an aftercooler, check the S/N: EXD1-Up
aftercooler for correct operation. Check for blockage
in the cores of the aftercooler. S/N: EYG1-Up
S/N: JXP1-Up
Results:
• OK – There is no problem with the aftercooler.
Proceed to Test Step 5. Conditions Which Generate This Code:
• Not OK – A problem has been identified with the The Electronic Control Module (ECM) detects an
aftercooler. excessive exhaust temperature for the engine at the
“FRONT LEFT EXHAUST TC”. This sensor is located
Repair: Resolve the problem and verify if the E321 in the exhaust manifold below the turbocharger.
code has been eliminated. This sensor measures the exhaust gas temperature
for cylinders 1, 3, and 5. Information on default
STOP. settings and ranges for this event can be found in
Troubleshooting, “Event Codes”.
Test Step 5. Check the Exhaust
Temperature Sensor System Response:
Use Cat ET to check the status of the exhaust The event code will be logged.
temperature.
A. Start the engine.
E322(1)
B. Use Cat ET to monitor the status of the exhaust
temperature while the engine is warming to • There are no performance effects.
operating temperature.
E322(2)
C. Ensure that the reading that is displayed is
reasonable. • The engine power will be derated.
• The temperature indicated by the sensor is not High exhaust temperature can be caused by
within reasonable expectations. problems with the following.
Repair: If an electronic problem with the sensor • Diagnostic codes

is suspected, refer to Troubleshooting, “Sensor
Signal (PWM) - Test” for information that is related • Air inlet and exhaust system
to troubleshooting the circuit that is for the exhaust
temperature sensor. • Fuel injectors
STOP. • Aftercooler (if applicable)
• Exhaust temperature sensor
Test Step 1. Check for Diagnostic Codes
diagnostic codes. Troubleshoot any active diagnostic
RENR9346-06 89
Results: Test Step 4. Inspect the Aftercooler (if

applicable)
• OK – There are no active diagnostic codes.
Proceed to Test Step 2. Normal intake manifold pressure with high exhaust
• Not OK – There are active diagnostic codes. aftercooler.
proceeding to Test Step 2. If the application has an aftercooler, check the
Test Step 2. Inspect the Air Inlet and in the cores of the aftercooler.
Exhaust System
Results:
Check for air inlet restrictions and/or leaks. A one
degree increase in the inlet manifold temperature will • OK – There is no problem with the aftercooler.
increase the exhaust temperature by approximately Proceed to Test Step 5.
manifold and the turbocharger. Check for exhaust • Not OK – A problem has been identified with the
restrictions. Refer to the Systems Operation/Testing aftercooler.
and Adjusting manual for more information on
inspecting the air inlet and exhaust system. Repair: Resolve the problem and verify if the E322
Results:
STOP.
• OK – There are no problems with the air inlet and
exhaust system. Proceed to Test Step 3. Test Step 5. Check the Exhaust
Temperature Sensor
air inlet or the exhaust system. Use Cat ET to check the status of the exhaust
temperature.
Repair: Resolve the problem and verify if the E322
code has been eliminated. A. Start the engine.
STOP. B. Use Cat ET to monitor the status of the exhaust

temperature while the engine is warming to
Test Step 3. Check for Faults with the operating temperature.
Fuel Injectors
Faulty injectors that deliver too much fuel will reasonable.
order to determine if any diagnostic codes for the Results:
Solenoid Test”. Observe that the injector solenoids • The temperature indicated by the sensor is not
are being energized on Cat ET. Perform the “Cylinder within reasonable expectations.
Troubleshooting, “Injector Solenoid - Test”. Repair: If an electronic problem with the sensor
Results: Signal (PWM) - Test” for information that is related
• OK – There are no problems with the fuel injectors. temperature sensor.
STOP.
fuel injectors.

STOP.
90 RENR9346-06
i02486798 C. The inlet screen of the oil suction tube for the
engine oil pump can have a restriction. This
E360 Low Engine Oil Pressure restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on
SMCS Code: 1348-038-LP the oil pickup tube and remove any material that
may be restricting engine oil flow. Low engine oil
Conditions Which Generate This Code: pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the
The Electronic Control Module (ECM) detects a oil pickup tube for cracks or a damaged O-ring
problem with the engine's oil pressure. Information seal.
found in Troubleshooting, “Event Codes”. D. If the engine oil bypass valves are held in the open
position, a reduction in the oil pressure can be the
System Response: result. This may be due to debris in the engine
oil. If the engine oil bypass valves are stuck in
The event code will be logged. the open position, remove each engine oil bypass
valve and clean each bypass valve in order to
Possible Performance Effect: correct this problem. You must also clean each
bypass valve bore.
E360(1)
E. Engine oil that is contaminated with fuel or coolant
• There are no performance effects. will cause low engine oil pressure. High engine
oil level in the crankcase can be an indication of
E360(3) contamination.
• The engine will be shut down. F. Excessive clearance at engine bearings will
cause low engine oil pressure. Check the engine
Troubleshooting: components for excessive bearing clearance.
There may be a problem with the engine's lubrication G. An oil line that is open, broken, or disconnected
system. will cause low engine oil pressure.
Check the Engine's Lubrication System Expected Result:
A. Check the engine oil level. If the oil level is below An inspection of the engine's lubrication system
the oil pump's supply tube, the oil pump will not indicated a problem.
have the ability to supply enough lubrication to
the engine components. If the engine oil level is Results:
low, add engine oil in order to obtain the correct
engine oil level. • OK – There is a problem in the engine's lubrication
system.
B. Check the following problems that may occur to
the engine oil pump: Repair: Repair the problem. Ensure that the repair
eliminates the problem.
a. Air leakage in the supply side of the oil pump
will also cause cavitation and loss of oil STOP.
pressure. Check the supply side of the oil pump
and make necessary repairs.
i02498357
b. Oil pump gears that have too much wear will
cause a reduction in oil pressure. Repair the E361 High Engine Coolant
engine oil pump. Temperature
c. If the engine is equipped with a scavenge SMCS Code: 1395-038-TA
pump, the scavenge pump may not be
supplying oil to the main engine oil pump. Conditions Which Generate This Code:

problem with the engine's cooling system. Information
found in Troubleshooting, “Event Codes”.
RENR9346-06 91
System Response: F. If the cooling system for this application is

equipped with a fan, check the operation of the
The event code will be logged. fan. A fan that is not turning at the correct speed
can cause improper air speed across the radiator
Possible Performance Effect: core. The lack of proper air flow across the
radiator core can cause the coolant not to cool to
E361(1) the proper temperature differential.
• There are no performance effects. G. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
E361(2) common causes of air in the cooling system are
the incorrect filling of the cooling system and
• The engine power will be derated. combustion gas leakage into the cooling system.
Combustion gas can get into the system through
E361(3) inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket.
• The engine may be derated or shut down.
H. Check the cooling system hoses and clamps.
Note: For certain applications, the ECM may only Damaged hoses with leaks can normally be seen.
derate the engine. The ECM will notify the operator Hoses that have no visual leaks can soften during
that the condition exists and that the engine must be operation. The soft areas of the hose can become
shutdown. kinked or crushed during operation. These areas
of the hose can restrict the coolant flow. Hoses
Troubleshooting: become soft and/or get cracks after a period of
time. The inside of a hose can deteriorate, and the
There may be a problem with the engine's cooling loose particles of the hose can restrict the coolant
system. flow.
Check the Engine's Cooling System I. If the cooling system for this application is
equipped with an expansion tank, check the shunt
A. Verify that the cooling system is filled to the proper line for the expansion tank. The shunt line must be
level. If the coolant level is too low, air will get into submerged in the expansion tank. A restriction of
the cooling system. Air in the cooling system will the shunt line from the expansion tank to the inlet
cause a reduction in coolant flow. of the jacket water pump will cause a reduction in
water pump efficiency. A reduction in water pump
B. Check the radiator or the heat exchanger for a efficiency will result in low coolant flow.
restriction to coolant flow.
J. If the cooling system for this application
a. Check for debris or damage between the fins is equipped with an aftercooler, check the
of the radiator core. Debris between the fins of aftercooler. A restriction of air flow through the air
the radiator core restricts air flow through the to air aftercooler can cause overheating. Check
radiator core. for debris or deposits which would prevent the free
flow of air through the aftercooler.
b. Check internally for debris, dirt, or deposits on
the radiator core. Debris, dirt, or deposits will K. Check for a restriction in the air inlet system. A
restrict the flow of coolant through the radiator. restriction of the air that is coming into the engine
can cause high cylinder temperatures. High
C. Check the mixture of antifreeze and water. cylinder temperatures cause higher than normal
Make sure that the coolant mixture meets temperatures in the cooling system.
recommendations.
L. Check for a restriction in the exhaust system.
D. Check the water temperature regulator. A water A restriction of the air that is coming out of the
temperature regulator that does not open, or a engine can cause high cylinder temperatures.
water temperature regulator that only opens part
of the way can cause overheating. M. Consider high ambient temperatures. When
ambient temperatures are too high for the rating
E. Check the water pump. A water pump with a of the cooling system, there is not enough of a
damaged impeller does not pump enough coolant. temperature difference between the ambient air
Remove the water pump and check for damage and coolant temperatures.
to the impeller.
92 RENR9346-06
N. Consider high altitude operation. The cooling The driven equipment may have caused the
capability of the cooling system is reduced at overspeed.
higher altitudes. A pressurized cooling system that
is large enough to keep the coolant from boiling Determine the events that caused the overspeed.
must be used. Make corrections in order to prevent the overspeed
from recurring.
O. The engine may be running in the lug condition.
When the load that is applied to the engine is Results:
too large, the engine will run in the lug condition.
When the engine is running in the lug condition, • OK – STOP.
engine rpm does not increase with an increase of
fuel. This lower engine rpm causes a reduction in
i02437229
coolant flow through the system.
Expected Result:
E363 High Fuel Supply
Temperature
A thorough inspection of the cooling system revealed
a problem. SMCS Code: 1250-038-TA
• OK – There is a problem with the cooling system. The Electronic Control Module (ECM) detects
an excessive fuel temperature for the engine.
Repair: Repair the problem. Ensure that the repair Information on default settings and ranges for this
eliminates the problem. event code can be found in troubleshooting with an
event code Troubleshooting, “Event Codes”.
STOP.
System Response:
i02510596 The event code is logged.
E362 Engine Overspeed Possible Performance Effect:
SMCS Code: 7410-038; 7427-038
E363-1 (Warning)
E363-2 (Derate)
engine overspeed. Information on default settings
and ranges for this event code can be found in
Troubleshooting, “Event Codes”. • The engine power is derated.
Troubleshooting:
System Response:
The event code is logged.

Check the Fuel System
Possible Performance Effect: Check the fuel system for problems.
Expected Result:
E362-1 (Warning)
A thorough inspection of the fuel system revealed
• There are no performance effects. a problem.
E362-2 (Derate)
Results:
• The ECM will stop sending signals to the injector
solenoids until the engine speed is 200 rpm below • OK – There is a problem with the fuel system.
the trip point.
Repair: Make the necessary repairs. Verify that
Troubleshooting: the repair eliminates the problem.
STOP.
The operator may be operating the engine incorrectly.
The atmosphere may be combustible.

RENR9346-06 93
i02637267 i02486656
E390 Fuel Filter Restriction E539 High Intake Manifold Air

SMCS Code: 1261-038
Temperature
The Electronic Control Module (ECM) detects an Conditions Which Generate This Code:
abnormal fuel filter differential pressure. Information
found in Troubleshooting, “Event Codes”. an excessive intake manifold air temperature.
Information on default settings and ranges for this
event can be found in troubleshooting with an event
System Response:
code Troubleshooting, “Event Codes”.
The ECM will log the event.
System Response:
The event code will be logged.
390(1)
• There are no performance effects. E539(1)
The delay time for this event code is one hour.
390(2)
E539(2)
• The engine power is derated.
• The engine power will be derated.
The delay time for this event code is four hours.
Troubleshooting:
Troubleshooting:
Intake manifold air temperature can be high for the
following reasons:
The fuel filter element may need to be replaced.
Replace the Fuel Filter Element • High ambient air temperature
A. Replace the fuel filter element. • High inlet air restriction and/or high altitude
Refer to the Operation and Maintenance Manual . • Restriction in the exhaust system
B. Restart the engine and check for an active event • Problem with the aftercooler
code.
• Faulty inlet air temperature sensor and/or circuit
Expected Result:
Perform the following Inspections
The event code is no longer active.
A. Check for High Ambient Air Temperature
Results:
a. Determine if the ambient air temperature is
within the design specifications for the inlet
• OK – The event code is no longer active. STOP. air system. When ambient temperatures
are too high for the rating of the inlet air
• Not OK – The event code is active. system, there is not enough of a temperature
difference between the ambient air and inlet
Repair: There may be an electrical problem with
air temperatures.
the circuit for the fuel filter differential pressure
switch. Refer to Troubleshooting, “Fuel Filter
b. Determine the cause of the high inlet air
Differential Pressure Switch Circuit - Test” for
temperature. Correct the situation, when
diagnostic information.
possible.
STOP.
B. Check for High Inlet Air Restriction and/or
High Altitude Operation
94 RENR9346-06
When inlet air pressure is low, the turbocharger Repair: Connect Caterpillar Electronic Technician
works harder in order to achieve the desired (ET) to the service tool connector. Check Cat ET
inlet manifold pressure. This increases inlet air for active/logged diagnostic codes related for the
temperature. inlet air system. If an active/logged code is found,
refer to the appropriate troubleshooting procedure.
a. Measure the inlet air pressure while the engine
is operating under load. For specific data, refer STOP.
to the Technical Marketing Information for the
engine.
i02513156
b. Check for plugged air filters. Check for

obstructions to the air inlet. A restriction of
E540 Low Engine Oil Refill
the air that enters the engine can cause Tank Level
high cylinder temperatures. High cylinder
temperatures cause higher than normal SMCS Code: 1300-038
temperatures in the cooling system.
c. Replace the air filters and/or remove the
obstruction from the air inlet. The engine Electronic Control Module (ECM) detects
a low oil level in the makeup oil tank for the oil
d. Consider high altitude operation. The cooling renewal system. The engine ECM generates an
capability of the cooling system is reduced event code and the engine ECM disables the oil
at higher altitudes. A pressurized cooling renewal system. Information on default settings and
system that has been designed for the higher ranges for this event can be found in Troubleshooting,
altitudes must be used. Ensure that the engine “Event Codes”.
is configured for high altitude operation.
Check the Oil level in the Makeup Oil
C. Check for Exhaust System Restriction Tank
Check for a restriction in the exhaust system. A. Turn the keyswitch to the STOP position.
A restriction of the air that is coming out of the
engine can cause high cylinder temperatures. B. Check the oil level in the makeup oil tank.
D. Check for Problems with the Aftercooler Expected Result:
If the air inlet system for this application The oil level in the makeup oil tank is low.
is equipped with an aftercooler, check the
aftercooler. A restriction of air flow through the air Results:
to air aftercooler can cause overheating. Check
for debris or deposits which would prevent the free • OK – The oil level in the makeup oil tank is low.
flow of air through the aftercooler. If the engine
is equipped with a liquid cooled aftercooler verify Repair: Refill the makeup oil tank to the proper
that the coolant flow is unobstructed. level.
Expected Result: STOP.
A problem has been found in the inlet air system • Not OK – The oil level in the makeup oil tank is
and/or the related engine systems. not low.
Results: Repair: Check the oil level switch in the makeup

oil tank for proper operation.
• OK – A thorough inspection revealed a problem.
STOP.
Repair: Repair the problem.
STOP.
• Not OK – A thorough inspection did not reveal a

problem.
RENR9346-06 95
i02817689 Results:
E775 High Left Exhaust #2 • OK – There are no active diagnostic codes.
Temperature Proceed to Test Step 2.
SMCS Code: 1088-038-TA • Not OK – There are active diagnostic codes.

S/N: EXD1-Up proceeding to Test Step 2.
S/N: EYG1-Up Test Step 2. Inspect the Air Inlet and
S/N: JXP1-Up Exhaust System
S/N: JRP1-Up; LJW1-Up Check for air inlet restrictions and/or leaks. A one
degree increase in the inlet manifold temperature will
Conditions Which Generate This Code: increase the exhaust temperature by approximately
The Electronic Control Module (ECM) detects an manifold and the turbocharger. Check for exhaust
excessive exhaust temperature for the engine at the restrictions. Refer to the Systems Operation/Testing
“REAR LEFT EXHAUST TC”. This sensor is located and Adjusting manual for more information on
in the exhaust manifold below the turbocharger. inspecting the air inlet and exhaust system.
This sensor measures the exhaust gas temperature
for cylinders 7, 9, and 11. Information on default Results:
settings and ranges for this event can be found in
Troubleshooting, “Event Codes”. • OK – There are no problems with the air inlet and
exhaust system. Proceed to Test Step 3.
System Response:
The event code will be logged. air inlet or the exhaust system.
Possible Performance Effect: Repair: Resolve the problem and verify if the E775
E775(1)
STOP.
Test Step 3. Check for Faults with the
E775(2) Fuel Injectors
• The engine power will be derated. Faulty injectors that deliver too much fuel will
Troubleshooting: order to determine if any diagnostic codes for the
High exhaust temperature can be caused by Solenoid Test”. Observe that the injector solenoids
problems with the following. are being energized on Cat ET. Perform the “Cylinder
• Diagnostic codes Troubleshooting, “Injector Solenoid - Test”.
• Air inlet and exhaust system Results:
• Fuel injectors • OK – There are no problems with the fuel injectors.

• Aftercooler (if applicable)
• Exhaust temperature sensor fuel injectors.
Test Step 1. Check for Diagnostic Codes Repair: Resolve the problem and verify if the E775
diagnostic codes. Troubleshoot any active diagnostic STOP.
96 RENR9346-06
Test Step 4. Inspect the Aftercooler (if i02817691

applicable)
E776 High Right Exhaust #2
Normal intake manifold pressure with high exhaust Temperature
aftercooler. SMCS Code: 1088-038-TA
If the application has an aftercooler, check the S/N: EXD1-Up
in the cores of the aftercooler. S/N: EYG1-Up
S/N: JXP1-Up
Results:
• OK – There is no problem with the aftercooler.
Proceed to Test Step 5. Conditions Which Generate This Code:
• Not OK – A problem has been identified with the The Electronic Control Module (ECM) detects an
aftercooler. excessive exhaust temperature for the engine at the
“REAR RIGHT EXHAUST TC”. This sensor is located
Repair: Resolve the problem and verify if the E775 in the exhaust manifold below the turbocharger.
code has been eliminated. This sensor measures the exhaust gas temperature
for cylinders 8, 10, and 12. Information on default
STOP. settings and ranges for this event can be found in
Troubleshooting, “Event Codes”.
Test Step 5. Check the Exhaust
Temperature Sensor System Response:
Use Cat ET to check the status of the exhaust The event code will be logged.
temperature.
E776(1)
B. Use Cat ET to monitor the status of the exhaust
temperature while the engine is warming to • There are no performance effects.
operating temperature.
E776(2)
reasonable. • The engine power will be derated.
• The temperature indicated by the sensor is not High exhaust temperature can be caused by
within reasonable expectations. problems with the following.
Repair: If an electronic problem with the sensor • Diagnostic codes

Signal (PWM) - Test” for information that is related • Air inlet and exhaust system
temperature sensor. • Fuel injectors
STOP. • Aftercooler (if applicable)
• Exhaust temperature sensor
Test Step 1. Check for Diagnostic Codes
diagnostic codes. Troubleshoot any active diagnostic
RENR9346-06 97
Results: Test Step 4. Inspect the Aftercooler (if

applicable)
• OK – There are no active diagnostic codes.
Proceed to Test Step 2. Normal intake manifold pressure with high exhaust
• Not OK – There are active diagnostic codes. aftercooler.
proceeding to Test Step 2. If the application has an aftercooler, check the
Test Step 2. Inspect the Air Inlet and in the cores of the aftercooler.
Exhaust System
Results:
Check for air inlet restrictions and/or leaks. A one
degree increase in the inlet manifold temperature will • OK – There is no problem with the aftercooler.
increase the exhaust temperature by approximately Proceed to Test Step 5.
manifold and the turbocharger. Check for exhaust • Not OK – A problem has been identified with the
restrictions. Refer to the Systems Operation/Testing aftercooler.
and Adjusting manual for more information on
inspecting the air inlet and exhaust system. Repair: Resolve the problem and verify if the E776
Results:
STOP.
• OK – There are no problems with the air inlet and
exhaust system. Proceed to Test Step 3. Test Step 5. Check the Exhaust
Temperature Sensor
air inlet or the exhaust system. Use Cat ET to check the status of the exhaust
temperature.
code has been eliminated. A. Start the engine.
STOP. B. Use Cat ET to monitor the status of the exhaust

temperature while the engine is warming to
Test Step 3. Check for Faults with the operating temperature.
Fuel Injectors
Faulty injectors that deliver too much fuel will reasonable.
order to determine if any diagnostic codes for the Results:
Solenoid Test”. Observe that the injector solenoids • The temperature indicated by the sensor is not
are being energized on Cat ET. Perform the “Cylinder within reasonable expectations.
Troubleshooting, “Injector Solenoid - Test”. Repair: If an electronic problem with the sensor
Results: Signal (PWM) - Test” for information that is related
• OK – There are no problems with the fuel injectors. temperature sensor.
STOP.
fuel injectors.

STOP.
98 RENR9346-06
i02513538 When inlet air pressure is low, the turbocharger

works harder in order to achieve the desired
E1000 High Left Intake inlet manifold pressure. This increases inlet air
Manifold Air Temperature temperature.
SMCS Code: 1050-038-TA a. Measure the inlet air pressure while the engine
is operating under load. For specific data, refer
Conditions Which Generate This Code: to the Technical Marketing Information for the
engine.
an excessive intake manifold air temperature. b. Check for plugged air filters. Check for
Information on default settings and ranges for this obstructions to the air inlet. A restriction of
event can be found in troubleshooting with an event the air that enters the engine can cause
code Troubleshooting, “Event Codes”. high cylinder temperatures. High cylinder
temperatures cause higher than normal
System Response: temperatures in the cooling system.
The event code will be logged. c. Replace the air filters and/or remove the
obstruction from the air inlet.
d. Consider high altitude operation. The cooling
E539(1) capability of the cooling system is reduced
at higher altitudes. A pressurized cooling
• There are no performance effects. system that has been designed for the higher
altitudes must be used. Ensure that the engine
E539(2) is configured for high altitude operation.
• The engine power will be derated. C. Check for Exhaust System Restriction
Troubleshooting: Check for a restriction in the exhaust system.

A restriction of the air that is coming out of the
Intake manifold air temperature can be high for the engine can cause high cylinder temperatures.
following reasons:
D. Check for Problems with the Aftercooler
• High ambient air temperature
If the air inlet system for this application
• High inlet air restriction and/or high altitude is equipped with an aftercooler, check the
aftercooler. A restriction of air flow through the air
• Restriction in the exhaust system to air aftercooler can cause overheating. Check
for debris or deposits which would prevent the free
• Problem with the aftercooler flow of air through the aftercooler. If the engine
is equipped with a liquid cooled aftercooler verify
• Faulty inlet air temperature sensor and/or circuit that the coolant flow is unobstructed.
Perform the following Inspections Expected Result:
A. Check for High Ambient Air Temperature A problem has been found in the inlet air system
and/or the related engine systems.
a. Determine if the ambient air temperature is
within the design specifications for the inlet Results:
air system. When ambient temperatures
are too high for the rating of the inlet air • OK – A thorough inspection revealed a problem.
system, there is not enough of a temperature
difference between the ambient air and inlet Repair: Repair the problem.
air temperatures.
STOP.
b. Determine the cause of the high inlet air
temperature. Correct the situation, when • Not OK – A thorough inspection did not reveal a
possible. problem.
B. Check for High Inlet Air Restriction and/or

High Altitude Operation
RENR9346-06 99
Repair: Connect Caterpillar Electronic Technician

(ET) to the service tool connector. Check Cat ET
for active/logged diagnostic codes related for the
inlet air system. If an active/logged code is found,
refer to the appropriate troubleshooting procedure.
STOP.
100 RENR9346-06
Diagnostic Functional A +5 V diagnostic code is probably caused by a

short circuit to ground or a short circuit to another
Tests voltage source in the harness. The next likely cause
is a problem with a sensor. The least likely cause is
a problem with the ECM.
i02517524
5 Volt Engine Pressure Sensor

Supply Circuit - Test
SMCS Code: 1439-038
System Operation Description:
Use this procedure to troubleshoot any suspect

problems with the +5 V sensor supply.
Use this procedure to troubleshoot the system when

one of the following diagnostic codes is active or
easily repeated:
• 262-03 5 Volt Sensor DC Power Supply short to

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

ground
The Electronic Control Module (ECM) supplies a

regulated voltage of 5.0 ± 0.2 VDC to the following
sensors:
• Atmospheric pressure sensor

• Turbocharger outlet pressure sensor (No. 2)
• Engine oil pressure sensor
• Fuel pressure sensor
• Turbocharger inlet pressure sensor
The supply for the +5 V engine pressure sensor is
routed from the ECM to terminal A of each pressure
sensor connector. The sensor return from the
ECM connector goes to terminal B of each sensor
connector. The 5 V sensor supply is output short
circuit protected. A short circuit to the battery will not
damage the circuit inside the ECM.
Note: The sensors are not protected from

overvoltage. A short from the supply line to the
+Battery may damage the sensors. If the CID-FMI
262-03 is logged, it is possible that all of the sensors
have been damaged. Repair the 5 V sensor supply
and check for any active diagnostic codes for the
sensor in order to determine if a sensor has failed.
RENR9346-06 101
g01259598
Illustration 12
Schematic for the 5 volt pressure sensor supply
g01270567 g01270590
Illustration 13 Illustration 14
Air cleaner assembly (2) J2/P2 ECM connector
(3) J1/P1 ECM connector
102 RENR9346-06
Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove electrical power from the ECM.
g01270593
Illustration 15
Left side engine view
(4) Turbocharger outlet pressure (No. 2) (6) Atmospheric pressure sensor (8) Engine oil pressure sensor
(5) Intake manifold pressure sensor (7) Fuel pressure sensor
RENR9346-06 103
B. Thoroughly inspect connectors (2) and (3).

Also, thoroughly inspect the connectors for
each pressure sensor. Refer to Troubleshooting,
g01212799
Illustration 17
P1 ECM connector
(P1-2) +5 V supply
(P1-3) Sensor return
(P1-15) Turbocharger inlet pressure
g01259697
Illustration 16
P2 terminal locations
(P2-15) Intake manifold pressure
(P2-41) Turbocharger outlet pressure (No. 2)
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-57) Atmospheric pressure
(P2-72) +5 V supply
g01159881
Illustration 18
Sensor connector
(Terminal A) +5 V supply
(Terminal B) Sensor return
(Terminal C) Sensor signal
C. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connectors that are associated
with the circuit.
104 RENR9346-06
D. Check the allen head screw of each ECM If the engine is running properly at this time, there
connector for the proper torque. Refer to may be an intermittent problem in a harness
Troubleshooting, “Electrical Connectors - Inspect” that is causing the codes to be logged. Refer to
for the correct torque values. Troubleshooting, “Electrical Connectors - Inspect”.
E. Check the harness and wiring for abrasion and STOP.

for pinch points from the pressure sensors back
to the ECM. • Not OK – Either the 262-03 or 262-04 diagnostic
code is active at this time. Proceed to Test Step 3.
Expected Result:
Test Step 3. Disconnect the Pressure
All connectors, pins and sockets are completely Sensors and Check for Active Diagnostic
coupled and/or inserted and the harness and wiring Codes
are free of corrosion, of abrasion or of pinch points.
A. Restore electrical power to the ECM.
Results:
B. Monitor the active diagnostic code screen on Cat
• OK – The harness and connectors appear to be ET while you disconnect each pressure sensor
OK. Proceed to Test Step 2. connector. Check for an active 262-03 code or an
active 262-04 code.
• Not OK – There is a problem with the connectors
and/or wiring. Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of a. Disconnect the following sensors one at a time:
the seals are properly in place and ensure that the
connectors are completely coupled. • Atmospheric pressure sensor
Verify that the repair eliminates the problem. • Intake manifold pressure sensor
STOP. • Turbocharger outlet pressure sensor (No. 2)
Test Step 2. Check for Active Diagnostic • Engine oil pressure sensor
Codes
A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to • Auxiliary pressure sensor
Expected Result:
B. Restore electrical power to the ECM.
The diagnostic code deactivates when a particular
C. Monitor the active diagnostic code screen on Cat sensor is disconnected.
ET. Check for an active 262-03 code and an active
262-04 code. Results:
Note: Wait at least 30 seconds in order for the • OK – The 262-03 or 262-04 diagnostic
diagnostic codes to become active. code deactivates when a particular sensor is
disconnected.
D. Remove electrical power from the ECM.
Repair: Connect the suspect sensor. If the code
Expected Result: returns, replace the sensor. Connect all of the
connectors. Verify that the problem is resolved.
No diagnostic codes are active.
STOP.
Results:
• Not OK – The 262-03 or 262-04 diagnostic
• OK – No diagnostic codes are active. code remains active after all of the sensors are
disconnected. The sensors are not the cause of the
Repair: If any of the above codes are logged diagnostic code. Leave the sensors disconnected.
and the engine is not running properly, refer to Proceed to Test Step 4.
Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
RENR9346-06 105
Test Step 4. Check the Supply Voltage at i02523791

the ECM
Cat Data Link Circuit - Test
SMCS Code: 1901-038
B. Disconnect the J1/P1 ECM connectors.
C. Disconnect the J2/P2 ECM connectors.
This procedure is used for the following diagnostic
D. Fabricate four jumper wires that are long enough codes:
to be used as test leads at the ECM connectors.
Crimp connector sockets to one end of each •
jumper wire.
• 533-09 Brake Control abnormal update rate
E. Remove the wires from terminal locations P1-2 (5
V sensor supply) and P1-3 (sensor return). Install • 533-14 Brake Control special instruction
a jumper wire into each of these terminal locations.
• 1273-09 Unable to communicate with Chassis
F. Remove the wires from terminal locations P2-72 Control Module
(5 V sensor supply) and P2-17 (sensor return).
Install a jumper wire into each of these terminal • 1273-14Chassis Control Module special instruction
locations.
The Cat Data Link provides data communication line
G. Connect the J1/P1 and J2/P2 ECM connectors. between the different control modules that are on the
machine. The Cat Data Link is used to communicate
H. Restore electrical power to the ECM. information from the engine's Electronic Control
Module (ECM) to the other electronic systems.
I. Measure the voltage between the jumper wire in The Cat Data Link is also used for communication
P1-2 (5 V sensor supply) and P1-3 (sensor return). between the control modules and Caterpillar
Electronic Technician (ET).
J. Measure the voltage between the jumper wire in
P2-72 (5 V sensor supply) and the jumper wire in The ECM communicates with Cat ET in order to
P2-17 (sensor return). share status information and diagnostic information.
Cat ET can also be used to configure the ECM
K. Remove electrical power from the ECM. parameters. This information will not be available if
communication fails across the Cat Data Link.
Expected Result:
The ECM sends information to the electronic dash
The voltage measurement is 5.0 ± 0.2 VDC at both displays in order to communicate the engine's
ECM connectors. operating status to the operator of the machine. The
ECM also communicates with other machine control
Results: modules in order to perform machine functions. The
following modules are available for this application.
• OK – The voltage measurement is 5.0 ± 0.2 VDC These modules communicate over the Cat Data Link:
at both ECM connectors.
• Engine ECM
Repair: The ECM is operating correctly. The
supply wires are shorted to another wire in the • Chassis ECM
harness or the supply wires are shorted to engine
ground. Repair the wiring and/or the connector. • Brake ECM
Replace parts, if necessary. Verify that the problem
is resolved. • Remote Access Control (RAC)
STOP. • Vital Information Management System (VIMS)
• Not OK – The voltage measurement is not 5.0 ± • Truck Payload Monitoring System (TPMS)
0.2 VDC at one or both of the ECM connectors.
• Advisor
Repair: There is a problem with the ECM. Replace
the ECM. Refer to Troubleshooting, “Replacing • Messenger
the ECM”.
STOP.
106 RENR9346-06
g01263929
Illustration 19

A. Remove electrical power from the engine ECM.
g01214624
Illustration 20
J1/P1 ECM connectors (typical left side engine view)
B. Thoroughly inspect the J1/P1 ECM connectors.

Inspect all of the connectors to other modules that
are on the Cat Data Link. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.
RENR9346-06 107
• Not OK – The connectors and/or wiring are not

OK.

replace the connectors or wiring. Ensure that all of
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Check for Shorts in the

Harness
A. Disconnect the J1/P1 ECM connectors.
B. Disconnect all control modules from the Cat Data

Link.
C. Disconnect Cat ET from the service tool connector

.
Note: Wiggle the harness during the following

measurements in order to reveal an intermittent
condition.
D. Measure the resistance from P1-8 to every

terminal on the P1 ECM connector.
E. Measure the resistance from P1-8 to the chassis

ground.
F. Measure the resistance from P1-9 to every

Illustration 21
g01207225 terminal on the P1 ECM connector.
Terminals at the P1 ECM connector for the Cat Data Link
G. Measure the resistance from P1-9 to the chassis
(P1-8) Cat Data Link + ground.
(P1-9) Cat Data Link −
Expected Result:
wires in the ECM connector that are associated Each check of the resistance indicates an open
with the circuit. circuit.
D. Check the allen head screw for each of the Results:
ECM connectors for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
• OK – Each check of the resistance indicates an
open circuit. There does not appear to be a short
in the harness. Proceed to Test Step 3.
E. Check the harness and the wiring for abrasion
and for pinch points.
• Not OK – At least one check of the resistance
does not indicate an open circuit.
Expected Result:
Repair: There is a short circuit in one of the
All of the connectors, pins and sockets are completely harnesses. There may be a problem with a
coupled and/or inserted and the harness and wiring connector. Repair the wiring and/or the connector.
are free of corrosion, of abrasion and of pinch points. Replace parts, if necessary. Verify that the problem
is resolved.
Results:
STOP.
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 2.
108 RENR9346-06
Test Step 3. Check for an Open in the • 2533-05 Compression Brake Low/High Solenoid
Harness #1 current below normal
A. Fabricate a jumper wire that is long enough to • 2533-06 Compression Brake Low/High Solenoid
create a short across two terminals at the service #1current above normal
tool connector. Crimp connector sockets to each
end of the jumper wire. • 2534-05 Compression Brake Low/High Solenoid
#2 current below normal
B. Install the jumper wire between terminals D and
E at the service tool connector. • 2534-06 Compression Brake Low/High Solenoid
#2 current above normal
C. Measure the resistance between P1-8 and P1-9.
• 2535-05 Compression Brake Medium/High
D. Measure the resistance at the connectors of all of Solenoid #1 current below normal
the other control modules.
• 2535-06 Compression Brake Medium/High
Expected Result: Solenoid #1 current above normal
The resistance is less than 5 Ohms for each • 2536-05 Compression Brake Medium/High
measurement. Solenoid #2 current below normal
Results: • 2536-06 Compression Brake Medium/High

Solenoid #2 current above normal
• OK – The resistance is less than 5 Ohms for each
measurement. Note: A switch input to the brake Electronic Control
Module (ECM) sets the status of the compression
Repair: The Cat Data Link does not have an open brake. The status is off or automatic. Software for the
in the harness. The problem seems to be resolved. brake ECM controls the level of braking. The levels
There may be an intermittent electrical problem in of braking are low, medium and high. The brake ECM
the wiring harness. There may be a problem with a requests the engine ECM in order to actuate the
connector. Inspect the harness and the connectors compression brake solenoids. The request is sent
carefully. If an intermittent problem is suspected, over the Cat data link.
refer to Troubleshooting, “Electrical Connectors -
Inspect”. Perform this procedure under conditions that are
identical to the conditions that exist when the problem
STOP. occurs. Typically, problems with the compression
brake solenoids occur when the engine is warmed
• Not OK – The resistance is greater than 5 Ohms up and/or when the engine is under vibration (heavy
for one or more of the measurements. There is loads).
excessive resistance or an open circuit in the
harness or the connectors. “Compression Brake Solenoid Test”
Repair: Repair the connectors or wiring and/or The “Compression Brake Solenoid Test” is a
replace the connectors or wiring. Verify that the diagnostic test that is available on Caterpillar
problem is resolved. Electronic Technician (ET). Use the “Compression
Brake Solenoid Test” to assist in troubleshooting
STOP. problems in the circuit for the compression brake.
The engine Electronic Control Module (ECM) will only
detect shorts in the circuit for the compression brake
i02520778
when the test is active. “Current high” diagnostic
Compression Brake Solenoid codes (short circuits) will be logged once the test has
been deactivated. The ECM will only detect opens
Circuit - Test in the circuit for the compression brake when the
test is not active. The test must be activated and
SMCS Code: 5479-038-BRK then deactivated before the ECM will detect an open
circuit. “Current low” diagnostic codes (open circuits)
System Operation Description: will be active once the test has been deactivated.
Use this procedure to troubleshoot any suspect Note: The engine speed must be zero before the
problems with the compression brake solenoids. “Compression Brake Solenoid Test” will function.
Use this procedure for the following diagnostic codes:

RENR9346-06 109
g01199118
Illustration 22
Location of the compression brake solenoid (typical example)
g01268745
Illustration 23
Schematic for the compression brake circuit
110 RENR9346-06
g01270061
Illustration 24
Right top side engine view (typical example)
(1) Connector for the left bank valve cover
(2) Connector for the right bank valve cover
(3) J2/P2 ECM connectors

Electrical shock hazard. The electronic unit injec- g01141312

tor system uses 90-120 volts. Illustration 25
P2Connector for the engine ECM
(P2-1) Compression brake solenoid low/high
A. Remove electrical power from the engine's ECM. (P2-8) Compression brake solenoid med/high
A strong electrical shock hazard is present if the (P2-14) Digital return
electrical power is not removed from the engine
ECM.
B. Thoroughly inspect connectors (1) and (2). Refer

to Troubleshooting, “Electrical Connectors -
Inspect” for details.
RENR9346-06 111
g01195659
Illustration 28
Connector for the right bank valve cover
(10) Compression brake solenoid med/high
(11) Compression brake solenoid low/high
(12) Digital return
g01270811
Illustration 26
P1Connector for the Engine ECM
(P1-8) Cat data link +
(P1-9) Cat data link −
g01195659
Illustration 27
g01270814
Illustration 29
Connector for the left bank valve cover
P1Connector for the Brake ECM
(10) Compression brake solenoid med/high
(11) Compression brake solenoid low/high (10) Cat data link +
(12) Digital return (20) Cat data link−
(34) Compression brake switch
(45) Sensor return
112 RENR9346-06
C. Perform a 45 N (10 lb) pull test on each of the Results:

wires in the ECM connector that are associated
with injector solenoids. • OK – No diagnostic codes are active. If a problem
is suspected with the “Compression Brake Switch”,
D. Check the allen head screw for each of the proceed to Test Step 9.
ECM connectors and the machine connectors
for the proper torque. Refer to Troubleshooting, • Not OK – A low current diagnostic code (05) is
“Electrical Connectors - Inspect” for the correct active at this time. Proceed to Test Step 3.
torque values.
• Not OK – A high current diagnostic code (06) is
E. Check the harness and wiring for abrasion and for logged at this time. Proceed to Test Step 5.
pinch points from the valve cover back to the ECM.
Test Step 3. Short the Wires of the
Expected Result: Suspect Compression Brake Solenoid at
the Valve Cover Connector
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring A. Turn the keyswitch to the OFF position.
are free of corrosion, of abrasion, or of pinch points.
B. Disconnect the valve cover connector for the
Results: suspect compression brake solenoid.
• OK – The harness and connectors appear to be C. Fabricate a jumper wire in order to create a short
OK. Proceed to Test Step 12. between the supply and the return for the suspect
compression brake solenoid.
• Not OK – There is a problem with the connectors
and/or wiring. D. Turn the keyswitch to the ON position.
Repair: Repair the connectors or wiring and/or E. Access the “Special Tests” under the “Diagnostics”
replace the connectors or wiring. Ensure that menu.
all of the seals for each of the connectors are
properly in place and ensure that the connectors F. Start the “Compression Brake Solenoid Test” on
are completely coupled. Verify that the repair Cat ET.
G. Once Cat ET displays the status of the
STOP. compression brake solenoid, stop the
“Compression Brake Solenoid Test”.
Test Step 2. Check for Active Diagnostic
Codes and/or Logged Diagnostic Codes H. Check for active diagnostic codes and/or logged
diagnostic codes that are associated with the
A. Connect Cat ET to the service tool connector. compression brake solenoids.
B. Turn the keyswitch to the ON position. Expected Result:
C. Access the “Special Tests” under the “Diagnostics” A high current diagnostic code (06) is logged at this
menu. time.
D. Start the “Compression Brake Solenoid Test” on Results:

Cat ET.
• OK – A high current diagnostic code (06) is logged
E. Once Cat ET displays the status of the at this time. The harness wiring between the valve
compression brake solenoid, stop the cover connector for the suspect compression brake
“Compression Brake Solenoid Test”. solenoid and ECM connector P2 is OK. Proceed
to Test Step 7.
F. Check for active diagnostic codes and/or logged
diagnostic codes that are associated with the • Not OK – A low current diagnostic code 05 is
compression brake solenoids. active at this time. The ECM did not detect the short
at the valve cover connector for the compression
Expected Result: brake solenoid. Proceed to Test Step 4.
No diagnostic codes are active. Test Step 4. Create a Short Circuit at the
ECM
A. Turn the keyswitch to the OFF position.
RENR9346-06 113
B. Disconnect the J2/P2 ECM connector. Check continuity of the return wire for the suspect
compression brake solenoid between the valve
C. Inspect the terminals on the J2 and P2 ECM cover connector for the suspect compression brake
connectors for damage. solenoid and P2. If the wire is open, replace the
wire.
Note: Refer to the Figure 25 for pin locations.
STOP.
D. Remove the return wire and the supply wire for
the suspect compression brake solenoid from the • Not OK – A low current diagnostic code 05 is
P2 ECM connector. active at this time. The ECM did not detect the
short circuit.
E. Fabricate a jumper wire in order to short the two
pins for the suspect compression brake solenoid Repair: Replace the ECM. Refer to
at the ECM. Crimp a socket to each end of the Troubleshooting, “Replacing the ECM”.
jumper wire. Insert the jumper wire into the P2 Verify that the problem is resolved.
ECM connector.
STOP.
F. Reconnect the P2 ECM connector.
Test Step 5. Open the Wires of the
G. Turn the keyswitch to the ON position. Suspect Compression Brake Solenoid at
the Valve Cover Connector
H. Access the “Special Tests” under the “Diagnostics”
menu. A. Turn the keyswitch to the OFF position.
I. Start the “Compression Brake Solenoid Test” on B. Disconnect the valve cover connector for the
Cat ET. suspect compression brake solenoid.
J. Once Cat ET displays the status of the C. Turn the keyswitch to the ON position.
compression brake solenoid, stop the
“Compression Brake Solenoid Test”. D. Access the “Special Tests” under the “Diagnostics”
menu.
K. Check for active diagnostic codes and/or logged
diagnostic codes that are associated with the E. Start the “Compression Brake Solenoid Test” on
compression brake solenoids. Cat ET.
Expected Result: F. Once Cat ET displays the status of the

A high current diagnostic code (06) is logged at this “Compression Brake Solenoid Test”.
time.
G. Check for active diagnostic codes and/or logged
Note: Disconnecting the supply wire for the suspect diagnostic codes that are associated with the
compression brake solenoid will cause an “Open” compression brake solenoids.
in the compression brake solenoid that shares the
supply wire with the suspect compression brake Expected Result:
solenoid.
A low current diagnostic code (05) is active at this
Results: time.
• OK – A high current diagnostic code (06) is logged Results:

at this time. The ECM detected the short.
• OK – A low current diagnostic code (05) is active
Repair: Check continuity of the supply wire for the at this time. The ECM detected the open at the
suspect compression brake solenoid between the valve cover connector for the compression brake
valve cover connector for the suspect compression solenoid. The harness wiring between the valve
brake solenoid and P2. If the wire is open, replace cover connector for the suspect compression brake
the wire. solenoid and ECM connector P2 is OK. Proceed
to Test Step 8.
• Not OK – A high current diagnostic code (06)

is logged at this time. The ECM did not detect
the open at the valve cover connector for the
compression brake solenoid. Proceed to Test Step
6.
114 RENR9346-06
Test Step 6. Create an Open at the ECM Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
A. Turn the keyswitch to the OFF position. Verify that the problem is resolved.
B. Disconnect the P2 ECM connector. STOP.
C. Inspect the terminals on the J2 and P2 ECM Test Step 7. Create a Short Circuit at the
connectors for damage. Compression Brake Solenoid
Note: Refer to the Figure 25 for pin locations. A. Turn the keyswitch to the OFF position.
D. Remove the return wire and the supply wire for B. Remove the valve cover.
the suspect compression brake solenoid from the
P2 ECM connector. C. Reconnect the valve cover connector.
E. Reconnect the P2 ECM connector. D. Disconnect the connector on the suspect

compression brake solenoid.
F. Turn the keyswitch to the ON position.
E. Inspect the terminals on the solenoid connector
G. Access the “Special Tests” under the “Diagnostics” for damage.
menu.
F. Fabricate a jumper wire in order to short the two
H. Start the “Compression Brake Solenoid Test” on wires for the suspect solenoid on the solenoid
Cat ET. connector. Crimp a pin to each end of the jumper
wire.
I. Once Cat ET displays the status of the
compression brake solenoid, stop the G. Make sure that the solenoid connector securely
“Compression Brake Solenoid Test”. holds the jumper wire.
J. Check for active diagnostic codes and/or logged Note: Worn terminals and/or damaged terminals on
diagnostic codes that are associated with the the solenoid connector could cause an intermittent
compression brake solenoids. “Open”.
Expected Result: H. Turn the keyswitch to the ON position.
A low current diagnostic code (05) is active at this I. Access the “Special Tests” under the “Diagnostics”
time. menu.
Results: J. Start the “Compression Brake Solenoid Test” on

Cat ET.
• OK – A low current diagnostic code (05) is active at
this time. The ECM detected the open at the ECM. K. Once Cat ET displays the status of the
Repair: Disconnect the P2 ECM connector. “Compression Brake Solenoid Test”.
Measure the resistance between the supply wire
for the suspect compression brake solenoid and L. Check for active diagnostic codes and/or logged
every terminal on ECM connector P1 and ECM diagnostic codes that are associated with the
connector P2. Measure the resistance between compression brake solenoids.
the supply wire for the suspect compression brake
solenoid and engine ground. If the wire is shorted, Expected Result:
replace the wire.
A high current diagnostic code (06) is logged at this
Measure the resistance between the return wire for time.
the suspect compression brake solenoid and every
terminal on ECM connector P1 and ECM connector Results:
P2. If the wire is shorted, replace the wire.
• OK – A high current diagnostic code (06) is logged
STOP. at this time. The harness wiring between the
solenoid connector for the suspect compression
• Not OK – A high current diagnostic code (06) is brake solenoid and ECM connector P2 is OK.
logged at this time. The ECM did not detect the
open.
RENR9346-06 115
Repair: Temporarily connect a new compression Results:

brake solenoid to the harness, but do not install
the new compression brake solenoid in the engine. • OK – A low current diagnostic code (05) is active
Verify that there are no active diagnostic codes for at this time. The ECM detected the open at the
the compression brake solenoid. If there are no compression brake solenoid. The harness wiring
active diagnostic codes for the compression brake between the solenoid connector for the suspect
solenoid, permanently install the new compression compression brake solenoid and ECM connector
brake solenoid. Clear any logged diagnostic codes. P2 is OK.
STOP. Repair: Temporarily connect a new compression

brake solenoid to the harness, but do not install
• Not OK – A low current diagnostic code (05) is the new compression brake solenoid in the engine.
active at this time. The ECM did not detect the Verify that there are no active diagnostic codes for
short circuit. the compression brake solenoid. If there are no
active diagnostic codes for the compression brake
Repair: Repair the harness between the connector solenoid, permanently install the new compression
for the compression brake solenoid and the valve brake solenoid. Clear any logged diagnostic codes.
cover connector for the suspect compression brake
solenoid. STOP.
Verify that the repair eliminates the problem. • Not OK – A high current diagnostic code (06) is
logged at this time. The ECM did not detect the
STOP. open.
Test Step 8. Create an Open Circuit at the Repair: Repair the harness between the connector
Compression Brake Solenoid for the compression brake solenoid and the valve
cover connector for the suspect compression brake
A. Turn the keyswitch to the OFF position. solenoid.
B. Reconnect the valve cover connector. Verify that the repair eliminates the problem.
C. Remove the valve cover. STOP.
D. Disconnect the connector on the suspect Test Step 9. Check the Status of the
compression brake solenoid. Compression Brake Switch
E. Inspect the terminals on the solenoid connector Note: A switch input to the brake electronic control
for damage. module sets the status of the compression brake.
The status is off or automatic. Software for the
F. Turn the keyswitch to the ON position. brake electronic control module controls the level of
braking. The levels of braking are low, medium and
G. Access the “Special Tests” under the “Diagnostics” high. The brake electronic control module requests
menu. the engine electronic control module in order to
actuate the compression brake solenoids. The
H. Start the “Compression Brake Solenoid Test” on request is sent over the Cat data link.
Cat ET.
A. Turn the keyswitch to the ON position.
I. Once Cat ET displays the status of the
compression brake solenoid, stop the B. Use Cat ET in order to connect to the brake ECM.
“Compression Brake Solenoid Test”.
C. Operate the compression brake switch and
J. Check for active diagnostic codes and/or logged monitor the status for the compression brake.
diagnostic codes that are associated with the
compression brake solenoids. Expected Result:
Expected Result: The status for the compression brake switch changes
from the off state to the automatic state.
A low current diagnostic code (05) is active at this
time. Results:
• OK – The compression brake switch is operating

correctly.
116 RENR9346-06
Repair: If the problem is intermittent, refer to B. Disconnect ECM connectors P1and P2.
C. Measure the resistance between P1-34 and
STOP. every terminal on ECM connector P1 and ECM
connector P2.
• Not OK – There is a problem in the circuit for the
compression brake switch. Proceed to Test Step Expected Result:
10.
The measured resistance indicates an open circuit.
Test Step 10. Short the Wires at the
Compression Brake Switch Results:
A. Turn the keyswitch to the OFF position. • OK – The resistance measurement indicates an
open circuit. Proceed to Test Step 12.
B. Disconnect the connector for the compression
brake switch. • Not OK – The resistance measurement indicates
a short circuit.
C. Insert a jumper wire between the following
terminals of the connector on the harness side: Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
• Terminal 2
STOP.
• Terminal 3
Test Step 12. Check for an Open in Wiring
D. Turn the keyswitch to ON position. Harness
E. Check the status for the compression brake switch A. Disconnect the connector for the compression
on Cat ET. brake switch.
F. Remove the jumper wire. B. Short the wires of the compression brake switch
at the compression brake switch. Insert a jumper
G. Check the status for the compression brake switch wire between the following terminals of the
on Cat ET. connector for the harness side:
H. Turn the keyswitch to the OFF position. • Terminal 2

Expected Result: • Terminal 3
The status for the compression brake switch indicates C. Measure the resistance between J1-34 and J1-45
“Automatic” when a jumper wire is installed between at the ECM connectors.
terminal 2 and terminal 3.
Expected Result:
The status for the compression brake switch indicates
“Off” when a jumper wire is removed from terminal 2 The measured resistance indicates a short circuit.
and terminal 3.
Results:
Results:
• OK – The resistance measurement indicates a
• OK – The status changed accordingly. short circuit. Proceed to Test Step13.
Repair: Temporarily replace the switch. Verify that • Not OK – The resistance measurement indicates
the new switch solves the problem before you an open circuit. There is an open circuit or
permanently install the new switch. excessive resistance in the wiring harness.
STOP. Repair: Repair the connectors or wiring and/or

• Not OK – The status did not change accordingly.
Proceed to Test Step11. STOP.
Test Step 11. Check for Shorts in the

Wiring Harness
A. Turn the keyswitch to OFF position.
RENR9346-06 117
Test Step 13. Short the Input Wires of the i02518170

Compression Brake Switch at the ECM
Connector Digital Sensor Supply Circuit
- Test
A. Disconnect the J1 ECM connector.
SMCS Code: 1439-038
B. Remove the wires from J1-34 compression brake
switch input and J1-45 sensor return. System Operation Description:
C. Fabricate two jumper wires with sockets on one Use this procedure to troubleshoot any suspect
end and insert one into J1-34 and J1-45. problems with the digital sensor supply.
D. Connect a jumper wire between the jumper wires Use this procedure to troubleshoot the system when
in J1-34 and J1-45. one of the following diagnostic codes is active or
easily repeated:
E. Reconnect the J1 ECM connector.
• 41-03 8 Volt DC Supply short to +batt
F. Turn the keyswitch to the ON position.
• 41-04 8 Volt DC Supply short to ground
G. Check the status for the compression brake switch
on Cat ET. The Electronic Control Module (ECM) creates a
regulated voltage of 8.0 ± 0.4 VDC that is supplied to
H. Disconnect the jumper wire between the jumper terminal A of the following sensors.
wires in J1-34 and J1-45.
• Throttle position sensor
Note: Ensure that the jumper wires are electrically
isolated from all contact. • Engine cooling fan speed sensor
I. Check the status for the compression brake switch Note: The engine cooling fan speed sensor is an
on Cat ET. integral part of the cooling fan drive assembly. The
engine cooling fan speed sensor is nonserviceable
J. Turn the keyswitch to OFF position. separately.
Expected Result: The supply for the +8 V digital sensors is routed from
the ECM to terminal A of each sensor connector.
The status for the compression brake switch indicates The sensor return from the ECM connector goes to
“Automatic” when a jumper wire is installed between terminal B of each sensor connector. The 8 V sensor
jumper wires J1-34 and J1-45. supply is output short circuit protected. A short circuit
to the battery will not damage the circuit inside the
The status for the compression brake switch indicates ECM.
“Off” when a jumper wire is removed between jumper
wires J1-34 andJ1-45. A +8 V diagnostic code is probably caused by a
short circuit to ground or a short circuit to another
Results: voltage source in the harness. The next likely cause
is a problem with a sensor. The least likely cause is
• OK – The status changed accordingly. a problem with the ECM.
STOP.
• Not OK – The status did not change accordingly.

Repair: Replace the ECM. Refer to
Verify that the problem is resolved.
STOP.
118 RENR9346-06
g01260600
Illustration 30
Schematic for the digital sensor supply
g01193730
Illustration 32
Mounting location of the throttle position sensor on the throttle
pedal (typical example)

g01267106
Illustration 31
RENR9346-06 119
g01270661
Illustration 33
ECM connectors (typical example)
B. Thoroughly inspect all connectors. Inspect the

connectors for each digital sensor. Refer to
g01260697
Illustration 34
P1 ECM connector
(P1-4) +8 V digital supply
(P1-32) Engine fan speed
(P1-66) Throttle position
g01159881
Illustration 35
Sensor connector
(Terminal A) +8 V supply
(Terminal C) Sensor signal
120 RENR9346-06
C. Perform a 45 N (10 lb) pull test on each of the Repair: If any of the above codes are logged
wires that are associated with the digital sensor and the engine is not running properly, refer to
supply. Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
D. Check the allen head screw on the ECM connector
for the proper torque. Refer to Troubleshooting, If the engine is running properly at this time, there
“Electrical Connectors - Inspect” for the correct may be an intermittent problem in a harness
torque values. that is causing the codes to be logged. Refer to
E. Check the harness and wiring for abrasions and
for pinch points from the battery to the ECM. STOP.
Expected Result: • Not OK – Either the 41-03 or 41-04 diagnostic

code is active at this time. Proceed to Test Step 3.
coupled and/or inserted, and the harness and wiring Test Step 3. Disconnect the Digital
are free of corrosion, of abrasion, and of pinch points. Sensors and Check for Active Diagnostic
Codes
Results:
A. Restore electrical power to the ECM.
• OK – The connectors and wiring are OK. Proceed
to Test Step 2. B. Monitor the active diagnostic code screen on
Cat ET while you disconnect each digital sensor
• Not OK – There is a problem in the connectors connector. Check for an active 41-03 code or an
and/or wiring. active 41-04 code.
Repair: Repair the connectors or wiring and/or Note: Wait at least 30 seconds in order for the
replace the connectors or wiring. Ensure that all of diagnostic codes to become active.
connectors are completely coupled. Verify that the a. Disconnect the following sensors one at a time:
repair eliminates the problem.
• Throttle position sensor
STOP.
• Engine fan speed sensor
Codes Expected Result:
A. Connect the Caterpillar Electronic Technician The diagnostic code deactivates when a particular
(ET) to the service tool connector. Refer to sensor is disconnected.
Results:
• OK – The 41-03 or 41-04 diagnostic code
C. Monitor the active diagnostic code screen on Cat deactivates when a particular sensor is
ET. Check for an active 41-03 code and an active disconnected.
41-04 code.
Repair: Connect the suspect sensor. If the code
Note: Wait at least 30 seconds in order for the returns, replace the sensor. The fan speed sensor
diagnostic codes to become active. is nonserviceable. The fan speed sensor is integral
to the fan drive assembly. Replace the fan drive
D. Remove electrical power from the ECM. assembly. Connect all of the connectors. Verify that
the problem is resolved.
Expected Result:
STOP.
• Not OK – The 41-03 or 41-04 diagnostic code
Results: remains active after all of the sensors are
disconnected. The sensors are not the cause of the
• OK – No diagnostic codes are active. diagnostic code. Leave the sensors disconnected.
RENR9346-06 121
Test Step 4. Check the Supply Voltage at i02416576

the ECM
Electrical Connectors - Inspect
SMCS Code: 7553-040-WW
B. Disconnect the J1/P1 ECM connectors.
C. Disconnect the J2/P2 ECM connectors.
Most electrical problems are caused by poor
D. Fabricate two jumper wires that are long enough connections. The following procedure will assist in
to be used as test leads at the ECM connectors. detecting problems with connectors and with wiring.
Crimp connector sockets to one end of each If a problem is found correct the condition and verify
jumper wire. that the problem is resolved.
E. Remove the wires from terminal locations P1-4 (8 Intermittent electrical problems are sometimes
V sensor supply) and P1-5 (sensor return). Install resolved by disconnecting and reconnecting
a jumper wire into each of these terminal locations. connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
F. Connect the J1/P1 and J2/P2 ECM connectors. Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
G. Restore electrical power to the ECM. changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
H. Measure the voltage between the jumper wire in likely reasons are loose terminals, improperly crimped
P1-4 (8 V sensor supply) and P1-5 (sensor return). terminals, moisture, corrosion, and inadequate
mating of a connection.
I. Remove electrical power from the ECM.
Follow these guidelines:
Expected Result:
• Always use a 1U-5804 Crimp Tool to service
The voltage measurement is 8.0 ± 0.4 VDC at the Deutsch HD and DT connectors. Never solder the
ECM connector. terminals onto the wires. Refer to “SEHS9615,
Servicing Deutsch HD and DT Style Connectors”.
Results:
• Always use a 147-6456 Wedge Removal Tool to
• OK – The voltage measurement is 8.0 ± 0.4 VDC remove wedges from DT connectors. Never use a
at the ECM connectors. screwdriver to pry a wedge from a connector.
Repair: The ECM is operating correctly. The • Always use a breakout harness for a voltmeter
supply wires are shorted to another wire in the probe or a test light. Never break the insulation
harness or the supply wires are shorted to engine of a wire in order to access to a circuit for
ground. Repair the wiring and/or the connector. measurements.
is resolved. • If a wire is cut, always install a new terminal for
the repair.
STOP.
• Not OK – The voltage measurement is not 8.0 ±

0.4 VDC at the ECM connector. The connection of any electrical equipment and
the disconnection of any electrical equipment may
Repair: There is a problem with the ECM. Replace cause an explosion hazard which may result in in-
the ECM. Refer to Troubleshooting, “Replacing jury or death. Do not connect any electrical equip-
the ECM”. ment or disconnect any electrical equipment in an
explosive atmosphere.
STOP.
122 RENR9346-06
Test Step 1. Check Connectors for B. Ensure that the sealing plugs are in place. If
Moisture and Corrosion any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into
the connector. Refer to Illustration 37.
g01131019
Illustration 38
Seal for a three-pin connector (typical example)
g01131211
Illustration 36
Leaky seal at the connector (typical example)
A. Inspect all wiring harnesses. Ensure that the

routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 36. This will create a
path for the entrance of moisture. Verify that the
seals for the wires are sealing correctly.
g01131165
Illustration 39
Seal for ECM connector (typical example)
C. Disconnect the suspect connector and inspect the

connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.
D. Thoroughly inspect the connectors for evidence

of moisture entry.
Note: It is normal to see some minor seal abrasion

on connector seals. Minor seal abrasion will not allow
Illustration 37
g01131276 the entry of moisture.
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
RENR9346-06 123
If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:
• Missing seals • Exposed insulation

• Improperly installed seals • Rubbing of a wire against the engine
• Nicks in exposed insulation • Rubbing of a wire against a sharp point
• Improperly mated connectors B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
Moisture can also travel to a connector through check all of the fasteners in order to verify that the
the inside of a wire. If moisture is found in a harness is not compressed. Pull back the harness
connector, thoroughly check the connector's sleeves in order to check for a flattened portion
harness for damage. Also check other connectors of wire. A fastener that has been overtightened
that share the harness for moisture. flattens the harness. This damages the wires that
are inside the harness.
Note: The ECM is a sealed unit. If moisture is found
in an ECM connector, the ECM is not the source of Expected Result:
the moisture. Do not replace the ECM.
The wires are free of abrasion, of nicks, and of cuts
Expected Result: and the harness is properly clamped.
The harness wiring, connectors, and seals are in Results:

good condition. There is no evidence of moisture in
the connectors. • OK – The harness is OK. Proceed to Test Step 3.
Results: • Not OK – There is damage to the harness.
• OK – The harness wiring, connectors, and seals Repair: Repair the wires or replace the wires,
are in good condition. Proceed to Test Step 2. as required. Verify that the repair eliminates the
problem.
• Not OK – A problem has been found with the
harness or the connectors. STOP.
Repair: Repair the connectors or the wiring, as Test Step 3. Inspect the Connector
required. Ensure that all of the seals are properly Terminals
in place. Ensure that the connectors have been
reattached. A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
If corrosion is evident on the pins, sockets or the Verify that the terminals are properly aligned in
connector, use only denatured alcohol to remove the connector and verify that the terminals are
the corrosion. Use a cotton swab or a soft brush properly located in the connector.
to remove the corrosion.
Expected Result:
If moisture was found in the connectors, run the
engine for several minutes and check again for The terminals are properly aligned and the terminals
moisture. If moisture reappears, the moisture is appear undamaged.
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to Results:
replace the wires.
• OK – The terminals are OK. Proceed to Test Step
Verify that the repair eliminates the problem. 4.
STOP. • Not OK – The terminals of the connector are

damaged.
124 RENR9346-06
Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
STOP.
Test Step 4. Perform a Pull Test on Each

Wire Terminal Connection
g01131604
Illustration 41
Diagram for testing pin retention (typical example)
A. Verify that the sockets provide good retention for

the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
g01131435
pin by the socket.
Illustration 40
Receptacle lock wedge (typical example) Expected Result:
A. Ensure that the locking wedge for the connector The sockets provide good retention for the new pin.
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not Results:
installed properly.
• OK – The terminals are OK. Proceed to Test Step
B. Perform the 45 N (10 lb) pull test on each wire. 6.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire • Not OK – Terminals are damaged.
should remain in the connector body. This test
checks whether the wire was properly crimped Repair: Use the 1U-5804 Crimp Tool to replace
in the terminal and whether the terminal was the damaged terminals. Verify that the repair
properly inserted into the connector. eliminates the problem.
Expected Result: STOP.
Each terminal and each connector easily withstands Test Step 6. Check the Locking
45 N (10 lb) of pull and each wire remains in the Mechanism of the Connectors
connector body.
A. Ensure that the connectors lock properly. After
Results: locking the connectors, ensure that the two halves
cannot be pulled apart.
• OK – All terminals pass the pull test. Proceed to
Test Step 5. B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
• Not OK – A wire has been pulled from a terminal the connector returns to the locked position.
or a terminal has been pulled from the connector.
Expected Result:
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as The connector will securely lock. The connector and
required. Verify that the repair eliminates the the locking mechanism are without cracks or breaks.
problem.
Results:
STOP.
• OK – The connectors are in good repair. Proceed
to Test Step 7.
RENR9346-06 125
• Not OK – The connector's locking mechanism is

damaged or missing.
Repair: Repair the connector or replace the

connector, as required. Verify that the repair
STOP.
Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged. g01132863
Illustration 44
A. Connect the ECM connectors. Allen head screw for the 40 pin ECM connector (typical example)
c. Torque the allen head screw for the 40 pin ECM

connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01132827
Illustration 42
Allen head screw for the 120 pin ECM connector (typical example)
g01133047
a. Torque the allen head bolt for the 120 pin ECM Illustration 45
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)
B. Connect the customer connector.
Torque the allen head screw for the 40 pin

customer connector and the 70 pin customer
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).
Expected Result:
The ECM connector is secure and the allen head

screws are properly torqued.
Results:
Illustration 43
g01132849
• OK – The ECM connectors and the customer
Allen head screw for the 70 pin ECM connector (typical example) connector is properly connected. Proceed to Test
Step 8.
b. Torque the allen head screw for the 70
pin ECM connector to 6.0 + 1.5 - 0.5 N·m • Not OK – The allen head screws for the ECM
(55 + 13 - 4 lb in). connector or the customer connector is damaged.
126 RENR9346-06
Repair: Repair the connector or replace the • 168-00 “System Voltage High”
connector, as required. Verify that the repair
eliminates the problem. • 168-01 “System Voltage Low”
STOP. • 168-02 “System Voltage intermittent/erratic”
Test Step 8. Perform the “Wiggle Test” (if Use this test if there are intermittent engine
applicable) on the Caterpillar Electronic shutdowns or if a difficulty in starting is not
Technician (ET) accompanied by loss of electrical accessories.
Engine shutdowns that are accompanied by a loss of
Note: Some applications support the “Wiggle Test” other electrical accessories indicate a problem in the
on Cat ET. The “Wiggle Test” (if applicable) can be keyswitch. This does not indicate a problem in the
used to determine if an intermittent problem exists. wiring at the engine's ECM. Verify that there are no
problems with the starting system or the charging
A. Select the “Wiggle Test” from the diagnostic tests system before you use this test.
on Cat ET.
Unswitched battery voltage is supplied to the ECM
B. Choose the appropriate group of parameters to at P1-48, P1-52, and P1-53. The negative battery
monitor. is supplied to the ECM at P1-61, P1-63, and P1-65.
The ECM receives the input from the keyswitch at
C. Press the “Start” button. Wiggle the wiring harness P1-70 when the keyswitch is in the ON position or in
in order to reproduce intermittent problems. the START position. When the ECM detects battery
voltage at this input, the ECM will power up. When
If an intermittent problem exists, the status will be battery voltage is removed from this input, the ECM
highlighted and an audible beep will be heard. will power down. The ECM continuously receives
battery voltage through the 15 Amp circuit breaker
Expected Result: for the ECM.
No intermittent problems were indicated during the The engine ECM requires the keyswitch to be in the
“Wiggle Test”. ON position in order to maintain communications with
Caterpillar Electronic Technician (ET).
Results:
• OK – No intermittent problems were found. The

harness and connectors appear to be OK. If you
were sent from another procedure, return to the
procedure and continue testing. If this test has
resolved the problem, return the engine to service.
STOP.
• Not OK – At least one intermittent problem was

indicated.
Repair: Repair the harness or the connector. Verify

that the repair eliminates the problem.
STOP.
i02527741
Electrical Power Supply Circuit

- Test
SMCS Code: 1401-038
Use this test to troubleshoot any suspect problems

with power to the Electronic Control Module (ECM).
This procedure covers the following diagnostic codes:

RENR9346-06 127
g01264617
Illustration 46
Schematic for the electrical power supply circuit
Test Step 1. Inspect the Electrical B. Thoroughly inspect the J1/P1 ECM connectors.
Connectors and the Wiring Inspect all of the connectors that are in the
circuit. Refer to the diagnostic functional test
A. Remove electrical power from the engine ECM. Troubleshooting, “Electrical Connectors - Inspect”
for details.
g01270849
Illustration 47
Location of the J1/P1 ECM connectors
128 RENR9346-06
Results:
• OK – The harness and wiring appear to be OK.

• Not OK – There is a problem in the connectors

and/or wiring.

connectors are completely coupled. Verify that the
STOP.
Test Step 2. Check the Battery Voltage at

the ECM
B. Disconnect the J1/P1 ECM connector.
C. Restore electrical power to the engine ECM.
D. Measure the voltage between P1-48 (Unswitched

+Battery) and P1-61 (−Battery).
E. Measure the voltage between P1-52 (Unswitched

F. Measure the voltage between P1-53 (Unswitched

Illustration 48
g01112632 G. Measure the voltage between P1-70 (Keyswitch)
and P1-63 (−Battery).
P1 connections for the electrical power supply circuit
(P1-48) +Battery Expected Result:
(P1-52) +Battery
(P1-53) +Battery
(P1-61) −Battery The measured voltage is between 22 VDC and 27
(P1-63) −Battery VDC.
(P1-65) −Battery
(P1-70) Keyswitch
Results:
• OK – The ECM is receiving the correct voltage.
with the circuit. Repair: There may be an intermittent electrical
problem in a harness or in a connector. If an
D. Check the allen head screw for each of the intermittent condition is suspected, refer to
ECM connectors for the proper torque. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
for the correct torque values. STOP.
• Unswitched power out of range – The voltage
is not correct for one of the unswitched battery
circuits at the ECM. Proceed to Test Step 3.
Expected Result:

• Keyswitch voltage out of range – The voltage is
not correct for the keyswitch circuit at the ECM.
inserted and coupled. The harness and wiring are Proceed to Test Step 4.
free of corrosion, of abrasion, and of pinch points.
All connections and grounds are tight and free of
corrosion.
RENR9346-06 129
Test Step 3. Check the Batteries Expected Result:
A. Measure the no-load battery voltage at the battery Voltage is present on terminal B and terminal R at
posts. the keyswitch.
B. Load test the batteries. Use the 4C-4911 Results:

Battery Load Tester. Refer to Special Instruction,
SEHS9249, “Use of 4C-4911 Battery Load Tester • OK – Voltage is present on terminal B and terminal
for 6, 8 and 12 Volt Lead Acid Batteries” and R at the keyswitch.
Special Instruction, SEHS7633, “Battery Test
Procedure”. Repair: If voltage is present on terminal R, repair
the circuit between the keyswitch and the ECM.
Expected Result: Verify that the problem is eliminated.
The batteries pass the load test. The measured STOP.

voltage is the minimum specification for a 24V
system. • Not OK – Voltage is not present on terminal B at
the keyswitch.
Results:
Repair: If voltage is not present on terminal B,
• OK – The batteries pass the load test. repair the circuit between the +Battery and the
keyswitch. Check the circuit protection for the
Repair: The batteries are OK. There is an open circuit. Verify that the problem is eliminated.
circuit or excessive resistance in the wiring or
connections between the batteries and the ECM. STOP.
Verify that the circuit breaker for the ECM is not
tripped. Verify that the connection at the engine • Not OK – Voltage is not present on terminal R at
ground stud is clean and tight and that the battery the keyswitch.
disconnect switch is functioning properly. Repair
the connectors or wiring and/or replace the Repair: If voltage is present on terminal B of the
connectors or wiring. keyswitch but not present on terminal R, replace
the keyswitch. Return all wiring to the original
STOP. configuration. Verify that the problem is eliminated.
• Not OK – The battery voltage is low or the battery STOP.

did not pass the load test.
i02514913
Repair: Recharge or replace the faulty batteries.
Verify that the repair eliminates the problem. Engine Fan Control Solenoid
STOP. Circuit - Test
Test Step 4. Check the Voltage from the SMCS Code: 5479-038
Keyswitch to the ECM
B. Remove the wire from the terminal R of the problems with the fan control solenoid for the engine
keyswitch. cooling fan.
C. Restore electrical power to the engine ECM. This procedure covers the following diagnostic codes:
D. Measure the voltage on terminal B of the keyswitch • 291-05 Engine Cooling Fan Solenoid open circuit
to engine ground.
• 291-06 Engine Cooling Fan Solenoid short to
E. Measure the voltage on terminal R of the ground
keyswitch to engine ground.
F. Remove electrical power from the engine ECM.

130 RENR9346-06
The Electronic Control Module (ECM) controls the

speed of the fan by controlling the current to the fan
control solenoid. The fan control solenoid controls
the displacement of the hydraulic pump that supplies
pressurized oil to the fan motor. The fan pump
defaults to maximum pressure and a diagnostic code
is generated if the ECM detects an open or a short
in the solenoid circuit. When the fan pump produces
maximum pressure the fan speed is maximum.
The engine cooling fan speed sensor provides

feedback to the engine's Electronic Control Module
(ECM). The ECM uses the feedback from the sensor
in order to compare actual fan speed to the desired
fan speed. The ECM controls fan speed by varying
the current to the fan control solenoid. The ECM
controls fan speed within ± 50 rpm of the desired
fan speed.
The ECM controls the rpm of the engine fan in order

to provide the following benefits:
• Increased productivity
• Noise from the fan is reduced.
• Improved fuel economy
• Overcooling of the engine is reduced.
The ECM monitors engine coolant temperature and
intake manifold air temperature in order to determine
the correct fan rpm. When a system fault is detected,
fan rpm is increased. When the engine is lugging,
the fan rpm is reduced in order to reduce the load
on the engine.
An override is available with the Caterpillar Electronic

Technician (ET). This allows the fan to be manually
changed from the minimum to the maximum possible
rpm. If the ECM detects a problem with the solenoid
circuit, a diagnostic code is generated. If the ECM
detects a problem with the solenoid circuit, the
current to the solenoid is set to the minimum value.
g01113248
Illustration 49
Schematic
RENR9346-06 131
g01258956
Illustration 50
(1) Location of the J1/P1 ECM connectors
g01266779
Illustration 52
(2) Engine fan control solenoid
Test Step 1. Inspect Electrical Connectors

and Wiring
A. Remove the electrical power from the ECM.
B. Thoroughly inspect the ECM connector J1/P1.

Inspect all of the other connectors for the

with the circuit.
D. Check the ECM connector (allen head screw)

for the proper torque. Refer to the diagnostic
Connectors - Inspect”.

Expected Result:
Illustration 51
g01113249 All connectors, pins, and sockets are completely
P1 ECM connector
coupled and/or inserted. The harness and wiring are
(P1-43) Engine fan control solenoid
(P1-51) Solenoid return
132 RENR9346-06
Results: B. Disconnect the connector for the fan control

solenoid.
• OK – The harness and wiring are OK. Proceed
to Test Step 2. C. Restore the electrical power to the ECM. Wait at
least 30 seconds for activation of the diagnostic
• Not OK – There is a problem in the connectors codes.
and/or wiring.
D. Access the “Active Diagnostic Code” screen on
Repair: Repair the connectors or wiring and/or Cat ET. Check for an active open circuit diagnostic
replace the connectors or wiring. Ensure that all of code (05) for the fan control solenoid.
connectors are completely coupled. E. Remove the electrical power from the ECM.
Verify that the repair eliminates the problem. Expected Result:
STOP. An open circuit diagnostic code (05) is now active for

the fan control solenoid.
Codes Results:
A. Connect Caterpillar Electronic Technician (ET) to • OK – A short circuit diagnostic code (06) was
the service tool connector. active before disconnecting the connector. An open
circuit diagnostic code (05) became active after
B. Restore the electrical power to the ECM. disconnecting the connector.
C. Monitor the active diagnostic code screen on Cat Repair: Temporarily connect a new fan control
ET. Check and record any active diagnostic codes. solenoid to the harness, but do not install the
new fan control solenoid. Verify that there are no
Note: Wait at least 30 seconds in order for the active diagnostic codes for the solenoid. If there
diagnostic codes to become active. are no active diagnostic codes for the solenoid,
permanently install the new solenoid. Clear any
D. Determine if the problem is related to an open logged diagnostic codes.
circuit diagnostic code (05) or a short circuit
diagnostic code (06). STOP.
Expected Result: • Not OK – There is a short circuit between the

solenoid harness connector and the ECM. Leave
No diagnostic codes are active. the solenoid connector disconnected. Proceed to
Test Step 5.
Results:
Test Step 4. Create a Short at the
• OK – No diagnostic codes are active. Connector for the Fan Control Solenoid
Repair: The problem may have been related A. Remove the electrical power from the ECM.
to a faulty connection in the harness. Carefully
reinspect the connectors and wiring. Refer to B. Install a jumper wire with Deutsch sockets on each
the diagnostic functional test Troubleshooting, end between terminal 1 (fan control solenoid) and
“Electrical Connectors - Inspect”. terminal 2 (solenoid return) on P508. Connect the
jumper on the harness side of the connector.
STOP.
C. Restore the electrical power to the ECM.
• Not OK – A short circuit diagnostic code (06) is
active at this time. Proceed to Test Step 3. D. Wait at least 30 seconds for activation of the short
circuit diagnostic code (06).
• Not OK – An open circuit diagnostic code (05) is
active at this time. Proceed to Test Step 4. Note: Monitor the “Active Diagnostic Codes” screen
on Cat ET before installing the jumper wire and after
Test Step 3. Disconnect the Connector installing the jumper wire.
for the Fan Control Solenoid in Order to
Create an Open Circuit E. Remove the jumper wire.
A. Remove the electrical power from the ECM. F. Remove the electrical power from the ECM.
RENR9346-06 133
Expected Result: c. Remove the wire jumpers. Reconnect all wires

and connectors.
A short circuit diagnostic code (06) is active when the
jumper wire is installed. An open circuit diagnostic Expected Result:
code (05) is active when the jumper wire is removed.
An open circuit diagnostic code (05) is active when
Results: the wire from the fan control solenoid is removed
from the ECM connector. A short circuit diagnostic
• OK – The engine harness and the ECM are OK. code (06) is active when the wire for the fan control
solenoid is connected to the solenoid return.
Repair: Temporarily connect a new fan control
solenoid to the harness, but do not install the Results:
new fan control solenoid. Verify that there are no
active diagnostic codes for the solenoid. If there • OK – The ECM is operating properly. The problem
are no active diagnostic codes for the solenoid, is in the wiring between the ECM and the connector
permanently install the new solenoid. Clear any for the fan control solenoid.
logged diagnostic codes.
STOP. replace the connectors or wiring.
• Not OK – The open circuit diagnostic code (05) STOP.

remains active with the jumper in place. The open
circuit is between the ECM and the connector for • Not OK – One of the following conditions exists:
the fan control solenoid. Proceed to Test Step 5. The open circuit diagnostic code (05) is not active
when the wire for the fan control solenoid is
Test Step 5. Check the Operation of the disconnected. The short circuit diagnostic code
ECM (06) is not active when the wire jumper is installed.
A. Disconnect the J1/P1 ECM connector. Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
B. Remove the wire for the fan control solenoid from ECM”. Verify that the problem is resolved.
P1-43. Install a jumper wire with Deutsch sockets
on each end into P1-43. STOP.
C. Remove the wire for the fan control solenoid from

i02724577
P1-51. Install a jumper wire with Deutsch sockets
on each end into P1-51. Engine Fan Speed Sensor
a. Reconnect the ECM connector. Circuit - Test
b. Restore the electrical power to the ECM. SMCS Code: 1439-038-VF
Monitor the “Active Diagnostic Code” screen on
Cat ET. Wait at least 30 seconds for activation System Operation Description:
of the code.
Use this procedure when the following diagnostic
An open circuit diagnostic code (05) should be codes are active:
active for the fan control solenoid.
• 544-02 Engine Cooling Fan Speed Sensor loss of
D. Check the operation of the ECM by creating a signal
short at the ECM.
• 544-08 Engine Cooling Fan Speed signal abnormal
a. Install a wire jumper between the jumper wire
for the fan control solenoid and the jumper wire The engine cooling fan speed sensor provides a
for the solenoid return. signal to the Electronic Control Module (ECM). The
ECM controls fan speed by varying the current to the
b. Monitor the “Active Diagnostic Code” screen on fan control solenoid.
Cat ET. Wait at least 30 seconds for activation
of the code.
A short circuit diagnostic code (06) should be

active when the wire jumper is installed.
134 RENR9346-06
The engine cooling fan speed sensor receives a

supply voltage of 8.0 ± 0.5 VDC from the ECM.
The sensor outputs a frequency that is directly
proportional to fan speed. The sensor generates a
signal pulse for each revolution of the fan. The output
frequency varies between 0.83 Hz to 30 Hz over the
speed range between 50 rpm and 1800 rpm.
g01258227
Illustration 53
Schematic for the fan speed sensor

and Wiring
g01167488
Illustration 54
Left side engine view (typical example)
g01267039
(1) J1/P1 ECM connector Illustration 55
B. Thoroughly inspect connectors (1). Also,

thoroughly inspect connector (3) that is for
the integral components of the fan drive
assembly(4). Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors -
Inspect”.
RENR9346-06 135

STOP.
Test Step 2. Check the Status of the

Engine Fan Speed with Caterpillar
Electronic Technician (ET)
B. Connect Cat ET to the service tool connector.

Start Cat ET.
D. Access the “Fan Override Test” under the

“Diagnostics” menu.
E. Start the “Fan Override Test” on Cat ET. Set the

fan speed to 800 rpm.
F. Use a 1U-6602 Photo-Tachometer to determine

the actual speed of the fan.
g01224573
Illustration 56 G. Compare the engine fan speed that is reported
P1 ECM connector by Cat ET to the actual engine fan speed that is
(P1-4) +8 V supply reported by the photo-tachometer.
(P1-5) Digital return
(P1-32) Engine cooling fan speed H. Deactivate the “Fan Override Test”.
C. Perform a 45 N (10 lb) pull test on each of the Expected Result:
with the circuit. The actual fan speed is within ± 50 rpm of the engine
fan speed that is reported by Cat ET.
D. Check the allen head screw for each ECM
connector for the proper torque. Refer to the Results:
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. • OK – The engine fan speed is within the desired
rpm range.
and for pinch points. Repair: The sensor is operating correctly. There
may be an intermittent electrical problem in a
Expected Result: connector or in the harness. If an intermittent
problem is suspected, refer to the diagnostic
All connectors, pins and sockets are completely functional test Troubleshooting, “Electrical
coupled and inserted and the harness and wiring are Connectors - Inspect”.
STOP.
Results:
• Not OK – The engine fan speed is not within the
• OK – The harness and connectors appear to be desired rpm range. Proceed to Test Step 3.
Test Step 3. Check the Sensor Supply
• Not OK – There is a problem with the connectors Voltage at the Connector for the Engine
and/or wiring. Cooling Fan Speed Sensor
136 RENR9346-06
B. Disconnect the connector for the engine cooling Results:

fan speed sensor.
• OK – The frequency is approximately 13.3 Hz.
C. Restore the electrical power to the ECM. The engine cooling fan speed sensor is generating
the correct signal. Reconnect the wire to terminal 1
D. Measure the sensor supply voltage on the harness (engine fan speed) of the connector for the engine
side of the connector for the engine cooling fan cooling fan speed sensor. Proceed to Test Step 5.
speed sensor between terminal 4 (8 V supply) and
terminal 5 (digital return). • Not OK – The frequency is not approximately 13.3
Hz.
Expected Result:
Repair: The engine cooling fan speed sensor is
The voltage is 8.0 ± 0.4 VDC. not generating the correct signal. The sensor is
nonserviceable. Replace the sensor. Verify that
Results: the replacement of the sensor corrects the original
problem.
• OK – The voltage is 8.0 ± 0.4 VDC. The supply
voltage is reaching the sensor connector. Proceed STOP.
to Test Step 4.
Test Step 5. Check the Signal Frequency
• Not OK – The voltage is not 8.0 ± 0.4 VDC. for the Engine Cooling Fan Speed Sensor
at the ECM Connector
Repair: The supply voltage is not reaching the
sensor. Refer to the diagnostic functional test A. Remove the electrical power from the ECM.
Troubleshooting, “Digital Sensor Supply Circuit -
Test”. B. Disconnect the J1/P1 ECM connector. Remove
the wire from terminal P1-32 (engine cooling fan
STOP. speed sensor) at the P1 connector.
Test Step 4. Check the Signal Frequency C. Fabricate a jumper wire that is long enough to be
for the Engine Cooling Fan Speed Sensor used in order to measure the signal frequency at
at the Sensor Connector the ECM connector. Crimp a connector socket to
one end of the jumper wire.
D. Install the jumper wire into terminal location P1-32.
B. Remove the wire from terminal 1 (engine fan Connect the J1/P1 connectors.
speed) on the sensor side of the connector for
the engine cooling fan speed sensor. Connect the E. Restore the electrical power to the ECM.
sensor connector.
F. Access the “Fan Override Test” under the
C. Restore the electrical power to the ECM. “Diagnostics” menu on Cat ET.
D. Access the “Fan Override Test” under the G. Start the “Fan Override Test” on Cat ET. Set the
“Diagnostics” menu on Cat ET. fan speed to 800 rpm.
E. Start the “Fan Override Test” on Cat ET. Set the H. Measure the frequency between the jumper wire
fan speed to 800 rpm. at P1-32 and engine ground.
F. Use a multimeter to measure the frequency I. Deactivate the “Fan Override Test”.
between the signal wire from the sensor and
engine ground. J. Remove the electrical power from the ECM.
G. Deactivate the “Fan Override Test”. K. Reconnect all connectors and wires.
H. Remove the electrical power from the ECM. Expected Result:
I. Restore all connectors and wiring to the original The frequency is approximately 13.3 Hz.
configuration.
Results:
Expected Result:
• OK – The frequency is approximately 13.3 Hz.
The frequency is approximately 13.3 Hz.
RENR9346-06 137
Repair: The ECM is not detecting the

signal. Replace the ECM. Refer to electronic
troubleshootingTroubleshooting, “Replacing the
ECM”.
STOP.
• Not OK – The frequency is not approximately 13.3

Hz.
Repair: There is a problem in the harness between

the ECM and the sensor connector. Repair the
harness. Replace parts, if necessary. Verify that
the problem has been resolved.
STOP.
i02515157
Engine Oil Level Switch Circuit

- Test
SMCS Code: 7422-038-OC
S/N: EXD1-Up
Perform this procedure for the E171 Low Engine Oil

Level. Perform this procedure if you suspect that
there is a problem in the circuit for the engine's oil
level switch.
The ECM may modify the operation of the engine in

the event of low oil level. The ECM cannot determine
if the oil level switch or associated components have
failed.
The low oil level switch signals the Electronic

Control Module (ECM) if the oil level falls below a
predetermined level in the oil pan. The ECM warns
the operator to take action in order to prevent engine
damage. The float closes a switch when the oil level
is above a predetermined level.
The E171 Low Engine Oil Level will disable the Oil
Renewal System (ORS).
The Electronic Control Module (ECM) adds a

controlled amount of engine oil to the fuel by
energizing the engine oil renewal solenoid. The
engine oil is added to the fuel and burned during
combustion. The need to drain the engine oil at a
typical oil change interval is avoided.
For further information, refer to Service Manual,

RENR2223, “Oil Renewal System”.
138 RENR9346-06
g01258295
Illustration 57
Schematic
g01270952
Illustration 58
(1) Engine oil level switch
RENR9346-06 139

Expected Result:

Results:

to Test Step 2.

and/or wiring.

STOP.
Test Step 2. Check the Level of the

Engine Oil
A. Check the engine oil level.
B. Ensure that the correct engine oil dipstick is

installed.
C. Check for external oil leaks.
Expected Result:
The engine oil is at the correct level.
Results:
g01258299
Illustration 59
P2 ECM connector • OK – The engine oil level is correct. Proceed to
(P2-94) Low oil level Test Step 3.
• Not OK – The engine oil level is low.
and Wiring Repair: Add oil to the engine.
A. Turn the keyswitch to the OFF position. STOP.
B. Thoroughly inspect the ECM connector J2/P2. Test Step 3. Check the Engine Oil Level
Inspect the connector for the low oil level switch. on Caterpillar Electronic Technician (ET)
Refer to Troubleshooting, “Inspecting Electrical
Connectors” for details. A. Connect Cat ET to the service tool connector.
C. Perform a 45 N (10 lb) pull test on each of the B. Turn the keyswitch to the ON position.
with the circuit. C. Observe the “Engine Oil Level” reading on Cat ET.
D. Check the ECM connector (allen head screw) Expected Result:

for the proper torque. Refer to Troubleshooting,
“Inspecting Electrical Connectors” for details. The “Engine Oil Level” reads “OK”.
140 RENR9346-06
Results: Test Step 5. Short the Input Wires of

the Low Oil Level Switch at the ECM
• OK – The “Engine Oil Level” reads “OK”. Connector
Repair: The switch signal is correct. A. Disconnect ECM connector P2.
STOP. B. Remove the wire from P2-94 (low oil level). Install
a wire jumper with a socket on one end into P2-94.
• Not OK – The “Engine Oil Level” does not read
“OK”. The switch signal is not correct. Proceed to C. Remove the wire from P2-83 (digital return). Install
Test Step 4. a wire jumper with a socket on one end into P2-83.
Test Step 4. Short the Wires at the Low D. Connect a wire jumper between the wire jumpers
Oil Level Switch in P2-94 and P2-83.
A. Disconnect connector J802/P802 of the low oil E. Reconnect all connectors.

level switch.
F. Turn the keyswitch to the ON position. The engine
B. Use a wire to short terminal J802-1 to J802-2. should be off.
Install the wire jumper on the harness side of the
connector. Note: Additional diagnostic codes will be generated
because the digital return will no longer be connected
C. Turn the keyswitch to the ON position. to the other sensors and switches. Ignore the codes
and clear the codes when you complete this test.
D. Observe the status of the “Engine Oil Level” on
Cat ET. G. Observe the status of the “Engine Oil Level” on
Cat ET.
E. Remove the wire short.
H. Turn the keyswitch to the OFF position.
F. Observe the status of the “Engine Oil Level” on
Cat ET. I. Remove the wire short.
G. Turn the keyswitch to the OFF position. J. Reconnect all connectors.
Expected Result: K. Turn the keyswitch to the ON position.
Cat ET indicates “OK” when the wire short is L. Observe the status of the “Engine Oil Level” on
installed. Cat ET indicates “LOW” when the wire short Cat ET.
is removed.
M. Turn the keyswitch to the OFF position.
Results:
N. Reconnect all connectors.
• OK – Cat ET indicates “OK”, when the wire short
is in place. Cat ET indicates “LOW”, when the wire Expected Result:
short is removed. Cat ET recognized the input from
the switch. Cat ET indicates “OK” when the wire short is
installed. Cat ET indicates “LOW” when the wire short
Repair: Temporarily replace the switch. Verify that is removed.
the new switch solves the problem before you
permanently install the new switch. Results:
STOP. • OK – Cat ET indicates “OK”, when the wire short

is installed. Cat ET indicates “LOW”, when the wire
• Not OK – Cat ET does not indicate “OK”, when short is removed. The harness is faulty.
the wire short is in place. Cat ET does not indicate
“LOW”, when the wire short is removed. Cat ET Repair: The ECM is OK. There is a short circuit or
does not recognize the input from the switch. there is an open circuit between the ECM and the
Proceed to Test Step 5. low oil level switch. Repair the connectors or wiring
and/or replace the connectors or wiring.
STOP.
RENR9346-06 141
• Not OK – Cat ET does not indicate “OK”, when

the wire short is in place. Cat ET does not indicate
“LOW”, when the wire short is removed. The ECM
is not reading the switch position.
Repair: Replace the ECM. Refer to

STOP.
i02526938
Engine Oil Renewal Solenoid

Circuit - Test
SMCS Code: 1349-038
S/N: EXD1-Up

problems with the system for the engine oil renewal
solenoid.
• 569-05 Oil Injection Solenoid Current below normal

• 569-06 Oil Renewal Solenoid short to ground
• 2271-05 Engine Oil Renewal System Actuation
Soleniod current below normal
• 2271-06 Engine Oil Renewal System Actuation

Soleniod current above normal
The Electronic Control Module (ECM) adds a

controlled amount of engine oil to the fuel by
energizing the engine oil renewal solenoid. The
engine oil is added to the fuel and burned during
combustion. The need to drain the engine oil at a
typical oil change interval is avoided.
The ECM energizes the engine oil renewal solenoid

which injects the engine oil into the return line for
the fuel.
For further information, refer to Service Manual,

RENR2223, “Oil Renewal System”.
142 RENR9346-06
g01264034
Illustration 60
Typical schematic
g01270974
Illustration 61
(1) Engine oil renewal solenoid
RENR9346-06 143
Expected Result:

Results:

to Test Step 2.

and/or wiring.

STOP.

Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Restore the electrical power to the ECM.
C. Monitor the active diagnostic code screen on Cat

ET. Check and record any active diagnostic codes.
Illustration 62
g01264035 Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
P1 ECM connector
(P1-18) Solenoid return D. Determine if the problem is related to an open
(P1-11) Engine oil renewal solenoid
circuit diagnostic code (05) or a short circuit
diagnostic code (06).
and Wiring Expected Result:
A. Remove the electrical power from the ECM. No diagnostic codes are active.
B. Thoroughly inspect the ECM connector J1/P1. Results:
Inspect all of the other connectors for the
Troubleshooting, “Electrical Connectors - Inspect”. • OK – No diagnostic codes are active.
Repair: The problem may have been related
C. Perform a 45 N (10 lb) pull test on each of the to a faulty connection in the harness. Carefully
wires in the ECM connector that are associated reinspect the connectors and wiring. Refer to
with the circuit. the diagnostic functional test Troubleshooting,
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to the diagnostic STOP.
Connectors - Inspect”.
• Not OK – A short circuit diagnostic code (06) is
active at this time. Proceed to Test Step 3.
• Not OK – An open circuit diagnostic code (05) is
active at this time. Proceed to Test Step 4.
144 RENR9346-06
Test Step 3. Disconnect the Connector Note: Monitor the “Active Diagnostic Codes” screen
for the Engine Oil Renewal Solenoid in on Cat ET before installing the jumper wire and after
Order to Create an Open Circuit installing the jumper wire.
A. Remove the electrical power from the ECM. E. Remove the jumper wire.
B. Disconnect the connector for the engine oil F. Remove the electrical power from the ECM.
renewal solenoid.
Expected Result:
C. Restore the electrical power to the ECM. Wait at
least 30 seconds for activation of the diagnostic A short circuit diagnostic code (06) is active when the
codes. jumper wire is installed. An open circuit diagnostic
code (05) is active when the jumper wire is removed.
Cat ET. Check for an active open circuit diagnostic Results:
code (05) for the engine oil renewal solenoid.
• OK – The engine harness and the ECM are OK.
E. Remove the electrical power from the ECM.
Repair: Temporarily connect a new engine oil
Expected Result: renewal solenoid to the harness, but do not
install the new engine oil renewal solenoid. Verify
An open circuit diagnostic code (05) is now active for that there are no active diagnostic codes for the
the engine oil renewal solenoid. solenoid. If there are no active diagnostic codes for
the solenoid, permanently install the new solenoid.
Results: Clear any logged diagnostic codes.
• OK – A short circuit diagnostic code (06) was STOP.

active before disconnecting the connector. An open
circuit diagnostic code (05) became active after • Not OK – The open circuit diagnostic code (05)
disconnecting the connector. remains active with the jumper in place. The open
circuit is between the ECM and the connector for
Repair: Temporarily connect a new engine oil the engine oil renewal solenoid. Proceed to Test
renewal solenoid to the harness, but do not Step 5.
install the new engine oil renewal solenoid. Verify
that there are no active diagnostic codes for the Test Step 5. Check the Operation of the
solenoid. If there are no active diagnostic codes for ECM
the solenoid, permanently install the new solenoid.
Clear any logged diagnostic codes. A. Disconnect the J1/P1 ECM connector.
STOP. B. Remove the wire for the engine oil renewal

solenoid from P1-43. Install a jumper wire with
• Not OK – There is a short circuit between the Deutsch sockets on each end into P1-43.
solenoid harness connector and the ECM. Leave
the solenoid connector disconnected. Proceed to C. Remove the wire for the engine oil renewal
Test Step 5. solenoid from P1-51. Install a jumper wire with
Deutsch sockets on each end into P1-51.
Test Step 4. Create a Short at the
Connector for the Engine Oil Renewal a. Reconnect the ECM connector.
Solenoid
b. Restore the electrical power to the ECM.
A. Remove the electrical power from the ECM. Monitor the “Active Diagnostic Code” screen on
B. Install a jumper wire with Deutsch sockets on of the code.
each end between terminal 1 (engine oil renewal
solenoid) and terminal 2 (solenoid return) on An open circuit diagnostic code (05) should be
P506. Connect the jumper on the harness side of active for the engine oil renewal solenoid.
the connector.
D. Check the operation of the ECM by creating a
C. Restore the electrical power to the ECM. short at the ECM.
D. Wait at least 30 seconds for activation of the short a. Install a wire jumper between the jumper wire
circuit diagnostic code (06). for the engine oil renewal solenoid and the
jumper wire for the solenoid return.
RENR9346-06 145
b. Monitor the “Active Diagnostic Code” screen on • Fuel pressure sensor

of the code. • Turbocharger inlet pressure sensor
A short circuit diagnostic code (06) should be This procedure covers the following open circuit
active when the wire jumper is installed. diagnostic codes and short circuit diagnostic codes:
c. Remove the wire jumpers. Reconnect all wires • 94-03 Fuel Pressure open/short to +batt
and connectors.
• 94-04 Fuel Pressure short to ground
Expected Result:
• 100-03 Engine Oil Pressure open/short to +batt
An open circuit diagnostic code (05) is active when
the wire from the engine oil renewal solenoid is • 100-04 Engine Oil Pressure short to ground
removed from the ECM connector. A short circuit
diagnostic code (06) is active when the wire for the • 274-03 Atmospheric Pressure open/short to +batt
engine oil renewal solenoid is connected to the
solenoid return. • 274-04 Atmospheric Pressure short to ground
Results: • 1589-03 Turbo Inlet Air Pressure Sensor
open/short to +batt
• OK – The ECM is operating properly. The problem
is in the wiring between the ECM and the connector • 1589-04 Turbo Inlet Air Pressure Sensor short to
for the engine oil renewal solenoid. ground
Repair: Repair the connectors or wiring and/or • 1785-03 Intake Manifold Pressure Sensor voltage
replace the connectors or wiring. high
STOP. • 1785-04 Intake Manifold Pressure Sensor voltage

low
• Not OK – One of the following conditions exists:
The open circuit diagnostic code (05) is not active • 1795-03 Turbo #2 Outlet Pressure Sensor voltage
when the wire for the engine oil renewal solenoid below normal
is disconnected. The short circuit diagnostic code
(06) is not active when the wire jumper is installed. • 1795-04 Turbo #2 Outlet Pressure Sensor voltage
above normal
Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the The 5 volt sensor supply provides power to all
ECM”. Verify that the problem is resolved. 5 volt sensors. The Electronic Control Module
(ECM) supplies 5.0 ± 0.2 VDC to terminal A of
STOP. each sensor connector. The sensor return from the
ECM connector goes to terminal B of each sensor
connector. The sensor supply is output short circuit
i02517708
protected. A short circuit to the battery will not
Engine Pressure Sensor Open damage the circuit inside the ECM.
or Short Circuit - Test Pull-up Voltage
SMCS Code: 1439-038-PX The ECM continuously outputs a pull-up voltage on

the circuit for the sensor signal wire. The ECM uses
System Operation Description: this pull-up voltage in order to detect a problem in the
signal circuit. When the ECM detects the presence
Use this procedure to troubleshoot any suspect of a voltage that is above a threshold on the signal
problems with the following sensors: circuit, the ECM will generate a 03 diagnostic code
for the sensor.
• Atmospheric pressure sensor
• Turbocharger outlet pressure sensor (No. 2)
146 RENR9346-06
If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are OK. If the sensor is
disconnected at the sensor connector, the absence
of pull-up voltage at the sensor connector indicates
a problem in the signal wire. If the sensor is
disconnected at the sensor connector and the voltage
at the sensor connector is different from pull-up
voltage, the signal wire is shorted to another wire in
the harness.
g01259598
Illustration 63
Schematic for the engine pressure sensors
RENR9346-06 147
g01270567
Illustration 64
Air cleaner assembly
g01270590
Illustration 65

148 RENR9346-06
g01270593
Illustration 66
Left side engine view
(4) Turbocharger outlet pressure (No. 2) (6) Atmospheric pressure sensor (8) Engine oil pressure sensor
(5) Intake manifold pressure sensor (7) Fuel pressure sensor
B. Thoroughly inspect connectors(2) and (3). Also,

thoroughly inspect the connectors for each
pressure sensor. Refer to Troubleshooting,
RENR9346-06 149
g01212799
Illustration 68
P1 ECM connector
(P1-2) +5 V sensor supply
(P1-15) Auxiliary pressure
g01259697
Illustration 67
P2 terminal locations
(P2-15) Intake manifold pressure
(P2-41) Turbocharger outlet pressure (No. 2)
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-57) Atmospheric pressure
(P2-72) +5 V supply
g01159881
Illustration 69
Sensor connector
(Terminal A) +5 V sensor supply
(Terminal C) Signal

wires in the ECM connectors and on each of the
wires in the pressure sensor connectors.
150 RENR9346-06
D. Check the allen head screw for each ECM D. Measure the voltage between terminals A and B
connector and the customer connector for at each sensor connector on the engine harness.
the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct E. Remove electrical power from the ECM.
torque values.
F. Connect all of the sensors.
E. Check the harness and wiring for abrasion and
for pinch points from the pressure sensors back Expected Result:
to the ECM.
Each voltage measurement is 5.0 ± 0.2 VDC.
Expected Result:
Results:
coupled and/or inserted. The harness and wiring are • OK – Each voltage measurement is 5.0 ± 0.2 VDC.
free of corrosion, of abrasion, and of pinch points. The voltage is correct at the sensor connectors.
Results:
• Not OK – At least one voltage measurement is not
• OK – The harness and wiring appear to be OK. 5.0 ± 0.2 VDC.
Repair: Refer to Troubleshooting, “5 Volt Engine
• Not OK – There is a problem in the connectors Pressure Sensor Supply Circuit - Test”.
and/or wiring.
STOP.
replace the connectors or wiring. Ensure that all of Test Step 3. Check for Active Diagnostic
the seals are properly in place and ensure that the Codes
A. Connect Caterpillar Electronic Technician (ET) to
Verify that the repair eliminates the problem. the service tool connector.
STOP. B. Restore electrical power to the ECM.
Test Step 2. Check the Supply Voltage at C. Monitor the active diagnostic code screen on Cat
the Sensor Connector ET. Look for an active diagnostic code for an
engine pressure sensor.
Note: Wait at least 30 seconds so that any codes
B. Disconnect the harness connectors for the may become active.
following sensors:
D. Determine if the problem is related to an open
• Atmospheric pressure sensor circuit diagnostic code (03) or a short circuit
diagnostic code (04).
• Auxiliary pressure sensor
Expected Result:
• Boost pressure sensor
Results:
• OK – No diagnostic codes are active for the engine
C. Restore electrical power to the ECM. pressure sensors.
Note: The original diagnostic code may not stay Repair: The original problem seems to be resolved.
active. An open circuit diagnostic code for the sensor The problem may have been related to a faulty
supply may become active when all of the sensors connection in the harness. Carefully reinspect the
are disconnected. Ignore the active codes at this time connectors and wiring. If an intermittent electrical
and continue with this test step. problem is suspected, refer to Troubleshooting,
Note: Be sure to wiggle the harness during the
following measurements in order to reveal an STOP.
intermittent condition.
RENR9346-06 151
• Not OK – A 03 diagnostic code is active at C. Install the jumper wire between terminal B (sensor
this time. The ECM is detecting an open circuit return) and terminal C (sensor signal) on the
condition. Proceed to Test Step 5. harness side of the suspect sensor's connector.
• Not OK – A 04 diagnostic code is active at this D. Restore electrical power to the ECM.
time. The ECM is detecting a short circuit condition.
Proceed to Test Step 4. E. Monitor the “Active Diagnostic Codes” screen on
Cat ET. Check for an active short circuit diagnostic
Test Step 4. Disconnect the Suspect code (04) while the jumper wire is installed.
Sensor in Order to Create an Open Circuit
Note: Wait at least 30 seconds for activation of the
A. Remove electrical power from the ECM. diagnostic code.
B. Disconnect the sensor connector of the sensor F. Remove electrical power from the ECM.
with the short circuit diagnostic code (04).
G. Remove the jumper wire.
C. Restore electrical power to the ECM.
Expected Result:
Cat ET. Check for an active open circuit diagnostic A 04 diagnostic code was active when the jumper
code (03) while the sensor is disconnected. wire was installed.
Note: Wait at least 30 seconds for activation of the Results:

diagnostic codes.
• OK – A 04 diagnostic code was active when the
E. Remove electrical power from the ECM. jumper wire was installed.
Expected Result: Repair: There is a problem with the sensor.

Temporarily connect a new sensor to the harness,
A 03 diagnostic code became active after the sensor but do not install the new sensor in the engine.
was disconnected. Verify that there are no active diagnostic codes for
the sensor. If there are no active diagnostic codes
Results: for the sensor, permanently install the new sensor.
Clear any logged diagnostic codes.
• OK – A 04 diagnostic code was active before the
sensor was disconnected. A 03 diagnostic code STOP.
became active after the sensor was disconnected.
• Not OK – The 03 diagnostic code remains active
Repair: There may be a problem with a sensor. with the jumper in place. There is a problem in
Temporarily connect a new sensor to the harness, the harness between the ECM and the sensor
but do not install the new sensor in the engine. connector. There may be a problem with the ECM.
Verify that there are no active diagnostic codes for Proceed to Test Step 6.
the sensor. If there are no active diagnostic codes
for the sensor, permanently install the new sensor. Test Step 6. Test the Operation of the
Clear any logged diagnostic codes. ECM
STOP. A. Remove electrical power from the ECM.
• Not OK – When the sensor is disconnected, a 04 B. Fabricate a jumper wire that is long enough to
diagnostic code remains active for the suspect create a test circuit from the ECM connector to the
sensor. There is a problem in the circuit between engine ground stud. Crimp a connector socket to
the sensor harness connector and the ECM. The one end of the jumper wire.
problem may be in the ECM. Leave the sensor
disconnected. Proceed to Test Step 6. C. Disconnect the appropriate ECM connector.
Test Step 5. Create a Short at the Suspect D. Remove the suspect sensor's signal wire from the
Sensor Connector ECM connector. Install the jumper wire into this
terminal location at the ECM connector.
E. Connect the ECM connectors.
B. Fabricate a jumper wire that is long enough to
short the terminals at the sensor connector. Crimp F. Check the operation of the ECM by creating
connector sockets to each end of the jumper wire. an open at the ECM:
152 RENR9346-06
a. Hold the loose end of the jumper wire away • Not OK – One of the following conditions exists:
from any ground source in order to create an The 03 diagnostic code is not active when the
open circuit condition. loose end of the jumper wire is open. The 04
diagnostic code is not active when the loose end
b. Restore electrical power to the ECM. of the jumper wire is grounded.
c. Monitor the “Active Diagnostic Code” screen Repair: There is a problem with the ECM. Replace
on Cat ET. Check the suspect sensor for an the ECM. Refer to Troubleshooting, “Replacing
active 03 diagnostic code. the ECM”.
Note: Wait at least 30 seconds so that any codes STOP.

may become active.
i02516052
d. Remove electrical power from the ECM.
G. Check the operation of the ECM by creating a

Engine Shutdown Switch
short circuit at the ECM: Circuit - Test
a. Connect the jumper wire to the engine ground SMCS Code: 7332-038
stud.
b. Restore electrical power to the ECM.
This procedure covers the 267-02 Incorrect Engine
c. Monitor the “Active Diagnostic Code” screen Shutdown Switch inputs.
on Cat ET. Check the suspect sensor for an
active 04 diagnostic code while the jumper wire The engine shutdown switch allows the operator
is installed. to shut down the engine from outside of the cab at
ground level. When the switch is toggled to the STOP
Note: Wait at least 30 seconds so that any codes position, the engine shuts down. The Electronic
may become active. Control Module (ECM) remains powered. The engine
shutdown switch must be returned to the RUN
d. Remove electrical power from the ECM. position and the electrical power to the ECM must be
cycled before the engine will be allowed to restart.
H. Remove the jumper wire. Return the wiring to the
original configuration. The status of the engine shutdown switch can be
observed using Caterpillar Electronic Technician
Expected Result: (ET).
A 03 diagnostic code is active when the loose end

of the jumper wire is open. A 04 diagnostic code
is active when the loose end of the jumper wire is
connected to the engine ground stud.
Results:
• OK – A 03 diagnostic code is active when the loose

end of the jumper wire is open. A 04 diagnostic
code is active when the loose end of the jumper
wire is connected to the engine ground stud.
Repair: The ECM is operating properly. The

problem is in the harness wiring between the ECM
and the sensor connector.
If the code is active for more than one sensor, the

problem is most likely in the return wire for the
sensor. Repair the return wire for the sensor or
replace the harness.
STOP.
RENR9346-06 153
g01258891
Illustration 70
Schematic

g01258956
Illustration 71
(1) J1/P1
B. Thoroughly inspect the J1/P1 ECM connectors

and the J700/P700 engine shutdown switch
connector. Also inspect each of the machine
connectors that are in the circuit. Refer to
for details. g01213917
Illustration 72
Terminal locations at the P1 ECM connector
(P1-5) Digital sensor return
(P1-40) Engine shutdown switch (N/C)
(P1-23) Engine shutdown switch (N/O)
154 RENR9346-06
C. Monitor the status screen on Cat ET while you

operate the shutdown switch. Observe the status
for the shutdown switch.
Note: Wait at least 30 seconds for the status of the

switch to change.
Expected Result:
The status of the shutdown switch reads “ON” with

the shutdown switch in the STOP position. The
status of the shutdown switch reads “OFF” when the
shutdown switch is in the RUN position.
g01159881
Results:
Illustration 73
Harness connector for the engine shutdown switch • OK – The status of the shutdown switch reads
(Terminal A) Engine shutdown switch (N/C) “ON” with the shutdown switch in the STOP
(Terminal B) Digital return position. The status of the shutdown switch
(Terminal C) Engine shutdown switch (N/O) reads “OFF” when the shutdown switch is in the
RUN position. The shutdown switch is operating
C. Perform a 45 N (10 lb) pull test on each of the normally.
wires for the engine shutdown switch.
Repair: The circuit for the shutdown switch
D. Check the torque of the allen head screw on appears to be operating correctly. There may be
the ECM connectors. Refer to Troubleshooting, an intermittent problem in the harness or in a
“Electrical Connectors - Inspect” for the correct connector. If an intermittent problem is suspected,
torque values. refer to Troubleshooting, “Inspecting Electrical
Connectors”.
E. Check the harness and the wiring for abrasion and
for pinch points from the switch back to the ECM. STOP.
Expected Result: • Not OK – The status of the switch does not
read “ON” with the shutdown switch in the STOP
All of the connectors, pins and sockets are completely position. The status of the shutdown switch does
coupled and/or inserted and the harness and wiring not read “OFF” when the shutdown switch is in the
are free of corrosion, of abrasion and of pinch points. RUN position. There is a problem with the circuit
for the shutdown switch. There may be a problem
Results: with the ECM. Proceed to Test Step 3.
• OK – The harness and the connectors appear to Test Step 3. Short the Terminals at the
be OK. Proceed to Test Step 2. Harness Connector for the Shutdown
Switch
• Not OK – The connectors and/or wiring need
repair. A. Remove electrical power from the ECM.
Repair: Repair the wiring and/or the connectors. B. Fabricate a jumper wire that is long enough to
Replace parts, if necessary. Ensure that all of the short circuit two terminals at the harness connector
seals are properly in place and ensure that the for the shutdown switch. Crimp connector pins to
connectors are completely coupled. Verify that the each end of the jumper wire.
C. Disconnect the harness connector for the
STOP. shutdown switch.
Test Step 2. Check the Status of the D. Check the status of the shutdown switch while
Shutdown Switch on Cat ET the circuit is shorted to the RUN position.
A. Connect Cat ET to the service tool connector. a. Install the jumper wire between terminals B
(digital return) and A (engine shutdown switch
B. Restore electrical power to the ECM. (N/C)) at the harness connector for the switch.
b. Restore electrical power to the ECM.

RENR9346-06 155
c. Observe the status of the shutdown switch on B. Fabricate three jumper wires that are long enough
Cat ET. to short circuit terminals at the P1 ECM connector.
Crimp connector sockets to one end of each of
Note: Wait at least 30 seconds for the status of the the jumper wires.
switch to change.
C. Remove the wires from terminal locations P1-5,
The correct status for the shutdown switch is P1-23, and P1-40 at the ECM connector. Install a
“OFF”. jumper wire into each of these terminal locations.
d. Remove electrical power from the ECM. D. Check the status of the shutdown switch while
the circuit is shorted to the RUN position.
E. Check the status of the shutdown switch while
the circuit is shorted to the STOP position. a. Short circuit the ends of the jumper wires that
are in terminal locations P1-5 (digital return)
a. Install the jumper wire between terminals C and P1-40 (engine shutdown switch (N/C)) at
(engine shutdown switch (N/O)) and B (digital the ECM connector.
return) at the harness connector for the switch.
Note: Ensure that the jumper wire that is in terminal
b. Restore electrical power to the ECM. location P1-23 is not in contact with any ground
source. The circuit for this terminal must be open.
c. Observe the status of the shutdown switch on
Cat ET. b. Restore electrical power to the ECM.
Note: Wait at least 30 seconds for the status of the c. Observe the status of the shutdown switch on
switch to change. Cat ET.
The correct status for the shutdown switch is Note: Wait at least 30 seconds for the status of the
“ON”. switch to change.
F. Remove electrical power from the ECM. The correct status for the shutdown switch is
“OFF”.
G. Remove the jumper wire from the harness
connector. d. Remove electrical power from the ECM.
Expected Result: E. Check the status of the shutdown switch while

the circuit is shorted to the STOP position.
The switch status on Cat ET agrees with the test
results that are stated above. a. Short circuit the ends of the jumper wires that
are in terminal locations P1-5 (digital return)
Results: and P1-23 (engine shutdown switch (N/O)) at
the ECM connector.
• OK – The switch status on Cat ET agrees with the
test results. Note: Ensure that the jumper wire that is in terminal
location P1-40 is not in contact with any ground
Repair: There is a problem with the shutdown source. The circuit for this terminal must be open.
switch. Replace the shutdown switch. Verify that
the new shutdown switch solves the problem. b. Restore electrical power to the ECM.
STOP. c. Observe the status of the shutdown switch on

Cat ET.
• Not OK – The switch status on Cat ET does not
agree with the test results that are stated above. Note: Wait at least 30 seconds for the status of the
The problem is in the harness between the ECM switch to change.
and the harness connector for the switch. There
may be a problem with the ECM. Proceed to Test The correct status for the shutdown switch is
Step 4. “ON”.
Test Step 4. Short the Terminals for the F. Remove electrical power from the ECM.
Shutdown Switch at the ECM
G. Restore the wiring to the original configuration.
A. Disconnect the J1/P1 ECM connectors.
156 RENR9346-06
Expected Result: The secondary engine speed/timing sensor detects

the reference for engine speed and timing from a
The switch status on Cat ET agrees with the test timing ring with a notched pattern that has been
results that are stated above. machined onto a portion of the camshaft gear.
Results: The Electronic Control Module (ECM) counts the

time between pulses that is created by the sensor as
• OK – The switch status on Cat ET agrees with the each gear rotates in order to determine rpm. Timing
test results. is provided by the unique pattern of notches in the
timing ring.
Repair: There is a problem in the harness
between the ECM and the harness connector for Under normal operation, the secondary engine
the shutdown switch. There may be a problem speed/timing sensor is used to determine timing
with a connector. Repair the harness and/or the for starting purposes. The secondary engine
connector. Replace parts, if necessary. Verify that speed/timing sensor is used to determine when
the repair resolves the original problem. the piston in the No. 1 cylinder is at the top of the
compression stroke. When the timing has been
STOP. established, the primary engine speed/timing sensor
is then used to determine engine speed.
• Not OK – The switch status on Cat ET does not
agree with the test results that are stated above. When the timing has been established, the ECM
triggers each injector in the correct firing order at the
Repair: There is a problem with the ECM. Replace correct time. The actual timing and duration of each
the ECM. Refer to Troubleshooting, “Replacing injection is based on engine rpm and on load.
the ECM”.
If the engine is running and the signal from one
STOP. sensor is lost, no change in engine performance will
be noticed. If the engine is running and the signals
from both sensors are lost, fuel injection will be
i02540812
terminated and the engine will be shut down by the
Engine Speed/Timing Sensor ECM.
Circuit - Test The engine will start when only one sensor signal is
present. The engine will not start if the signals from
SMCS Code: 1439-038-VF; 1912-038 both sensors are lost.
System Operation Description: Both sensors are magnetic sensors. The two sensors
are not interchangeable. If a sensor is replaced, a
Use this procedure to troubleshoot any suspect timing calibration is not necessary.
problems with the following sensors:
If a replacement of the ECM is required, the ECM
• Primary engine speed/timing sensor parameters and the timing calibration can be
transferred from the suspect ECM to the replacement
• Secondary engine speed/timing sensor ECM. Timing calibration will not be necessary. This
feature requires the Caterpillar Electronic Technician
This procedure covers the following diagnostic codes: (ET) and this feature is only possible if the existing
ECM can communicate with Cat ET. Use the “Copy
• 190-08 Engine Speed Signal abnormal Configuration - ECM Replacement” feature on Cat
ET.
• 342-08 Secondary Engine Speed signal abnormal
A timing calibration is necessary after the
The engine uses two engine speed/timing sensors. ECM software has been updated. Refer to
The primary engine speed/timing sensor detects the Troubleshooting, “Engine Speed/Timing Sensor -
reference for engine speed and timing from a timing Calibrate” for information that is related to timing
ring with a notched pattern that has been machined calibration.
onto a portion of the crankshaft gear. The signal from
the primary engine speed/timing sensor is also used Complete all of the following tasks when you
by the ECM as a control reference during a timing install a speed/timing sensor:
calibration.
• Ensure that an O-ring is installed on the sensor.
If the O-ring is damaged or missing, replace the
O-ring.
RENR9346-06 157
• Lubricate the O-ring with oil.

• Ensure that the sensor is fully seated into the
engine before tightening the bracket bolt.
• Ensure that the electrical connector is latched.

• Ensure that the harness is properly secured, and
ensure that each tie-wrap is placed in the correct
location.
g01212495
Illustration 74
Schematic for the engine speed/timing sensors
Test Step 1. Check for Diagnostic Codes • 190-08 or 342-08 code – There is an active
diagnostic code or a logged diagnostic code for
A. Connect Cat ET to the service tool connector. an engine speed/timing sensor. Proceed to Test
Refer to Troubleshooting, “Electronic Service Step 4.
Tools”.
• No codes – Neither code is active or logged.
Repair: Refer to the appropriate symptoms in
C. Start the engine and run the engine until the Troubleshooting, “Troubleshooting Without a
engine is at the normal operating temperature. Diagnostic Code”.
Note: If the engine will not start, monitor the engine STOP.
rpm on Cat ET while the engine is being cranked. Cat
ET may need to be powered from another battery Test Step 2. Check the Installation of the
while the engine is being cranked. Sensor Assembly
D. Look for these codes on Cat ET: A. Remove electrical power from the ECM.
• 190-08
• 342-08
Expected Result:
One or both of the diagnostic codes that are listed

above are logged or active.
Note: If the engine will not start and Cat ET displayed

0 rpm during cranking, select “No Engine rpm”.
Results:
• No Engine rpm – Engine rpm is not indicated on

Cat ET. Proceed to Test Step 2.
158 RENR9346-06
3. Tighten the bracket bolt.
4. Connect the sensor's electrical connectors.

Verify that the connectors are latched on both
sides.
5. Ensure that the harness is properly secured,

and that the tie-wraps are placed in the correct
location.
• Not OK – At least one of the sensor assembly's

components is not OK.
g01167684
Illustration 75 Repair: Obtain a new sensor assembly. Perform
Typical engine speed/timing sensor the following procedure in order to properly install
(1) Mounting flange the sensor assembly:
(2) Mounting surface
1. Lubricate each O-ring with engine oil.
B. Visually inspect each sensor assembly without
removing the sensor assembly from the engine. 2. Fully seat the sensor assembly in the engine.
Ensure that flange (1) is installed squarely against
surface (2). Note: If the sensor assembly will not fully seat into
the engine, replace the sensor assembly.
C. Remove the suspect sensor assembly from the
engine. 3. Tighten the bracket bolt.
4. Connect the sensor's electrical connectors.

Verify that the connector is latched.
5. Ensure that the harness is properly secured,

and that the tie-wraps are placed in the correct
location.
STOP.
g01167704
Illustration 76
Typical engine speed/timing sensor
(3) O-ring
D. Ensure that one O-ring (3) is installed on the

sensor. Check the O-ring for damage. Replace
the O-ring, if necessary.
Results:
• OK – The sensor's components are OK.

Repair: Perform the following procedure in order
to properly install the sensor assembly:
1. Lubricate the O-ring with engine oil.
2. Fully seat the sensor assembly in the engine.
Note: If the sensor assembly will not fully seat into

the engine, replace the sensor assembly.
RENR9346-06 159

g01167708
Illustration 77
Location of the engine speed/timing sensors (typical front engine
view)
(4) Harness connectors for the secondary engine speed/timing
sensor
(5) Harness connectors for the primary engine speed/timing sensor
g01212538
Illustration 79
P2 terminals that are associated with the engine speed/timing
sensors
(P2-25) Primary engine speed/timing −
(P2-35) Primary engine speed/timing +
(P2-46) Secondary engine speed/timing +
(P2-47) Secondary engine speed/timing −
(P2-92) Speed/timing shield
B. Perform a 45 N (10 lb) pull test on each of

Illustration 78
g01167873 the wires that are associated with the engine
speed/timing sensors.
C. Check the allen head screw on each ECM

A. Thoroughly inspect connectors (4), (5), and (6). connector for the proper torque. Refer to
Refer to Troubleshooting, “Electrical Connectors Troubleshooting, “Electrical Connectors - Inspect”
- Inspect”. for the correct torque values.
D. Check the harness and the wiring for abrasion

and for pinch points from each sensor back to the
ECM.
160 RENR9346-06
Expected Result: Expected Result:
All of the connectors, pins and sockets are completely The resistance measurement is within the
coupled and/or inserted and the harness and wiring specifications.
are free of corrosion, of abrasion, and of pinch points.
Results:
Results:
• OK – The resistance measurement is within the
• OK – The harness and connectors appear to be specifications.
Repair: Neither a short circuit nor an open circuit
• Not OK – The connectors and/or wiring are not is indicated in the circuit. Replace the ECM. Refer
OK. to Troubleshooting, “Replacing the ECM”.
Repair: Repair the wiring and/or the connectors. STOP.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the • Not OK – The readings are not within the
connectors are completely coupled. Verify that the specifications. The sensor resistance is not within
repair eliminates the problem. the acceptable range when the sensor resistance
is measured through the engine harness. Proceed
STOP. to Test Step 5.
Test Step 4. Measure the Sensor Test Step 5. Measure the Resistance of
Resistance through the Engine Harness the Sensor
A. Disconnect the J2/P2 ECM connectors. A. Disconnect the harness connector for the suspect
sensor.
B. If you are troubleshooting a problem with the
primary engine speed/timing sensor, perform the B. Thoroughly inspect the sensor's connectors.
following procedure: Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
a. Measure the sensor's resistance between
P2-25 (primary engine speed/timing +) and C. Measure the sensor's resistance between
P2-35 (primary engine speed/timing -). terminals 1 and 2.
b. Check for an intermittent open circuit or for Resistance for primary engine speed/timing
a short circuit by moving the harness while sensor at 25 °C (77 °F) ............... 75 to 230 Ohms
you take the resistance measurement. Pull
the wires that are directly behind the sensor Resistance for secondary engine speed/timing
or shake the wires that are directly behind the sensor at 25 °C (77 °F) ........... 600 to 1800 Ohms
sensor.
Expected Result:
Resistance at 25 °C (77 °F) ... 75 to 230 Ohms
The resistance measurement is within specifications.
C. If you are troubleshooting a problem with the
secondary engine speed/timing sensor, perform Results:
the following procedure:
• OK – The reading is within the specification. There
a. Measure the sensor's resistance between is a problem with the wiring between the engine
P2-47 (secondary engine speed/timing +) and speed/timing sensor and the ECM. There may be
P2-46 (secondary engine speed/timing -). a problem with a connector.
b. Check for an intermittent open circuit or for Repair: Repair the wiring and/or the connector.
a short circuit by moving the harness while Replace parts, if necessary. Verify that the problem
you take the resistance measurement. Pull is resolved.
the wires that are directly behind the sensor
or shake the wires that are directly behind the STOP.
sensor.
• Not OK – The reading is not within the
Resistance at 25 °C specification. There is an electrical problem with
(77 °F) ................................ 600 to 1800 Ohms the engine speed/timing sensor.
RENR9346-06 161
Repair: Perform the following procedure in order • 172-04 Intake Manifold Air Temp short to ground
to check and install the new sensor assembly:
• 174-03 Fuel Temperature open/short to +batt
1. Before you install the new sensor assembly,
measure the resistance of the new sensors. • 174-04 Fuel Temperature short to ground
If the resistance measurements of the new • 1796-03 Intake Manifold #2 Air Temperature
sensors are within the specifications, install the Sensor voltage above normal
new sensor assembly in the engine according
to the following procedure: • 1796-04 Intake Manifold #2 Air Temperature
Sensor voltage below normal
a. Loosen the bolt and remove the bolt that
holds the sensor to the engine. The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical.
b. Ensure that an O-ring is installed on the new The temperature sensors are passive sensors that
sensor assembly. Verify that the O-ring is have two terminals. The temperature sensors do not
free of damage. require supply voltage from the Electronic Control
Module (ECM).
c. Prior to installation, lubricate the O-ring with
clean engine oil. Pull-up Voltage
d. Seat the sensor and tighten the bolt. The ECM continuously outputs a pull-up voltage
on the circuit for the sensor signal wire. The ECM
If the sensor will not seat, replace the sensor. uses this pull-up voltage in order to detect a problem
in the signal circuit. When the ECM detects the
e. Ensure that the harness is secured in the presence of a voltage that is above a threshold on the
proper location. signal circuit, the ECM will generate an open circuit
diagnostic code 03 for the sensor.
2. Verify that the repair eliminates the problem.
If the sensor is disconnected at the sensor connector,
STOP. the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are OK. If the sensor is
i02517861
disconnected at the sensor connector, the absence
Engine Temperature Sensor of pull-up voltage at the sensor connector indicates
a problem in the signal wire. If the sensor is
Open or Short Circuit - Test disconnected at the sensor connector and the voltage
at the sensor connector is different from pull-up
SMCS Code: 1439-038-TA; 1906-038 voltage, the signal wire is shorted to another wire in
the harness.

problems with the following sensors:
• Auxiliary temperature sensor

• Engine coolant temperature sensor
• Fuel temperature sensor
• Intake manifold air temperature sensor
• 110-03 Engine Coolant Temperature open/short

to +batt
• 110-04 Engine Coolant Temperature short to

ground
• 172-03 Intake Manifold Air Temp open/short to

+batt
162 RENR9346-06
g01259793
Illustration 80
Schematic for the engine temperature sensors
RENR9346-06 163
g01270819
Illustration 81
Locations of the engine temperature sensors (typical engine view)
(1) Intake manifold (No.2) air temperature (2) Intake manifold air temperature sensor (4) Fuel temperature sensor
sensor (3) Engine coolant temperature sensor
Test Step 1. Inspect the Electrical B. Thoroughly inspect all electrical connectors.
Connectors and the Wiring Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
164 RENR9346-06
g01270820
Illustration 82
(5) J2/P2ECM connector
g01270822
Illustration 83
P2 terminals that are associated with the engine temperature
sensors
(P2-13) Engine coolant temperature
(P2-56) Intake manifold air temperature
(P2-62) Fuel temperature
(P2-91) Intake manifold (No.2) air temperature sensor
g01155187
Illustration 84
Harness connector for the temperature sensors
(1) Sensor signal
(2) Sensor return
RENR9346-06 165
C. Perform a 45 N (10 lb) pull test on each of the Repair: The problem appears to be resolved.
wires at the connectors for the temperature The problem may have been related to a faulty
sensors. connection in the harness. Carefully reinspect the
connectors and wiring. Refer to Troubleshooting,
D. Check the allen head screw on each ECM “Electrical Connectors - Inspect” for additional
connector and the customer connector for information.
the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct STOP.
torque values.
• Not OK – A 03 diagnostic code is active at this
E. Check the harness and wiring for abrasions and time. The ECM detects an open circuit condition.
for pinch points from each sensor to the ECM. Proceed to Test Step 4.
Expected Result: • Not OK – A 04 diagnostic code is active at this

time. The ECM detects a short circuit condition.
All connectors, pins, and sockets are completely Proceed to Test Step 3.
free of corrosion, of abrasion, and of pinch points. Test Step 3. Create an Open Circuit by
Disconnecting the Sensor Connector
Results:
• OK – The connectors and wiring appear to be OK.
Proceed to Test Step 2. B. Disconnect the suspect sensor from the harness
at the sensor connector.
and/or wiring. C. Restore electrical power to the ECM.
Repair: Repair the connectors or wiring and/or D. Access the “Active Diagnostic Codes” screen on
replace the connectors or wiring. Ensure that all of Cat ET. Check for an active 03 diagnostic code
the seals are properly in place and ensure that the for the suspect sensor.
Verify that the repair eliminates the problem. diagnostic codes.
STOP. E. Remove electrical power from the ECM.
Test Step 2. Check for Active Diagnostic Expected Result:

Codes
A 03 diagnostic code is now active for the suspect
A. Connect the Caterpillar Electronic Technician (ET) sensor.
to the service tool connector.
Results:
• OK – A 03 diagnostic code became active after
C. Monitor the active diagnostic code screen on Cat the sensor was disconnected.
ET. Check and record any active diagnostic codes.
Repair: There may be a problem with the sensor.
Note: Wait at least 30 seconds in order for the Temporarily connect a new sensor to the harness,
diagnostic codes to become active. but do not install the new sensor in the engine.
Verify that there are no active diagnostic codes for
D. Check for an active 03 or 04 diagnostic code. the sensor. If there are no active diagnostic codes
for the sensor, permanently install the new sensor.
Expected Result: Clear any logged diagnostic codes.
No diagnostic codes are active. STOP.
Results: • Not OK – The 04 diagnostic code is still present

while the sensor is disconnected from the harness.
• OK – No diagnostic codes are active. The sensor is OK. There is a problem in the
harness between the ECM and the sensor
connector. There may be a problem with the ECM.
Leave the suspect sensor disconnected. Proceed
to Test Step 5.
166 RENR9346-06
Test Step 4. Short at the Suspect Sensor b. Fabricate a jumper wire that is long enough
at the Harness Connector to create a test circuit between the ECM
connector and the engine ground stud. Crimp a
A. Remove electrical power from the ECM. connector socket to one end of the jumper wire.
B. Disconnect the suspect sensor at the harness c. Remove the signal wire for the suspect sensor
connector. from the appropriate ECM connector. Install the
jumper wire into this terminal location.
C. Fabricate a jumper wire that is long enough to
short circuit the two terminals at the connector for d. Connect the ECM connectors.
the suspect sensor. Crimp connector pins to each
end of the jumper wire. Hold the loose end of the jumper wire away
from any ground source in order to create an
D. Install the jumper wire between terminal 1 (sensor open circuit condition.
signal) and terminal 2 (sensor return) on the
harness side of the suspect sensor's connector. e. Restore electrical power to the ECM.
E. Restore electrical power to the ECM. f. Monitor the “Active Diagnostic Code” screen
on Cat ET. A 03 diagnostic code will become
F. Monitor the “Active Diagnostic Codes” screen on active for the suspect sensor.
Cat ET after installing the jumper wire. Check for
an active 04 diagnostic code. Note: Wait at least 30 seconds for activation of the
code.
04 diagnostic code. g. Remove electrical power from the ECM.
G. Remove electrical power from the ECM. C. Check the operation of the ECM by creating a
short at the ECM.
Expected Result:
a. Connect the loose end of the jumper wire to the
A 04 diagnostic code is now active for the suspect engine ground stud in order to create a short
sensor. circuit condition.
Results: b. Restore electrical power to the ECM.
• OK – A 04 diagnostic code is active when the c. Monitor the “Active Diagnostic Code” screen
jumper wire is installed. on Cat ET. A 04 diagnostic code will become
active when the jumper wire is grounded.
Repair: There may be a problem with the sensor.
Temporarily connect a new sensor to the harness, Note: Wait at least 30 seconds for activation of the
but do not install the new sensor in the engine. code.
Verify that there are no active diagnostic codes for
the sensor. If there are no active diagnostic codes d. Remove electrical power from the ECM.
for the sensor, permanently install the new sensor.
Clear any logged diagnostic codes. D. Restore all wiring to the original configuration.
STOP. Expected Result:
• Not OK – The 03 diagnostic code remains active A 03 diagnostic code is active when the jumper wire
with the jumper in place. There is an open circuit is open. A 04 diagnostic code becomes active when
between the ECM and the sensor connector. There the jumper wire is shorted to the engine ground stud.
may be a problem with the ECM. Proceed to Test
Step 5. Results:
Test Step 5. Check the Operation of the • OK – A 03 diagnostic code is active when the
ECM jumper wire is open. A 04 diagnostic code becomes
active when the jumper wire is shorted to the
A. Remove electrical power from the ECM. engine ground stud.
B. Check the operation of the ECM by creating

an open at the ECM:
a. Disconnect the appropriate ECM connector.

RENR9346-06 167
Repair: The ECM is working properly. The problem

is in the wiring harness between the ECM and the
sensor connector. Repair the harness and/or the
connectors. Replace parts, if necessary.
STOP.
• Not OK – One of the following conditions exists:

The 03 diagnostic code is not active when the
jumper wire is open. The 04 diagnostic code is not
active when the wire jumper is shorted to ground.
Repair: There is a problem with the ECM. Replace

the ECM. Refer to Troubleshooting, “Replacing
the ECM”.
STOP.
i02533981
Ether Injection System - Test

SMCS Code: 1456-038

problems with the electrical circuit for the ether
injection system.
• 2417-05 Ether Injection Control Solenoid current

low
• 2417-06 Ether Injection Control Solenoid current

high
The ether injection system improves cold weather

starting of the engine. The Electronic Control Module
(ECM) provides total control of the ether injection
system.
An override feature on the Caterpillar Electronic

Technician (ET) allows the technician to activate
the ether system. The test is only functional while
the engine is not running. Activate this feature
by selecting the “Override Parameters” from the
diagnostic menu in Cat ET.
g01267513
Illustration 85
Schematic of the ether injection system
168 RENR9346-06
Breathing ether vapors or repeated contact of

ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living

areas or in the operator's compartment. Illustration 87
g01217609
Components for the ether injection system (typical view)

Do not store ether cylinders in direct sunlight or
(2) Ether injection solenoid
at temperatures above 49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture B. Thoroughly inspect connectors (1) and (2). Also,
or burn cylinders. thoroughly inspect the connectors for solenoid
(3). Refer to the diagnostic functional test
Keep ether cylinders out of the reach of unautho- Troubleshooting, “Electrical Connectors - Inspect”.
rized personnel.
To avoid possible injury, be sure the brakes are ap-

plied and all controls are in Hold or Neutral when
starting the engine.

g01167488
Illustration 86
Location of the J1/P1 connectors (typical engine view)
g01215917
(1) J1/P1 connectors Illustration 88
Terminal locations at the P1 connector for the ether injection
system
(P1-18) Solenoid return
(P1-20) Ether injection solenoid
RENR9346-06 169
Results:
• OK – The ether canister is not empty. Remove

the ether canister from the ether valve for the
remainder of this test. Proceed to Test Step 3.
• Not OK – The ether canister is empty.

Illustration 89
g01155187 Repair: Replace the empty ether canister with a
Terminal locations at the connector for the ether injection solenoid full ether canister. Retry the system.
(Terminal 1) Ether injection solenoid
(Terminal 2) Solenoid return STOP.
C. Perform a 45 N (10 lb) pull test on each of the Test Step 3. Check for Signal Voltage
wires that are associated with the ether injection at the Harness Connector for the Ether
system. Injection Solenoid
D. Check the torque of the allen head screws for each A. Remove the electrical power from the ECM.
of the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, “Electrical B. Disconnect the harness connector at the ether
Connectors - Inspect”. injection solenoid.
E. Check the harness and the wiring for abrasion and C. Restore the electrical power to the ECM.
for pinch points from the ether injection solenoid
to the ECM connector. D. Proceed to the “Diagnostic Overrides” screen on
Cat ET.
Expected Result:
E. Activate the ether injection system. The system
All connectors, pins, and sockets are completely will activate for ten seconds.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. F. Check for a signal voltage between the terminals
at the harness connector for the ether injection
Results: solenoid.
• OK – The connectors and the wiring appear to be G. Remove the electrical power from the ECM.
Expected Result:
• Not OK – The connectors and/or the wiring are
not OK. The signal voltage is 8.0 ± 0.5 VDC at the connector
for the ether injection solenoid.
Repair: Repair the connectors and/or the wiring.
Replace parts, if necessary. Verify that the problem Results:
is resolved.
• OK – The signal voltage is 8.0 ± 0.5 VDC at the
STOP. connector for the ether injection solenoid.
Test Step 2. Check the Ether Canisters Repair: Voltage is reaching the ether injection
for Fluid solenoid. There is a problem with the solenoid.
Connect a new ether solenoid to the harness.
A. Ensure that the electrical power is removed from Verify that the problem has been corrected prior to
the ECM. installing the new solenoid.
B. Remove the ether canister from the ether valve. STOP.
C. Determine if the canister is empty. • Not OK – The signal voltage is not 8.0 ± 0.5 VDC
at the connector for the ether injection solenoid.
Expected Result: There is a problem in the harness or in a connector
between the ECM and the connector for the ether
The ether canister is not empty. injection solenoid. There may be a problem with
the ECM. Proceed to Test Step 4.
170 RENR9346-06
Test Step 4. Check the Operation of the Repair: The ECM is not producing the correct
ECM signal voltage. There is a problem with the
ECM. Replace the ECM. Refer to electronic
A. Disconnect the J1/P1 ECM connectors. troubleshooting Troubleshooting, “Replacing the
ECM”.
B. Fabricate two jumper wires that are long enough to
provide a test circuit at the ECM. Crimp connector STOP.
sockets onto one end of each of the jumper wires.
i02627384
C. Remove the wires from terminal locations P1-18
(digital return) and P1-20 (ether injection solenoid)
at the ECM connector. Install a jumper wire into
Fuel Filter Differential Pressure
each of these terminal locations. Switch Circuit - Test
D. Connect the J1/P1 ECM connectors. SMCS Code: 1435-038-FI
E. Restore the electrical power to the ECM. System Operation Description:
F. Proceed to the “Diagnostic Overrides” screen on Perform this procedure if you suspect that there is
Cat ET. a problem in the circuit for the fuel filter differential
pressure switch.
G. Activate the ether injection system. The system
will activate for ten seconds. This procedure covers the following event codes:
H. Check for a signal voltage between the jumper • E390-1 Fuel Filter Restriction Warning
wires at the ECM connector for the ether injection
solenoid. • E390-2 Fuel Filter Restriction Derate
I. Remove the electrical power from the ECM. The fuel filter differential pressure switch is used
to detect excessive restriction in the fuel filter. The
J. Restore all of the wiring to the original switch is normally closed. When the fuel pressure
configuration. at the switch reaches 103 ± 14 kPa (15 ± 2 psi) the
switch will open. The switch is used in order to detect
Expected Result: a plugged fuel filter element. The Electronic Control
Module (ECM) will alert the operator of the condition.
The signal voltage is 8.0 ± 0.5 VDC at the ECM for Use this test in order to verify that the fuel filter
the ether injection solenoid. differential pressure switch is operating correctly.
Results:
• OK – The signal voltage is 8.0 ± 0.5 VDC at the

ECM.
Repair: The ECM is producing the correct signal

for the ether injection solenoid. The ECM is OK.
The problem is in the harness or in a connector
between the ECM and the ether injection solenoid.
Repair the wiring harness and/or the connector.
has been corrected prior to returning the engine
to service.
STOP.
• Not OK – The signal voltage is not 8.0 ± 0.5 VDC

at the ECM.
RENR9346-06 171
g01322152
Illustration 90
Schematic for fuel filter differential pressure switch

g01161069
Illustration 92
Fuel filter base (typical example)
(2) Fuel filter differential pressure switch
g01214446
Illustration 91 B. Thoroughly inspect connectors (1). Also,
Left side engine view (typical example) thoroughly inspect each connector for switch (2).
Refer to the diagnostic functional test
for details.
172 RENR9346-06
g01155187
Illustration 94
Connector for the fuel filter differential pressure switch
(Terminal 1) Fuel filter differential pressure switch
(Terminal 2) Signal return

wires in the ECM connector and the sensor
connectors that are associated with the active
diagnostic code.
D. Check the allen head screw of each ECM

connector for the proper torque. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect” for details.
E. Check the harness and wiring for abrasions and

for pinch points from the switch back to the ECM.
Expected Result:

Results:
• OK – The harness and wiring appear to be OK.


and/or wiring.

STOP.
g01321577
Illustration 93
P2 ECM connector
Test Step 2. Check the Switch Circuit
(P2-65) Fuel filter differential pressure switch
(P2-83) Signal return
A. Disconnect the connector for the differential
pressure switch.
B. Check continuity between the terminals for the

differential pressure switch at the connector.
Expected Result:
The resistance check indicates a short circuit.

RENR9346-06 173
Results: i03793013
• OK – The resistance check indicates a short Injector Solenoid Circuit - Test

circuit. The differential pressure switch is OK.
Proceed to Test Step 3. SMCS Code: 1290-038
• Not OK – The resistance check indicates an open System Operation Description:

circuit. There is an open circuit in the wiring for the
fuel filter differential pressure switch. Use this procedure for the following conditions:
Repair: Replace the differential pressure switch. • A suspected problem with an injector solenoid
STOP. • You have been directed to this procedure from

Troubleshooting, “Troubleshooting without a
Test Step 3. Check the Wiring between Diagnostic Code”.
the Connector for the Differential
Pressure Switch and the ECM • There is an active diagnostic code for an injector
solenoid.
A. Disconnect the J2/P2 ECM connector.
Use this procedure for the following diagnostic codes:
B. Create a short between the terminals of the
connector for the differential pressure switch. • 1-05 Cylinder #1 Injector open circuit
C. Check continuity at the ECM connector between • 1-06 Cylinder #1 Injector short
terminal P2-65 (fuel filter pressure switch) and
terminal P2-83 (switch return). • 2-05 Cylinder #2 Injector open circuit
Expected Result: • 2-06 Cylinder #2 Injector short
The resistance check indicates a short circuit. • 3-05 Cylinder #3 Injector open circuit
Results: • 3-06 Cylinder #3 Injector short
• OK – The resistance check indicates a short • 4-05 Cylinder #4 Injector open circuit
circuit.
• 4-06 Cylinder #4 Injector short
Repair: Check all connectors and wiring. Ensure
that there are clean, solid connections at each • 5-05 Cylinder #5 Injector open circuit
connector. Return all wiring to the original
configuration and retest the circuit. The most • 5-06 Cylinder #5 Injector short
likely cause of the problem is a poor connection.
The next most likely cause of the problem is the • 6-05 Cylinder #6 Injector open circuit
differential pressure switch. The least likely cause
of the problem is the ECM. The ECM can be tested • 6-06 Cylinder #6 Injector short
by creating a short between the ECM terminals for
the differential pressure switch. Start and run the • 7-05 Cylinder #7 Injector open circuit
engine. After an hour, check for an E390 event
code. If the event code is activated with the short • 7-06 Cylinder #7 Injector short
in place at the ECM connector, replace the ECM.
Refer to Troubleshooting, “Replacing the ECM”. • 8-05 Cylinder #8 Injector open circuit
• 8-06 Cylinder #8 Injector short
STOP.
• 9-05 Cylinder #9 Injector open circuit
• Not OK – The resistance check indicates an open
circuit. • 9-06 Cylinder #9 Injector short
Repair: Repair the connectors or wiring and/or • 10-05 Cylinder #10 Injector open circuit
replace the connectors or wiring between the ECM
and the connector for the differential pressure • 10-06 Cylinder #10 Injector short
switch.
• 11-05 Cylinder #11 Injector open circuit
STOP.
174 RENR9346-06
• 11-06 Cylinder #11 Injector short During the test, when a cylinder is cut out, an
increase in “Fuel Position” will be noticed for the
• 12-05 Cylinder #12 Injector open circuit remaining cylinders. This increase in “Fuel Position”
represents an increase in the amount of fuel that
• 12-06 Cylinder #12 Injector short must be delivered by the remaining cylinders in order
to maintain the desired engine speed.
Perform this procedure under conditions that are
identical to the conditions that exist when the problem When a weak cylinder (malfunctioning injector) is cut
occurs. Typically, problems with the injector solenoid out, the increase in “Fuel Position” will not be as large
occur when the engine is warmed up and/or when as the increase for a cylinder that has an acceptable
the engine is under vibration (heavy loads). level of performance.
These engines have Electronic Unit Injectors (EUI) Note: Prior to running the “Cylinder Cutout Test”, all
that are mechanically actuated and electronically active diagnostic codes must be repaired.
controlled. The Engine Control Module (ECM) sends
a high voltage signal to each injector solenoid. The “Injector Solenoid Test”
signal is sent with the proper injection duration and
injection timing for the current engine load and Use the “Injector Solenoid Test” to diagnose an open
speed. The injector solenoid is mounted on top of circuit or a short circuit in the wiring for the injector
the fuel injector body. solenoids. With the engine stopped, the “Injector
Solenoid Test” will briefly activate each injector
If an open circuit condition is detected in the solenoid solenoid. An audible click can be heard as each
circuit, a diagnostic code is generated. The ECM will solenoid is activated. After performing the test, Cat
continue to try to fire the injector. If a short circuit ET will indicate the status of the solenoid as “OK”,
condition is detected, a diagnostic code is generated. “Open”, or “Short”.
The ECM will disable the solenoid circuit. The ECM
will periodically try to fire the injector. If the short
circuit condition remains, this sequence of events will
be repeated until the problem is corrected.
Note: Refer to Illustration 95. Two injector solenoids

share a supply wire. For this reason, an open
circuit or a short circuit in a supply wire could cause
diagnostic codes for two injector solenoids.
When an injector is replaced, new injector trim files

must be programmed into the ECM. If the ECM is
replaced, all injector trim files must be programmed
into the new ECM. Refer to Troubleshooting, “Injector
Trim File” for more information.
The Caterpillar Electronic Technician (ET) includes

the following tests that aid in troubleshooting the
injector solenoids:
“Cylinder Cutout Test”
The “Cylinder Cutout Test” is used on an engine

in order to determine the individual cylinder
performance while the engine is running. As one
or more cylinders are cut out during the test, the
“Cylinder Cutout Test” uses “Fuel Position” in order
to evaluate the performance of the cylinders that
are cut out. As the different cylinders are cut out, a
comparison of the change in “Fuel Position” is used
to identify cylinders that are weak or misfiring. One
reason for a cylinder that is weak or misfiring is an
injector that is malfunctioning.
The “Cylinder Cutout Test” can be used to isolate a

malfunctioning injector in order to avoid replacement
of injectors that are in good condition.
RENR9346-06 175
g02050353
Illustration 95
Schematic for the injector solenoids
176 RENR9346-06

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.
g01166729
Illustration 96
Left side engine view (typical example)
(1) J2/P2 ECM connectors Illustration 97
g01202827
(2) R1/P3 Injector valve cover entry connectors (right bank)
(3) R1/P4 Injector valve cover entry connectors (left bank) P2 terminals that are associated with the injector solenoids
(P2-18) Injector 8 return
B. Thoroughly inspect connectors (1), (2), and (3). (P2-21) Injector 10 return
Refer to Troubleshooting, “Electrical Connectors (P2-22) Injector 4 return
- Inspect”. (P2-42) Injector 12 return
(P2-58) Injectors 10 & 12 supply
RENR9346-06 177
Expected Result:

coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion, or of pinch points.
Results:
• OK – The harnesses and the wiring appear to be


and/or wiring.
g01161232
Illustration 98 replace the connectors or wiring. Ensure that all of
P3 terminals that are associated with the injector solenoids the seals are properly in place and ensure that the
(P3-1) Injector 12 return connectors are completely coupled.
(P3-3) Injector 8 return Verify that the repair eliminates the problem.
(P3-6) Injector 2 return STOP.
(P3-8) Injectors 6 & 8 supply Test Step 2. Check for Logged Diagnostic
Codes for the Injector Solenoids
A. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service
Tools”.
B. Restore the electrical power to the ECM.
C. Check Cat ET for logged diagnostic codes related

to the injector solenoids.
Expected Result:
There are no logged diagnostic codes for the injector

solenoids .
g01161232
Illustration 99
Results:
P4 terminals that are associated with the injector solenoids
(P4-1)
(P4-2)
Injector 1 return
Injector 3 return
• OK – No diagnostic codes for the injector solenoids
are logged. The injector solenoids are operating
(P4-4) Injector 7 return correctly. There may be a mechanical problem with
(P4-5) Injector 9 return the injector's fuel delivery. Proceed to Test Step 3.
• Not OK – A diagnostic code is logged for one
or more injector solenoid. There is an electrical
problem with an injector solenoid or with the circuit.
C. Perform a 45 N (10 lb) pull test on each of the Proceed to Test Step 4.
wires that are associated with injector solenoids.
Test Step 3. Perform the “Cylinder Cutout
D. Check the allen head screw on each ECM Test”
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect” A. Start the engine.
B. Allow the engine to warm up to normal operating
E. Check the harness and the wiring for abrasion temperature 77 °C (171 °F).
and for pinch points from each P300 connector
to the ECM. C. Access the “Cylinder Cutout Test” by accessing
the following display screens:
178 RENR9346-06
• “Diagnostics” • “Diagnostic Tests”

• “Diagnostic Tests” • “Injector Solenoid Test”
• “Cylinder Cutout Test” F. Activate the “Injector Solenoid Test”.
D. Shut off all parasitic loads such as air compressors G. As each solenoid is energized by the ECM, an
which could affect the results of the test. audible click can be heard at the valve cover.
Allow the “Injector Solenoid Test” to continue until
E. Follow the instructions that are given on the each cylinder is activated at least two times.
screen.
Expected Result:
F. To start the test, select the start button at the
bottom of the screen. All cylinders indicate “OK” on Cat ET.
G. Use Cat ET to manually cut out the cylinders Results:

in order to identify injectors that may have a
performance problem. Highlight a cylinder and • OK – There is not an electronic problem with the
select the “Change” button at the bottom of injectors at this time.
the screen. The injector for that cylinder will be
disabled. Check for a difference in the sound, feel, Repair: The problem appears to be resolved.
or power of the engine. Also, look for a change to There may be an intermittent problem in the
the operating parameters that are displayed on harness. The problem may have been caused by a
the “Cylinder Cutout Test” screen. poor electrical connection in a connector.
Expected Result: If the codes continue to be logged, refer to

The cylinder cutout test indicates that all of the
injectors are operating correctly. If the engine is misfiring or if the engine has low
power, refer to Troubleshooting, “Engine Misfires,
Results: Runs Rough or Is Unstable” or Troubleshooting,
“Low Power/Poor or No Response to Throttle”.
• OK – The cylinder cutout test indicates that all of
the injectors are operating correctly. STOP.
Repair: If a problem with the fuel system is • Not OK - “Open” – Note the cylinder that indicates
suspected and diagnostic codes are not active or “Open”. Proceed to Test Step 5.
logged, refer to Systems Operation/Testing and
Adjusting for information that is related to the low • Not OK - “Short” – Note the cylinder that indicates
pressure fuel system. “Short”. Proceed to Test Step 6.
STOP. Test Step 5. Check the Harness between

the ECM and the Valve Cover Base for an
• Not OK – The cylinder cutout test indicates that at Open Circuit
least one of the injectors is not operating correctly.
Test Step 4. Perform the “Injector

Solenoid Test” Electrical shock hazard. The electronic unit injec-
B. Allow the engine to warm up to normal operating
temperature 77 °C (171 °F). B. Disconnect the appropriate P300 connector at the
valve cover base.
C. Stop the engine.
D. Restore the electrical power to the ECM.
D. Fabricate a jumper wire that will be long enough
E. Access the “Injector Solenoid Test” by accessing to short circuit two terminal locations at the P300
the following display screens: connector. Crimp connector pins to both ends of
the jumper wire.
• “Diagnostics”
RENR9346-06 179
G. Repeat this test for each suspect circuit. Stop

the “Injector Solenoid Test” before handling the
jumper wire.
Restore the wiring to the original configuration.
Expected Result:
Cat ET displays “Short” for each circuits that was

jumpered.
Results:
• OK – Cat ET displays “Short” for each circuit that

g01203187
was jumpered. The harness between the ECM and
Illustration 100 the P300 connector does not have an open circuit.
P3 terminals that are associated with the injector solenoids Proceed to Test Step 7.
(harness side of connector)
(P3-1) Injector 12 return • Not OK – Cat ET displays “Open” for the cylinder
(P3-2) Injector 10 return with the jumper wire. There is a problem in the
(P3-4) Injector 6 return wiring between the ECM and the P300 connector.
(P3-5) Injector 4 return There may be a problem with the ECM. Proceed
(P3-6) Injector 2 return to Test Step 8.
Test Step 6. Check the Harness between
the ECM and the Valve Cover Base for a
Short Circuit

B. Disconnect the appropriate P300 connector.
Illustration 101
g01161304 D. Perform the “Injector Solenoid Test” at least two
times.
P4 terminals that are associated with the injector solenoids
(harness side of connector)
Expected Result:
(P4-3) Injector 5 return All of the cylinders in the appropriate bank indicate
(P4-4) Injector 7 return “Open” on Cat ET.
Results:
(P4-9) Injectors 9 & 11 supply • OK – All cylinders indicate “Open” on Cat ET. The
ECM and the engine harness are OK. Proceed to
E. Insert one end of the jumper wire into the P300 Test Step 7.
connector socket for the suspect injector's supply
wire. Insert the other end of the jumper wire • Not OK – One or more cylinders indicate “Short”
into the P300 connector socket for the suspect on Cat ET. Note the cylinders that indicate “Short”.
injector's return wire. This will replace the injector Proceed to Test Step 8.
solenoid with a short circuit.
F. Perform the “Injector Solenoid Test” at least two

times.
180 RENR9346-06
Test Step 7. Check the Injector Harness L. Remove the electrical power from the ECM.
Under the Valve Cover for an Open
Circuit or a Short Circuit Expected Result:
Cat ET displays “Short” for the cylinder with the

jumper wire and “Open” when the jumper wire is
removed.
Results:
A. Remove the electrical power from the ECM. • OK – Cat ET displays the correct status during
the test.
B. Remove the valve cover in order to gain access
to the suspect injector. Repair: The harness wiring is OK. There may be a
problem with the injector. Use a multimeter to check
C. Disconnect the harness connector from the the resistance of the suspect injector solenoid.
suspect injector.
The correct resistance of each injector solenoid is
1.06 ± 0.05 Ohms at 25 °C (77 °F).
If the resistance of the solenoid is not within

specifications replace the faulty injector. Verify that
the problem is resolved.
If the resistance of the solenoid is within

specifications the problem may be intermittent. If
the problem is intermittent, refer to the diagnostic
functional test Troubleshooting, “Inspecting
Electrical Connectors”.
STOP.
g01147088
Illustration 102 • Not OK – Cat ET did not display the correct status
Connector terminals for the injector solenoid during the test.
D. Thoroughly clean the terminals on the injector Repair: There is a problem with the injector
solenoid and on the harness connector. harness under the valve cover. There may be a
problem with a connector. Repair the wiring and/or
E. Use a jumper wire to short circuit the connector the connector, when possible. Replace parts, if
terminals for the suspect injector. This will necessary.
effectively replace the injector solenoid with a
short circuit. STOP.
F. Restore the electrical power to the ECM. Test Step 8. Check the ECM for Proper
Operation
G. Perform the “Injector Solenoid Test” at least two
times.
Note: The injector solenoid that shares the supply

wire of the injector that is short circuited may indicate
a false test result. Disregard this test result.
H. Remove the electrical power from the ECM. A. Remove the electrical power from the ECM.
I. Remove the jumper wire from the injector B. Fabricate a jumper that is long enough to reach
connector. This will effectively replace the injector from the P2 ECM connector to the engine ground
solenoid with an open circuit. stud. Crimp a connector socket to one end of the
jumper wire.
J. Restore the electrical power to the ECM.
C. Disconnect the P2 connector.
K. Perform the “Injector Solenoid Test” at least two
times.
RENR9346-06 181
D. Remove the supply wire from the terminal location Repair: There is a problem with the ECM. Replace
for the suspect injector at the ECM connector. the ECM. Refer to Troubleshooting, “Replacing the
Install the jumper wire into this socket. ECM”. Verify that the problem is resolved.
E. Connect the J2/P2 ECM connectors. STOP.
F. Verify that the ECM will detect an open circuit for

i02818270
the suspect injector:
a. Ensure that the jumper wire is not in contact

Sensor Signal (PWM) - Test
with a ground source or another circuit. Do not SMCS Code: 1439-038
touch the jumper wire during the test. A strong
electrical shock hazard is present at the jumper S/N: EXD1-Up
wire while the test is running.
S/N: EYG1-Up
S/N: JXP1-Up
c. Perform the “Injector Solenoid Test” at least S/N: JRP1-Up; LJW1-Up
two times.
d. Remove the electrical power from the ECM.
Use this procedure to troubleshoot the electrical
Cat ET displays “Open” for the two injectors system if a problem is suspected with the sensor or if
that share the supply wire. any one of the diagnostic codes in Table 15 is active
or easily repeated.
G. Verify that the ECM detects a short circuit for the
suspect injector:
a. Connect the jumper wire to the engine ground

stud. Do not touch the jumper wire during the
test. A strong electrical shock hazard is present
at the jumper wire while the test is running.
c. Perform the “Injector Solenoid Test” at least

two times.
d. Remove the electrical power from the ECM.
Cat ET displays “Short” for the two injectors

that share the supply wire.
Expected Result:
Cat ET displays the correct status for each test circuit.
Results:
• OK – The ECM detects the correct status of the

circuit.
Repair: The ECM is OK. The problem is in the

engine harness or in a connector. Inspect the
connectors for moisture and for corrosion. Repair
the wiring and/or the connector, when possible.
Replace parts, if necessary. Clear all diagnostic
codes after you complete this test step.
STOP.
• Not OK – The ECM does not detect the correct

status of the circuit.
182 RENR9346-06
Table 15
Diagnostic Codes Table
Code and Description Conditions which Generate System Response Label on Sensor
this Code
827-3 Left Exhaust The Electronic Control The code is logged. “FRONT LEFT EXHAUST
Temperature Sensor voltage Module (ECM) detects a The ECM flags the exhaust TC”
above normal signal voltage that is above temperature as invalid data. Located in the exhaust
normal. manifold below the
turbocharger
827-4 Left Exhaust The Electronic Control
Temperature Sensor voltage Module (ECM) detects a
below normal signal voltage that is below
normal.
Temperature Sensor Module (ECM) detects a
abnormal frequency, pulse sensor frequency that is
width, or period greater than 600 Hz or less
than 400 Hz.
The ECM detects a duty
cycle that is greater than 88
percent or a duty cycle that is
less than 22 percent.
828-3 Right Exhaust The Electronic Control The code is logged. “FRONT RIGHT EXHAUST
turbocharger
828-4 Right Exhaust The Electronic Control
normal.
Temperature Sensor Module (ECM) detects a
than 400 Hz.
2350-3 Left Exhaust #2 The Electronic Control The code is logged. “REAR LEFT EXHAUST TC”
Temperature Sensor voltage Module (ECM) detects a The ECM flags the exhaust Located in the exhaust
above normal signal voltage that is above temperature as invalid data. manifold below the
normal. turbocharger
2350-4 Left Exhaust #2 The Electronic Control
normal.
#2 Temperature Sensor Module (ECM) detects a
than 400 Hz.
(continued)
RENR9346-06 183
(Table 15, contd)

Diagnostic Codes Table
Code and Description Conditions which Generate System Response Label on Sensor
this Code
2351-3 Right Exhaust #2 The Electronic Control The code is logged. “REAR RIGHT EXHAUST
turbocharger
2351-4 Right Exhaust #2 The Electronic Control
normal.
#2 Temperature Sensor Module (ECM) detects a
than 400 Hz.
System Operation
A Pulse Width Modulated Sensor (PWM) provides a

signal to the Electronic Control Module (ECM) from
the exhaust temperature sensor. The sensor receives
a 8.0 ± 0.4 VDC regulated voltage from the ECM.
The sensor generates a PWM signal that is in a

specific range of duty cycle that is sent to the ECM.
This range is directly related to the temperature
that is sampled by the temperature probe. When
the temperature of the sensor probe is 50 °C
(122 °F) the duty cycle output of the sensor is 22
percent. When the temperature of the sensor probe
is 850 °C (1550 °F) the duty cycle output of the
sensor is 88 percent. As the temperature of the probe
fluctuates between the minimum and the maximum
temperatures, the duty cycle fluctuates on a scale
that is directly related to the temperature of the
temperature probe.
The ECM performs an automatic calibration of this

sensor whenever the ECM is powered and the engine
has been off for at least five seconds.
The ECM provides short circuit protection for the

internal power supply. A short circuit to the battery will
not damage the internal power supply of the ECM.
184 RENR9346-06
g01405556
Illustration 103
Schematic of the sensor circuit for the PWM sensors
g01406331
Illustration 104
Locations of the left side exhaust temperature sensors
(1) “FRONT LEFT EXHAUST TC” (2) “REAR LEFT EXHAUST TC”
RENR9346-06 185

g01406077
Illustration 105
Location of the ECM connector that is for the exhaust temperature
sensors
A. Thoroughly inspect connectors (1),(2) and (3).

Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details that are related to inspection of
the electrical connectors.
g01406078
Illustration 106
Terminal locations at the P2 ECM connector that are for the
exhaust temperature sensor
(P2-29) Digital sensor supply
(P2-39) Front left exhaust temperature
(P2-49) Front right exhaust temperature
(P2-65) Rear left exhaust temperature
(P2-73) Rear right exhaust temperature
186 RENR9346-06
C. Measure the voltage across terminal A (digital

sensor supply) and terminal B (digital return) on
the harness side of the connector.
D. Remove electrical power from the ECM. Turn the

keyswitch to the OFF position.
E. Restore the wiring to the original configuration.
Expected Result:
The supply voltage measures 8.0 ± 0.4 VDC at the

sensor connector.
g01159881
Results:
Illustration 107
Terminal locations at the connectors for the exhaust temperature • OK – The correct supply voltage is measured at
sensor the sensor connector. The sensor is receiving the
(Terminal A) Digital sensor supply correct supply voltage. Proceed to Test Step 3.
(Terminal B) Digital return
(Terminal C) Exhaust temperature
• Not OK – The voltage is not correct at the sensor
connector.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the customer
Repair: There is a problem in the circuit for the
connector that are associated with the circuit.
digital sensor supply that is between the ECM and
the exhaust temperature sensor. Repair the circuit.
C. Check the allen head screw on each ECM
Refer to Troubleshooting, “Sensor Supply - Test”
connector for the proper torque. refer to
for details that are related to troubleshooting a
problem with the circuit.
STOP.
D. Check the harness and the wiring for abrasion
Expected Result:
and the Duty Cycle at the Sensor
A. Disconnect the sensor connector from the exhaust
temperature sensor.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
B. Remove the signal wire from terminal C of the
harness side of the connector for the exhaust
Results:
temperature sensor.
• OK – The connectors and wiring appear to be OK. C. Install a 7X-6370 Adapter Cable As (3-PIN
BREAKOUT) at the sensor connector.
• Not OK – The connectors and/or wiring are not D. Connect the sensor to the breakout harness.
OK.
E. Restore electrical power to the ECM. Turn the
keyswitch to the ON position.
F. Measure the frequency and the duty cycle
STOP.
between terminal B (digital return) and terminal C
(exhaust temperature) at the 7X-6370 Adapter
Test Step 2. Check the Supply Voltage at Cable As (3-PIN BREAKOUT).
the Sensor
G. Remove electrical power from the ECM. Turn the
A. Disconnect the exhaust temperature sensor at the
harness connector.
H. Remove the breakout harness. Restore the wiring
B. Restore electrical power to the ECM. Turn the
to the original configuration.
keyswitch to the ON position.
RENR9346-06 187
Expected Result: Results:
The frequency is between 400 and 600 Hz. The duty • OK – The frequency and the duty cycle are within
cycle is between 22 and 88 percent. specifications.
Note: When the temperature of the sensor probe is Repair: A valid signal appears at the ECM, but the
50 °C (122 °F) the duty cycle output of the sensor ECM is not detecting the signal properly. There is a
is 22 percent. When the temperature of the sensor problem with the ECM. Replace the ECM. Refer to
probe is 850 °C (1550 °F) the duty cycle output of Troubleshooting, “ECM - Replace” for details.
the sensor is 88 percent.
STOP.
Results:
• Not OK – The frequency and the duty cycle are
• OK – The frequency and the duty cycle are within not within specifications.
specifications. The sensor is producing a valid
signal. Proceed to Test Step 4. Repair: There is not a valid signal at the ECM
connector. Repair the signal wire in the harness
• Not OK – The frequency and the duty cycle are that is between the ECM connector and the harness
not within specifications. connector for the suspect exhaust temperature
sensor. Verify that the repair eliminates the
Repair: The sensor is not producing a valid signal. problem.
Replace the exhaust temperature sensor. Verify
that the repair eliminates the problem. STOP.
STOP.
i02517370
Test Step 4. Check the Signal Frequency Throttle Position Sensor

and the Duty Cycle at the ECM
Circuit - Test
A. Remove the signal wire of the suspect sensor
from the P2 ECM connector in order to isolate the SMCS Code: 1439-038; 1913-038
circuit. Refer to illustration 103 for the number of
the P2 terminal of the suspect sensor. System Operation Description:
B. Restore electrical power to the ECM. Turn the Use this procedure to troubleshoot the system when
keyswitch to the ON position. a 91-08 Throttle Position Signal abnormal is active.
C. Install a 7X-1709 Multimeter Probe (BLACK) into The throttle position sensor provides the throttle
terminal location P2-14 (digital return) at the ECM signal to the Electronic Control Module (ECM).
connector.
Note: Ensure that the multimeter probe is in good

repair. A bent probe may contact other terminals
inside the connector.
D. Measure the duty cycle and the frequency

between the loose wire and the multimeter probe
at the ECM connector.
E. Remove electrical power from the ECM. Turn the

Expected Result:
g01193730
The frequency is between 400 and 600 Hz. The duty Illustration 108
cycle is between 22 and 88 percent. Mounting location of the throttle position sensor on the throttle
pedal (typical example)
Note: When the temperature of the sensor probe is
50 °C (122 °F) the duty cycle output of the sensor
is 22 percent. When the temperature of the sensor
probe is 850 °C (1550 °F) the duty cycle output of
the sensor is 88 percent.
188 RENR9346-06
The throttle position sensor is mounted to a pedal

assembly that allows the operator to control the
speed of the engine. The geometry of the pedal
assembly controls both the travel of the sensor and
the range of the output signal. The throttle position
sensor cannot be adjusted.
The output from the throttle position sensor is a

PWM signal that varies with the position of the
throttle pedal. The throttle position sensor produces
a minimum duty cycle in the released position and a
maximum duty cycle in the fully depressed position.
When the pedal is released, the ECM translates
the sensor's output signal to a throttle position of 0
percent. When the pedal is fully depressed, the ECM
translates the output signal to a throttle position of
100 percent.
The throttle position sensor is powered by 8.0 ± 0.4

VDC that is provided by the ECM. A digital return for
the sensor is also provided by the ECM.
The ECM uses an automatic calibration function that

allows the ECM to minimize the deadband of the
sensor. The automatic calibration function assumes
a range of PWM duty cycle at powerup. If the duty
cycle of the sensor exceeds this initial range, the
automatic calibration function adjusts the limits of the
duty cycle in order to adjust for the new range.
g01259511
Illustration 109
Schematic for throttle position sensor

RENR9346-06 189
g01258956
Illustration 110
Location of the J1/P1 ECM connectors
B. Thoroughly inspect the J1/P1 ECM connector

and the connector for the throttle position sensor.
Inspect” for details.
g01214474
Illustration 111
P1 ECM connector
(P1-4) 8 VDC supply
(P1-66) Throttle position
g01159881
Illustration 112
Terminal locations for the throttle position sensor
(Terminal A) 8 V supply
(Terminal B) Digital return
(Terminal C) Throttle position

wires in the ECM connector and the connector for
the throttle position sensor.
190 RENR9346-06
D. Check the allen head screw from each ECM Test Step 3. Check the Status for
connector for the proper torque. Refer to “Throttle Position” on Cat ET
for the correct torque value. A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.
and for pinch points. B. Restore electrical power to the ECM.
Expected Result: C. Observe the status for “Throttle Position” on Cat

ET while you operate the throttle pedal through
All of the connectors, pins and sockets are completely the entire range of travel.
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points. Expected Result:
Results: The status is zero percent when the throttle pedal is

released. The status progressively increases to 100
• OK – The harness and connectors appear to be percent when the throttle pedal is fully depressed.
Results:
• Not OK – The connectors and/or wiring are not
OK. • OK – The throttle position sensor is working
properly.
replace the connectors or wiring. Ensure that all of Repair: The original problem seems to be
the seals are properly in place and ensure that the resolved. There may be an intermittent electrical
connectors are completely coupled. problem with the harness or the connectors.
Verify that the repair eliminates the problem. Inspect” if the problem is intermittent.
STOP. STOP.
Test Step 2. Inspect the Throttle Pedal • Not OK – The throttle position that is displayed on
Assembly Cat ET is questionable. There may be a problem
with the sensor. Proceed to Test Step 4.
A. Inspect the throttle pedal assembly for components
that are loose, bent, missing, or worn. Test Step 4. Check the Supply Voltage at
the Sensor
B. Slowly depress the pedal and release the pedal.
Expected Result:
B. Disconnect the harness connector for the throttle
The throttle pedal assembly operates smoothly position sensor.
without excessive drag. The pedal springs back
smoothly to the low idle position without assistance. C. Restore electrical power to the ECM.
Results: D. Measure the voltage across terminal A (8 V

supply) and terminal B (digital return) on the
• OK – The throttle pedal assembly functions harness side of the connector.
properly. The throttle pedal assembly is OK.
Proceed to Test Step 3. E. Remove electrical power from the ECM.
• Not OK – The throttle pedal assembly is in poor Expected Result:

repair.
The supply voltage measures 8.0 ± 0.4 VDC at the
Repair: There is excessive drag or improper sensor connector.
operation of the throttle pedal assembly. Repair
the throttle pedal assembly or replace the throttle Results:
pedal assembly, as required.
• OK – The correct voltage is measured at the
STOP. sensor connector. The sensor is receiving the
correct supply voltage. Proceed to Test Step 5.
RENR9346-06 191
• Not OK – The voltage is not correct at the sensor Test Step 6. Check the Signal Frequency
connector. and the Duty Cycle at the ECM
Repair: The sensor is not receiving the correct A. Disconnect the J1/P1 ECM connectors.
supply voltage. There may be a problem
in the circuit for the digital supply. Refer to B. Remove the wire from terminal location P1-66
Troubleshooting, “Digital Sensor Supply Circuit (throttle position) at the ECM connector.
- Test” for details.
C. Install a 208-0059 Adapter Cable As (70-PIN
STOP. BREAKOUT) between the J1 and the P1 ECM
connectors.
and the Duty Cycle at the Sensor D. Connect the J1/P1 ECM connectors.
A. Remove the wire from terminal location C (throttle E. Restore electrical power to the ECM.
position) on the harness side of the connector for
the throttle position sensor. F. Measure the frequency between the loose signal
wire (throttle position) and P1-5 (digital return)
B. Install a 7X-6370 Adapter Cable As (3-PIN on the breakout harness while you operate the
BREAKOUT) at the connector for the throttle throttle pedal.
position sensor.
G. Set the multimeter to read the duty cycle of the
C. Connect the connector for the throttle position sensor. Measure the duty cycle between the loose
sensor. signal wire (throttle position) and P1-5 (digital
return) on the breakout harness while you operate
D. Restore electrical power to the ECM. the throttle pedal.
E. Measure the frequency and the duty cycle H. Remove electrical power from the ECM.
between terminal B (digital return) and terminal C
(throttle position) at the 7X-6370 Adapter Cable Expected Result:
As (3-PIN BREAKOUT) while you operate the
throttle pedal. The frequency is between 150 and 1000 Hz. The
duty cycle is between 5 percent and 95 percent.
F. Remove electrical power from the ECM.
Results:
G. Remove the breakout harness. Restore the
wiring for the harness connector to the original • OK – The frequency and the duty cycle are within
configuration. specifications for the entire range of the pedal.
Expected Result: Repair: A valid signal appears at the ECM, but the
ECM is not reading the signal properly. Replace
The frequency is between 150 and 1000 Hz. The the ECM. Refer to Troubleshooting, “Replacing
duty cycle is between 5 and 95 percent. the ECM” for complete instructions. Verify that the
Results:
STOP.
• OK – The frequency and the duty cycle are within
specifications for the entire range of the pedal. The • Not OK – The frequency and the duty cycle are
sensor is producing a valid signal. Proceed to Test not within specifications.
Step 6.
Repair: There is a valid signal in the isolated circuit
• Not OK – The frequency and the duty cycle are between the sensor and the sensor connector, but
not within specifications. there is not a valid signal at the ECM connector.
The problem is in the harness wiring or in a
Repair: The sensor is not producing a valid signal. connector between the ECM and the harness
Replace the throttle position sensor. Verify that the connector for the throttle position sensor. Repair
repair eliminates the problem. the harness and/or the connectors. Replace parts,
if necessary. Verify that the repair eliminates the
STOP. problem.
STOP.
192 RENR9346-06
Calibration Procedures Results:
• OK – No active diagnostic codes are present. If a

i02348860 timing calibration is necessary due to service to
the ECM or to the front gear train, proceed to Test
Engine Speed/Timing Sensor - Step 2.
Calibrate
• Not OK – 261-13 Engine Timing Calibration
SMCS Code: 1439-524; 1912-524 required is the only active diagnostic code that is
present. Proceed to Test Step 2.
• Not OK – There are active diagnostic codes. A
Use this procedure if a 261-13 Engine Timing 261-13 is not one of the active diagnostic codes.
Calibration required is active.
Repair: Troubleshoot the active diagnostic codes.
Also use this procedure if any of the following Make the necessary repairs.
conditions exist:
STOP.
• The Electronic Control Module (ECM) has been
replaced. • Not OK – A 261-13 and other active diagnostic
codes are present.
• The ECM software has been updated.
Repair: Make the necessary repairs in order to
• The front gear group has been serviced. resolve the active diagnostic codes. The 261-13
Engine Timing Calibration required may remain
The ECM has the ability to calibrate the mechanical active while the repairs are made.
differences between the Top Center (TC) of the No. 1
piston and the orientation of the camshaft. The ECM Repeat Test Step 1.
uses the signal from the primary engine speed/timing
sensor as a control reference that identifies the exact Test Step 2. Calibrate the Engine
orientation of the crankshaft. The ECM uses the Speed/Timing Sensor
signal that is detected from the secondary engine
speed/timing sensor to identify the exact orientation A. Start the engine. Run the engine until the engine
of the camshaft. has exited cold mode operation.
The two signals are then used by the ECM to B. After the engine has warmed up, access the
calculate a timing offset. The offset is used by the “Timing Calibration” screen on Cat ET. Access the
ECM to calibrate the signal from the secondary following display screens in order:
engine speed/timing sensor.
• “Service”
Note: A timing calibration will not increase the
available engine power. • “Calibrations”
Test Step 1. Check for Active Diagnostic • “Timing Calibration”
Codes
C. To calibrate the timing to the correct setting, set
A. Turn the keyswitch to the OFF position. the engine speed to 1100 ± 50 rpm and select
“Continue” on Cat ET. Wait until Cat ET indicates
B. Connect the Caterpillar Electronic Technician that the timing is calibrated.
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”. D. Press the “Continue” button on Cat ET. Wait until
Cat ET indicates that the ECM has calculated the
C. Turn the keyswitch to the ON position. timing reference.
D. Check for any active diagnostic codes. Note: If Cat ET displays “Calibration Unsuccessful”,
the electronic injection timing has not been calibrated.
Expected Result:
Expected Result:
No active diagnostic codes are present.
The timing calibration was successful.
RENR9346-06 193
Results:
• OK – The timing calibration was successful.

Repair: Return the engine to service.
STOP.
• Not OK – The timing calibration was unsuccessful.

Repair: The following conditions can cause the
timing calibration to fail:
• If the crankshaft and camshaft gears have been

reassembled incorrectly, the timing will not
calibrate.
• Verify that the engine speed/timing sensors are

installed correctly.
• Verify that the engine speed is correct and that

the engine speed is stable. If the engine speed
is unstable, refer to Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable”.
If a problem with the engine speed/timing sensors

is suspected, refer to Troubleshooting, “Engine
Speed/Timing Sensor Circuit - Test”.
STOP.
194 RENR9346-06
Index Section
Index
Numerics CID 0091 FMI 08 Throttle Position signal
abnormal.............................................................. 57
5 Volt Engine Pressure Sensor Supply Circuit - CID 0094 FMI 03 Fuel Pressure open/short to
Test .................................................................... 100 +batt..................................................................... 58
CID 0094 FMI 04 Fuel Pressure short to ground... 58
CID 0100 FMI 03 Engine Oil Pressure open/short to
A +batt..................................................................... 58
CID 0100 FMI 04 Engine Oil Pressure short to
Alternator (Noisy Operation).................................. 26 ground.................................................................. 58
Probable Causes ............................................... 26 CID 0100 FMI 10 Engine Oil Pressure Sensor
Recommended Actions...................................... 26 abnormal rate of change...................................... 59
CID 0110 FMI 03 Engine Coolant Temperature
open/short to +batt............................................... 59
C CID 0110 FMI 04 Engine Coolant Temperature short
to ground.............................................................. 59
Calibration Procedures ........................................ 192 CID 0168 FMI 00 System Voltage High................. 60
Can Not Reach Top Engine RPM .......................... 26 CID 0168 FMI 01 System Voltage Low.................. 60
Probable Causes ............................................... 26 CID 0168 FMI 02 System Voltage intermittent/
Recommended Actions...................................... 26 erratic................................................................... 60
Cat Data Link Circuit - Test.................................. 105 CID 0172 FMI 03 Intake Manifold Air Temp open/short
CID 0001 FMI 05 Cylinder #1 Injector open to +batt................................................................. 61
circuit ................................................................... 50 CID 0172 FMI 04 Intake Manifold Air Temp short to
CID 0001 FMI 06 Cylinder #1 Injector short .......... 50 ground.................................................................. 61
CID 0002 FMI 05 Cylinder #2 Injector open CID 0174 FMI 03 Fuel Temperature open/short to
circuit ................................................................... 50 +batt..................................................................... 61
CID 0002 FMI 06 Cylinder #2 Injector short .......... 51 CID 0174 FMI 04 Fuel Temperature short to
CID 0003 FMI 05 Cylinder #3 Injector open ground.................................................................. 62
circuit ................................................................... 51 CID 0190 FMI 08 Engine Speed signal abnormal.. 62
CID 0003 FMI 06 Cylinder #3 Injector short .......... 51 CID 0253 FMI 02 Personality Module mismatch ... 62
CID 0004 FMI 05 Cylinder #4 Injector open CID 0261 FMI 11 Engine Timing Offset fault ......... 63
circuit ................................................................... 52 CID 0261 FMI 13 Engine Timing Calibration
CID 0004 FMI 06 Cylinder #4 Injector short .......... 52 required................................................................ 64
CID 0005 FMI 05 Cylinder #5 Injector open CID 0262 FMI 03 5 Volt Sensor DC Power Supply
circuit ................................................................... 52 short to +batt........................................................ 64
CID 0005 FMI 06 Cylinder #5 Injector short .......... 52 CID 0262 FMI 04 5 Volt Sensor DC Power Supply
CID 0006 FMI 05 Cylinder #6 Injector open short to ground..................................................... 64
circuit ................................................................... 53 CID 0267 FMI 02 Incorrect Engine Shutdown Switch
CID 0006 FMI 06 Cylinder #6 Injector short .......... 53 inputs ................................................................... 65
CID 0007 FMI 05 Cylinder #7 Injector open CID 0268 FMI 02 Check Programmable
circuit ................................................................... 53 Parameters .......................................................... 65
CID 0007 FMI 06 Cylinder #7 Injector short .......... 54 CID 0274 FMI 03 Atmospheric Pressure open/short
CID 0008 FMI 05 Cylinder #8 Injector open to +batt................................................................. 65
circuit ................................................................... 54 CID 0274 FMI 04 Atmospheric Pressure short to
CID 0008 FMI 06 Cylinder #8 Injector short .......... 54 ground.................................................................. 66
CID 0009 FMI 05 Cylinder #9 Injector open CID 0291 FMI 05 Engine Cooling Fan Solenoid open
circuit ................................................................... 54 circuit ................................................................... 66
CID 0009 FMI 06 Cylinder #9 Injector short .......... 55 CID 0291 FMI 06 Engine Cooling Fan Solenoid short
CID 0010 FMI 05 Cylinder #10 Injector open to ground.............................................................. 66
circuit ................................................................... 55 CID 0342 FMI 08 Secondary Engine Speed signal
CID 0010 FMI 06 Cylinder #10 Injector short ........ 55 abnormal.............................................................. 66
CID 0011 FMI 05 Cylinder #11 Injector open CID 0533 FMI 09 Brake Control abnormal update
circuit ................................................................... 56 rate....................................................................... 67
CID 0011 FMI 06 Cylinder #11 Injector short......... 56 CID 0533 FMI 14 Brake Control special
CID 0012 FMI 05 Cylinder #12 Injector open instruction ............................................................ 67
circuit ................................................................... 56 CID 0544 FMI 02 Engine Cooling Fan Speed Sensor
CID 0012 FMI 06 Cylinder #12 Injector short ........ 56 loss of signal ........................................................ 67
CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 57 CID 0544 FMI 08 Engine Cooling Fan Speed signal
CID 0041 FMI 04 8 Volt DC Supply short to abnormal.............................................................. 68
ground.................................................................. 57 CID 0569 FMI 05 Oil Injection Solenoid current below
normal.................................................................. 68
RENR9346-06 195
Index Section
CID 0569 FMI 06 Oil Renewal Solenoid short to CID 2534 FMI 05 Compression Brake Low/High
ground.................................................................. 68 Solenoid #2 current below normal ....................... 78
CID 0827 FMI 03 Left Exhaust Temperature CID 2534 FMI 06 Compression Brake Low/High
open/short to +batt............................................... 69 Solenoid #2 current above normal....................... 79
CID 0827 FMI 04 Left Exhaust Temperature short to CID 2535 FMI 05 Compression Brake Medium/High
ground.................................................................. 69 Solenoid #1 current below normal ....................... 79
CID 0827 FMI 08 Left Exhaust Temperature signal CID 2535 FMI 06 Compression Brake Medium/High
abnormal.............................................................. 69 Solenoid #1 current above normal....................... 79
CID 0828 FMI 03 Right Exhaust Temperature CID 2536 FMI 05 Compression Brake Medium/High
open/short to +batt............................................... 70 Solenoid #2 current below normal ....................... 79
CID 0828 FMI 04 Right Exhaust Temperature short CID 2536 FMI 06 Compression Brake Medium/High
to ground.............................................................. 70 Solenoid #2 current above normal....................... 80
CID 0828 FMI 08 Right Exhaust Temperature signal Compression Brake Solenoid Circuit - Test ......... 108
abnormal.............................................................. 70 Coolant in Engine Oil............................................. 27
CID 1273 FMI 09 Unable to Communicate with Probable Causes ............................................... 27
Chassis Control Module....................................... 71 Recommended Actions...................................... 27
CID 1273 FMI 14 Chassis Control Module special Coolant Temperature Is Too High .......................... 28
instruction ............................................................ 71 Probable Causes ............................................... 28
CID 1589 FMI 03 Turbo Inlet Air Pressure Sensor Recommended Repairs ..................................... 28
open/shrt to +bat.................................................. 71
CID 1589 FMI 04 Turbo Inlet Air Pressure Sensor
short to ground..................................................... 72 D
CID 1785 FMI 03 Intake Manifold Pressure Sensor
voltage high ......................................................... 72 Diagnostic Codes .................................................. 49
CID 1785 FMI 04 Intake Manifold Pressure Sensor Active Diagnostic Codes .................................... 49
voltage low........................................................... 72 Diagnostic Codes............................................... 49
CID 1785 FMI 10 Intake Manifold Pressure Signal Logged Diagnostic Codes.................................. 50
abnormal rate of change...................................... 72 Diagnostic Functional Tests................................. 100
CID 1795 FMI 03 Turbo #2 Outlet Pressure Sensor Digital Sensor Supply Circuit - Test ...................... 117
voltage above normal .......................................... 73
CID 1795 FMI 04 Turbo #2 Outlet Pressure Sensor
voltage below normal........................................... 73 E
CID 1795 FMI 10 Turbo #2 Outlet Pressure Sensor
abnormal rate of change...................................... 74 E096 High Fuel Pressure ...................................... 84
CID 1796 FMI 03 Intake Manifold #2 Air Temperature E1000 High Left Intake Manifold Air Temperature.. 98
Sensor voltage above normal .............................. 74 E171 Low Engine Oil Level ................................... 84
CID 1796 FMI 04 Intake Manifold #2 Air Temperature E172 High Air Filter Restriction ............................. 85
Sensor voltage below normal .............................. 74 E194 High Exhaust Temperature........................... 85
CID 2271 FMI 05 Engine Oil Renewal System E321 High Right Exhaust Temperature ................. 87
Actuation Solenoid current below normal ............ 75 E322 High Left Exhaust Temperature.................... 88
CID 2271 FMI 06 Engine Oil Renewal System E360 Low Engine Oil Pressure.............................. 90
Actuation Solenoid current above normal............ 75 E361 High Engine Coolant Temperature ............... 90
CID 2350 FMI 03 Left Exhaust #2 Temperature E362 Engine Overspeed ....................................... 92
voltage above normal .......................................... 75 E363 High Fuel Supply Temperature..................... 92
CID 2350 FMI 04 Left Exhaust #2 Temperature E390 Fuel Filter Restriction ................................... 93
voltage below normal........................................... 76 E539 High Intake Manifold Air Temperature.......... 93
CID 2350 FMI 08 Left Exhaust #2 Temperature E540 Low Engine Oil Refill Tank Level.................. 94
abnormal frequency, pulse width, or period ......... 76 E775 High Left Exhaust #2 Temperature............... 95
CID 2351 FMI 03 Right Exhaust #2 Temperature E776 High Right Exhaust #2 Temperature ............ 96
voltage above normal .......................................... 76 ECM Will Not Accept Factory Passwords.............. 29
CID 2351 FMI 04 Right Exhaust #2 Temperature Probable Causes ............................................... 29
voltage below normal........................................... 77 Recommended Actions...................................... 30
CID 2351 FMI 08 Right Exhaust #2 Temperature ECM Will Not Communicate with Other Systems or
abnormal frequency, pulse width, or period ......... 77 Display Modules .................................................. 30
CID 2417 FMI 05 Ether Injection Control Solenoid Probable Causes ............................................... 30
current low ........................................................... 77 Recommended Actions...................................... 30
CID 2417 FMI 06 Ether Injection Control Solenoid Electrical Connectors - Inspect............................ 121
current high.......................................................... 78 Electrical Power Supply Circuit - Test.................. 126
CID 2533 FMI 05 Compression Brake Low/High Electronic Service Tool Will Not Communicate with
Solenoid #1 current below normal ....................... 78 ECM..................................................................... 30
CID 2533 FMI 06 Compression Brake Low/High Probable Causes ............................................... 30
Solenoid #1 current above normal....................... 78 Recommended Actions...................................... 30
196 RENR9346-06
Index Section
Electronic Service Tools .......................................... 7 Exhaust Temperature Is Too High ......................... 41

Caterpillar Electronic Technician.......................... 8 Probable Causes ............................................... 41
Optional Service Tools ......................................... 7 Recommended Actions...................................... 41
PL1000E Communication ECM ......................... 10
Service Tools........................................................ 7
Electronic Troubleshooting ...................................... 6 F
Engine Cranks but Will Not Start ........................... 31
Probable Causes ............................................... 31 Factory Passwords ................................................ 20
Recommended Actions...................................... 31 Flash Programming ............................................... 20
Engine Fan Control Solenoid Circuit - Test.......... 129 Programming a Flash File.................................. 20
Engine Fan Speed Sensor Circuit - Test ............. 133 Fuel Dilution of Engine Oil ..................................... 42
Engine Has Early Wear ......................................... 33 Probable Causes ............................................... 42
Probable Causes ............................................... 33 Recommended Actions...................................... 42
Recommended Actions...................................... 33 Fuel Filter Differential Pressure Switch Circuit -
Engine Misfires, Runs Rough or Is Unstable......... 33 Test .................................................................... 170
Probable Causes ............................................... 33 Fuel in Cooling System.......................................... 41
Recommended Actions...................................... 33
Engine Oil in Cooling System ................................ 34
Probable Causes ............................................... 34 I
Engine Oil Level Switch Circuit - Test.................. 137 Important Safety Information ................................... 2
Engine Oil Renewal Solenoid Circuit - Test ......... 141 Injector Solenoid Circuit - Test............................. 173
Engine Oil Temperature Is Too High...................... 35 Injector Trim File.................................................... 21
Probable Causes ............................................... 35 Intermittent Engine Shutdown ............................... 42
Recommended Actions...................................... 35 Probable Causes ............................................... 42
Engine Pressure Sensor Open or Short Circuit - Recommended Actions...................................... 42
Test .................................................................... 145
Engine Shutdown Switch Circuit - Test................ 152
Engine Speed/Timing Sensor - Calibrate ............ 192 L
Engine Speed/Timing Sensor Circuit - Test ......... 156
Engine Stalls at Low RPM ..................................... 35 Low Engine Oil Pressure ....................................... 43
Probable Causes ............................................... 35 Probable Causes ............................................... 43
Recommended Actions...................................... 35 Recommended Actions...................................... 43
Engine Temperature Sensor Open or Short Circuit - Low Power/Poor or No Response to Throttle ........ 44
Test .................................................................... 161 Probable Causes ............................................... 44
Engine Vibration .................................................... 36 Recommended Actions...................................... 44
Probable Causes ............................................... 36
Engine Will Not Crank ........................................... 36 M
Probable Causes ............................................... 36
Recommended Actions...................................... 37 Mechanical Noise (Knock) in Engine..................... 46
Ether Injection System - Test............................... 167
Event Codes .......................................................... 81
Active Event Codes............................................ 81 N
Clearing Event Codes ........................................ 82
Logged Event Codes ......................................... 82 Noise Coming from Cylinder.................................. 46
Trip Points for the Monitoring System ................ 82 Probable Causes ............................................... 46
Troubleshooting ................................................. 82 Recommended Actions...................................... 46
Excessive Black Smoke ........................................ 37
Probable Causes ............................................... 37
Recommended Actions...................................... 38 P
Excessive Engine Oil Consumption....................... 38
Probable Causes ............................................... 38 Poor Acceleration or Response............................. 46
Recommended Actions...................................... 38 Probable Causes ............................................... 46
Excessive Fuel Consumption ................................ 39 Recommended Actions...................................... 47
Probable Causes ............................................... 39 Programming Parameters ..................................... 19
Excessive Valve Lash............................................ 40
Probable Causes ............................................... 40 R
Excessive White Smoke ........................................ 40 Replacing the ECM................................................. 11
Probable Causes ............................................... 40
RENR9346-06 197
Index Section
Self-Diagnostics..................................................... 12
Sensor Signal (PWM) - Test ................................ 181
Sensors and Electrical Connectors ....................... 13
C27 and C32 Engines........................................ 15
System Configuration Parameters......................... 22
Parameter Descriptions ..................................... 22
Parameter Table................................................. 24
Parameter Worksheet ........................................ 24
System Overview..................................................... 6
Passwords ........................................................... 7
Programmable Parameters.................................. 7
System Operation ................................................ 6
Table of Contents..................................................... 3
Test ECM Mode ..................................................... 19
Throttle Position Sensor Circuit - Test ................. 187
Troubleshooting Section.......................................... 6
Troubleshooting with a Diagnostic Code ............... 49
Troubleshooting with an Event Code..................... 81
Troubleshooting without a Diagnostic Code .......... 26
Valve Rotator or Spring Lock Is Free..................... 48

Probable Cause ................................................. 48
198 RENR9346-06
Index Section
RENR9346-06 199
Index Section
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All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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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 CID 0002 FMI 05 Cylinder #2 Injector open

Diagnostic Functional Tests

Troubleshooting Section Cold Mode

i02397878 • Increased cold weather starting capability

Once the ECM determines the amount of fuel that Table 1

SMCS Code: 0785 270-5051 Connector Repair Kit (AMPSEAL)

Two short jumper wires are needed to check the

Optional Service Tools

Table 2 Note: For more information regarding the use of

Caterpillar Electronic Technician 317-7484

• Calibrations 353-5083 Cable As (USB)

• Event codes 1. Remove the electrical power from the ECM.

Once you have downloaded Cat ET onto your

Dual Data Links

When the connection of the communication adapter

Refer to Troubleshooting, “Electronic Service Tool

Communicating with the Wireless Communication

Table 5 lists the optional hardware that is needed

6. Establish communication between Cat ET and the

7. If Cat ET and the communication adapter

Refer to Troubleshooting, “Electronic Service Tool

• Cat ET displays a message that refers to a

• Cat ET displays “Error #142 The interface

• Cat ET displays a message that indicates that g01297379

Use the following procedure in order to connect the

1. Remove the electrical power from the ECM.

2. Ensure that the computer has been correctly

3. Connect cable (9) between communication radio

4. Restore the electrical power to the ECM. If Cat ET

PL1000E Communication ECM

The “PL1000E” is an ECM that provides the

i02881454 1. Print the parameters from the “Configuration”

4. Install the replacement ECM.

Note: If the “Copy Configuration” process fails and

Logged codes may not indicate that a repair is

An event code is generated by the detection of an

Sensors and Electrical

C27 and C32 Engines

Programming Parameters 2. Use the “Copy Configuration/ECM Replacement”

i02433393 Flash Programming – This is a method of

• Program a new Electronic Control Module (ECM). Programming a Flash File

4. Start the engine and check for proper operation.

Exchanging injectors can help determine if a

Note: The injector serial number and the injector

1. Record the injector serial number and the injector

2. Click on “Service Software Files” in SIS Web.

3. Enter the serial number for the injector in the

4. Download the injector trim file to the PC. Repeat

System Configuration Software Group Release Date

System configuration parameters are parameters

Parameter Descriptions Rated Power

Ether Solenoid Configuration

Engine Retarder Enable Command

System Configuration Parameters

Engine Serial Number

ECM Serial Number

ECM Part Number

Software Group Part